Variations of Loading of Zero-PGM Oxidation Catalyst on Metallic Substrate

摘要

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.

主权项

1. A method for improving performance of catalytic systems, comprising:
providing at least one substrate; depositing a washcoat suitable for deposition on the substrate, the washcoat comprising at least one oxide solid further comprising at least one carrier metal oxide and at least one first ZPGM catalyst; depositing an overcoat suitable for deposition on the substrate, the overcoat comprising at least one second ZPGM catalyst; wherein the washcoat is deposited at about 60 g/L to about 120 g/L; wherein the overcoat is deposited at about 120 g/L; and wherein the substrate exhibits a back pressure of about 0.400 kPa to about 0.750 kPa when receiving an air flow of about 1.0 m3/min.