Catalyst with specific Mn loading for treating exhaust gas streams containing one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons

Abstract

The present invention relates to a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons, the catalyst comprising a first washcoat layer comprising Mn; the catalyst comprises a first washcoat layer, and a substrate wherein the substrate has an inlet end and an outlet end wherein the catalyst further comprises one or more platinum group metals comprising Pt, Pd, or Pt and Pd wherein the one or more platinum group metals are at least partially comprised in one or more of (a) the first washcoat layer, and (b) optionally a second washcoat layer, or (c) optionally a second washcoat layer and a third washcoat layer wherein the loading amount of Mn in the catalyst is in the range of 0.04 g / in3 to 0.9 g / in3, calculated as an element. Further, the present invention relates to an exhaust gas treatment system comprising said catalyst, to a method for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons using said catalyst, and to the use of said catalyst.

Description

Technical Field

[0001] The present invention relates to a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NOx) and hydrocarbons, an exhaust gas treatment system comprising the catalyst, a method for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NOx) and hydrocarbons using the catalyst, and use of the catalyst for oxidizing one or more of formaldehyde, nitrogen oxides (NOx) and hydrocarbons. Background Art

[0002] The present invention relates to a diesel oxidation catalyst (DOC) having an enhanced oxidation function, in particular having an enhanced oxidation function of one or more of formaldehyde (HCHO), nitrogen oxides (NO) and hydrocarbons (including diesel fuel). Formaldehyde is known to be a toxic substance and is increasingly regulated in indoor air spaces due to its release from various building materials used in the construction industry. Stricter regulations are also being implemented for formaldehyde emissions from engine exhaust gases of passenger and transportation vehicles. Generally, manganese oxides (e.g., MnO 2 ) are active in destroying formaldehyde under ambient conditions, but they do not have the thermal stability required to survive in a typical engine exhaust environment. In particular, phase changes at high temperatures (e.g., above 400°C) can cause MnO 2 The structure of the Mn oxides collapses, making the surface area and pore volume so low that they are catalytically ineffective. One way to improve the stability of Mn oxides (and other catalytically useful base metal oxides such as copper, ceria, and iron) at high temperatures may be to support them on refractory oxide materials that themselves have high stability when exposed to the high temperatures in engine exhaust. In this regard, materials such as alumina (Al 2 O 3 ) and zirconium oxide (ZrO 2 ) and other materials may be useful.

[0003] A key challenge in including Mn-containing base metal oxide (BMO) catalysts in technologies for reducing exhaust emissions from diesel vehicles can be seen in the inherently poor sulfur tolerance of manganese.

[0004] Pt and Pd supported on high temperature refractory metal oxide supports are known to provide effective oxidation of CO and HC pollutants emitted from diesel engines. Vehicle manufacturers require such DOC compositions to meet increasingly stringent CO and HC exhaust emission requirements worldwide. When placed in the exhaust of a diesel vehicle, the additional function of the DOC composition is to oxidize the diesel fuel injected into the exhaust upstream of the DOC to produce a high temperature exotherm, which is used to thermally oxidize the soot accumulated on the diesel particulate filter (DPF) or catalytic soot filter (CSF) located downstream of the DOC composition. Alternatively, the combustion process can be adjusted by various post-injection methods, etc. to increase the concentration of hydrocarbons in the exhaust gas flow to produce exotherm. Temperatures greater than 600°C at the inlet of the DPF or CSF are preferred to provide effective oxidation of the retained soot. The concentration of diesel fuel injected into the exhaust gas stream required to provide the desired exotherm is very high, about 1% (10,000 ppm) or more based on C1. The temperature at which the DOC composition can oxidize ("ignite") the injected fuel needs to be as low as possible, preferably below 300°C. Additionally, the amount of hydrocarbon slip that bypasses the DOC catalyst during exotherm generation needs to be as low as possible, preferably less than 3,000 ppm, 2,000 ppm, or even 1,000 ppm.

[0005] WO 2022 / 047132 A1 relates to an oxidation catalyst composition for a catalytic article, an exhaust gas treatment system for reducing the level of formaldehyde in engine exhaust emissions. In particular, claim 1 discloses an oxidation catalyst comprising a platinum group metal (PGM) component comprising Pd, Pt or a combination thereof, a manganese component and a first refractory metal oxide support material containing zirconium oxide.

[0006] US 10,598,061 B2 relates to a method and system for a diesel oxidation catalyst. In particular, claim 1 discloses a method comprising: generating NO in a catalyst comprising a washcoat having zirconium, one or more base metal oxides and palladium oxide 2 , wherein the exhaust gas flow rate is between a lower threshold flow rate and an upper threshold flow rate; and when the exhaust gas temperature is higher than the threshold temperature, promoting the particulate filter located downstream of the catalyst to pass NO 2 Regeneration, wherein the palladium oxide is contained in an upstream portion of the catalyst relative to the exhaust gas flow direction; and the one or more base metal oxides are contained in a downstream portion of the catalyst relative to the exhaust gas flow direction.

[0007] US10,392,980B2 relates to a method and system for a diesel oxidation catalyst. In particular, a method is disclosed in claim 1, which comprises: passing diesel combustion exhaust gas through a diesel oxidation catalyst having a washcoat comprising zirconium oxide, palladium oxide and at least one base metal oxide, the washcoat being coated on a substrate surface, wherein the at least one base metal oxide is coated on a downstream portion of the substrate in a greater amount than on an upstream portion, and the palladium oxide is coated on an upstream portion of the substrate in a greater amount than on a downstream portion, the downstream being the axial direction of the exhaust gas flow, and wherein the palladium oxide accounts for 0.5 wt% to 3 wt% of the washcoat.

[0008] WO 2021 / 198680 A1 relates to an oxidation catalyst for a diesel engine and an exhaust system for a diesel engine comprising the oxidation catalyst. According to claim 1, a layered diesel oxidation catalyst for treating exhaust emissions from a diesel engine comprises a flow-through monolithic substrate having a honeycomb structure and comprising a front zone and a rear zone, wherein the front zone of the substrate comprises a combination of layers, one layer above the other and comprising two or more of specific layers A, B and C; and the rear zone comprises a specific layer D.

[0009] US 2019 / 262772 A1 relates to an oxidation catalyst for a diesel engine and an exhaust system for a diesel engine including the oxidation catalyst. In particular, claim 1 defines an oxidation catalyst for treating exhaust gas from a diesel engine, the oxidation catalyst comprising: a first carrier coating region comprising Pt, Mn and a first carrier material; a second carrier coating region comprising a platinum group metal and a second carrier material; and a substrate having an inlet end and an outlet end; wherein the second carrier coating region is arranged at the outlet end of the substrate and contacts the exhaust gas after the exhaust gas contacts the first carrier coating region.

[0010] US 2017 / 009623 A1 relates to a catalyst for storing nitrogen oxides (NOx) in exhaust gas from a lean-burn engine. In particular, claim 1 defines a catalyst for storing nitrogen oxides in exhaust gas from a lean-burn engine, the catalyst comprising a NOx storage material and a substrate, wherein the NOx storage material comprises a NOx storage component and a NO oxidation promoter on a carrier material, wherein the NO oxidation promoter is manganese or its oxide, hydroxide or carbonate.

[0011] US 2015 / 352493 A1 relates to catalytic articles, and in particular to catalytic articles containing both platinum group metals and non-platinum group metals. In particular, a catalytic article is defined in claim 1, the catalyst comprising a first catalytic coating comprising platinum group metals, 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 non-PGM metals, wherein the second catalytic coating is substantially free of platinum group metals; and one or more substrates, wherein the first catalytic coating is separated from the second catalytic coating.

[0012] US 2018 / 318805 A1 relates to a diesel oxidation catalyst composition, a catalyst article coated with such a composition, an exhaust gas treatment system including such a catalyst article, and a method of using the same. In particular, claim 1 defines a diesel oxidation catalyst composition comprising at least one platinum group metal impregnated on a porous refractory oxide material in particle form and at least one base metal oxide impregnated on a porous refractory oxide material in particle form, wherein the porous refractory oxide material impregnated with at least one platinum group metal and the porous refractory oxide material impregnated with at least one base metal oxide are in the form of a mixture, or wherein at least one platinum group metal and at least one base metal oxide are impregnated on the same porous refractory oxide material.

[0013] MC - Galván et al., Applied Catalysis B. 2004, 51, 83-91, disclose alumina-supported manganese catalysts, wherein the manganese loading ranges from 3.9 wt.% to 18.2 wt.%. The catalysts were prepared and tested in the combustion of a formaldehyde / methanol mixture in an air stream. DETAILED DESCRIPTION

[0014] It is therefore an object of the present invention to provide a catalyst having improved performance in the conversion of one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons, particularly after exposure to sulfation and desulfation treatments.

[0015] Surprisingly, it has been found that improved catalysts can be provided for converting one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons in exhaust gas. In particular, it has been surprisingly found that a catalyst showing improved performance in the conversion of one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons can be provided after exposure to sulfation and desulfation treatments encountered in typical applications. In addition, it has been surprisingly found that the catalyst according to the present invention shows enhanced hydrocarbon (HC) and nitrogen oxide (NO) oxidation functions. In particular, it has been surprisingly found that the benefits of using a BMO-containing catalyst to reduce platinum group metals in a diesel exhaust treatment system are not limited to HCHO oxidation, but also to hydrocarbon and NO oxidation. This enables vehicle manufacturers to meet increasingly stringent vehicle emission standards while also reducing total PGM usage and costs. It has also been surprisingly found that a diesel oxidation catalyst (DOC) comprising a platinum group metal (PGM) and a base metal oxide (BMO) catalyst produces a catalyst with enhanced fuel combustion functions. Furthermore, it is expected that the catalysts of the present invention are capable of oxidizing soot accumulated on a substrate, particularly on a wall-flow substrate, especially because the Mn-containing washcoat layer can generate NO that oxidizes the soot. 2 In addition, the catalyst of the present invention can achieve relatively low N 2 O production, particularly due to its relatively low platinum group metal content.

[0016] Therefore, the present invention relates to a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons, the catalyst comprising

[0017] a first washcoat layer comprising Mn; and

[0018] Base material,

[0019] wherein the substrate has an inlet end and an outlet end, the exhaust gas stream can enter the catalyst through the inlet end, and the exhaust gas stream can leave the catalyst through the outlet end,

[0020] Wherein the catalyst further comprises one or more platinum group metals, the one or more platinum group metals comprising Pt, Pd or Pt and Pd, wherein the one or more platinum group metals are at least partially comprised in one or more of the following:

[0021] (a) the first washcoat layer, and

[0022] (b) an optional second washcoat layer, or

[0023] (c) an optional second washcoat layer and a third washcoat layer, wherein the Mn loading in the catalyst is 0.04 g / in calculated as the element 3 Up to 0.9g / in 3, preferably 0.05 g / in 3 Up to 0.8g / in 3 , more preferably 0.06 g / in 3 Up to 0.7g / in 3 , more preferably 0.07 g / in 3 Up to 0.6g / in 3 , more preferably 0.08 g / in 3 Up to 0.5g / in 3 , more preferably 0.1 g / in 3 Up to 0.25g / in 3 , more preferably 0.12 g / in 3 Up to 0.22g / in 3 , more preferably 0.14 g / in 3 Up to 0.2g / in 3 , more preferably 0.16 g / in 3 Up to 0.18g / in 3 within the range.

[0024] Preferably, the optional second washcoat layer is substantially free of Mn, wherein more preferably the optional second washcoat layer is free of Mn. It should be noted that the Mn contained in the second washcoat layer may result from its leakage into said layer from another layer containing Mn, in particular from the first washcoat layer.

[0025] Within the meaning of the present invention, a washcoat layer is substantially free of said element or compound when it contains said element or compound in an amount of 1 wt.-% or less, preferably 0.5 wt.-% or less, more preferably 0.1 wt.-% or less, more preferably 0.05 wt.-% or less, more preferably 0.01 wt.-% or less, more preferably 0.005 wt.-% or less and more preferably 0.001 wt.-% less, calculated as the element or compound and based on 100 wt.-% of the washcoat layer.

[0026] Preferably, the loading amount of Mn in the first washcoat layer, calculated as the element, is in the range of 1 wt.-% to 50 wt.-%, more preferably 2 wt.-% to 30 wt.-%, more preferably 5 wt.-% to 20 wt.-%, more preferably 8 wt.-% to 12 wt.-%, based on 100 wt.-% of the first washcoat layer.

[0027] Preferably, Mn is present in the form of one or more Mn cations, wherein Mn is more preferably contained in the first washcoat layer as one or more oxides, wherein Mn is more preferably contained in the first washcoat layer as one or more oxides of Mn(II), Mn(III), Mn(II / III) and Mn(IV), more preferably as a member selected from the group consisting of MnO, Mn 2 O 3 , Mn 3 O 4 、MnO 2 One or more oxides from the group consisting of Mn(O)OH and Mn-Zr mixed oxides (including mixtures of two or more thereof) are contained in the first carrier coating layer, wherein the Mn-Zr mixed oxide is preferably contained in the first carrier coating layer as a solid solution.

[0028] Preferably, the first washcoat layer comprises a particulate support material, wherein Mn is supported on the particulate support material, wherein the particulate support material is more preferably selected from the group consisting of: ZrO 2 、Al 2 O 3 、SiO 2 、TiO 2 ,La 2 O 3 Doping is ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, praseodymium oxide-doped CeO 2 -ZrO 2 Mixed oxides, ZrO 2 -doped Al 2 O 3 、ZrO 2 Doped SiO 2 、SiO 2 Doped Al 2 O 3 、CuO-Al 2 O 3mixed oxides and mixtures of two or more thereof, more preferably selected from the group consisting of: ZrO 2 ,La 2 O 3 Doped ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 6 O 11 Doped CeO 2 -ZrO 2 Mixed oxides, PrO 2 Doped CeO 2 -ZrO 2 Mixed oxides, ZrO 2 Doped Al 2 O 3 、ZrO 2 Doped SiO 2 and a mixture of two or more thereof, more preferably selected from the group consisting of: ZrO 2 ,La 2 O 3 Doped ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 2 O3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 6 O 11 Doped CeO 2 -ZrO 2 mixed oxides and mixtures of two or more thereof, wherein Mn is more preferably supported on particles of La 2 O 3 Doped ZrO 2 Among them, ZrO is preferred 2 Doped with La 2 O 3 , based on 100 wt.-% ZrO 2 and La 2 O 3 , the amount thereof ranges from 1 wt.-% to 50 wt.-%, preferably from 3 wt.-% to 30 wt.-%, more preferably from 5 wt.-% to 15 wt.-%, more preferably from 8 wt.-% to 10 wt.-%.

[0029] Preferably, the first washcoat layer comprises Ce, wherein Ce is more preferably present as CeO 2 and / or Ce 2 O 3 Included in the first washcoat layer.

[0030] In case the first washcoat layer comprises Ce, it is preferred that the loading amount of Ce in the first washcoat layer, calculated as the element, is in the range of 1 wt.-% to 50 wt.-%, more preferably 2 wt.-% to 30 wt.-%, more preferably 5 wt.-% to 20 wt.-%, more preferably 8 wt.-% to 12 wt.-%, based on 100 wt.-% of the first washcoat layer.

[0031] Further, in the case where the first washcoat layer comprises Ce, it is preferred that Ce is supported on a particulate support material, wherein the particulate support material is more preferably selected from the group consisting of: ZrO 2 、Al 2 O 3 、SiO 2 、TiO 2 ,La 2 O 3 Doping is ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, praseodymium oxide-doped CeO 2 -ZrO 2 Mixed oxides, ZrO 2 -doped Al 2 O 3 、ZrO 2 Doped SiO 2 、SiO 2 Doped Al 2 O 3 、CuO-Al 2 O 3 Mixed oxides and mixtures of two or more thereof, more preferably selected from the group consisting of: ZrO 2 ,La 2 O 3 Doped ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 6 O 11 Doped CeO 2 -ZrO 2 Mixed oxides, PrO 2 Doped CeO 2 -ZrO 2 Mixed oxides, ZrO 2 Doped Al 2 O 3 、ZrO 2 Doped SiO 2and a mixture of two or more thereof, more preferably selected from the group consisting of: ZrO 2 ,La 2 O 3 Doped ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 6 O 11 Doped CeO 2 -ZrO 2 mixed oxides and mixtures of two or more thereof, wherein Ce is more preferably supported on particles La 2 O 3 Doped ZrO 2 Among them, ZrO is preferred 2 Doped with La 2 O 3 , based on 100 wt.-% ZrO 2 and La 2 O 3 , the amount thereof ranges from 1 wt.-% to 50 wt.-%, preferably from 3 wt.-% to 30 wt.-%, more preferably from 5 wt.-% to 15 wt.-%, more preferably from 8 wt.-% to 10 wt.-%.

[0032] Alternatively, it is preferred that the first washcoat layer is substantially free of Ce, wherein preferably the first washcoat layer is free of Ce.

[0033] In case the first washcoat layer is substantially free of Ce, preferably the catalyst is substantially free of Ce, wherein more preferably the catalyst is free of Ce.

[0034] Preferably, the first washcoat layer comprises Cu, wherein the first washcoat layer preferably comprises CuO, Cu 2 O or CuO and Cu 2O, more preferably CuO.

[0035] In case the first washcoat layer comprises Cu, it is preferred that the loading amount of Cu in the first washcoat layer, calculated as the element, is in the range of 1 wt.-% to 50 wt.-%, more preferably 2 wt.-% to 30 wt.-%, more preferably 5 wt.-% to 20 wt.-%, more preferably 8 wt.-% to 12 wt.-%, based on 100 wt.-% of the first washcoat layer.

[0036] Further, in the case where the first washcoat layer comprises Cu, it is preferred that Cu is supported on a particulate support material, wherein the particulate support material is more preferably selected from the group consisting of: ZrO 2 、Al 2 O 3 、SiO 2 、TiO 2 ,La 2 O 3 Doping is ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, praseodymium oxide-doped CeO 2 -ZrO 2 Mixed oxides, ZrO 2 -doped Al 2 O 3 、ZrO 2 Doped SiO 2 、SiO 2 Doped Al 2 O 3 、CuO-Al 2 O 3 Mixed oxides and mixtures of two or more thereof, more preferably selected from the group consisting of: ZrO 2 ,La 2 O 3 Doped ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La2 O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 6 O 11 Doped CeO 2 -ZrO 2 Mixed oxides, PrO 2 Doped CeO 2 -ZrO 2 Mixed oxides, ZrO 2 Doped Al 2 O 3 、ZrO 2 Doped SiO 2 and a mixture of two or more thereof, more preferably selected from the group consisting of: ZrO 2 ,La 2 O 3 Doped ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 6 O 11 Doped CeO 2 -ZrO 2mixed oxides and mixtures of two or more thereof, wherein Cu is more preferably supported on particles of La 2 O 3 Doped ZrO 2 Among them, ZrO is preferred 2 Doped with La 2 O 3 , based on 100 wt.-% ZrO 2 and La 2 O 3 , the amount thereof ranges from 1 wt.-% to 50 wt.-%, preferably from 3 wt.-% to 30 wt.-%, more preferably from 5 wt.-% to 15 wt.-%, more preferably from 8 wt.-% to 10 wt.-%.

[0037] Alternatively, it is preferred that the first washcoat layer is substantially free of Cu, wherein more preferably the first washcoat layer is free of Cu.

[0038] In case the first washcoat layer is substantially free of Cu, preferably the catalyst is substantially free of Cu, wherein more preferably the catalyst is free of Cu.

[0039] Preferably, the substrate is a wall flow substrate or a flow-through substrate, more preferably a honeycomb wall flow substrate or a honeycomb flow-through substrate, more preferably a honeycomb flow-through substrate, wherein the flow-through substrate is more preferably a flow-through substrate with high porosity walls.

[0040] Preferably, the first washcoat layer has a loading of 0.3 g / in 3 Up to 6g / in 3 , more preferably 1 g / in 3 Up to 5g / in 3 , more preferably 1.5 g / in 3 Up to 4g / in 3 , more preferably 2 g / in 3 Up to 3.5g / in 3 , more preferably 2.3 g / in 3 Up to 2.9g / in 3 , more preferably 2.5 g / in 3 Up to 2.7g / in 3 within the range.

[0041] Within the meaning of the present invention, the loading of a washcoat layer in a catalyst refers to the loading of the washcoat layer based on the volume of the catalyst in which the washcoat layer is contained. Thus, within the meaning of the present invention, the loading of a washcoat layer contained only in a certain portion or zone of the catalyst is based on the volume of that portion or zone of the catalyst. Thus, for example, if a washcoat layer is provided over 50% of the axial length of the honeycomb substrate, its loading is calculated based on 50% of the total volume of the honeycomb substrate.

[0042] Preferably, the loading of the second washcoat layer is between 0.25 g / in 3 Up to 6g / in 3 , preferably 0.3 g / in 3 Up to 6g / in 3 , more preferably 1 g / in 3 Up to 5g / in 3 , more preferably 1.5 g / in 3 Up to 4g / in 3 , more preferably 2 g / in 3 Up to 3.5g / in 3 , more preferably 2.2 g / in 3 Up to 3.0g / in 3 , more preferably 2.3 g / in 3 Up to 2.9g / in 3 , more preferably 2.5 g / in 3 Up to 2.7g / in 3 within the range.

[0043] Preferably, the catalyst comprises one or more platinum group metals consisting of Pt, Pd or Pt and Pd, wherein more preferably the catalyst comprises Pt or Pt and Pd as one or more platinum group metals, wherein more preferably the catalyst comprises Pt and Pd as one or more platinum group metals.

[0044] Preferably, the catalyst comprises a loading of 2 g / ft 3 Up to 250g / ft 3 , more preferably 5g / ft 3 Up to 150g / ft 3 , more preferably 10g / ft 3 Up to 125g / ft 3 , more preferably 20g / ft 3 Up to 100g / ft 3 , more preferably 25g / ft 3 Up to 85g / ft 3 , more preferably 30g / ft 3 Up to 80g / ft 3, more preferably 40g / ft 3 Up to 60g / ft 3 Within the range of Pt.

[0045] Within the meaning of the present invention, the loading of Pt, Pd or Pt and Pd in ​​the catalyst refers to the loading of Pt, Pd or Pt and Pd based on the volume of the catalyst in which Pt, Pd or Pt and Pd are contained. In case Pt, Pd or Pt and Pd are contained in one or more zones of the catalyst, it is preferred within the meaning of the present invention that the loading of Pt, Pd or Pt and Pd is based on the volume of the catalyst in which one or more zones of Pt, Pd or Pt and Pd are contained. Thus, for example, if Pt, Pd or Pt and Pd are provided in a zone extending over 50% of the axial length of the honeycomb substrate, their loading is calculated based on 50% of the total volume of the honeycomb substrate.

[0046] Preferably, the catalyst comprises a loading of 5 g / ft 3 Up to 100g / ft 3 , more preferably 5g / ft 3 Up to 60g / ft 3 , more preferably 10g / ft 3 Up to 50g / ft 3 , more preferably 15g / ft 3 Up to 40g / ft 3 , more preferably 20g / ft 3 Up to 30g / ft 3 within the range of Pd.

[0047] Preferably, the catalyst includes a total Pt and Pd loading of 2 g / ft 3 Up to 250g / ft 3 , more preferably 5g / ft 3 Up to 200g / ft 3 , more preferably 10g / ft 3 Up to 150g / ft 3 , more preferably 20g / ft 3 Up to 130g / ft 3 , more preferably 30g / ft 3 Up to 125g / ft 3 , more preferably 40g / ft 3 Up to 110g / ft 3 , more preferably 50g / ft 3 Up to 100g / ft 3 , more preferably 60g / ft 3 Up to 90g / ft 3 , more preferably 70g / ft3 Up to 80g / ft 3 range of Pt and Pd.

[0048] Preferably, the catalyst comprises Pt and Pd in ​​a Pt:Pd weight ratio in the range of 1:2 to 20:1, more preferably 50:50 to 80:20, more preferably 60:40 to 75:25, more preferably 65:35 to 70:30.

[0049] Preferably, the one or more platinum group metals are supported on a particulate support material, wherein the particulate support material is more preferably selected from the group consisting of: Al 2 O 3 、SiO 2 、TiO 2 、SiO 2 Doped Al 2 O 3 , Mn oxide doped Al 2 O 3 and a mixture of two or more thereof, wherein more preferably the one or more platinum group metals are supported on Al 2 O 3 and / or SiO 2 Doped Al 2 O 3 and / or Mn oxide doped Al 2 O 3 , more preferably SiO 2 Doped Al 2 O 3 or Al 2 O 3 or Mn oxide doped Al 2 O 3 On the basis of 100 wt-% Mn oxide doped Al 2 O 3 , calculated as Mn oxide, Mn oxide doped Al 2 O 3 Preferably, 1 to 10 wt-%, more preferably 4 to 6 wt-%, of Mn oxide is contained.

[0050] Preferably, the first washcoat layer comprises a hydrocarbon capture material, wherein the hydrocarbon capture material comprises a molecular sieve, more preferably a zeolite, more preferably a zeolite having a maximum pore size of 12-membered rings, more preferably zeolite beta, wherein the molecular sieve, more preferably a zeolite, more preferably comprises SiO 2 and Al 2 O 3 , wherein the molecular sieve, more preferably a zeolite, more preferably has a SiO ratio in the range of 10:1 to 500:1 2With Al 2 O 3 The molar ratio of the molecular sieve, preferably the zeolite, more preferably comprises Fe, based on the weight of the molecular sieve, is 1:1 to 100:1, more preferably 10:1 to 40:1, more preferably 15:1 to 30:1, more preferably 20:1 to 25:1, wherein the molecular sieve, preferably the zeolite, more preferably comprises Fe ... based on the weight of the molecular sieve, is 1:1 to 100:1, more preferably 10:1 to 40:1, more preferably 15:1 to 30:1, more preferably 20:1 to 25:1 2 O 3 Calculated, the amount ranges from 1.0 wt-% to 7.0 wt-%, more preferably from 3.0 wt-% to 5.0 wt-%, more preferably from 4.0 wt-% to 4.5 wt-%.

[0051] In the case where the first washcoat layer comprises a hydrocarbon capture material, it is preferred that the hydrocarbon capture material is loaded in the first washcoat layer in an amount of 0.01 g / in 3 Up to 2.0g / in 3 In the range of 0.05 g / in 3 Up to 1.0g / in 3 In the range of 0.05 g / in 3 Up to 0.3g / in 3 within the range.

[0052] Preferably, the catalyst comprises a second washcoat layer, wherein the one or more platinum group metals are at least partially contained in the second washcoat layer, wherein more preferably the one or more platinum group metals are entirely contained in the second washcoat layer.

[0053] Preferably, the second washcoat layer comprises a hydrocarbon capture material, wherein the hydrocarbon capture material comprises a molecular sieve, more preferably a zeolite, more preferably a zeolite having a maximum pore size defined by a 12-membered ring, more preferably zeolite beta, wherein the molecular sieve, preferably the zeolite, preferably comprises SiO 2 and Al 2 O 3 , wherein the molecular sieve, preferably a zeolite, more preferably has a SiO ratio in the range of 10:1 to 40:1 2 With Al 2 O 3 The molar ratio of the molecular sieve, preferably the zeolite, preferably comprises Fe, wherein the molecular sieve, preferably the zeolite, more preferably comprises Fe, based on the weight of the molecular sieve, is 1:1 to 30:1, more preferably 20:1 to 25:1. 2 O 3 Calculated, the amount ranges from 1.0 wt-% to 7.0 wt-%, more preferably from 3.0 wt-% to 5.0 wt-%, more preferably from 4.0 wt-% to 4.5 wt-%.

[0054] In the case where the second washcoat layer comprises a hydrocarbon capture material, wherein the hydrocarbon capture material comprises a molecular sieve, preferably, the hydrocarbon capture material is loaded in the second washcoat layer in an amount of 0.01 g / in 3 Up to 2.0g / in 3 In the range of 0.05 g / in 3 Up to 1.0g / in 3 g / in 3 In the range of 0.05 g / in 3 Up to 0.3g / in 3 within the range.

[0055] According to a first alternative, it is preferred that the catalyst comprises a second washcoat layer, wherein the catalyst shows a layered arrangement of the first washcoat layer and the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0056] In case the catalyst comprises a second washcoat layer, wherein the catalyst shows a layered arrangement of a first washcoat layer and a second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer, according to a first alternative, it is preferred that the first washcoat layer is disposed on the substrate and the second washcoat layer is disposed on the first washcoat layer.

[0057] Further, in case the catalyst comprises a second washcoat layer, wherein the catalyst shows a layered arrangement of a first washcoat layer and a second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer, according to the first alternative, it is preferred that the second washcoat layer is disposed on the substrate and the first washcoat layer is disposed on the second washcoat layer.

[0058] Further, in the case where the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a layered arrangement of a first washcoat layer and a second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer, according to a first alternative, it is preferred that the catalyst comprises a third washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer, the second washcoat layer and the third washcoat layer, wherein the third washcoat layer is disposed on the substrate starting from the inlet end of the substrate along the axial length of the substrate, and wherein the first washcoat layer is disposed on the substrate starting from the outlet end of the substrate along the axial length of the substrate, and wherein the second washcoat layer is disposed on the first washcoat layer and completely covers the first washcoat layer, wherein the length of the first washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the third washcoat layer and a downstream zone comprising the first washcoat layer and the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the third washcoat layer. Alternatively, it is preferred that the catalyst comprises a third washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer, the second washcoat layer and the third washcoat layer, wherein the third washcoat layer is disposed on the substrate along the axial length of the substrate starting from the inlet end of the substrate, and wherein the second washcoat layer is disposed on the substrate along the axial length of the substrate starting from the outlet end of the substrate, and wherein the first washcoat layer is disposed on and completely covers the second washcoat layer, wherein the length of the second washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the third washcoat layer and a downstream zone comprising the first washcoat layer and the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the third washcoat layer. Alternatively, it is preferred that the catalyst comprises a third washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer, the second washcoat layer and the third washcoat layer, wherein the third washcoat layer is disposed on the substrate along the axial length of the substrate starting from the outlet end of the substrate, and wherein the first washcoat layer is disposed on the substrate along the axial length of the substrate starting from the inlet end of the substrate, and wherein the second washcoat layer is disposed on the first washcoat layer and completely covers the first washcoat layer, wherein the length of the first washcoat layer is less than the axial length of the substrate, thereby creating a downstream zone comprising the third washcoat layer and an upstream zone comprising the first washcoat layer and the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the third washcoat layer.Alternatively, it is preferred that the catalyst comprises a third washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer, the second washcoat layer and the third washcoat layer, wherein the third washcoat layer is disposed on the substrate along the axial length of the substrate starting from the outlet end of the substrate, and wherein the second washcoat layer is disposed on the substrate along the axial length of the substrate starting from the inlet end of the substrate, and wherein the first washcoat layer is disposed on and completely covers the second washcoat layer, wherein the length of the second washcoat layer is less than the axial length of the substrate, thereby creating a downstream zone comprising the third washcoat layer and an upstream zone comprising the first washcoat layer and the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the third washcoat layer.

[0059] According to a second alternative, it is preferred that the catalyst comprises a second washcoat layer, wherein the catalyst shows a zoned arrangement of the first washcoat layer and the second washcoat layer, wherein the second washcoat layer is disposed on the substrate along the axial length of the substrate starting from the inlet end of the substrate, and wherein the first washcoat layer is disposed on the substrate along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0060] According to a third alternative, it is preferred that the catalyst comprises a second washcoat layer, wherein the catalyst shows a zoned arrangement of the first washcoat layer and the second washcoat layer, wherein the first washcoat layer is disposed on the substrate along the axial length of the substrate starting from the inlet end of the substrate, and wherein the second washcoat layer is disposed on the substrate along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0061] According to a fourth alternative, it is preferred that the catalyst comprises a second washcoat layer, wherein the catalyst shows a zoned arrangement of the first washcoat layer and the second washcoat layer, wherein the second washcoat layer is disposed on the substrate along the axial length of the substrate starting from the inlet end of the substrate, and wherein the first washcoat layer is disposed on the substrate along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0062] According to a fifth alternative, it is preferred that the catalyst comprises a second washcoat layer, wherein the catalyst shows a zoned arrangement of the first washcoat layer and the second washcoat layer, wherein the first washcoat layer is disposed on the substrate along the axial length of the substrate starting from the inlet end of the substrate, and wherein the second washcoat layer is disposed on the substrate along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0063] In the case where the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer according to the second alternative or the fourth alternative, preferably, the catalyst comprises a third washcoat layer, wherein the third washcoat layer is disposed on the first layer, wherein the catalyst exhibits a zoned arrangement of the second washcoat layer and the third washcoat layer, wherein the second washcoat layer is disposed on the substrate starting from the inlet end of the substrate along the axial length of the substrate, and wherein the third washcoat layer is disposed on the first washcoat layer starting from the outlet end of the substrate along the axial length of the substrate, wherein the length of the third washcoat layer is less than the axial length of the substrate, thereby producing an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer and the third washcoat layer.

[0064] In the case where the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer according to the third alternative or the fifth alternative, it is preferred that the catalyst comprises a third washcoat layer, wherein the third washcoat layer is disposed on the first layer, wherein the catalyst exhibits a zoned arrangement of the second washcoat layer and the third washcoat layer, wherein the third washcoat layer is disposed on the first washcoat layer starting from the inlet end of the substrate along the axial length of the substrate, and wherein the second washcoat layer is disposed on the substrate starting from the outlet end of the substrate along the axial length of the substrate, wherein the length of the third washcoat layer is less than the axial length of the substrate, thereby producing an upstream zone comprising the first washcoat layer and the third washcoat layer and a downstream zone comprising the second washcoat layer.

[0065] In case the catalyst comprises a second washcoat layer, wherein the catalyst shows a zoned arrangement of the first washcoat layer and the second washcoat layer according to the second alternative, the third alternative, the fourth alternative or the fifth alternative, it is preferred that the first washcoat layer and the second washcoat layer are adjacent to each other.

[0066] Further, in the case where the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer according to the second alternative, the third alternative, the fourth alternative or the fifth alternative, it is preferred that the second washcoat layer and the third washcoat layer are adjacent to each other.

[0067] Further, in the case where the catalyst comprises a second washcoat layer, wherein the catalyst shows a zoned arrangement of the first washcoat layer and the second washcoat layer according to the second alternative, the third alternative, the fourth alternative or the fifth alternative, preferably, a portion of the second washcoat layer overlaps with at least a portion of the first washcoat layer, wherein more preferably the second washcoat layer overlaps with the first washcoat layer over a portion of the axial length of the first washcoat layer in the range of 10% to 100%, more preferably 15% to 80%, and more preferably 20% to 50%.

[0068] Further, in the case where the catalyst comprises a second washcoat layer, wherein the catalyst shows a zoned arrangement of the first washcoat layer and the second washcoat layer according to the second alternative, the third alternative, the fourth alternative or the fifth alternative, preferably, a portion of the first washcoat layer overlaps with at least a portion of the second washcoat layer, wherein more preferably the first washcoat layer overlaps with the second washcoat layer over a portion of the axial length of the second washcoat layer in the range of 10% to 100%, more preferably 15% to 80%, and more preferably 20% to 50%.

[0069] Further, in case the catalyst comprises a second washcoat layer, wherein the catalyst shows a zoned arrangement of the first washcoat layer and the second washcoat layer according to the second alternative, the third alternative, the fourth alternative or the fifth alternative, it is preferred that a portion of the third washcoat layer overlaps with at least a portion of the first washcoat layer, wherein preferably the third washcoat layer overlaps with the first washcoat layer over a portion of the axial length of the first washcoat layer in the range of 10% to 100%, more preferably 15% to 80%, and more preferably 20% to 50%.

[0070] According to a sixth alternative, it is preferred that the catalyst comprises a second washcoat layer, wherein the catalyst shows a zoned arrangement of the first washcoat layer and the second washcoat layer, wherein the second washcoat layer is disposed on the substrate along the entire length of the substrate, and wherein the first washcoat layer is disposed on the second washcoat layer starting from the outlet end of the substrate along the axial length of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer above the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0071] According to a seventh alternative, it is preferred that the catalyst comprises a second washcoat layer, wherein the catalyst shows a zoned arrangement of the first washcoat layer and the second washcoat layer, wherein the second washcoat layer is disposed on the substrate along the entire length of the substrate, and wherein the first washcoat layer is disposed on the second washcoat layer along the axial length of the substrate starting from the inlet end of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the first washcoat layer above the second washcoat layer and a downstream zone comprising the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0072] In the case where the catalyst comprises a second washcoat layer, wherein the catalyst shows a zoned arrangement of the first washcoat layer and the second washcoat layer according to the sixth alternative or the seventh alternative, it is preferred that the length of the first washcoat layer ranges from 10% to 90%, more preferably from 30% to 80%, more preferably from 50% to 70% of the axial length of the substrate.

[0073] According to an eighth alternative, preferably, the catalyst comprises a second washcoat layer, wherein the catalyst shows a zoned arrangement of the first washcoat layer and the second washcoat layer, wherein the first washcoat layer is disposed on the substrate along the entire length of the substrate, and wherein the second washcoat layer is disposed on the first washcoat layer starting from the inlet end of the substrate along the axial length of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second washcoat layer above the first washcoat layer and a downstream zone comprising the first washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0074] In the case where the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first and second washcoat layers according to the eighth alternative, preferably, the catalyst comprises a third washcoat layer, wherein the third washcoat layer is disposed on the first layer, wherein the catalyst exhibits a zoned arrangement of the second and third washcoat layers, wherein the second washcoat layer is disposed on the first washcoat layer starting from the inlet end of the substrate along the axial length of the substrate, and wherein the third washcoat layer is disposed on the first washcoat layer starting from the outlet end of the substrate along the axial length of the substrate, wherein the length of the third washcoat layer is less than the axial length of the substrate, thereby producing an upstream zone comprising the second washcoat layer and a downstream zone comprising the third washcoat layer.

[0075] According to a ninth alternative, preferably, the catalyst comprises a second washcoat layer, wherein the catalyst shows a zoned arrangement of the first washcoat layer and the second washcoat layer, wherein the first washcoat layer is disposed on the substrate along the entire length of the substrate, and wherein the second washcoat layer is disposed on the first washcoat layer starting from the outlet end of the substrate along the axial length of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer above the first washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0076] In the case where the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first and second washcoat layers according to the ninth alternative, preferably, the catalyst comprises a third washcoat layer, wherein the third washcoat layer is disposed on the first layer, wherein the catalyst exhibits a zoned arrangement of the second and third washcoat layers, wherein the third washcoat layer is disposed on the first washcoat layer starting from the inlet end of the substrate along the axial length of the substrate, and wherein the second washcoat layer is disposed on the first washcoat layer starting from the outlet end of the substrate along the axial length of the substrate, wherein the length of the third washcoat layer is less than the axial length of the substrate, thereby producing an upstream zone comprising the third washcoat layer and a downstream zone comprising the second washcoat layer.

[0077] In the case where the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer according to the eighth alternative or the ninth alternative, and wherein the catalyst comprises a third washcoat layer, it is preferred that the second washcoat layer and the third washcoat layer are adjacent to each other.

[0078] Preferably, the length of the first washcoat layer ranges from 5% to 100% of the axial length of the substrate, more preferably from 10% to 90% of the axial length of the substrate, preferably from 15% to 75%, more preferably from 20% to 60%, more preferably from 25% to 50%, and more preferably from 35% to 45%.

[0079] In the case where the catalyst comprises a second washcoat layer, wherein the catalyst preferably shows a zoned arrangement of the first washcoat layer and the second washcoat layer according to the eighth alternative or the ninth alternative, it is preferred that the length of the second washcoat layer ranges from 5% to 100% of the axial length of the substrate, more preferably from 10% to 90% of the axial length of the substrate, more preferably from 15% to 75%, even more preferably from 20% to 60%, more preferably from 25% to 50%, and more preferably from 35% to 45%.

[0080] Where the catalyst comprises a second washcoat layer and a third washcoat layer, it is preferred that the third washcoat layer has a length in the range of 5% to 100% of the axial length of the substrate, preferably 10% to 90% of the axial length of the substrate, more preferably 15% to 75%, more preferably 20% to 60%, more preferably 25% to 50%, and more preferably 35% to 45%.

[0081] Further, where the catalyst comprises a second washcoat layer and a third washcoat layer, it is preferred that the third washcoat layer is substantially free of sulfur trapping material, wherein preferably the third washcoat layer is free of sulfur trapping material.

[0082] Further, where the catalyst comprises a second washcoat layer and a third washcoat layer, it is preferred that the third layer comprises a hydrocarbon capture material, wherein the hydrocarbon capture material comprises a molecular sieve, preferably a zeolite, more preferably a zeolite having a maximum pore size of 12-membered rings, more preferably zeolite beta, wherein the molecular sieve, preferably a zeolite, preferably comprises SiO 2 and Al 2 O 3 , wherein the molecular sieve, preferably a zeolite, more preferably has a SiO ratio in the range of 10:1 to 500:1 2 With Al 2 O 3 The molar ratio of the molecular sieve, preferably the zeolite, preferably comprises Fe, wherein the molecular sieve, preferably the zeolite, more preferably comprises Fe, based on the weight of the molecular sieve, is 1:1 to 100:1, more preferably 10:1 to 40:1, more preferably 15:1 to 30:1, more preferably 20:1 to 25:1. 2 O 3Calculated, the amount ranges from 1.0 wt-% to 7.0 wt-%, more preferably from 3.0 wt-% to 5.0 wt-%, more preferably from 4.0 wt-% to 4.5 wt-%.

[0083] In the case where the third layer comprises a hydrocarbon capture material, it is preferred that the loading of the hydrocarbon capture material in the third washcoat layer is between 0.01 g / in 3 Up to 2.0g / in 3 In the range of 0.05 g / in 3 Up to 1.0g / in 3 In the range of 0.05 g / in 3 Up to 0.3g / in 3 within the range.

[0084] Further, where the catalyst comprises a second washcoat layer and a third washcoat layer, it is preferred that the one or more platinum group metals are at least partially contained in the third washcoat layer.

[0085] Where one or more platinum group metals are at least partially contained in the third washcoat layer, it is preferred that the one or more platinum group metals are supported on a particulate support material, wherein the particulate support material is preferably selected from the group consisting of: Al 2 O 3 、SiO 2 、TiO 2 、SiO 2 Doped Al 2 O 3 , Mn oxide doped Al 2 O 3 and a mixture of two or more thereof, wherein preferably the one or more platinum group metals are supported on Al 2 O 3 and / or SiO 2 Doped Al 2 O 3 and / or Mn oxide doped Al 2 O 3 , more preferably SiO 2 Doped Al 2 O 3 or Al 2 O 3 or Mn oxide doped Al 2 O 3 On the basis of 100 wt-% Mn oxide doped Al 2 O 3 , with MnO 2 Calculation, Mn oxide doped Al 2 O3 Preferably, 1 to 10 wt-%, more preferably 4 to 6 wt-%, of Mn oxide is contained.

[0086] Further, in case the catalyst comprises a second washcoat layer and a third washcoat layer, it is preferred that the catalyst comprises a second washcoat layer and a third washcoat layer, wherein the one or more platinum group metals are completely contained in the second washcoat layer and the third washcoat layer, wherein the weight ratio of the one or more platinum group metals contained in the second washcoat layer to the one or more platinum group metals contained in the third washcoat layer is in the range of 0.5:1 to 5.0:1, more preferably 1.0:1 to 2.0:1, more preferably in the range of 1.4:1 to 1.6:1, wherein the one or more platinum group metals contained in the second washcoat layer preferably comprise, more preferably consist of, Pt and Pd, wherein the one or more platinum group metals contained in the third washcoat layer preferably comprise, more preferably consist of, Pt and Pd.

[0087] In the case where the catalyst comprises a second washcoat layer, wherein the catalyst shows a zoned arrangement of the first washcoat layer and the second washcoat layer according to the second alternative, the third alternative, the fourth alternative, the fifth alternative, the sixth alternative, the seventh alternative, the eighth alternative or the ninth alternative, it is preferred that in the zone of the catalyst containing the first washcoat layer, the Mn loading is calculated as the element, based on the volume of the zone of the catalyst containing the first washcoat layer, at 0.04 g / in 3 Up to 0.9g / in 3 In the range of 0.05 g / in 3 Up to 0.8g / in 3 , more preferably 0.15 g / in 3 Up to 0.5g / in 3 , more preferably 0.2 g / in 3 Up to 0.35g / in 3 , more preferably 0.23 g / in 3 Up to 0.29g / in 3 , more preferably 0.25 g / in 3 Up to 0.27g / in 3 .

[0088] In the case where the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer according to the first, second, third, fourth, fifth, sixth, seventh, eighth or ninth alternatives, it is preferred that the one or more platinum group metals are completely contained in the second washcoat layer or in the second and third washcoat layers.

[0089] Further, in the case where the catalyst comprises a second washcoat layer, wherein the catalyst shows a zoned arrangement of the first washcoat layer and the second washcoat layer according to the first, second, third, fourth, fifth, sixth, seventh, eighth or ninth alternatives, it is preferred that the one or more platinum group metals are at least partially contained in the first washcoat layer.

[0090] Preferably, the substrate is a metal substrate or a ceramic substrate, wherein preferably the substrate is a ceramic substrate, wherein more preferably the substrate comprises cordierite and / or SiC, preferably cordierite, wherein more preferably the substrate consists of cordierite and / or SiC, preferably consists of cordierite.

[0091] In the case where the catalyst includes a second washcoat layer, wherein the catalyst shows a zoned arrangement of the first washcoat layer and the second washcoat layer according to the second, third, fourth, fifth, sixth, seventh, eighth or ninth alternatives, it is preferred that the substrate consists of two separate monoliths, wherein the first monolith is disposed upstream of the second monolith, wherein the one or more washcoat layers of the upstream zone are contained on the first monolith, and the one or more washcoat layers of the downstream zone are contained on the second monolith, wherein preferably the first monolith comprising the one or more washcoat layers of the upstream zone and the second monolith comprising the one or more washcoat layers of the downstream zone are obtained or obtainable by dividing the catalyst according to any one of the embodiments disclosed herein according to the second, third, fourth, fifth, sixth, seventh, eighth or ninth alternatives into two separate monoliths, wherein the one or more washcoat layers of the upstream zone are contained on the first monolith, and the one or more washcoat layers of the downstream zone are contained on the second monolith.

[0092] Preferably, the waste gas stream contains hydrocarbons, preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons.

[0093] Further, the present invention relates to an exhaust gas treatment system, which comprises an internal combustion engine and an exhaust gas conduit for exhaust gas from the internal combustion engine, wherein the exhaust gas conduit comprises one or more catalysts according to any one of the embodiments disclosed herein, preferably one, two, three or four catalysts according to any one of the embodiments disclosed herein.

[0094] Preferably, the internal combustion engine is a compression ignition engine, more preferably a diesel engine.

[0095] Preferably, the internal combustion engine is a lean burn gasoline engine.

[0096] Alternatively, it is preferred that the internal combustion engine is powered by an oxygenated fuel, wherein the oxygenated fuel preferably comprises one or more of methanol and a biofuel.

[0097] Preferably, the system includes one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on a filter (SCRoF) and a diesel exothermic catalyst (DEC).

[0098] According to a first alternative, it is preferred that the system comprises in sequential order in the direction of the exhaust gases: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments disclosed herein, a catalyst according to any of the embodiments disclosed herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a diesel exothermic catalyst (DEC), a catalytic soot filter (CSF), a selective catalytic reduction (SCR) catalyst and a selective catalytic reduction (SCR) catalyst.

[0099] According to a second alternative, it is preferred that the system comprises in sequential order in the direction of the exhaust gases: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments disclosed herein, a catalyst according to any of the embodiments disclosed herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a diesel exothermic catalyst (DEC), a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst and a selective catalytic reduction (SCR) catalyst.

[0100] According to a third alternative, it is preferred that the system comprises in sequential order in the direction of the exhaust gases: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments disclosed herein, a catalyst according to any of the embodiments disclosed herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a diesel exothermic catalyst (DEC), a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst and an ammonia oxidation (AMOX) catalyst.

[0101] According to a fourth alternative, it is preferred that the system comprises in sequential order in the direction of the exhaust gases: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any embodiment of the embodiments disclosed herein, a catalyst according to any embodiment of the embodiments disclosed herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any embodiment of the embodiments disclosed herein, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst and a selective catalytic reduction (SCR) catalyst.

[0102] According to a fifth alternative, it is preferred that the system comprises in sequential order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any embodiment of the embodiments disclosed herein, a catalyst according to any embodiment of the embodiments disclosed herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any embodiment of the embodiments disclosed herein, a catalyst according to any embodiment of the embodiments disclosed herein (wherein the substrate is a wall-flow substrate), a selective catalytic reduction (SCR) catalyst and an ammonia oxidation (AMOX) catalyst.

[0103] According to a sixth alternative, it is preferred that the system comprises in sequential order in the direction of the exhaust gases: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments disclosed herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a catalytic soot filter (CSF), a selective catalytic reduction (SCR) catalyst and a selective catalytic reduction (SCR) catalyst.

[0104] According to the seventh alternative, it is preferred that the system comprises in sequential order in the direction of the exhaust gases: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments disclosed herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a catalytic soot filter (CSF), a selective catalytic reduction (SCR) catalyst and an ammonia oxidation (AMOX) catalyst.

[0105] According to an eighth alternative, it is preferred that the system comprises in sequential order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments disclosed herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of the embodiments disclosed herein (wherein the substrate is a wall-flow substrate), a selective catalytic reduction (SCR) catalyst and an ammonia oxidation (AMOX) catalyst.

[0106] According to a ninth alternative, it is preferred that the system comprises in sequential order in the direction of the exhaust gases: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments disclosed herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction catalyst on a filter (SCRoF) and an ammonia oxidation (AMOX) catalyst.

[0107] According to a tenth alternative, it is preferred that the system comprises in sequential order in the direction of the exhaust gases: optionally an electric heater or a fuel burner and / or a fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of the embodiments disclosed herein, a selective catalytic reduction catalyst on a filter (SCRoF) and an ammonia oxidation (AMOX) catalyst.

[0108] According to an eleventh alternative, it is preferred that the system comprises in sequential order in the direction of the exhaust gases: optionally an electric heater or a fuel burner and / or a fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of the embodiments disclosed herein, a catalytic soot filter (CSF), a selective catalytic reduction (SCR) catalyst and an ammonia oxidation (AMOX) catalyst.

[0109] According to the twelfth alternative, it is preferred that the system comprises in sequential order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of the embodiments disclosed herein, a catalyst according to any of the embodiments disclosed herein (wherein the substrate is a wall-flow substrate), a selective catalytic reduction (SCR) catalyst and an ammonia oxidation (AMOX) catalyst.

[0110] According to a thirteenth alternative, it is preferred that the system comprises in sequential order in the direction of the exhaust gases: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments disclosed herein, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst and an ammonia oxidation (AMOX) catalyst.

[0111] According to a fourteenth alternative, it is preferred that the system comprises in sequential order in the direction of the exhaust gases: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments disclosed herein, a selective catalytic reduction catalyst on a filter (SCRoF), a selective catalytic reduction (SCR) catalyst and an ammonia oxidation (AMOX) catalyst.

[0112] According to the fifteenth alternative, it is preferred that the system comprises in sequential order in the direction of the exhaust gases: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments disclosed herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction catalyst on a filter (SCRoF), a selective catalytic reduction (SCR) catalyst and an ammonia oxidation (AMOX) catalyst.

[0113] Still further, the present invention relates to a method for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO) and one or more hydrocarbons, the method comprising

[0114] (A) providing an exhaust gas stream comprising one or more of formaldehyde, nitrogen oxides (NO), and one or more hydrocarbons;

[0115] (B) directing the exhaust gas stream provided in (A) through a catalyst according to any one of the embodiments disclosed herein.

[0116] Preferably, the waste gas stream provided in (A) comprises one or more sulfur-containing compounds, more preferably SO 2 and / or SO 3 .

[0117] Preferably, the exhaust gas stream provided in (A) comprises NO x .

[0118] Preferably, the waste gas stream provided in (A) comprises CO.

[0119] Preferably, the waste gas stream provided in (A) comprises formaldehyde.

[0120] Preferably, the exhaust gas stream provided in (A) comprises nitrogen oxides (NO).

[0121] Preferably, the waste gas stream provided in (A) comprises hydrocarbons, preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons.

[0122] Still further, the present invention relates to the use of a catalyst according to any one of the embodiments disclosed herein for oxidizing one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons, more preferably for oxidizing one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons in an exhaust gas stream, more preferably for oxidizing one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons in an exhaust gas stream of an internal combustion engine, more preferably for oxidizing one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons in an exhaust gas stream of a compression ignition engine, and more preferably for oxidizing one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons in an exhaust gas stream of a diesel engine.

[0123] The invention is further illustrated by the following set of embodiments and combinations of embodiments resulting from the indicated dependencies and back-references. In particular, it should be noted that in each case where a range of embodiments is mentioned, for example in the context of a term such as "a catalyst according to any one of embodiments 1 to 4", each embodiment within the range is meant to be explicitly disclosed to the skilled person, i.e. the wording of the term should be understood by the skilled person as being synonymous with "a catalyst according to any one of embodiments 1, 2, 3 and 4". Furthermore, it should be explicitly pointed out that the following set of embodiments represents a properly structured part of a general description of preferred aspects of the invention and therefore properly supports but does not represent the claims of the invention.

[0124] 1. A catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons, the catalyst comprising

[0125] a first washcoat layer comprising Mn; and

[0126] Base material,

[0127] wherein the substrate has an inlet end and an outlet end, the exhaust gas stream can enter the catalyst through the inlet end, and the exhaust gas stream can leave the catalyst through the outlet end,

[0128] Wherein the catalyst further comprises one or more platinum group metals, the one or more platinum group metals comprising Pt, Pd or Pt and Pd, wherein the one or more platinum group metals are at least partially comprised in one or more of the following:

[0129] (a) the first washcoat layer, and

[0130] (b) an optional second washcoat layer, or

[0131] (c) optionally a second washcoat layer and a third washcoat layer,

[0132] Calculated by element, the loading amount of Mn in the catalyst is 0.04 g / in 3 Up to 0.9g / in 3 , preferably 0.05 g / in 3 Up to 0.8g / in 3 , more preferably 0.06 g / in 3 Up to 0.7g / in 3 , more preferably 0.07 g / in 3 Up to 0.6g / in 3 , more preferably 0.08 g / in 3 Up to 0.5g / in 3 , more preferably 0.1 g / in 3 Up to 0.25g / in 3 , more preferably 0.12 g / in 3 Up to 0.22g / in 3 , more preferably 0.14 g / in 3 Up to 0.2g / in 3 , more preferably 0.16 g / in 3 Up to 0.18g / in 3 within the range.

[0133] 2. The catalyst according to embodiment 1, wherein the optional second washcoat layer is substantially free of Mn, wherein preferably the optional second washcoat layer is free of Mn.

[0134] 3. The catalyst according to embodiment 1 or 2, wherein the loading of Mn in the first washcoat layer, calculated as element, is in the range of 1 wt.-% to 50 wt.-%, preferably 2 wt.-% to 30 wt.-%, more preferably 5 wt.-% to 20 wt.-%, more preferably 8 wt.-% to 12 wt.-%, based on 100 wt.-% of the first washcoat layer.

[0135] 4. The catalyst according to any one of embodiments 1 to 3, wherein Mn is present in the form of one or more Mn cations, wherein Mn is preferably contained in the first washcoat layer as one or more oxides, wherein Mn is more preferably contained in the first washcoat layer as one or more oxides of Mn(II), Mn(III), Mn(II / III) and Mn(IV), more preferably as a cation selected from the group consisting of MnO, Mn 2 O 3 , Mn 3 O 4 、MnO 2 One or more oxides from the group consisting of Mn(O)OH and Mn-Zr mixed oxides (including mixtures of two or more thereof) are contained in the first washcoat layer, wherein the Mn-Zr mixed oxides are preferably contained in the first washcoat layer as a solid solution.

[0136] 5. The catalyst according to any one of embodiments 1 to 4, wherein the first washcoat layer comprises a particulate support material, wherein Mn is supported on the particulate support material, wherein the particulate support material is preferably selected from the group consisting of: ZrO 2 、Al 2 O 3 、SiO 2 、TiO 2 ,La 2 O 3 Doping is ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, praseodymium oxide-doped CeO 2 -ZrO 2 Mixed oxides, ZrO 2 -doped Al 2 O 3 、ZrO 2 Doped SiO 2 、SiO 2 Doped Al 2O 3 、CuO-Al 2 O 3 Mixed oxides and mixtures of two or more thereof, more preferably selected from the group consisting of: ZrO 2 ,La 2 O 3 Doped ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 6 O 11 Doped CeO 2 -ZrO 2 Mixed oxides, PrO 2 Doped CeO 2 -ZrO 2 Mixed oxides, ZrO 2 Doped Al 2 O 3 、ZrO 2 Doped SiO 2 and a mixture of two or more thereof, more preferably selected from the group consisting of: ZrO 2 ,La 2 O 3 Doped ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO2 -ZrO 2 Mixed oxides, Pr 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 6 O 11 Doped CeO 2 -ZrO 2 mixed oxides and mixtures of two or more thereof, wherein Mn is more preferably supported on particles of La 2 O 3 Doped ZrO 2 Among them, ZrO is preferred 2 Doped with La 2 O 3 , based on 100 wt.-% ZrO 2 and La 2 O 3 , the amount thereof ranges from 1 wt.-% to 50 wt.-%, preferably from 3 wt.-% to 30 wt.-%, more preferably from 5 wt.-% to 15 wt.-%, more preferably from 8 wt.-% to 10 wt.-%.

[0137] 6. The catalyst according to any one of embodiments 1 to 5, wherein the first washcoat layer comprises Ce, wherein Ce is preferably present as CeO 2 and / or Ce 2 O 3 Contained in the first washcoat layer.

[0138] 7. The catalyst according to embodiment 6, wherein the loading of Ce in the first washcoat layer, calculated as the element, is in the range of 1 wt.-% to 50 wt.-%, preferably 2 wt.-% to 30 wt.-%, more preferably 5 wt.-% to 20 wt.-%, more preferably 8 wt.-% to 12 wt.-%, based on 100 wt.-% of the first washcoat layer.

[0139] 8. The catalyst according to embodiment 6 or 7, wherein Ce is supported on a particulate support material, wherein the particulate support material is preferably selected from the group consisting of: ZrO 2 、Al 2 O 3 、SiO 2 、TiO 2 ,La 2 O 3 Doping is ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La 2O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, praseodymium oxide-doped CeO 2 -ZrO 2 Mixed oxides, ZrO 2 -doped Al 2 O 3 、ZrO 2 Doped SiO 2 、SiO 2 Doped Al 2 O 3 、CuO-Al 2 O 3 Mixed oxides and mixtures of two or more thereof, more preferably selected from the group consisting of: ZrO 2 ,La 2 O 3 Doped ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 6 O 11 Doped CeO 2 -ZrO 2 Mixed oxides, PrO 2 Doped CeO 2 -ZrO 2 Mixed oxides, ZrO 2 Doped Al 2 O3 、ZrO 2 Doped SiO 2 and a mixture of two or more thereof, more preferably selected from the group consisting of: ZrO 2 ,La 2 O 3 Doped ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 6 O 11 Doped CeO 2 -ZrO 2 mixed oxides and mixtures of two or more thereof, wherein Ce is more preferably supported on particles La 2 O 3 Doped ZrO 2 Among them, ZrO is preferred 2 Doped with La 2 O 3 , based on 100 wt.-% ZrO 2 and La 2 O 3 , the amount thereof ranges from 1 wt.-% to 50 wt.-%, preferably from 3 wt.-% to 30 wt.-%, more preferably from 5 wt.-% to 15 wt.-%, more preferably from 8 wt.-% to 10 wt.-%.

[0140] 9. The catalyst according to any one of embodiments 1 to 5, wherein the first washcoat layer is substantially free of Ce, wherein preferably the first washcoat layer is free of Ce.

[0141] 10. The catalyst according to embodiment 9, wherein the catalyst is substantially free of Ce, wherein preferably the catalyst is free of Ce.

[0142] 11. The catalyst according to any one of embodiments 1 to 10, wherein the first washcoat layer comprises Cu, wherein the first washcoat layer preferably comprises CuO, Cu 2 O or CuO and Cu 2 O, more preferably CuO.

[0143] 12. The catalyst according to embodiment 11, wherein the loading of Cu in the first washcoat layer, calculated as the element, is in the range of 1 wt.-% to 50 wt.-%, preferably 2 wt.-% to 30 wt.-%, more preferably 5 wt.-% to 20 wt.-%, more preferably 8 wt.-% to 12 wt.-%, based on 100 wt.-% of the first washcoat layer.

[0144] 13. The catalyst according to embodiment 11 or 12, wherein Cu is supported on a particulate support material, wherein the particulate support material is preferably selected from the group consisting of: ZrO 2 、Al 2 O 3 、SiO 2 、TiO 2 ,La 2 O 3 Doping is ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, praseodymium oxide-doped CeO 2 -ZrO 2 Mixed oxides, ZrO 2 -doped Al 2 O 3 、ZrO 2 Doped SiO 2 、SiO 2 Doped Al 2 O 3 、CuO-Al 2 O 3 Mixed oxides and mixtures of two or more thereof, more preferably selected from the group consisting of: ZrO 2 ,La2 O 3 Doped ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 6 O 11 Doped CeO 2 -ZrO 2 Mixed oxides, PrO 2 Doped CeO 2 -ZrO 2 Mixed oxides, ZrO 2 Doped Al 2 O 3 、ZrO 2 Doped SiO 2 and a mixture of two or more thereof, more preferably selected from the group consisting of: ZrO 2 ,La 2 O 3 Doped ZrO 2 、CeO 2 -ZrO 2 Mixed oxides, La 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxide, Nd 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Y 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr 2 O 3 Doped CeO 2 -ZrO 2 Mixed oxides, Pr6 O 11 Doped CeO 2 -ZrO 2 mixed oxides and mixtures of two or more thereof, wherein Cu is more preferably supported on particles of La 2 O 3 Doped ZrO 2 Among them, ZrO is preferred 2 Doped with La 2 O 3 , based on 100 wt.-% ZrO 2 and La 2 O 3 , the amount thereof ranges from 1 wt.-% to 50 wt.-%, preferably from 3 wt.-% to 30 wt.-%, more preferably from 5 wt.-% to 15 wt.-%, more preferably from 8 wt.-% to 10 wt.-%.

[0145] 14. The catalyst according to any one of embodiments 1 to 10, wherein the first washcoat layer is substantially free of Cu, wherein preferably the first washcoat layer is free of Cu.

[0146] 15. The catalyst according to embodiment 14, wherein the catalyst is substantially free of Cu, wherein preferably the catalyst is free of Cu.

[0147] 16. A catalyst according to any one of embodiments 1 to 15, wherein the substrate is a wall-flow substrate or a flow-through substrate, preferably a honeycomb wall-flow substrate or a honeycomb flow-through substrate, more preferably a honeycomb flow-through substrate, wherein the flow-through substrate is more preferably a flow-through substrate having a high-porosity wall.

[0148] 17. The catalyst according to any one of embodiments 1 to 16, wherein the loading of the first washcoat layer is between 0.3 g / in 3 Up to 6g / in 3 , preferably 1 g / in 3 Up to 5g / in 3 , more preferably 1.5 g / in 3 Up to 4g / in 3 , more preferably 2 g / in 3 Up to 3.5g / in 3 , more preferably 2.3 g / in 3 Up to 2.9g / in 3 , more preferably 2.5 g / in 3 Up to 2.7g / in 3 within the range.

[0149] 18. The catalyst according to any one of embodiments 1 to 17, wherein the loading of the second washcoat layer is between 0.25 g / in 3 Up to 6g / in 3 , preferably 0.3 g / in 3 Up to 6g / in 3 , more preferably 1 g / in 3 Up to 5g / in 3 , more preferably 1.5 g / in 3 Up to 4g / in 3 , more preferably 2 g / in 3 Up to 3.5g / in 3 , more preferably 2.2 g / in 3 Up to 3.0g / in 3 , more preferably 2.3 g / in 3 Up to 2.9g / in 3 , more preferably 2.5 g / in 3 Up to 2.7g / in 3 within the range.

[0150] 19. The catalyst according to any one of embodiments 1 to 18, wherein the catalyst comprises one or more platinum group metals consisting of Pt, Pd or Pt and Pd, wherein preferably the catalyst comprises Pt or Pt and Pd as one or more platinum group metals, wherein more preferably the catalyst comprises Pt and Pd as one or more platinum group metals.

[0151] 20. The catalyst according to any one of embodiments 1 to 19, wherein the catalyst comprises a loading of 2 g / ft 3 Up to 250g / ft 3 , preferably 5g / ft 3 Up to 150g / ft 3 , more preferably 10g / ft 3 Up to 125g / ft 3 , more preferably 20g / ft 3 Up to 100g / ft 3 , more preferably 25g / ft 3 Up to 85g / ft 3 , more preferably 30g / ft 3 Up to 80g / ft 3 , more preferably 40g / ft 3 Up to 60g / ft 3 Within the range of Pt.

[0152] 21. The catalyst according to any one of embodiments 1 to 20, wherein the catalyst comprises a loading of 5 g / ft3 Up to 100g / ft 3 , preferably 5g / ft 3 Up to 60g / ft 3 , more preferably 10g / ft 3 Up to 50g / ft 3 , more preferably 15g / ft 3 Up to 40g / ft 3 , more preferably 20g / ft 3 Up to 30g / ft 3 within the range of Pd.

[0153] 22. The catalyst according to any one of embodiments 1 to 21, wherein the catalyst comprises a total Pt and Pd loading of 2 g / ft 3 Up to 250g / ft 3 , preferably 5g / ft 3 Up to 200g / ft 3 , more preferably 10g / ft 3 Up to 150g / ft 3 , more preferably 20g / ft 3 Up to 130g / ft 3 , more preferably 30g / ft 3 Up to 125g / ft 3 , more preferably 40g / ft 3 Up to 110g / ft 3 , more preferably 50g / ft 3 Up to 100g / ft 3 , more preferably 60g / ft 3 Up to 90g / ft 3 , more preferably 70g / ft 3 Up to 80g / ft 3 range of Pt and Pd.

[0154] 23. The catalyst according to any one of embodiments 1 to 22, wherein the catalyst comprises Pt and Pd, and the Pt:Pd weight ratio ranges from 1:2 to 20:1, preferably 50:50 to 80:20, more preferably 60:40 to 75:25, more preferably 65:35 to 70:30.

[0155] 24. The catalyst according to any one of embodiments 1 to 23, wherein the one or more platinum group metals are supported on a particulate support material, wherein the particulate support material is preferably selected from the group consisting of: Al 2 O 3 、SiO 2 、TiO 2 、SiO 2Doped Al 2 O 3 , Mn oxide doped Al 2 O 3 and a mixture of two or more thereof, wherein preferably the one or more platinum group metals are supported on Al 2 O 3 and / or SiO 2 Doped Al 2 O 3 and / or Mn oxide doped Al 2 O 3 , more preferably SiO 2 Doped Al 2 O 3 or Al 2 O 3 or Mn oxide doped Al 2 O 3 wherein based on 100 wt-% of the Mn oxide doped Al 2 O 3 , calculated as Mn oxide, the Mn oxide doped Al 2 O 3 Preferably, 1 to 10 wt-%, more preferably 4 to 6 wt-%, of Mn oxide is contained.

[0156] 25. The catalyst according to any one of embodiments 1 to 24, wherein the first washcoat layer comprises a hydrocarbon capture material, wherein the hydrocarbon capture material comprises a molecular sieve, preferably a zeolite, more preferably a zeolite having a maximum pore size of 12-membered rings, more preferably zeolite beta, wherein the molecular sieve, preferably the zeolite, preferably comprises SiO 2 and Al 2 O 3 , wherein the molecular sieve, preferably the zeolite, more preferably has a SiO ratio in the range of 10:1 to 500:1 2 With Al 2 O 3 The molar ratio of the molecular sieve, preferably the zeolite, preferably comprises Fe, wherein the molecular sieve, preferably the zeolite, more preferably comprises Fe, based on the weight of the molecular sieve, is 10:1 to 100:1, more preferably 10:1 to 40:1, more preferably 15:1 to 30:1, more preferably 20:1 to 25:1, wherein the molecular sieve, preferably the zeolite, preferably comprises Fe, based on the weight of the molecular sieve, as Fe 2 O 3 Calculated, the amount ranges from 1.0 wt-% to 7.0 wt-%, more preferably from 3.0 wt-% to 5.0 wt-%, more preferably from 4.0 wt-% to 4.5 wt-%.

[0157] 26. The catalyst according to embodiment 25, wherein the loading amount of the hydrocarbon capture material in the first washcoat layer is between 0.01 g / in 3 Up to 2.0g / in 3 In the range of 0.05 g / in 3 Up to 1.0g / in 3 In the range of 0.05 g / in 3 Up to 0.3g / in 3 within the range.

[0158] 27. The catalyst according to any one of embodiments 1 to 26, wherein the catalyst comprises a second washcoat layer, wherein the one or more platinum group metals are at least partially contained in the second washcoat layer, wherein preferably the one or more platinum group metals are all contained in the second washcoat layer.

[0159] 28. The catalyst according to any one of embodiments 1 to 27, wherein the second washcoat layer comprises a hydrocarbon capture material, wherein the hydrocarbon capture material comprises a molecular sieve, preferably a zeolite, more preferably a zeolite having a maximum pore size defined by a 12-membered ring, more preferably zeolite beta, wherein the molecular sieve, preferably the zeolite, preferably comprises SiO 2 and Al 2 O 3 , wherein the molecular sieve, preferably the zeolite, more preferably has a SiO ratio in the range of 10:1 to 40:1 2 With Al 2 O 3 The molar ratio of the molecular sieve, preferably the zeolite, preferably comprises Fe, wherein the molecular sieve, preferably the zeolite, more preferably comprises Fe, based on the weight of the molecular sieve, as Fe 2 O 3 Calculated, the amount ranges from 1.0 wt-% to 7.0 wt-%, more preferably from 3.0 wt-% to 5.0 wt-%, more preferably from 4.0 wt-% to 4.5 wt-%.

[0160] 29. The catalyst according to embodiment 28, wherein the loading amount of the hydrocarbon capture material in the second washcoat layer is between 0.01 g / in 3 Up to 2.0g / in 3 In the range of 0.05 g / in 3 Up to 1.0g / in 3 g / in 3 In the range of 0.05 g / in 3 Up to 0.3g / in 3 within the range.

[0161] 30. The catalyst according to any one of embodiments 1 to 29, wherein the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a layered arrangement of the first washcoat layer and the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0162] 31. The catalyst of embodiment 30, wherein the first washcoat layer is disposed on the substrate and the second washcoat layer is disposed on the first washcoat layer.

[0163] 32. The catalyst of embodiment 30 or 31, wherein the second washcoat layer is disposed on the substrate and the first washcoat layer is disposed on the second washcoat layer.

[0164] 33. The catalyst of embodiment 30 or 31, wherein the catalyst comprises a third washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer, the second washcoat layer, and the third washcoat layer, wherein the third washcoat layer is disposed on the substrate starting from the inlet end of the substrate along the axial length of the substrate, and wherein the first washcoat layer is disposed on the substrate starting from the outlet end of the substrate along the axial length of the substrate, and wherein the second washcoat layer is disposed on the first washcoat layer and completely covers the first washcoat layer, wherein the length of the first washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the third washcoat layer and a downstream zone comprising the first washcoat layer and the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the third washcoat layer.

[0165] 34. The catalyst of embodiment 30 or 32, wherein the catalyst comprises a third washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer, the second washcoat layer, and the third washcoat layer, wherein the third washcoat layer is disposed on the substrate along the axial length of the substrate starting from the inlet end of the substrate, and wherein the second washcoat layer is disposed on the substrate along the axial length of the substrate starting from the outlet end of the substrate, and wherein the first washcoat layer is disposed on and completely covers the second washcoat layer, wherein the length of the second washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the third washcoat layer and a downstream zone comprising the first washcoat layer and the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the third washcoat layer.

[0166] 35. The catalyst of embodiment 30 or 31, wherein the catalyst comprises a third washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer, the second washcoat layer, and the third washcoat layer, wherein the third washcoat layer is disposed on the substrate along the axial length of the substrate starting from the outlet end of the substrate, and wherein the first washcoat layer is disposed on the substrate along the axial length of the substrate starting from the inlet end of the substrate, and wherein the second washcoat layer is disposed on the first washcoat layer and completely covers the first washcoat layer, wherein the length of the first washcoat layer is less than the axial length of the substrate, thereby creating a downstream zone comprising the third washcoat layer and an upstream zone comprising the first washcoat layer and the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the third washcoat layer.

[0167] 36. The catalyst of embodiment 30 or 32, wherein the catalyst comprises a third washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer, the second washcoat layer, and the third washcoat layer, wherein the third washcoat layer is disposed on the substrate starting from the outlet end of the substrate along the axial length of the substrate, and wherein the second washcoat layer is disposed on the substrate starting from the inlet end of the substrate along the axial length of the substrate, and wherein the first washcoat layer is disposed on and completely covers the second washcoat layer, wherein the length of the second washcoat layer is less than the axial length of the substrate, thereby creating a downstream zone comprising the third washcoat layer and an upstream zone comprising the first washcoat layer and the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the third washcoat layer.

[0168] 37. The catalyst according to any one of embodiments 1 to 29, wherein the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer, wherein the second washcoat layer is disposed on the substrate along the axial length of the substrate starting from the inlet end of the substrate, and wherein the first washcoat layer is disposed on the substrate along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0169] 38. The catalyst according to any one of embodiments 1 to 29, wherein the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer, wherein the first washcoat layer is disposed on the substrate along an axial length of the substrate starting from the inlet end of the substrate, and wherein the second washcoat layer is disposed on the substrate along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0170] 39. The catalyst according to any one of embodiments 1 to 29, wherein the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer, wherein the second washcoat layer is disposed on the substrate along the axial length of the substrate starting from the inlet end of the substrate, and wherein the first washcoat layer is disposed on the substrate along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0171] 40. The catalyst according to any one of embodiments 1 to 29, wherein the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer, wherein the first washcoat layer is disposed on the substrate along an axial length of the substrate starting from the inlet end of the substrate, and wherein the second washcoat layer is disposed on the substrate along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0172] 41. The catalyst of embodiment 37 or 39, wherein the catalyst comprises a third washcoat layer, wherein the third washcoat layer is disposed on the first layer, wherein the catalyst exhibits a zoned arrangement of the second washcoat layer and the third washcoat layer, wherein the second washcoat layer is disposed on the substrate starting from the inlet end of the substrate along the axial length of the substrate, and wherein the third washcoat layer is disposed on the first washcoat layer starting from the outlet end of the substrate along the axial length of the substrate, wherein the length of the third washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer and the third washcoat layer.

[0173] 42. The catalyst of embodiment 38 or 40, wherein the catalyst comprises a third washcoat layer, wherein the third washcoat layer is disposed on the first layer, wherein the catalyst exhibits a zoned arrangement of the second washcoat layer and the third washcoat layer, wherein the third washcoat layer is disposed on the first washcoat layer starting from the inlet end of the substrate along the axial length of the substrate, and wherein the second washcoat layer is disposed on the substrate starting from the outlet end of the substrate along the axial length of the substrate, wherein the length of the third washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the first washcoat layer and the third washcoat layer and a downstream zone comprising the second washcoat layer.

[0174] 43. The catalyst according to any one of embodiments 33 to 42, wherein the first washcoat layer and the second washcoat layer are adjacent to each other.

[0175] 44. The catalyst according to embodiments 33 to 43, wherein the second washcoat layer and the third washcoat layer are adjacent to each other.

[0176] 45. The catalyst according to any one of embodiments 33 to 44, wherein a portion of the second washcoat layer overlaps at least a portion of the first washcoat layer, wherein preferably the second washcoat layer overlaps the first washcoat layer over a portion of the axial length of the first washcoat layer in the range of 10% to 100%, more preferably 15% to 80%, and more preferably 20% to 50%.

[0177] 46. ​​The catalyst according to any one of embodiments 33 to 45, wherein a portion of the first washcoat layer overlaps at least a portion of the second washcoat layer, wherein preferably the first washcoat layer overlaps the second washcoat layer over a portion of the axial length of the second washcoat layer in the range of 10% to 100%, more preferably 15% to 80%, and more preferably 20% to 50%.

[0178] 47. The catalyst according to any one of embodiments 33 to 46, wherein a portion of the third washcoat layer overlaps at least a portion of the first washcoat layer, wherein preferably the third washcoat layer overlaps the first washcoat layer over a portion of the axial length of the first washcoat layer in the range of 10% to 100%, more preferably 15% to 80%, and more preferably 20% to 50%.

[0179] 48. The catalyst according to any one of embodiments 1 to 29, wherein the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer, wherein the second washcoat layer is disposed on the substrate along the entire length of the substrate, and wherein the first washcoat layer is disposed on the second washcoat layer along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer above the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0180] 49. The catalyst according to any one of embodiments 1 to 29, wherein the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer, wherein the second washcoat layer is disposed on the substrate along the entire length of the substrate, and wherein the first washcoat layer is disposed on the second washcoat layer along the axial length of the substrate starting from the inlet end of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the first washcoat layer above the second washcoat layer and a downstream zone comprising the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0181] 50. The catalyst according to embodiment 48 or 49, wherein the length of the first washcoat layer ranges from 10% to 90%, preferably 30% to 80%, and more preferably 50% to 70% of the axial length of the substrate.

[0182] 51. The catalyst according to any one of embodiments 1 to 29, wherein the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer, wherein the first washcoat layer is disposed on the substrate along the entire length of the substrate, and wherein the second washcoat layer is disposed on the first washcoat layer starting from the inlet end of the substrate along the axial length of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second washcoat layer above the first washcoat layer and a downstream zone comprising the first washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0183] 52. The catalyst of embodiment 51, wherein the catalyst comprises a third washcoat layer, wherein the third washcoat layer is disposed on the first layer, wherein the catalyst exhibits a zoned arrangement of the second washcoat layer and the third washcoat layer, wherein the second washcoat layer is disposed on the first washcoat layer starting from the inlet end of the substrate along the axial length of the substrate, and wherein the third washcoat layer is disposed on the first washcoat layer starting from the outlet end of the substrate along the axial length of the substrate, wherein the length of the third washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second washcoat layer and a downstream zone comprising the third washcoat layer.

[0184] 53. The catalyst according to any one of embodiments 1 to 29, wherein the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer, wherein the first washcoat layer is disposed on the substrate along the entire length of the substrate, and wherein the second washcoat layer is disposed on the first washcoat layer starting from the outlet end of the substrate along the axial length of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer above the first washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0185] 54. The catalyst of embodiment 53, wherein the catalyst comprises a third washcoat layer, wherein the third washcoat layer is disposed on the first layer, wherein the catalyst exhibits a zoned arrangement of the second washcoat layer and the third washcoat layer, wherein the third washcoat layer is disposed on the first washcoat layer starting from the inlet end of the substrate along the axial length of the substrate, and wherein the second washcoat layer is disposed on the first washcoat layer starting from the outlet end of the substrate along the axial length of the substrate, wherein the length of the third washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the third washcoat layer and a downstream zone comprising the second washcoat layer.

[0186] 55. The catalyst according to embodiment 52 or 54, wherein the second washcoat layer and the third washcoat layer are adjacent to each other.

[0187] 56. The catalyst according to any one of embodiments 1 to 55, wherein the length of the first washcoat layer ranges from 5% to 100% of the axial length of the substrate, preferably from 10% to 90% of the axial length of the substrate, preferably from 15% to 75%, more preferably from 20% to 60%, more preferably from 25% to 50%, and more preferably from 35% to 45%.

[0188] 57. The catalyst according to any one of embodiments 30 to 56, wherein the length of the second washcoat layer ranges from 5% to 100% of the axial length of the substrate, preferably from 10% to 90% of the axial length of the substrate, more preferably from 15% to 75%, more preferably from 20% to 60%, more preferably from 25% to 50%, and more preferably from 35% to 45%.

[0189] 58. The catalyst according to any one of embodiments 33 to 57, wherein the length of the third washcoat layer ranges from 5% to 100% of the axial length of the substrate, preferably from 10% to 90% of the axial length of the substrate, preferably from 15% to 75%, more preferably from 20% to 60%, more preferably from 25% to 50%, and more preferably from 35% to 45%.

[0190] 59. The catalyst according to any one of embodiments 33 to 58, wherein the third washcoat layer is substantially free of sulfur trapping material, wherein preferably the third washcoat layer is free of sulfur trapping material.

[0191] 60. The catalyst according to any one of embodiments 33 to 59, wherein the third washcoat layer comprises a hydrocarbon capture material, wherein the hydrocarbon capture material comprises a molecular sieve, preferably a zeolite, more preferably a zeolite having a maximum pore size of 12-membered rings, more preferably zeolite beta, wherein the molecular sieve, preferably the zeolite, preferably comprises SiO 2 and Al 2 O 3 , wherein the molecular sieve, preferably the zeolite, more preferably has a SiO ratio in the range of 10:1 to 500:1 2 With Al 2 O 3 The molar ratio of the molecular sieve, preferably the zeolite, preferably comprises Fe, wherein the molecular sieve, preferably the zeolite, more preferably comprises Fe, based on the weight of the molecular sieve, is 10:1 to 100:1, more preferably 10:1 to 40:1, more preferably 15:1 to 30:1, more preferably 20:1 to 25:1, wherein the molecular sieve, preferably the zeolite, preferably comprises Fe, based on the weight of the molecular sieve, as Fe 2 O 3 Calculated, the amount ranges from 1.0 wt-% to 7.0 wt-%, more preferably from 3.0 wt-% to 5.0 wt-%, more preferably from 4.0 wt-% to 4.5 wt-%.

[0192] 61. The catalyst according to embodiment 60, wherein the loading amount of the hydrocarbon capture material in the third washcoat layer is between 0.01 g / in 3 Up to 2.0g / in 3 In the range of 0.05 g / in 3 Up to 1.0g / in 3 In the range of 0.05 g / in 3 Up to 0.3g / in 3 within the range.

[0193] 62. The catalyst according to any one of embodiments 33 to 61, wherein the one or more platinum group metals are at least partially contained in the third washcoat layer.

[0194] 63. The catalyst according to embodiment 62, wherein the one or more platinum group metals are supported on a particulate support material, wherein the particulate support material is preferably selected from the group consisting of: Al 2 O 3 、SiO 2 、TiO 2 、SiO 2 Doped Al 2 O 3 , Mn oxide doped Al 2 O 3and a mixture of two or more thereof, wherein preferably the one or more platinum group metals are supported on Al 2 O 3 and / or SiO 2 Doped Al 2 O 3 and / or Mn oxide doped Al 2 O 3 , more preferably SiO 2 Doped Al 2 O 3 or Al 2 O 3 or Mn oxide doped Al 2 O 3 wherein based on 100 wt-% of the Mn oxide doped Al 2 O 3 , with MnO 2 Calculation shows that the Mn oxide doped Al 2 O 3 Preferably, 1 to 10 wt-%, more preferably 4 to 6 wt-%, of Mn oxide is contained.

[0195] 64. The catalyst according to any one of embodiments 33 to 63, wherein the catalyst comprises a second washcoat layer and a third washcoat layer, wherein the one or more platinum group metals are completely contained in the second washcoat layer and the third washcoat layer, wherein the weight ratio of the one or more platinum group metals contained in the second washcoat layer to the one or more platinum group metals contained in the third washcoat layer is in the range of 0.5:1 to 5.0:1, more preferably 1.0:1 to 2.0:1, more preferably in the range of 1.4:1 to 1.6:1, wherein the one or more platinum group metals contained in the second washcoat layer preferably comprise, more preferably consist of, Pt and Pd, wherein the one or more platinum group metals contained in the third washcoat layer preferably comprise, more preferably consist of, Pt and Pd.

[0196] 65. The catalyst according to any one of embodiments 33 to 64, wherein in the zone of the catalyst containing the first washcoat layer, the loading of Mn, calculated as element, is between 0.04 g / in 3 Up to 0.9g / in 3 In the range of 0.05 g / in 3 Up to 0.8g / in 3 , more preferably 0.15 g / in 3 Up to 0.5g / in 3, more preferably 0.2 g / in 3 Up to 0.35g / in 3 , more preferably 0.23 g / in 3 Up to 0.29g / in 3 , more preferably 0.25 g / in 3 Up to 0.27g / in 3 .

[0197] 66. The catalyst according to any one of embodiments 30 to 65, wherein the one or more platinum group metals are entirely contained in the second washcoat layer or in the second washcoat layer and the third washcoat layer.

[0198] 67. The catalyst according to any one of embodiments 30 to 66, wherein the one or more platinum group metals are at least partially contained in the first washcoat layer.

[0199] 68. The catalyst according to any one of embodiments 1 to 67, wherein the substrate is a metal substrate or a ceramic substrate, wherein preferably the substrate is a ceramic substrate, wherein more preferably the substrate comprises cordierite and / or SiC, preferably cordierite, wherein more preferably the substrate consists of cordierite and / or SiC, preferably consists of cordierite.

[0200] 69. The catalyst according to any one of embodiments 33 to 68, wherein the substrate consists of two separate monoliths, wherein a first monolith is disposed upstream of a second monolith, wherein the one or more washcoat layers of the upstream zone are contained on the first monolith, and the one or more washcoat layers of the downstream zone are contained on the second monolith, wherein preferably the first monolith comprising the one or more washcoat layers of the upstream zone and the second monolith comprising the one or more washcoat layers of the downstream zone are obtained or obtainable by dividing the catalyst according to any one of embodiments 31 to 68 into two separate monoliths, wherein the one or more washcoat layers of the upstream zone are contained on the first monolith, and the one or more washcoat layers of the downstream zone are contained on the second monolith.

[0201] 70. The catalyst according to any one of embodiments 1 to 69, wherein the exhaust gas stream contains hydrocarbons, preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons.

[0202] 71. An exhaust gas treatment system, comprising an internal combustion engine and an exhaust gas conduit for exhaust gas from the internal combustion engine, wherein the exhaust gas conduit comprises one or more catalysts according to any one of embodiments 1 to 70, preferably one, two, three or four catalysts according to any one of embodiments 1 to 70.

[0203] 72. An exhaust treatment system according to embodiment 71, wherein the internal combustion engine is a compression ignition engine, preferably a diesel engine.

[0204] 73. An exhaust treatment system according to embodiment 71 or 72, wherein the internal combustion engine is a lean burn gasoline engine.

[0205] 74. An exhaust gas treatment system according to embodiment 71, wherein the internal combustion engine is powered by an oxygen-containing fuel, wherein the oxygen-containing fuel preferably includes one or more of methanol and biofuel.

[0206] 75. An exhaust treatment system according to any one of embodiments 71 to 74, wherein the system includes one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on a filter (SCRoF) and a diesel exothermic catalyst (DEC).

[0207] 76. An exhaust gas treatment system according to embodiment 75, which includes, in a continuous order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any one of embodiments 1 to 70, a catalyst according to any one of embodiments 1 to 70, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a diesel exothermic catalyst (DEC), a catalytic soot filter (CSF), a selective catalytic reduction (SCR) catalyst and a selective catalytic reduction (SCR) catalyst.

[0208] 77. An exhaust gas treatment system according to embodiment 75, which includes in a continuous order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any one of embodiments 1 to 70, a catalyst according to any one of embodiments 1 to 70, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a diesel exothermic catalyst (DEC), a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst and a selective catalytic reduction (SCR) catalyst.

[0209] 78. An exhaust gas treatment system according to embodiment 75, which includes, in sequential order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any one of embodiments 1 to 70, a catalyst according to any one of embodiments 1 to 70, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a diesel exothermic catalyst (DEC), a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst and an ammonia oxidation (AMOX) catalyst.

[0210] 79. An exhaust gas treatment system according to embodiment 75, which includes in a continuous order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any one of embodiments 1 to 70, a catalyst according to any one of embodiments 1 to 70, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any one of embodiments 1 to 70, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst and a selective catalytic reduction (SCR) catalyst.

[0211] 80. An exhaust gas treatment system according to embodiment 75, which includes, in sequential order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any one of embodiments 1 to 70, a catalyst according to any one of embodiments 1 to 70, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any one of embodiments 1 to 70, a catalyst according to any one of embodiments 1 to 70 (wherein the substrate is a wall-flow substrate), a selective catalytic reduction (SCR) catalyst and an ammonia oxidation (AMOX) catalyst.

[0212] 81. An exhaust gas treatment system according to embodiment 75, which includes in a continuous order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any one of embodiments 1 to 70, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a catalytic soot filter (CSF), a selective catalytic reduction (SCR) catalyst and a selective catalytic reduction (SCR) catalyst.

[0213] 82. An exhaust gas treatment system according to embodiment 75, which includes in a continuous order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any one of embodiments 1 to 70, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a catalytic soot filter (CSF), a selective catalytic reduction (SCR) catalyst and an ammonia oxidation (AMOX) catalyst.

[0214] 83. An exhaust gas treatment system according to embodiment 75, which includes, in a continuous order in the direction of the exhaust gas: an optional electric heater or a fuel burner and / or a fuel injector, a catalyst according to any one of embodiments 1 to 70, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any one of embodiments 1 to 70 (wherein the substrate is a wall-flow substrate), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0215] 84. An exhaust gas treatment system according to embodiment 75, which includes, in a continuous order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any one of embodiments 1 to 70, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction catalyst on a filter (SCRoF) and an ammonia oxidation (AMOX) catalyst.

[0216] 85. An exhaust gas treatment system according to embodiment 75, which includes in a continuous order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any one of embodiments 1 to 70, a selective catalytic reduction catalyst on a filter (SCRoF) and an ammonia oxidation (AMOX) catalyst.

[0217] 86. An exhaust gas treatment system according to embodiment 75, which includes in a continuous order in the direction of the exhaust gas: an optional electric heater or a fuel burner and / or a fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any one of embodiments 1 to 70, a catalytic soot filter (CSF), a selective catalytic reduction (SCR) catalyst and an ammonia oxidation (AMOX) catalyst.

[0218] 87. An exhaust gas treatment system according to embodiment 75, which includes, in sequential order in the direction of the exhaust gas: an optional electric heater or a fuel burner and / or a fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any one of embodiments 1 to 70, a catalyst according to any one of embodiments 1 to 70 (wherein the substrate is a wall-flow substrate), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0219] 88. An exhaust gas treatment system according to embodiment 75, which includes in a continuous order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any one of embodiments 1 to 70, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst and an ammonia oxidation (AMOX) catalyst.

[0220] 89. An exhaust gas treatment system according to embodiment 75, which includes, in a continuous order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any one of embodiments 1 to 70, a selective catalytic reduction catalyst on a filter (SCRoF), a selective catalytic reduction (SCR) catalyst and an ammonia oxidation (AMOX) catalyst.

[0221] 90. An exhaust gas treatment system according to embodiment 75, which includes in a continuous order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any one of embodiments 1 to 70, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction catalyst on a filter (SCRoF), a selective catalytic reduction (SCR) catalyst and an ammonia oxidation (AMOX) catalyst.

[0222] 91. A method for treating a waste gas stream containing one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons, the method comprising

[0223] (A) providing an exhaust gas stream comprising one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons;

[0224] (B) directing the exhaust gas stream provided in (A) through a catalyst according to any one of Embodiments 1 to 70.

[0225] 92. The method according to embodiment 91, wherein the waste gas stream provided in (A) comprises one or more sulfur-containing compounds, preferably SO 2and / or SO 3 .

[0226] 93. The method according to embodiment 91 or 92, wherein the exhaust gas stream provided in (A) comprises NO x .

[0227] 94. A method according to any one of embodiments 91 to 93, wherein the exhaust gas stream provided in (A) contains CO.

[0228] 95. The method of any one of embodiments 91 to 94, wherein the waste gas stream provided in (A) comprises formaldehyde.

[0229] 96. The method of any one of embodiments 91 to 95, wherein the exhaust gas stream provided in (A) comprises nitrogen oxides (NO).

[0230] 97. A method according to any one of embodiments 91 to 96, wherein the waste gas stream provided in (A) comprises hydrocarbons, preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons.

[0231] 98. The catalyst according to any one of embodiments 1 to 70 is used to oxidize one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons, preferably to oxidize one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons in an exhaust gas stream, more preferably to oxidize one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons in the exhaust gas stream of an internal combustion engine, more preferably to oxidize one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons in the exhaust gas stream of a compression ignition engine, more preferably to oxidize one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons in the exhaust gas stream of a diesel engine.

[0232] The present invention is further illustrated by the following examples.

[0233] Experimental Section

[0234] Example 1: Preparation of a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons Example 2: Preparation of a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons

[0235] The catalyst was prepared by coating a front zone containing a platinum group metal (PGM) and a back zone containing a base metal oxide (BMO) on a 1" diameter cordierite honeycomb substrate, respectively, and then combining the coated cores in sequence for subsequent S aging and testing. The catalyst was prepared by first mixing Pt (using an aqueous solution containing an ammonia-stabilized hydroxyl Pt(IV) complex, the solution having a Pt content ranging from 10 wt.-% to 20 wt.-%), Pd (using Pd nitrate), beta zeolite, and a 5 wt.-% silica having a Pt content of about 150 m 2 / g and a BET surface area of ​​about 0.6 cm 3 The front zone segment was prepared by combining a commercial alumina support powder with a pore volume of 1.5 g / g in an aqueous slurry composition. After the slurry was coated on the cordierite substrate, followed by drying and calcination at 590°C, a 1" diameter x 1.2" long core was cut from the monolith to be used as the front zone segment. The Pt-Pd weight ratio was 2:1, and the total Pt-Pd loading was 75 g / ft 3 Monolith volume. The washcoat loading with PGM layer was 2.9 g / in 3 , containing about 91 wt.-% alumina and about 9 wt.-% beta zeolite. 2 O 3 And has about 75m 2 A commercial zirconia support powder with a BET surface area of ​​1.5475 Å / g was combined with a solution of Mn nitrate and Ce nitrate in deionized (Di) water to prepare a BMO-containing back zone segment. After the resulting mixture was ground to a particle size suitable for coating, a boehmite alumina binder was added. The resulting slurry was then coated onto a 1" diameter x 1.8" long cordierite substrate, dried and subsequently calcined at 590°C for 1 hour. The total washcoat loading containing the BMO layer was 1.9 g / in 3 The monolith volume contains 9.2 wt% Mn, 9.2 wt% Ce, 3 wt% Al 2 O 3 Binder and remaining La 2 O 3 Stable ZrO 2 (1.5g / in 3 ).

[0236] Based on the total catalyst including the front zone section and the rear zone section, the corresponding loading amount of Mn and Ce in the catalyst is 0.114 g / in 3 .

[0237] Example 3: Preparation of a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons Example 4: Preparation of a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons

[0238] The catalyst was prepared in the same manner as described in Example 1, except that the total washcoat loading of the BMO-containing rear zone section was 2.3 g / in 3 And La 2 O 3 Stable ZrO 2 The carrier coating loading of the carrier is 1.8 g / in 3 Based on the total catalyst including the front zone section and the rear zone section, the corresponding loading of Mn and Ce in the catalyst is 0.138 g / in 3 .

[0239] Example 5: Aging and Catalytic Testing Figure 1

[0240] The catalyst was prepared by coating the front zone containing PGM and the back zone containing BMO on a 1" diameter cordierite honeycomb substrate, respectively, and then combining the coated cores in sequence for subsequent S aging and testing. The front zone segment was prepared in the same manner as in the previous example. 2 O 3 And has about 75m 2 / g and a BET surface area of ​​about 0.5 cm 3 The rear zone segment was prepared by combining a commercial zirconia support powder with a pore volume of 2.5 g / g with a solution of Mn nitrate in deionized (Di) water. After the resulting mixture was ground to a particle size suitable for coating, a boehmite alumina binder was added. The resulting slurry was then coated onto a 1" diameter x 1.8" long cordierite substrate, dried and subsequently calcined at 590°C for 1 hour. The total washcoat loading was 2.3 g / in 3 The monolith volume contains 9.4 wt% Mn, 3 wt% Al 2 O 3 Binder and remaining La 2 O 3 Stable ZrO 2 (1.8g / in 3 ).

[0241] Based on the total catalyst including the front zone section and the rear zone section, the Mn loading in the catalyst is 0.138 g / in calculated as the element. 3 .

[0242] Figure 2 Example 6: Preparation of a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons

[0243] The catalyst was prepared in the same manner as described in Example 3, except that the total washcoat loading of the BMO-containing rear zone section was 3.4 g / in 3 And La 2 O 3 Stable ZrO 2 The carrier coating loading of the carrier is 3.0 g / in 3 Based on the total catalyst including the front zone section and the rear zone section, the Mn loading in the catalyst is 0.204 g / in 3 .

[0244] Comparative Example 7: Preparation of a copper-containing catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons

[0245] Sulfur aging (S aging) of the catalysts of Examples 1-4 was carried out on a laboratory reactor at 300°C in a reactor containing 15 ppm SO2 、150ppm NO、10% O 2 and 5% H 2 The flow rate through the catalyst, measured as space velocity, was 35,000 / hour. The exposure time was 88 minutes, corresponding to a target S exposure of 1 g (S) / L monolith volume. 2 and 5% H 2 Desulfurization was accomplished at 750°C for 30 minutes under isothermal conditions in a feed of 1% O. The flow rate through the catalyst, measured as space velocity, was 32,000 / hour.

[0246] After sulfation and desulfation, a mixture containing 180 ppm NO, 1000 ppm CO, 25 ppm HCHO, 100 ppm from C 2 H 4 C1, 190ppm from C 10 H 22 C1, 10% O 2 , 10% H 2 O and 10% CO 2 The formaldehyde (HCHO) light-off performance of the sample was tested with a feed of 50,000 t / h. The flow rate through the catalyst, measured as space velocity, was 50,000 / h. The sample was placed in the reactor and first equilibrated in flowing air at 80°C. The formaldehyde-containing feed was then introduced and the temperature was started to 300°C at a ramp rate of 15°C / min. The formaldehyde concentration was monitored by FTIR during the light-off ramp and the conversion performance versus temperature was subsequently calculated from these measurements.

[0247] The results for the catalysts of Examples 1 and 2 are shown in Example 8: Aging and Catalytic Testing The formaldehyde oxidation performance at low temperature is higher for the catalyst of Example 2 having a higher total washcoat loading in the BMO-containing rear zone.

[0248] The results for the catalysts of Examples 3 and 4 are shown in Figure 3 The low temperature formaldehyde oxidation performance is higher for the catalyst of Example 4 having a higher total washcoat loading in the BMO-containing rear zone.

[0249] As can be seen from the results, the catalyst according to the invention may contain a small or large amount of Mn supported on a support material such as refractory zirconia. In particular, low amounts of Mn may benefit engine operation by limiting the pressure drop in the exhaust system, while increasing the amount of catalytically active Mn components is critical for maximizing HCHO oxidation performance, especially after exposure to the detrimental effects of S present in the engine exhaust. In particular, for a catalyst comprising 9 wt.-% La supported on 2 O 3 Stable ZrO2 For catalysts with 10 wt.-% Mn and 10 wt.-% Ce on the zirconia support, it has been found that increasing the zirconia support loading from 1.5 g / in 3 Increased by 20% to 1.8 g / in 3 The sulfation and desulfation performance of formaldehyde (HCHO) was significantly positively affected. For the relevant catalyst containing Mn but no Ce, when the zirconia support loading was increased to 3 g / in 3 even higher performance when

[0250] Figure 1 Figure 2

[0251] The catalyst was prepared in the same manner as described in Example 1, except that the Pt-Pd weight ratio in the front zone was 4:1 and the total Pt-Pd loading was 180 g / ft 3 The monolith volume, and the BMO-containing layer comprises 10 wt% Mn and 10 wt% Ce, 3 wt% Al 2 O 3 Binder and remaining La 2 O 3 Stable ZrO 2 .

[0252] Figure 3 Cited References

[0253] The catalyst was prepared in the same manner as described in Example 6, except that the BMO-containing layer contained 10 wt % Mn, 10 wt % Cu and 10 wt % Ce, 3 wt % Al 2 O 3 Binder and remaining La 2 O 3 Stable ZrO 2 .

[0254] ​

[0255] Steam aging of the catalysts of Example 6 and Comparative Example 7 was carried out at 800°C for 16 hours.

[0256] After steam aging, a mixture containing 180 ppm NO, 1000 ppm CO, 25 ppm HCHO, 100 ppm from C 2 H 4 C1, 190ppm from C 10 H 22 C1, 10% O 2 , 10% H 2 O and 10% CO 2The formaldehyde (HCHO) light-off performance of the sample was tested with a feed of 50,000 t / h. The flow rate through the catalyst, measured as space velocity, was 50,000 / h. The sample was placed in the reactor and first equilibrated in flowing air at 80°C. The formaldehyde-containing feed was then introduced and the temperature was started to 300°C at a ramp rate of 15°C / min. The formaldehyde concentration was monitored by FTIR during the light-off ramp and the conversion performance versus temperature was subsequently calculated from these measurements.

[0257] The results of the catalysts of Example 6 and Comparative Example 7 are shown in ​ Compared to Comparative Example 7, in which the first washcoat loading contained Cu, the formaldehyde oxidation performance at low temperature was higher for the catalyst of Example 6, in which the first washcoat loading did not contain Cu. BRIEF DESCRIPTION OF THE DRAWINGS

[0258] ​ : Shows the formaldehyde (HCHO) oxidation performance of the catalysts of Examples 1 and 2 after sulfation and desulfation at 750°C. Both samples contained 75 g / ft 3 The 2:1 Pt-Pd front zone contains 9 wt.-% La 2 O 3 Stable ZrO 2 The samples differed in the amount of total washcoat loaded onto the monolith for the rear zone.

[0259] ​ : Shows the formaldehyde (HCHO) oxidation performance of the catalysts of Examples 3 and 4 after sulfation and desulfation at 750°C. Both samples contained 75 g / ft 3 The 2:1 Pt-Pd front zone contains 9 wt.-% La 2 O 3 Stable ZrO 2 The samples differed in the amount of total washcoat loaded onto the monolith for the rear zone.

[0260] ​ : Shows the formaldehyde (HCHO) oxidation performance of the catalysts of Example 6 and Comparative Example 7 after steam aging (800° C., 16 hours).

[0261] ​

[0262] -WO 2022 / 047132 A1

[0263] -US 10,598,061 B2

[0264] -US 10,392,980 B2

[0265] -WO 2021 / 198680 A1

[0266] -US 2019 / 262772 A1

[0267] -US 2017 / 009623 A1

[0268] -US 2015 / 352493 A1

[0269] -US 2018 / 318805 A1

[0270] -MC -Galván et al. Applied Catalysis B. 2004, 51, 83-91

Claims

1. A catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons, the catalyst comprising a first support coating layer comprising Mn; and a substrate, wherein the substrate has an inlet end and an outlet end, and the exhaust gas stream can enter the catalyst through the inlet end and leave the catalyst through the outlet end, wherein the catalyst further comprises one or more platinum group metals, the one or more platinum group metals comprising Pt, Pd, or Pt and Pd, and wherein the one or more platinum group metals are at least partially contained in one or more of the following: (a) the first support coating layer, and (b) an optional second support coating layer, or (c) an optional second support coating layer and a third support coating layer, Calculated as an element, the loading amount of Mn in the catalyst is 0.04 g / in 3 Up to 0.9g / in 3 within the range.

2. The catalyst according to claim 1, wherein the first support coating layer comprises a particulate support material, and Mn is loaded on the particulate support material.

3. The catalyst according to claim 1 or 2, wherein the first support coating layer is substantially free of Cu.

4. The catalyst according to any one of claims 1 to 3, wherein the catalyst comprises a loading of 2 g / ft 3 Up to 250g / ft 3 Pt in range.

5. The catalyst according to any one of claims 1 to 4, wherein the catalyst comprises a loading of 5 g / ft 3 Up to 100g / ft 3 Pd in ​​the range.

6. The catalyst according to any one of claims 1 to 5, wherein the one or more platinum group metals are loaded on a particulate support material.

7. The catalyst according to any one of claims 1 to 6, wherein the second support coating layer comprises a hydrocarbon trapping material, and the hydrocarbon trapping material comprises a molecular sieve.

8. The catalyst according to any one of claims 1 to 7, wherein the one or more platinum group metals are completely contained in the second support coating layer.

9. The catalyst according to any one of claims 1 to 8, wherein the catalyst comprises a second support coating layer, and the catalyst exhibits a zoned arrangement of the first support coating layer and the second support coating layer, and wherein the second support coating layer is disposed on the substrate along the axial length of the substrate starting from the inlet end of the substrate, and the first support coating layer is disposed on the substrate along the axial length of the substrate starting from the outlet end of the substrate, and the length of the first support coating layer is less than the axial length of the substrate, thereby creating an upstream zone containing the second support coating layer and a downstream zone containing the first support coating layer, and wherein the one or more platinum group metals are at least partially contained in the second support coating layer.

10. The catalyst according to any one of claims 1 to 8, wherein the catalyst comprises a second support coating layer, and the catalyst exhibits a zoned arrangement of the first support coating layer and the second support coating layer, and wherein the second washcoat layer is disposed on the substrate along an axial length of the substrate starting from the inlet end of the substrate, wherein the first washcoat layer is disposed on the substrate along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

11. The catalyst according to any one of claims 1 to 8, wherein the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer, and wherein the second washcoat layer is disposed on the substrate along the entire length of the substrate, wherein the first washcoat layer is disposed on the second washcoat layer along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate, thereby creating an upstream region comprising the second washcoat layer and a downstream region comprising the first washcoat layer above the second washcoat layer, wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

12. The catalyst according to any one of claims 1 to 8, wherein the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer, and wherein the first washcoat layer is disposed on the substrate along the entire length of the substrate, wherein the second washcoat layer is disposed on the first washcoat layer along the axial length of the substrate starting from the inlet end of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate, thereby creating an upstream region comprising the second washcoat layer above the first washcoat layer and a downstream region comprising the first washcoat layer, wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

13. An exhaust gas treatment system comprising an internal combustion engine and an exhaust gas duct for exhaust gases from the internal combustion engine, wherein the exhaust gas duct comprises a catalyst according to any one of claims 1 to 12.

14. The exhaust treatment system of claim 13, wherein the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on a filter (SCRoF), and a diesel exothermic catalyst (DEC).

15. A method for treating a waste gas stream containing one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons, the method comprising (A) providing an exhaust gas stream comprising one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons; (B) directing the exhaust gas flow provided in (A) through a catalyst according to any one of claims 1 to 12.

16. Use of the catalyst according to any one of claims 1 to 12 for the oxidation of one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons.

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