Exhaust gas purification catalyst

Patent metadata

Field	Value
Publication number	US-12350653-B2
Application number	US-202017780622-A
Country	US
Kind code	B2
Filing date	Nov 27, 2020
Priority date	Nov 29, 2019
Publication date	Jul 8, 2025
Grant date	Jul 8, 2025

Abstract

An object of the present invention is to provide an exhaust gas purification catalyst having improved exhaust gas (e.g., NOx) purifying performance at low to medium temperature. In order to achieve the object, the present invention provides an exhaust gas purification catalyst including: a substrate; and a catalyst layer formed on the substrate, wherein the catalyst layer contains rhodium element, phosphorus element and a rare earth element other than cerium element, wherein a ratio of a mass of the phosphorus element contained in the catalyst layer to the mass of the rhodium element contained in the catalyst layer is from 1 to 10, and wherein a ratio of a mass of the rare earth element other than cerium element in terms of an oxide thereof contained in the catalyst layer to the mass of the rhodium element contained in the catalyst layer is from 1 to 5.

First claim

The invention claimed is:

1. An exhaust gas purification catalyst, comprising:
a substrate; and
a catalyst layer formed on the substrate,
wherein the catalyst layer contains rhodium element, phosphorus element and a rare earth element other than cerium element,
wherein a ratio of a mass of the phosphorus element in terms of the phosphorus element contained in the catalyst layer to a mass of the rhodium element in terms of the rhodium element contained in the catalyst layer is from 1.0 to 10,
wherein a ratio of a mass of the rare earth element other than cerium element in terms of an oxide thereof contained in the catalyst layer to the mass of the rhodium element in terms of the rhodium element contained in the catalyst layer is from 1.0 to 5.0, and
wherein the catalyst layer does not contain any noble metal element other than the rhodium element.

2. The exhaust gas purification catalyst according to claim 1 , wherein a ratio of the mass of the rare earth element other than cerium element in terms of an oxide thereof contained in the catalyst layer to the mass of the phosphorus element in terms of the phosphorus element contained in the catalyst layer is from 0.50 to 5.0.

3. The exhaust gas purification catalyst according to claim 1 ,
wherein the catalyst layer further contains inorganic oxide particles, and
wherein the rhodium element, the phosphorus element and the rare earth element other than cerium element are supported on the inorganic oxide particles.

4. The exhaust gas purification catalyst according to claim 1 , wherein any surface of the catalyst layer is not provided with another catalyst layer.

5. The exhaust gas purification catalyst according to claim 1 , wherein the substrate is a wall-flow substrate.

6. The exhaust gas purification catalyst according to claim 5 ,
wherein the wall-flow substrate comprises:
an inflow-side cell extending in an exhaust gas flow direction, wherein the inflow-side cell has an open end on an exhaust gas inflow side in the exhaust gas flow direction and a closed end on an exhaust gas outflow side in the exhaust gas flow direction;
an outflow-side cell extending in the exhaust gas flow direction, wherein the outflow-side cell has a closed end on an exhaust gas inflow side in the exhaust gas flow direction and an open end on an exhaust gas outflow side in the exhaust gas flow direction; and
a porous partition wall that separates the inflow-side cell and the outflow-side cell from each other, and

wherein the catalyst layer is formed on an inflow-side cell side or an outflow-side cell side of the partition wall.

7. The exhaust gas purification catalyst according to claim 1 , wherein the mass of the rhodium element in terms of the rhodium element contained in the catalyst layer is from 0.10 g/L to 1.2 g/L based on an apparent volume of the substrate.

8. The exhaust gas purification catalyst according to claim 1 , wherein the ratio of the mass of the phosphorus element in terms of the phosphorus element contained in the catalyst layer to the mass of the rhodium element in terms of the rhodium element contained in the catalyst layer is from 3.0 to 7.0.

Assignees

• Mitsui Mining & Smelting Co Ltd

Inventors

• Baba Takashi
• ISAYAMA Akihiro

Classifications

• F01N3/101

  Three-way catalysts · CPC title

• B01J2523/822

  Rhodium · CPC title

• B01J2523/51

  Phosphorus · CPC title

• B01J2523/37

  Lanthanides · CPC title

• B01J27/1856

  with platinum group metals · CPC title