Catalyst containing copper and manganeum for the treatment of exhaust gas streams containing one or more of formaldehyde

Abstract

The present invention relates to a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons, the catalyst comprising a first washcoat layer comprising Mn and Cu wherein the first washcoat layer is substantially free of Ce, 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. Further, the present invention relates to an exhaust gas treatment system comprising said catalyst, a method for treating an exhaust gas stream containing formaldehyde, nitric oxide (NO) and hydrocarbons using said catalyst, and the use of said catalyst.

Description

Technical Field

[0001] The present invention relates to a Cu- and Mn-containing catalyst for treating exhaust gas streams containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons, an exhaust gas treatment system comprising the catalyst, a method for treating exhaust gas streams containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons using the catalyst, and the use of the catalyst for oxidizing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons. Background Art

[0002] The present invention relates to diesel oxidation catalysts (DOCs) having enhanced oxidation functionality, particularly enhanced oxidation functionality for one or more of formaldehyde (HCHO), nitric oxide (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. More stringent regulations have also been implemented for formaldehyde emissions from engine exhausts of passenger and transport vehicles. Generally, manganese oxides (e.g., MnO2) are known to have activity for 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 transitions at high temperatures (e.g., above 400 °C) can cause the structure of MnO2 to collapse, resulting in such low surface area and pore volume that the catalysis is ineffective. One way to improve the stability of Mn oxides (as well as other catalytically useful base metal oxides such as copper, cerium dioxide, and iron) at high temperatures can be to support them on refractory oxide materials that themselves have high stability when exposed to the high temperatures in engine exhausts. In this regard, materials such as alumina (Al2O3) and zirconia (ZrO2) can be useful.

[0003] A key challenge in technologies incorporating Mn base metal oxide (BMO) catalysts for reducing exhaust emissions from diesel vehicles is seen in the inherently poor sulfur resistance of manganese exhibited at the high desulfation temperature of manganese sulfate. As described in the literature, at typical temperatures (about 650 °C to 700 °C) for filter regeneration or desulfation (desulfurization of SOx) on diesel engines, significant desulfation of MnSO4 does not occur.

[0004] Pt and Pd supported on a high-temperature refractory metal oxide support 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 gas of a diesel vehicle, an additional function of the DOC composition is to oxidize diesel fuel injected into the exhaust gas upstream of the DOC to produce a high-temperature exotherm, which is used to thermally oxidize soot accumulated on a diesel particulate filter (DPF) or a 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 hydrocarbon concentration in the exhaust gas stream to produce an exotherm. A temperature greater than 600 °C at the DPF or CSF inlet is 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, approximately 1% (10,000 ppm) or more based on C1. The temperature at which the DOC composition can oxidize ( "light off") the injected fuel needs to be as low as possible, preferably below 300 °C. Additionally, the amount of hydrocarbon slip bypassing 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 and an exhaust gas treatment system for reducing the formaldehyde level 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 zirconia.

[0006] US10,598,061B2 relates to methods and systems for diesel oxidation catalysts. In particular, claim 1 discloses a method comprising: generating NO2 in a catalyst comprising a support coating having zirconium, one or more base metal oxides, and palladium oxide, wherein the exhaust gas flow rate is between a lower threshold flow rate and an upper threshold flow rate; and promoting regeneration of a particulate filter located downstream of the catalyst via NO2 when the exhaust gas temperature is higher than a threshold temperature, wherein the palladium oxide is contained in an upstream portion of the catalyst with respect to the exhaust gas flow direction; and the one or more base metal oxides are contained in a downstream portion of the catalyst with respect to the exhaust gas flow direction.

[0007] US 10,392,980 B2 relates to methods and systems for diesel oxidation catalysts. In particular, claim 1 discloses a method that includes passing diesel combustion exhaust gas through a diesel oxidation catalyst having a washcoat containing zirconia, 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 an amount greater than that coated on an upstream portion, and the palladium oxide is coated on an upstream portion of the substrate in an amount greater than that coated on a downstream portion, downstream referring to the axial direction of exhaust gas flow, and wherein the palladium oxide accounts for 0.5 wt% to 3 wt% of the washcoat.

[0008] WO 2020 / 089043 A1 relates to the field of exhaust gas treatment systems for purifying exhaust gas discharged from lean burn engines. Disclosed therein is an exhaust gas treatment system for a lean burn engine, the exhaust gas treatment system including a diesel oxidation catalyst (DOC), a catalytic soot filter (CSF), a first reductant injector, an AEI zeolite-based selective catalytic reduction (SCR) catalyst, and a first ammonia oxidation catalyst (AMOx) downstream of the AEI zeolite-based SCR catalyst; wherein the AEI zeolite has a silica to alumina molar ratio of 10 to 19.

[0009] In view of more stringent regulations imposed on formaldehyde emissions from engine exhaust gases of passengers and transport vehicles, there is a need to provide an improved catalyst for treating exhaust gas streams containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons. In particular, there is a need for an improved catalyst suitable for the oxidation of HCHO, nitric oxide (NO), and hydrocarbons, which can be implemented in a mid-size diesel pickup truck. Detailed Description

[0010] Accordingly, an object of the present invention is to provide a catalyst for treating exhaust gas streams containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons, which has improved properties in terms of performance, particularly after exposure to sulfation and desulfation treatments.

[0011] Surprisingly, it has been found that improved catalysts can be provided for the conversion of one or more of formaldehyde, nitric oxide (NO), and hydrocarbons in exhaust gases. In particular, it has surprisingly been found that catalysts can be provided that exhibit improved performance in the conversion of one or more of formaldehyde, nitric oxide (NO), and hydrocarbons after exposure to sulfation and desulfation treatments encountered in typical applications. In addition, it has surprisingly been found that the catalysts according to the present invention exhibit enhanced hydrocarbon (HC) and nitric oxide (NO) oxidation functions. In particular, it has surprisingly been found that the benefits of using BMO-containing catalysts to reduce platinum group metals in diesel exhaust treatment systems 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 the total PGM usage and cost. It has also surprisingly been found that using a diesel oxidation catalyst (DOC) comprising a platinum group metal (PGM) and a base metal oxide (BMO) produces a catalyst with enhanced fuel combustion function. In addition, 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 since the Mn-containing washcoat layer can produce NO2 that oxidizes soot. Additionally, the catalysts of the present invention can achieve a relatively low N2O yield, particularly due to their relatively low platinum group metal content.

[0012] Accordingly, the present invention relates to a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons, the catalyst comprising

[0013] a first washcoat layer comprising Mn and Cu, wherein the first washcoat layer is substantially free of Ce, preferably wherein the first washcoat layer is free of Ce, and

[0014] a substrate,

[0015] wherein the substrate has an inlet end and an outlet end, the exhaust gas stream being able to enter the catalyst through the inlet end and being able to leave the catalyst through the outlet end,

[0016] 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:

[0017] (a) the first washcoat layer, and

[0018] (b) an optional second washcoat layer, or

[0019] (c) an optional second washcoat layer and a third washcoat layer.

[0020] Within the meaning of the present invention, when the carrier coating layer contains an element or compound in an amount of 1% by weight or less, preferably 0.5% by weight or less, more preferably 0.1% by weight or less, more preferably 0.05% by weight or less, more preferably 0.01% by weight or less, more preferably 0.005% by weight or less, and even more preferably 0.001% by weight or less, calculated as the element or compound and based on 100% by weight of the carrier coating layer, the carrier coating layer is substantially free of the element or compound.

[0021] Preferably, the optional second carrier coating layer is substantially free of Mn, and more preferably the optional second carrier coating layer is free of Mn. It should be noted that the Mn contained in the second carrier coating layer may be generated by its leakage from another layer containing Mn, especially from the first carrier coating layer, into the said layer.

[0022] Preferably, the optional second carrier coating layer is substantially free of Ce, and more preferably the optional second carrier coating layer is free of Ce.

[0023] Preferably, the optional second carrier coating layer is substantially free of Cu, and more preferably the optional second carrier coating layer is free of Cu.

[0024] Preferably, based on 100% by weight of the first carrier coating layer, the loading amount of Mn in the first carrier coating layer is in the range of 1% to 50% by weight, more preferably 2% to 30% by weight, more preferably 5% to 20% by weight, and even more preferably 8% to 12% by weight, calculated as the element.

[0025] Preferably, Mn exists in the form of one or more Mn cations, and more preferably Mn is included in the first carrier coating layer as one or more oxides, and more preferably Mn is included in the first carrier coating layer as one or more oxides selected from the group consisting of MnO, Mn2O3, Mn3O4, MnO2, Mn(O)OH, and Mn-Zr mixed oxides (including mixtures of two or more of them), and the Mn-Zr mixed oxide is preferably included in the first carrier coating layer as a solid solution.

[0026] Preferably, Cu exists in the first carrier coating layer as CuO, Cu2O, or CuO and Cu2O, and more preferably as CuO.

[0027] Preferably, based on 100% by weight of the first carrier coating layer, the loading amount of Cu in the first carrier coating layer is in the range of 1% to 50% by weight, more preferably 2% to 30% by weight, more preferably 5% to 20% by weight, and more preferably 8% to 12% by weight, calculated on an elemental basis.

[0028] Preferably, the first carrier coating layer contains a particulate carrier material on which Mn and Cu are respectively loaded, and the particulate carrier material is more preferably selected from the group consisting of: ZrO2, Al2O3, SiO2, TiO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, Pr2O3-doped CeO2-ZrO2 mixed oxide, ZrO2-doped Al2O3, ZrO2-doped SiO2, SiO2-doped Al2O3, CuO-Al2O3 mixed oxide, and mixtures of two or more of them, and more preferably selected from the group consisting of: ZrO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, Pr2O3-doped CeO2-ZrO2 mixed oxide, Pr6O 11 -doped CeO2-ZrO2 mixed oxide, PrO2-doped CeO2-ZrO2 mixed oxide, ZrO2-doped Al2O3, ZrO2-doped SiO2, and mixtures of two or more of them, and more preferably selected from the group consisting of: ZrO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, Pr2O3-doped CeO2-ZrO2 mixed oxide, Pr6O 11 -doped CeO2-ZrO2 mixed oxide, and mixtures of two or more of them, wherein more preferably Mn is loaded on particulate La2O3-doped ZrO2, and wherein preferably ZrO2 is doped with La2O3, and based on 100% by weight of ZrO2 and La2O3, the amount of ZrO2 is in the range of 1% to 50% by weight, preferably 3% to 30% by weight, more preferably 5% to 15% by weight, and more preferably 8% to 10% by weight.

[0029] Preferably, the catalyst is substantially free of Ce, and more preferably the catalyst is free of Ce.

[0030] 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, still more preferably a honeycomb flow-through substrate, wherein the flow-through substrate is more preferably a flow-through substrate having a high-porosity wall.

[0031] Preferably, the loading of the first washcoat layer is in the range of 0.1 g / in 3 to 6 g / in 3 , more preferably 0.3 g / in 3 to 4 g / in 3 , more preferably 0.5 g / in 3 to 3 g / in 3 , more preferably 1 g / in 3 to 2.5 g / in 3 , more preferably 1.3 g / in 3 to 2.2 g / in 3 , more preferably 1.5 g / in 3 to 2 g / in 3 .

[0032] Within the meaning of the present invention, the loading of the washcoat layer in the catalyst refers to the loading of the washcoat layer based on the volume of the catalyst containing the washcoat layer. Thus, within the meaning of the present invention, the loading of the washcoat layer contained only in a certain part or zone of the catalyst is based on the volume of that part or zone of the catalyst. Thus, for example, if the washcoat layer is provided on 50% of the axial length of the honeycomb substrate, its loading is calculated based on 50% of the total volume of the honeycomb substrate.

[0033] Preferably, the loading of the second washcoat layer is in the range of 0.25 g / in 3 to 6 g / in 3 , more preferably 0.3 g / in 3 to 6 g / in 3 , more preferably 0.5 g / in 3 to 5 g / in 3 , more preferably 1 g / in 3 to 4 g / in 3 , more preferably 1.5 g / in 3 to 3 g / in 3 , more preferably 2 g / in 3 to 2.5 g / in 3 , more preferably 1.8 g / in 3 to 2.2 g / in 3 .

[0034] Preferably, the catalyst comprises one or more platinum group metals consisting of Pt, Pd, or Pt and Pd, more preferably the catalyst comprises Pt or Pt and Pd as one or more platinum group metals, and even more preferably the catalyst comprises Pt and Pd as one or more platinum group metals.

[0035] Preferably, calculated on an elemental basis, the catalyst comprises Pt in a loading range of 2 g / ft 3 to 250 g / ft 3 , more preferably 5 g / ft 3 to 150 g / ft 3 , even more preferably 10 g / ft 3 to 125 g / ft 3 , even more preferably 20 g / ft 3 to 100 g / ft 3 , even more preferably 25 g / ft 3 to 85 g / ft 3 , even more preferably 30 g / ft 3 to 80 g / ft 3 , even more preferably 40 g / ft 3 to 60 g / ft 3 .

[0036] 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 containing Pt, Pd, or Pt and Pd. In the case where Pt, Pd, or Pt and Pd is contained in one or more zones of the catalyst, within the meaning of the present invention, preferably, the loading of Pt, Pd, or Pt and Pd is based on the volume of the catalyst containing one or more zones of Pt, Pd, or Pt and Pd. Thus, for example, if Pt, Pd, or Pt and Pd is provided in a zone extending 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.

[0037] Preferably, calculated on an elemental basis, the catalyst comprises Pd in a loading range of 5 g / ft 3 to 100 g / ft 3 , more preferably 5 g / ft 3 to 60 g / ft 3 , even more preferably 10 g / ft 3 to 50 g / ft 3 , even more preferably 15 g / ft 3 to 40 g / ft 3 , even more preferably 20 g / ft 3 to 30 g / ft 3 .

[0038] Preferably, calculated on a corresponding element basis, the catalyst comprises a total Pt and Pd loading in the range of 2 g / ft 3 to 250 g / ft 3 , more preferably 5 g / ft 3 to 200 g / ft 3 , more preferably 10 g / ft 3 to 150 g / ft 3 , more preferably 20 g / ft 3 to 130 g / ft 3 , more preferably 30 g / ft 3 to 125 g / ft 3 , more preferably 40 g / ft 3 to 110 g / ft 3 , more preferably 50 g / ft 3 to 100 g / ft 3 , more preferably 60 g / ft 3 to 90 g / ft 3 , more preferably 70 g / ft 3 to 80 g / ft 3 of Pt and Pd.

[0039] Preferably, the catalyst comprises Pt and Pd, with 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.

[0040] Preferably, one or more platinum group metals are supported on a particulate support material, where the particulate support material is more preferably selected from the group consisting of: Al2O3, SiO2, TiO2, SiO2-doped Al2O3, Mn oxide-doped Al2O3, and mixtures of two or more thereof, where more preferably one or more platinum group metals are supported on Al2O3 and / or SiO2-doped Al2O3 and / or Mn oxide-doped Al2O3, more preferably on SiO2-doped Al2O3 or Al2O3 or Mn oxide-doped Al2O3, where based on 100 wt% of the Mn oxide-doped Al2O3, calculated as MnO2, the Mn oxide-doped Al2O3 preferably contains 1 wt% to 10 wt%, more preferably 4 wt% to 6 wt% of Mn oxide.

[0041] Preferably, the catalyst comprises a second support coating layer, where one or more platinum group metals are at least partially contained in the second support coating layer, where more preferably one or more platinum group metals are entirely contained in the second support coating layer.

[0042] Preferably, the first carrier coating layer contains a hydrocarbon trapping material, wherein the first carrier coating layer contains a hydrocarbon trapping material, and the hydrocarbon trapping material includes a molecular sieve, preferably zeolite, more preferably zeolite with a maximum pore diameter of 12-membered ring, more preferably zeolite β, wherein the molecular sieve, preferably zeolite, preferably contains SiO2 and Al2O3, wherein the molecular sieve, preferably zeolite, more preferably has a molar ratio of SiO2 to Al2O3 in the range of 10:1 to 500:1, more preferably 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 zeolite, preferably contains Fe, wherein the molecular sieve, preferably zeolite, more preferably contains Fe, based on the weight of the molecular sieve, calculated as Fe2O3, the amount of Fe is in the range of 1.0 wt% to 7.0 wt%, more preferably 3.0 wt% to 5.0 wt%, more preferably 4.0 wt% to 4.5 wt%.

[0043] When the first carrier coating layer contains a hydrocarbon trapping material, wherein the hydrocarbon trapping material includes a molecular sieve, preferably, the loading amount of the hydrocarbon trapping material in the first carrier coating layer is in 0.01 g / in 3 to 2.0 g / in 3 range, more preferably in 0.05 g / in 3 to 1.0 g / in 3 range.

[0044] Preferably, the second carrier coating layer contains a hydrocarbon trapping material, wherein the hydrocarbon trapping material includes a molecular sieve, more preferably zeolite, more preferably zeolite with a maximum pore diameter defined by 12-membered ring, more preferably zeolite β, wherein the molecular sieve, preferably zeolite, preferably contains SiO2 and Al2O3, wherein the molecular sieve, preferably zeolite, more preferably has a molar ratio of SiO2 to Al2O3 in the range of 10:1 to 500:1, more preferably 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 zeolite, preferably contains Fe, wherein the molecular sieve, preferably zeolite, more preferably contains Fe, based on the weight of the molecular sieve, calculated as Fe2O3, the amount of Fe is in the range of 1.0 wt% to 7.0 wt%, more preferably 3.0 wt% to 5.0 wt%, more preferably 4.0 wt% to 4.5 wt%.

[0045] When the second carrier coating layer contains a hydrocarbon trapping material, wherein the hydrocarbon trapping material includes a molecular sieve, preferably, the loading amount of the hydrocarbon trapping material in the second carrier coating layer is in 0.01 g / in 3 to 2.0 g / in 3within the range, more preferably in the range of 0.05 g / in 3 to 1.0 g / in 3 g / in 33 within the range, more preferably in the range of 0.05 g / in 3 to 0.3 g / in 3 within the range.

[0046] According to the first alternative, preferably, the catalyst comprises a second support coating layer, wherein the catalyst exhibits a layered arrangement of the first support coating layer and the second support coating layer, and wherein one or more platinum group metals are at least partially contained in the second support coating layer.

[0047] In the case where the catalyst comprises a second support coating layer, wherein the catalyst exhibits a layered arrangement of the first support coating layer and the second support coating layer, and wherein one or more platinum group metals are at least partially contained in the second support coating layer, according to the first alternative, preferably, the first support coating layer is disposed on the substrate, and the second support coating layer is disposed on the first support coating layer.

[0048] Furthermore, in the case where the catalyst comprises a second support coating layer, wherein the catalyst exhibits a layered arrangement of the first support coating layer and the second support coating layer, and wherein one or more platinum group metals are at least partially contained in the second support coating layer, according to the first alternative, preferably, the second support coating layer is disposed on the substrate, and the first support coating layer is disposed on the second support coating layer.

[0049] 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 one or more platinum group metals are at least partially contained in the second washcoat layer, according to a first alternative, preferably, the catalyst comprises a third washcoat layer, wherein the catalyst exhibits a partitioned arrangement of a first washcoat layer, a second washcoat layer and a 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 one or more platinum group metals are at least partially contained in the third washcoat layer. Alternatively, preferably, the catalyst comprises a third washcoat layer, wherein the catalyst exhibits a partitioned arrangement of a first washcoat layer, a second washcoat layer and a 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 second 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 first washcoat layer is disposed on the second washcoat layer 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 one or more platinum group metals are at least partially contained in the third washcoat layer. Alternatively, preferably, the catalyst comprises a third washcoat layer, wherein the catalyst exhibits a partitioned arrangement of a first washcoat layer, a second washcoat layer and a 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 first 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 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 one or more platinum group metals are at least partially contained in the third washcoat layer.Alternatively, preferably, the catalyst comprises a third washcoat layer, wherein the catalyst exhibits a zoned arrangement of a first washcoat layer, a second washcoat layer, and a 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 one or more platinum group metals are at least partially contained in the third washcoat layer.

[0050] According to a second alternative, preferably, the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of a first washcoat layer and a second 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 first 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 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 one or more platinum group metals are at least partially contained in the second washcoat layer.

[0051] According to a third alternative, preferably, the catalyst comprises a second washcoat layer, wherein the first 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 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 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 one or more platinum group metals are at least partially contained in the second washcoat layer.

[0052] According to a fourth alternative, preferably, the catalyst comprises a second washcoat layer, wherein the catalyst exhibits a zoned arrangement of a first washcoat layer and a second 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 first 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 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 one or more platinum group metals are at least partially contained in the second washcoat layer.

[0053] According to the fifth alternative, preferably, the catalyst comprises a second carrier coating layer, wherein the catalyst exhibits a zoned arrangement of the first carrier coating layer and the second carrier coating layer, wherein the first carrier coating layer is disposed on the substrate starting from the inlet end of the substrate along the axial length of the substrate, and wherein the second carrier coating 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 second carrier coating layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the first carrier coating layer and a downstream zone comprising the second carrier coating layer, and wherein one or more platinum group metals are at least partially contained in the second carrier coating layer.

[0054] In the case where the catalyst comprises a second carrier coating layer, wherein the catalyst exhibits a zoned arrangement of the first carrier coating layer and the second carrier coating layer according to the second alternative or the fourth alternative, preferably, the catalyst comprises a third carrier coating layer, wherein the third carrier coating layer is disposed on the first layer, wherein the catalyst exhibits a zoned arrangement of the second carrier coating layer and the third carrier coating layer, wherein the second carrier coating 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 carrier coating layer is disposed on the first carrier coating layer starting from the outlet end of the substrate along the axial length of the substrate, wherein the length of the third carrier coating layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second carrier coating layer and a downstream zone comprising the first carrier coating layer and the third carrier coating layer.

[0055] In the case where the catalyst comprises a second carrier coating layer, wherein the catalyst exhibits a zoned arrangement of the first carrier coating layer and the second carrier coating layer according to the third alternative or the fifth alternative, preferably, the catalyst comprises a third carrier coating layer, wherein the third carrier coating layer is disposed on the first layer, wherein the catalyst exhibits a zoned arrangement of the second carrier coating layer and the third carrier coating layer, wherein the third carrier coating layer is disposed on the first carrier coating layer starting from the inlet end of the substrate along the axial length of the substrate, and wherein the second carrier coating 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 carrier coating layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the first carrier coating layer and the third carrier coating layer and a downstream zone comprising the second carrier coating layer.

[0056] In the case where the catalyst comprises a second carrier coating layer, wherein the catalyst exhibits a zoned arrangement of the first carrier coating layer and the second carrier coating layer according to the second alternative, the third alternative, the fourth alternative or the fifth alternative, preferably, the first carrier coating layer and the second carrier coating layer are adjacent to each other.

[0057] Further, in the case where the catalyst includes a second carrier coating layer, in which the catalyst exhibits a partitioned arrangement of the first carrier coating layer and the second carrier coating layer according to the second, third, fourth, or fifth alternative, preferably, the second carrier coating layer and the third carrier coating layer are adjacent to each other.

[0058] Further, in the case where the catalyst includes a second carrier coating layer, in which the catalyst exhibits a partitioned arrangement of the first carrier coating layer and the second carrier coating layer according to the second, third, fourth, or fifth alternative, preferably, a part of the second carrier coating layer overlaps at least a part of the first carrier coating layer, wherein preferably the second carrier coating layer overlaps the first carrier coating layer on a part within the range of 5% to 100% of the axial length of the substrate, preferably 10% to 100% of the axial length of the first carrier coating layer, more preferably 15% to 80%, and even more preferably 20% to 50%.

[0059] Further, in the case where the catalyst includes a second carrier coating layer, in which the catalyst exhibits a partitioned arrangement of the first carrier coating layer and the second carrier coating layer according to the second, third, fourth, or fifth alternative, preferably, a part of the first carrier coating layer overlaps at least a part of the second carrier coating layer, wherein more preferably the first carrier coating layer overlaps the second carrier coating layer on a part within the range of 5% to 100% of the axial length of the substrate, preferably 10% to 100% of the axial length of the second carrier coating layer, more preferably 15% to 80%, and even more preferably 20% to 50%.

[0060] Further, in the case where the catalyst includes a second carrier coating layer, in which the catalyst exhibits a partitioned arrangement of the first carrier coating layer and the second carrier coating layer according to the second, third, fourth, or fifth alternative, preferably, a part of the third carrier coating layer overlaps at least a part of the first carrier coating layer, wherein preferably the third carrier coating layer overlaps the first carrier coating layer on a part within the range of 10% to 100% of the axial length of the first carrier coating layer, more preferably 15% to 80%, and even more preferably 20% to 50%.

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

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

[0063] In the case where the catalyst comprises a second carrier coating layer, wherein the catalyst exhibits a zoned arrangement of a first carrier coating layer and a second carrier coating layer according to the sixth or seventh alternative, preferably, the length of the first carrier coating layer ranges from 10% to 90% of the axial length of the substrate, more preferably 30% to 80%, and even more preferably 50% to 70%.

[0064] According to the eighth alternative, preferably, the catalyst comprises a second carrier coating layer, wherein the catalyst exhibits a zoned arrangement of a first carrier coating layer and a second carrier coating layer, wherein the first carrier coating layer is disposed on the substrate along the entire length of the substrate, and wherein the second carrier coating layer is disposed on the first carrier coating layer starting from the inlet end of the substrate along the axial length of the substrate, wherein the length of the second carrier coating layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second carrier coating layer and a downstream zone comprising the first carrier coating layer, and wherein one or more platinum group metals are at least partially contained in the second carrier coating layer.

[0065] In the case where the catalyst includes a second support coating layer, where the catalyst exhibits a zoned arrangement of the first support coating layer and the second support coating layer according to the eighth alternative, preferably, the catalyst includes a third support coating layer, where the third support coating layer is disposed on the first layer, where the catalyst exhibits a zoned arrangement of the second support coating layer and the third support coating layer, where the second support coating layer is disposed on the first support coating layer starting from the inlet end of the substrate along the axial length of the substrate, and where the third support coating layer is disposed on the first support coating layer starting from the outlet end of the substrate along the axial length of the substrate, where the length of the third 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 third support coating layer.

[0066] According to the ninth alternative, preferably, the catalyst includes a second support coating layer, where the catalyst exhibits a zoned arrangement of the first support coating layer and the second support coating layer, where the first support coating layer is disposed on the substrate along the entire length of the substrate, and where the second support coating layer is disposed on the first support coating layer starting from the outlet end of the substrate along the axial length of the substrate, where the length of the second support coating layer is less than the axial length of the substrate, thereby creating an upstream zone containing the first support coating layer and a downstream zone containing the second support coating layer, and where one or more platinum group metals are at least partially contained in the second support coating layer.

[0067] In the case where the catalyst includes a second support coating layer, where the catalyst exhibits a zoned arrangement of the first support coating layer and the second support coating layer according to the ninth alternative, preferably, the catalyst includes a third support coating layer, where the third support coating layer is disposed on the first layer, where the catalyst exhibits a zoned arrangement of the second support coating layer and the third support coating layer, where the third support coating layer is disposed on the first support coating layer starting from the inlet end of the substrate along the axial length of the substrate, and where the second support coating layer is disposed on the first support coating layer starting from the outlet end of the substrate along the axial length of the substrate, where the length of the third support coating layer is less than the axial length of the substrate, thereby creating an upstream zone containing the third support coating layer and a downstream zone containing the second support coating layer.

[0068] In the case where the catalyst includes a second support coating layer, where the catalyst exhibits a zoned arrangement of the first support coating layer and the second support coating layer according to the eighth alternative or the ninth alternative, and where the catalyst includes a third support coating layer, preferably, the second support coating layer and the third support coating layer are adjacent to each other.

[0069] Preferably, the length of the first support coating 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 even more preferably from 35% to 45%.

[0070] In the case where the catalyst comprises a second support coating layer, wherein the catalyst preferably exhibits a partitioned arrangement of the first support coating layer and the second support coating layer according to the eighth or ninth alternative, preferably, the length of the second support coating 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%, more preferably from 20% to 60%, more preferably from 25% to 50%, and even more preferably from 35% to 45%.

[0071] In the case where the catalyst comprises a second support coating layer and a third support coating layer, preferably, the length of the third support coating 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 even more preferably from 35% to 45%.

[0072] Furthermore, in the case where the catalyst comprises a second support coating layer and a third support coating layer, preferably, the third support coating layer is substantially free of sulfur-trapping material, wherein preferably the third support coating layer is free of sulfur-trapping material.

[0073] Furthermore, in the case where the catalyst comprises a second support coating layer and a third support coating layer, preferably, wherein the third layer comprises a hydrocarbon-trapping material, wherein the hydrocarbon-trapping material comprises a molecular sieve, preferably zeolite, more preferably zeolite with a maximum pore size of 12-membered rings, more preferably zeolite β, wherein the molecular sieve, preferably zeolite, preferably comprises SiO2 and Al2O3, wherein the molecular sieve, preferably zeolite, more preferably has a molar ratio of SiO2 to Al2O3 in the range of 10:1 to 500:1, more preferably 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 zeolite, preferably comprises Fe, wherein the molecular sieve, preferably zeolite, more preferably comprises Fe, based on the weight of the molecular sieve, calculated as Fe2O3, the amount of Fe is in the range of 1.0 wt% to 7.0 wt%, more preferably 3.0 wt% to 5.0 wt%, more preferably 4.0 wt% to 4.5 wt%.

[0074] In the case where the third layer comprises a hydrocarbon-trapping material, preferably, the loading amount of the hydrocarbon-trapping material in the third support coating layer is 0.01 g / in3 to 2.0 g / in 3 and more preferably in the range of 0.05 g / in 3 to 1.0 g / in 3 and more preferably in the range of 0.05 g / in 3 to 0.3 g / in 3 range.

[0075] Further, in the case where the catalyst includes a second support coating layer and a third support coating layer, preferably, one or more platinum group metals are at least partially contained in the third support coating layer.

[0076] In the case where one or more platinum group metals are at least partially contained in the third support coating layer, preferably, one or more platinum group metals are supported on a particulate support material, where the particulate support material is preferably selected from the group consisting of: Al2O3, SiO2, TiO2, SiO2-doped Al2O3, Mn oxide-doped Al2O3, and mixtures of two or more of them, where preferably one or more platinum group metals are supported on Al2O3 and / or SiO2-doped Al2O3 and / or Mn oxide-doped Al2O3, more preferably on SiO2-doped Al2O3 or Al2O3 or Mn oxide-doped Al2O3, where based on 100% by weight of Mn oxide-doped Al2O3, calculated as MnO2, Mn oxide-doped Al2O3 preferably contains 1% to 10% by weight, more preferably 4% to 6% by weight of Mn oxide.

[0077] Further, in the case where the catalyst includes a second support coating layer and a third support coating layer, preferably, the catalyst includes a second support coating layer and a third support coating layer, where one or more platinum group metals are completely contained in the second support coating layer and the third support coating layer, where the weight ratio of one or more platinum group metals contained in the second support coating layer to one or more platinum group metals contained in the third support coating 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, where one or more platinum group metals contained in the second support coating layer preferably include Pt and Pd, more preferably consist of Pt and Pd, and where one or more platinum group metals contained in the third support coating layer preferably include Pt and Pd, more preferably consist of Pt and Pd.

[0078] In the case where the catalyst includes a second support coating layer, wherein the catalyst exhibits a partitioned arrangement of the first support coating layer and the second support coating 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, preferably, in the region of the catalyst containing the first support coating layer, based on the volume of the region of the catalyst containing the first support coating layer, calculated in terms of elements, the loading amount of Mn is in the range of 0.01 g / in 3 to 1 g / in 3 and more preferably 0.05 g / in 3 to 0.5 g / in 3 and more preferably 0.08 g / in 3 to 0.35 g / in 3 and more preferably 0.1 g / in 3 to 0.25 g / in 3 and more preferably 0.13 g / in 3 to 0.2 g / in 3 and more preferably 0.15 g / in 3 to 0.18 g / in 3 within the range.

[0079] Furthermore, in the case where the catalyst includes a second support coating layer, wherein the catalyst exhibits a partitioned arrangement of the first support coating layer and the second support coating 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, preferably, in the region of the catalyst containing the first support coating layer, based on the volume of the region of the catalyst containing the first support coating layer, calculated in terms of elements, the loading amount of Cu is in the range of 0.01 g / in 3 to 1.5 g / in 3 and more preferably 0.05 g / in 3 to 1 g / in 3 and more preferably 0.1 g / in 3 to 0.5 g / in 3 and more preferably 0.13 g / in 3 to 0.35 g / in 3 and more preferably 0.15 g / in 3 to 0.25 g / in 3 and more preferably 0.17 g / in 3 to 0.22 g / in 3 within the range.

[0080] Preferably, one or more platinum group metals are completely included in the second washcoat layer or in the second and third washcoat layers. Alternatively, preferably, one or more platinum group metals are at least partially included in the first washcoat layer.

[0081] Preferably, the substrate is a metallic substrate or a ceramic substrate, more preferably a ceramic substrate, more preferably a substrate comprising cordierite and / or SiC, preferably cordierite, more preferably a substrate consisting of cordierite and / or SiC, preferably consisting of cordierite.

[0082] In the case where the catalyst comprises a second washcoat layer, where the catalyst exhibits a zoned arrangement of the first and second washcoat layers according to the second, third, fourth, fifth, sixth, seventh, eighth or ninth alternative, preferably, the substrate consists of two separate monoliths, where the first monolith is disposed upstream of the second monolith, where one or more washcoat layers of the upstream zone are included on the first monolith, and one or more washcoat layers of the downstream zone are included on the second monolith, more preferably, the first monolith comprising one or more washcoat layers of the upstream zone and the second monolith comprising one or more washcoat layers of the downstream zone are obtained or obtainable by dividing a catalyst according to any one of the embodiments disclosed herein into two separate monoliths according to any one of the second, third, fourth, fifth, sixth, seventh, eighth and ninth alternatives, where one or more washcoat layers of the upstream zone are included on the first monolith, and one or more washcoat layers of the downstream zone are included on the second monolith.

[0083] Preferably, the exhaust gas stream contains hydrocarbons, preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons.

[0084] Furthermore, the present invention relates to an exhaust gas treatment system comprising an internal combustion engine and an exhaust gas duct for exhaust gas from the internal combustion engine, where the exhaust gas duct 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.

[0085] Preferably, the internal combustion engine is a compression ignition engine, more preferably a diesel engine.

[0086] Preferably, the internal combustion engine is a lean burn gasoline engine.

[0087] Alternatively, preferably, the internal combustion engine is powered by an oxygenated fuel, where the oxygenated fuel preferably includes one or more of methanol and biofuel.

[0088] 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 catalytic soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on a filter (SCRoF), and a diesel exothermic catalyst (DEC).

[0089] According to a first alternative, preferably, the system includes, in a continuous sequence 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 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.

[0090] According to a second alternative, preferably, the system includes, in a continuous sequence 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 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.

[0091] According to a third alternative, preferably, the system includes, in a continuous sequence 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 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.

[0092] According to a fourth alternative, it is preferred that the system in the direction of the exhaust gas includes, in a continuous sequence: 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 catalyst according to any of the embodiments disclosed herein, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst.

[0093] According to a fifth alternative, it is preferred that the system in the direction of the exhaust gas includes, in a continuous sequence: 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 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.

[0094] According to a sixth alternative, it is preferred that the system in the direction of the exhaust gas includes, in a continuous sequence: 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.

[0095] According to a seventh alternative, it is preferred that the system in the direction of the exhaust gas includes, in a continuous sequence: 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.

[0096] According to the eighth alternative, it is preferred that the system comprises, in a continuous sequence 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.

[0097] According to the ninth alternative, it is preferred that the system comprises, in a continuous sequence 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 on filter catalyst (SCRoF), and an ammonia oxidation (AMOX) catalyst.

[0098] According to the tenth alternative, it is preferred that the system comprises, in a continuous sequence 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 selective catalytic reduction on filter catalyst (SCRoF), and an ammonia oxidation (AMOX) catalyst.

[0099] According to the eleventh alternative, it is preferred that the system comprises, in a continuous sequence 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 catalytic soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0100] According to the twelfth alternative, it is preferred that the system comprises, in a continuous sequence 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.

[0101] According to the thirteenth alternative, it is preferred that the system comprises, in a continuous sequence 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 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, and an ammonia oxidation (AMOX) catalyst.

[0102] According to the fourteenth alternative, it is preferred that the system comprises, in a continuous sequence 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 catalyst on a filter (SCRoF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0103] According to the fifteenth alternative, it is preferred that the system comprises, in a continuous sequence 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 catalyst on a filter (SCRoF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0104] Furthermore, the present invention relates to a method for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen monoxide (NO), and hydrocarbons, the method comprising

[0105] (A) providing an exhaust gas stream containing one or more of formaldehyde, nitrogen monoxide (NO), and hydrocarbons;

[0106] (B) guiding the exhaust gas stream provided in (A) through a catalyst according to any one of the embodiments disclosed herein.

[0107] Preferably, the exhaust gas stream provided in (A) contains one or more sulfur-containing compounds, more preferably SO2 and / or SO3.

[0108] Preferably, the exhaust gas stream provided in (A) contains NO X .

[0109] Preferably, the exhaust gas stream provided in (A) contains CO.

[0110] Preferably, the exhaust gas stream provided in (A) contains formaldehyde.

[0111] Preferably, the exhaust gas stream provided in (A) contains nitrogen monoxide (NO).

[0112] Preferably, the exhaust gas stream provided in (A) contains hydrocarbons, more preferably C1 to C20 hydrocarbons, even more preferably C2 to C10 hydrocarbons.

[0113] Furthermore, 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, nitric oxide (NO), and hydrocarbons, preferably for oxidizing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons in an exhaust gas stream, more preferably for oxidizing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons in the exhaust gas stream of an internal combustion engine, even more preferably for oxidizing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons in the exhaust gas stream of a compression ignition engine, even more preferably for oxidizing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons in the exhaust gas stream of a diesel engine.

[0114] The present invention is further illustrated by the following set of embodiments and combinations of embodiments obtained from the indicated dependencies and cross-references. In particular, it should be noted that in each case where a range of embodiments is mentioned, for example in the context of terms such as "a catalyst according to any one of embodiments 1 to 4", each embodiment within that range is meant to be explicitly disclosed to the person skilled in the art, i.e., the wording of the term should be understood by the person skilled in the art as being synonymous with "a catalyst according to any one of embodiments 1, 2, 3, and 4". Furthermore, it should be explicitly stated that the following set of embodiments represents a properly structured part of the general description of the preferred aspects of the present invention and thus appropriately supports but does not represent the claims of the present invention.

[0115] 1. A catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons, the catalyst comprising

[0116] a first support coating layer comprising Mn and Cu, wherein

[0117] the first support coating layer is substantially free of Ce, preferably wherein the first support coating layer is free of Ce, and

[0118] a substrate,

[0119] 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,

[0120] 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:

[0121] (a) the first carrier coating layer, and

[0122] (b) an optional second carrier coating layer, or

[0123] (c) an optional second carrier coating layer and a third carrier coating layer.

[0124] 2. The catalyst according to embodiment 1, wherein the optional second carrier coating layer is substantially free of Mn, and preferably the optional second carrier coating layer is free of Mn.

[0125] 3. The catalyst according to embodiment 1 or 2, wherein the optional second carrier coating layer is substantially free of Ce, and preferably the optional second carrier coating layer is free of Ce.

[0126] 4. The catalyst according to any one of embodiments 1 to 3, wherein the optional second carrier coating layer is substantially free of Cu, and preferably the optional second carrier coating layer is free of Cu.

[0127] 5. The catalyst according to any one of embodiments 1 to 4, wherein based on 100% by weight of the first carrier coating layer, calculated in terms of elements, the loading amount of Mn in the first carrier coating layer is in the range of 1% to 50% by weight, preferably 2% to 30% by weight, more preferably 5% to 20% by weight, and even more preferably 8% to 12% by weight.

[0128] 6. The catalyst according to any one of embodiments 1 to 5, wherein Mn exists in the form of one or more Mn cations, and Mn is preferably included in the first carrier coating layer as one or more oxides, and more preferably Mn is included in the first carrier coating layer as one or more oxides selected from Mn(II), Mn(III) and Mn(IV), and even more preferably Mn is included in the first carrier coating layer as one or more oxides selected from the group consisting of: MnO, Mn2O3, Mn3O4, MnO2, Mn(O)OH and Mn-Zr mixed oxides, including mixtures of two or more of them, and the Mn-Zr mixed oxide is preferably included in the first carrier coating layer as a solid solution.

[0129] 7. An embodiment according to any one of embodiments 1 to 6, wherein Cu is present in the first carrier coating layer as CuO, Cu2O, or CuO and Cu2O, more preferably as CuO. Based on 100% by weight of the first carrier coating layer, the loading amount of Cu in the first carrier coating layer, calculated as an element, is in the range of 1% to 50% by weight, more preferably 2% to 30% by weight, more preferably 5% to 20% by weight, and more preferably 8% to 12% by weight.

[0130] 8. The catalyst according to any one of embodiments 1 to 7, wherein the first carrier coating layer comprises a particulate carrier material, on which Mn and Cu are respectively loaded. The particulate carrier material is preferably selected from the group consisting of: ZrO2, Al2O3, SiO2, TiO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, Praseodymium oxide-doped CeO2-ZrO2 mixed oxide, ZrO2-doped Al2O3, ZrO2-doped SiO2, SiO2-doped Al2O3, CuO-Al2O3 mixed oxide, and mixtures of two or more of them. More preferably, it is selected from the group consisting of: ZrO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, Pr2O3-doped CeO2-ZrO2 mixed oxide, Pr6O 11 Doped CeO2-ZrO2 mixed oxide, PrO2-doped CeO2-ZrO2 mixed oxide, ZrO2-doped Al2O3, ZrO2-doped SiO2, and mixtures of two or more of them. More preferably, it is selected from the group consisting of: ZrO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, Pr2O3-doped CeO2-ZrO2 mixed oxide, Pr6O 11Doped CeO2-ZrO2 mixed oxides and mixtures of two or more of them, wherein more preferably Mn is supported on particulate La2O3-doped ZrO2, wherein preferably ZrO2 is doped with La2O3, and based on 100% by weight of ZrO2 and La2O3, the amount of ZrO2 is in the range of 1% to 50% by weight, preferably 3% to 30% by weight, more preferably 5% to 15% by weight, and even more preferably 8% to 10% by weight.

[0131] 9. The catalyst according to any one of embodiments 1 to 8, wherein the catalyst is substantially free of Ce, and preferably the catalyst is free of Ce.

[0132] 10. The catalyst according to any one of embodiments 1 to 9, 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, and wherein the flow-through substrate is more preferably a flow-through substrate with a highly porous wall.

[0133] 11. The catalyst according to any one of embodiments 1 to 10, wherein the loading of the first carrier coating layer is in the range of 0.1 g / in 3 to 6 g / in 3 , preferably 0.3 g / in 3 to 4 g / in 3 , more preferably 0.5 g / in 3 to 3 g / in 3 , even more preferably 1 g / in 3 to 2.5 g / in 3 , even more preferably 1.3 g / in 3 to 2.2 g / in 3 , even more preferably 1.5 g / in 3 to 2 g / in 3 .

[0134] 12. The catalyst according to any one of embodiments 1 to 11, wherein the loading of the second carrier coating layer is in the range of 0.25 g / in 3 to 6 g / in 3 , preferably 0.3 g / in 3 to 6 g / in 3 , more preferably 0.5 g / in 3 to 5 g / in 3 , even more preferably 1 g / in 3 to 4 g / in 3 , even more preferably 1.5 g / in 3 to 3 g / in 3 , even more preferably 2 g / in3 to 2.5 g / in 3 , more preferably 1.8 g / in 3 to 2.2 g / in 3 within the range of

[0135] 13. The catalyst according to any one of embodiments 1 to 12, wherein the catalyst comprises one or more platinum group metals composed of Pt, Pd, or Pt and Pd, preferably the catalyst comprises Pt or Pt and Pd as the one or more platinum group metals, and more preferably the catalyst comprises Pt and Pd as the one or more platinum group metals.

[0136] 14. The catalyst according to any one of embodiments 1 to 13, wherein, calculated on an elemental basis, the catalyst comprises a loading of 2 g / ft 3 to 250 g / ft 3 , preferably 5 g / ft 3 to 150 g / ft 3 , more preferably 10 g / ft 3 to 125 g / ft 3 , more preferably 20 g / ft 3 to 100 g / ft 3 , more preferably 30 g / ft 3 to 80 g / ft 3 , more preferably 25 g / ft 3 to 85 g / ft 3 , more preferably 40 g / ft 3 to 60 g / ft 3 of Pt within the range of

[0137] 15. The catalyst according to any one of embodiments 1 to 14, wherein, calculated on an elemental basis, the catalyst comprises a loading of 5 g / ft 3 to 100 g / ft 3 , preferably 5 g / ft 3 to 60 g / ft 3 , more preferably 10 g / ft 3 to 50 g / ft 3 , more preferably 15 g / ft 3 to 40 g / ft 3 , more preferably 20 g / ft 3 to 30 g / ft 3 of Pd within the range of

[0138] 16. The catalyst according to any one of embodiments 1 to 15, wherein, calculated on the basis of the respective elements, the catalyst comprises a total Pt and Pd loading of 2 g / ft 3Up to 250 g / ft 3 , preferably 5 g / ft 3 Up to 200 g / ft 3 , more preferably 10 g / ft 3 Up to 150 g / ft 3 , preferably 20 g / ft 3 Up to 130 g / ft 3 , more preferably 30 g / ft 3 Up to 125 g / ft 3 , more preferably 40 g / ft 3 Up to 110 g / ft 3 , more preferably 50 g / ft 3 Up to 100 g / ft 3 , more preferably 60 g / ft 3 Up to 90 g / ft 3 , more preferably 70 g / ft 3 Up to 80 g / ft 3 Pt and Pd within the range of

[0139] 17. The catalyst according to any one of embodiments 1 to 16, wherein the catalyst comprises Pt and Pd, and the weight ratio of Pt:Pd ranges from 1:2 to 20:1, preferably from 50:50 to 80:20, more preferably from 60:40 to 75:25, even more preferably from 65:35 to 70:30.

[0140] 18. The catalyst according to any one of embodiments 1 to 17, wherein the one or more platinum group metals are supported on a particulate support material, and the particulate support material is preferably selected from the group consisting of: Al2O3, SiO2, TiO2, SiO2-doped Al2O3, Mn oxide-doped Al2O3, and mixtures of two or more thereof, and preferably the one or more platinum group metals are supported on Al2O3 and / or SiO2-doped Al2O3 and / or Mn oxide-doped Al2O3, more preferably on SiO2-doped Al2O3 or Al2O3 or Mn oxide-doped Al2O3, and based on 100% by weight of the Mn oxide-doped Al2O3, calculated as MnO2, the Mn oxide-doped Al2O3 preferably contains from 1% to 10% by weight, more preferably from 4% to 6% by weight of Mn oxide.

[0141] 19. The catalyst according to any one of embodiments 1 to 18, wherein the catalyst comprises a second support coating layer, and the one or more platinum group metals are at least partially contained in the second support coating layer, and preferably all of the one or more platinum group metals are contained in the second support coating layer.

[0142] 20. The catalyst according to any one of embodiments 1 to 19, wherein the first support coating layer comprises a hydrocarbon trapping material, wherein the hydrocarbon trapping 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 SiO2 and Al2O3, wherein the molecular sieve, preferably the zeolite, more preferably has a molar ratio of SiO2 to Al2O3 in the range of 10:1 to 500:1, more preferably 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, wherein the molecular sieve, preferably the zeolite, more preferably comprises Fe, based on the weight of the molecular sieve, calculated as Fe2O3, the amount of Fe is in the range of 1.0 wt% to 7.0 wt%, more preferably 3.0 wt% to 5.0 wt%, more preferably 4.0 wt% to 4.5 wt%.

[0143] 21. The catalyst according to embodiment 20, wherein the loading amount of the hydrocarbon trapping material in the first support coating layer is in the range of 0.01 g / in 3 to 2.0 g / in 3 preferably in the range of 0.05 g / in 3 to 1.0 g / in 3 more preferably in the range of 0.05 g / in 3 to 0.3 g / in 3 of the range.

[0144] 22. The catalyst according to any one of embodiments 1 to 21, wherein the second support coating layer comprises a hydrocarbon trapping material, wherein the hydrocarbon trapping material comprises a molecular sieve, preferably a zeolite, more preferably a zeolite having a maximum pore size defined by 12-membered rings, more preferably zeolite beta, wherein the molecular sieve, preferably the zeolite, preferably comprises SiO2 and Al2O3, wherein the molecular sieve, preferably the zeolite, more preferably has a molar ratio of SiO2 to Al2O3 in the range of 10:1 to 500:1, more preferably 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, wherein the molecular sieve, preferably the zeolite, more preferably comprises Fe, based on the weight of the molecular sieve, calculated as Fe2O3, the amount of Fe is in the range of 1.0 wt% to 7.0 wt%, more preferably 3.0 wt% to 5.0 wt%, more preferably 4.0 wt% to 4.5 wt%.

[0145] 23. The catalyst according to embodiment 22, wherein the loading amount of the hydrocarbon trapping material in the second carrier coating layer is in the range of 0.01 g / in 3 to 2.0 g / in 3 preferably in the range of 0.05 g / in 3 to 1.0 g / in 3 g / in 3 more preferably in the range of 0.05 g / in 3 to 0.3 g / in 3 .

[0146] 24. The catalyst according to any one of embodiments 1 to 23, wherein the catalyst comprises a second carrier coating layer, wherein the catalyst exhibits a layered arrangement of the first carrier coating layer and the second carrier coating layer, and wherein the one or more platinum group metals are at least partially contained in the second carrier coating layer.

[0147] 25. The catalyst according to embodiment 24, wherein the first carrier coating layer is disposed on the substrate, and the second carrier coating layer is disposed on the first carrier coating layer.

[0148] 26. The catalyst according to embodiment 24 or 25, wherein the second carrier coating layer is disposed on the substrate, and the first carrier coating layer is disposed on the second carrier coating layer.

[0149] 27. The catalyst according to embodiment 24 or 25, wherein the catalyst comprises a third carrier coating layer, wherein the catalyst exhibits a partitioned arrangement of the first carrier coating layer, the second carrier coating layer and the third carrier coating layer, wherein the third carrier coating 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 carrier coating 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 carrier coating layer is disposed on the first carrier coating layer and completely covers the first carrier coating layer, wherein the length of the first carrier coating layer is less than the axial length of the substrate, thereby creating an upstream region containing the third carrier coating layer and a downstream region containing the first carrier coating layer and the second carrier coating layer, and wherein the one or more platinum group metals are at least partially contained in the third carrier coating layer.

[0150] 28. The catalyst according to embodiment 24 or 26, wherein the catalyst comprises a third support coating layer, wherein the catalyst exhibits a zoned arrangement of the first support coating layer, the second support coating layer, and the third support coating layer, wherein the third support coating layer is disposed on the substrate starting from the inlet end of the substrate along the axial length of the substrate, and wherein the second support coating layer is disposed on the substrate starting from the outlet end of the substrate along the axial length of the substrate, and wherein the first support coating layer is disposed on the second support coating layer and completely covers the second support coating layer, wherein the length of the second support coating layer is less than the axial length of the substrate, thereby creating an upstream zone containing the third support coating layer and a downstream zone containing the first support coating layer and the second support coating layer, and wherein the one or more platinum group metals are at least partially contained in the third support coating layer.

[0151] 29. The catalyst according to embodiment 24 or 25, wherein the catalyst comprises a third support coating layer, wherein the catalyst exhibits a zoned arrangement of the first support coating layer, the second support coating layer, and the third support coating layer, wherein the third support coating layer is disposed on the substrate starting from the outlet end of the substrate along the axial length of the substrate, and wherein the first support coating layer is disposed on the substrate starting from the inlet end of the substrate along the axial length of the substrate, and wherein the second support coating layer is disposed on the first support coating layer and completely covers the first support coating layer, wherein the length of the first support coating layer is less than the axial length of the substrate, thereby creating a downstream zone containing the third support coating layer and an upstream zone containing the first support coating layer and the second support coating layer, and wherein the one or more platinum group metals are at least partially contained in the third support coating layer.

[0152] 30. The catalyst according to embodiment 24 or 26, wherein the catalyst comprises a third support coating layer, wherein the catalyst exhibits a zoned arrangement of the first support coating layer, the second support coating layer, and the third support coating layer, wherein the third support coating 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 support coating 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 support coating layer is disposed on the second support coating layer and completely covers the second support coating layer, wherein the length of the second support coating layer is less than the axial length of the substrate, thereby creating a downstream zone comprising the third support coating layer and an upstream zone comprising the first support coating layer and the second support coating layer, and wherein the one or more platinum group metals are at least partially contained in the third support coating layer.

[0153] 31. The catalyst according to any one of embodiments 1 to 23, wherein the catalyst comprises a second support coating layer, wherein the catalyst exhibits a zoned arrangement of the first support coating layer and the second support coating layer, wherein the second support coating 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 support coating 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 first support coating layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second support coating layer and a downstream zone comprising 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.

[0154] 32. The catalyst according to any one of embodiments 1 to 23, wherein the catalyst comprises a second support coating layer, wherein the first support coating layer is disposed on the substrate starting from the inlet end of the substrate along the axial length of the substrate, and wherein the second support coating 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 first support coating layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the first support coating layer and a downstream zone comprising the second support coating layer, and wherein the one or more platinum group metals are at least partially contained in the second support coating layer.

[0155] 33. The catalyst according to any one of embodiments 1 to 23, wherein the catalyst comprises a second support coating layer, wherein the catalyst exhibits a zoned arrangement of the first support coating layer and the second support coating layer, wherein the second support coating 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 support coating 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 second support coating layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second support coating layer and a downstream zone comprising 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.

[0156] 34. The catalyst according to any one of embodiments 1 to 23, wherein the catalyst comprises a second support coating layer, wherein the catalyst exhibits a zoned arrangement of the first support coating layer and the second support coating layer, wherein the first support coating layer is disposed on the substrate starting from the inlet end of the substrate along the axial length of the substrate, and wherein the second support coating 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 second support coating layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the first support coating layer and a downstream zone comprising the second support coating layer, and wherein the one or more platinum group metals are at least partially contained in the second support coating layer.

[0157] 35. The catalyst according to embodiment 31 or 33, wherein the catalyst comprises a third support coating layer, wherein the third support coating layer is disposed on the first layer, wherein the catalyst exhibits a zoned arrangement of the second support coating layer and the third support coating layer, wherein the second support coating 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 support coating layer is disposed on the first support coating layer starting from the outlet end of the substrate along the axial length of the substrate, wherein the length of the third support coating layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second support coating layer and a downstream zone comprising the first support coating layer and the third support coating layer.

[0158] 36. The catalyst according to embodiment 32 or 34, wherein the catalyst comprises a third support coating layer, wherein the third support coating layer is disposed on the first layer, wherein the catalyst exhibits a partitioned arrangement of the second support coating layer and the third support coating layer, wherein the third support coating layer is disposed on the first support coating layer starting from the inlet end of the substrate along the axial length of the substrate, and wherein the second support coating 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 support coating layer is less than the axial length of the substrate, thereby creating an upstream region comprising the first support coating layer and the third support coating layer and a downstream region comprising the second support coating layer.

[0159] 37. The catalyst according to any one of embodiments 27 to 36, wherein the first support coating layer and the second support coating layer are adjacent to each other.

[0160] 38. The catalyst according to embodiments 27 to 37, wherein the second support coating layer and the third support coating layer are adjacent to each other.

[0161] 39. The catalyst according to any one of embodiments 27 to 38, wherein a portion of the second support coating layer overlaps at least a portion of the first support coating layer, wherein preferably the second support coating layer overlaps the first support coating layer on a portion within the range of 5% to 100% of the axial length of the substrate, preferably 10% to 100% of the axial length of the first support coating layer, more preferably 15% to 80%, and even more preferably 20% to 50%.

[0162] 40. The catalyst according to any one of embodiments 27 to 39, wherein a portion of the first support coating layer overlaps at least a portion of the second support coating layer, wherein preferably the first support coating layer overlaps the second support coating layer on a portion within the range of 5% to 100% of the axial length of the substrate, preferably 10% to 100% of the axial length of the second support coating layer, more preferably 15% to 80%, and even more preferably 20% to 50%.

[0163] 41. The catalyst according to any one of embodiments 27 to 40, wherein a portion of the third support coating layer overlaps at least a portion of the first support coating layer, wherein preferably the third support coating layer overlaps the first support coating layer on a portion within the range of 10% to 100% of the axial length of the first support coating layer, more preferably 15% to 80%, and even more preferably 20% to 50%.

[0164] 42. The catalyst according to any one of embodiments 1 to 23, wherein the catalyst comprises a second support coating layer, wherein the catalyst exhibits a zoned arrangement of the first support coating layer and the second support coating layer, wherein the second support coating layer is disposed on the substrate along the entire length of the substrate, and wherein the first support coating layer is disposed on the second support coating layer starting from the outlet end of the substrate along the axial length of the substrate, wherein the length of the first support coating layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second support coating layer and a downstream zone comprising 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.

[0165] 43. The catalyst according to any one of embodiments 1 to 23, wherein the catalyst comprises a second support coating layer, wherein the catalyst exhibits a zoned arrangement of the first support coating layer and the second support coating layer, wherein the second support coating layer is disposed on the substrate along the entire length of the substrate, and wherein the first support coating layer is disposed on the second support coating layer starting from the inlet end of the substrate along the axial length of the substrate, wherein the length of the first support coating layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the first support coating layer and a downstream zone comprising the second support coating layer, and wherein the one or more platinum group metals are at least partially contained in the second support coating layer.

[0166] 44. The catalyst according to embodiment 42 or 43, wherein the length of the first support coating layer ranges from 10% to 90%, preferably 30% to 80%, and more preferably 50% to 70% of the axial length of the substrate.

[0167] 45. The catalyst according to any one of embodiments 1 to 23, wherein the catalyst comprises a second support coating layer, wherein the catalyst exhibits a zoned arrangement of the first support coating layer and the second support coating layer, wherein the first support coating layer is disposed on the substrate along the entire length of the substrate, and wherein the second support coating layer is disposed on the first support coating layer starting from the inlet end of the substrate along the axial length of the substrate, wherein the length of the second support coating layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second support coating layer and a downstream zone comprising 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.

[0168] 46. The catalyst according to embodiment 45, wherein the catalyst comprises a third support coating layer, wherein the third support coating layer is disposed on the first layer, wherein the catalyst exhibits a zoned arrangement of the second support coating layer and the third support coating layer, wherein the second support coating layer is disposed on the first support coating layer along the axial length of the substrate starting from the inlet end of the substrate, and wherein the third support coating layer is disposed on the first support coating layer along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the third support coating layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the second support coating layer and a downstream zone comprising the third support coating layer.

[0169] 47. The catalyst according to any one of embodiments 1 to 23, wherein the catalyst comprises a second support coating layer, wherein the catalyst exhibits a zoned arrangement of the first support coating layer and the second support coating layer, wherein the first support coating layer is disposed on the substrate along the entire length of the substrate, and wherein the second support coating layer is disposed on the first support coating layer along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the second support coating layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the first support coating layer and a downstream zone comprising the second support coating layer, and wherein the one or more platinum group metals are at least partially contained in the second support coating layer.

[0170] 48. The catalyst according to embodiment 47, wherein the catalyst comprises a third support coating layer, wherein the third support coating layer is disposed on the first layer, wherein the catalyst exhibits a zoned arrangement of the second support coating layer and the third support coating layer, wherein the third support coating layer is disposed on the first support coating layer along the axial length of the substrate starting from the inlet end of the substrate, and wherein the second support coating layer is disposed on the first support coating layer along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the third support coating layer is less than the axial length of the substrate, thereby creating an upstream zone comprising the third support coating layer and a downstream zone comprising the second support coating layer.

[0171] 49. The catalyst according to embodiment 47 or 48, wherein the second support coating layer and the third support coating layer are adjacent to each other.

[0172] 50. The catalyst according to any one of embodiments 1 to 49, wherein the length of the first support coating 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 even more preferably from 35% to 45%.

[0173] 51. The catalyst according to any one of embodiments 24 to 50, wherein the length of the second support coating 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 even more preferably from 35% to 45%.

[0174] 52. The catalyst according to any one of embodiments 27 to 51, wherein the length of the third support coating 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 even more preferably from 35% to 45%.

[0175] 53. The catalyst according to any one of embodiments 27 to 52, wherein the third support coating layer is substantially free of sulfur-trapping material, and preferably the third support coating layer is free of sulfur-trapping material.

[0176] 54. The catalyst according to any one of embodiments 27 to 53, wherein the third layer comprises a hydrocarbon-trapping material, wherein the hydrocarbon-trapping material comprises a molecular sieve, preferably zeolite, more preferably zeolite with a maximum pore diameter of 12-membered ring, more preferably zeolite β, wherein the molecular sieve, preferably the zeolite, preferably comprises SiO2 and Al2O3, wherein the molecular sieve, preferably the zeolite, more preferably has a molar ratio of SiO2 to Al2O3 in the range of 10:1 to 500:1, more preferably 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, wherein the molecular sieve, preferably the zeolite, more preferably comprises Fe, based on the weight of the molecular sieve, calculated as Fe2O3, the amount of Fe is in the range of 1.0 wt% to 7.0 wt%, more preferably 3.0 wt% to 5.0 wt%, more preferably 4.0 wt% to 4.5 wt%.

[0177] 55. The catalyst according to embodiment 54, wherein the loading amount of the hydrocarbon-trapping material in the third support coating layer is in the range of 0.01 g / in 3 to 2.0 g / in 3 preferably in the range of 0.05 g / in 3 to 1.0 g / in 3 more preferably in the range of 0.05 g / in 3 to 0.3 g / in 3 and preferably in the range of 0.05 g / in

[0178] 56. The catalyst according to any one of embodiments 27 to 55, wherein the one or more platinum group metals are at least partially included in the third support coating layer.

[0179] 57. The catalyst according to embodiment 56, wherein the one or more platinum group metals are supported on a particulate support material, and the particulate support material is preferably selected from the group consisting of Al2O3, SiO2, TiO2, SiO2-doped Al2O3, Mn oxide-doped Al2O3, and mixtures of two or more thereof, and preferably the one or more platinum group metals are supported on Al2O3 and / or SiO2-doped Al2O3 and / or Mn oxide-doped Al2O3, more preferably on SiO2-doped Al2O3 or Al2O3 or Mn oxide-doped Al2O3. Based on 100% by weight of the Mn oxide-doped Al2O3, calculated as MnO2, the Mn oxide-doped Al2O3 preferably contains 1% to 10% by weight, more preferably 4% to 6% by weight of Mn oxide.

[0180] 58. The catalyst according to any one of embodiments 27 to 57, wherein the catalyst comprises a second support coating layer and a third support coating layer, and the one or more platinum group metals are completely included in the second support coating layer and the third support coating layer. The weight ratio of the one or more platinum group metals included in the second support coating layer to the one or more platinum group metals included in the third support coating layer is in the range of 0.5:1 to 5.0:1, more preferably 1.0:1 to 2.0:1, and more preferably in the range of 1.4:1 to 1.6:1. The one or more platinum group metals included in the second support coating layer preferably include Pt and Pd, more preferably consist of Pt and Pd. The one or more platinum group metals included in the third support coating layer preferably include Pt and Pd, more preferably consist of Pt and Pd.

[0181] 59. The catalyst according to any one of embodiments 27 to 58, wherein in the region of the catalyst comprising the first support coating layer, based on the volume of the region of the catalyst containing the first support coating layer, the loading amount of Mn in terms of element is in the range of 0.01 g / in 3 to 1 g / in 3 preferably 0.05 g / in 3 to 0.5 g / in 3 more preferably 0.08 g / in 3 to 0.35 g / in 3 more preferably 0.1 g / in 3 to 0.25 g / in 3 more preferably 0.13 g / in 3 to 0.2 g / in 3 more preferably 0.15 g / in 3 to 0.18 g / in 3 within the range of.

[0182] 60. The catalyst according to any one of embodiments 27 to 59, wherein in the region of the catalyst comprising the first support coating layer, based on the volume of the region of the catalyst containing the first support coating layer, the loading amount of Cu in terms of element is in the range of 0.01 g / in 3 to 1.5 g / in 3 preferably 0.05 g / in 3 to 1 g / in 3 more preferably 0.1 g / in 3 to 0.5 g / in 3 more preferably 0.13 g / in 3 to 0.35 g / in 3 more preferably 0.15 g / in 3 to 0.25 g / in 3 more preferably 0.17 g / in 3 to 0.22 g / in 3 within the range of.

[0183] 61. The catalyst according to any one of embodiments 1 to 60, wherein the one or more platinum group metals are completely contained in the second support coating layer or the second support coating layer and the third support coating layer.

[0184] 62. The catalyst according to any one of embodiments 1 to 60, wherein the one or more platinum group metals are at least partially contained in the first support coating layer.

[0185] 63. The catalyst according to any one of embodiments 1 to 62, wherein the substrate is a metal substrate or a ceramic substrate, preferably the substrate is a ceramic substrate, more preferably the substrate comprises cordierite and / or SiC, preferably cordierite, and even more preferably the substrate consists of cordierite and / or SiC, preferably consists of cordierite.

[0186] 64. The catalyst according to any one of embodiments 27 to 63, wherein the substrate consists of two separate monoliths, with the first monolith disposed upstream of the second monolith, and wherein the one or more washcoat layers in the upstream zone are included on the first monolith, and the one or more washcoat layers in the downstream zone are included on the second monolith, and preferably the first monolith comprising the one or more washcoat layers in the upstream zone and the second monolith comprising the one or more washcoat layers in the downstream zone are obtained or obtainable by dividing the catalyst according to any one of embodiments 27 to 63 into two separate monoliths, with the one or more washcoat layers in the upstream zone included on the first monolith and the one or more washcoat layers in the downstream zone included on the second monolith.

[0187] 65. The catalyst according to any one of embodiments 1 to 64, wherein the exhaust gas stream contains hydrocarbons, preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons.

[0188] 66. An exhaust gas treatment system comprising an internal combustion engine and an exhaust gas duct for exhaust gas from the internal combustion engine, wherein the exhaust gas duct comprises one or more catalysts according to any one of embodiments 1 to 65, preferably one, two, three or four catalysts according to any one of embodiments 1 to 65.

[0189] 67. The exhaust gas treatment system according to embodiment 66, wherein the internal combustion engine is a compression ignition engine, preferably a diesel engine.

[0190] 68. The exhaust gas treatment system according to embodiment 66 or 67, wherein the internal combustion engine is a lean burn gasoline engine.

[0191] 69. The exhaust gas treatment system according to embodiment 68, wherein the internal combustion engine is powered by an oxygenated fuel, and the oxygenated fuel preferably comprises one or more of methanol and biofuel.

[0192] 70. The exhaust gas treatment system according to any one of embodiments 66 to 69, 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 catalytic soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on a filter (SCRoF), and a diesel exothermic catalyst (DEC).

[0193] 71. The exhaust gas treatment system according to embodiment 70, the exhaust gas treatment system comprising, in a continuous sequence in the direction of the exhaust gas: optionally an electric heater or a fuel burner and /

[0194] or a fuel injector, a catalyst according to any one of embodiments 1 to 65, a catalyst according to any one of embodiments 1 to 65, 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.

[0195] 72. The exhaust gas treatment system according to embodiment 70, the exhaust gas treatment system comprising, in a continuous sequence in the direction of the exhaust gas: optionally an electric heater or a fuel burner and /

[0196] or a fuel injector, a catalyst according to any one of embodiments 1 to 65, a catalyst according to any one of embodiments 1 to 65, 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.

[0197] 73. The exhaust gas treatment system according to embodiment 70, the exhaust gas treatment system comprising, in a continuous sequence in the direction of the exhaust gas: optionally an electric heater or a fuel burner and /

[0198] or a fuel injector, a catalyst according to any one of embodiments 1 to 65, a catalyst according to any one of embodiments 1 to 65, 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.

[0199] 74. The exhaust gas treatment system according to embodiment 70, the exhaust gas treatment system comprising, in a continuous sequence in the direction of the exhaust gas: optionally an electric heater or a fuel burner and /

[0200] or a fuel injector, a catalyst according to any one of embodiments 1 to 65, a catalyst according to any one of embodiments 1 to 65, 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 65, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst.

[0201] 75. The exhaust gas treatment system according to embodiment 70, the exhaust gas treatment system comprising, in a continuous sequence in the direction of the exhaust gas: optionally an electric heater or a fuel burner and /

[0202] or a fuel injector, a catalyst according to any one of embodiments 1 to 65, a catalyst according to any one of embodiments 1 to 65, 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 65, a catalyst according to any one of embodiments 1 to 65 (wherein the substrate is a wall-flow substrate), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0203] 76. The exhaust gas treatment system according to embodiment 70, the exhaust gas treatment system comprising, in a continuous sequence in the direction of the exhaust gas: optionally an electric heater or a fuel burner and /

[0204] or a fuel injector, a catalyst according to any one of embodiments 1 to 65, 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.

[0205] 77. The exhaust gas treatment system according to embodiment 70, the exhaust gas treatment system comprising, in a continuous sequence in the direction of the exhaust gas: optionally an electric heater or a fuel burner and /

[0206] or a fuel injector, a catalyst according to any one of embodiments 1 to 65, 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.

[0207] 78. The exhaust gas treatment system according to embodiment 70, the exhaust gas treatment system comprising, in a continuous sequence in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or

[0208] a fuel injector, a catalyst according to any one of embodiments 1 to 65, 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 65 (wherein the substrate is a wall-flow substrate), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0209] 79. The exhaust gas treatment system according to embodiment 70, the exhaust gas treatment system comprising, in a continuous sequence in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or

[0210] a fuel injector, a catalyst according to any one of embodiments 1 to 65, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction on filter catalyst (SCRoF), and an ammonia oxidation (AMOX) catalyst.

[0211] 80. The exhaust gas treatment system according to embodiment 70, the exhaust gas treatment system comprising, in a continuous sequence in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or

[0212] a fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any one of embodiments 1 to 65, a selective catalytic reduction on filter catalyst (SCRoF), and an ammonia oxidation (AMOX) catalyst.

[0213] 81. The exhaust gas treatment system according to embodiment 70, the exhaust gas treatment system comprising, in a continuous sequence in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or

[0214] a fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any one of embodiments 1 to 65, a catalytic soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0215] 82. The exhaust gas treatment system according to embodiment 70, the exhaust gas treatment system comprising, in a continuous sequence 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 65, a catalyst according to any one of embodiments 1 to 65 (wherein the substrate is a wall-flow substrate), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0216] 83. The exhaust gas treatment system according to embodiment 70, the exhaust gas treatment system comprising, in a continuous sequence 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 65, 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, and an ammonia oxidation (AMOX) catalyst.

[0217] 84. The exhaust gas treatment system according to embodiment 70, the exhaust gas treatment system comprising, in a continuous sequence 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 65, a selective catalytic reduction catalyst on a filter (SCRoF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0218] 85. The exhaust gas treatment system according to embodiment 70, the exhaust gas treatment system comprising, in a continuous sequence 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 65, 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.

[0219] 86. A method for treating an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons, the method comprising

[0220] (A) providing an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons;

[0221] (B) passing the exhaust gas stream provided in (A) through a catalyst according to any one of claims 1 to 65.

[0222] 87. The method according to embodiment 86, wherein the waste gas stream provided in (A) comprises one or more sulfur-containing compounds, preferably SO2 and / or SO3.

[0223] 88. The method according to embodiment 86 or 87, wherein the waste gas stream provided in (A) comprises NO x .

[0224] 89. The method according to any one of embodiments 86 to 88, wherein the waste gas stream provided in (A) comprises CO.

[0225] 90. The method according to any one of embodiments 86 to 89, wherein the waste gas stream provided in (A) comprises formaldehyde.

[0226] 91. The method according to any one of embodiments 86 to 89, wherein the waste gas stream provided in (A) comprises hydrocarbons, preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons.

[0227] 92. Use of the catalyst according to any one of embodiments 1 to 65 for oxidizing one or more of formaldehyde, nitrogen monoxide (NO) and hydrocarbons, preferably for oxidizing one or more of formaldehyde, nitrogen monoxide (NO) and hydrocarbons in a waste gas stream, more preferably for oxidizing one or more of formaldehyde, nitrogen monoxide (NO) and hydrocarbons in the waste gas stream of an internal combustion engine, more preferably for oxidizing one or more of formaldehyde, nitrogen monoxide (NO) and hydrocarbons in the waste gas stream of a compression ignition engine, more preferably for oxidizing one or more of formaldehyde, nitrogen monoxide (NO) and hydrocarbons in the waste gas stream of a diesel engine.

[0228] The present invention is further illustrated by the following examples and comparative examples.

[0229] Experimental Section

[0230] Comparative Example 1: Preparation of a DOC catalyst

[0231] A catalyst according to the prior art is prepared by separately coating a front section containing platinum group metals (PGM) and a rear section containing base metal oxides (BMO) on a 1" diameter cordierite honeycomb substrate, and then successively combining the coated cores for subsequent sulfur aging and testing. Using techniques well known in the art, by first combining Pt, Pd, β-zeolite with a material containing 5% silica and having a BET surface area of approximately 150 m 2 / g and a pore volume of about 0.6 cm 3Commercial alumina support powder with a pore volume of / g is combined in an aqueous slurry composition to prepare the front zone section. After coating the slurry onto a cordierite substrate, it is then dried and calcined at 590 °C, and subsequently a 1" diameter × 1.2" long core is cut from the monolith to be used as the front zone section. The weight ratio of Pt to Pd is 2:1, and the total Pt and Pd loading is 75 g / ft 3 monolith volume. The rear zone section containing BMO is prepared by: combining commercial zirconia support powder containing 9 wt% La2O3 and having a BET surface area of approximately 75 m 2 / g and a pore volume of about 0.5 cm 3 / g with deionized (DI) water to form a slurry. After milling the resulting mixture to a particle size suitable for coating, boehmite alumina binder is added. The resulting slurry is then coated onto a 1" diameter × 1.8" long cordierite substrate, dried and then calcined at 590 °C for 1 hour. The total support coating loading is 1.8 g / in 3 monolith volume.

[0232] for treating waste gas streams containing one or more of formaldehyde, nitrogen monoxide (NO), and hydrocarbons DOC catalyst

[0233] A catalyst according to the prior art is prepared in the same manner as described in Comparative Example 1, except that the rear zone slurry contains manganese nitrate and cerium nitrate. The resulting rear zone catalyst has a support coating loading of 1.7 g / in 3 monolith volume, where the Mn concentration and Ce concentration of the support coating are approximately 10 wt% respectively.

[0234] Example 3: Preparation of a catalyst

[0235] A catalyst is prepared in the same manner as described in Comparative Example 2, except that the rear zone slurry contains copper nitrate but no Ce. The resulting rear zone catalyst has a support coating loading of 1.7 g / in 3 monolith volume, where the Mn concentration and Cu concentration of the support coating are approximately 10 wt% respectively.

[0236] for treating waste gas streams containing one or more of formaldehyde, nitrogen monoxide (NO), and hydrocarbons DOC catalyst

[0237] A catalyst according to the prior art is prepared in the same manner as described in Comparative Example 2, except that the rear zone slurry contains manganese nitrate, cerium nitrate and copper nitrate. The resulting rear zone catalyst has a support coating loading of 1.8 g / in 3 monolith volume, where the Mn concentration, Ce concentration and Cu concentration of the support coating are approximately 10 wt% respectively.

[0238] Comparative Example 4: Preparation of a DOC catalyst

[0239] The catalyst according to the prior art was prepared in the same manner as described in Comparative Example 4, except that the rear zone included two layers. The bottom layer was the same as in Comparative Example 4, except that the support coating loading was 1.0 g / in 3 monolith volume. The added top coating contained CuO (17 wt%) supported on an Al2O3 compound (1.0 g / in 3 ). The resulting rear zone catalyst had a support coating loading of approximately 2.0 g / in 3 monolith volume.

[0240] for treating waste gas streams containing one or more of formaldehyde, nitrogen monoxide (NO), and one or more hydrocarbons catalyst

[0241] The catalyst according to the present invention was prepared in the same manner as described in Comparative Example 5, except that the rear zone had a different top coating. The bottom layer was the same as described in Comparative Example 5 and thus had a support coating loading of 1.0 g / in 3 monolith volume. The added top coating contained an Al2O3 compound (0.9 g / in 3 ) and additional manganese oxide (0.1 g / in 3 ) supported on CuO (17%). The resulting rear zone catalyst had a support coating loading of approximately 2.0 g / in 3 monolith volume.

[0242] Example 7: Catalytic Testing

[0243] The catalysts of Example 3 and Comparative Examples 1, 2, and 4 were sulfur-aged. The sulfur aging was done in a laboratory reactor at 300 °C in a feed containing 15 ppm SO2, 150 ppm NO, 10% O2, and 5% H2O. The flow rate through the catalyst measured at space velocity was 35,000 / hour. The exposure time was 88 minutes, corresponding to a target sulfur exposure of 1 g (sulfur) / L monolith volume. Desulfation was done at 700 °C for 30 minutes under isothermal conditions in a feed containing 10% O2 and 5% H2O. The flow rate through the catalyst measured at space velocity was 32,000 / hour.

[0244] After sulfation and desulfation, a feed containing 180 ppm NO, 1000 ppm CO, 25 ppm HCHO, 100 ppm C1 from C2H4, 190 ppm from C 10 H 22HCHO ignition performance of the feed test sample of C1, 10% O2, 10% H2O and 10% CO2. The flow rate through the catalyst measured by the space velocity was 50,000 / hour. The sample was placed in the reactor and first equilibrated in flowing air at 80 °C. Then the formaldehyde-containing feed was introduced and the temperature was raised to 300 °C at a ramp rate of 15 °C / minute. The formaldehyde concentration was monitored by FTIR during the ignition ramp, and the conversion performance versus temperature was then calculated from these measurements.

[0245] The results of the HCHO performance of the fresh samples of Comparative Example 1, Comparative Example 2 and Comparative Example 4 and Example 3 are shown in Figure 1 In. Further results of the HCHO performance of the catalyst samples according to Comparative Example 1, Comparative Example 2 and Comparative Example 4 and Example 3 that were each sulfur-aged as described above are shown separately in Figure 2 In.

[0246] As Figure 1 shown, the catalysts according to Example 3 and Comparative Examples 2 and 4 provided good low-temperature HCHO conversion performance, especially the example showed relatively better low-temperature performance than the catalyst of Comparative Example 1.

[0247] After sulfur exposure and subsequent desulfurization steps ( Figure 2 ), the catalyst of Example 3 showed the best performance, especially at temperatures in the range of about 110 °C to 220 °C. The above results indicate that the catalyst of Example 3 (Cu + Mn sample) is the most sulfur-tolerant catalyst.

[0248] For the samples that have undergone sulfur exposure and subsequent desulfurization steps, the results of the hydrocarbon conversion performance of the catalysts of Comparative Example 1, Comparative Example 2 and Comparative Example 4 and Example 3 are shown in Figure 3 In.

[0249] In addition, as Figure 3 shown, the catalyst of Example 3 (Cu + Mn sample) is the most sulfur-tolerant catalyst for HC conversion, especially at temperatures in the range of about 160 °C to 300 °C.

[0250] For the samples that have undergone sulfur exposure and subsequent desulfurization steps, the results of the CO conversion performance of the catalysts of Comparative Example 1, Comparative Example 2 and Comparative Example 4 and Example 3 are shown in Figure 4 In.

[0251] As Figure 4 shown, the catalyst of Example 3 (Cu + Mn sample) is the most sulfur-tolerant catalyst for CO conversion.

[0252] As Figure 5 and Figure 6As shown, similar results can be observed for the catalysts of Comparative Example 5 and Example 6. In particular, the figure shows that the catalyst of Example 6 (comprising a washcoat layer of the support having Cu + Mn and no Ce) provides better sulfur tolerance than Comparative Example 5. Description of the Drawings

[0253] Figure 1 : Shows the HCHO conversion performance of fresh samples of the catalysts of Comparative Example 1, Comparative Example 2, Comparative Example 4, and Example 3. All samples contain a 2:1 Pt- 3 of 75 g / ft

[0254] Pd front zone, but contain different back zones.

[0255] Figure 2 : Shows the HCHO conversion performance of the catalysts of Comparative Example 1, Comparative Example 2, Comparative Example 4, and Example 3 after sulfation and desulfation at 700 °C (catalysts with a total sulfur exposure of approximately 1 g / L). All samples contain a 2:1 Pt-Pd front zone of 75 g / ft 3 ,

[0256] but contain different back zones.

[0257] Figure 3 : Shows the HC conversion performance of the catalysts of Comparative Example 1, Comparative Example 2, Comparative Example 4, and Example 3 after sulfation and desulfation at 700 °C (catalysts with a total sulfur exposure of approximately 1 g / L). All samples contain a 2:1 Pt-Pd front zone of 75 g / ft 3 but contain different back zones.

[0258] Figure 4 : Shows the CO conversion performance of the catalysts of Comparative Example 1, Comparative Example 2, Comparative Example 4, and Example 3 after sulfation and desulfation at 700 °C (catalysts with a total sulfur exposure of approximately 1 g / L). All samples contain a 2:1 Pt-Pd front zone of 75 g / ft 3 but contain different back zones.

[0259] Figure 5 : Shows the HCHO conversion performance of the catalysts of Comparative Example 5 and Example 6 after sulfation at 300 °C (sulfur exposure of 1 g / L). Both samples contain a 2:1 3 Pt-Pd front zone of 75 g / ft

[0260] but the different back zones contain two washcoats in each sample.

[0261] Figure 6: Shows the HCHO conversion performance of the catalysts of Comparative Example 5 and Example 6 after sulfation at 300 °C (1 g / L sulfur exposure) and desulfation at 700 °C. Both samples contain a 2:1 Pt-Pd front zone of 75 g / ft 3 but different back zones contain two coatings in each sample.

[0262] Cited References -WO 2022 / 047132 A1

[0263] -US 10,598,061 B2

[0264] -US 10,392,980 B2

[0265] -WO 2020 / 089043 A1

Claims

1. A catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen monoxide (NO), and hydrocarbons, the catalyst comprising a first support coating layer comprising Mn and Cu, wherein the first support coating layer is substantially free of Ce, 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, 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.

2. The catalyst according to claim 1, wherein, based on 100% by weight of the first support coating layer, calculated on an elemental basis, the loading amount of Mn in the first support coating layer is in the range of 1% to 50% by weight.

3. The catalyst according to claim 1 or 2, wherein, based on 100% by weight of the first support coating layer, calculated on an elemental basis, the loading amount of Cu in the first support coating layer is in the range of 1% to 50% by weight.

4. The catalyst according to any one of claims 1 to 3, wherein the first support coating layer comprises a particulate support material, and Mn and Cu are respectively loaded on the particulate support material.

5. The catalyst according to any one of claims 1 to 4, wherein, calculated on an elemental basis, the catalyst comprises Pt in a loading range of 2 g / ft 3 to 250 g / ft 3 range.

6. The catalyst according to any one of claims 1 to 5, wherein, calculated as an element, the catalyst comprises Pd in a loading range of 5 g / ft 3 to 100 g / ft 3 .

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

8. The catalyst according to any one of claims 1 to 7, wherein the catalyst comprises a second support coating layer, and the one or more platinum group metals are at least partially contained in the second support coating layer.

9. The catalyst according to any one of claims 1 to 8, wherein the second support coating layer comprises a hydrocarbon trapping material, and the hydrocarbon trapping material comprises a molecular sieve.

10. The catalyst according to any one of claims 1 to 9, wherein the catalyst comprises a second support coating layer, and the catalyst exhibits a layered arrangement of the first support coating layer and the second support coating layer, and the one or more platinum group metals are at least partially contained in the second support coating layer.

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

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

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

14. The exhaust gas treatment system according to 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 catalytic 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 an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons, the method comprising (A) providing an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons; (B) guiding the exhaust gas stream provided in (A) through the 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 oxidizing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons.

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