WO2008088649A1 - Engine exhaust catalysts containing palladium-gold - Google Patents
Engine exhaust catalysts containing palladium-gold Download PDFInfo
- Publication number
- WO2008088649A1 WO2008088649A1 PCT/US2007/088085 US2007088085W WO2008088649A1 WO 2008088649 A1 WO2008088649 A1 WO 2008088649A1 US 2007088085 W US2007088085 W US 2007088085W WO 2008088649 A1 WO2008088649 A1 WO 2008088649A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- catalyst
- emission control
- washcoat
- coated
- supported
- Prior art date
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- 239000003054 catalyst Substances 0.000 title claims abstract description 217
- 239000010931 gold Substances 0.000 title claims abstract description 68
- 229910052737 gold Inorganic materials 0.000 title claims abstract description 55
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims abstract description 107
- 229910052697 platinum Inorganic materials 0.000 claims abstract description 60
- 239000000758 substrate Substances 0.000 claims abstract description 51
- 239000010457 zeolite Substances 0.000 claims abstract description 47
- 229910021536 Zeolite Inorganic materials 0.000 claims abstract description 44
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 claims abstract description 44
- KDLHZDBZIXYQEI-UHFFFAOYSA-N palladium Substances [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 claims description 84
- 229910052763 palladium Inorganic materials 0.000 claims description 54
- 239000002923 metal particle Substances 0.000 claims description 33
- 239000000203 mixture Substances 0.000 claims description 22
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims description 6
- 238000011144 upstream manufacturing Methods 0.000 claims 11
- 229930195733 hydrocarbon Natural products 0.000 abstract description 30
- 150000002430 hydrocarbons Chemical class 0.000 abstract description 30
- 239000004215 Carbon black (E152) Substances 0.000 abstract description 12
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- 238000000034 method Methods 0.000 description 53
- 239000000843 powder Substances 0.000 description 37
- 229910052878 cordierite Inorganic materials 0.000 description 29
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 29
- 239000008367 deionised water Substances 0.000 description 27
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- 239000000463 material Substances 0.000 description 19
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 18
- 230000003197 catalytic effect Effects 0.000 description 18
- 229910052751 metal Inorganic materials 0.000 description 16
- 239000002184 metal Substances 0.000 description 16
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 15
- 229910002091 carbon monoxide Inorganic materials 0.000 description 15
- 239000007788 liquid Substances 0.000 description 14
- 230000003647 oxidation Effects 0.000 description 14
- 238000007254 oxidation reaction Methods 0.000 description 14
- 239000010970 precious metal Substances 0.000 description 14
- 239000000243 solution Substances 0.000 description 14
- 238000012360 testing method Methods 0.000 description 14
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 12
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 12
- 239000011358 absorbing material Substances 0.000 description 9
- CIWBSHSKHKDKBQ-JLAZNSOCSA-N Ascorbic acid Chemical compound OC[C@H](O)[C@H]1OC(=O)C(O)=C1O CIWBSHSKHKDKBQ-JLAZNSOCSA-N 0.000 description 8
- 238000001914 filtration Methods 0.000 description 8
- GPNDARIEYHPYAY-UHFFFAOYSA-N palladium(II) nitrate Inorganic materials [Pd+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O GPNDARIEYHPYAY-UHFFFAOYSA-N 0.000 description 8
- 230000008929 regeneration Effects 0.000 description 8
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- 229910002058 ternary alloy Inorganic materials 0.000 description 5
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 4
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- QYIGOGBGVKONDY-UHFFFAOYSA-N 1-(2-bromo-5-chlorophenyl)-3-methylpyrazole Chemical compound N1=C(C)C=CN1C1=CC(Cl)=CC=C1Br QYIGOGBGVKONDY-UHFFFAOYSA-N 0.000 description 2
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- 239000007864 aqueous solution Substances 0.000 description 2
- JCXGWMGPZLAOME-UHFFFAOYSA-N bismuth atom Chemical compound [Bi] JCXGWMGPZLAOME-UHFFFAOYSA-N 0.000 description 2
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- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 description 2
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- 150000002739 metals Chemical class 0.000 description 2
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- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
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- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 239000005977 Ethylene Substances 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 229910002835 Pt–Ir Inorganic materials 0.000 description 1
- 229910002848 Pt–Ru Inorganic materials 0.000 description 1
- 229910018879 Pt—Pd Inorganic materials 0.000 description 1
- 229910018967 Pt—Rh Inorganic materials 0.000 description 1
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 230000003679 aging effect Effects 0.000 description 1
- 239000000809 air pollutant Substances 0.000 description 1
- 231100001243 air pollutant Toxicity 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 229910002056 binary alloy Inorganic materials 0.000 description 1
- 239000004202 carbamide Substances 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 238000006555 catalytic reaction Methods 0.000 description 1
- 238000010531 catalytic reduction reaction Methods 0.000 description 1
- 239000013025 ceria-based material Substances 0.000 description 1
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 230000009849 deactivation Effects 0.000 description 1
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- 230000003247 decreasing effect Effects 0.000 description 1
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- BBKFSSMUWOMYPI-UHFFFAOYSA-N gold palladium Chemical compound [Pd].[Au] BBKFSSMUWOMYPI-UHFFFAOYSA-N 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
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- 239000012808 vapor phase Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
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- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J29/00—Catalysts comprising molecular sieves
- B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
- B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
- B01J29/40—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J29/00—Catalysts comprising molecular sieves
- B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
- B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
- B01J29/70—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65
- B01J29/7007—Zeolite Beta
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J29/00—Catalysts comprising molecular sieves
- B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
- B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
- B01J29/80—Mixtures of different zeolites
Definitions
- Embodiments of the present invention generally relate to supported catalysts containing precious group metals and, and more particularly, to engine exhaust catalysts containing palladium and gold, and methods of production thereof.
- Catalysts are also essential for the reduction of pollutants, particularly air pollutants created during the production of energy and by automobiles.
- Many industrial catalysts are composed of a high surface area support material upon which chemically active metal nanoparticles (i.e., nanometer sized metal particles) are dispersed.
- the support materials are generally inert, ceramic type materials having surface areas on the order of hundreds of square meters/gram. This high specific surface area usually requires a complex internal pore system.
- the metal nanoparticles are deposited on the support and dispersed throughout this internal pore system, and are generally between 1 and 100 nanometers in size.
- Processes for making supported catalysts go back many years.
- One such process for making platinum catalysts involves the contacting of a support material such as alumina with a metal salt solution such as hexachloroplatinic acid in water.
- the metal salt solution "impregnates" or fills the pores of the support during this process.
- the support containing the metal salt solution would be dried, causing the metal salt to precipitate within the pores.
- the support containing the precipitated metal salt would then be calcined (typically in air) and, if necessary, exposed to a reducing gas environment (e.g., hydrogen or carbon monoxide) for further reduction to form metal particles.
- a reducing gas environment e.g., hydrogen or carbon monoxide
- Supported catalysts are quite useful in removing pollutants from vehicle exhausts.
- Vehicle exhausts contain harmful pollutants, such as carbon monoxide (CO), unburned hydrocarbons (HC), and nitrogen oxides (NOx), that contribute to the "smog-effect" that have plagued major metropolitan areas across the globe.
- Catalytic converters containing supported catalysts and particulate filters have been used to remove such harmful pollutants from the vehicle exhaust.
- the present invention provides emission control catalysts for treating emissions that include CO and HC, and methods for producing the same.
- the engine may be a vehicle engine, an industrial engine, or generally, any type of engine that burns hydrocarbons.
- An emission control catalyst includes a supported platinum-based catalyst and a supported palladium- gold catalyst.
- the two catalysts are coated onto different layers, zones, or monoliths of the substrate for the emission control catalyst such that the platinum- based catalyst encounters the exhaust stream before the palladium-gold catalyst.
- Zeolite may be added to the emission control catalyst as a hydrocarbon absorbing component to boost the oxidation activity of the palladium-gold catalyst.
- the inventors have enabled the use of supported catalysts comprising palladium and gold species as emission control catalysts by overcoming the problem which they have discovered through tests that HC species present in the exhaust inhibit the oxidation activity of such catalysts.
- HC inhibition effects are reduced sufficiently by exposing the exhaust to the platinum-based catalyst before the palladium-gold catalyst and/or by adding a hydrocarbon absorbing material, so that the oxidation activity of the palladium-gold catalyst can be improved and the overall catalytic activity of the emission control catalyst can be boosted to effective levels.
- the inventors have confirmed through vehicle performance tests that the emission control catalysts according to embodiments of the present invention perform as well as platinum-palladium catalysts in reducing CO and HC emissions from a vehicle.
- FIGS. 1A-1 D are schematic representations of different engine exhaust systems in which embodiments of the present invention may be used.
- FIG. 2 is an illustration of a catalytic converter with a cut-away section that shows a substrate onto which emission control catalysts according to embodiments of the present invention are coated.
- FIGS. 3A-3D illustrate different configurations of a substrate for an emission control catalyst.
- Figure 4 is a flow diagram illustrating the steps for preparing an emission control catalyst according to an embodiment of the present invention.
- Figure 5 is a flow diagram illustrating the steps for preparing an emission control catalyst according to another embodiment of the present invention.
- FIGS 1A-1 D are schematic representations of different engine exhaust systems in which embodiments of the present invention may be used.
- the combustion process that occurs in an engine 102 produces harmful pollutants, such as CO, various hydrocarbons, particulate matter, and nitrogen oxides (NOx), in an exhaust stream that is discharged through a tail pipe 108 of the exhaust system.
- harmful pollutants such as CO, various hydrocarbons, particulate matter, and nitrogen oxides (NOx)
- the exhaust stream from an engine 102 passes through a catalytic converter 104, before it is discharged into the atmosphere (environment) through a tail pipe 108.
- the catalytic converter 104 contains supported catalysts coated on a monolithic substrate that treat the exhaust stream from the engine 102.
- the exhaust stream is treated by way of various catalytic reactions that occur within the catalytic converter 104. These reactions include the oxidation of CO to form CO 2 , burning of hydrocarbons, and the conversion of NO to NO 2 .
- the exhaust stream from the engine 102 passes through a catalytic converter 104 and a particulate filter 106, before it is discharged into the atmosphere through a tail pipe 108.
- the catalytic converter 104 operates in the same manner as in the exhaust system of Figure 1A.
- the particulate filter 106 traps particulate matter that is in the exhaust stream, e.g., soot, liquid hydrocarbons, generally particulates in liquid form.
- the particulate filter 106 includes a supported catalyst coated thereon for the oxidation of NO and/or to aid in combustion of particulate matter.
- the exhaust stream from the engine 102 passes through a catalytic converter 104, a pre-filter catalyst 105 and a particulate filter 106, before it is discharged into the atmosphere through a tail pipe 108.
- the catalytic converter 104 operates in the same manner as in the exhaust system of Figure 1A.
- the pre-filter catalyst 105 includes a monolithic substrate and supported catalysts coated on the monolithic substrate for the oxidation of NO.
- the particulate filter 106 traps particulate matter that is in the exhaust stream, e.g., soot, liquid hydrocarbons, generally particulates in liquid form.
- the exhaust stream passes from the engine 102 through a catalytic converter 104, a particulate filter 106, a selective catalytic reduction (SCR) unit 107 and an ammonia slip catalyst 110, before it is discharged into the atmosphere through a tail pipe 108.
- the catalytic converter 104 operates in the same manner as in the exhaust system of Figure 1A.
- the particulate filter 106 traps particulate matter that is in the exhaust stream, e.g., soot, liquid hydrocarbons, generally particulates in liquid form.
- the particulate filter 106 includes a supported catalyst coated thereon for the oxidation of NO and/or to aid in combustion of particulate matter.
- the SCR unit 107 is provided to reduce the NO x species to N 2 .
- the SCR unit 107 may be ammonia/urea based or hydrocarbon based.
- the ammonia slip catalyst 110 is provided to reduce the amount of ammonia emissions through the tail pipe 108.
- An alternative configuration places the SCR unit 107 in front of the particulate filter 106.
- Alternative configurations of the exhaust system includes the provision of SCR unit 107 and the ammonia slip catalyst 110 in the exhaust system of Figure 1A or 1C, and the provision of just the SCR unit 107, without the ammonia slip catalyst 110, in the exhaust system of Figures 1A, 1 B or 1C.
- the regeneration of the particulate filter can be either passive or active. Passive regeneration occurs automatically in the presence of NO 2 . Thus, as the exhaust stream containing NO 2 passes through the particulate filter, passive regeneration occurs. During regeneration, the particulates get oxidized and NO 2 gets converted back to NO. In general, higher amounts of NO 2 improve the regeneration performance, and thus this process is commonly referred to as NO 2 assisted oxidation. However, too much NO 2 is not desirable because excess NO 2 is released into the atmosphere and NO 2 is considered to be a more harmful pollutant than NO.
- the NO 2 used for regeneration can be formed in the engine during combustion, from NO oxidation in the catalytic converter 104, from NO oxidation in the pre-filter catalyst 105, and/or from NO oxidation in a catalyzed version of the particulate filter 106.
- Active regeneration is carried out by heating up the particulate filter 106 and oxidizing the particulates. At higher temperatures, NO 2 assistance of the particulate oxidation becomes less important.
- the heating of the particulate filter 106 may be carried out in various ways known in the art. One way is to employ a fuel burner which heats the particulate filter 106 to particulate combustion temperatures. Another way is to increase the temperature of the exhaust stream by modifying the engine output when the particulate filter load reaches a pre-determined level.
- the present invention provides catalysts that are to be used in the catalytic converter 104 shown in FIGS. 1A-1 D, or generally as catalysts in any vehicle emission control system, including as a diesel oxidation catalyst, a diesel filter catalyst, an ammonia-slip catalyst, an SCR catalyst, or as a component of a three- way catalyst.
- the present invention further provides a vehicle emission control system, such as the ones shown in FIGS. 1A-1 D, comprising an emission control catalyst comprising a monolith and a supported catalyst coated on the monolith.
- FIG. 2 is an illustration of a catalytic converter with a cut-away section that shows a substrate 210 onto which supported metal catalysts are coated.
- the exploded view of the substrate 210 shows that the substrate 210 has a honeycomb structure comprising a plurality of channels into which washcoats containing supported metal catalysts are flowed in slurry form so as to form coating 220 on the substrate 210.
- FIGS. 3A-3D illustrate different embodiments of the present invention.
- coating 220 comprises two washcoat layers 221 , 223 on top of substrate 210.
- Washcoat layer 221 is the bottom layer that is disposed directly on top of the substrate 210 and contains metal particles having palladium and gold in close contact (also referred to as "palladium-gold metal particles").
- Washcoat layer 223 is the top layer that is in direct contact with the exhaust stream and contains metal particles having platinum alone or in close contact with another metal species such as palladium (also referred to as "platinum-containing metal particles"). Based on their positions relative to the exhaust stream, washcoat layer 223 encounters the exhaust stream before washcoat layer 221.
- coating 220 comprises three washcoat layers 221 , 222, 223 on top of substrate 210.
- Washcoat layer 221 is the bottom layer that is disposed directly on top of the substrate 210 and includes palladium-gold metal particles.
- Washcoat layer 223 is the top layer that is in direct contact with the exhaust stream and includes platinum-containing metal particles.
- Washcoat layer 222 is the middle layer or buffer layer that is disposed in between washcoat layers 221 , 223.
- the middle layer is provided to minimize the interaction between the R and Pd-Au components.
- the middle layer may be a blank support or may contain zeolites, rare earth oxides, inorganic oxides, and/or supported palladium particles. Based on their positions relative to the exhaust stream, washcoat layer 223 encounters the exhaust stream before washcoat layers 221 , 222, and washcoat layer 222 encounters the exhaust stream before washcoat layer 221.
- the substrate 210 is a single monolith that has two coating zones 210A, 210B.
- a washcoat including platinum-containing metal particles is coated onto a first zone 210A and a washcoat including palladium-gold metal particles is coated onto a second zone 210B.
- the substrate 210 includes first and second monoliths 231 , 232, which are physically separate monoliths.
- a washcoat including platinum-containing metal particles is coated onto the first monolith 231 and a washcoat including palladium-gold metal particles is coated onto the second monolith 232.
- All of the embodiments described above include a palladium-gold catalyst in combination with a platinum-based catalyst.
- the weight ratio of palladium to gold in the palladium-gold catalyst is about 0.05:1 to 20:1 , preferably from about 0.5:1 to about 2:1.
- the palladium-gold catalyst may be promoted with bismuth or other known promoters.
- the platinum-based catalyst may be a platinum catalyst, a platinum-palladium catalyst, a platinum catalyst promoted with bismuth or other known promoters, or other platinum-based catalysts (e.g., Pt-Rh, Pt-Ir, Pt-Ru, Pt- Au, Pt-Ag, Pt-Rh-Ir, Pt-Ir-Au, etc.).
- the preferred embodiments employ a platinum- palladium catalyst as the platinum-based catalyst.
- the weight ratio of platinum to palladium in this catalyst is about 0.05:1 to 20:1 , preferably from about 2:1 to about 4:1.
- the platinum-based catalyst is situated so that it encounters the exhaust stream prior to the palladium-gold catalyst.
- the platinum- based catalyst is included in the top layer 223 and the palladium-gold catalyst is included in the bottom layer 221.
- the platinum- based catalyst is included in the first zone 210A and the palladium-gold catalyst is included in the second zone 210B.
- the platinum- based catalyst is included in the first monolith 231 and the palladium-gold catalyst is included in the second monolith 232.
- a hydrocarbon absorbing material is added to the emission control catalyst.
- the hydrocarbon absorbing material is added to the emission control catalyst so that it encounters exhaust stream prior to the palladium-gold catalyst.
- the hydrocarbon absorbing material may be included in the top layer 223.
- the hydrocarbon absorbing material may be included in the middle layer 222 or the top layer 223. In the configuration shown in FIG.
- the hydrocarbon absorbing material may be included in the first zone 210A.
- the hydrocarbon absorbing material may be included in the front monolith 231.
- a hydrocarbon absorbing material is zeolite.
- Zeolite may be a beta zeolite, ZSM-5 zeolite, and mixtures of the two, with or without other types of zeolites, in any weight ratio.
- any of the washcoat layers or zones, or monoliths may include rare-earth oxides, such as cerium(IV) oxide (CeOa) and ceria-zirconia (CeO 2 -ZrO 2 ).
- rare-earth oxides such as cerium(IV) oxide (CeOa) and ceria-zirconia (CeO 2 -ZrO 2 ).
- FIG. 4 is a flow diagram that illustrates the steps for preparing an emission control catalyst according to an embodiment of the present invention using the substrate 210.
- a first supported catalyst e.g., supported palladium- gold catalyst
- a second supported catalyst e.g., supported platinum-based catalyst
- a monolithic substrate such as substrate 210 shown in FIG. 2 (or monolithic substrates 231 , 232 shown in FIG. 3D) is provided in step 414.
- Exemplary monolithic substrates include those that are ceramic (e.g., cordierite), metallic, or silicon carbide based.
- the first supported catalyst in powder form are mixed in a solvent to form a washcoat slurry, and the washcoat slurry is coated as the bottom layer of the substrate 210 or onto a rear zone or rear monolith of the substrate 210.
- the second supported catalyst in powder form are mixed in a solvent to form a washcoat slurry, and the washcoat slurry is coated as the top layer of the substrate 210 or onto a front zone or front monolith of the substrate 210.
- zeolite or zeolite mixture including one or more of beta zeolite, ZSM-5 zeolite, and other types of zeolites is added to the washcoat slurry before the washcoat slurry is coated in step 418.
- FIG. 5 is a flow diagram that illustrates the steps for preparing an emission control catalyst according to another embodiment of the present invention using the substrate 210.
- a first supported catalyst e.g., supported palladium- gold catalyst
- a second supported catalyst e.g., supported platinum-based catalyst
- a monolithic substrate such as substrate 210 shown in FIG. 2, is provided in step 514.
- Exemplary monolithic substrates include those that are ceramic (e.g., cordierite), metallic, or silicon carbide based.
- step 516 the first supported catalyst in powder form are mixed in a solvent to form a washcoat slurry, and the washcoat slurry is coated as the bottom layer of the substrate 210.
- step 517 zeolite or zeolite mixture is added to a solvent to form a washcoat slurry and this washcoat slurry is coated as the middle layer of the substrate 210.
- step 518 the second supported catalyst in powder form are mixed in a solvent to form a washcoat slurry, and the washcoat slurry is coated as the top layer of the substrate 210.
- Examples of Table 1 were tested under low engine out temperatures (around 150 0 C to 300 0 C) and Examples of Table 2 were tested under high engine out temperatures (around 200 0 C to 350 °C).
- the catalysts of Examples 1-3 and 11 were coated on a cordierite substrate with a diameter of 5.66 inches and length of 2.5 inches.
- the catalysts of Examples 4-10 were coated on a pair of cordierite substrates, each with a diameter of 5.66 inches and length of 1.25 inches.
- Table 1 presents data for emission control catalysts having a tri-layer configuration (see FIG. 3B).
- Example 1 represents a benchmark emission control catalyst and includes metal particles having platinum and palladium in close contact (also referred to as "platinum-palladium metal particles") having a weight ratio of 2.8%:1.4% in the bottom layer and the top layer.
- the middle layer comprises beta zeolite.
- Example 2 also represents a benchmark emission control catalyst and has the same composition as Example 1 except the middle layer comprises a zeolite mixture of beta zeolite and ZSM-5 zeolite at a weight ratio of 1 :1.
- Example 3 represents an emission control catalyst according to an embodiment of the present invention and includes palladium-gold metal particles having a weight ratio of 1.7%:2.0% in the bottom layer and platinum-palladium metal particles having a weight ratio of 3.0%:0.75% in the top layer.
- the middle layer comprises a zeolite mixture of beta zeolite and ZSM-5 zeolite at a weight ratio of 1 :1. Relative to the benchmark emission control catalysts of Examples 1 and 2, a reduction in both HC and CO emissions has been observed with the emission control catalyst of Example 3.
- Table 2 presents data for emission control catalysts having a dual-brick configuration (see FIG. 3D).
- Example 4 represents a benchmark emission control catalyst and includes platinum-palladium metal particles having a weight ratio of 2.0%:1.0% in the front brick and the rear brick.
- Examples 5, 6 and 7 represent emission control catalysts according to embodiments of the present invention, each of which includes palladium-gold metal particles.
- Example 5 includes platinum- palladium metal particles having a weight ratio of 2.0%:1.0% in the front brick and palladium-gold metal particles having weight ratio of 1.7%:2.0% in the rear brick.
- Example 6 includes platinum-palladium metal particles having a weight ratio of 4.0%:1.0% in the front brick and palladium-gold metal particles having weight ratio of 1.7%:2.0% in the rear brick.
- Example 7 includes platinum-palladium metal particles having a weight ratio of 2.0%: 1.0% in the front brick and palladium-gold metal particles having weight ratio of 1.7%:2.0% in the rear brick. Both bricks in Example 7 used a washcoat slurry with approximately 28% ceria-zirconia added in (the rest was the precious group metal and alumina powder). Relative to the benchmark emission control catalyst of Example 4, a reduction in HC emissions and similar or better CO oxidation performance have been observed with the emission control catalysts of Examples 5, 6 and 7.
- FIGS. 3B-3D illustrate three different configurations of a substrate 210 of an engine exhaust catalyst that is designed to suppress these catalyst aging effects and allow maximum performance.
- the three configurations of the substrate 210 described above suppress the formation of the ternary alloy by keeping the platinum physically separate from palladium-gold.
- Vehicle CO emission data for examples of some of the above described configurations are shown in Tables 1- 4. It is clear that the benefits of combining a Pt-based catalyst with a Pd-Au catalyst are maintained while the possibility of forming a ternary alloy upon extensive aging has been significantly reduced in the case of multi-layer systems or eliminated completely in the case of multi-brick systems.
- ceria-based materials in the middle layer might further slow down Pt migration and suppress ternary alloy formation. See Nagai, et. al., "Sintering inhibition mechanism of platinum supported on ceria- based oxide and Pt-oxide-support interaction," J. Catal. Vol. 242, pp. 103-109 (2006).
- a palladium-containing middle layer will allow formation of additional binary alloys upon sintering and slow down the sintering process as alloys tend to sinter less than individual metals.
- Lanthanum-stabilized alumina (578 g, having a surface area of -200 m 2 g "1 ) and 2940 ml_ of de-ionized water (>18M ⁇ ) were added to a 5 L plastic beaker and magnetically stirred at about 500 rpm. The pH measured was 8.5 and the temperature measured was 25 0 C. After 20 minutes, Pd(NO 3 ) 2 (67.8 g of 14.8% aqueous solution) was gradually added over a period of 10 min. The pH measured was 4.3. After stirring for 20 minutes, a second metal, HAuCI 4 (24 g dissolved in 50 ml_ of de-ionized water), was added over a period of 5 min.
- HAuCI 4 24 g dissolved in 50 ml_ of de-ionized water
- the pH was 4.0 and the temperature of the metal-support slurry was 25 °C.
- the metal-support slurry was stirred for an additional 30 min.
- NaBH 4 (29.4 g) and NaOH (31.1 g) were added to N 2 H 4 (142 ml_ of 35% aqueous solution) and stirred until the mixture became clear.
- This mixture constituted the reducing agent mixture.
- the metal-support slurry and reducing agent mixture were combined continuously using two peristaltic pumps. The two streams were combined using a Y joint connected to a Vigreux column to cause turbulent mixing.
- the reaction product leaving the mixing chamber, i.e., the Vigreux column was pumped into an intermediate vessel of smaller volume and continuously stirred.
- the product in the intermediate vessel was continuously pumped into a larger vessel, i.e., 5 L beaker, for residence and with continued stirring. The entire addition/mixing process lasted about 30 min.
- the resulting product slurry was stirred in the larger vessel for an additional period of 1 h.
- the final pH was 11.0 and the temperature was 25 0 C.
- the product slurry was then filtered using vacuum techniques via Buchner funnels provided with a double layer of filter paper having 3 ⁇ m porosity. The filter cake was then washed with about 20 L of de-ionized water in several approximately equal portions.
- the solid La-doped alumina supported Pt catalyst was separated from the liquid via filtration, dried at 120 °C for 2 hours, ground into a fine powder, and calcined in air for 2 hours at a temperature of 500 0 C (heated at 8 °C min "1 ) to give a 3% Pt material.
- the solid La-doped alumina supported PtPd catalyst was separated from the liquid via filtration, dried at 120 0 C for 2 hours, ground into a fine powder, and calcined in air for 2 hours at a temperature of 500 0 C (heated at 8 °C min "1 ) to give a 3% Pt, 1.5% Pd material. This material was diluted to 2.8% Pt, 1.4% Pd via addition of blank La-doped alumina support and the diluted mixture was used in preparing Examples 1 , 2, 8, 9, and 11.
- the solid La-doped alumina supported Pt catalyst was separated from the liquid via filtration, dried at 120 0 C for 2 hours, ground into a fine powder, and calcined in air for 2 hours at a temperature of 500 0 C (heated at 8 °C min "1 ) to give a 2% Pt material.
- the solid La-doped alumina supported PtPd catalyst was separated from the liquid via filtration, dried at 120 0 C for 2 hours, ground into a fine powder, and calcined in air for 2 hours at a temperature of 500 0 C (heated at 8 0 C min "1 ) to give a 2% Pt, 1% Pd material. This material was used in preparing Examples 4, 5 and 7.
- the solid La-doped alumina supported Pt catalyst was separated from the liquid via filtration, dried at 120 0 C for 2 hours, ground into a fine powder, and calcined in air for 2 hours at a temperature of 500 0 C (heated at 8 °C min "1 ) to give a 4% Pt material.
- the solid La-doped alumina supported PtPd catalyst was separated from the liquid via filtration, dried at 120 0 C for 2 hours, ground into a fine powder, and calcined in air for 2 hours at a temperature of 500 0 C (heated at 8 °C min "1 ) to give a 4% Pt, 1% Pd material. This material was then diluted to 3.0% Pt, 0.75% Pd via addition of blank La-doped alumina support and the diluted mixture was used in preparing Examples 3 and 6.
- the solid La-doped alumina supported Pt catalyst was separated from the liquid via filtration, dried at 120 0 C for 2 hours, ground into a fine powder, and calcined in air for 2 hours at a temperature of 500 0 C (heated at 8 °C min "1 ).
- the solid La-doped alumina supported PtPd catalyst was separated from the liquid via filtration, dried at 120 0 C for 2 hours, ground into a fine powder, and calcined in air for 2 hours at a temperature of 500 0 C (heated at 8 °C min "1 ) to give a supported 3% Pd material. This material was used in preparing Example 11.
- Example 1 - Tri-layer PtPd (at 57.5 g/ft 3 ) 1st layer, beta zeolite 2nd layer, PtPd (at 57.5 g/ft 3 ) 3rd layer.
- the supported PtPd catalyst powder (2.8% Pt, 1.4% Pd) prepared as described above was made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the washcoat slurry was coated onto a round cordierite monolith (Corning, 400 cpsi, 5.66 inches X 2.5 inches), dried at 120 °C and calcined at 500 0 C to give the first layer of the multi-layer coated monolith, such that the PtPd loading was -57.5 g/ft 3 .
- beta zeolite was made into a washcoat slurry via addition to de- ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the zeolite washcoat slurry was coated onto the cordierite monolith (with the first layer of PtPd), dried at 120 °C and calcined at 500 °C to give the second layer of the multi-layer coated monolith.
- the zeolite mixture comprises about 20% of the total washcoat loading.
- the supported PtPd catalyst powder (2.8% Pt, 1.4% Pd) prepared as described above was made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the washcoat slurry was coated onto the cordierite monolith (with the first layer of PtPd and the second layer of zeolite), dried at 120 °C and calcined at 500 °C to give the third layer of the multi-layer coated monolith, such that the PtPd loading was -57.5 g/ft 3 .
- the multi-layer coated monolith was canned according to methods known in the art and tested using a certified testing facility on a light-duty diesel vehicle, as described above.
- Example 2 - Tri-layer PtPd (at 57.5 g/ft 3 ) 1st layer, zeolite mixture 2nd layer, PtPd (at 57.5 g/ft 3 ) 3rd layer.
- the supported PtPd catalyst powder (2.8% Pt, 1.4% Pd) prepared as described above was made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the washcoat slurry was coated onto a round cordierite monolith (Corning, 400 cpsi, 5.66 inches X 2.5 inches), dried at 120 0 C and calcined at 500 0 C to give the first layer of the multi-layer coated monolith, such that the PtPd loading was -57.5 g/ft 3 .
- a beta zeolite and a ZSM-5 zeolite were combined and made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the zeolite washcoat slurry was coated onto the cordierite monolith (with the first layer of PtPd) 1 dried at 120 °C and calcined at 500 0 C to give the second layer of the multi-layer coated monolith.
- the zeolite mixture comprises about 20% of the total washcoat loading.
- the supported PtPd catalyst powder (2.8% Pt, 1.4% Pd) prepared as described above was made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the washcoat slurry was coated onto the cordierite monolith (with the first layer of PtPd and the second layer of zeolite), dried at 120 °C and calcined at 500 °C to give the third layer of the multi-layer coated monolith, such that the PtPd loading was -57.5 g/ft 3 .
- the multi-layer coated monolith was canned according to methods known in the art and tested using a certified testing facility on a light-duty diesel vehicle, as described above.
- Example 3 PdAu (at 65 g/ft 3 ) 1st layer, zeolite mixture 2nd layer, PtPd (at 65 g/ft 3 ) 3rd layer.
- the supported PdAu catalyst powder (1.7% Pd, 2.0% Au) prepared as described above was made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the washcoat slurry was coated onto a round cordierite monolith (Corning, 400 cpsi, 5.66 inches X 2.5 inches), dried at 120 °C and calcined at 500 0 C to give the first layer of the multi-layer coated monolith, such that the PdAu loading was -65 g/ft 3 .
- a beta zeolite and a ZSM-5 zeolite were combined and made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the zeolite washcoat slurry was coated onto the cordierite monolith (with the first layer of PtPd), dried at 120 °C and calcined at 500 0 C to give the second layer of the multi-layer coated monolith.
- the zeolite mixture comprises about 20% of the total washcoat loading.
- the supported PtPd catalyst powder (3.0% Pt, 0.75% Pd) prepared as described above was made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the washcoat slurry was coated onto the cordierite monolith (with the first layer of PdAu and the second layer of zeolite), dried at 120 0 C and calcined at 500 °C to give the third layer of the multi-layer coated monolith, such that the PtPd loading was -65 g/ft 3 .
- the multi-layer coated monolith was canned according to methods known in the art and tested using a certified testing facility on a light-duty diesel vehicle, as described above.
- the supported PtPd catalyst powder (2.0% Pt, 1.0% Pd) prepared above was made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the washcoat slurry was coated onto both the front brick and the rear brick of a round cordierite monolith (each brick: Corning, 400 cpsi, 5.66 inches X 1.25 inches), dried at 120 °C and calcined at 500 0 C to give the final coated monolith with a precious metal (Pt + Pd) loading of 120 g/ft 3 .
- the coated monolith was canned according to methods known in the art and tested using a certified testing facility on a light-duty diesel vehicle, as described above.
- Example 5 Multi-brick: Pt/Pd (at 120 g/ft 3 ) front and PdAu (at 175 g/ft 3 ) rear
- the supported PtPd catalyst powder (2.0% Pt, 1.0% Pd) prepared as described above was made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the washcoat slurry was coated onto a round cordierite monolith (Corning, 400 cpsi, 5.66 inches X 1.25 inches), dried at 120 °C and calcined at 500 °C to give the final coated monolith with a precious metal loading of 120 g/ft 3 PtPd. This represented the front brick of a two brick system.
- the supported PdAu catalyst powder (1.7% Pd, 2.0% Au) prepared as described above was made into a washcoat slurry via addition to de- ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the washcoat slurry was coated onto a round cordierite monolith (Corning, 400 cpsi, 5.66 inches X 1.25 inches), dried at 120 °C and calcined at 500 °C to give the final coated monolith with a precious metal loading of 175 g/ft 3 PdAu. This represented the outlet brick of a two brick system.
- coated PtPd monolith front brick
- coated PdAu monolith rear brick
- Example 6 Multi-brick: Pt/Pd (at 130 g/ft 3 ) front and PdAu (at 130 g/ft 3 ) rear
- the supported PtPd catalyst powder (3.0% Pt, 0.75% Pd) prepared as described above was made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the washcoat slurry was coated onto a round cordierite monolith (Corning, 400 cpsi, 5.66 inches X 1.25 inches), dried at 120 °C and calcined at 500 °C to give the final coated monolith with a precious metal loading of 130 g/ft 3 PtPd. This represented the front brick of a two brick system.
- the supported PdAu catalyst powder (1.7% Pd, 2.0% Au) prepared as described above was made into a washcoat slurry via addition to de- ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the washcoat slurry was coated onto a round cordierite monolith (Corning, 400 cpsi, 5.66 inches X 1.25 inches), dried at 120 °C and calcined at 500 °C to give the final coated monolith with a precious metal loading of 130 g/ft 3 PdAu. This represented the outlet brick of a two brick system.
- the supported PtPd catalyst powder (2.0% Pt, 1.0% Pd) prepared as described above was made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- Ceria-zirconia was added to this washcoat slurry so that ceria-zirconia represented about 28% by weight.
- the washcoat slurry was coated onto a round cordierite monolith (Corning, 400 cpsi, 5.66 inches X 1.25 inches), dried at 120 0 C and calcined at 500 0 C to give the final coated monolith with a precious metal loading of 150 g/ft 3 PtPd.
- the supported PdAu catalyst powder (1.7% Pd, 2.0% Au) prepared as described above was made into a washcoat slurry via addition to de- ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- Ceria-zirconia was added to this washcoat slurry so that ceria-zirconia represented about 28% by weight.
- the washcoat slurry was coated onto a round cordierite monolith (Corning, 400 cpsi, 5.66 inches X 1.25 inches), dried at 120 0 C and calcined at 500 °C to give the final coated monolith with a precious metal loading of 130 g/ft 3 PdAu. This represented the outlet brick of a two brick system.
- coated PtPd monolith front brick
- coated PdAu monolith rear brick
- Example 8 Multi-brick control: Pt/Pd (at 170 g/ft3) front and a blank rear
- the supported PtPd catalyst powder (2.8% Pt, 1.4% Pd) prepared as described above was made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the washcoat slurry was coated onto a round cordierite monolith (Corning, 400 cpsi, 5.66 inches X 1.25 inches), dried at 120 °C and calcined at 500 0 C to give the final coated monolith with a precious metal loading of 170 g/ft 3 PtPd. This represented the front brick of a two brick system.
- a blank cordierite monolith of equal size (Corning, 400 cpsi, 5.66 inches X 1.25 inches) was designated as the rear brick.
- the coated monolith and the blank brick were then canned according to methods known in the art such that the front brick was closest to the engine (and hence would be exposed to the exhaust first), and tested using a certified testing facility on a light-duty diesel vehicle, as described above.
- Example 9 Multi-brick: Pt/Pd (at 170 g/ft3) front and PdAu (at 146 g/ft 3) rear
- the supported PtPd catalyst powder (2.8% Pt, 1.4% Pd) prepared as described above was made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the washcoat slurry was coated onto a round cordierite monolith (Corning, 400 cpsi, 5.66 inches X 1.25 inches), dried at 120 °C and calcined at 500 0 C to give the final coated monolith with a precious metal loading of 170 g/ft 3 PtPd. This represented the front brick of a two brick system.
- the supported PdAu catalyst powder (1.7% Pd, 2.0% Au) prepared as described above was made into a washcoat slurry via addition to de- ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the washcoat slurry was coated onto a round cordierite monolith (Corning, 400 cpsi, 5.66 inches X 1.25 inches), dried at 120 0 C and calcined at 500 0 C to give the final coated monolith with a precious metal loading of 146 g/ft 3 PdAu. This represented the rear brick of a two brick system.
- coated PtPd monolith front brick
- coated PdAu monolith rear brick
- Example 10 Multi-brick: PtBi (at 120 g/ft3) front and PdAu (at 146 g/ft3) rear
- the supported PtBi catalyst powder (3.0% Pt, 2.0% Bi) prepared as described above was made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the washcoat slurry was coated onto a round cordierite monolith (Corning, 400 cpsi, 5.66 inches X 1.25 inches), dried at 120 0 C and calcined at 500 °C to give the final coated monolith with a precious metal loading of 120 g/ft 3 Pt. This represented the front brick of a two brick system.
- the supported PdAu catalyst powder (1.7% Pd, 2.0% Au) prepared as described above was made into a washcoat slurry via addition to de- ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the washcoat slurry was coated onto a round cordierite monolith (Corning, 400 cpsi, 5.66 inches X 1.25 inches), dried at 120 °C and calcined at 500 °C to give the final coated monolith with a precious metal loading of 146 g/ft 3 PdAu. This represented the rear brick of a two brick system.
- Example 11 - Multi-layer PdAu (at 73 g/ft3) 1st layer, Pd (at 30 g/ft3) 2nd layer, PtPd (at 85 g/ft3) 3rd layer.
- the supported PdAu catalyst powder (1.7% Pd, 2.0% Au) prepared above was made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the washcoat slurry was coated onto a round cordierite monolith (Corning, 400 cpsi, 5.66 inches X 2.5 inches), dried at 120 °C and calcined at 500 0 C to give the first layer of the multi-layer coated monolith.
- the supported Pd catalyst powder (3.0% Pd) prepared above was made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size (typically with a d 50 range from 3 to 7 ⁇ m), and pH adjustment to give an appropriate viscosity for washcoating.
- the Pd washcoat slurry was coated onto the multi-layer coated cordierite monolith (with the 1 st layer of PdAu) such that the Pd loading was -30 g/ft 3 after appropriate drying at 120 °C and calcination at 500 °C to give the second layer of the multi-layer coated monolith.
- the supported PtPd catalyst powder (2.8% Pt, 1.4% Pd) prepared above was made into a washcoat slurry via addition to de-ionized water, milling to an appropriate particle size, and pH adjustment to give an appropriate viscosity for washcoating.
- the PtPd washcoat slurry was coated onto the multi-layer coated cordierite monolith (with the 1 st layer of PdAu and the 2 nd layer of Pd) such that the PtPd loading was -85 g/ft 3 after appropriate drying at 120 0 C and calcination at 500 °C to give the third layer of the multi-layer coated monolith.
- the resulting multi-layer (tri-layer in this case) coated monolith had precious metal loadings of 73 g/ft 3 PdAu (1 st layer), 30 g/ft 3 Pd (2 nd layer), and 85 g/ft 3 PtPd (3 rd layer).
- the multi-layer coated monolith was canned according to methods known in the art and tested using a certified testing facility on a light-duty diesel vehicle, as described above.
Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP07869495A EP2106291A4 (en) | 2007-01-17 | 2007-12-19 | Engine exhaust catalysts containing palladium-gold |
KR1020097016749A KR101051874B1 (en) | 2007-01-17 | 2007-12-19 | Engine Exhaust Catalysts Containing Palladium-Gold |
CN2007800501179A CN101583423B (en) | 2007-01-17 | 2007-12-19 | Engine exhaust catalysts containing palladium-gold |
JP2009546387A JP5196674B2 (en) | 2007-01-17 | 2007-12-19 | Engine exhaust gas catalyst containing palladium-gold |
Applications Claiming Priority (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/624,116 | 2007-01-17 | ||
US11/624,128 US7709414B2 (en) | 2006-11-27 | 2007-01-17 | Engine exhaust catalysts containing palladium-gold |
US11/624,116 US20080125313A1 (en) | 2006-11-27 | 2007-01-17 | Engine Exhaust Catalysts Containing Palladium-Gold |
US11/624,128 | 2007-01-17 | ||
US11/942,710 | 2007-11-20 | ||
US11/942,710 US7534738B2 (en) | 2006-11-27 | 2007-11-20 | Engine exhaust catalysts containing palladium-gold |
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WO2008088649A1 true WO2008088649A1 (en) | 2008-07-24 |
Family
ID=39637672
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PCT/US2007/088085 WO2008088649A1 (en) | 2007-01-17 | 2007-12-19 | Engine exhaust catalysts containing palladium-gold |
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EP (1) | EP2106291A4 (en) |
JP (2) | JP5196674B2 (en) |
KR (1) | KR101051874B1 (en) |
CN (1) | CN101683622B (en) |
WO (1) | WO2008088649A1 (en) |
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CN101683622A (en) | 2010-03-31 |
JP2010516445A (en) | 2010-05-20 |
KR20090101377A (en) | 2009-09-25 |
JP5226633B2 (en) | 2013-07-03 |
JP5196674B2 (en) | 2013-05-15 |
JP2010042408A (en) | 2010-02-25 |
CN101683622B (en) | 2013-03-06 |
KR101051874B1 (en) | 2011-07-25 |
EP2106291A1 (en) | 2009-10-07 |
EP2106291A4 (en) | 2011-10-26 |
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