Exhaust system for a compression ignition engine comprising a water adsorbent material

Patent metadata

Field	Value
Publication number	US-9777609-B2
Application number	US-201414576584-A
Country	US
Kind code	B2
Filing date	Dec 19, 2014
Priority date	Dec 23, 2013
Publication date	Oct 3, 2017
Grant date	Oct 3, 2017

Abstract

An exhaust system for a compression ignition engine comprising: a water adsorbent material; and a catalyst composition for treating an exhaust gas pollutant produced by the compression ignition engine; wherein the water adsorbent material is: (i) arranged to contact exhaust gas from the compression ignition engine before the catalyst composition; and (ii) in thermal communication with the catalyst composition.

First claim

The invention claimed is:

1. A diesel engine exhaust system comprising an oxidation catalyst, wherein the oxidation catalyst comprises:
a water adsorbent material consisting of a zeolite having a silica to alumina ratio (SAR) of 35:1 to 8:1, wherein the zeolite is at least one of a transition metal ion-exchanged zeolite, a zeolite impregnated with a transition metal ion, or a non-transition metal ion-exchanged zeolite that is not impregnated with a transition metal ion,
a catalyst composition for treating an exhaust gas pollutant produced by the compression ignition engine wherein the catalyst composition comprises a platinum group metal (PGM) and a support material, wherein the platinum group metal comprises platinum; and
a substrate;

wherein the catalyst composition and the water adsorbent material is each disposed on the substrate, and wherein a first washcoat zone is disposed at an inlet end of the substrate and a second washcoat zone is disposed downstream of the first washcoat zone, wherein the first washcoat zone consists of the water adsorbent material and the second washcoat zone comprises the catalyst composition, wherein the water adsorbent material is arranged to contact exhaust gas directly from the diesel engine, and wherein there is no emissions control device upstream of the oxidation catalyst.

2. A diesel engine exhaust system according to claim 1 further comprising an emissions control device downstream of the oxidation catalyst, wherein the emissions control device is selected from a diesel particulate filter (DPF), a lean NOx trap (LNT), a lean NOx catalyst (LNC), a selective catalytic reduction (SCR) catalyst, a diesel oxidation catalyst (DOC), a catalysed soot filter (CSF), a selective catalytic reduction filter catalyst, and a combination of two or more thereof.

3. A diesel engine exhaust system according to claim 1 , wherein the zeolite has a pore size of from 3Å to 15Å.

4. A diesel engine exhaust system according to claim 1 , wherein the zeolite is selected from the group consisting of faujasite, clinoptilolite, mordenite, silicalite, ferrierite, zeolite X, zeolite Y, ultrastable zeolite Y, beta zeolite, AEI zeolite, ZSM-5 zeolite, ZSM-12 zeolite, ZSM-20 zeolite, ZSM-34 zeolite, CHA zeolite, SSZ-3 zeolite, SAPO-5 zeolite and offretite.

5. A diesel engine exhaust system according to claim 1 , wherein the substrate of the oxidation catalyst is a substrate monolith, which is a flow-through monolith or a filtering monolith.

6. A diesel engine exhaust system according to claim 1 , wherein the platinum group metal comprises a combination of platinum and palladium.

7. A diesel engine exhaust system according to claim 6 , wherein the ratio by weight of platinum to palladium is 10:1 to 1:1.

8. A diesel engine exhaust system according to claim 1 , wherein the 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.

9. A diesel engine exhaust system according to claim 1 , wherein the first washcoat zone overlaps the second washcoat zone.

10. A diesel engine exhaust system according to claim 1 , wherein the second washcoat zone overlaps the first washcoat zone.

11. A diesel engine exhaust system according to claim 1 , wherein the catalyst composition does not comprise rhodium (Rh).

12. A diesel engine exhaust system according to claim 1 further comprising a diesel particulate filter (DPF) or a catalysed soot filter (CSF), wherein an outlet of the oxidation catalyst is connected to an inlet of the DPF or the CSF.

13. A diesel engine exhaust system according to claim 1 , further comprising a selective catalytic reduction (SCR) catalyst.

14. A diesel engine exhaust system according to claim 1 further comprising a selective catalytic reduction filter catalyst.

15. A diesel engine exhaust system according to claim 1 further comprising a diesel particulate filter (DPF) or a catalysed soot filter (CSF), and a selective catalytic reduction (SCR) catalyst, wherein the oxidation catalyst is upstream of the DPF or the CSF, and the DPF or the CSF is upstream of the SCR catalyst.

16. A diesel engine exhaust system according to claim 1 further comprising a selective catalytic reduction (SCR) catalyst and either a diesel particulate filter (DPF) or a catalysed soot filter (CSF), wherein the oxidation catalyst is upstream of the SCR catalyst, and the SCR catalyst is upstream of the DPF or the CSF.

17. A vehicle comprising a diesel engine and a diesel engine exhaust system according to claim 1 .

Assignees

• Johnson Matthey Plc

Inventors

• Chandler Guy Richard
• Green Alexander Nicholas Michael
• Phillips Paul Richard
• Walker Andrew

Classifications

• F01N2330/06

  Ceramic, e.g. monoliths · CPC title

• B01J37/0248

  Coatings comprising impregnated particles · CPC title

• F01N2370/04

  Zeolitic material · CPC title

• B01J23/40

  of the platinum group metals · CPC title

• B01J23/44

  Palladium · CPC title