Porous catalyst washcoats

Patent metadata

Field	Value
Publication number	US-9868088-B2
Application number	US-201615388944-A
Country	US
Kind code	B2
Filing date	Dec 22, 2016
Priority date	Mar 6, 2013
Publication date	Jan 16, 2018
Grant date	Jan 16, 2018

Abstract

Catalyst washcoats with improved porosity and methods for making the washcoats are provided. The process comprises incorporation of an oil-in-water macroemulsion into the catalyst slurry prior to washcoating the carrier substrate, and calcining the washcoated carrier substrate to remove the oil-in-water macroemulsion. Also provided are catalyst articles comprising the washcoat and methods for abatement of exhaust gas emissions.

First claim

What is claimed is:

1. A catalyst article comprising a catalyst washcoat on a carrier substrate, wherein about 30%-100% of pores within the catalyst washcoat are about 15 μm-100 μm in size in at least one dimension.

2. The catalyst article of claim 1 , wherein about 70%-100% of the pores within the catalyst washcoat are about 15 μm-100 μm in size in at least one dimension.

3. The catalyst article of claim 1 , wherein about 70%-100% of the pores within the catalyst washcoat are about 15 μm-50 μm in size in at least one dimension.

4. The catalyst article of claim 1 , wherein the carrier substrate is cordierite or metal.

5. The catalyst article of claim 1 , wherein the catalyst washcoat comprises a precious group metal catalyst and/or a base metal catalyst.

6. The catalyst article of claim 5 , wherein the precious group metal catalyst and/or base metal catalyst is impregnated on a support material.

7. A system for abatement of exhaust gas emissions comprising a source of exhaust gases in fluid flow communication with a catalyst article according to claim 1 , and at least one of a soot filter, a catalyzed soot filter and a second catalyst article in fluid flow communication with the catalyst article.

8. The system of claim 7 , wherein the carrier substrate is a ceramic or metal honeycomb substrate.

9. The system of claim 8 , wherein the carrier substrate is a flow-through monolithic substrate or a wall flow substrate.

Assignees

• Basf Corp

Inventors

• Liu Xinsheng
• Cinar Esra
• Zhang Chunjuan
• Tran Pascaline Harrison

Classifications

• B01D2255/102

  Platinum group metals · CPC title

• B01D2255/9202

  Linear dimensions · CPC title

• B01J37/0246

  Coatings comprising a zeolite · CPC title

• B01D2255/915

  Catalyst supported on particulate filters · CPC title

• B01D53/9459 Primary

  Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts (layered catalysts with only one function B01D53/9413, B01D53/944 or B01D53/945) · CPC title