Next Patent: Plasma production device and method and RF driver circuit
Next Patent: Plasma production device and method and RF driver circuit
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[0001] Internal combustion engines produce large amounts of exhaust gases consisting primarily of carbon dioxide (CO
[0002] As a result, many present day engines, especially gasoline-fueled engines used for passenger automobiles and the like, operate very near stoichiometric conditions, where catalyst technology that allows simultaneous abatement of unburned HCs, CO, and NO
[0003] Although lean burn engines provide enhanced fuel economy, they have the disadvantage that conventional three-way catalysts (TWC) cannot adequately abate the NO
[0004] In another approach numerous research agencies have investigated the use of non-thermal plasma devices (“NTPDs”) in processes that reduce NO
[0005] In a third approach a two-stage process for reducing NO
[0006] Considerable research is currently underway toward the development of catalysts that are capable of decomposing or reducing the amount of NO
[0007] Much of this research focuses on using hydrocarbons in engine exhaust to reduce oxides of nitrogen under lean conditions. Interestingly, reacting NO with HC will result in limited N
[0008] Disclosed herein is a gas treatment system and a process for treating gas. The gas treatment system comprises: a non-thermal plasma reactor; and a catalyst composition disposed within said non-thermal plasma reactor, said catalyst composition comprising a MZr
[0009] A process for treating gas, comprises: exposing said gas to a plasma field; and exposing said gas to a catalyst composition comprising MZr
[0010] The above described and other features are exemplified by the following figures and detailed description.
[0011] Referring now to the figures wherein the like elements are numbered alike:
[0012]
[0013]
[0014]
[0015]
[0016]
[0017]
[0018] The exhaust gas system herein concerns a non-thermal plasma reactor and a catalyst composition. Not to be limited by theory, the catalyst composition contained within the non-thermal plasma reactor disclosed herein is believed to employ a two stage chemical phenomena that will result in reduction in the amount of NO
[0019] Exhaust gasses passing through the plasma will be ionized, and some will be converted NO to NO
[0020] This process enables the removal of greater than or equal to about 66% of the nitrogen oxides in the gas stream, with greater than or equal to about 78% preferred, and greater than or equal to about 90% especially preferred.
[0021] The catalyst composition preferably comprises a metal zirconium phosphate (MZr
[0022] For the metal-zirconium phosphate (MZr
[0023] In addition to the MZr
[0024] The catalyst(s) are preferably disposed within a non-thermal plasma reactor. The non-thermal plasma reactor can be any non-thermal plasma reactor, such as a glow discharge reactor, RF discharge reactor, pulsed corona reactor, dielectric-barrier discharge reactor, electrified packed bed reactor, surface discharge reactor, and the like, with a pulse corona reactor preferred. (See FIGS.
[0025] During use, the non-thermal plasma reactor, which is connected to a power supply, is capable of generating a non-thermal plasma. The plasma generated has a mixture of reactive free radicals, ions, and electrons that cause the ionization of exhaust gasses, as well as neutral species. In a non-thermal plasma, the electron mean energy is much higher than the ion and gas mean energies. A non-thermal plasma can be generated by a number of methods, including electrical fields, electron beams, irradiation with electromagnetic energy of appropriate intensity and wavelength, and the like.
[0026] Non-thermal plasmas for treatment of exhaust of internal combustion engines are preferably generated by electrical fields. In this type of generation, the plasma is generated by using a high voltage electrical field that approaches the breakdown voltage for the gas and gap geometry, usually about 20 kilovolts per centimeter (KV/cm) or so, where a local dissociation of electrons results. The electrons accelerate rapidly in the electrical field, striking and ionizing other molecules. The path of ionized molecules and electrons is called the streamer. If the voltage is stopped before or shortly after the streamer crosses the gas gap causing an arc discharge, then a non-thermal plasma of ions and free electrons is formed.
[0027] When the plasma reactor is a corona discharge reactor, the electrical field may be designed to be non-uniform. For example, a small wire can be disposed along the length of the reactor. The electrical field will then be very strong at the wire, but fall off rapidly with increasing distance from the wire and extinguishing before reaching the wall of the reactor, preventing formation of an arc. Alternatively, arc formation can be prevented by supplying a pulsed voltage.
[0028] In a dielectric barrier reactor, one or both electrodes are coated with a dielectric barrier. In this case, the streamer is extinguished on the surface of the dielectric material.
[0029] Packed bed plasma reactors are particularly preferred. In a packed bed reactor, the volume between the electrodes is packed with a dielectric material, for example, with beads. The electrical field is concentrated at the point of contact of the beads because of the difference in dielectric constants of the bead material and the gas.
[0030] The dielectric material of the non-thermal plasma reactors can be partially or wholly coated with the catalyst composition as described above. The packing can be a material such as zirconia, alumina, titanium, a ceramic, or the like, as well as mixtures comprising at least one of the foregoing materials. For example, the plasma reactor can be a reactor packed with zirconia beads and/or alumina beads that have been first coated with gamma-alumina and then impregnated with the catalyst composition. This maximizes the adsorbent surface to which the exhaust stream will be exposed.
[0031] Preferably, the plasma reactor is operated for a sufficient period of time to consume a minimal fraction of the engine energy consumption, with an energy consumption of about 3% or less preferred. The amount of energy consumption for the plasma reactor depends upon the particular type and geometry of reactor as well as the length of time it is operated to convert the NO
[0032] Optionally, a catalytic converter can be disposed in fluid communication with the non-thermal plasma reactor wherein at least a portion, and preferably all of the exhaust from the non-thermal plasma reactor passes through the catalytic converter. The catalytic converter can comprise various three-way catalysts and/or catalysts capable of reducing hydrocarbon and/or carbon monoxide emissions. Some possible catalysts include those described above as oxidation catalysts.
[0033] 81.9 grams zirconium oxynitrate and 244.7 grams of 14.0 wt % platinum ammine nitrate solution are mixed in a 2,000 milliliter (ml) beaker. 100 grams 2.0 N ammonium hydroxide is slowly dripped into the solution. 530 ml of 1 M ammonium dihydrogen phosphate is added dropwise to the solution. The resulting reaction mixture is reduced in volume to about 400 ml.
[0034] A complete non-thermal reactor is immersed into the solution. The reactor is withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor with flow passages coated with PtZr
[0035] Alternatively, about 1,000 grams of ceramic beads are immersed in the solution. The ceramic beads may be aluminum oxide, zirconium oxide, titanium oxide, and the like, as well as mixtures comprising at least one of the foregoing types of beads. The beads are withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor bed beads coated with PtZr
[0036] 232 grams of 50 wt % zirconium n-propoxide in n-propanol and 244.7 grams of a 14.0 wt % platinum ammine nitrate solution are mixed in a 2,000 ml beaker. 100 grams 2.0 N ammonium hydroxide is slowly dripped into the solution. 530 ml of 1 M ammonium dihydrogen phosphate is added dropwise to the solution. The resulting reaction mixture is reduced in volume to about 400 ml.
[0037] A complete non-thermal reactor is immersed into the solution. The reactor is withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor with flow passages coated with PtZr
[0038] Alternatively, about 1,000 grams of ceramic beads are immersed in the solution. The ceramic beads may be aluminum oxide, zirconium oxide, titanium oxide, and the like, as well as mixtures comprising at least one of the foregoing types of beads. The beads are withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor bed beads coated with PtZr
[0039] 81.9 grams zirconium oxynitrate and 195.5 grams of a 10.0 wt % silver ammine nitrate solution are mixed in a 2,000 ml beaker. 100 grams 2.0 N ammonium hydroxide is slowly dripped into the solution. 530 ml of 1 M ammonium dihydrogen phosphate is added dropwise to the solution. The resulting reaction mixture is reduced in volume to about 400 ml.
[0040] A complete non-thermal reactor is immersed into the solution. The reactor is withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor with flow passages coated with AgZr
[0041] Alternatively, about 1,000 grams of ceramic beads are immersed in the solution. The ceramic beads may be aluminum oxide, zirconium oxide, titanium oxide, and the like, as well as mixtures comprising at least one of the foregoing types of beads. The beads are withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor bed beads coated with AgZr
[0042] 26.2 grams of titanium isopropoxide, 180.9 grams of 50 wt % zirconium n-propoxide Zr(OC
[0043] A complete non-thermal reactor is immersed into the solution. The reactor is withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor with flow passages coated with PtTiZr
[0044] Alternatively, about 1,000 grams of ceramic beads are immersed in the solution. The ceramic beads may be aluminum oxide, zirconium oxide, titanium oxide, and the like, as well as mixtures comprising at least one of the foregoing types of beads. The beads are withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor bed beads coated with PtTiZr
[0045] 19.2 grams of aluminum isopropoxide, 184.0 grams of 50 wt % zirconium n-propoxide in n-propanol, and 259.3 grams of a 14.0 wt % platinum ammine nitrate solution are mixed in a 2,000 ml beaker. 100 grams 2.0 N ammonium hydroxide is slowly dripped into the solution. 530 ml of 1 M ammonium dihydrogen phosphate is added dropwise to the solution. The resulting reaction mixture is reduced in volume to about 300 ml.
[0046] A complete non-thermal reactor is immersed into the solution. The reactor is withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor with flow passages coated with PtAlZr
[0047] Alternatively, about 1000 grams of ceramic beads are immersed in the solution. The ceramic beads may be aluminum oxide, zirconium oxide, titanium oxide, and the like, as well as mixtures comprising at least one of the foregoing types of beads. The beads are withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor bed beads coated with PtAlZr
[0048] 81.9 grams zirconium oxynitrate, 195.5 grams of a 10.0 wt % silver ammine nitrate and 26.8 grams of 10.0 wt % palladium ammine nitrate solution are mixed in a 2,000 ml beaker. 100 grams 2.0 N ammonium hydroxide is slowly dripped into the solution. 530 ml of 1 M ammonium dihydrogen phosphate is added dropwise to the solution. The resulting reaction mixture is reduced in volume to about 400 ml.
[0049] A complete non-thermal reactor is immersed into the solution. The reactor is withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor with flow passages coated with (Ag/Pd)Zr4
[0050] Alternatively, about 1,000 grams of ceramic beads are immersed in the solution. The ceramic beads may be aluminum oxide, zirconium oxide, titanium oxide, and the like, as well as mixtures comprising at least one of the foregoing types of beads. The beads are withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor bed beads coated with (Ag/Pd)Zr4
[0051] 81.9 grams zirconium oxynitrate and 244.7 grams of 14.0 wt % platinum ammine nitrate solution are mixed in a 2,000 ml beaker. 100 grams 2.0 N ammonium hydroxide is slowly dripped into the solution. 530 ml of 1 M ammonium dihydrogen phosphate is added dropwise to the solution. The resulting reaction mixture is reduced in volume to about 400 ml. 100 grams of 25 wt % alkaline colloidal alumina and 3.6 grams of 14.0 wt % platinum ammine nitrate solution are added to the PtZr
[0052] A complete non-thermal reactor is immersed into the solution. The reactor is withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor with flow passages coated with 80 wt % PtZr
[0053] Alternatively, about 1,000 grams of ceramic beads are immersed in the solution. The ceramic beads may be aluminum oxide, zirconium oxide, titanium oxide, and the like, as well as mixtures comprising at least one of the foregoing types of beads. The beads are withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor bed beads coated with 80 wt % PtZr
[0054] 81.9 grams zirconium oxynitrate and 244.7 grams of 14.0 wt % platinum ammine nitrate solution are mixed in a 2,000 ml beaker. 100 grams 2.0 N ammonium hydroxide is slowly dripped into the solution. 530 ml of 1 M ammonium dihydrogen phosphate is added dropwise to the solution. The resulting reaction mixture is reduced in volume to about 400 ml. 100 grams of 25 wt % alkaline colloidal alumina, 11.16 g barium isopropoxide and 3.6 grams of 14.0 wt % platinum ammine nitrate solution are added to the PtZr
[0055] A complete non-thermal reactor is immersed into the solution. The reactor is withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor with flow passages coated with 80 wt % PtZr
[0056] Alternatively, about 1,000 grams of ceramic beads are immersed in the solution. The ceramic beads may be aluminum oxide, zirconium oxide, titanium oxide, and the like, as well as mixtures comprising at least one of the foregoing types of beads. The beads are withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor bed beads coated with 80 wt % PtZr
[0057] 81.9 grams zirconium oxynitrate and 244.7 grams of 14.0 wt % platinum ammine nitrate solution are mixed in a 2000 ml beaker. 100 grams 2.0 N ammonium hydroxide is slowly dripped into the solution. 530 ml of 1 M ammonium dihydrogen phosphate is added dropwise to the solution. The resulting reaction mixture is reduced in volume to about 400 ml. 168 grams of 15 wt % alkaline colloidal tin oxide, 11.16 g barium isopropoxide, and 3.6 grams of 14.0 wt % platinum ammine nitrate solution are added to the PtZr
[0058] A complete non-thermal reactor is immersed into the solution. The reactor is withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor with flow passages coated with 80 wt % Ptzr
[0059] Alternatively, about 1,000 grams of ceramic beads are immersed in the solution. The ceramic beads may be aluminum oxide, zirconium oxide, titanium oxide, and the like, as well as mixtures comprising at least one of the foregoing types of beads. The beads are withdrawn and calcined at 725° C. for 4 hours. The resulting product is non-thermal plasma reactor bed beads coated with 80 wt % PtZr
[0060] Some suitable zirconium sources are zirconium dioxide, zirconium oxychloride, zirconium tert-butoxide, zirconium ethoxide, zirconium isopropoxide, colloidal zirconium oxide, and the like, as well as mixtures comprising at least one of the foregoing sources.
[0061] Some suitable phosphate sources are phosphoric acid, ammonium dihydrogen phosphate, diammonium hydrogen phosphate, triammonium phosphate, ammonium phosphate, and the like, as well as mixtures comprising at least one of the foregoing sources.
[0062] Some suitable precious metal sources are nitrates such as platinum nitrate, palladium nitrate, iridium nitrate, rhodium nitrate, ruthenium nitrate or silver nitrate, and the like, as well as mixtures comprising at least one of the foregoing sources. Chlorides such as platinum chloride, palladium chloride, iridium chloride, rhodium chloride, ruthenium chloride, silver chloride, and the like, as well as mixtures comprising at least one of the foregoing chlorides, may be employed. Ammines such as platinum ammine nitrate, platinum ammine chloride, platinum ammine hydroxide, palladium ammine nitrate, palladium ammine chloride, palladium ammine hydroxide, rhodium ammine nitrate, rhodium ammine chloride, rhodium ammine hydroxide, ruthenium ammine nitrate, ruthenium ammine chloride, ruthenium ammine hydroxide, iridium ammine nitrate, iridium ammine chloride, iridium anunine hydroxide, silver ammine nitrate, silver ammine chloride, and the like, as well as mixtures comprising at least one of the foregoing ammines, may also be employed. Additionally, silver acetate, silver carbonate, silver citrate, silver oxylate, and the like, as well as mixtures comprising at least one of the foregoing, may also be used.
[0063] Some suitable titanium sources are titanium dioxide, titanium oxychloride, titanium oxynitrate, titanium isobutoxide, titanium n-butoxide, titanium tert-butoxide, titanium ethoxide, titanium isopropoxide, titanium methoxide, titanium n-propoxide, colloidal titanium oxide, and the like, as well as mixtures comprising at least one of the foregoing sources.
[0064] Some suitable aluminum sources are aluminum oxide, aluminum hydroxide, aluminum methoxide, aluminum n-butoxide, aluminum ethoxide, alkaline colloidal alumina, aluminum isopropoxide, and the like, as well as mixtures comprising at least one of the foregoing sources.
[0065] Some suitable barium sources are barium acetate, barium ethoxide, barium isopropoxide, barium 2-methoxide, barium zirconium isopropoxide, and the like, as well as mixtures comprising at least one of the foregoing.
[0066] Some suitable tin sources are tin oxide colloidal in water stabilized by NH4+, pH 9-11, tin acetate, tin ethoxide, tin isopropoxide, tin 2-methoxide, and the like, as well as mixtures comprising at least one of the foregoing sources.
[0067] Additionally directing agents such as quaternary alkylammonium ions, and the like, may be used.
[0068] Zirconium phosphate possesses the following advantageous characteristics: (1) density of about 2.83 g/cc; (2) an open porosity percentage of about 15% to about 20%; (3) a thermal conductivity value of about 6.2 BTU-in/hr-ft
[0069] A catalyst composition comprising a metal zirconium phosphate provides reduced NO
[0070] A standard catalyst of platinum on alumina lasts 0 hours in the plasma region of the nonthermal plasma reactor. The described platinum zirconium phosphate lasts for at least 25 hours, when the test was stopped. It is believed, due to the adhesion and visual observation and comparisons, the metal zirconium phosphate (e.g., platinum zirconium phosphate) on alumina plates will have about 2,000 hour or greater durability. Typical exhaust catalysts such as platinum on gamma alumina do not adhere to dense, non-porous alumina plates or beads. In contrast, the metal phosphate catalyst exhibits good adherence to alumina plates and beads, even in non-thermal plasma reactor space velocities (e.g., velocities up to about 100 times greater than a standard catalyst bed). In a rub test, alumina deposited on an alumina plate will rub off with the use of a finger, while the metal phosphate deposited on the alumina plate can not be rubbed of with a finger.
[0071] While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.