Basf Corporation

Other

Basf Se Corporation

Stephan Siemund

Knut Wassermann

Attilio Siani

Thomas Schmitz

Janosch Cravillon

Torsten Neubauer

Harold N Rabinowitz

Stefan Kotrel

Mirko Arnold

Michel Deeba

Gary A Gramiccioni

Markus Kinne

Oliver Seel

Florian Waltz

Marcus Hilgendorff

Xinyi Wei

Gerd Grubert

Shau-Lin Franklin Chen

Tian Luo

Alfred Helmut Punke

Karifala Dumbuya

Harold Rabinowitz

Junmei Wei

Jin Sakakibara

Shau-Lin Frank Chen

Kenneth R Brown

Hao Li

Burkhard Rabe

Glenn Svoboda

David Schlereth

The disclosure relates to a three-way conversion catalyst for the treatment of an exhaust gas comprising nitrogen monoxide, carbon monoxide, and hydrocarbon, wherein the catalyst comprises: (i) a substrate; (ii) a first coating comprising rhodium supported on a first oxidic component; (iii) a second coating comprising palladium supported on a non-zeolitic oxidic material, wherein the non-zeolitic oxidic material comprises manganese and a second oxidic component, wherein the second coating consists of 0 weight-% to 0.001 weight-% of platinum; wherein the first coating is disposed on the substrate over x % of the axial length, with x ranging from 80 to 100; wherein the second coating extends over y % of the axial length from the inlet end to the outlet end and is disposed on the first coating, with y ranging from 20 to x.

Three-way conversion catalyst in gasoline-natural gas applications

A four-way conversion catalyst for the treatment of an exhaust gas stream of a gasoline engine, the catalyst comprising a porous wall flow filter substrate comprising an inlet end, an outlet end, a substrate axial length extending between the inlet end and the outlet end, and a plurality of passages defined by porous internal walls of the porous wall flow filter substrate, wherein the plurality of passages comprise inlet passages having an open inlet end and a closed outlet end, and outlet passages having a closed inlet end and an open outlet end; wherein in the pores of the porous internal walls and on the surface of the porous internal walls, which surface defines the interface between the porous internal walls and the passages, the catalyst comprises a three-way conversion catalytic coating comprising an oxygen storage compound and a platinum group metal supported on a refractory metal oxide; wherein in the pores of the porous internal walls, the three-way conversion catalytic coating is present as in-wall-coating and on the surface of the porous internal walls, the three-way conversion catalytic coating is present as on-wall-coating; wherein in addition to said three-way conversion catalytic coating, the catalyst comprises no further coating in the pores of the porous internal walls and no further coating on the surface of the porous internal walls.

Four-way conversion catalyst having improved filter properties

Catalyzed particulate filters comprise three-way conversion (TWC) catalytic material, which comprises rhodium as the only platinum group metal, that permeates walls of a particulate filter. Such catalyzed particulate filters may be located downstream of close-coupled three-way conversion (TWC) composites in an emission treatment system downstream of a gasoline direct injection engine for treatment of an exhaust stream comprising hydrocarbons, carbon monoxide, nitrogen oxides, and particulates.

Monometallic rhodium-containing four-way conversion catalysts for gasoline engine emissions treatment systems

A four-way conversion catalyst for treating a gasoline engine exhaust gas has a porous wall flow filter substrate with an inlet end, outlet end, substrate axial length extending between the inlet and outlet end, and passages defined by porous internal walls of the substrate, the passages having inlet passages with an open inlet and closed outlet, and outlet passages having a closed inlet and open outlet. The internal wall pores have a three-way conversion catalytic in-wall coating with an oxygen storage compound and a platinum group metal supported on a refractory metal oxide. On at least a portion of the internal wall surface defining the interface between the internal walls and the passages, the catalyst has a porous on-wall coating from the internal wall surface to the passage. The coating has porous oxidic compound and platinum group metal content of 0 to 0.001 wt. %, of the total coating weight.

Catalyzed particulate filters comprise three-way conversion (TWC) catalytic material that permeates walls of a particulate filter such that the catalyzed particulate filter has a coated porosity that is less than an uncoated porosity of the particulate filter. The coated porosity is linearly proportional to a washcoat loading of the TWC catalytic material. A coated backpressure is non-detrimental to performance of the engine. Such catalyzed particulate filters may be used in an emission treatment system downstream of a gasoline direct injection engine for treatment of an exhaust stream comprising hydrocarbons, carbon monoxide, nitrogen oxides, and particulates.

Four way conversion catalysts for gasoline engine emissions treatment systems

Provided are catalyst composites whose catalytic material is effective to substantially simultaneously oxidize carbon monoxide and hydrocarbons and reduce nitrogen oxides. The catalyst composites have a two-metal layer on a carrier, the two-metal layer comprising a rhodium component supported by a first support comprising a refractory metal oxide component or a first ceria-zirconia composite; a palladium component supported by a second support comprising a second ceria-zirconia composite; one or more of a promoter, stabilizer, or binder; wherein the amount of the total of the first and second ceria-zirconia composites in the two-metal layer is equal to or greater than the amount of the refractory metal oxide component. Methods of making and using the same are also provided.

Automotive catalyst composites having a two-metal layer

A catalyst material including a catalyst carrier including a porous alumina support and a hindrance layer on the alumina support, the hindrance layer comprising one or more barium sulfate, strontium sulfate, zirconium sulfate, and calcium sulfate is described. The catalyst carrier further includes a rare earth oxide. The catalyst material can further comprise a platinum group metal oxide. The hindrance layer may prevent the rare earth oxide from forming a complex with the support. The catalyst material is useful for methods and systems of abating pollutants from automotive exhaust gas.

Catalyst materials

Exhaust systems and components are suitable for use with gasoline engines to capture particulates and to reduce gaseous emissions, where three-way conversion (TWC) catalysts located on a particulate filters are provided. Coated particle filters having washcoat loadings in the range of 1 to 4 g/ftresult in minimal impact on back pressure while simultaneously providing TWC catalytic activity and particle trapping functionality to meet increasingly stringent regulations such as Euro 6. Sufficient to high levels of oxygen storage components (OSC) are also delivered on and/or within the filter. The filters can have a coated porosity that is substantially the same as its uncoated porosity. The TWC catalytic material can comprise a particle size distribution such that a first set of particles has a first dparticle size of 7.5 &#x3bc;m or less and a second set of particles has a second dparticle size of more than 7.5 &#x3bc;m.

Gasoline engine emissions treatment systems having particulate filters

The present invention relates to a treatment system for a gasoline engine exhaust gas stream comprising a particulate filter, said particulate filter comprising: a particulate filter substrate, an inlet layer disposed on the exhaust gas inlet surface of the filter substrate, and an outlet layer disposed on the exhaust gas outlet surface of the filter substrate, wherein the inlet layer comprises Rh and/or Pd, and the outlet layer comprises Rh and/or a zeolite.

Treatment system for gasoline engine exhaust gas

Provided are exhaust systems and components suitable for use in conjunction with gasoline engines to treat gaseous emissions such as hydrocarbons, nitrogen oxides, and carbon monoxides. Layered three-way conversion (TWC) catalysts comprise an outer layer whose rhodium is supported by an oxygen storage component, such as a ceria-zirconia composite, and the outer layer is substantially free from alumina as a support. The rhodium-containing layer can be free of all other precious metals, such as platinum and palladium. A lower palladium layer is provided where the palladium is supported by a refractory metal oxide. The lower palladium layer can be free of rhodium and platinum and can contain an oxygen storage component that is the same or different from that in the rhodium-containing layer. Methods of making and using these catalysts are also provided.

Three way conversion catalyst with alumina-free rhodium layer

A layered three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides is disclosed. Engine exhaust treatment system and methods of using the same are also provided. The catalytic material can be provided in layers such that a larger amount of oxygen storage component is provided in a downstream zone as compared to an upstream zone. For example, the upstream zone can be configured to have one, two, or three layers, and the downstream zone can be independently configured to have one, two, or three layers. In one or more embodiments, the catalyst supported on a carrier has three layers, where at least two of the layers are zoned to have an oxygen storage component being present in an upstream zone in an amount that is less than the oxygen storage component present in the downstream zone.

Multilayered catalyst compositions

Provided are catalyst composites comprising: a catalytic material on a carrier, the catalytic material comprising a precious metal selected from a palladium component and an oxygen storage component, the oxygen storage component being present in an amount of at least 10% by weight, wherein substantially all of the oxygen storage component is in intimate contact with the palladium component and the catalytic material is effective to substantially simultaneously oxidize carbon monoxide and hydrocarbons and reduce nitrogen oxides. A catalyst composite comprising: a catalytic material on a carrier, the catalytic material comprising a palladium component and a ceria-zirconia composite support, the ceria being present in an amount in the range of 10 to 70% by weight, wherein substantially all of the ceria is in intimate contact with at least a portion of the palladium component. Methods of making and using these catalysts are also provided.

Catalyst compositions

A multilayered, three-way conversion catalyst having the capability of simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides is disclosed. Provided is a catalytic material of at least four layers in conjunction with a carrier, where each of the layers includes a support, at least three layers comprise a precious metal component, and at least one layer comprises an oxygen storage component (OSC). The catalytic material can further comprise a fifth layer, where at least four layers comprise a precious metal component, at least one layer comprises an oxygen storage component, and at least one layer is substantially free of an oxygen storage component.

Growing community of inventors

Pattensen, Germany

Stephan Siemund