Abstract: Hybrid PGM-ZPGM exhaust treatment systems are disclosed. The systems include a PGM close-couple catalytic converter followed by an underfloor ZPGM catalytic converter. The disclosed hybrid systems, including PGM based catalysts and zero-PGM based catalysts may replace pure PGM based exhaust treatment systems. The ZPGM catalyst compositions used may include copper and cerium as active ZPGM catalysts. The disclosed ZPGM underfloor converters may be designed to convert leaks from close-couple converters.

Abstract: Synergies resulting from combinations of catalyst systems including Copper-Manganese material compositions and PGM catalysts are disclosed. Variations of catalyst system configurations are tested to determine most effective material composition, formulation, and configuration for an optimal synergized PGM (SPGM) catalyst system. The synergistic effect of the selected SPGM catalyst system is determined under steady state and oscillating test conditions, from which the optimal NO/CO cross over R-value indicates enhanced catalytic behavior of the selected SPGM catalyst system as compared with current PGM catalysts for TWC applications. According to principles in the present disclosure, application of Pd on alumina-based support as overcoat and Cu—Mn spinel structure supported on Nb2O5—ZrO2 as washcoat on suitable ceramic substrate, produce higher catalytic activity, efficiency, and better performance in TWC condition, especially under lean condition, than commercial PGM catalysts.

Abstract: ZPGM-ZRE catalyst system substantially free from platinum group (PGM) and rare earth (RE) metals for TWC application is disclosed. Disclosed ZPGM-ZRE catalyst system may include pure alumina as washcoat and a Cu—Mn stoichiometric spinel with Nb2O5—ZrO2 support oxide, as ZPGM-ZRE catalyst in overcoat. Disclosed ZPGM-ZRE catalyst systems are found to have high thermal stability, catalyst activity, and high oxygen storage capacity compared to commercial PGM catalyst system that includes Ce-based oxygen storage material (OSM).

Abstract: The present disclosure relates to an enhanced oxygen storage material (OSM) that may be converted into powder form and used as a raw material for a vast number of applications, and more particularly in catalyst systems. The disclosed OSM, substantially free from PGM and rare earth (RE) metals, has significantly higher oxygen storage capacity (OSC) than conventional OSM including PGM and RE metals. The disclosed OSM may be converted into powder, including a formulation of Cu—Mn spinel structure deposited on Nb—Zr oxide support. The disclosed OSM may also be coated onto a ceramic substrate as washcoat layer for characterization under OSC isothermal oscillating condition. The disclosed OSM may have an optimal OSC property that increases with the temperature, showing acceptable level of O2 storage even at low temperatures.

Abstract: The present disclosure provides identification techniques on platinum group metal (PGM) and zero platinum group metal (ZPGM) catalyst systems, in order to identify responsible materials for the formation of corrosion products, such as hexavalent chromium compounds. Identification analyses, such as X-ray diffraction analysis (XRD) and X-ray fluorescence (XRF) may be performed on various thermally treated PGM and ZPGM catalyst systems. Results of identification analyses may show that for both PGM and ZPGM catalysts, hexavalent chromium (Cr6+) may be formed during thermal aging at range of 600C to 900C. This may be due to the high concentration of chromium in substrate alloys. Therefore, occurrence of corrosion and production of hexavalent chromium may initiate from elements found in the substrate and not from elements within the PGM and ZPGM catalysts.

Abstract: Solutions to the problem of washcoat and/or overcoat adhesion loss of ZPGM catalyst on metallic substrates are disclosed. Present disclosure provides an enhanced process for improving WCA to metallic substrates of ZPGM catalyst systems. Reduction of WCA loss and improved catalyst activity may be enabled by the selection of processing parameters determined from variation of rheological properties by the solid content of the overcoat slurry and variation of the overcoat slurry particle size distribution to produce desirable homogeneity, specific loading, and adherence of the coating on metallic substrates. Processing parameters may be applied to a plurality of metallic substrates of different geometries and cell densities.

Abstract: The present disclosure refers to processes and formulations employed for optimization of variations of Zero-PGM catalyst coated on metallic substrates. Deposition of a uniform and well-adhered layer of catalyst on the metallic substrate may be enabled by the selection of a washcoat loading resulting from variation of metal loadings. Characterization of catalysts may be performed using a plurality of catalytic tests, including but not limited to washcoating adherence test, back pressure test, inspection of textural characteristics, and catalyst activity. Optimized variations may be applied to a plurality of metallic substrates for achieving coating uniformity, desired level of WCA loss, and optimized performance of catalyst activity.

Abstract: The present disclosure refers to a plurality of process employed for optimization of Zero-PGM washcoat and overcoat loadings on metallic substrates. According to an embodiment a substantial increase in conversion of HC and CO may be achieved by optimizing the total washcoat and overcoat loadings of the catalyst. According to another embodiment, the present disclosure may provide solutions to determine the optimum total washcoat and overcoat loadings for minimizing washcoat adhesion loss. As a result, may increase the conversion of HC and CO from discharge of exhaust gases from internal combustion engines, optimizing performance of Zero-PGM catalyst systems.

Abstract: Systems and Methods for manufacturing ZPGM catalysts systems that may allow the prevention of formation or the conversion of corrosion causing compounds, such as hexavalent chromium compounds, within ZPGM catalyst systems are disclosed. ZPGM catalysts systems, may include metallic substrate, which may include alloys of iron and chromium, a washcoat and an overcoat. Disclosed manufacturing processes may include a thermal decomposition of hexavalent chromium compounds which may allow the decomposition of such compounds into trivalent chromium compounds, and may also produce metallic catalyst, such as silver.

Abstract: Solutions to the problem of washcoat and/or overcoat adhesion loss of ZPGM catalyst on metallic substrates are disclosed. Present disclosure provides a novel process for improving WCA to metallic substrates of ZPGM catalyst systems. Reduction of WCA loss and improved catalyst activity may be enabled by the selection of processing parameters determined from variations of pH and addition of binder to overcoat slurry, and particle size of washcoat. Processing parameters may be applied to a plurality of metallic substrates of different geometries and cell densities.

Abstract: The present disclosure refers to a plurality of process employed for optimization of Zero-PGM metal loading in Washcoat and Overcoat on metallic substrates. According to an embodiment a substantial increase in conversion of HC and CO may be achieved by optimizing the metal loading of the catalyst. According to another embodiment, the present disclosure may provide solutions to determine the optimum metal loading in washcoat for minimizing washcoat adhesion loss. As a result, may increase the conversion of HC and CO from discharge of exhaust gases from internal combustion engines, optimizing performance of Zero-PGM catalyst systems.

Abstract: The present disclosure provides an identification process which may employ various identification techniques on Zero platinum group metal (ZPGM) catalyst systems, in order to identify responsible materials for the formation of corrosion material, such as hexavalent chromium compounds. Identification analysis, such as X-ray diffraction analysis (XRD), X-ray fluorescence (XRF), and X-ray Photoelectron Spectroscopy (XPS) may be performed on various thermally treated ZPGM catalyst systems, such as in bare substrate, substrate with one type of ZPGM in washcoat, a substrate with one type of ZPGM in overcoat and substrate combination of ZPGM metals in both washcoat and overcoat. Results of identification analysis may show that regardless of metal catalyst (for example Ag, Cu, Ce), hexavalent chromium (Cr6+) may be formed on aged catalysts systems, which may be due to the high concentration of chromium in substrate.

Abstract: Present disclosure provides a novel process for optimization of Zero-PGM catalyst systems using metallic substrate. Deposition of a homogeneous and well-adhered layer of catalyst on the metallic substrate may be enabled by the selection of a washcoat loading resulting from variation of metal loadings. Characterization of catalysts may be performed using a plurality of catalytic tests, including but not limited to washcoating adherence test, back pressure test, inspection of textural characteristics, and catalyst activity. Optimization may be applied to a plurality of metallic substrates of different geometries and cell densities.

Abstract: Disclosed here are systems and methods including one or more FBCs and one or more suitable aftertreatment devices, including DOCs, DPFs, and suitable combinations thereof. The systems and methods disclosed may include selecting a suitable FBC for use with a fuel with a specified sulfur content. Systems and methods disclosed here may also include using one or more ECUs to control one or more FBC dosing/metering devices to supply FBCs from one or more FBC reservoirs in the presence of a specified event.

Abstract: Stabilized palladium (+1) compounds to mimic rhodium's electronic configuration and catalytic properties are disclosed. Palladium (+1) compounds may be stabilized in perovskite or delafossite structures and may be employed in Three-Way Catalysts (TWC) for at least the conversion of HC, CO and NOx, in exhaust gases. The TWC may include a substrate, a wash-coat and, a first impregnation layer, a second impregnation layer and an over-coat. The second impregnation layer and the over-coat may include palladium (+1) based compounds as catalyst.

Abstract: Diesel oxidation ZPGM catalyst systems using Y1-x AgxMnO3 perovskite are disclosed. The ZPGM catalyst system compositions may include Y1-x AgxMnO3perovskite in impregnation component and at least one carrier material oxide in washcoat. The ZPGM catalyst system compositions may also include Y1-x AgxMnO3 perovskite co-precipitated in a carrier material oxide as washcoat. The catalyst activity is measured with an inlet gas mixture containing diesel exhaust composition and characterized according to performance in NO oxidation, NO2 production, NO storage capability and diesel oxidation applications.

Abstract: Disclosed here are variations of carrier material oxide formulations to create Cu—Mn spinel, where the formulations may include Ti1-xNbxO2, TiO2, SiO2, Doped alumina, Nb2O5—ZrO2, Nb2O5—ZrO2—CeO2, Doped ZrO2 and combinations thereof. The formation of type of Cu—Mn oxide phase depends on type of carrier material oxide. The crystallite size of Cu—Mn spinel, NO and CO conversion rate of Cu—Mn Spinel may vary according to the carrier material oxide and condition treatment used to form the spinel during co-precipitation method.

Abstract: Variations of synthesis methods for Zero Platinum Group Metal (ZPGM) catalyst systems are disclosed herein. The methodologies of influence of synthesis methods on Cu—Mn catalyst systems which may include a variation of carrier metal oxides are disclosed. The XRD characterization and activity measurements of a series of stoichiometric and non-stoichiometric Cu—Mn spinels with different support oxide are discussed.

Abstract: Disclosed here are material formulations of use in the conversion of exhaust gases. A catalyst is formed by using a perovskite structure having the general formula ABO3 or a mullite structure having the general formula of AB2O5 where components “A” and “B” may be any suitable non-platinum group metals. Suitable materials may include Yttrium, Lanthanum, Silver, Manganese and formulations thereof.

Abstract: Diesel oxidation ZPGM catalyst systems are disclosed. ZPGM catalyst systems may oxidize toxic gases, such as carbon monoxide, hydrocarbons and nitrogen oxides that may be included in exhaust gases. ZPGM catalyst systems may include: a substrate, a washcoat, and an impregnation layer. The washcoat may include at least one carrier material oxides. The impregnation layer may include at least one ZPGM catalyst, carrier material oxides and OSMs. Suitable known in the art chemical techniques, deposition methods and treatment systems may be employed in order to form the disclosed ZPGM catalyst systems.