Catalysed substrate monolith

Patent metadata

Field	Value
Publication number	US-10207254-B2
Application number	US-201715447294-A
Country	US
Kind code	B2
Filing date	Mar 2, 2017
Priority date	Dec 12, 2011
Publication date	Feb 19, 2019
Grant date	Feb 19, 2019

Abstract

A catalyzed substrate monolith 12 for use in treating exhaust gas emitted from a lean-burn internal combustion engine, which catalyzed substrate monolith 12 comprising a first washcoat coating 16 and a second washcoat coating 18 , wherein the first washcoat coating comprises a catalyst composition comprising at least one platinum group metal (PGM) and at least one support material for the at least one PGM, wherein at least one PGM in the first washcoat coating is liable to volatilize when the first washcoat coating is exposed to relatively extreme conditions including relatively high temperatures, wherein the second washcoat coating comprises at least one metal oxide for trapping volatilized PGM and wherein the second washcoat coating is oriented to contact exhaust gas that has contacted the first washcoat coating.

First claim

The invention claimed is:

1. A catalyzed substrate monolith for use in treating exhaust gas emitted from a lean-burn internal combustion engine comprising:
a first washcoat coating comprising a catalyst composition comprising platinum and palladium and at least one support material for the platinum and palladium,
wherein at least one of platinum and palladium in the first washcoat coating is liable to volatilize when the first washcoat coating is exposed to temperatures of 700° C. or greater, and

a second washcoat coating comprising a catalyst composition comprising at least one metal selected from the group consisting of palladium, silver, gold and combinations of any two or more thereof, and at least one metal oxide for trapping at least one of volatilised platinum and palladium,
wherein the at least one metal oxide supports the at least one metal, and
wherein the second washcoat coating is oriented to contact exhaust gas that has contacted the first washcoat coating, and

wherein the substrate monolith is a flow-through substrate monolith, and
wherein a weight ratio of Pt:Pd in the catalyzed substrate monolith is <2.

2. The catalyzed substrate monolith of claim 1 , wherein the at least one metal oxide comprises a metal oxide selected from the group consisting of optionally stabilised alumina, amorphous silica-alumina, optionally stabilised zirconia, ceria, titania, an optionally stabilised ceria-zirconia mixed oxide and mixtures of any two or more thereof.

3. The catalyzed substrate monolith of claim 1 , wherein the first washcoat coating is disposed in a first washcoat zone of the substrate monolith and the second washcoat coating is disposed in a second washcoat zone of the substrate monolith, wherein there is substantially no overlap between the first washcoat zone and the second washcoat zone.

4. The catalyzed substrate monolith of claim 1 , wherein the second washcoat coating is disposed in a layer above the first washcoat coating.

5. An exhaust system for a lean-burn internal combustion engine, comprising a catalyzed substrate monolith of claim 1 as a first catalyzed substrate monolith.

6. The exhaust system of claim 5 , comprising a second catalyzed substrate monolith comprising a selective catalytic reduction (SCR) catalyst, wherein the second catalyzed substrate monolith is disposed downstream from the first catalyzed substrate monolith.

7. The exhaust system of claim 6 , comprising an injector for injecting a nitrogenous reductant into exhaust gas between the first catalyzed substrate monolith and the second catalyzed substrate monolith.

8. The exhaust system of claim 5 , comprising a third substrate monolith, wherein the third substrate monolith is a filtering substrate monolith and is disposed downstream of the second catalyzed substrate monolith.

9. The exhaust system of claim 8 , wherein the third substrate monolith comprises an oxidation catalyst.

Assignees

• Johnson Matthey Plc

Inventors

• Blakeman Philip Gerald
• Brown Gavin Michael
• Chatterjee Sougato
• Chiffey Andrew Francis
• Gast Jane
• Phillips Paul Richard
• Rajaram Raj Rao
• Spreitzer Glen
• Walker Andrew Peter

Classifications

• B01D2258/012

  Diesel engines and lean burn gasoline engines · CPC title

• B01J2229/42

  Addition of matrix or binder particles · CPC title

• B01D2255/106

  Gold · CPC title

• B01J2229/186

  not in framework positions · CPC title

• B01D2255/2092

  Aluminium · CPC title