Substrate monolith comprising SCR catalyst

Patent metadata

Field	Value
Publication number	US-9333461-B2
Application number	US-201213711134-A
Country	US
Kind code	B2
Filing date	Dec 11, 2012
Priority date	Dec 12, 2011
Publication date	May 10, 2016
Grant date	May 10, 2016

Abstract

A substrate monolith 6 having a length L and comprising a first zone 11 of substantially uniform length defined at one end by a first end of the substrate monolith, which first zone comprising a selective catalytic reduction (SCR) catalyst for reducing oxides of nitrogen with a nitrogenous reductant in exhaust gas emitted from an internal combustion engine and a second zone 8 of substantially uniform length less than L defined at one end by a second end of the substrate monolith, which second zone comprising (a) at least one particulate metal oxide or a mixture of any two or more thereof for trapping gas phase platinum group metal (PGM), which at least one particulate metal oxide does not act as a support for any other catalytic component; or (b) a component capable of trapping and/or alloying with gas phase PGM.

First claim

The invention claimed is:

1. An exhaust system for a vehicular lean-burn internal combustion engine comprising:
(i) a catalysed substrate monolith comprising a catalyst, wherein the catalyst comprises at least one platinum group metal (PGM), which comprises platinum (Pt) and palladium (Pd) in a weight ratio of Pt:Pd≧1.25:1; and
(ii) a substrate monolith having a length L and comprising a first zone of substantially uniform length defined at one end by a first end of the substrate monolith, which first zone comprising a selective catalytic reduction (SCR) catalyst for reducing oxides of nitrogen with a nitrogenous reductant in exhaust gas emitted from an internal combustion engine and a second zone of substantially uniform length less than L defined at one end by a second end of the substrate monolith, wherein the second end of the substrate monolith is oriented to an upstream side, and wherein:
(a) the second zone consists of at least one particulate metal oxide or a mixture of any two or more thereof for trapping gas phase platinum group metal (PGM), wherein the at least one particulate metal oxide is selected from the group consisting of optionally stabilised alumina, amorphous silica-alumina, optionally stabilised zirconia, titania and mixtures of any two or more thereof, which at least one particulate metal oxide does not act as a support for any other catalytic component; or
(b) the second zone comprises a component capable of at least one of trapping or alloying with gas phase platinum group metal (PGM), which comprises (i) a metal selected from the group consisting of gold and silver, or (ii) a mixture of an alloy of palladium and gold,

wherein the catalysed substrate monolith is disposed upstream of the substrate monolith.

2. An exhaust system according to claim 1 , wherein the first zone extends over the entire length L and wherein the second zone overlies the first zone.

3. An exhaust system according to claim 2 , wherein the SCR catalyst in the first zone is present as a coating on the substrate monolith.

4. An exhaust system according to claim 2 , wherein (b) the second zone comprises the component capable of at least one of trapping or alloying with gas phase platinum group metal (PGM), which is supported by the SCR catalyst per se.

5. An exhaust system according to claim 2 , wherein (b) the second zone comprises the component capable of at least one of trapping or alloying with gas phase platinum group metal (PGM), which comprises at least one metal oxide on which the component capable of at least one of trapping or alloying with gas phase platinum group metal (PGM) is supported.

6. An exhaust system according to claim 1 , wherein the SCR catalyst in the first zone is present as a coating on the substrate monolith of substantially uniform length less than L, wherein the component capable of at least one of trapping or alloying with gas phase platinum group metal (PGM) comprises at least one metal oxide on which the component capable of at least one of trapping or alloying with gas phase platinum croup metal (PGM) is supported and wherein there is substantially no overlap between the first zone and the second zone.

7. An exhaust system according to claim 1 which is a filtering substrate monolith having inlet surfaces and outlet surfaces, wherein the inlet surfaces are separated from the outlet surfaces by a porous structure.

8. An exhaust system according to claim 7 , wherein the filtering substrate monolith is a wall-flow filter, and wherein the SCR catalyst is disposed in open channels at the first end of the wall-flow filter and the second zone is disposed in open channels at the second end thereof, wherein the porous structure defines a transition between the first zone and the second zone.

9. An exhaust system according to claim 1 , wherein the catalyst comprising at least one platinum group metal (PGM) is a diesel oxidation catalyst or a NO x absorber catalyst.

10. An exhaust system according to claim 1 , wherein the substrate monolith which comprises a catalyst comprising platinum group metal (PGM) is a filtering substrate monolith.

11. An exhaust system according to claim 10 , wherein the filtering substrate monolith is a wall-flow filter.

12. An exhaust system according to claim 1 comprising means for injecting ammonia or a precursor thereof between the catalysed substrate monolith and the substrate monolith comprising the SCR catalyst.

13. A lean-burn internal combustion engine comprising an exhaust system according to claim 1 .

14. An exhaust system according to claim 1 , wherein the weight ratio of Pt:Pd is greater than 2:1.

Assignees

• Johnson Matthey Plc

Inventors

• Castagnola Mario Jaime
• Chiffey Andrew Francis
• Phillips Paul Richard
• Rajaram Raj Rao
• Walker Andrew Peter

Classifications

• B01D2255/104

  Silver · CPC title

• B01D2255/1021

  Platinum · CPC title

• B01D53/9481 Primary

  Catalyst preceded by an adsorption device without catalytic function for temporary storage of contaminants, e.g. during cold start · CPC title

• F01N3/035

  with catalytic reactors · CPC title

• B01J29/7415

  Zeolite Beta · CPC title