Catalyst design for heavy-duty diesel combustion engines

• US 9,566,568 B2
• Filed: 05/11/2016
• Issued: 02/14/2017
• Est. Priority Date: 10/22/2013
• Status: Active Grant

• Current Assignee: Umicore AG & Company KG (Umicore S.A.)
• Original Assignee: SDC Materials,Inc.
• Inventors: Yin, Qinghua, Qi, Xiwang, Biberger, Maximilian A.
• Primary Examiner(s): Nguyen, Cam N.
• Application Number:
  US15/152,409
• Publication Number:
  US 20160310930A1
• Time in Patent Office: 279 Days
• Field of Search: 502/66, 502/73, 502/74, 502/87, 502/327, 502332-334, 502/339, 502/355, 502/439, 502/527.12, 502/527.13
• US Class Current: 1/1
• CPC Class Codes: B01D 2255/1021 Platinum
• CPC Class Codes: B01D 2255/1023 Palladium
• CPC Class Codes: B01D 2255/2092 Aluminium
• CPC Class Codes: B01D 2255/40 Mixed oxides
• CPC Class Codes: B01D 2255/50 Zeolites
• CPC Class Codes: B01D 2255/9022 Two layers
• CPC Class Codes: B01D 2255/9202 Linear dimensions
• CPC Class Codes: B01D 53/94 by catalytic processes
• CPC Class Codes: B01D 53/945 characterised by a specific catalyst
• CPC Class Codes: B01J 21/04 Alumina
• CPC Class Codes: B01J 23/42 Platinum
• CPC Class Codes: B01J 23/44 Palladium
• CPC Class Codes: B01J 29/068 Noble metals
• CPC Class Codes: B01J 35/00 Catalysts, in general, characterised by their form or physical properties
• CPC Class Codes: B01J 35/19 Catalysts containing parts with different compositions
• CPC Class Codes: B01J 35/23 in a colloidal state
• CPC Class Codes: B01J 35/30 characterised by their physical properties
• CPC Class Codes: B01J 37/0228 in several steps
• CPC Class Codes: B01J 37/349 making use of flames, plasmas or lasers
• CPC Class Codes: Y02A 50/20 Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

Disclosed are washcoats, coated substrates formed from such washcoats, and catalytic converters for use in diesel applications, such as heavy duty diesel applications. Methods of preparing the coated substrates are also disclosed.

Claims

1. A coated substrate comprising:

a) a substrate;

b) a first washcoat layer on the substrate comprising zeolites;

c) a second washcoat layer on the substrate comprising a first catalytically active material comprising platinum and palladium, wherein the first catalytically active material comprises first composite nanoparticles embedded within porous micron-sized carrier particles;

wherein the first composite nanoparticles comprises a first support nanoparticle and a first catalytic nanoparticle, wherein the first catalytic nanoparticle comprises a platinum-palladium alloy; and

d) a third washcoat layer on the substrate comprising a second catalytically active material comprising platinum and palladium;

wherein the second catalytically active material comprises second composite nanoparticles embedded within porous micron-sized carrier particles;

wherein the second composite nanoparticles comprises a second support nanoparticle and a second catalytic nanoparticle, wherein the second catalytic nanoparticle comprises a platinum-palladium alloy;

wherein the second washcoat layer is deposited on the first washcoat layer, and the third washcoat layer is deposited on the second washcoat layer.

2. The coated substrate of claim 1, wherein the platinum-palladium alloy of the first catalytic nanoparticle comprises a platinum:

palladium ratio of less than about 4;

1 Pt;

Pd.

3. The coated substrate of claim 2, wherein the platinum-palladium alloy of the first catalytic nanoparticle comprises a platinum:

palladium ratio of about 1;

1 to about 4;

1 Pt;

Pd.

4. The coated substrate of claim 1, wherein the platinum-palladium alloy of the second catalytic nanoparticle comprises a platinum:

palladium ratio of greater than about 4;

1 Pt;

Pd.

5. The coated substrate of claim 4, wherein the platinum-palladium alloy of the second catalytic nanoparticle comprises a platinum:

palladium ratio of about 10;

1 to about 100;

1 Pt;

Pd.

6. The coated substrate of claim 1, wherein the first composite nanoparticle and the second composite nanoparticle are plasma-created.

7. The coated substrate of claim 1, wherein the first support nanoparticle, the second support nanoparticle, or both the first support nanoparticle and the second support nanoparticle comprise aluminum oxide.

8. The coated substrate of claim 1, wherein the first washcoat layer has a thickness of about 30 g/L to about 100 g/L.

9. The coated substrate of claim 1, wherein the second washcoat layer has a thickness of about 50 g/l to about 140 g/l.

10. The coated substrate of claim 1, wherein the third washcoat layer has a thickness of about 50 g/l to about 140 g/l.