Three-way-catalyst system

Patent metadata

Field	Value
Publication number	US-9522360-B2
Application number	US-201314405778-A
Country	US
Kind code	B2
Filing date	Jun 5, 2013
Priority date	Jun 6, 2012
Publication date	Dec 20, 2016
Grant date	Dec 20, 2016

Abstract

The present invention describes a three-way-catalyst system comprising a first three-way catalyst on an inert catalyst support which is a double-layer catalyst comprising a first layer on the inert catalyst support, comprising active alumina, a cerium/zirconium mixed oxide and palladium and a second layer applied to the first layer and in direct contact with the exhaust gas to be purified, comprising active alumina and rhodium and being free of cerium and cerium containing materials and a second three-way-catalyst located upstream of the first three-way catalyst.

First claim

The invention claimed is:

1. A three-way-catalyst system comprising
a first three-way catalyst on an inert catalyst support which is a double-layer catalyst comprising
a first layer on the inert catalyst support, comprising active alumina, a cerium/zirconium mixed oxide and palladium as a catalytically active noble metal and
a second layer applied to the first layer and in direct contact with the exhaust gas to be purified, comprising active alumina and rhodium as a catalytically active noble metal, wherein the second layer is free of cerium and cerium containing materials and does not contain any catalytically active noble metal besides rhodium, and

a second three-way-catalyst, wherein
the weight of cerium oxide to zirconium oxide in the cerium/zirconium mixed oxide of the first layer of the first three-way catalyst is from 0.1 to 1.2.

2. The three-way-catalyst system according to claim 1 , further comprising platinum, rhodium, or mixtures thereof in the first layer of the first three-way catalyst.

3. The three-way-catalyst system according to claim 2 , wherein the second three-way catalyst comprises one or more oxygen storage components.

4. The three-way-catalyst system according to claim 1 , wherein the first layer of the first three-way catalyst does not contain any catalytically active noble metal besides palladium.

5. The three-way-catalyst system according to claim 4 , wherein the second three-way catalyst comprises one or more oxygen storage components.

6. The three-way-catalyst system according to claim 1 , wherein the second layer of the first three-way catalyst completely covers the first layer of the first three-way catalyst.

7. The three-way-catalyst system according to claim 1 , wherein the inert catalyst support of the first three-way catalyst is a flow-through monolith having a honeycomb-structure.

8. The three-way-catalyst system according to claim 1 , wherein the second three-way catalyst comprises one or more platinum group metals on a high surface area, refractory oxide support.

9. The three-way-catalyst system according to claim 1 , wherein the second three-way catalyst comprises one or more oxygen storage components.

10. The three-way-catalyst system according to claim 1 , wherein the first three-way catalyst is different from the second three-way catalyst.

11. The three-way-catalyst system according claim 1 , wherein in that the first three-way catalyst and the second three-way catalyst are supported on different inert catalyst supports.

12. The three-way-catalyst system according to claim 1 , wherein the first three-way catalyst and the second three-way catalyst are supported on the same inert catalyst support.

13. The three-way-catalyst system according to claim 1 , wherein the second layer of the first three-way catalyst comprises a neodymium/zirconium mixed oxide.

14. A method for cleaning exhaust gas of a motor vehicle equipped with a gasoline engine, comprising contracting the exhaust gas with the three-way-catalyst system according to claim 1 , and wherein the second three-way catalyst is located upstream of the first three-way catalyst.

15. A three-way-catalyst system comprising
a first three-way catalyst on an inert catalyst support which is a double-layer catalyst comprising
a first layer on the inert catalyst support, comprising active alumina, a cerium/zirconium mixed oxide and palladium as a catalytically active noble metal and
a second layer applied to the first layer and in direct contact with the exhaust gas to be purified, comprising active alumina and rhodium as a catalytically active noble metal, wherein the second layer is free of cerium and cerium containing materials and does not contain any catalytically active noble metal besides rhodium, and

a second three-way-catalyst, wherein
the second layer of the first three-way catalyst comprises a neodymium/zirconium mixed oxide.

16. The three-way-catalyst system according to claim 15 , wherein the weight ratio of neodymium oxide to zirconium oxide in the neodymium/zirconium mixed oxide of the second layer of the first three-way catalyst is from 0.2 to 0.5.

17. The three-way-catalyst system according to claim 15 , wherein the rhodium in the second layer of the first three-way catalyst is deposited on both, active alumina and neodymium/zirconium mixed oxide.

18. The three-way-catalyst system according to claim 15 , wherein the second three-way catalyst comprises one or more oxygen storage components.

19. A three-way catalyst system comprising
a first three-way catalyst on an inert catalyst support which is a double-layer catalyst comprising
a first layer on the inert catalyst support, comprising active alumina, a cerium/zirconium mixed oxide and palladium as a catalytically active noble metal and
a second layer applied to the first layer and in direct contact with the exhaust gas to be purified, comprising active alumina and rhodium as a catalytically active noble metal, wherein the second layer is free of cerium and cerium containing materials and does not contain any catalytically active noble metal besides rhodium, and

a second three-way-catalyst, wherein
the first three-way catalyst and the second three-way catalyst are supported, either:
on different inert catalyst supports, or
on the same inert catalyst support.

20. The three-way-catalyst system according to claim 19 , wherein the first three-way catalyst and the second three-way catalyst are supported on the same inert catalyst support.

Assignees

• Umicore Ag & Co Kg

Inventors

• Schmidt Marcus
• Despres Joel
• Roesch Martin
• Klingmann Raoul
• Richter Joerg-Michael

Classifications

• F01N3/101

  Three-way catalysts · CPC title

• B01D2255/1023

  Palladium · CPC title

• B01D2255/2068

  Neodymium · CPC title

• B01D2258/014

  Stoichiometric gasoline engines · CPC title

• F01N2510/0684

  having more than one coating layer, e.g. multi-layered coatings · CPC title