Catalyst and method of manufacture

Abstract

A catalyst system comprising a first catalytic composition comprising a homogeneous solid mixture containing at least one catalytic metal and at least one metal inorganic support. The pores of the solid mixture have an average diameter in a range of about 1 nanometer to about 15 nanometers. The catalytic metal comprises nanocrystals.

1 . A catalyst system comprising:
 a first catalytic composition comprising a homogeneous solid mixture containing at least one catalytic metal and at least one metal inorganic support; wherein the pores of the solid mixture have an average diameter in a range of about 1 nanometer to about 15 nanometers; and   wherein the catalytic metal comprises nanocrystals.   
     
     
         2 . The catalyst system of  claim 1 , wherein the nanocrystals have a particle size distribution of less than about 20 percent. 
     
     
         3 . The catalyst system of  claim 1 , wherein the catalytic metal comprises transition metals. 
     
     
         4 . The catalyst system of  claim 1 , wherein the catalytic metal comprises silver, platinum, gold, palladium, iron, nickel, cobalt, gallium, indium, ruthenium, rhodium, osmium, iridium, or combinations of at least two of the foregoing metals. 
     
     
         5 . The catalyst system of  claim 1 , wherein the catalytic metal comprises silver. 
     
     
         6 . The catalyst system of  claim 1 , wherein the catalytic metal is present in an amount less than or equal to about 6 mole percent based on the weight of the homogenous solid mixture. 
     
     
         7 . The catalyst system of  claim 1 , wherein the system provides a NO x  conversion of at least about 40 percent based on the initial amount of NO x  at a temperature of about 275 degrees C. to about 425 degrees C. 
     
     
         8 . The catalyst system of  claim 7 , wherein the system provides a NO x  conversion of about 40 percent to about 70 percent based on the initial amount of NO x  at a temperature of about 325 degrees C. to about 375 degrees C. 
     
     
         9 . The catalyst system of  claim 1 , wherein the metal inorganic support comprises alumina. 
     
     
         10 . The catalyst system of  claim 1 , further comprising at least one promoting metal. 
     
     
         11 . The catalyst system of  claim 10 , wherein the at least one promoting metal is selected from the group consisting of gallium, indium, gold, vanadium, zinc, tin, bismuth, cobalt, molybdenum, and tungsten. 
     
     
         12 . The catalyst system of  claim 1 , further comprising a second catalytic composition, wherein the second catalytic composition comprises:
 (i) a zeolite, or   (ii) a first catalytic material disposed on a first substrate, the first catalytic material comprising an element selected from the group consisting of tungsten, titanium, and vanadium.   
     
     
         13 . The catalyst system of  claim 12 , further comprising a third catalytic composition, wherein the third catalytic composition comprises: a second catalytic material disposed on a second substrate, wherein the second catalytic material is selected from the group consisting of platinum, palladium, ruthenium, osmium, and iridium. 
     
     
         14 . The catalyst system of  claim 1 , further comprising a delivery system configured to deliver a reductant. 
     
     
         15 . The catalyst system of  claim 14 , wherein the reductant is one or more of diesel, ultra-low sulfur diesel, ethanol, gasoline, and octane. 
     
     
         16 . The catalyst system of  claim 14 , wherein the reductant is an oxygenated hydrocarbon. 
     
     
         17 . The catalyst system of  claim 14 , wherein the delivery system further comprises a co-reductant. 
     
     
         18 . The catalyst system of  claim 17 , wherein the co-reductant is hydrogen. 
     
     
         19 . A catalyst system comprising:
 a first catalytic composition comprising;
 a homogeneous solid mixture containing at least one catalytic metal and at least one metal inorganic support; wherein the pores of the solid mixture have an average diameter in a range of about 1 nanometer to about 15 nanometers; wherein the catalytic metal comprises nanocrystals; and 
 at least one promoting metal; 
   a second catalytic composition comprising;
 (i) a zeolite, or 
 (ii) a first catalytic material disposed on a first substrate, the first catalytic material comprising an element selected from the group consisting of tungsten, titanium, and vanadium. 
   
     
     
         20 . The catalyst system of  claim 19 , wherein the catalytic metal comprises alkali metals, alkaline earth metals, transition metals, or a combination thereof. 
     
     
         21 . The catalyst system of  claim 19 , wherein the metal inorganic support comprises alumina. 
     
     
         22 . The catalyst system of  claim 19 , wherein the at least one promoting metal is selected from the group consisting of gallium, indium, gold, vanadium, zinc, tin, bismuth, cobalt, molybdenum, and tungsten. 
     
     
         23 . The catalyst system of  claim 19 , wherein the zeolite comprises zeolite Y, zeolite beta, mordenite, ferrierite, ZSM-5, ZSM-12, ZSM-22, ZSM-23, ZSM-34, ZSM-35, ZSM-38, ZSM-48, ZSM-50, ZSM-57, zeolite A, zeolite X or a combination comprising at least two of the foregoing zeolites. 
     
     
         24 . The catalyst system of  claim 19 , further comprising a delivery system configured to deliver a reductant. 
     
     
         25 . The catalyst system of  claim 24 , wherein the delivery system further comprises a co-reductant. 
     
     
         26 . A method comprising:
 providing nanocrystals of at least one catalytic metal;   incorporating the nanocrystals in at least one metal inorganic support; and   forming a first catalytic composition comprising a homogeneous solid mixture containing at least one catalytic metal and at least one metal inorganic support; wherein the pores of the solid mixture have an average diameter in a range of about 1 nanometer to about 15 nanometers, wherein the catalytic metal comprises nanocrystals.   
     
     
         27 . The method of  claim 26 , wherein the providing nanocrystals of the at least one catalytic metal comprises preparing the nanocrystals of the catalytic metal in the presence of a surfactant. 
     
     
         28 . The method of  claim 26 , wherein the providing nanocrystals of the catalytic metal is carried out a temperature in a range of about 10 degrees C. to about 200 degrees C. 
     
     
         29 . The method of  claim 26 , wherein the providing nanocrystals of the catalytic metal is carried out under vacuum in a range of about 0.5 millimeter of mercury to about 10 millimeter of mercury. 
     
     
         30 . The method of  claim 26 , wherein the nanocrystals have a particle size distribution of less than about 20 percent. 
     
     
         31 . The method of  claim 26 , wherein the catalytic metal is present in an amount less than or equal to about 6 mole percent based on the weight of the homogenous solid mixture. 
     
     
         32 . An exhaust system comprising:
 a fuel delivery system configured to deliver a fuel to an engine;   an exhaust stream path configured to receive an exhaust stream from the engine;   a reductant delivery system configured to deliver a reductant to the exhaust stream path; and   a catalyst system disposed in the exhaust stream path, wherein the catalyst system comprises:
 a first catalytic composition comprising; 
 a homogeneous solid mixture containing at least one catalytic metal and at least one metal inorganic support; wherein the pores of the solid mixture have an average diameter in a range of about 1 nanometer to about 15 nanometers; wherein the catalytic metal is in the form of nanocrystals. 
   
     
     
         33 . A catalyst system comprising:
 a homogeneous solid mixture containing at least one catalytic metal and at least one metal inorganic support; wherein the pores of the solid mixture have an average diameter in a range of about 1 nanometer to about 15 nanometers;   wherein the catalytic metal comprises nanocrystals;   wherein the nanocrystals have a particle size distribution of less than about 20 percent; and   wherein the catalytic metal is present in an amount less than or equal to about 6 mole percent based on the weight of the homogenous solid mixture.