Catalytic Articles Containing Platinum Group Metals And Non-Platinum Group Metals And Methods Of Making And Using Same

• US 20150352493A1
• Filed: 05/27/2015
• Published: 12/10/2015
• Est. Priority Date: 06/05/2014
• Status: Active Grant

• Current Assignee: BASF Corporation (BASF SE)
• Original Assignee: BASF Corporation (BASF SE)
• Inventors: Zhang, Qinglin, Liu, Ye, Tran, Pascaline Harrison, Liu, Xinsheng, Galligan, Michael P., Adomaitis, John R., Chen, Shau-Lin F., Casper, Michelle, Feng, Weiliang
• Granted Patent: US 10,252,217 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B01D 2255/1021 Platinum
• CPC Class Codes: B01D 2255/1023 Palladium
• CPC Class Codes: B01D 2255/1025 Rhodium
• CPC Class Codes: B01D 2255/204 Alkaline earth metals
• CPC Class Codes: B01D 2255/2042 Barium
• CPC Class Codes: B01D 2255/2045 Calcium
• CPC Class Codes: B01D 2255/2047 Magnesium
• CPC Class Codes: B01D 2255/2061 Yttrium
• CPC Class Codes: B01D 2255/2063 Lanthanum
• CPC Class Codes: B01D 2255/2065 Cerium
• CPC Class Codes: B01D 2255/2066 Praseodymium
• CPC Class Codes: B01D 2255/2068 Neodymium
• CPC Class Codes: B01D 2255/20715 Zirconium
• CPC Class Codes: B01D 2255/20723 Vanadium
• CPC Class Codes: B01D 2255/2073 Manganese
• CPC Class Codes: B01D 2255/20746 Cobalt
• CPC Class Codes: B01D 2255/20769 Molybdenum
• CPC Class Codes: B01D 2255/20784 Chromium
• CPC Class Codes: B01D 2255/20792 Zinc
• CPC Class Codes: B01D 2255/209 Other metals
• CPC Class Codes: B01D 2255/2092 : Aluminium
• CPC Class Codes: B01D 2255/40 : Mixed oxides
• CPC Class Codes: B01D 2255/407 : Zr-Ce mixed oxides
• CPC Class Codes: B01D 2255/65 : Catalysts not containing noble metals
• CPC Class Codes: B01D 2255/9022 : Two layers
• CPC Class Codes: B01D 2255/9025 : Three layers
• CPC Class Codes: B01D 2255/9032 : Two zones
• CPC Class Codes: B01D 2255/908 : O2-storage component incorporated in the catalyst
• CPC Class Codes: B01D 2257/404 : Nitrogen oxides other than dinitrogen oxide
• CPC Class Codes: B01D 2257/502 : Carbon monoxide
• CPC Class Codes: B01D 2257/702 : Hydrocarbons
• CPC Class Codes: B01D 2258/012 : Diesel engines and lean burn gasoline engines
• CPC Class Codes: B01D 53/945 : characterised by a specific catalyst
• CPC Class Codes: B01J 21/04 : Alumina
• CPC Class Codes: B01J 23/10 : of rare earths
• CPC Class Codes: B01J 23/42 : Platinum
• CPC Class Codes: B01J 23/44 : Palladium
• CPC Class Codes: B01J 23/464 : Rhodium
• CPC Class Codes: B01J 23/8892 : Manganese
• CPC Class Codes: B01J 23/894 : with rare earths or actinides
• CPC Class Codes: B01J 23/8986 : with manganese, technetium or rhenium
• CPC Class Codes: B01J 35/19 : Catalysts containing parts with different compositions
• CPC Class Codes: B01J 35/31 : Density
• CPC Class Codes: B01J 35/56 : Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: B01J 37/0244 : Coatings comprising several layers
• CPC Class Codes: B01J 37/038 : to form slurries or suspensions, e.g. a washcoat
• CPC Class Codes: B01J 37/08 : Heat treatment B01J37/0009, B01J37/0018 take precedence
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

Aspects of the invention pertain to catalytic articles and methods of making catalytic articles comprising a first catalytic coating comprising a platinum group metal, wherein the first catalytic coating is substantially free of Cu, Ni, Fe, Mn, V, Co, Ga, Mo, Mg, Cr and Zn; a second catalytic coating comprising a non-PGM metal, wherein the second catalytic coating is substantially free of any platinum group metal; and one or more substrates, wherein the first catalytic coating is separated from the second catalytic coating, optionally with a barrier layer.

Claims

1. A catalytic article comprising

a first catalytic coating comprising a platinum group metal, wherein the first catalytic coating is substantially free of Cu, Ni, Fe, Mn, V, Co, Ga, Mo, Mg, Cr and Zn;

a second catalytic coating comprising a non-PGM metal, wherein the second catalytic coating is substantially free of a platinum group metal; and

one or more substrates, wherein the first catalytic coating is separated from the second catalytic coating.

2. The catalytic article of claim 1, wherein the first catalytic coating is layered over the second catalytic coating.

3. The catalytic article of claim 2, further comprising a barrier layer between the first and second catalytic coatings.

4. The catalytic article of claim 3, wherein the barrier layer is substantially free of first transition metals selected from Cu, Ni, Fe, Mn, V, Co, Ga, Mo, Mg, Cr and Zn.

5. The catalytic article of claim 3, wherein the barrier layer is substantially free of platinum group metal.

6. The catalytic article of claim 3, wherein the barrier layer comprises a carrier selected from stabilized alumina, ceria, zirconia, ceria-zirconia composite, titania, and combinations thereof.

7. The catalytic article of claim 6, wherein the barrier layer further comprises a stabilizer for the carrier selected from barium, strontium, calcium, magnesium, as lanthana, neodymia, praseodymia, yttria or combinations thereof.

8. The catalytic article of claim 1, wherein the first catalytic coating is in an upstream zone from the second catalytic coating.

9. The catalytic article of claim 8, wherein the upstream zone has a length of about 5 to about 90% of the substrate.

10. The catalytic article of claim 1, wherein the platinum group metal comprises Pt, Pd, Rh or a combination thereof.

11. The catalytic article of claim 1, wherein the platinum group metal is supported on a carrier comprising alumina, ceria, zirconia, ceria-zirconia composite, titania, or combinations thereof.

12. The catalytic article of claim 11, wherein the carrier is stabilized by an element selected from the group consisting of La, Ba, Y, Pr, Sr and combinations thereof.

13. The catalytic article of claim 1, wherein the non-PGM metal comprises one or more of Cu, Ni, Fe, Mn, Ti, V, Co, Ga, Ca, Sr, Mo, Ba, Mg, Al, La, Zn and Ce.

14. The catalytic article of claim 1, wherein the non-PGM metal is present at a loading of greater than 0 to about 50 wt % of the total second catalytic loading.

15. The catalytic article of claim 4, wherein the first catalytic coating is on a first substrate and the second catalytic coating is on a second substrate, and the substrates are in contact with each other.

16. The catalytic article of claim 4, wherein the first and second catalytic coatings are on the same substrate.

17. The catalytic article of claim 2, wherein the total catalyst coating comprises about 5 to about 90% by weight PGM.

18. The catalytic article of claim 1, wherein the first and second catalytic coating are coated onto wall flow monolith having a plurality of longitudinally extending passages formed by longitudinally extending walls bounding and defining said passages, wherein the 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, and wherein the first or second catalytic coating permeates the walls.

19. A method of making the catalytic article of claim 1, the method comprising:

providing a first slurry comprising a platinum group metal, wherein the first slurry is substantially free of Cu, Ni, Fe, Mn, V, Co, Ga, Mo, Mg, Cr and Zn;

providing a second slurry comprising a non-PGM metal, wherein the second slurry is substantially free of any platinum group metal;

coating one or more substrates with the first and second slurries to provide the catalytic article of claim 1; and

calcining the catalytic article at a temperature ranging from about 300 to about 1100°

C.

20. A method of treating exhaust from an internal combustion engine, the method comprising

contacting the exhaust from the engine with the catalytic article of claim 1.