ZPGM Catalyst Systems and Methods of Making Same

A zero platinum group metal (ZPGM) catalyst system, comprising:

• a substrate;
• a washcoat suitable for deposition on the substrate, comprising at least one oxide solid selected from the group consisting of at least one of a carrier metal oxide, and a ZPGM catalyst;
• and
• an overcoat suitable for deposition on the substrate, comprising at least one overcoat oxide solid selected from the group consisting of at least one of a carrier metal oxide, and a ZPGM catalyst;
• wherein at least one of the ZPGM catalysts comprises at least one perovskite structured compound having a formula ABO3, wherein A is selected from the group consisting of at least one of, magnesium, calcium, barium, strontium, and mixtures thereof, and wherein B comprises at least one transition metal.

A zero platinum group metal (ZPGM) catalyst system, comprising:

• a substrate;
• a washcoat suitable for deposition on the substrate, comprising at least one oxide solid selected from the group consisting at least one of a carrier metal oxide, and a ZPGM catalyst;
• and
• an overcoat suitable for deposition on the substrate, comprising at least one overcoat oxide solid selected from the group consisting at least one of a carrier metal oxide, and a ZPGM catalyst;
• wherein at least one of the ZPGM catalysts comprises at least one spinel structured compound having the formula AB2O4, wherein each of A and B is selected from the group consisting at least one of aluminum, magnesium, manganese, gallium, nickel, copper, cobalt, molybdenum, vanadium, iron, chromium, titanium, and tin.

A method of making a zero platinum group metal (ZPGM) catalyst system, comprising:

• depositing at least one washcoat and at least one transition metal salt on to a substrate;
• heat treating the washcoat for about 2 to about 6 hours at about 300° C. to about 700° C.;
• depositing at least one overcoat comprising an overcoat oxide solid selected from the group consisting at least one of a carrier metal oxide, and a ZPGM catalyst;
• wherein the ZPGM catalyst comprises at least one spinel structured compound having the formula AB2O4, wherein each of A and B is selected from the group consisting of at least one of aluminum, magnesium, manganese, gallium, nickel, copper, cobalt, molybdenum, vanadium, iron, chromium, titanium and tin.

An apparatus for reducing emissions from an engine having associated therewith an exhaust system, the apparatus providing a reaction effective for selective catalytic reduction, comprising:

• at least one source of exhaust comprising hydrocarbons and carbon monoxide;
• and
• a catalyst system, comprising:
• a substrate;
• a catalyst;
• a washcoat suitable for deposition on the substrate;
• and
• an overcoat suitable for deposition on the substrate or the washcoat;
• wherein the catalyst is selected from the group consisting at least one of copper, cerium, manganese, and silver;
• and
• wherein the catalyst is suitable for deposition on a coat selected from the group consisting of at least one of the washcoat and the overcoat.

A zero platinum group metal (ZPGM) catalyst system, comprising:

• a substrate;
• a washcoat suitable for deposition on the substrate, comprising at least an OSM and at least one oxide solid selected from the group consisting of at least one of a carrier metal oxide, and a ZPGM catalyst;
• and
• an overcoat suitable for deposition on the substrate, comprising at least an OSM and at least one overcoat oxide solid selected from the group consisting of at least one of a carrier metal oxide, and a ZPGM catalyst;
• wherein at least one of the ZPGM catalysts comprises either a perovskite structured compound or a spinel structured compound.