Exhaust gas purification catalyst device and exhaust gas purification method

Patent metadata

Field	Value
Publication number	US-9890676-B2
Application number	US-201515023129-A
Country	US
Kind code	B2
Filing date	May 18, 2015
Priority date	Aug 29, 2014
Publication date	Feb 13, 2018
Grant date	Feb 13, 2018

Abstract

A device includes a first catalyst 41 including a Pd-containing catalyst layer and a Rh-containing catalyst layer and a second catalyst 42 containing Pt-loaded alumina and containing neither Rh nor Pd. The first catalyst or the second catalyst are disposed in one place in such a manner that one of the first catalyst 41 or the second catalyst 42 is located upstream of the other in a flow direction of an exhaust gas from an engine 1.

First claim

The invention claimed is:

1. An exhaust gas purification catalyst device for purifying saturated hydrocarbon and unsaturated hydrocarbon included in an exhaust gas from an engine configured to operate with selective switching between a spark ignition combustion mode and a homogeneous charge compression ignition combustion mode, the exhaust gas purification catalyst device comprising:
a first catalyst including a Pd-containing catalyst layer and a Rh-containing catalyst layer; and
a second catalyst containing Pt-loaded alumina and containing neither Rh nor Pd, wherein
the first catalyst or the second catalyst is disposed in one place in such a manner that the first catalyst is located upstream of the second catalyst in a flow direction of the exhaust gas,
a heating unit configured to heat an exhaust gas flowing into the first catalyst is disposed upstream of the first catalyst in the flow direction of the exhaust gas, the heating unit is operated in switching the engine from the homogeneous charge compression ignition combustion mode to the spark ignition combustion mode,
the engine is started in the spark ignition combustion mode,
the first catalyst shows activity to purification of the unsaturated hydrocarbon at a temperature lower than the second catalyst, and
the second catalyst shows activity to purification of the saturated hydrocarbon at a temperature lower than the first catalyst.

2. The exhaust gas purification catalyst device of claim 1 , wherein
the first catalyst includes a honeycomb substrate supporting the Pd-containing catalyst layer and the Rh-containing catalyst layer,
the second catalyst includes a honeycomb substrate supporting the Pt-loaded alumina, and
the honeycomb substrate of the second catalyst has a thermal capacity smaller than a thermal capacity of the honeycomb substrate of the first catalyst.

3. The exhaust gas purification catalyst device of claim 1 , wherein
the Pd-containing catalyst layer of the first catalyst contains Pd-loaded alumina and a Pd-loaded CeZr-based composite oxide.

4. The exhaust gas purification catalyst device of claim 1 , wherein
the first catalyst and the second catalyst are disposed in series and housed in one container.

5. The exhaust gas purification catalyst device of claim 1 , wherein
the first catalyst is a catalyst including the Pd-containing catalyst layer and the Rh-containing catalyst layer and containing Pt.

6. The exhaust gas purification catalyst device of claim 1 , wherein
the first catalyst shows activity to purification of propylene as the unsaturated hydrocarbon at a temperature lower than the second catalyst, and
the second catalyst shows activity to purification of iso-pentane as the saturated hydrocarbon at a temperature lower than the first catalyst.

7. An exhaust gas purification method for purifying saturated hydrocarbon and unsaturated hydrocarbon included in an exhaust gas from an engine configured to operate with selective switching between a spark ignition combustion mode and a homogeneous charge compression ignition combustion mode, wherein
a first catalyst including a Pd-containing catalyst layer and a Rh-containing catalyst layer and a second catalyst containing Pt-loaded alumina and containing neither Rh nor Pd are used,
the first catalyst or the second catalyst is disposed in one place in such a manner that the first catalyst is located upstream of the second catalyst in a flow direction of the exhaust gas,
a heating unit configured to heat an exhaust gas flowing into the first catalyst is disposed upstream of the first catalyst in the flow direction of the exhaust gas,
the engine is started in the spark ignition combustion mode,
the heating unit is operated in switching the engine from the homogeneous charge compression ignition combustion mode to the spark ignition combustion mode, and
the saturated hydrocarbon is purified mainly by the second catalyst and the unsaturated hydrocarbon is purified mainly by the first catalyst.

8. An exhaust gas purification catalyst device for purifying saturated hydrocarbon and unsaturated hydrocarbon included in an exhaust gas from an engine configured to operate with selective switching between a spark ignition combustion mode and a homogeneous charge compression ignition combustion mode, the exhaust gas purification catalyst device comprising:
a first catalyst including a Pd-containing catalyst layer and a Rh-containing catalyst layer; and
a second catalyst containing Pt-loaded alumina and containing neither Rh nor Pd, wherein the first catalyst or the second catalyst is disposed in one place in such a manner that the first catalyst is located upstream of the second catalyst in a flow direction of the exhaust gas,
the Rh-containing catalyst layer of the first catalyst is stacked on the Pd-containing catalyst layer,
the Rh-containing catalyst layer contains a Rh-doped CeZr-based composite oxide binder having a median diameter of 300 nm or less,
a heating unit configured to heat an exhaust gas flowing into the first catalyst is disposed upstream of the first catalyst in the flow direction of the exhaust gas,
the heating unit is operated in switching the engine from the homogeneous charge compression ignition combustion mode to the spark ignition combustion mode, and
the first catalyst shows activity to purification of the unsaturated hydrocarbon at a temperature lower than the second catalyst, and
the second catalyst shows activity to purification of the saturated hydrocarbon at a temperature lower than the first catalyst.

9. The exhaust gas purification catalyst device of claim 8 , wherein
the first catalyst includes a honeycomb substrate supporting the Pd-containing catalyst layer and the Rh-containing catalyst layer,
the second catalyst includes a honeycomb substrate supporting the Pt-loaded alumina, and
the honeycomb substrate of the second catalyst has a thermal capacity smaller than a thermal capacity of the honeycomb substrate of the first catalyst.

10. The exhaust gas purification catalyst device of claim 8 , wherein
the Pd-containing catalyst layer of the first catalyst contains Pd-loaded alumina and a Pd-loaded CeZr-based composite oxide.

11. The exhaust gas purification catalyst device of claim 8 , wherein
the first catalyst and the second catalyst are disposed in series and housed in one container.

12. The exhaust gas purification catalyst device of claim 8 , wherein
the first catalyst is a catalyst including the Pd-containing catalyst layer and the Rh-containing catalyst layer and containing Pt.

13. The exhaust gas purification catalyst device of claim 8 , wherein
the first catalyst shows activity to purification of propylene as the unsaturated hydrocarbon at a temperature lower than the second catalyst, and
the second catalyst shows activity to purification of iso-pentane as the saturated hydrocarbon at a temperature lower than the first catalyst.

Assignees

• Mazda Motor

Inventors

• Kawabata Hisaya
• Matsumura Yasuhiro
• Yamada Hiroshi
• Shigetsu Masahiko

Classifications

• B01J35/57

  Honeycombs · CPC title

• B01D2255/9022

  Two layers · CPC title

• B01J23/44

  Palladium · CPC title

• F01N2510/06

  for exhaust purification, e.g. catalytic reaction · CPC title

• B01D2255/407

  Zr-Ce mixed oxides · CPC title