Noble metal-molecular sieve catalysts

Patent metadata

Field	Value
Publication number	US-10618003-B2
Application number	US-201414563382-A
Country	US
Kind code	B2
Filing date	Dec 8, 2014
Priority date	Dec 6, 2013
Publication date	Apr 14, 2020
Grant date	Apr 14, 2020

Abstract

Exhaust gas catalysts are disclosed. One exhaust gas catalyst comprises a noble metal and a molecular sieve, and has an infrared spectrum having a characteristic absorption peak from 750 cm−1 to 1050 cm−1 in addition to the absorption peaks for the molecular sieve itself. The exhaust gas catalyst also comprises a noble metal and a molecular sieve, having greater than 5 percent of the noble metal amount located inside pores of the molecular sieve. The exhaust gas catalyst also comprises a first and second molecular sieve catalyst. The first molecular sieve catalyst comprises a first noble metal and a first molecular sieve, and the second molecular sieve catalyst comprises a second noble metal and a second molecular sieve. The first and second molecular sieves are different. The invention also includes exhaust systems comprising the exhaust gas catalysts, and a method for treating exhaust gas utilizing the exhaust gas catalysts.

First claim

We claim:

1. An exhaust gas catalyst effective to adsorb NO x and hydrocarbons (HC) at or below a low temperature and to convert and release the adsorbed NO x and HC at temperatures above the low temperature, said exhaust gas catalyst comprising a first molecular sieve catalyst and a second molecular sieve catalyst, wherein the first molecular sieve catalyst comprises a first noble metal and a first molecular sieve, and the second molecular sieve catalyst comprises a second noble metal and a second molecular sieve, wherein the first molecular sieve is different than the second molecular sieve, and wherein greater than 5 percent of the total amount of first noble metal is located inside pores of the first molecular sieve and greater than 5 percent of the total amount of second noble metal is located inside pores of the second molecular sieve.

2. The exhaust gas catalyst of claim 1 wherein the first noble metal and the second noble metal are independently selected from the group consisting of platinum, palladium, rhodium, gold, silver, iridium, ruthenium, osmium, and mixtures thereof.

3. The exhaust gas catalyst of claim 2 wherein the first noble metal and the second noble metal are both palladium.

4. The exhaust gas catalyst of claim 1 wherein the first molecular sieve is a small pore molecular sieve selected from the group of Framework Type consisting of ACO, AEI, AEN, AFN, AFT, AFX, ANA, APC, APD, ATT, CDO, CHA, DDR, DFT, EAB, EDI, EPI, ERI, GIS, GOO, IHW, ITE, ITW, LEV, KFI, MER, MON, NSI, OWE, PAU, PHI, RHO, RTH, SAT, SAV, SIV, THO, TSC, UEI, UFI, VNI, YUG AND ZON, and intergrowths of two or more.

5. The exhaust gas catalyst of claim 4 wherein the small pore molecular sieve is selected from the group Framework Type consisting of AEI and CHA.

6. The exhaust gas catalyst of claim 1 wherein the second molecular sieve is a medium or large pore molecular sieve selected from the group consisting of BEA and MFI.

7. The exhaust gas catalyst of claim 1 wherein the exhaust gas catalyst is coated onto a flow-through or filter substrate.

8. The exhaust gas catalyst of claim 1 wherein the exhaust gas catalyst is extruded to form a flow-through or filter substrate.

9. The exhaust gas catalyst of claim 1 wherein the exhaust gas catalyst comprises a first layer comprising the first molecular sieve catalyst and a second layer comprising the second molecular sieve catalyst.

10. The exhaust gas catalyst of claim 1 wherein the exhaust gas catalyst comprises a first zone comprising the first molecular sieve catalyst and a second zone comprising the second molecular sieve catalyst.

11. The exhaust gas catalyst of claim 10 wherein the first zone comprising the first molecular sieve catalyst is located on a separate brick than the second zone comprising the second molecular sieve catalyst.

12. An exhaust system for internal combustion engines comprising the exhaust gas catalyst of claim 1 and a catalyst component selected from the group consisting a selective catalytic reduction (SCR) catalyst, a particulate filter, a SCR filter, a NO x adsorber catalyst, a three-way catalyst, an oxidation catalyst, and combinations thereof.

13. A method for treating an exhaust gas from an internal combustion engine, said method comprising adsorbing NO x and hydrocarbons (HC) onto the exhaust gas catalyst of claim 1 at or below a low temperature, converting and thermally desorbing NO x and HC from the exhaust gas catalyst at a temperature above the low temperature, and catalytically removing the desorbed NO x and HC on a catalyst component downstream of the exhaust gas catalyst.

14. The method of claim 13 wherein the low temperature is in the range of 200° C. to 250° C.

15. The method of claim 13 wherein the second molecular sieve catalyst is located upstream of the first molecular sieve catalyst so that the exhaust gas contacts the second molecular sieve catalyst prior to contacting the first molecular sieve catalyst.

16. An exhaust gas catalyst effective to adsorb NO x and hydrocarbons (HC) at or below a low temperature and to convert and release the adsorbed NO x and HC at temperatures above the low temperature, said exhaust gas catalyst comprising a first molecular sieve catalyst having a first noble metal and a first molecular sieve selected from CHA, AEI, and an AEI-CHA intergrowth, and a second molecular sieve catalyst having a second noble metal and a second molecular sieve selected from BEA and MFI.

Assignees

• Johnson Matthey Plc

Inventors

• Rajaram Raj Rao
• Mckenna Fiona-Mairead
• Chen Hai-Ying
• Liu Dongxia

Classifications

• B01J29/80 Primary

  Mixtures of different zeolites · CPC title

• B01J37/0244

  Coatings comprising several layers · CPC title

• B01J29/74

  Noble metals · CPC title

• B01D53/9459

  Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts (layered catalysts with only one function B01D53/9413, B01D53/944 or B01D53/945) · CPC title

• B01D2255/915

  Catalyst supported on particulate filters · CPC title