Diesel oxidation catalyst and exhaust system

Patent metadata

Field	Value
Publication number	US-9636634-B2
Application number	US-201514603550-A
Country	US
Kind code	B2
Filing date	Jan 23, 2015
Priority date	Jan 23, 2014
Publication date	May 2, 2017
Grant date	May 2, 2017

Abstract

An oxidation catalyst for treating an exhaust gas from a diesel engine, which oxidation catalyst comprises: a first washcoat region comprising a first platinum group metal (PGM), a first support material and a NO x storage component; a second washcoat region comprising platinum (Pt), manganese (Mn) and a second support material; and a substrate having an inlet end and an outlet end.

First claim

The invention claimed is:

1. An oxidation catalyst for treating an exhaust gas from a diesel engine, which oxidation catalyst comprises:
a first washcoat region effective for NO x storage, which comprises a first platinum group metal (PGM), a first support material and a NO x storage component, wherein the first platinum group metal (PGM) is selected from platinum, palladium, a combination of platinum and palladium, a combination of platinum and rhodium, a combination of palladium and rhodium, and a combination of platinum, palladium and rhodium;
a second washcoat region effective for oxidizing nitric oxide (NO) to nitrogen dioxide (NO 2 ), which comprises a platinum group metal and manganese (Mn) disposed or supported on a second support material, wherein the second support material comprises a refractory oxide comprising alumina, and the platinum group metal is selected from the group consisting of (i) platinum and (ii) a combination of platinum and palladium in a ratio of platinum to palladium by total weight of ≧2:1, and wherein the second washcoat region does not comprise a hydrocarbon adsorbent material, which is a zeolite; and
a substrate having an inlet end and an outlet end, wherein the first washcoat region is arranged or oriented to contact exhaust gas before the second washcoat region.

2. An oxidation catalyst according to claim 1 , wherein the second washcoat region has a ratio by total weight of manganese (Mn) to platinum of 5:1 to 0.2:1.

3. An oxidation catalyst according to claim 1 , wherein the second washcoat region comprises palladium.

4. An oxidation catalyst according to claim 1 , wherein the second washcoat region has a ratio of platinum to palladium by total weight of 1:0 to 2:1.

5. An oxidation catalyst according to claim 1 , wherein the refractory metal oxide is alumina doped with silica or silica-alumina.

6. An oxidation catalyst according to claim 1 , wherein the NO x storage component comprises at least one of an alkali metal, alkaline earth metal and a rare earth metal selected from the group consisting of lanthanum, yttrium and a combination thereof.

7. An oxidation catalyst according to claim 1 , wherein the first PGM is disposed or supported on the first support material.

8. An oxidation catalyst according to claim 1 , wherein the first support material comprises a refractory metal oxide comprising an alkaline earth metal aluminate.

9. 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, optionally doped with a dopant.

10. An oxidation catalyst according to claim 9 , wherein the refractory metal oxide is alumina doped with magnesium oxide.

11. An oxidation catalyst according to claim 1 , wherein the first PGM is a combination of platinum and palladium, and wherein at least one of the platinum and the palladium is disposed or supported on the first support material.

12. An oxidation catalyst according to claim 1 , wherein the first PGM is a combination of platinum and palladium, a combination of palladium and rhodium or a combination of platinum, palladium and rhodium, and wherein the first washcoat region further comprises a palladium support material.

13. An oxidation catalyst according to claim 12 , wherein at least one of the platinum and the rhodium is disposed or supported on the first support material and the palladium is disposed or supported on the palladium support material.

14. An oxidation catalyst according to claim 12 , wherein the NO x storage component is disposed or supported on the palladium support material.

15. An oxidation catalyst according to claim 12 , wherein the palladium support material comprises a refractory metal oxide comprising ceria or a mixed or composite oxide of ceria.

16. An oxidation catalyst according to claim 1 , wherein the substrate is a through-flow substrate.

17. An oxidation catalyst according to claim 1 , wherein the second washcoat region is a second washcoat zone disposed at the inlet end of the substrate and the first washcoat region is a first washcoat zone disposed at the outlet end.

18. An oxidation catalyst according to claim 1 , wherein the first washcoat region is a first washcoat layer and the second washcoat region is a second washcoat zone, and wherein the second washcoat zone is disposed on the first washcoat layer at an inlet end of the substrate.

19. An oxidation catalyst according to claim 1 , wherein the first washcoat region is a first washcoat layer and the second washcoat region is a second washcoat layer, and wherein the first washcoat layer is disposed on the second washcoat layer.

20. An exhaust system for a diesel engine comprising an oxidation catalyst as defined in claim 1 and an emissions control device.

Assignees

• Johnson Matthey Plc

Inventors

• Chiffey Andrew Francis
• Goodwin John Benjamin
• Leeland James
• Moreau Francois
• Reid Stuart David
• Swallow Daniel

Classifications

• B01J23/38

  of noble metals · CPC title

• B01J23/44

  Palladium · CPC title

• B01D53/92

  of engine exhaust gases (exhaust {or silencing} apparatus {for internal combustion engines, machines or engines in general}, having means for purifying, {rendering innocuous} or otherwise treating exhaust gases F01N3/00) · CPC title

• B01D53/72

  Organic compounds not provided for in groups B01D53/48 - B01D53/70, e.g. hydrocarbons · CPC title

• B01D53/94

  by catalytic processes · CPC title