Johnson Matthey Public Limited Company

David Micallef

Paul Richard Phillips

Andrew Francis Chiffey

Francois Moreau

Kieran John Cole

Mikael Larsson

Robert Hanley

Christopher Daly

Lee Alexander Gilbert

Oliver Cooper

George Platt

Neil Greenham

Jing Lu

Andrew Newman

Per Marsh

Hai-Ying Chen

Joseph Michael Fedeyko

James Alexander Wylie

Alexander Green

Caitlin Lucy Jenkins

Alex Parsons

Jonas Edvardsson

Heledd Howells

A compression ignition internal combustion engine () for a heavy-duty diesel vehicle comprising an exhaust system () comprising a composite oxidation catalyst () and a soot filter substrate () disposed downstream from the composite oxidation catalyst comprising: a substrate (), preferably a honeycomb flow-through substrate monolith, having a total length L and a longitudinal axis and having a substrate surface extending axially between a first substrate end (I) and a second substrate end (O); two catalyst washcoat zones () arranged axially in series on and along the substrate surface, wherein a first catalyst washcoat zone () having a length Land comprising a first catalyst washcoat layer (), wherein L<L, is defined at one end by the first substrate end (I) and at a second end by a first end () of a second catalyst washcoat zone () having a length Land comprising a second catalyst washcoat layer (), wherein L<L, wherein the second catalyst washcoat zone () is defined at a second end thereof by the second substrate end (O), and wherein the first substrate end (I) of the composite oxidation catalyst () is oriented to an upstream side and wherein the first catalyst washcoat zone () comprises a first refractory metal oxide support material and two or more platinum group metal components supported thereon comprising both platinum and palladium at a weight ratio of platinum to palladium of <1; and the second catalyst washcoat zone () comprises a second refractory metal oxide support material and one or more platinum group metal components supported thereon; and a washcoat overlayer (G) extending axially from the first substrate end (I) comprising a particulate metal oxide having a loading of >48.8 g/l (>0.8 g/in), wherein a total platinum group metal loading in the first catalyst washcoat zone () defined in grams of platinum group metal per litre of substrate volume (g/l) is greater than a total platinum group metal loading in the second catalyst washcoat zone () and wherein the first catalyst washcoat zone () comprises one or more first alkaline earth metal components, preferably barium, supported on the first refractory metal oxide support material.

Composite, zoned oxidation catalyst for a compression ignition internal combustion engine

A composite, zone-coated, dual-use ammonia (AMOX) and nitric oxide oxidation catalyst () comprises: a substrate () having a total length L and a longitudinal axis and having a substrate surface extending axially between a first substrate end (I) and a second substrate end (O); two or more catalyst washcoat zones () comprised of a first catalyst washcoat layer () comprising a refractory metal oxide support material and one or more platinum group metal components supported thereon and a second catalyst washcoat layer () different from the first catalyst washcoat layer () and comprising a refractory metal oxide support material and one or more platinum group metal components supported thereon, which two or more catalyst washcoat zones () being arranged axially in series on and along the substrate surface, wherein a first catalyst washcoat zone () having a length L, wherein L<L, is defined at one end by the first substrate end (I) and at a second end () by a first end () of a second catalyst washcoat zone () having a length L, wherein L<L, wherein the first catalyst washcoat zone () comprises a first refractory metal oxide support material and one or more platinum group metal components supported thereon; and the second catalyst washcoat zone comprises a second refractory metal oxide support material and one or more platinum group metal components supported thereon; and a washcoat overlayer (G) extending axially from the first substrate end for up to 200% of the axial length of the underlying first catalyst washcoat layer, which washcoat overlayer comprising a particulate metal oxide loading of >48.8 g/l (>0.8 g/in), wherein the particulate metal oxide is an aluminosilicate zeolite including at least one of copper, iron and manganese, wherein a total platinum group metal loading in the first catalyst washcoat zone () defined in grams of platinum group metal per litre of substrate volume (g/l) is different from the total platinum group metal loading in the second catalyst washcoat zone ().

Composite, zone-coated, dual-use ammonia (AMOX) and nitric oxide oxidation catalyst

A composite oxidation catalyst for use in an exhaust system for treating an exhaust gas produced by a vehicular compression ignition internal combustion engine is disclosed. The composite oxidation catalyst comprises a honeycomb flow-through substrate monolith and two catalyst washcoat zones arranged axially in series on and along the substrate surface.

Composite, zoned oxidation catalys for a compression ignition internal combustion engine

A composite oxidation catalyst () for use in an exhaust system for treating an exhaust gas produced by a vehicular compression ignition internal combustion engine () and upstream of a particulate matter filter () in the exhaust system comprises a substrate () having a total length L and a longitudinal axis and having a substrate surface extending axially between a first substrate end (I) and a second substrate end (O); and three or more catalyst washcoat zones (; or) arranged axially in series on and along the substrate surface, wherein a first catalyst washcoat zone () having a length L, wherein L<L, is defined at one end by the first substrate end (I) and at a second end by a first end () of a second catalyst washcoat zone () having a length L, wherein L<L, wherein the first catalyst washcoat zone () comprises a first refractory metal oxide support material and two or more platinum group metal components supported thereon comprising both platinum and palladium at a weight ratio of platinum to palladium of ≥1; the second catalyst washcoat zone () comprises a second refractory metal oxide support material and one or more platinum group metal components supported thereon; and a third catalyst washcoat zone () comprising a third refractory metal oxide support material and one or more platinum group metal components supported thereon is defined at a second end thereof by the second substrate end (O), wherein a total platinum group metal loading in the first catalyst washcoat zone () defined in grams of platinum group metal per cubic foot of substrate volume (g/l) (g/ft) is greater than a total platinum group metal loading in the second catalyst washcoat zone (), wherein a total platinum group metal loading in the third catalyst washcoat zone () defined in grams of platinum group metal per cubic foot of substrate volume (g/l) (g/ft) is less than the total platinum group metal loading in the second catalyst washcoat zone () and wherein the first catalyst washcoat zone () comprises one or more first alkaline earth metal components supported on the first refractory metal oxide support material.

A catalyst article including a substrate with an inlet end and an outlet end, a first zone and a second zone, where the first zone comprises: a) an ammonia slip catalyst (ASC) bottom layer comprising a platinum group metal on a support; and b) an SCR layer comprising a second SCR catalyst, the SCR layer located over the ASC bottom layer; where the second zone comprises a catalyst ('second zone catalyst') selected from the group consisting of a diesel oxidation catalyst (DOC) and a diesel exotherm catalyst (DEC); wherein the ASC bottom layer extends into the second zone; and where the first zone is located upstream of the second zone. The ASC bottom layer may include a blend of: (1) the platinum group metal on a support and (2) a first SCR catalyst.

SCR with turbo and ASC/DOC close-coupled system

Catalyst articles having an ammonia slip catalyst (ASC) comprising a blend of platinum on a support with low ammonia storage and a first SCR catalyst, and a second catalyst, such as a diesel oxidation catalyst, a diesel exotherm catalyst (DEC), a NOx absorber, a selective catalytic reduction/passive NOx adsorber (SCR/PNA), a cold-start catalyst (CSC) or a three-way catalyst (TWC) are disclosed. The catalyst articles can also contain one or two additional SCR catalysts. The catalysts can be present in one of various configurations. The catalytic articles are useful for selective catalytic reduction (SCR) of NOx in exhaust gases and in reducing the amount of ammonia slip. Methods of using the catalytic articles in an SCR process, where the amount of ammonia slip is reduced, are also described.

Ammonia slip catalyst designed to be first in an SCR system

A catalyst article for treating a flow of a combustion exhaust gas comprises: a catalytically active substrate comprising one or more channels extending along an axial length thereof through which, in use, a combustion exhaust gas flows, the one or more channels having a first surface for contacting a flow of combustion exhaust gas; wherein the substrate is formed of an extruded vanadium-containing SCR catalyst material, wherein a first layer is provided on at least a portion of said first surface, wherein the first layer comprises an ammonia slip catalyst composition comprising one or more platinum group metals supported on titania, a silica-titania mixed oxide, a Ce&#x2014;Zr mixed oxide, or a mixture thereof, and a second layer is provided on at least a portion of the first layer and comprises an SCR catalyst composition.

Catalyst article for use in an emission treatment system

A catalyst article for treating an emission gas is provided comprising (a) an oxidation catalyst comprising at least one noble metal on a WO&#x2014;TiOsupport, wherein the support contains about 1 to about 20 weight percent WObased on the combined weight of the WOand TiO; and (b) a substrate, wherein the first and second catalyst layers are on and/or within the substrate.

Tungsten/titania oxidation catalyst

A catalyst article having an extruded support having a plurality of channels through which exhaust gas flows during operation of an engine, and a single layer coating or a bi-layer coating on the support, where the extruded support contains a third SCR catalyst, the single layer coating and the bilayer-coating contain platinum on a support with low ammonia storage and a first SCR catalyst. The catalytic articles are useful for selective catalytic reduction (SCR) of NOx in exhaust gases and in reducing the amount of ammonia slip. Methods for producing such articles are described. Methods of using the catalytic articles in an SCR process, where the amount of ammonia slip is reduced, are also described.

Growing community of inventors

Royston, United Kingdom

David Micallef