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Layered catalyst composite for exhaust gas purification

A composite material and catalyst technology, applied in physical/chemical process catalysts, catalyst activation/preparation, metal/metal oxide/metal hydroxide catalysts, etc., can solve the loss of catalyst surface area, reduction of catalytic activity, and durability of catalysts offset, etc.

Active Publication Date: 2009-09-09
BASF CATALYSTS LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

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Problems solved by technology

Although many of these materials have the disadvantage of much lower initial BET surface area than activated alumina, this disadvantage is often offset by the greater durability of the resulting catalyst
[0007] In a moving vehicle, exhaust gas temperatures may reach 1000°C, such high temperatures cause activated alumina (or other) support materials to undergo thermal degradation with volume shrinkage caused by phase transitions, especially in the presence of steam, whereby Catalytic metals become enclosed in the shrinking support medium, resulting in a loss of exposed catalyst surface area and a corresponding reduction in catalytic activity

Method used

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  • Layered catalyst composite for exhaust gas purification
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preparation example Construction

[0051] Preparation of layered catalyst composites

[0052] The layered catalyst composites of the present invention can be readily prepared by methods well known in the art. Representative methods are given below.

[0053] Catalyst composites can be easily layered on monolithic supports. For the first layer, finely divided particles of a high surface area refractory metal oxide such as gamma alumina are slurried in a suitable medium such as water. The support may then be dipped in such a slurry one or more times or the slurry may be coated on the support to deposit a desired loading of metal oxide on the support, for example from about 0.5 to about 2.5 g / in 3 . For the introduction of components such as palladium or palladium and platinum, stabilizers and / or accelerators, these components may be introduced into the slurry as a mixture of water soluble or water dispersible compounds or complexes. Thereafter, the coated support is calcined by heating, eg, at 500-600° C. for ...

Embodiment 1

[0060] level one

[0061]The components present in the first layer are gamma-alumina stabilized with 10% barium oxide, lanthanum oxide, strontium oxide, zirconium oxide, neodymium oxide, ceria and zirconium oxide with a ceria content of approximately 30%. Composites and palladium at concentrations of 64%, 6.4%, 6.4%, 2.6%, 6.4%, 12.8% and 1.1%, respectively, based on the calcined weight of the catalyst. Palladium in the form of palladium nitrate solution (30 g / ft 3 ) onto the stabilized alumina to form a wet powder while achieving incipient wetness. Other components such as accelerators and stabilizers were introduced as their soluble salts using water as the pulping medium. An aqueous slurry was formed by combining all of the above components and milled to a particle size of 90% less than 9 microns and coated onto a cordierite support. After coating, the support plus the first layer was calcined at a temperature of 550° C. for at least 2 hours.

[0062] Second floor

[0...

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Abstract

The invention discloses 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. In one or more embodiments, the catalyst comprises three layers in conjunction with a carrier: a first layer deposited on the carrier and comprising palladium deposited on a refractory metal oxide and an oxygen storage component; a second layer deposited on the first layer and comprising rhodium deposited on a refractory metal oxide and an oxygen storage component; and a third layer deposited on the second layer and comprising palladium deposited on a refractory metal oxide.

Description

[0001] Cross References to Related Applications [0002] This application claims priority to U.S. Patent No. 11 / 840,715, filed August 17, 2007, which is a continuation-in-part of U.S. Patent Application No. 11 / 759,695, filed June 7, 2007, which U.S. Patent Application No. 11 / 759,695 is a continuation-in-part of US Patent Application Serial No. 11 / 507,340, filed August 21, 2006, which is hereby incorporated by reference in its entirety. technical field [0003] Embodiments of the invention relate to layered catalyst composites that can be used to treat gases to reduce the levels of pollutants contained therein. More specifically, embodiments of the present invention relate to catalysts of the class commonly referred to as "three-way conversion" or "TWC" catalysts, which are capable of substantially simultaneously catalyzing the oxidation of hydrocarbons and carbon monoxide and the reduction of nitrogen oxides. Background technique [0004] Three-way conversion catalysts are...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): B01J23/63B01J37/02B01D53/94
CPCB01D2255/908B01J23/63B01D53/945B01D2255/204B01D2255/9025B01D2255/1025Y02T10/22B01D2255/206B01J23/464B01J37/0244B01D2255/1023B01J37/0248B01J23/40Y02T10/12
Inventor S·F·陈H·拉比诺维茨J·萨卡基巴拉T·罗
Owner BASF CATALYSTS LLC
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