Johnson Matthey Public Limited Company

Johnson Matthey Inc.

Francois Moreau

Andrew Francis Chiffey

Paul Richard Phillips

John Benjamin Goodwin

David Bergeal

Daniel Hatcher

James Leeland

Raj Rao Rajaram

Agnes Suganya Raj

Cathal Francis Prendergast

Christopher Daly

Matthew O'Brien

Oliver Cooper

Neil Robert Collins

Kieran John Cole

David Micallef

Robert Hanley

Lee Alexander Gilbert

George Platt

Gavin Michael Brown

Laura Mitchell-Downie

Jack Corps

Stuart David Reid

Daniel Swallow

Peter Johnston

David Thompsett

Jillian Elaine Collier

Mark Robert Feaviour

Neil Greenham

Sanyuan Yang

James Alexander Wylie

Alexander Green

Yannick Bidal

Andrew Armitage

Caitlin Lucy Jenkins

Per Marsh

Nuria Lastra-Calvo

Bergeal David

Jonas Edvardsson

Steven Merrick

David Xuereb

Freyja Woods

Kamila Goldyn

Amelie Duraud

Kieran Cole

Agnes Raj

David Micallief

Cathal Prendergast

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 system comprising (i) a vehicular compression ignition engine comprising one or more engine cylinders and one or more electronically-controlled fuel injectors therefor; (ii) an exhaust line for the engine comprising: a first emissions control device comprising a first honeycomb substrate, which comprises a hydrocarbon adsorbent component; and a second emissions control device comprising an electrically heatable element and a catalysed second honeycomb substrate, which comprises a rhodium-free platinum group metal comprising platinum, wherein the electrically heatable element is disposed upstream from the catalysed second honeycomb substrate and wherein both the electrically heatable element and the catalysed second honeycomb substrate are disposed downstream from the first honeycomb substrate; a third emissions control device, which is a third honeycomb substrate comprising an ammonia-selective catalytic reduction catalyst disposed downstream from the second emissions control device; and one or more temperature sensors located: upstream of the electrically heatable element and/or upstream of the first honeycomb substrate; and between the electrically heatable element and the catalysed second honeycomb substrate; and (iii) an engine control unit comprising a central processing unit pre-programmed, when in use, to control both a heating activation state of the electrically heatable element; an injection timing strategy of the one or more electronically-controlled fuel injector to increase the temperature of at least the first emissions control device following key-on/cold-starting a vehicle comprising the system, wherein the one or more temperature sensors are electrically connected to the engine control unit for feedback control in the system.

System comprising vehicular compression ignition engine and an emissions control device comprising an electrically heatable element

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 system () comprising (i) a vehicular compression ignition engine () comprising one or more engine cylinders and one or more electronically-controlled fuel injectors therefor; (ii) an exhaust line () for the engine comprising: a first emissions control device () comprising a first honeycomb substrate, which comprises a hydrocarbon adsorbent component; and a second emissions control device () comprising an electrically heatable element () and a catalysed second honeycomb substrate (), which comprises a rhodium-free platinum group metal (PGM) comprising platinum, wherein the electrically heatable element () is disposed upstream from the catalysed second honeycomb substrate () and wherein both the electrically heatable element () and the catalysed second honeycomb substrate () are disposed downstream from the first honeycomb substrate; a third emissions control device (), which is a third honeycomb substrate comprising an ammonia-selective catalytic reduction catalyst disposed downstream from the second emissions control device (); and one or more temperature sensors located: upstream of the electrically heatable element and/or upstream of the first honeycomb substrate; and between the electrically heatable element () and the catalysed second honeycomb substrate (); and (iii) an engine control unit () comprising a central processing unit pre-programmed, when in use, to control both a heating activation state of the electrically heatable element (); an injection timing strategy of the one or more electronically-controlled fuel injector to increase the temperature of at least the first emissions control device following key-on/cold-starting a vehicle comprising the system, wherein the one or more temperature sensors are electrically connected to the engine control unit for feedback control in the system.

An oxidation catalyst for treating an exhaust gas from a compression ignition engine, which oxidation catalyst comprises: a substrate; a first washcoat region comprising palladium (Pd) and a first support material comprising cerium oxide; and a second washcoat region comprising platinum (Pt) and a second support material.

Oxidation catalyst for a compression ignition engine

A passive NOx absorber for treating an exhaust gas from a diesel engine is described. The passive NOx absorber comprises a first washcoat region comprising a zeolite catalyst, the zeolite catalyst comprising a noble metal and a zeolite having a SAR of 2-15.

Passive NOadsorber

An exhaust system for treating an exhaust gas produced by a lean burn engine comprising: (i) a NOabsorber catalyst comprising a molecular sieve catalyst disposed on a substrate, wherein the molecular sieve catalyst comprises a noble metal and a molecular sieve, wherein the molecular sieve contains the noble metal; (ii) means for introducing hydrocarbons into the exhaust gas; and (iii) a lean NOtrap; wherein the NOabsorber catalyst is upstream of both the means for introducing hydrocarbons into the exhaust gas and the lean NOtrap.

Exhaust system comprising a passive NOadsorber

An oxidation catalyst for treating an exhaust gas from a diesel engine, which oxidation catalyst comprises: a first washcoat region comprising platinum (Pt), manganese (Mn) and a first support material; a second washcoat region comprising a platinum group metal (PGM) and a second support material; and a substrate having an inlet end and an outlet end; wherein the second washcoat region is arranged to contact the exhaust gas at the outlet end of the substrate and after contact of the exhaust gas with the first washcoat region.

Diesel oxidation catalyst and exhaust system

An oxidation catalyst for treating an exhaust gas from a diesel engine comprises: a first washcoat region for oxidising carbon monoxide (CO) and hydrocarbons (HCs), wherein the first washcoat region comprises a first platinum group metal (PGM) and a first support material, and wherein the first washcoat region does not comprise manganese or an oxide thereof; a second washcoat region for oxidising nitric oxide (NO), wherein the second washcoat region comprises platinum (Pt), manganese (Mn) and a second support material comprising a refractory metal oxide, which is silica-alumina or alumina doped with silica in a total amount of 0.5 to 45% by weight of the alumina, wherein the platinum (Pt) is disposed or supported on the second support material and the manganese (Mn) is disposed or supported on the second support material; and a substrate having an inlet end and an outlet end, and wherein the first washcoat region is a first washcoat layer and the second washcoat region is a second washcoat layer, and the second washcoat layer is disposed on the first washcoat layer; and wherein when the oxidation catalyst comprises a hydrocarbon adsorbent, which is a zeolite, then the first washcoat region further comprises the hydrocarbon adsorbent.

A method of preparing a catalyst composition for producing a stable ratio of NOto NO in an exhaust system of a compression ignition engine is described. The method comprises: (i) preparing a first composition comprising a platinum (Pt) compound disposed or supported on a support material; (ii) preparing a second composition by reducing the platinum (Pt) compound to platinum (Pt) with a reducing agent; and (iii) heating the second composition to at least 650&#xb0; C.

Catalyst with stable nitric oxide (NO) oxidation performance

A NOabsorber catalyst for treating an exhaust gas from a lean burn engine. The NOabsorber catalyst comprises a molecular sieve catalyst comprising a noble metal and a molecular sieve, wherein the molecular sieve contains the noble metal; an oxygen storage material for protecting the molecular sieve catalyst; and a substrate having an inlet end and an outlet end.

Passive NOx adsorber

A NOabsorber catalyst for treating an exhaust gas from a diesel engine. The NOabsorber catalyst comprises a first NOabsorber material comprising a molecular sieve catalyst, wherein the molecular sieve catalyst comprises a noble metal and a molecular sieve, and wherein the molecular sieve contains the noble metal; a second NOabsorber material comprising palladium (Pd) supported on an oxide of cerium; and a substrate having an inlet end and an outlet end.

An exhaust system for a diesel engine comprises an oxidation catalyst for treating an exhaust gas from the diesel engine and an emissions control device, wherein the oxidation catalyst comprises: a first washcoat zone for oxidizing carbon monoxide (CO) and hydrocarbons (HCs), wherein the first washcoat zone comprises a first platinum group metal (PGM), which is a combination of platinum and palladium, a first support material and a hydrocarbon adsorbent material, which is a zeolite, and wherein the first washcoat zone does not comprise rhodium and is substantially free of manganese or an oxide thereof; a second washcoat zone for oxidizing nitric oxide (NO), wherein the second washcoat zone comprises platinum (Pt) and manganese (Mn) disposed or supported on a second support material, wherein the second support material comprises a refractory metal oxide, wherein the refractory metal oxide is silica-alumina or an alumina doped with silica in a total amount of 0.5 to 45% by weight of the alumina, and wherein the second washcoat zone does not comprise a hydrocarbon adsorbent material, which is a zeolite; and a substrate having and inlet end and an outlet end, and wherein the second washcoat zone is disposed at an outlet end of the substrate, and the first washcoat zone disposed at an inlet end of the substrate; and wherein the emissions control device is a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction filter catalyst, a diesel particulate filter (DPF), or a catalyzed soot filter (CSF).

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Royston, United Kingdom

Francois Moreau