Catalyst design for heavy-duty diesel combustion engines

• US 9,950,316 B2
• Filed: 12/21/2016
• Issued: 04/24/2018
• Est. Priority Date: 10/22/2013
• Status: Active Grant

• Current Assignee: Umicore AG & Company KG (Umicore S.A.)
• Original Assignee: Umicore AG & Company KG (Umicore S.A.)
• Inventors: Yin, Qinghua, Qi, Xiwang, Biberger, Maximilian A.
• Primary Examiner(s): Nguyen, Cam N.
• Application Number:
  US15/387,445
• Publication Number:
  US 20170165653A1
• Time in Patent Office: 489 Days
• 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 method of forming a coated substrate, comprising:

coating a substrate with a first washcoat layer comprising zeolites;

coating the first washcoat layer with a second washcoat layer comprising a first catalytically active material comprising first composite nanoparticles embedded within porous micron-sized carrier particles, wherein the first composite nanoparticles comprise a first support nanoparticle and a first catalytic nanoparticle, and wherein the first catalytic nanoparticle comprises a platinum-palladium alloy; and

coating the second washcoat layer with a third washcoat layer comprising a second catalytically active material comprising second composite nanoparticles embedded within porous micron-sized carrier particles, wherein the second composite nanoparticles comprise a second support nanoparticle and a second catalytic nanoparticle, and wherein the second catalytic nanoparticle comprises a platinum-palladium alloy.

2. The method 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 method 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 method 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 method 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 method of claim 5, wherein the platinum-palladium alloy of the first catalytic nanoparticle comprises a platinum:

palladium ratio of less than about 4;

1 Pt;

Pd.

7. The method of claim 6, 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.

8. The method of claim 4, wherein the platinum-palladium alloy of the first catalytic nanoparticle comprises a platinum:

palladium ratio of less than about 4;

1 Pt;

Pd.

9. The method of claim 8, 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.

10. The method of claim 1, wherein the first composite nanoparticle and the second composite nanoparticle are plasma-created.

11. The method of claim 1, wherein the first support nanoparticle or the second support nanoparticle comprises aluminum oxide.

12. The method of claim 1, wherein the first support nanoparticle and the second support nanoparticle comprise aluminum oxide.

13. The method of claim 1, wherein the first washcoat layer is coated onto the substrate at a thickness of about 30 g/l to about 100 g/l.

14. The method of claim 1, wherein the second washcoat layer is coated onto the first washcoat layer at a thickness of about 50 g/l to about 140 g/l.

15. The method of claim 1, wherein the third washcoat layer is coated onto the second washcoat layer at a thickness of about 50 g/l to about 140 g/l.

16. The method of claim 1, wherein the first washcoat layer is coated onto the substrate at a thickness of about 30 g/l to about 100 g/l, the second washcoat layer is coated onto the first washcoat layer at a thickness of about 50 g/l to about 140 g/l, and the third washcoat layer is coated onto the second washcoat layer at a thickness of about 50 g/l to about 140 g/l.

17. The method of claim 1, further comprising:

drying and calcining the substrate after coating the substrate with the first washcoat layer;

drying and calcining the substrate after coating the first washcoat layer with the second washcoat layer; and

drying and calcining the substrate after coating the second washcoat layer with the third washcoat layer.