Diesel oxidation catalyst and exhaust system

Patent metadata

Field	Value
Publication number	US-11338245-B2
Application number	US-201916409969-A
Country	US
Kind code	B2
Filing date	May 13, 2019
Priority date	Jan 23, 2014
Publication date	May 24, 2022
Grant date	May 24, 2022

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, which oxidation catalyst comprises:
a flow-through substrate having an inlet end and an outlet end and a total length therebetween;
a first washcoat zone disposed directly on to a surface of the substrate at an inlet end of the substrate and having a length that is less than the total length of the substrate, the first washcoat zone comprising platinum (Pt), palladium (Pd), manganese (Mn) and a first support material;
a second washcoat zone disposed directly on to the substrate at an outlet end of the substrate and having a length that is less than the total length of the substrate, the second washcoat region comprising a platinum group metal (PGM) which is platinum (Pt) or a combination of platinum (Pt) and palladium (Pd), a zeolite, manganese (Mn) and a second support material; and
a third washcoat zone disposed on the first washcoat zone and having a length that is less than the total length of the substrate, the third washcoat zone comprising a zeolite catalyst, the zeolite catalyst comprising a noble metal, which is palladium (Pd) and/or platinum (Pt), and a zeolite,
wherein the second washcoat zone is in contact with the first washcoat zone and the second washcoat zone 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 zone,
wherein the first washcoat zone is substantially free of a zeolite, and
wherein the first washcoat zone and the second washcoat zone have different compositions.

2. An oxidation catalyst according to claim 1 , wherein the manganese (Mn) in the first washcoat zone is disposed or supported on the first support material.

3. An oxidation catalyst according to claim 1 , wherein the first washcoat zone comprises a ratio of platinum (Pt) to palladium (Pd) by total weight of 1:1.

4. An oxidation catalyst according to claim 1 , wherein the first support material comprises a refractory metal oxide selected from the group consisting of alumina, silica, titania, zirconia, ceria and a mixed or composite oxide thereof, wherein the refractory metal oxide is optionally doped with a dopant.

5. An oxidation catalyst according to claim 4 , wherein the refractory metal oxide is alumina doped with silica.

6. An oxidation catalyst according to claim 1 , wherein the second support material comprises a refractory metal oxide selected from the group consisting of alumina, silica, titania, zirconia, ceria and a mixed or composite oxide of two or more thereof, wherein the refractory metal oxide is optionally doped with a dopant.

7. An oxidation catalyst according to claim 6 , wherein the refractory metal oxide is alumina doped with silica.

8. An oxidation catalyst according to claim 1 , wherein the second washcoat zone comprises platinum (Pt) as the only platinum group metal (PGM).

9. An oxidation catalyst according to claim 1 , wherein the manganese (Mn) in the second washcoat zone is disposed or supported on the second support material.

10. An exhaust system comprising an oxidation catalyst as defined in claim 1 and an emissions control device.

11. A method of treating an exhaust gas from a diesel engine, which method comprises either contacting the exhaust gas with an oxidation catalyst as defined in claim 1 .

12. An oxidation catalyst according to claim 1 , wherein the first washcoat zone has a length of 10 to 90% of the length of the substrate.

13. An oxidation catalyst according to claim 1 , wherein the second washcoat zone has a length of 10 to 90% of the length of the substrate.

14. An oxidation catalyst according to claim 1 , wherein the third washcoat zone has a length of 10 to 90% of the length of the substrate.

15. An oxidation catalyst according to claim 1 , wherein the first washcoat zone overlaps the second washcoat zone.

16. An oxidation catalyst according to claim 1 , wherein the third washcoat zone has a total noble metal loading of 1-250 gft −3 .

17. An oxidation catalyst according to claim 1 , wherein the only noble metal in the third washcoat zone is Pd.

18. An oxidation catalyst according to claim 1 , wherein the zeolite in the third zone has a Framework Type selected from the group consisting of AEI, MFI, EMT, ERI, MOR, FER, BEA, FAU, CHA, LEV, MWW, CON and EUO and mixtures of any two or more thereof.

19. An oxidation catalyst according to claim 1 , wherein the first washcoat zone comprises a weight ratio of platinum (Pt) to palladium (Pd) of 10:1 to 1:1.

20. An oxidation catalyst according to claim 1 , wherein the second washcoat zone comprises a weight ratio of platinum (Pt) to palladium (Pd) of 1:0 to 2:1.

21. An oxidation catalyst according to 5 , wherein the alumina is doped with silica in a total amount of 0.5 to 45% by weight.

22. An oxidation catalyst according to 7 , wherein the alumina is doped with silica in a total amount of 0.5 to 45% by weight.

Assignees

• Johnson Matthey Plc

Inventors

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

Classifications

• B01J35/56

  Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths · CPC title

• F01N3/022

  characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous · CPC title

• B01J23/40

  of the platinum group metals · CPC title

• B01J37/0246

  Coatings comprising a zeolite · CPC title

• F01N2330/06

  Ceramic, e.g. monoliths · CPC title