Diesel oxidation catalyst and exhaust system

Patent metadata

Field	Value
Publication number	US-10286359-B2
Application number	US-201514603537-A
Country	US
Kind code	B2
Filing date	Jan 23, 2015
Priority date	Jan 23, 2014
Publication date	May 14, 2019
Grant date	May 14, 2019

Abstract

An oxidation catalyst for treating an exhaust gas from a diesel engine, which oxidation catalyst comprises: a first washcoat region comprising platinum (Pt), manganese (Mn) and a first support material; a second washcoat region comprising a platinum group metal (PGM) and a second support material; and a substrate having an inlet end and an outlet end; wherein the second washcoat region is arranged to contact the exhaust gas at the outlet end of the substrate and after contact of the exhaust gas with the first washcoat region.

First claim

The invention claimed is:

1. An oxidation catalyst for treating an exhaust gas from a diesel engine, wherein the oxidation catalyst comprises:
a first washcoat zone for oxidizing carbon monoxide (CO) and hydrocarbons (HCs), which comprises platinum (Pt) and manganese (Mn) disposed or supported on a first support material, wherein the first support material comprises a refractory oxide comprising silica-alumina or alumina doped with silica;
a second washcoat zone for oxidizing nitric oxide (NO) to nitrogen dioxide (NO 2 ), which comprises a platinum group metal (PGM), and manganese (Mn) disposed or supported on a second support material, wherein the second support material comprises a refractory oxide comprising alumina, and the platinum group metal (PGM) is selected from the group consisting of (i) platinum and (ii) a combination of platinum and palladium in a ratio of platinum to palladium by total weight of ≥2:1, and the second washcoat zone is substantially free of a zeolite; and
a flow-through substrate monolith or a filtering substrate monolith having a length defined by an inlet end and an outlet end;
wherein the first washcoat zone is compositionally different from the second washcoat zone, and wherein the second washcoat zone is disposed at an outlet end of the substrate monolith, and the first washcoat zone is disposed at an inlet end of the substrate monolith and wherein the first washcoat zone has a length of 10 to 90% of the length of the substrate monolith.

2. The oxidation catalyst of claim 1 , wherein the first washcoat zone and the second washcoat zone are disposed on the substrate monolith as a single layer.

3. The oxidation catalyst of claim 1 , wherein the first washcoat zone further comprises palladium.

4. The oxidation catalyst of claim 3 , wherein the first washcoat zone comprises a ratio of platinum to palladium by total weight of ≥1:1.

5. The oxidation catalyst of claim 1 , wherein the second support material comprises alumina doped with silica.

6. The oxidation catalyst of claim 1 , wherein the second washcoat zone comprises platinum (Pt) as the only platinum group metal (PGM).

7. The oxidation catalyst of claim 1 , wherein at least one of the first washcoat zone and the second washcoat zone is substantially free of palladium (Pd) disposed or supported on the second support material.

8. The oxidation catalyst of claim 1 , wherein the second support material comprises a refractory oxide comprising silica-alumina.

9. The oxidation catalyst of claim 1 , wherein the first washcoat zone comprises ≥40% of the total concentration of platinum group metal.

10. The oxidation catalyst of claim 1 , wherein the total concentration of platinum in the first washcoat zone is greater than the total concentration of platinum group metal (PGM) in the second washcoat zone.

11. The oxidation catalyst of claim 1 , wherein the first washcoat zone has a length of from 10 to 45% of the length of the substrate monolith.

12. The oxidation catalyst of claim 1 , wherein the first washcoat zone and the second washcoat zone each has a length, wherein the length of the first washcoat zone is greater than the length of the second washcoat zone.

13. The oxidation catalyst of claim 1 , wherein at least one of the first washcoat region and the second washcoat region do not comprise rhodium.

14. The oxidation catalyst of claim 1 , wherein the first washcoat zone and the second washcoat zone are disposed directly on to the substrate monolith.

15. The oxidation catalyst of claim 1 further comprising a third washcoat layer disposed directly on to the substrate monolith, wherein the first washcoat zone and the second washcoat zone are each disposed or supported on the third washcoat layer, and wherein the third washcoat layer comprises a zeolite catalyst comprising a noble metal and a zeolite, wherein the noble metal is selected from the group consisting of palladium (Pd), platinum (Pt), rhodium (Rh), gold (Au), silver (Ag), iridium (Ir), ruthenium (Ru) and mixtures of two or more thereof.

16. The oxidation catalyst of claim 1 , wherein the first washcoat zone does not comprise a zeolite.

17. The oxidation catalyst of claim 1 , wherein the first washcoat zone comprises a zeolite, in a total amount of from 0.2 to 3.00 g in −3 .

18. An exhaust system for a diesel engine comprising an oxidation catalyst as defined in claim 1 and an emissions control device.

19. The exhaust system of claim 18 , wherein the emissions control device is selected from the group consisting of a diesel particulate filter, a selective catalytic reduction catalyst, a catalyzed soot filter, a selective catalytic reduction filter catalyst, and combinations of two or more thereof.

20. A vehicle comprising a diesel engine and an exhaust system of claim 18 .

Assignees

• Johnson Matthey Plc

Inventors

• Chiffey Andrew Francis
• Goodwin John Benjamin
• Leeland James
• Moreau Francois

Classifications

• B01J23/34

  Manganese · CPC title

• B01D53/94

  by catalytic processes · CPC title

• F01N3/28

  Construction of catalytic reactors · CPC title

• B01J23/42

  Platinum · CPC title

• B01J23/58

  with alkali- or alkaline earth metals · CPC title