CATALYST COMPRISING Mn SUPPORTED ON A CuO-Al2O3 MIXED OXIDE FOR TREATING EXHAUST GAS STREAM CONTAINING ONE OR MORE OF FORMALDEHYDE, NITROGEN OXIDE

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 supported on a CuO-Al2O3 mixed oxide; 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. Furthermore, the present invention relates to an exhaust gas treatment system comprising the catalyst, a method for treating an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO) and hydrocarbons using the catalyst, and to the use of the catalyst for oxidizing one or more of formaldehyde, nitric oxide (NO) and hydrocarbons.

Description

Technical Field

[0001] The present invention relates to a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen monoxide (NO), and hydrocarbons, an exhaust gas treatment system including the catalyst, a method for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen monoxide (NO), and hydrocarbons using the catalyst, and the use of the catalyst for oxidizing one or more of formaldehyde, nitrogen monoxide (NO), and hydrocarbons. Background Art

[0002] The present invention relates to the use of a diesel oxidation catalyst (DOC) having enhanced oxidation functionality, particularly enhanced oxidation functionality for one or more of formaldehyde (HCHO), nitrogen monoxide (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 the engine exhaust of passenger and transport vehicles. Generally, manganese oxides (such as 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) result in the structural collapse of MnO2, such that the surface area and pore volume are so low that 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 load them on refractory oxide materials that themselves have high stability when exposed to the high temperatures in engine exhaust. In this regard, materials such as alumina (Al2O3) and zirconia (ZrO2) can be useful.

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

[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 the diesel fuel injected into the exhaust gas upstream of the DOC to produce a high-temperature exotherm, which is used to thermally oxidize the 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 flow 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 flow required to provide the desired exotherm is very high, about 1% (10,000 ppm) or more based on C1. The temperature at which the DOC composition can oxidize ( "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, 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 containing Pd, Pt or a combination thereof, a manganese component, and a first refractory metal oxide support material containing zirconia.

[0006] US 10,598,061 B2 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 above 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 comprising zirconia, palladium oxide, and at least one base metal oxide, the washcoat being coated on a substrate surface, wherein the amount of the at least one base metal oxide coated on a downstream portion of the substrate is greater than the amount coated on an upstream portion, and the amount of palladium oxide coated on the upstream portion of the substrate is greater than the amount coated on the 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] US 2018 / 333677 A1 relates to a catalyst article coated with a multi-layer catalyst composition, an emissions treatment system including such a catalyst article, and uses and manufacturing methods thereof. In particular, claim 1 defines a catalyst article that includes a multi-layer catalyst composition suitable for the oxidation of gaseous HC and CO emissions and the conversion of NOx to N2, the catalyst article including: a substrate adhered to the multi-layer catalyst composition; the multi-layer catalyst composition including a first layer, a second layer, and an optional intermediate layer between the first layer and the second layer; the first layer being positioned between the substrate and the second layer and including a first porous refractory oxide material impregnated with at least one base metal component; the second layer including a second porous refractory oxide material impregnated with at least one platinum group metal; and the intermediate layer including a refractory oxide material, wherein the second layer is substantially free of alumina, and / or the intermediate layer is present and substantially free of alumina.

[0009] US 2018 / 318805 A1 relates to a diesel oxidation catalyst composition, a catalyst article coated with such a composition, an exhaust gas treatment system including such a catalyst article, and a method of using the same. In particular, claim 1 defines a diesel oxidation catalyst composition that includes at least one platinum group metal impregnated into a particulate form of a porous refractory oxide material and at least one base metal oxide impregnated into a particulate form of a porous refractory oxide material, wherein the porous refractory oxide material impregnated with at least one platinum group metal and the porous refractory oxide material impregnated with at least one base metal oxide are in the form of a mixture, or wherein at least one platinum group metal and at least one base metal oxide are impregnated on the same porous refractory oxide material.

[0010] M.C. et al. disclosed an alumina-supported manganese catalyst in Applied Catalysis B, 2004, 51, pp. 83 - 91, wherein the manganese loading ranged from 3.9 wt% to 18.2 wt%. The catalyst was prepared and tested in the combustion of a formaldehyde / methanol mixture in an air stream.

[0011] Accordingly, an object of the present invention is to provide a catalyst that has improved performance in the conversion of one or more of formaldehyde, nitric oxide (NO), and hydrocarbons, particularly after exposure to sulfation and desulfation treatments. Detailed Description

[0012] 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 been surprisingly 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. Furthermore, it has been surprisingly found that the catalysts according to the present invention exhibit enhanced hydrocarbon (HC) and nitric oxide (NO) oxidation functions. In particular, it has been surprisingly 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 extend 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 been surprisingly found that using a diesel oxidation catalyst (DOC) comprising a platinum group metal (PGM) and a base metal oxide (BMO) catalyst produces a catalyst with enhanced fuel combustion 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 for oxidizing 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.

[0013] 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

[0014] a first washcoat layer comprising Mn supported on a CuO - Al2O3 mixed oxide, and

[0015] a substrate,

[0016] 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,

[0017] The catalyst further contains one or more platinum group metals, and the one or more platinum group metals include Pt, Pd, or Pt and Pd, wherein the one or more platinum group metals are at least partially included in one or more of the following:

[0018] (a) the first carrier coating layer, and

[0019] (b) an optional second carrier coating layer, or

[0020] (c) an optional second carrier coating layer and a third carrier coating layer.

[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] Within the meaning of the present invention, when the carrier coating layer contains the 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 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.

[0023] 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 more preferably 8% to 12% by weight, calculated as the element.

[0024] 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.

[0025] Preferably, the CuO-Al2O3 mixed oxide is a particulate carrier material.

[0026] Preferably, the first support coating layer contains Ce, and more preferably Ce is contained in the first support coating layer as CeO2 and / or Ce2O3.

[0027] When the first support coating layer contains Ce, preferably, based on 100% by weight of the first support coating layer, calculated as an element, the loading amount of Ce in the first support 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.

[0028] In addition, when the first support coating layer contains Ce, preferably, Ce is loaded on the CuO-Al2O3 mixed oxide.

[0029] Alternatively, preferably, the first support coating layer is substantially free of Ce, and more preferably the first support coating layer does not contain Ce.

[0030] When the first support coating layer is substantially free of Ce, preferably, the catalyst is substantially free of Ce, and preferably the catalyst does not contain Ce.

[0031] Preferably, the first support coating layer contains Cu loaded on the particulate support material, and more preferably Cu is loaded on the CuO-Al2O3 mixed oxide, and the first support coating layer preferably contains CuO, Cu2O or CuO and Cu2O, and more preferably CuO.

[0032] It should be noted that according to the preferred embodiment, in addition to the Cu in the CuO-Al2O3 mixed oxide, the first support coating layer also contains Cu.

[0033] When the first support coating layer contains Cu loaded on the particulate support material, preferably, based on 100% by weight of the first support coating layer, calculated as an element, the loading amount of Cu loaded on the particulate support material in the first support 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.

[0034] Alternatively, preferably, the first support coating layer is substantially free of Cu that is not contained in the CuO-Al2O3 mixed oxide, and more preferably the first support coating layer does not contain Cu that is not contained in the CuO-Al2O3 mixed oxide.

[0035] In the case where the first carrier coating layer is substantially free of Cu that is not contained in the CuO - Al2O3 mixed oxide, preferably, the catalyst is substantially free of Cu that is not contained in the CuO - Al2O3 mixed oxide, and more preferably the catalyst is free of Cu that is not contained in the CuO - Al2O3 mixed oxide.

[0036] 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, and even more preferably a honeycomb flow - through substrate, where the flow - through substrate is more preferably a flow - through substrate having a high - porosity wall.

[0037] Preferably, the loading of the first carrier coating layer is in the range of 0.5 g / in 3 to 5 g / in 3 , more preferably 1 g / in 3 to 3 g / in 3 , more preferably 1.5 g / in 3 to 2.5 g / in 3 , more preferably 1.7 g / in 3 to 2 g / in 3 range.

[0038] Within the meaning of the present invention, the loading of the carrier coating layer in the catalyst refers to the loading of the carrier coating layer based on the volume of the catalyst including the carrier coating layer. Thus, within the meaning of the present invention, the loading of the carrier coating layer included only in a certain part or region of the catalyst is based on the volume of that part or region of the catalyst. Thus, for example, if the carrier coating layer is provided over 50% of the axial length of a honeycomb substrate, its loading is calculated based on 50% of the total volume of the honeycomb substrate.

[0039] Preferably, 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 1 g / in 3 to 5 g / in 3 , more preferably 1.5 g / in 3 to 4 g / in 3 , more preferably 2 g / in 3 to 3.5 g / in 3 , more preferably 2.2 g / in 3 to 3.0 g / in 3 , more preferably 2.3 g / in 3 to 2.9 g / in 3 , more preferably 2.5 g / in 3 to 2.7 g / in3 within the range of

[0040] Preferably, the catalyst contains one or more platinum group metals composed of Pt, Pd, or Pt and Pd, more preferably the catalyst contains Pt or Pt and Pd as one or more platinum group metals, and even more preferably the catalyst contains Pt and Pd as one or more platinum group metals.

[0041] Preferably, calculated on an elemental basis, the catalyst contains a loading of from 2 g / ft 3 to 250 g / ft 3 , more preferably from 5 g / ft 3 to 150 g / ft 3 , more preferably from 10 g / ft 3 to 125 g / ft 3 , more preferably from 20 g / ft 3 to 100 g / ft 3 , more preferably from 25 g / ft 3 to 85 g / ft 3 , more preferably from 30 g / ft 3 to 80 g / ft 3 , more preferably from 40 g / ft 3 to 60 g / ft 3 of Pt.

[0042] 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 are 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 are 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.

[0043] Preferably, calculated on an elemental basis, the catalyst contains a loading of from 1 g / ft 3 to 80 g / ft 3 , more preferably from 5 g / ft 3 to 60 g / ft 3 , more preferably from 10 g / ft 3 to 50 g / ft 3 , more preferably from 15 g / ft 3 to 40 g / ft 3 , more preferably from 20 g / ft 3Pd within the range of 0 to 30 g / ft 3

[0044] Preferably, calculated on the basis of the respective elements, the catalyst contains a total Pt and Pd loading within the range of 2 g / ft 3 to 250 g / ft 3 and more preferably 5 g / ft 3 to 200 g / ft 3 and more preferably 10 g / ft 3 to 150 g / ft 3 and more preferably 20 g / ft 3 to 130 g / ft 3 and more preferably 30 g / ft 3 to 125 g / ft 3 and more preferably 40 g / ft 3 to 110 g / ft 3 and more preferably 50 g / ft 3 to 100 g / ft 3 and more preferably 60 g / ft 3 to 90 g / ft 3 and more preferably 70 g / ft 3 to 80 g / ft 3 of Pt and Pd.

[0045] Preferably, the catalyst contains Pt and Pd, and the Pt:Pd weight ratio is within the range of 30:70 to 90:10, more preferably 50:50 to 80:20, more preferably 60:40 to 75:25, and more preferably 65:35 to 70:30.

[0046] Preferably, one or more platinum group metals are supported on a particulate support material, and 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, and 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, and 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.

[0047] ​Preferably, the first carrier coating layer contains a hydrocarbon trapping material, wherein 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%.

[0048] When the first carrier coating layer contains a hydrocarbon trapping material, preferably, the loading amount of the hydrocarbon trapping material in the first 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 more preferably in the range of 0.05 g / in 3 to 0.3 g / in 3 range.

[0049] Preferably, the catalyst includes a second carrier coating layer, wherein one or more platinum group metals are at least partially contained in the second carrier coating layer, and more preferably all of the one or more platinum group metals are contained in the second carrier coating layer.

[0050] 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 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%.

[0051] In the case where the second carrier coating layer contains a hydrocarbon trapping material, where 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 the range of 0.01 g / in 3 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 .

[0052] According to the first alternative, preferably, the catalyst includes a second carrier coating layer, where the catalyst exhibits a layered arrangement of the first carrier coating layer and the second carrier coating layer, and where one or more platinum group metals are at least partially contained in the second carrier coating layer.

[0053] In the case where the catalyst includes a second carrier coating layer, where the catalyst exhibits a layered arrangement of the first carrier coating layer and the second carrier coating layer, and where one or more platinum group metals are at least partially contained in the second carrier coating layer, according to the first alternative, preferably, the first carrier coating layer is disposed on the substrate, and the second carrier coating layer is disposed on the first carrier coating layer.

[0054] Further, in the case where the catalyst includes a second carrier coating layer, where the catalyst exhibits a layered arrangement of the first carrier coating layer and the second carrier coating layer, and where one or more platinum group metals are at least partially contained in the second carrier coating layer, according to the first alternative, preferably, the second carrier coating layer is disposed on the substrate, and the first carrier coating layer is disposed on the second carrier coating layer.

[0055] Further, in the case where the catalyst comprises a second support coating layer, wherein the catalyst exhibits a layered arrangement of a first support coating layer and a 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 a first alternative, preferably, the catalyst comprises a third support coating layer, wherein the catalyst exhibits a zoned arrangement of a first support coating layer, a second support coating layer and a 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 first 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 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 an upstream zone including the third support coating layer and a downstream zone including 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 third support coating layer. Alternatively, preferably, the catalyst comprises a third support coating layer, wherein the catalyst exhibits a zoned arrangement of a first support coating layer, a second support coating layer and a 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 including the third support coating layer and a downstream zone including 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 third support coating layer. Alternatively, preferably, the catalyst comprises a third support coating layer, wherein the catalyst exhibits a zoned arrangement of a first support coating layer, a second support coating layer and a 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 including the third support coating layer and an upstream zone including 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 third support coating 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 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 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.

[0056] 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.

[0057] According to a third 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 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.

[0058] 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.

[0059] According to the sixth 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.

[0060] 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.

[0061] 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.

[0062] 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.

[0063] Further, in the case where the catalyst comprises a second support coating layer, in which the catalyst exhibits a zoned arrangement of the first and second support coating layers according to the second, third, fourth or fifth alternative, preferably the second support coating layer and the third support coating layer are adjacent to each other.

[0064] Further, in the case where the catalyst comprises a second support coating layer, in which the catalyst exhibits a zoned arrangement of the first and second support coating layers according to the second, third, fourth or fifth alternative, preferably a part of the second support coating layer overlaps at least a part of the first support coating layer, wherein more preferably the second support coating layer overlaps the first support coating layer over a range of 10% to 100%, more preferably 15% to 80%, and even more preferably 20% to 50% of the axial length of the first support coating layer.

[0065] Further, in the case where the catalyst comprises a second support coating layer, in which the catalyst exhibits a zoned arrangement of the first and second support coating layers according to the second, third, fourth or fifth alternative, preferably a part of the first support coating layer overlaps at least a part of the second support coating layer, wherein more preferably the first support coating layer overlaps the second support coating layer over a range of 10% to 100%, more preferably 15% to 80%, and even more preferably 20% to 50% of the axial length of the second support coating layer.

[0066] Further, in the case where the catalyst comprises a second support coating layer, in which the catalyst exhibits a zoned arrangement of the first and second support coating layers according to the second, third, fourth or fifth alternative, preferably a part of the third support coating layer overlaps at least a part of the first support coating layer, wherein preferably the third support coating layer overlaps the first support coating layer over a range of 10% to 100%, more preferably 15% to 80%, and even more preferably 20% to 50% of the axial length of the first support coating layer.

[0067] According to the sixth alternative, preferably the catalyst comprises a second support coating layer, in which the catalyst exhibits a zoned arrangement of the first and second support coating layers, wherein the second support coating layer is provided on the substrate along the entire length of the substrate, and wherein the first support coating layer is provided 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 one or more platinum group metals are at least partially contained in the second support coating layer.

[0068] According to the seventh alternative, preferably, the catalyst comprises a second support coating layer, wherein the catalyst exhibits a zoned arrangement of a first support coating layer and a 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 region comprising the first support coating layer and a downstream region comprising the second support coating layer, and wherein one or more platinum group metals are at least partially contained in the second support coating layer.

[0069] In the case where the catalyst comprises a second support coating layer, wherein the catalyst exhibits a zoned arrangement of a first support coating layer and a second support coating layer according to the sixth or seventh alternative, preferably, the length of the first support 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%.

[0070] According to the eighth alternative, preferably, the catalyst comprises a second support coating layer, wherein the catalyst exhibits a zoned arrangement of a first support coating layer and a 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 region comprising the second support coating layer and a downstream region comprising the first support coating layer, and wherein one or more platinum group metals are at least partially contained in the second support coating layer.

[0071] In the case where the catalyst comprises a second support coating layer, wherein the catalyst exhibits a zoned arrangement of a first support coating layer and a second support coating layer according to the eighth alternative, preferably, 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 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 region comprising the second support coating layer and a downstream region comprising the third support coating layer.

[0072] According to the ninth alternative, preferably, 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 provided on the substrate along the entire length of the substrate, and wherein the second support coating layer is provided 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 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 one or more platinum group metals are at least partially contained in the second support coating layer.

[0073] In the case where 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 according to the ninth alternative, preferably, the catalyst comprises a third support coating layer, wherein the third support coating layer is provided 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 provided 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 provided 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 third support coating layer and a downstream zone comprising the second support coating layer.

[0074] In the case where the catalyst comprises a second support coating layer, wherein the catalyst preferably exhibits a zoned arrangement of the first support coating layer and the second support coating layer according to the eighth or ninth alternative, and wherein the catalyst comprises a third support coating layer, preferably, the second support coating layer and the third support coating layer are adjacent to each other.

[0075] 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 more preferably from 35% to 45%.

[0076] In the case where the catalyst comprises a second support coating layer, wherein the catalyst preferably exhibits a zoned 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 more preferably from 35% to 45%.

[0077] In the case where the catalyst comprises a second support coating layer and a third support coating layer, preferably, the length range of the third support coating layer is 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%.

[0078] 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, and preferably the third support coating layer is free of sulfur-trapping material.

[0079] Furthermore, in the case where the catalyst comprises a second support coating layer and a third support coating layer, preferably, the third layer contains 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 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%.

[0080] In the case where the third layer contains a hydrocarbon-trapping material, preferably, 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 more 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.

[0081] Furthermore, in the case where the catalyst comprises 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.

[0082] In the case where one or more platinum group metals are at least partially included in the third support coating layer, preferably, the 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 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, where based on 100% by weight of 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.

[0083] 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 included in the second support coating layer and the third support coating layer, where 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, more preferably in the range of 1.4:1 to 1.6:1, where 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, and where 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.

[0084] In the case where the catalyst includes a second support coating layer, where the catalyst shows a partitioned arrangement of the first support coating layer and the second support coating layer according to the first alternative, 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, one or more platinum group metals are completely included in the second support coating layer or in the second support coating layer and the third support coating layer.

[0085] Further, in the case where the catalyst includes a second support coating layer, where the catalyst shows a partitioned arrangement of the first support coating layer and the second support coating layer according to the first alternative, 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, one or more platinum group metals are at least partially included in the first support coating layer.

[0086] Preferably, the substrate is a metal substrate or a ceramic substrate, more preferably a ceramic substrate, still more preferably the ceramic substrate contains cordierite and / or SiC, preferably cordierite, still more preferably the ceramic substrate consists of cordierite and / or SiC, preferably consists of cordierite.

[0087] In the case where the catalyst includes a second washcoat layer, wherein the catalyst exhibits a partitioned arrangement of the first washcoat layer and the second washcoat layer according to the second alternative, third alternative, fourth alternative, fifth alternative, sixth alternative, seventh alternative, eighth alternative or ninth alternative, preferably, the substrate consists of two separate monoliths, wherein the first monolith is disposed upstream of the second monolith, and one or more washcoat layers in the upstream region are included on the first monolith, and one or more washcoat layers in the downstream region are included on the second monolith, wherein more preferably the first monolith including one or more washcoat layers in the upstream region and the second monolith including one or more washcoat layers in the downstream region are obtained by or can be obtained by dividing a catalyst according to any one of the embodiments disclosed herein into two separate monoliths according to the second alternative, third alternative, fourth alternative, fifth alternative, sixth alternative, seventh alternative, eighth alternative or ninth alternative, and one or more washcoat layers in the upstream region are included on the first monolith, and one or more washcoat layers in the downstream region are included on the second monolith.

[0088] Furthermore, the present invention relates to an exhaust gas treatment system, which includes an internal combustion engine and an exhaust gas duct for the exhaust gas from the internal combustion engine, wherein the exhaust gas duct includes 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.

[0089] Preferably, the internal combustion engine is a compression ignition engine, more preferably a diesel engine.

[0090] Preferably, the internal combustion engine is a lean burn gasoline engine.

[0091] Alternatively, preferably, the internal combustion engine is powered by an oxygenated fuel, wherein the oxygenated fuel preferably contains one or more of methanol and biofuel.

[0092] 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).

[0093] According to the first alternative, it is preferred that 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.

[0094] According to the second alternative, it is preferred that 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.

[0095] According to the third alternative, it is preferred that 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.

[0096] According to the fourth alternative, it is preferred that 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 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.

[0097] According to a fifth 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 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.

[0098] According to a sixth 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, a catalytic soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst.

[0099] According to a seventh 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, a catalytic soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0100] According to an 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.

[0101] According to a 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.

[0102] According to a 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.

[0103] According to an 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.

[0104] According to a 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.

[0105] According to a 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.

[0106] According to a 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 on filter catalyst (SCRoF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0107] 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 on filter catalyst (SCRoF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0108] Furthermore, the present invention relates to a method for treating an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons, the method comprising

[0109] (A) providing an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons;

[0110] (B) guiding the exhaust gas stream provided in (A) through a catalyst according to any of the embodiments disclosed herein.

[0111] Preferably, the exhaust gas stream provided in (A) contains one or more sulfur-containing compounds, more preferably SO2 and / or SO3.

[0112] Preferably, the exhaust gas stream provided in (A) contains NO x .

[0113] Preferably, the exhaust gas stream provided in (A) contains CO.

[0114] Preferably, the exhaust gas stream provided in (A) contains formaldehyde.

[0115] Preferably, the exhaust gas stream provided in (A) contains nitric oxide (NO).

[0116] Preferably, the exhaust gas stream provided in (A) contains hydrocarbons, preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons.

[0117] Furthermore, the present invention relates to the use of a catalyst according to any of the embodiments disclosed herein for oxidizing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons, more 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, more preferably for oxidizing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons in the exhaust gas stream of a compression ignition engine, more preferably for oxidizing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons in the exhaust gas stream of a diesel engine.

[0118] 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 a term 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 a 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.

[0119] 1. A catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons, the catalyst comprising

[0120] a first support coating layer comprising Mn supported on a CuO-

[0121] Al2O3 mixed oxide, and

[0122] a substrate,

[0123] 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,

[0124] wherein the catalyst further comprises one or more platinum group metals, the one or more platinum group metals comprising Pt, Pd, or Pt and Pd, and wherein the one or more platinum group metals are at least partially included in one or more of the following:

[0125] (a) the first support coating layer, and

[0126] (b) an optional second support coating layer, or

[0127] (c) an optional second support coating layer and a third support coating layer.

[0128] 2. The catalyst according to embodiment 1, wherein the optional second support coating layer is substantially free of Mn, and preferably the optional second support coating layer is free of Mn.

[0129] 3. The catalyst according to embodiment 1 or 2, 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, preferably 2% to 30% by weight, more preferably 5% to 20% by weight, and even more preferably 8% to 12% by weight.

[0130] 4. The catalyst according to any one of embodiments 1 to 3, wherein Mn is present in the form of one or more Mn cations, wherein Mn is preferably included in the first support coating layer as one or more oxides, and wherein Mn is more preferably included in the first support coating layer as one or more oxides of Mn(II), Mn(III), Mn(II / III), and Mn(IV), and more preferably as one or more oxides selected from the group consisting of MnO, Mn2O3, Mn3O4, MnO2, Mn(O)OH, and Mn-Zr mixed oxides (mixtures containing two or more of them) included in the first support coating layer, wherein the Mn-Zr mixed oxide is preferably included in the first support coating layer as a solid solution.

[0131] 5. The catalyst according to any one of embodiments 1 to 4, wherein the CuO-Al2O3 mixed oxide is a particulate support material.

[0132] 6. The catalyst according to any one of embodiments 1 to 5, wherein the first support coating layer contains Ce, and wherein Ce is preferably included in the first support coating layer as CeO2 and / or Ce2O3.

[0133] 7. The catalyst according to embodiment 6, wherein, based on 100% by weight of the first support coating layer, calculated in terms of elements, the loading amount of Ce in the first support 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.

[0134] 8. The catalyst according to embodiment 6 or 7, wherein Ce is loaded on the CuO-Al2O3 mixed oxide.

[0135] 9. The catalyst according to any one of embodiments 1 to 5, wherein the first support coating layer is substantially free of Ce, and wherein preferably the first support coating layer does not contain Ce.

[0136] 10. The catalyst according to embodiment 9, wherein the catalyst is substantially free of Ce, and wherein preferably the catalyst does not contain Ce.

[0137] 11. The catalyst according to any one of embodiments 1 to 10, wherein the first support coating layer contains Cu loaded on a particulate support material, and wherein preferably the Cu is loaded on the CuO-Al2O3 mixed oxide.

[0138] 12. The catalyst according to embodiment 11, wherein based on 100% by weight of the first carrier coating layer, calculated on an elemental basis, the loading amount of Cu loaded on the particulate carrier material 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.

[0139] 13. The catalyst according to any one of embodiments 1 to 10, wherein the first carrier coating layer is substantially free of Cu not contained in the CuO-Al2O3 mixed oxide, and preferably the first carrier coating layer is free of Cu not contained in the CuO-Al2O3 mixed oxide.

[0140] 14. The catalyst according to embodiment 13, wherein the catalyst is substantially free of Cu not contained in the CuO-Al2O3 mixed oxide, and preferably the catalyst is free of Cu not contained in the CuO-Al2O3 mixed oxide.

[0141] 15. The catalyst according to any one of embodiments 1 to 14, 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, and more preferably a honeycomb flow-through substrate, and the flow-through substrate is more preferably a flow-through substrate having a high-porosity wall.

[0142] 16. The catalyst according to any one of embodiments 1 to 15, wherein the loading amount of the first carrier coating layer is from 0.5 g / in 3 to 5 g / in 3 , preferably from 1 g / in 3 to 3 g / in 3 , more preferably from 1.5 g / in 3 to 2.5 g / in 3 , even more preferably from 1.7 g / in 3 to 2 g / in 3 within the range.

[0143] 17. The catalyst according to any one of embodiments 1 to 16, wherein the loading amount of the second carrier coating layer is from 0.25 g / in 3 to 6 g / in 3 , preferably from 0.3 g / in 3 to 6 g / in 3 , more preferably from 1 g / in 3 to 5 g / in 3 , even more preferably from 1.5 g / in 3 to 4 g / in 3 , even more preferably from 2 g / in 3to 3.5 g / in 3 and more preferably 2.2 g / in 3 to 3.0 g / in 3 and more preferably 2.3 g / in 3 to 2.9 g / in 3 and more preferably 2.5 g / in 3 to 2.7 g / in 3 within the range of

[0144] 18. The catalyst according to any one of embodiments 1 to 17, 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.

[0145] 19. The catalyst according to any one of embodiments 1 to 18, wherein, calculated on an elemental basis, the catalyst comprises Pt in a loading amount in the range of 2 g / ft 3 to 250 g / ft 3 and preferably 5 g / ft 3 to 150 g / ft 3 and more preferably 10 g / ft 3 to 125 g / ft 3 and more preferably 20 g / ft 3 to 100 g / ft 3 and more preferably 25 g / ft 3 to 85 g / ft 3 and more preferably 30 g / ft 3 to 80 g / ft 3 and more preferably 40 g / ft 3 to 60 g / ft 3 of Pt.

[0146] 20. The catalyst according to any one of embodiments 1 to 19, wherein, calculated on an elemental basis, the catalyst comprises Pd in a loading amount in the range of 1 g / ft 3 to 80 g / ft 3 and preferably 5 g / ft 3 to 60 g / ft 3 and more preferably 10 g / ft 3 to 50 g / ft 3 and more preferably 15 g / ft 3 to 40 g / ft 3 and more preferably 20 g / ft 3 to 30 g / ft 3 of Pd.

[0147] 21. The catalyst according to any one of Embodiments 1 to 20, wherein, calculated based on the corresponding elements, the total Pt and Pd loading amount of the catalyst is in the range of 2 g / ft 3 to 250 g / ft 3 , 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.

[0148] 22. The catalyst according to any one of Embodiments 1 to 21, wherein the catalyst contains Pt and Pd, and the Pt:Pd weight ratio is in the range of 30:70 to 90:10, preferably 50:50 to 80:20, more preferably 60:40 to 75:25, and even more preferably 65:35 to 70:30.

[0149] 23. The catalyst according to any one of Embodiments 1 to 22, 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 of them, 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.

[0150] 24. The catalyst according to any one of embodiments 1 to 23, wherein the first carrier 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%.

[0151] 25. The catalyst according to embodiment 24, wherein the loading amount of the hydrocarbon trapping material in the first carrier coating layer is in the range of 0.01 g / in 3 to 2.0 g / in 3 and 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 and more preferably in the range of 0.05 g / in

[0152] 26. The catalyst according to any one of embodiments 1 to 25, wherein the catalyst comprises a second carrier coating layer, wherein the one or more platinum group metals are at least partially contained in the second carrier coating layer, and preferably all of the one or more platinum group metals are contained in the second carrier coating layer.

[0153] 27. The catalyst according to any one of embodiments 1 to 26, 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 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%.

[0154] 28. The catalyst according to embodiment 27, wherein the loading amount of the hydrocarbon trapping material in the second 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.

[0155] 29. The catalyst according to any one of embodiments 1 to 28, wherein 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 the one or more platinum group metals are at least partially contained in the second support coating layer.

[0156] 30. The catalyst according to embodiment 29, wherein the first support coating layer is disposed on the substrate, and the second support coating layer is disposed on the first support coating layer.

[0157] 31. The catalyst according to embodiment 29 or 30, wherein the second support coating layer is disposed on the substrate, and the first support coating layer is disposed on the second support coating layer.

[0158] 32. The catalyst according to embodiment 29 or 30, 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 first 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 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 an upstream region including the third support coating layer and a downstream region including 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.

[0159] 33. The catalyst according to embodiment 29 or 31, 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 region including the third support coating layer and a downstream region including 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.

[0160] 34. The catalyst according to embodiment 29 or 30, 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 including the third support coating layer and an upstream zone including 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.

[0161] 35. The catalyst according to embodiment 29 or 31, 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 including the third support coating layer and an upstream zone including 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.

[0162] 36. The catalyst according to any one of embodiments 1 to 28, 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 including the second support coating layer and a downstream zone including 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.

[0163] 37. The catalyst according to any one of embodiments 1 to 28, 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 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.

[0164] 38. The catalyst according to any one of embodiments 1 to 28, 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.

[0165] 39. The catalyst according to any one of embodiments 1 to 28, 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.

[0166] 40. The catalyst according to embodiment 36 or 38, 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 second support coating layer is disposed on the substrate along the axial length of the substrate starting from the inlet end of the substrate, and 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 region comprising the second support coating layer and a downstream region comprising the first support coating layer and the third support coating layer.

[0167] 41. The catalyst according to embodiment 37 or 39, 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 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 substrate 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 region comprising the first support coating layer and the third support coating layer and a downstream region comprising the second support coating layer.

[0168] 42. The catalyst according to any one of embodiments 32 to 41, wherein the first support coating layer and the second support coating layer are adjacent to each other.

[0169] 43. The catalyst according to embodiments 32 to 42, wherein the second support coating layer and the third support coating layer are adjacent to each other.

[0170] 44. The catalyst according to any one of embodiments 32 to 43, 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 over a range of 10% to 100%, more preferably 15% to 80%, and even more preferably 20% to 50% of the axial length of the first support coating layer.

[0171] 45. The catalyst according to any one of embodiments 32 to 44, wherein a part of the first carrier coating layer overlaps at least a part of the second carrier coating layer, wherein preferably the first carrier coating layer overlaps the second carrier coating layer on a part ranging from 10% to 100%, more preferably from 15% to 80%, and still more preferably from 20% to 50% of the axial length of the second carrier coating layer.

[0172] 46. The catalyst according to any one of embodiments 32 to 45, wherein 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 ranging from 10% to 100%, more preferably from 15% to 80%, and still more preferably from 20% to 50% of the axial length of the first carrier coating layer.

[0173] 47. The catalyst according to any one of embodiments 1 to 28, wherein the catalyst comprises a second carrier coating layer, wherein the catalyst exhibits a partitioned arrangement of the first carrier coating layer and the second carrier coating layer, wherein the second carrier coating layer is provided on the substrate along the entire length of the substrate, and wherein the first carrier coating layer is provided on the second carrier coating layer along the axial length of the substrate starting from the outlet end 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 region comprising the second carrier coating layer and a downstream region comprising the first carrier coating layer, and wherein the one or more platinum group metals are at least partially contained in the second carrier coating layer.

[0174] 48. The catalyst according to any one of embodiments 1 to 28, wherein the catalyst comprises a second carrier coating layer, wherein the catalyst exhibits a partitioned arrangement of the first carrier coating layer and the second carrier coating layer, wherein the second carrier coating layer is provided on the substrate along the entire length of the substrate, and wherein the first carrier coating layer is provided on the second carrier coating layer along the axial length of the substrate starting from the inlet end 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 region comprising the first carrier coating layer and a downstream region comprising 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.

[0175] 49. The catalyst according to embodiment 47 or 48, wherein the length of the first carrier coating layer ranges from 10% to 90%, preferably from 30% to 80%, and more preferably from 50% to 70% of the axial length of the substrate.

[0176] 50. The catalyst according to any one of embodiments 1 to 28, 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.

[0177] 51. The catalyst according to embodiment 50, 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 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 third support coating layer.

[0178] 52. The catalyst according to any one of embodiments 1 to 28, 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 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.

[0179] 53. The catalyst according to embodiment 52, 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 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 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 including the third support coating layer and a downstream region including the second support coating layer.

[0180] 54. The catalyst according to embodiment 51 or 53, wherein the second support coating layer and the third support coating layer are adjacent to each other.

[0181] 55. The catalyst according to embodiments 1 to 54, 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%.

[0182] 56. The catalyst according to embodiments 29 to 55, 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%.

[0183] 57. The catalyst according to embodiments 32 to 56, 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%.

[0184] 58. The catalyst according to any one of embodiments 32 to 57, 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.

[0185] 59. The catalyst according to any one of embodiments 32 to 58, wherein the third 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 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%.

[0186] 60. The catalyst according to embodiment 59, 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 of the range.

[0187] 61. The catalyst according to any one of embodiments 32 to 60, wherein the one or more platinum group metals are at least partially contained in the third support coating layer.

[0188] 62. The catalyst according to embodiment 61, wherein the one or more platinum group metals are supported on a particulate support material, wherein the particulate support material is preferably selected from the group consisting of: Al2O3, SiO2, TiO2, SiO2-doped Al2O3, Mn oxide-doped Al2O3, and mixtures of two or more thereof, wherein 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, wherein 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.

[0189] 63. The catalyst according to any one of embodiments 32 to 62, wherein the catalyst comprises a second support coating layer and a third support coating layer, wherein the one or more platinum group metals are completely contained in the second support coating layer and the third support coating layer, and the weight ratio of the one or more platinum group metals contained in the second support coating layer to the 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, even more preferably in the range of 1.4:1 to 1.6:1, wherein the one or more platinum group metals contained in the second support coating layer preferably comprise Pt and Pd, more preferably consist of Pt and Pd, and wherein the one or more platinum group metals contained in the third support coating layer preferably comprise Pt and Pd, more preferably consist of Pt and Pd.

[0190] 64. The catalyst according to any one of embodiments 29 to 63, wherein the one or more platinum group metals are completely contained in the second support coating layer or in the second support coating layer and the third support coating layer.

[0191] 65. The catalyst according to any one of embodiments 29 to 64, wherein the one or more platinum group metals are at least partially contained in the first support coating layer.

[0192] 66. The catalyst according to any one of embodiments 1 to 65, 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.

[0193] 67. The catalyst according to any one of embodiments 32 to 66, wherein the substrate consists of two separate monoliths, with a first monolith disposed upstream of a second monolith, and wherein the one or more support coating layers in the upstream region are included on the first monolith and the one or more support coating layers in the downstream region are included on the second monolith, and preferably the first monolith including the one or more support coating layers in the upstream region and the second monolith including the one or more support coating layers in the downstream region are obtained by or can be obtained by splitting the catalyst according to any one of embodiments 30 to 68 into two separate monoliths, with the one or more support coating layers in the upstream region included on the first monolith and the one or more support coating layers in the downstream region included on the second monolith.

[0194] 68. The catalyst according to any one of embodiments 1 to 67, wherein the exhaust gas stream contains hydrocarbons, preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons.

[0195] 69. An exhaust gas treatment system comprising an internal combustion engine and an exhaust gas duct for the 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 68, preferably one, two, three or four catalysts according to any one of embodiments 1 to 68.

[0196] 70. The exhaust gas treatment system according to embodiment 69, wherein the internal combustion engine is a compression ignition engine, preferably a diesel engine.

[0197] 71. The exhaust gas treatment system according to embodiment 69 or 70, wherein the internal combustion engine is a lean burn gasoline engine.

[0198] 72. The exhaust gas treatment system according to embodiment 69, wherein the internal combustion engine is powered by an oxygenated fuel, wherein the oxygenated fuel preferably comprises one or more of methanol and biofuel.

[0199] 73. The exhaust gas treatment system according to any one of embodiments 69 to 72, 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).

[0200] 74. The exhaust gas treatment system according to embodiment 73, 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 68, a catalyst according to any one of embodiments 1 to 68, 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.

[0201] 75. The exhaust gas treatment system according to embodiment 73, wherein the exhaust gas treatment 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 one of embodiments 1 to 68, a catalyst according to any one of embodiments 1 to 68, 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.

[0202] 76. The exhaust gas treatment system according to embodiment 73, wherein the exhaust gas treatment 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 one of embodiments 1 to 68, a catalyst according to any one of embodiments 1 to 68, 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.

[0203] 77. The exhaust gas treatment system according to embodiment 73, wherein the exhaust gas treatment 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 one of embodiments 1 to 68, a catalyst according to any one of embodiments 1 to 68, 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 68, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst.

[0204] 78. The exhaust gas treatment system according to embodiment 73, wherein the exhaust gas treatment 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 one of embodiments 1 to 68, a catalyst according to any one of embodiments 1 to 68, 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 68, a catalyst according to any one of embodiments 1 to 68 (wherein the substrate is a wall-flow substrate), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0205] 79. The exhaust gas treatment system according to embodiment 73, wherein the exhaust gas treatment 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 one of embodiments 1 to 68, 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.

[0206] 80. The exhaust gas treatment system according to embodiment 73, wherein the exhaust gas treatment 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 one of embodiments 1 to 68, 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] 81. The exhaust gas treatment system according to embodiment 73, wherein the exhaust gas treatment 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 one of embodiments 1 to 68, 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 68 (wherein the substrate is a wall-flow substrate), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0208] 82. The exhaust gas treatment system according to embodiment 73, wherein the exhaust gas treatment 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 one of embodiments 1 to 68, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction on filter catalyst (SCRoF), and an ammonia oxidation (AMOX) catalyst.

[0209] 83. The exhaust gas treatment system according to embodiment 73, wherein the exhaust gas treatment 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 one of embodiments 1 to 68, a selective catalytic reduction on filter catalyst (SCRoF), and an ammonia oxidation (AMOX) catalyst.

[0210] 84. The exhaust gas treatment system according to embodiment 73, 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 68, a catalytic soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0211] 85. The exhaust gas treatment system according to embodiment 73, 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 68, a catalyst according to any one of embodiments 1 to 68 (wherein the substrate is a wall-flow substrate), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0212] 86. The exhaust gas treatment system according to embodiment 73, 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 68, 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.

[0213] 87. The exhaust gas treatment system according to embodiment 73, 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 68, a selective catalytic reduction catalyst on a filter (SCRoF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0214] 88. The exhaust gas treatment system according to embodiment 73, 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 68, 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.

[0215] 89. A method for treating an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons, the method comprising

[0216] (A) Provide an exhaust gas stream containing one or more of formaldehyde, nitrogen monoxide (NO), and hydrocarbons;

[0217] (B) Direct the exhaust gas stream provided in (A) through a catalyst according to any one of Embodiments 1 to 68.

[0218] 90. The method according to Embodiment 89, wherein the exhaust gas stream provided in (A) contains one or more sulfur-containing compounds, preferably SO2 and / or SO3.

[0219] 91. The method according to Embodiment 89 or 90, wherein the exhaust gas stream provided in (A) contains NO x .

[0220] 92. The method according to any one of Embodiments 89 to 91, wherein the exhaust gas stream provided in (A) contains CO.

[0221] 93. The method according to any one of Embodiments 89 to 92, wherein the exhaust gas stream provided in (A) contains hydrocarbons, preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons.

[0222] 94. The use of a catalyst according to any one of Embodiments 1 to 68 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 an exhaust gas stream, more preferably for oxidizing one or more of formaldehyde, nitrogen monoxide (NO), and hydrocarbons in the exhaust gas stream of an internal combustion engine, more preferably for oxidizing one or more of formaldehyde, nitrogen monoxide (NO), and hydrocarbons in the exhaust gas stream of a compression ignition engine, more preferably for oxidizing one or more of formaldehyde, nitrogen monoxide (NO), and hydrocarbons in the exhaust gas stream of a diesel engine.

[0223] The present invention is further illustrated by the following Examples and Comparative Examples.

[0224] Experimental Section

[0225] Comparative Example 1: Preparation of a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons Example 2: Preparation of a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons

[0226] The catalyst is prepared by separately coating a platinum group metal (PGM)-containing front section and a base metal oxide (BMO)-containing rear section on a 1" diameter cordierite honeycomb substrate, and then sequentially combining the coated cores for subsequent sulfur aging (S-aging) and testing. Pt (using an aqueous solution containing an ammonia-stabilized hydroxo Pt(IV) complex having a Pt content in the range of 10 wt% to 20 wt%), Pd (using Pd nitrate), β-zeolite, and a commercially available alumina support powder containing 5 wt% silica and having a BET surface area of approximately 150 m 2 / g and a pore volume of about 0.6 cm 3 / g are combined in an aqueous slurry composition to prepare the front section. After coating the slurry onto the 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 section. The Pt-Pd weight ratio is 2:1, and the total Pt-Pd loading is 75 g / ft 3 of the monolith volume. The support coating loading of the PGM-containing layer is 2.9 g / in 3 , containing approximately 91 wt% alumina and approximately 9 wt% β-zeolite. The BMO-containing rear section is prepared by first combining a commercially available zirconia support powder containing 9 wt% La2O3 and having a BET surface area of approximately 75 m 2 / g with a solution of Mn nitrate, Ce nitrate, and Cu nitrate in deionized (DI) water. After grinding the resulting mixture to a coating-suitable particle size, boehmite alumina binder is added. The resulting slurry is then coated onto a 1" diameter × 1.8" long cordierite substrate, dried, and subsequently calcined at 590 °C for 1 hour. The total support coating layer loading of the BMO-containing layer is 1.83 g / in 3 of the monolith volume, and this monolith volume contains 8.8 wt% of Mn, 8.8 wt% of Ce, 8.8 wt% of Cu, 3 wt% of Al2O3 binder, and the balance of La2O3-stabilized ZrO2.

[0227] Example 3: Preparation of a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons Comparative Example 4: Preparation of a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons

[0228] The catalyst is prepared by separately coating a PGM-containing front section and a BMO-containing rear section on a 1" diameter cordierite honeycomb substrate, and then sequentially combining the coated cores for subsequent sulfur aging (S-aging) and testing. The front section is prepared as described in Comparative Example 1. By first combining a commercially available zirconia support powder containing 17 wt% CuO and having a BET surface area of approximately 200 m 2 / g and a pore volume of about 0.8 cm 3The rear zone section is prepared by combining Al2O3 support powder with a pore volume of / g with a solution of manganese nitrate and cerium nitrate in deionized (DI) water. After grinding the resulting mixture to a coating-suitable particle size, boehmite alumina binder is added. The resulting slurry is then coated onto a 1" diameter × 1.8" long cordierite substrate, dried, and subsequently calcined at 590 °C for 1 hour. The total support coating layer loading of the BMO-containing layer is 2.1 g / in 3 of the monolith volume, which contains 9.3 wt% Mn, 9.3 wt% Ce, 3 wt% Al2O3 binder, and the balance CuO-doped Al2O3.

[0229] Comparative Example 5: Preparation of a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons Comparative Example 6: Preparation of a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons

[0230] The catalyst is prepared in the same manner as described in Example 2, except that Ce is not included. The total support coating layer loading of the BMO-containing layer is 1.9 g / in 3 of the monolith volume, which contains 9.4 wt% Mn, 3 wt% Al2O3 binder, and the balance CuO-doped Al2O3.

[0231] Comparative Example 7: Preparation of a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons Example 8: Catalyst Aging and Catalytic Testing

[0232] The catalyst is prepared similar to Comparative Example 1, except that the Pt-Pd loading in the front zone is 240 g / ft 3 (4:1 Pt-Pd), and the total support coating layer loading of the BMO-containing layer is 2.2 g / in 3 of the monolith volume, which contains 8.9 wt% Mn, 8.9 wt% Ce, 8.9 wt% Cu, 3 wt% Al2O3 binder, and the balance La2O3-stabilized ZrO2.

[0233] Figure 1 Figure 2

[0234] The catalyst is prepared similar to Comparative Example 4, except that the support for Mn, Ce, and Cu in the rear zone is composed of alumina with a BET surface area of approximately 150 m 2 / g and a pore volume of about 0.9 cm 3 / g. The total support coating layer loading of the BMO-containing layer is 2.2 g / in 3 of the monolith volume, which contains 8.9 wt% Mn, 8.9 wt% Ce, 8.9 wt% Cu, 3 wt% Al2O3 binder, and the balance Al2O3.

[0235] Figure 3Figure 4

[0236] The catalyst was prepared similar to Comparative Example 1, except that the Pt-Pd loading in the front zone was 180 g / ft 3 .

[0237] Figure 1 Figure 2

[0238] The catalyst was prepared similar to Comparative Example 6, except that it did not contain Cu. The total support coating loading of the BMO-containing layer was 1.9 g / in 3 of the monolith volume, which monolith volume contained 9.0 wt% Mn, 9.0 wt% Ce, 3 wt% Al2O3 binder, and the balance La2O3-stabilized ZrO2.

[0239] Figure 3

[0240] The sulfur aging (S-aging) of the catalysts of Comparative Examples 1, 4, and 5 and the sulfur aging (S-aging) of the catalysts of Examples 2 to 3 were carried out on 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 / h. The exposure time under these conditions was 88 minutes, corresponding to a target sulfur exposure of 1 g(S) / L of monolith volume. Desulfation was carried out at 750 °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 / h.

[0241] After sulfation and desulfation, the formaldehyde (HCHO) light-off performance of the test samples was tested using a feed containing 180 ppm NO, 1000 ppm CO, 25 ppm HCHO, 100 ppm C1 from C2H4, 190 ppm C1 from C 10 H 22 of C1, 10% O2, 10% H2O, and 10% CO2. The flow rate through the catalyst measured at space velocity was 50,000 / h. The samples were placed in the reactor and first equilibrated in flowing air at 80 °C. Then the formaldehyde-containing feed was introduced and heating was started at a rate of 15 °C / min to 300 °C. The formaldehyde concentration was monitored by FTIR during the light-off heating, and then the conversion performance versus temperature was calculated from these measurements.

[0242] The results of Comparative Example 1 and the catalysts of Examples 2 and 3 are shown in Figure 4Among them. After sulfation and desulfation at 750 °C, the formaldehyde oxidation performance of the two samples according to the present invention is higher, confirming the higher sulfur resistance of the Cu-containing formaldehyde oxidation catalyst containing the CuO-Al2O3 support. It seems that CuO-Al2O3 helps to mitigate the negative impact of S on Mn supported on La2O3-stabilized ZrO2 when combined with Cu. As Cited References shown, it was also found that the stability of the catalyst of Example 3 prepared with CuO-Al2O3 was improved before and after S exposure. In particular, after sulfation and desulfation at 750 °C, the performance hardly changed. In fact, after sulfation / desulfation, the HCHO oxidation performance of the sample containing Mn supported on the CuO / Al2O3 support is higher than that of Mn, Cu, and Ce supported on the La2O3 / ZrO2 support.

[0243] From the results, it has been found that when using Mn in combination with a support containing alumina doped with CuO in the catalyst, the HCHO oxidation performance is unexpectedly higher. This is particularly surprising because it is well known that alumina is a poor Mn support for HCHO oxidation compared to zirconia, even when freshly tested before exposure to the detrimental effects of S (see ​ ). In addition, even when copper is added to Mn supported on 9 wt% La2O3-stabilized ZrO2, the HCHO oxidation performance is lower than that of the catalyst containing only Mn and Ce when tested before any exposure to the detrimental effects of S after hydrothermal aging at 800 °C ( ​ ). In particular, after sulfation and desulfation, the HCHO oxidation performance of Mn and Mn-Ce supported on CuO-Al2O3 is surprisingly higher than that of Mn, Ce, and Cu supported on 9 wt% La2O3-stabilized ZrO2. Description of the Drawings

[0244] ​ : Shows the formaldehyde (HCHO) oxidation performance of the catalysts of Comparative Example 1 and Examples 2 and 3 after sulfation and desulfation at 750 °C. All samples contain a 2:1 Pt-Pd front zone of 75 g / ft 3 . The rear zone of the catalyst of Comparative Example 1 contains Mn, Ce, and Cu supported on 9 wt% La2O3-ZrO2, while the catalysts of Examples 2 and 3 contain Mn-Ce or Mn supported on CuO-Al2O3, respectively.

[0245] ​ : Shows the formaldehyde (HCHO) oxidation performance of the catalysts of Comparative Example 1 and Example 3 before and after sulfation and desulfation at 750 °C. Both samples contain a 75 g / ft 3The 2:1 Pt-Pd front zone. The rear zone of the catalyst of Comparative Example 1 contains Mn, Ce, and Cu supported on 9 wt% La2O3-ZrO2, while the catalyst of Example 3 contains Mn supported on CuO-Al2O3 in the rear zone.

[0246] ​ : Shows the formaldehyde (HCHO) oxidation performance of fresh samples containing 8.9 wt% Mn, 8.9 wt% Cu, and 8.9 wt% Ce supported on Al2O3 (Comparative Example 5) or 9 wt% La2O3-stabilized ZrO2 (Comparative Example 4) after calcination at 590 °C.

[0247] ​ : Shows the formaldehyde (HCHO) oxidation performance of samples containing 8.9 wt% Mn, 8.9 wt% Cu, and 8.9 wt% Ce supported on 9 wt% La2O3-stabilized ZrO2 (Comparative Example 6) or 9.0 wt% Mn and 9.0 wt% Ce supported on 9 wt% La2O3-stabilized ZrO2 (Comparative Example 7) after hydrothermal aging at 800 °C for 16 hours in the presence of 10% steam in air.

[0248] ​

[0249] -WO 2022 / 047132 A1

[0250] -US 10,598,061 B2

[0251] -US 10,392,980 B2

[0252] -US 2018 / 333677 A1

[0253] -US 2018 / 318805 A1

[0254] -M.C. et al., Applied Catalysis B. 2004, 51, 83-91

Claims

1. A catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitric oxide (NO), and hydrocarbons, the catalyst comprising a first support coating layer comprising Mn supported on a CuO - Al2O3 mixed oxide, and a substrate, 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, wherein the catalyst further comprises one or more platinum group metals, the one or more platinum group metals comprising Pt, Pd, or Pt and Pd, and wherein the one or more platinum group metals are at least partially comprised 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 the first support coating layer comprises Ce.

4. The catalyst according to claim 3, wherein Ce is supported on the CuO - Al2O3 mixed oxide.

5. The catalyst according to any one of claims 1 to 4, wherein the first support coating layer comprises Cu supported on a particulate support material.

6. The catalyst according to any one of claims 1 to 5, 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.

7. The catalyst according to any one of claims 1 to 6, wherein, calculated on an elemental basis, the catalyst contains Pd in a loading range of 1 g / ft 3 to 80 g / ft 3 in range.

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

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

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

11. The catalyst according to any one of claims 1 to 10, wherein 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 the one or more platinum group metals are at least partially comprised in the second support coating layer.

12. The catalyst according to any one of claims 1 to 10, wherein the catalyst comprises a second support coating layer, wherein 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 including the second carrier coating layer and a downstream region including 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 including an internal combustion engine and an exhaust gas duct for exhaust gas from the internal combustion engine, wherein the exhaust gas duct includes the catalyst according to any one of claims 1 to 12.

14. The exhaust gas treatment system according to claim 13, wherein the system includes one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a 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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