US 2026/0175207 A1 · MULTI-PHASE CATALYST SYSTEM FOR SUSTAINABLE REDUCTION OF NITROUS OXIDE EMISSIONS

Abstract

A multi-phase catalyst structure for reducing nitrous oxide emissions in exhaust streams is disclosed. The structure includes a primary phase with nickel-copper alloy nanoparticles (10-50 nm, Ni: Cu ratio 3:1 to 4:1) supported on modified alumina (150-200 m2/g) and a manganese oxide promoter; a secondary phase with iron-chromium oxide spinel particles supported on silicon carbide (0.6-0.8 cm3/g) and a zinc oxide modifier; and a tertiary phase with copper-cobalt mixed oxides supported on titanium dioxide (2-50 nm pore size) and a magnesium oxide stabilizer. Interface regions optimize gas flow and phase interactions, while a distributed pore structure facilitates efficient gas diffusion. The system achieves at least 90% nitrous oxide reduction efficiency under optimal conditions using sustainable materials. Additionally, apparatuses for exhaust gas flow optimization and thermal management are disclosed, featuring smart flow architectures, uniform heat distribution, emergency cooling channels, and phase-change material chambers for enhanced catalytic performance and durability.

Claims20

Dependent claims

A multi-phase catalyst structure for reducing nitrous oxide emissions in an exhaust stream, comprising:

a primary catalyst phase, including:
nickel-copper alloy nanoparticles having a particle size of 10-50 nm, a Ni:
Cu ratio of 3:1 to 4:1, and supported on modified alumina with a surface area of 150-200 m2/g;
and
a manganese oxide promoter distributed within the primary catalyst phase to enhance catalytic activity;
a secondary catalyst phase, including:
iron-chromium oxide spinel particles supported on silicon carbide with a pore volume of 0.6-0.8 cm3/g;
and
a zinc oxide modifier integrated into the secondary catalyst phase to improve stability and performance;
a tertiary catalyst phase, including:
copper-cobalt mixed oxides supported on titanium dioxide with a pore size distribution of 2-50 nm;
and
a magnesium oxide stabilizer incorporated into the tertiary catalyst phase to enhance thermal durability;
interface regions between the primary, secondary, and tertiary catalyst phases, configured to optimize gas flow and promote interaction between the phases;
a pore structure distributed across the multi-phase catalyst structure, comprising micropores and mesopores to facilitate efficient gas diffusion and catalytic reactions;
wherein the multi-phase catalyst structure is designed to achieve a nitrous oxide reduction efficiency of at least 90% under optimal operating conditions and is constructed from sustainable and readily available materials.

13 more elements

A method for managing thermal conditions in a catalytic converter system, comprising:

performing a step of defining an interior chamber within a housing, the interior chamber being configured to accommodate a catalyst structure;
performing a step of integrating an advanced thermal management system with the housing, the advanced thermal management system comprising:
ensuring uniform temperature distribution across the catalyst structure by operating a heat distribution network;
monitoring real-time temperature data by positioning temperature monitoring points within the housing;
activating emergency cooling channels operatively connected to the housing during overheating conditions to prevent thermal damage;
optimizing heat transfer and maintaining stable operating temperatures by configuring thermal gradient zones;
minimizing heat loss and improving thermal efficiency by surrounding the housing with insulation layers;
and
stabilizing temperature fluctuations by storing and releasing thermal energy through a phase-change material chamber integrated within the thermal management system;
wherein the method is adapted to operate the catalytic converter system within a temperature range of 150° C. to 900 °C., ensuring efficient catalytic reactions and prolonged durability of the catalyst structure under varying exhaust gas conditions.

7 more elements

Dependencies are inferred from the claim text.

Multi-phase catalyst system for sustainable reduction of nitrous oxide emissions

Life of this patent

Multi-phase catalyst system for sustainable reduction of nitrous oxide emissions

Life of this patent

Abstract

Claims20