Zoned catalyst for diesel applications

Patent metadata

Field	Value
Publication number	US-9333490-B2
Application number	US-201414205469-A
Country	US
Kind code	B2
Filing date	Mar 12, 2014
Priority date	Mar 14, 2013
Publication date	May 10, 2016
Grant date	May 10, 2016

Abstract

An oxidation catalyst composite, methods, and systems for the treatment of exhaust gas emissions from a diesel engine are described. More particularly, an oxidation catalyst composite including a zoned diesel oxidation catalyst with a first washcoat zone with a Pt/Pd ratio that is less than 3:1 and a PGM loading at least twice that of a second washcoat zone.

First claim

What is claimed is:

1. An oxidation catalyst composite for abatement of exhaust gas emissions from a diesel engine comprising:
a substrate having a length, an inlet end and an outlet end, a catalytic material on the substrate, the catalytic material including a first washcoat zone and a second washcoat zone;
the first washcoat zone comprising a first washcoat layer including platinum (Pt) and palladium (Pd) platinum group metal (PGM) components and a first refractory metal oxide support, the first washcoat zone adjacent the inlet end of the substrate; and
the second washcoat zone comprising a second washcoat layer including platinum and palladium PGM components and a second refractory metal oxide support, the second washcoat layer adjacent the outlet end of the substrate; and
wherein the first washcoat zone has a length that is shorter than the second washcoat zone, wherein the oxidation catalyst does not include an elevated PGM loading on the inlet face of the catalyst and the first washcoat zone has a PGM loading at least twice that of the second washcoat zone, and the first washcoat zone has a Pt/Pd ratio less than 3:1.

2. The oxidation catalyst composite of claim 1 , wherein the second washcoat zone has a Pt:Pd ratio greater than 3:1.

3. The oxidation catalyst composite of claim 2 , wherein the Pt:Pd ratio in the second washcoat zone is greater than 5:1.

4. The oxidation catalyst composite of claim 3 , wherein the Pt:Pd ratio in the second washcoat zone is greater than 8:1.

5. The oxidation catalyst composite of claim 1 , wherein the first refractory metal oxide support and second refractory metal oxide support comprises a large pore alumina.

6. The oxidation catalyst composite of claim 5 , wherein the alumina is stabilized by doping.

7. The oxidation catalyst composite of claim 6 , wherein the washcoat loading is the same in the first washcoat zone and the second washcoat zone.

8. The oxidation catalyst composite of claim 6 , wherein the washcoat loading is different in the first washcoat zone than in the second washcoat zone.

9. The oxidation catalyst composite of claim 1 , wherein the first washcoat zone comprises a Pt/Pd component in an amount in the range of about 40 g/ft 3 to 60 g/ft 3 .

10. The oxidation catalyst composite of claim 9 , wherein the first washcoat zone further comprises an alkaline earth metal in an amount in the range of about 60 g/ft 3 to 70 g/ft 3 .

11. The oxidation catalyst composite of claim 1 , wherein the second washcoat zone comprises a Pd/Pd component in an amount in the range of about 15 g/ft 3 to 25 g/ft 3 .

12. The oxidation catalyst of claim 1 , wherein the ratio of the length of the second washcoat zone to the length of the first washcoat zone is 1.5:1 or greater.

13. A system for treatment of a lean burn engine exhaust gas stream including hydrocarbons, carbon monoxide, and other exhaust components, the emission treatment system comprising:
an exhaust conduit in fluid communication with the lean burn engine via an exhaust manifold;
the oxidation catalyst composite of claim 1 wherein the substrate is a flow through substrate or a wall-flow substrate; and
a catalyzed soot filter and an SCR catalyst located downstream from the oxidation catalyst composite.

14. The system of claim 13 , wherein the SCR catalyst is loaded on the catalyzed soot filter.

15. A method for treating a diesel exhaust gas stream comprising passing the exhaust gas stream through an inlet end towards an outlet end of a catalyzed soot filter, the exhaust gas first passing through a first washcoat zone on the catalyzed soot filter comprising a first washcoat layer including platinum (Pt) and palladium (Pd) components and a first refractory metal oxide support, and then passing the exhaust gas stream through a second washcoat zone on the catalyzed soot filter comprising a second washcoat layer including platinum and palladium components and a second refractory metal oxide support, wherein the first washcoat zone has a length that is shorter than the second washcoat zone, wherein the first washcoat zone has a PGM loading at least twice that of the second washcoat zone, and the first washcoat zone has a Pt/Pd ratio less than 3:1.

16. The method claim 15 , wherein the second washcoat zone has a Pt:Pd ratio greater than 3:1.

17. The method of claim 16 , wherein the Pt:Pd ratio in the second washcoat zone is greater than 5:1.

18. The method of claim 17 , wherein the Pt:Pd ratio in the second washcoat zone is greater than 8:1.

19. The method of claim 15 , wherein the washcoat loading is the same in the first washcoat zone and the second washcoat zone.

20. The method of claim 15 , wherein the washcoat loading is different in the first washcoat zone and the second washcoat zone.

21. The method of claim 15 , wherein the oxidation catalyst composite is effective to abate carbon monoxide and hydrocarbons, and to oxidize NO to NO 2 from the exhaust gas stream.

Assignees

• Basf Corp

Inventors

• Kazi M Shahjahan
• Rioult Fabien A
• Roth Stanley A
• Voss Kenneth E

Classifications

• B01D53/945 Primary

  characterised by a specific catalyst · CPC title

• B01J35/56

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

• B01D2255/1021

  Platinum · CPC title

• B01J37/0248

  Coatings comprising impregnated particles · CPC title

• B01D2255/9032

  Two zones · CPC title