Copper and manganese-containing catalyst for the treatment of exhaust gas streams containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons

Abstract

The present invention relates to a catalyst for treating an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons, the catalyst comprising: a first washcoat layer comprising Mn and Cu, the first washcoat layer being substantially free of Ce; and a substrate, the substrate having an inlet end and an outlet end, the catalyst further comprising one or more platinum group metals comprising Pt, Pd, or Pt and Pd, the one or more platinum group metals being at least partially contained in one or more of: (a) the first washcoat layer, (b) an optional second washcoat layer, or (c) the optional second and third washcoat layers. The present invention also relates to an exhaust gas treatment system including the catalyst, a method for treating an exhaust gas stream containing formaldehyde, nitrogen oxides (NO), and hydrocarbons using the catalyst, and uses of the catalyst.

Description

[Technical Field]

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

[0002] The present invention relates to a diesel oxidation catalyst (DOC) with improved oxidation capabilities, particularly for the oxidation of one or more of formaldehyde (HCHO), nitrogen oxides (NO), and hydrocarbons (including diesel fuel). Formaldehyde is known to be a toxic material under increasingly stringent regulations in indoor air spaces due to emissions from various building materials used in the construction industry. Stricter regulations are also being implemented for formaldehyde emissions from the engine exhaust of passenger vehicles and delivery vehicles. Manganese oxides (e.g., MnO) are generally known to be active in destroying formaldehyde under ambient conditions, but do not possess the thermal stability required to survive in a typical engine exhaust environment. In particular, phase transitions at high temperatures (e.g., above 400°C) can cause the structure of MnO to collapse, resulting in surface area and pore volume that are so low that they are no longer catalytically effective. One way to improve the stability of Mn oxide (and other catalytically useful base metal oxides such as copper, ceria, and iron) at high temperatures may be to support them on refractory oxide materials that themselves have high stability when exposed to high temperatures in engine exhaust. Materials such as aluminum oxide (Al2O3) and zirconium oxide (ZrO2) may be useful in this area.

[0003] A significant challenge to the inclusion of Mn-containing base metal oxide (BMO) catalysts in technologies for the reduction of exhaust emissions from diesel vehicles can be seen in the inherently low S tolerance of Mn, which is reflected in the high desulfation temperature of manganese sulfate. As documented in the literature, significant desulfation of MnSO4 does not occur at temperatures (approximately 650-700 °C) typical for diesel engine filter regeneration or desulfation (de-SOx).

[0004] Pt and Pd supported on high-temperature resistant refractory metal oxide supports are known to provide efficient 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. An additional function of DOC compositions, when placed in the exhaust of a diesel vehicle, is to oxidize diesel fuel injected into the exhaust upstream of the DOC, creating a high-temperature exotherm that is used to thermally oxidize soot accumulated on a diesel particulate filter (DPF) or catalyzed soot filter (CSF) located downstream of the DOC composition. Alternatively, the hydrocarbon concentration in the exhaust stream may be increased for exotherm generation by adjusting the combustion process, such as through various post-injection methods. Temperatures above 600°C at the DPF or CSF inlet are preferred to provide efficient oxidation of retained soot. The concentration of diesel fuel injected into the exhaust stream required to provide the desired exotherm is fairly high, approximately 1% (10,000 ppm) or more on a C1 basis. The temperature at which the DOC composition can oxidize ("light-off") the injected fuel must be as low as possible, preferably below 300°C. In addition, the amount of hydrocarbon slip that bypasses the DOC catalyst during exotherm production must be as low as possible, preferably below 3,000 ppm, 2,000 ppm, or even 1,000 ppm.

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

[0006] US Patent No. 10,598,061 (B2) relates to a method and system for a diesel oxidation catalyst. In particular, claim 1 discloses a method comprising: producing NO2 in a catalyst comprising a washcoat containing zirconium, one or more base metal oxides, and palladium oxide, wherein the exhaust gas flow rate is between a lower threshold flow rate and an upper threshold flow rate; and promoting regeneration of a particulate filter located downstream of the catalyst via NO2 when the exhaust gas temperature is higher than the threshold temperature, wherein the palladium oxide is contained in an upstream portion of the catalyst relative to the direction of exhaust gas flow, and the one or more base metal oxides are contained in a downstream portion of the catalyst relative to the direction of exhaust gas flow.

[0007] U.S. Patent No. 10,392,980 (B2) relates to a method and system for a diesel oxidation catalyst. In particular, claim 1 discloses a method comprising passing a diesel combustion exhaust gas over a diesel oxidation catalyst having a washcoat containing zirconium oxide, palladium oxide, and at least one base metal oxide, wherein the washcoat is coated on a surface of a substrate, the at least one base metal oxide is coated on a downstream portion of the substrate in an amount greater than that coated on an upstream portion, and the palladium oxide is coated on an upstream portion of the substrate in an amount greater than that coated on a downstream portion, downstream referring to the axial direction of the exhaust gas flow, and the palladium oxide is 0.5 to 3 weight percent of the washcoat.

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

[0009] In view of the stricter regulations being implemented on formaldehyde emissions from the engine exhaust of passenger vehicles and delivery vehicles, there has been a need to provide improved catalysts for the treatment of exhaust gas streams containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons. In particular, there has been a need for improved catalysts suitable for the oxidation of HCHO, nitrogen oxides (NO), and hydrocarbons that can be implemented in medium-duty diesel pickup trucks. DETAILED DESCRIPTION OF THE INVENTION

[0010] It was therefore an object of the present invention to provide a catalyst for the treatment of exhaust gas streams containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons, which has improved properties in terms of performance, in particular after exposure to sulfation and desulfation treatments.

[0011] It has been surprisingly found that an improved catalyst can be provided for the conversion of one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons in exhaust gases. In particular, it has been surprisingly found that a catalyst can be provided that exhibits improved performance with respect to the conversion of one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons after exposure to sulfation and desulfation treatments such as those encountered in typical applications. Furthermore, it has been surprisingly found that the catalyst according to the present invention exhibits improved oxidation function for hydrocarbons (HC) and nitrogen oxides (NO). In particular, it has been surprisingly found that the benefits of using a BMO-containing catalyst 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 allows vehicle manufacturers to meet ever-more stringent vehicle emissions standards while also reducing the overall usage and cost of PGMs. It has also been surprisingly found that the use of a diesel oxidation catalyst (DOC) containing both a platinum group metal (PGM) catalyst and a base metal oxide (BMO) catalyst results in a catalyst with improved fuel combustion function. Furthermore, the catalysts of the present invention can be expected to be capable of oxidizing soot buildup on substrates, particularly wall-flow substrates, because they can produce NO, which oxidizes the soot, particularly with a Mn-containing washcoat layer. Additionally, the catalysts of the present invention can enable relatively low NO production, particularly due to the relatively low content of platinum group metals.

[0012] Accordingly, the present invention provides a catalyst for the treatment of an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons, the catalyst comprising: a first washcoat layer containing Mn and Cu, wherein the first washcoat layer is substantially free of Ce, preferably the first washcoat layer is free of Ce; A substrate, the substrate having an inlet end through which the exhaust gas flow can enter the catalyst and an outlet end through which the exhaust gas flow can exit the catalyst; The catalyst further comprises one or more platinum group metals, including Pt, Pd, or Pt and Pd, wherein the one or more platinum group metals are: (a) a first washcoat layer; and (b) an optional second washcoat layer; or (c) the catalyst being at least partially contained in one or more of the optional second and third washcoat layers.

[0013] Within the meaning of the present invention, a washcoat layer is substantially free of an element or compound when the washcoat layer contains the element or compound in an amount of 1 wt. % or less, preferably 0.5 wt. % or less, more preferably 0.1 wt. % or less, more preferably 0.05 wt. % or less, more preferably 0.01 wt. % or less, more preferably 0.005 wt. % or less, more preferably 0.001 wt. % or less, calculated as the element or compound, based on 100 wt. % of the washcoat layer.

[0014] Preferably, the optional second washcoat layer is substantially free of Mn, and more preferably the optional second washcoat layer is free of Mn. Note that the Mn contained in the second washcoat layer may result from leakage of Mn into that layer from another layer containing Mn, particularly from the first washcoat layer.

[0015] It is preferred that the optional second washcoat layer is substantially free of Ce, and more preferably where the optional second washcoat layer is free of Ce.

[0016] It is preferred that the optional second washcoat layer is substantially free of Cu, and more preferably where the optional second washcoat layer is free of Cu.

[0017] It is preferred that the loading of Mn in the first washcoat layer, calculated as element, is in the range of 1 to 50 wt%, more preferably 2 to 30 wt%, more preferably 5 to 20 wt%, more preferably 8 to 12 wt%, based on 100 wt% of the first washcoat layer.

[0018] It is preferred that Mn is present in the form of one or more cations of Mn, and that Mn is more preferably contained in the first washcoat layer as one or more oxides, and that Mn is more preferably contained in the first washcoat layer as one or more oxides of Mn(II), Mn(III), Mn(II / III), and Mn(IV), more preferably as 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 the following, and that the Mn-Zr mixed oxides are preferably contained in the first washcoat layer as a solid solution.

[0019] It is preferred that Cu be present in the first washcoat layer as CuO, Cu2O, or CuO and Cu2O, more preferably as CuO.

[0020] It is preferred that the loading of Cu in the first washcoat layer, calculated as an element, is in the range of 1 to 50 wt%, more preferably 2 to 30 wt%, more preferably 5 to 20 wt%, more preferably 8 to 12 wt%, based on 100 wt% of the first washcoat layer.

[0021] The first washcoat layer comprises a particulate support material, and Mn and Cu are each supported on the particulate support material, and the particulate support material is more preferably selected from the group consisting of ZrO2, Al2O3, SiO2, TiO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, praseodymium oxide-doped CeO2-ZrO2 mixed oxide, From the group consisting of ZrO2-doped AI2O3, ZrO2-doped SiO2, SiO2-doped AI2O3, CuO-AI2O3 mixed oxide, and mixtures of two or more thereof, more preferably ZrO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, Pr2O3-doped CeO2-ZrO2 mixed oxide, Pr6O 11 From the group consisting of doped CeO2-ZrO2 mixed oxide, PrO2-doped CeO2-ZrO2 mixed oxide, ZrO2-doped Al2O3, ZrO2-doped SiO2, and mixtures of two or more thereof, more preferably ZrO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, Pr2O3-doped CeO2-ZrO2 mixed oxide, Pr6O 11 Preferably, the Mn is supported on particulate La2O3-doped ZrO2, and the ZrO2 is doped with La2O3 in an amount ranging from 1 to 50 wt%, preferably 3 to 30 wt%, more preferably 5 to 15 wt%, more preferably 8 to 10 wt%, based on 100 wt% of ZrO2 and La2O3.

[0022] It is preferred that the catalyst is substantially free of Ce, and more preferably that the catalyst is free of Ce.

[0023] It is preferred that the substrate is a wall-flow or flow-through substrate, more preferably a honeycomb wall-flow or honeycomb flow-through substrate, more preferably a honeycomb flow-through substrate, and the flow-through substrate is more preferably a flow-through substrate with highly porous walls.

[0024] The loading in the first washcoat layer is 0.1 to 6 g / in 3 , more preferably 0.3 to 4 g / in 3 , more preferably 0.5 to 3 g / in 3 , more preferably 1 to 2.5 g / in 3 , more preferably 1.3 to 2.2 g / in 3 , more preferably 1.5 to 2 g / in 3 It is preferable that the range is:

[0025] Within the meaning of the present invention, the loading in a washcoat layer in a catalyst refers to the loading in the washcoat layer based on the volume of catalyst contained in the washcoat layer. Thus, within the meaning of the present invention, the loading in a washcoat layer contained only in a specific portion or zone of the catalyst is based on the volume of that portion or zone of the catalyst. Thus, as an example, if a washcoat layer is provided over 50% of the axial length of a honeycomb substrate, the loading is calculated based on 50% of the total volume of the honeycomb substrate.

[0026] The loading in the second washcoat layer is 0.25 to 6 g / in 3 , more preferably 0.3 to 6 g / in 3 , more preferably 0.5 to 5 g / in 3 , more preferably 1 to 4 g / in 3 , more preferably 1.5 to 3 g / in 3 , more preferably 2 to 2.5 g / in 3 , more preferably 1.8 to 2.2 g / in 3 It is preferable that the range is:

[0027] It is preferred that the catalyst comprises one or more platinum group metals consisting of Pt, Pd, or Pt and Pd, more preferably that the catalyst comprises Pt, or Pt and Pd as the one or more platinum group metals, and even more preferably that the catalyst comprises Pt and Pd as the one or more platinum group metals.

[0028] Catalyst, calculated as element, 2 to 250 g / ft 3 , more preferably 5 to 150 g / ft 3 , more preferably 10 to 125 g / ft 3 , more preferably 20 to 100 g / ft 3 , more preferably 25 to 85 g / ft 3 , more preferably 30 to 80 g / ft 3 , more preferably 40 to 60 g / ft 3 It is preferable that Pt is contained in a loading amount in the range of .

[0029] Within the meaning of the present invention, the loading of Pt, Pd, or Pt and Pd in ​​a catalyst refers to the loading of Pt, Pd, or Pt and Pd based on the volume of the catalyst in which Pt, Pd, or Pt and Pd are contained. If Pt, Pd, or Pt and Pd are contained in one or more zones of the catalyst, the loading of Pt, Pd, or Pt and Pd within the meaning of the present invention is preferably based on the volume of the catalyst in which one or more Pt, Pd, or Pt and Pd zones are contained. Thus, by way of example, if Pt, Pd, or Pt and Pd are provided in a zone extending over 50% of the axial length of a honeycomb substrate, the loading is calculated based on 50% of the total volume of the honeycomb substrate.

[0030] Catalyst, calculated as element, 5 to 100 g / ft 3 , more preferably 5 to 60 g / ft 3 , more preferably 10 to 50 g / ft 3 , more preferably 15 to 40 g / ft 3 , more preferably 20 to 30 g / ft 3 It is preferable that Pd is contained in a loading amount in the range of .

[0031] Catalyst, calculated as an element, 2 to 250 g / ft 3 , more preferably 5 to 200 g / ft 3 , more preferably 10 to 150 g / ft 3 , preferably 20 to 130 g / ft 3 , more preferably 30 to 125 g / ft 3 , more preferably 40 to 110 g / ft 3 , more preferably 50 to 100 g / ft 3 , more preferably 60 to 90 g / ft 3 , more preferably 70 to 80 g / ft 3 It is preferred to include Pt and Pd with a total loading of Pt and Pd in ​​the range of

[0032] It is preferred that the catalyst comprises Pt and Pd in ​​a Pt:Pd weight ratio in the range of 1:2 to 20:1, more preferably 50:50 to 80:20, more preferably 60:40 to 75:25, more preferably 65:35 to 70:30.

[0033] One or more platinum group metals are supported on a particulate support material, more preferably selected from the group consisting of AI2O3, SiO2, TiO2, SiO2-doped AI2O3, Mn-oxide-doped AI2O3, and mixtures of two or more thereof, and more preferably the one or more platinum group metals are supported on AI2O3, and / or SiO2-doped AI2O3, and / or Mn-oxide-doped AI2O3, more preferably SiO2-doped AI2O3, or AI2O3, or Mn-oxide-doped AI2O3, the Mn-oxide-doped AI2O3 preferably containing 1 to 10 wt. %, more preferably 4 to 6 wt. %, Mn oxide, calculated as MnO2, based on 100 wt. % Mn-oxide-doped AI2O3.

[0034] It is preferred that the catalyst comprises a second washcoat layer, and that the one or more platinum group metals are at least partially contained in the second washcoat layer, and more preferably that the one or more platinum group metals are completely contained in the second washcoat layer.

[0035] The first washcoat layer preferably comprises a hydrocarbon trap material, the first washcoat layer comprising a hydrocarbon trap material, the hydrocarbon trap material comprising a molecular sieve, preferably a zeolite, more preferably a zeolite having a maximum pore size of 12-membered rings, more preferably zeolite beta, the molecular sieve, preferably the zeolite, preferably comprising SiO2 and Al2O3, the molecular sieve, preferably the zeolite, preferably having a pore size of 10:1 to 500:1, more preferably 1 The molecular sieve, preferably a zeolite, preferably has a molar ratio of SiO2 to Al2O3 in the range of 0:1 to 100:1, more preferably 10:1 to 40:1, more preferably 15:1 to 30:1, more preferably 20:1 to 25:1, and the molecular sieve, preferably a zeolite, preferably contains Fe, and the molecular sieve, preferably a zeolite, more preferably contains Fe in an amount in the range of 1.0 to 7.0 wt. %, more preferably 3.0 to 5.0 wt. %, more preferably 4.0 to 4.5 wt. %, calculated as Fe2O3, based on the weight of the molecular sieve.

[0036] When the first washcoat layer includes a hydrocarbon trap material, and the hydrocarbon trap material includes a molecular sieve, the loading of the hydrocarbon trap material in the first washcoat layer is 0.01 to 2.0 g / in 3 in the range of 0.05 to 1.0 g / in 3 g / in 3 It is preferable that the range is:

[0037] The second washcoat layer comprises a hydrocarbon trap material, the hydrocarbon trap material comprising a molecular sieve, more preferably a zeolite, more preferably a zeolite having a maximum pore size defined by a 12-membered ring, more preferably zeolite beta, the molecular sieve, preferably the zeolite, preferably comprising SiO2 and Al2O3, the molecular sieve, preferably the zeolite, more preferably having a pore size ratio of 10:1 to 500:1, more preferably 10:1 to 100:1, more preferably has a molar ratio of SiO2 to Al2O3 in the range of 10:1 to 40:1, more preferably 15:1 to 30:1, more preferably 20:1 to 25:1, and the molecular sieve, preferably zeolite, preferably contains Fe, and the molecular sieve, preferably zeolite, more preferably contains Fe in an amount in the range of 1.0 to 7.0 wt. %, more preferably 3.0 to 5.0 wt. %, more preferably 4.0 to 4.5 wt. %, calculated as Fe2O3, based on the weight of the molecular sieve.

[0038] When the second washcoat layer includes a hydrocarbon trap material, and the hydrocarbon trap material includes a molecular sieve, the loading of the hydrocarbon trap material in the second washcoat layer is 0.01 to 2.0 g / in 3 in the range of 0.05 to 1.0 g / in 3 g / in 33 in the range of 0.05 to 0.3 g / in 3 It is preferable that the range is:

[0039] According to a first alternative, the catalyst preferably comprises a second washcoat layer, the catalyst exhibiting a layered arrangement of the first washcoat layer and the second washcoat layer, and the one or more platinum group metals being at least partially contained in the second washcoat layer.

[0040] When the catalyst comprises a second washcoat layer, the catalyst exhibits a layered arrangement of a first washcoat layer and a second washcoat layer, and one or more platinum group metals are at least partially contained in the second washcoat layer, it is preferred, according to a first alternative, that the first washcoat layer is provided on the substrate and the second washcoat layer is provided on the first washcoat layer.

[0041] Furthermore, when the catalyst comprises a second washcoat layer, the catalyst exhibits a layered arrangement of a first washcoat layer and a second washcoat layer, and one or more platinum group metals are at least partially contained in the second washcoat layer, it is preferred, according to a first alternative, that the second washcoat layer is provided on the substrate and the first washcoat layer is provided on the second washcoat layer.

[0042] Furthermore, when the catalyst comprises a second washcoat layer, the catalyst exhibits a layered arrangement of the first washcoat layer and the second washcoat layer, and the one or more platinum group metals are at least partially contained in the second washcoat layer, according to a first alternative, the catalyst comprises a third washcoat layer, the catalyst exhibits a zoned arrangement of the first washcoat layer, the second washcoat layer, and the third washcoat layer, and the third washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate. Preferably, a first washcoat layer is disposed on the substrate along its axial length beginning at the outlet end of the substrate, a second washcoat layer is disposed completely over the first washcoat layer, the length of the first washcoat layer is less than the axial length of the substrate to create an upstream zone including the third washcoat layer and a downstream zone including the first and second washcoat layers, and one or more platinum group metals are at least partially contained in the third washcoat layer. Alternatively, it is preferred that the catalyst includes a third washcoat layer, the catalyst exhibiting a zoned arrangement of a first washcoat layer, a second washcoat layer, and a third washcoat layer, the third washcoat layer being disposed on the substrate along its axial length starting from the inlet end of the substrate, the second washcoat layer being disposed on the substrate along its axial length starting from the outlet end of the substrate, the first washcoat layer being disposed completely over the second washcoat layer, the length of the second washcoat layer being shorter than the axial length of the substrate to create an upstream zone comprising the third washcoat layer and a downstream zone comprising the first and second washcoat layers, and the one or more platinum group metals being at least partially contained in the third washcoat layer.Alternatively, it is preferred that the catalyst includes a third washcoat layer, the catalyst exhibiting a zoned arrangement of the first, second, and third washcoat layers, the third washcoat layer being disposed on the substrate along its axial length beginning at the outlet end of the substrate, the first washcoat layer being disposed on the substrate along its axial length beginning at the inlet end of the substrate, and the second washcoat layer being disposed completely over the first washcoat layer, the length of the first washcoat layer being shorter than the axial length of the substrate to create a downstream zone comprising the third washcoat layer and an upstream zone comprising the first and second washcoat layers, and the one or more platinum group metals being at least partially contained in the third washcoat layer. Alternatively, it is preferred that the catalyst includes a third washcoat layer, the catalyst exhibiting a zoned arrangement of the first, second, and third washcoat layers, the third washcoat layer being disposed on the substrate along its axial length beginning at the outlet end of the substrate, the second washcoat layer being disposed on the substrate along its axial length beginning at the inlet end of the substrate, the first washcoat layer being disposed completely over the second washcoat layer, the length of the second washcoat layer being shorter than the axial length of the substrate to create a downstream zone comprising the third washcoat layer and an upstream zone comprising the first and second washcoat layers, and the one or more platinum group metals being at least partially contained in the third washcoat layer.

[0043] According to a second alternative, the catalyst comprises a second washcoat layer, the catalyst exhibiting a zoned arrangement of the first and second washcoat layers, the second washcoat layer being provided on the substrate along its axial length starting from the inlet end of the substrate, the first washcoat layer being provided on the substrate along its axial length starting from the outlet end of the substrate, the length of the first washcoat layer being shorter than the axial length of the substrate so as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and it is preferred that the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0044] According to a third alternative, the catalyst preferably comprises a second washcoat layer, wherein a first washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate, and a second washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate, the length of the first washcoat layer being shorter than the axial length of the substrate so as to create an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0045] According to a fourth alternative, the catalyst comprises a second washcoat layer, the catalyst exhibits a zoned arrangement of the first and second washcoat layers, the second washcoat layer being provided on the substrate along its axial length starting from the inlet end of the substrate, the first washcoat layer being provided on the substrate along its axial length starting from the outlet end of the substrate, the length of the second washcoat layer being shorter than the axial length of the substrate so as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and it is preferred that the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0046] According to a fifth alternative, the catalyst comprises a second washcoat layer, the catalyst exhibiting a zoned arrangement of the first and second washcoat layers, the first washcoat layer being provided on the substrate along its axial length starting from the inlet end of the substrate, the second washcoat layer being provided on the substrate along its axial length starting from the outlet end of the substrate, the length of the second washcoat layer being shorter than the axial length of the substrate so as to create an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and it is preferred that the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0047] When the catalyst includes a second washcoat layer and the catalyst exhibits a zoned arrangement of the first and second washcoat layers according to the second or fourth alternative, it is preferred that the catalyst includes a third washcoat layer, the third washcoat layer being disposed on the first layer, the catalyst exhibits a zoned arrangement of the second and third washcoat layers, the second washcoat layer being disposed on the substrate along the axial length of the substrate starting from the inlet end of the substrate, and the third washcoat layer being disposed on the first washcoat layer along the axial length of the substrate starting from the outlet end of the substrate, the length of the third washcoat layer being shorter than the axial length of the substrate so as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first and third washcoat layers.

[0048] When the catalyst includes a second washcoat layer and the catalyst exhibits a zoned arrangement of the first and second washcoat layers according to the third or fifth alternative, it is preferred that the catalyst includes a third washcoat layer, the third washcoat layer being disposed on the first layer, the catalyst exhibits a zoned arrangement of the second and third washcoat layers, the third washcoat layer being disposed on the first washcoat layer along the axial length of the substrate starting from the inlet end of the substrate, and the second washcoat layer being disposed on the substrate along the axial length of the substrate starting from the outlet end of the substrate, and the length of the third washcoat layer being shorter than the axial length of the substrate to create an upstream zone comprising the first and third washcoat layers, and a downstream zone comprising the second washcoat layer.

[0049] When the catalyst comprises a second washcoat layer and the catalyst exhibits a zoned arrangement of the first and second washcoat layers according to the second, third, fourth, or fifth alternative, it is preferred that the first and second washcoat layers are adjacent to each other.

[0050] Furthermore, when the catalyst comprises a second washcoat layer and the catalyst exhibits a zoned arrangement of the first and second washcoat layers according to the second, third, fourth, or fifth alternative, it is preferred that the second and third washcoat layers are adjacent to each other.

[0051] Furthermore, when the catalyst comprises a second washcoat layer and the catalyst exhibits a zoned arrangement of the first and second washcoat layers according to the second, third, fourth, or fifth alternative, it is preferred that a portion of the second washcoat layer overlaps at least a portion of the first washcoat layer, and preferably the second washcoat layer overlaps the first washcoat layer over a portion in the range of 5 to 100% of the axial length of the substrate, preferably 10 to 100%, more preferably 15 to 80%, more preferably 20 to 50% of the axial length of the first washcoat layer.

[0052] Furthermore, when the catalyst comprises a second washcoat layer and the catalyst exhibits a zoned arrangement of the first and second washcoat layers according to the second, third, fourth, or fifth alternative, it is preferred that a portion of the first washcoat layer overlaps at least a portion of the second washcoat layer, and more preferably that the first washcoat layer overlaps the second washcoat layer over a portion in the range of 5 to 100% of the axial length of the substrate, preferably 10 to 100%, more preferably 15 to 80%, more preferably 20 to 50% of the axial length of the second washcoat layer.

[0053] Furthermore, when the catalyst comprises a second washcoat layer and the catalyst exhibits a zoned arrangement of the first and second washcoat layers according to the second, third, fourth, or fifth alternative, it is preferred that a portion of the third washcoat layer overlaps at least a portion of the first washcoat layer, and preferably the third washcoat layer overlaps the first washcoat layer over a portion in the range of 10 to 100%, more preferably 15 to 80%, more preferably 20 to 50% of the axial length of the first washcoat layer.

[0054] According to a sixth alternative, the catalyst comprises a second washcoat layer, the catalyst exhibiting a zoned arrangement of the first and second washcoat layers, the second washcoat layer being provided on the substrate along its entire length, the first washcoat layer being provided on the second washcoat layer along its axial length starting from the outlet end of the substrate, the length of the first washcoat layer being shorter than the axial length of the substrate so as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and it is preferred that the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0055] According to a seventh alternative, the catalyst comprises a second washcoat layer, the catalyst exhibiting a zoned arrangement of the first and second washcoat layers, the second washcoat layer being provided on the substrate along its entire length, the first washcoat layer being provided on the second washcoat layer along its axial length starting from the inlet end of the substrate, the length of the first washcoat layer being shorter than the axial length of the substrate so as to create an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and it is preferred that the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0056] When the catalyst comprises a second washcoat layer and the catalyst exhibits a zoned arrangement of the first and second washcoat layers according to the sixth or seventh alternative, it is preferred that the length of the first washcoat layer is in the range of 10 to 90%, more preferably 30 to 80%, more preferably 50 to 70% of the axial length of the substrate.

[0057] According to an eighth alternative, the catalyst comprises a second washcoat layer, the catalyst exhibiting a zoned arrangement of the first and second washcoat layers, the first washcoat layer being provided on the substrate along its entire length, the second washcoat layer being provided on the first washcoat layer along its axial length starting from the inlet end of the substrate, the length of the second washcoat layer being shorter than the axial length of the substrate so as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and it is preferred that the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0058] When the catalyst includes a second washcoat layer and the catalyst exhibits a zoned arrangement of the first and second washcoat layers according to the eighth alternative, it is preferred that the catalyst includes a third washcoat layer, the third washcoat layer being disposed on the first layer, the catalyst exhibits a zoned arrangement of the second and third washcoat layers, the second washcoat layer being disposed on the first washcoat layer along the axial length of the substrate starting from the inlet end of the substrate, and the third washcoat layer being disposed on the first washcoat layer along the axial length of the substrate starting from the outlet end of the substrate, and the length of the third washcoat layer being shorter than the axial length of the substrate to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the third washcoat layer.

[0059] According to a ninth alternative, the catalyst comprises a second washcoat layer, the catalyst exhibiting a zoned arrangement of the first and second washcoat layers, the first washcoat layer being provided on the substrate along its entire length, the second washcoat layer being provided on the first washcoat layer along its axial length starting from the outlet end of the substrate, the length of the second washcoat layer being shorter than the axial length of the substrate so as to create an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and it is preferred that the one or more platinum group metals are at least partially contained in the second washcoat layer.

[0060] When the catalyst includes a second washcoat layer and the catalyst exhibits a zoned arrangement of the first and second washcoat layers according to the ninth alternative, it is preferred that the catalyst includes a third washcoat layer, the third washcoat layer being disposed on the first layer, the catalyst exhibits a zoned arrangement of the second and third washcoat layers, the third washcoat layer being disposed on the first washcoat layer along the axial length of the substrate starting from the inlet end of the substrate, and the second washcoat layer being disposed on the first washcoat layer along the axial length of the substrate starting from the outlet end of the substrate, and the length of the third washcoat layer being shorter than the axial length of the substrate to create an upstream zone comprising the third washcoat layer and a downstream zone comprising the second washcoat layer.

[0061] When the catalyst comprises a second washcoat layer, the catalyst exhibits a zoned arrangement of the first and second washcoat layers according to the eighth or ninth alternative, and the catalyst comprises a third washcoat layer, it is preferred that the second and third washcoat layers are adjacent to each other.

[0062] The length of the first washcoat layer is preferably in the range of 5 to 100% of the axial length of the substrate, more preferably 10 to 90% of the axial length of the substrate, preferably 15 to 75%, more preferably 20 to 60%, more preferably 25 to 50%, more preferably 35 to 45%.

[0063] When the catalyst comprises a second washcoat layer and the catalyst exhibits a zoned arrangement of the first and second washcoat layers, preferably according to the eighth or ninth alternative, it is preferred that the length of the second washcoat layer is in the range of 5 to 100% of the axial length of the substrate, more preferably 10 to 90%, more preferably 15 to 75%, more preferably 20 to 60%, more preferably 25 to 50%, more preferably 35 to 45% of the axial length of the substrate.

[0064] When the catalyst includes a second washcoat layer and a third washcoat layer, the length of the third washcoat layer is preferably in the range of 5 to 100% of the axial length of the substrate, preferably 10 to 90%, more preferably 15 to 75%, more preferably 20 to 60%, more preferably 25 to 50%, and more preferably 35 to 45% of the axial length of the substrate.

[0065] Furthermore, when the catalyst comprises a second washcoat layer and a third washcoat layer, it is preferred that the third washcoat layer is substantially free of sulfur trapping material, and preferably the third washcoat layer is free of sulfur trapping material.

[0066] Furthermore, when the catalyst comprises a second washcoat layer and a third washcoat layer, the third layer comprises a hydrocarbon trap material, and the hydrocarbon trap 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, and the molecular sieve, preferably the zeolite, preferably comprises SiO2 and Al2O3, and the molecular sieve, preferably the zeolite, preferably has a pore size of 10:1 to 500:1, more preferably 10:1 to 1000:1. Preferably, the molecular sieve, preferably the zeolite, has a molar ratio of SiO2 to Al2O3 in the range of 0.00:1, more preferably 10:1 to 40:1, more preferably 15:1 to 30:1, more preferably 20:1 to 25:1, and the molecular sieve, preferably the zeolite, preferably contains Fe, and the molecular sieve, preferably the zeolite, more preferably contains Fe in an amount in the range of 1.0 to 7.0 wt. %, more preferably 3.0 to 5.0 wt. %, more preferably 4.0 to 4.5 wt. %, calculated as Fe2O3, based on the weight of the molecular sieve.

[0067] If the third layer includes a hydrocarbon trapping material, the loading of the hydrocarbon trapping material in the third washcoat layer is 0.01 to 2.0 g / in 3 in the range of 0.05 to 1.0 g / in 3 in the range of 0.05 to 0.3 g / in 3 It is preferable that the range is:

[0068] Furthermore, when the catalyst comprises a second washcoat layer and a third washcoat layer, it is preferred that the one or more platinum group metals are at least partially contained in the third washcoat layer.

[0069] When one or more platinum group metals are at least partially contained in the third washcoat layer, the one or more platinum group metals are supported on a particulate support material, preferably selected from the group consisting of Al2O3, SiO2, TiO2, SiO2-doped Al2O3, Mn-oxide-doped Al2O3, and mixtures of two or more thereof, and preferably the one or more platinum group metals are supported on Al2O3, and / or SiO2-doped Al2O3, and / or Mn-oxide-doped Al2O3, more preferably SiO2-doped Al2O3, or Al2O3, or Mn-oxide-doped Al2O3, and the Mn-oxide-doped Al2O3 preferably contains 1 to 10 wt. %, more preferably 4 to 6 wt. %, Mn oxide, calculated as MnO2, based on 100 wt. % Mn-oxide-doped Al2O3.

[0070] Furthermore, when the catalyst comprises a second washcoat layer and a third washcoat layer, it is preferred that the catalyst comprises the second washcoat layer and the third washcoat layer, the one or more platinum group metals are completely contained in the second washcoat layer and the third washcoat layer, the weight ratio of the one or more platinum group metals contained in the second washcoat layer to the one or more platinum group metals contained in the third washcoat layer is in the range of 0.5:1 to 5.0:1, more preferably 1.0:1 to 2.0:1, more preferably 1.4:1 to 1.6:1, the one or more platinum group metals contained in the second washcoat layer preferably include, and more preferably consist of, Pt and Pd, and the one or more platinum group metals contained in the third washcoat layer preferably include, and more preferably consist of Pt and Pd.

[0071]

[0023] When the catalyst comprises a second washcoat layer and the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer according to the second, third, fourth, fifth, sixth, seventh, eighth, or ninth alternative, the loading of Mn in the zone of the catalyst comprising the first washcoat layer, calculated as the element, is between 0.01 and 1 g / in, based on the volume of the zone of the catalyst containing the first washcoat layer. 3, more preferably 0.05 to 0.5 g / in 3 , more preferably 0.08 to 0.35 g / in 3 , more preferably 0.1 to 0.25 g / in 3 , more preferably 0.13 to 0.2 g / in 3 , more preferably 0.15 to 0.18 g / in 3 It is preferable that the range is:

[0072] Furthermore, when the catalyst comprises a second washcoat layer and the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer according to the second, third, fourth, fifth, sixth, seventh, eighth, or ninth alternative, the loading of Cu in the zone of the catalyst comprising the first washcoat layer, calculated as element, is between 0.01 and 1.5 g / in, based on the volume of the zone of the catalyst containing the first washcoat layer. 3 , more preferably 0.05 to 1 g / in 3 , more preferably 0.1 to 0.5 g / in 3 , more preferably 0.13 to 0.35 g / in 3 , more preferably 0.15 to 0.25 g / in 3 , more preferably 0.17 to 0.22 g / in 3 It is preferable that the range is:

[0073] Preferably, the one or more platinum group metals are contained entirely in the second washcoat layer, or in the second and third washcoat layers, or alternatively, at least partially in the first washcoat layer.

[0074] It is preferred that the substrate is a metallic substrate or a ceramic substrate, more preferably the substrate is a ceramic substrate, more preferably the substrate comprises cordierite and / or SiC, preferably cordierite, more preferably the substrate consists of cordierite and / or SiC, preferably cordierite.

[0075] When the catalyst comprises a second washcoat layer and the catalyst exhibits a zoned arrangement of the first and second washcoat layers according to the second, third, fourth, fifth, sixth, seventh, eighth or ninth alternative, the substrate consists of two separate monoliths, the first monolith being provided upstream of the second monolith, the washcoat layer or layers of the upstream zone being contained on the first monolith and the washcoat layer or layers of the downstream zone being contained on the second monolith, more preferably the washcoat layer or layers of the upstream zone being contained on the first monolith and the washcoat layer or layers of the downstream zone being contained on the second monolith. The first monolith containing the washcoat layer and the second monolith containing the downstream zone washcoat layer or layers are obtained or obtainable by compartmentalizing the catalyst according to any one of the embodiments disclosed herein into two separate monoliths, according to any one of the second, third, fourth, fifth, sixth, seventh, eighth and ninth alternatives, wherein the upstream zone washcoat layer or layers are contained on the first monolith and the downstream zone washcoat layer or layers are contained on the second monolith.

[0076] It is preferred that the exhaust gas stream contains hydrocarbons, preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons.

[0077] The present invention further relates to an exhaust gas treatment system comprising an internal combustion engine and an exhaust gas conduit for exhaust gases from the internal combustion engine, wherein the exhaust gas conduit contains one or more catalysts according to any one of the embodiments disclosed herein, preferably one, two, three, or four catalysts according to any of the embodiments disclosed herein.

[0078] Preferably, the internal combustion engine is a compression ignition engine, more preferably a diesel engine.

[0079] Preferably the internal combustion engine is a lean gasoline engine.

[0080] Alternatively, the internal combustion engine is powered by an oxygenated fuel, which preferably comprises one or more of methanol and biofuel.

[0081] Preferably, the system includes one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC).

[0082] According to a first alternative, the system preferably comprises, in consecutive order in the direction of the exhaust gases, optionally an electric heater or 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 catalyzed soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst.

[0083] According to a second alternative, the system preferably comprises, in consecutive order in the direction of the exhaust gases, optionally an electric heater or 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.

[0084] According to a third alternative, the system preferably comprises, in sequential order in the direction of the exhaust gases, optionally an electric heater or 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.

[0085] According to a fourth alternative, the system preferably comprises, in consecutive order in the direction of the exhaust gases, optionally an electric heater or 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.

[0086] According to a fifth alternative, the system comprises, in consecutive order in the direction of the exhaust gases, optionally an electric heater or 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, and wherein the substrates are preferably a wall-flow substrate, a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0087] According to a sixth alternative, the system preferably comprises, in consecutive order in the direction of the exhaust gases, optionally an electric heater or 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 catalyzed soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst.

[0088] According to a seventh alternative, the system preferably comprises, in consecutive order in the direction of the exhaust gases, optionally an electric heater or 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 catalyzed soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0089] According to an eighth alternative, the system comprises, in sequential order in the direction of the exhaust gases, optionally an electric heater or 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, optional fuel injector, a catalyst according to any of the embodiments disclosed herein, and preferably the substrates are a wall-flow substrate, a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0090] According to a ninth alternative, the system preferably comprises, in sequential order in the direction of the exhaust gases, optionally an electric heater or 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 over filter (SCRoF), and an ammonia oxidation (AMOX) catalyst.

[0091] According to a tenth alternative, the system preferably comprises, in sequential order in the direction of the exhaust gases, optionally an electric heater or fuel burner and / or 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 over filter (SCRoF), and an ammonia oxidation (AMOX) catalyst.

[0092] According to an eleventh alternative, the system preferably comprises, in consecutive order in the direction of the exhaust gases, optionally an electric heater or fuel burner and / or fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of the embodiments disclosed herein, a catalyzed soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0093] According to a twelfth alternative, the system comprises, in sequential order in the direction of the exhaust gases, optionally an electric heater or fuel burner and / or 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, and preferably the substrates are a wall-flow substrate, a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0094] According to a thirteenth alternative, it is preferred that the system comprises, in consecutive order in the direction of the exhaust gases, optionally an electric heater or 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.

[0095] According to a fourteenth alternative, the system preferably comprises, in sequential order in the direction of the exhaust gases, optionally an electric heater or fuel burner and / or a fuel injector, a catalyst according to any of the embodiments disclosed herein, a selective catalytic reduction catalyst on filter (SCRoF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0096] According to a fifteenth alternative, the system preferably comprises, in consecutive order in the direction of the exhaust gases, optionally an electric heater or fuel burner and / or a fuel injector, a catalyst according to any of the embodiments disclosed herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction catalyst on a filter (SCRoF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.

[0097] Still further, the present invention provides a method for the treatment of an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons, the method comprising: (A) providing an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons; (B) directing the exhaust gas stream provided in (A) through a catalyst according to any one of the embodiments disclosed herein.

[0098] Preferably, the exhaust gas stream provided in (A) comprises one or more sulfur-containing compounds, more preferably SO2 and / or SO3.

[0099] The exhaust gas flow provided at (A) is NO X It is preferred that the compound contains:

[0100] Preferably, the exhaust gas stream provided in (A) comprises CO.

[0101] Preferably, the exhaust gas stream provided in (A) comprises formaldehyde.

[0102] Preferably, the exhaust gas stream provided in (A) comprises nitrogen oxides (NO).

[0103] It is preferred that the exhaust gas stream provided in (A) comprises hydrocarbons, more preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons.

[0104] Still further, the present invention relates to the use of a catalyst according to any one of the embodiments disclosed herein for the oxidation of one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons, preferably for the oxidation of one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons in an exhaust gas stream, more preferably for the oxidation of one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons in the exhaust gas stream of an internal combustion engine, more preferably for the oxidation of one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons in the exhaust gas stream of a compression ignition engine, more preferably for the oxidation of one or more of formaldehyde, nitrogen oxides (NO) and hydrocarbons in the exhaust gas stream of a diesel engine.

[0105] The present invention is further illustrated by the following set of embodiments and combinations of embodiments resulting from the dependencies and reverse references as indicated. In particular, in each case where a range of embodiments is mentioned, for example, in the context of a term such as "the catalyst of any one of embodiments 1 to 4," it is noted that all embodiments within this range are expressly disclosed to those skilled in the art, that is, this expression is understood by those skilled in the art to be synonymous with "the catalyst of any one of embodiments 1, 2, 3, and 4." Furthermore, it is clearly noted that the following set of embodiments represents a suitably structured portion of a general description directed to preferred aspects of the present invention, and therefore suitably supports, but does not represent, the scope of the claims of the present invention.

[0106] 1. A catalyst for the treatment of an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons, the catalyst comprising: a first washcoat layer containing Mn and Cu, wherein the first washcoat layer is substantially free of Ce, preferably the first washcoat layer is free of Ce; A substrate, the substrate having an inlet end through which the exhaust gas flow can enter the catalyst and an outlet end through which the exhaust gas flow can exit the catalyst; The catalyst further comprises one or more platinum group metals, including Pt, Pd, or Pt and Pd, wherein the one or more platinum group metals are: (a) a first washcoat layer; and (b) an optional second washcoat layer; or (c) a catalyst at least partially contained in one or more of the optional second and third washcoat layers. 2. The catalyst of embodiment 1, wherein the optional second washcoat layer is substantially free of Mn, preferably the optional second washcoat layer is free of Mn. 3. The catalyst of embodiment 1 or 2, wherein the optional second washcoat layer is substantially free of Ce, preferably the optional second washcoat layer is free of Ce. 4. The catalyst of any of embodiments 1-3, wherein the optional second washcoat layer is substantially free of Cu, preferably the optional second washcoat layer is free of Cu. 5. The catalyst of any of embodiments 1-4, wherein the loading of Mn in the first washcoat layer, calculated as element, is in the range of 1 to 50 wt.%, preferably 2 to 30 wt.%, more preferably 5 to 20 wt.%, more preferably 8 to 12 wt.%, based on 100 wt.% of the first washcoat layer. 6. The catalyst of any one of embodiments 1 to 5, wherein Mn is present in the form of one or more cations of Mn, and wherein Mn is preferably contained in the first washcoat layer as one or more oxides, 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, including mixtures of two or more of the following, and wherein the Mn-Zr mixed oxides are preferably contained in the first washcoat layer as a solid solution. 7. The catalyst of any of embodiments 1-6, wherein the Cu is present in the first washcoat layer as CuO, Cu2O, or CuO and Cu2O, more preferably as CuO, and the loading of Cu in the first washcoat layer, calculated as element, is in the range of 1 to 50 wt%, more preferably 2 to 30 wt%, more preferably 5 to 20 wt%, more preferably 8 to 12 wt%, based on 100 wt% of the first washcoat layer. 8. The first washcoat layer comprises a particulate support material, and Mn and Cu are each supported on the particulate support material, and the particulate support material is preferably selected from the group consisting of ZrO2, AI2O3, SiO2, TiO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, praseodymium oxide-doped CeO2-ZrO2 mixed oxide, From the group consisting of ZrO2-doped AI2O3, ZrO2-doped SiO2, SiO2-doped AI2O3, CuO-AI2O3 mixed oxide, and mixtures of two or more thereof, more preferably ZrO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, Pr2O3-doped CeO2-ZrO2 mixed oxide, Pr6O 11From the group consisting of doped CeO2-ZrO2 mixed oxide, PrO2-doped CeO2-ZrO2 mixed oxide, ZrO2-doped Al2O3, ZrO2-doped SiO2, and mixtures of two or more thereof, more preferably ZrO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, Pr2O3-doped CeO2-ZrO2 mixed oxide, Pr6O 11 8. The catalyst of any of embodiments 1-7, wherein the Mn is selected from the group consisting of: doped CeO-ZrO, and mixtures of two or more thereof, more preferably Mn is supported on particulate LaO-doped ZrO, preferably ZrO is doped with La in an amount ranging from 1 to 50 wt. %, preferably 3 to 30 wt. %, more preferably 5 to 15 wt. %, more preferably 8 to 10 wt. %, based on 100 wt. % ZrO and LaO. 9. The catalyst of any of embodiments 1-8, wherein the catalyst is substantially free of Ce, preferably the catalyst is free of Ce. 10. The catalyst of any of embodiments 1-9, wherein the substrate is a wall-flow substrate or a flow-through substrate, preferably a honeycomb wall-flow substrate or a honeycomb flow-through substrate, more preferably a honeycomb flow-through substrate, and the flow-through substrate is more preferably a flow-through substrate having highly porous walls. 11. The loading in the first washcoat layer is 0.1 to 6 g / in 3 , preferably 0.3 to 4 g / in 3 , more preferably 0.5 to 3 g / in 3 , more preferably 1 to 2.5 g / in 3 , more preferably 1.3 to 2.2 g / in 3 , more preferably 1.5 to 2 g / in 3 11. The catalyst of any of embodiments 1 to 10, wherein 12. The loading in the second washcoat layer is 0.25 to 6 g / in 3 , preferably 0.3 to 6 g / in 3 , more preferably 0.5 to 5 g / in 3, more preferably 1 to 4 g / in 3 , more preferably 1.5 to 3 g / in 3 , more preferably 2 to 2.5 g / in 3 , more preferably 1.8 to 2.2 g / in 3 12. The catalyst of any one of embodiments 1 to 11, wherein 13. The catalyst of any of embodiments 1-12, wherein the catalyst comprises one or more platinum group metals consisting of Pt, Pd, or Pt and Pd; preferably, the catalyst comprises Pt, or Pt and Pd as the one or more platinum group metals; more preferably, the catalyst comprises Pt and Pd as the one or more platinum group metals. 14. The catalyst, calculated as element, is 2 to 250 g / ft 3 , preferably 5 to 150 g / ft 3 , more preferably 10 to 125 g / ft 3 , more preferably 20 to 100 g / ft 3 , more preferably 30 to 80 g / ft 3 , more preferably 25 to 85 g / ft 3 , more preferably 40 to 60 g / ft 3 14. The catalyst of any of embodiments 1-13, comprising Pt at a loading in the range of 15. The catalyst, calculated as element, is 5 to 100 g / ft 3 , preferably 5 to 60 g / ft 3 , more preferably 10 to 50 g / ft 3 , more preferably 15 to 40 g / ft 3 , more preferably 20 to 30 g / ft 3 15. The catalyst of any of embodiments 1-14, comprising Pd at a loading in the range of 16. The catalyst, calculated as an element, is 2 to 250 g / ft 3 , preferably 5 to 200 g / ft 3 , more preferably 10 to 150 g / ft 3 , preferably 20 to 130 g / ft 3 , more preferably 30 to 125 g / ft 3 , more preferably 40 to 110 g / ft 3 , more preferably 50 to 100 g / ft 3, more preferably 60 to 90 g / ft 3 , more preferably 70 to 80 g / ft 3 16. The catalyst of any of embodiments 1-15, comprising Pt and Pd, with a total loading of Pt and Pd in ​​the range of 17. The catalyst of any of embodiments 1-16, wherein the catalyst comprises Pt and Pd in ​​a Pt:Pd weight ratio ranging from 1:2 to 20:1, preferably from 50:50 to 80:20, more preferably from 60:40 to 75:25, more preferably from 65:35 to 70:30. 18. The catalyst of any of embodiments 1-17, wherein the one or more platinum group metals are supported on a particulate support material, 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 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 SiO2-doped Al2O3, or Al2O3, or Mn-oxide-doped Al2O3, and the Mn-oxide-doped Al2O3 preferably contains 1 to 10 wt. %, more preferably 4 to 6 wt. %, Mn oxide, calculated as MnO2, based on 100 wt. % Mn-oxide-doped Al2O3. 19. The catalyst of any of embodiments 1-18, wherein the catalyst comprises a second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer, preferably, the one or more platinum group metals are completely contained in the second washcoat layer. 20. The first washcoat layer comprises a hydrocarbon trap material, the hydrocarbon trap material comprising a molecular sieve, preferably a zeolite, more preferably a zeolite having a maximum pore size of 12-membered rings, more preferably zeolite beta, the molecular sieve, preferably the zeolite, preferably comprising SiO2 and Al2O3, the molecular sieve, preferably the zeolite, more preferably having a pore size of 10:1 to 500:1, more preferably 10:1 to 100:1, more preferably 10:1 to 40 19. The catalyst of any of embodiments 1-19, wherein the molecular sieve, preferably zeolite, preferably contains Fe, and the molecular sieve, preferably zeolite, more preferably contains Fe in an amount ranging from 1.0 to 7.0 wt. %, more preferably 3.0 to 5.0 wt. %, more preferably 4.0 to 4.5 wt. %, calculated as FeO, based on the weight of the molecular sieve. 21. The loading of hydrocarbon trap material in the first washcoat layer is 0.01 to 2.0 g / in 3 in the range of 0.05 to 1.0 g / in 3 in the range of 0.05 to 0.3 g / in 3 21. The catalyst of embodiment 20, wherein 22. The second washcoat layer comprises a hydrocarbon trap material, the hydrocarbon trap material comprising a molecular sieve, preferably a zeolite, more preferably a zeolite having a maximum pore size defined by a 12-membered ring, more preferably zeolite beta, the molecular sieve, preferably the zeolite, preferably comprising SiO2 and Al2O3, the molecular sieve, preferably the zeolite, more preferably having a pore ratio of 10:1 to 500:1, more preferably 10:1 to 100:1, more preferably 10: 22. The catalyst of any of embodiments 1-21, having a molar ratio of SiO2 to Al2O3 in the range of 1 to 40:1, more preferably 15:1 to 30:1, more preferably 20:1 to 25:1, and wherein the molecular sieve, preferably zeolite, preferably contains Fe, and the molecular sieve, preferably zeolite, more preferably contains Fe in an amount in the range of 1.0 to 7.0 wt. %, more preferably 3.0 to 5.0 wt. %, more preferably 4.0 to 4.5 wt. %, calculated as Fe2O3, based on the weight of the molecular sieve. 23. The loading of the hydrocarbon trap material in the second washcoat layer is 0.01 to 2.0 g / in 3 in the range of 0.05 to 1.0 g / in 3 g / in 3 in the range of 0.05 to 0.3 g / in 3 23. The catalyst of embodiment 22, wherein 24. The catalyst of any of embodiments 1-23, wherein the catalyst comprises a second washcoat layer, the catalyst exhibiting a layered arrangement of the first washcoat layer and the second washcoat layer, and the one or more platinum group metals are at least partially contained in the second washcoat layer. 25. The catalyst of embodiment 24, wherein a first washcoat layer is provided on the substrate, and a second washcoat layer is provided on the first washcoat layer. 26. The catalyst of embodiment 24 or 25, wherein a second washcoat layer is provided on the substrate, and the first washcoat layer is provided on the second washcoat layer. 27. The catalyst of embodiment 24 or 25, wherein the catalyst comprises a third washcoat layer, the catalyst exhibiting a zoned arrangement of the first washcoat layer, the second washcoat layer, and the third washcoat layer, the third washcoat layer being disposed on the substrate along its axial length starting from an inlet end of the substrate, the first washcoat layer being disposed on the substrate along its axial length starting from an outlet end of the substrate, and the second washcoat layer being disposed completely over the first washcoat layer, the length of the first washcoat layer being less than the axial length of the substrate so as to create an upstream zone comprising the third washcoat layer and a downstream zone comprising the first washcoat layer and the second washcoat layer, and the one or more platinum group metals are at least partially contained in the third washcoat layer. 28. The catalyst of embodiment 24 or 26, wherein the catalyst comprises a third washcoat layer, the catalyst exhibiting a zoned arrangement of the first washcoat layer, the second washcoat layer, and the third washcoat layer, the third washcoat layer being disposed on the substrate along its axial length starting from an inlet end of the substrate, the second washcoat layer being disposed on the substrate along its axial length starting from an outlet end of the substrate, the first washcoat layer being disposed completely over the second washcoat layer, the length of the second washcoat layer being less than the axial length of the substrate so as to create an upstream zone comprising the third washcoat layer and a downstream zone comprising the first washcoat layer and the second washcoat layer, and the one or more platinum group metals are at least partially contained in the third washcoat layer. 29. The catalyst of embodiment 24 or 25, wherein the catalyst comprises a third washcoat layer, the catalyst exhibiting a zoned arrangement of the first washcoat layer, the second washcoat layer, and the third washcoat layer, the third washcoat layer being disposed on the substrate along its axial length starting from the outlet end of the substrate, the first washcoat layer being disposed on the substrate along its axial length starting from the inlet end of the substrate, and the second washcoat layer being disposed completely over the first washcoat layer, the length of the first washcoat layer being less than the axial length of the substrate so as to create a downstream zone comprising the third washcoat layer and an upstream zone comprising the first washcoat layer and the second washcoat layer, and the one or more platinum group metals are at least partially contained in the third washcoat layer. 30. The catalyst of embodiment 24 or 26, wherein the catalyst comprises a third washcoat layer, the catalyst exhibiting a zoned arrangement of the first washcoat layer, the second washcoat layer, and the third washcoat layer, the third washcoat layer being disposed on the substrate along its axial length starting from the outlet end of the substrate, the second washcoat layer being disposed on the substrate along its axial length starting from the inlet end of the substrate, the first washcoat layer being disposed completely over the second washcoat layer, the length of the second washcoat layer being less than the axial length of the substrate so as to create a downstream zone comprising the third washcoat layer and an upstream zone comprising the first washcoat layer and the second washcoat layer, and the one or more platinum group metals are at least partially contained in the third washcoat layer. 31. The catalyst of any of embodiments 1-23, wherein the catalyst comprises a second washcoat layer, the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer, the second washcoat layer being disposed on the substrate along its axial length beginning at an inlet end of the substrate, the first washcoat layer being disposed on the substrate along its axial length beginning at an outlet end of the substrate, the length of the first washcoat layer being less than the axial length of the substrate so as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and the one or more platinum group metals being at least partially contained in the second washcoat layer. 32. The catalyst of any of embodiments 1-23, wherein the catalyst comprises a second washcoat layer, a first washcoat layer disposed on the substrate along its axial length beginning at an inlet end of the substrate, and a second washcoat layer disposed on the substrate along its axial length beginning at an outlet end of the substrate, the length of the first washcoat layer being less than the axial length of the substrate so as to create an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and wherein the one or more platinum group metals are at least partially contained in the second washcoat layer. 33. The catalyst of any of embodiments 1-23, wherein the catalyst comprises a second washcoat layer, the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer, the second washcoat layer being disposed on the substrate along its axial length beginning at an inlet end of the substrate, the first washcoat layer being disposed on the substrate along its axial length beginning at an outlet end of the substrate, the length of the second washcoat layer being less than the axial length of the substrate so as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and the one or more platinum group metals being at least partially contained in the second washcoat layer. 34. The catalyst of any of embodiments 1-23, wherein the catalyst comprises a second washcoat layer, the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer, the second washcoat layer being disposed on the substrate along its axial length beginning at an inlet end of the substrate, the first washcoat layer being disposed on the substrate along its axial length beginning at an outlet end of the substrate, the length of the second washcoat layer being less than the axial length of the substrate so as to create an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and the one or more platinum group metals being at least partially contained in the second washcoat layer. 35. The catalyst of embodiment 31 or 33, wherein the catalyst comprises a third washcoat layer, the third washcoat layer being disposed on the first layer, the catalyst exhibiting a zoned arrangement of the second washcoat layer and the third washcoat layer, the second washcoat layer being disposed on the substrate along the axial length of the substrate starting from the inlet end of the substrate, and the third washcoat layer being disposed on the first washcoat layer along the axial length of the substrate starting from the outlet end of the substrate, the length of the third washcoat layer being shorter than the axial length of the substrate so as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer and the third washcoat layer. 36. The catalyst of embodiment 32 or 34, wherein the catalyst comprises a third washcoat layer, the third washcoat layer being disposed on the first layer, the catalyst exhibiting a zoned arrangement of the second washcoat layer and the third washcoat layer, the third washcoat layer being disposed on the first washcoat layer along the axial length of the substrate starting from an inlet end of the substrate, and the second washcoat layer being disposed on the substrate along the axial length of the substrate starting from an outlet end of the substrate, the length of the third washcoat layer being shorter than the axial length of the substrate so as to create an upstream zone comprising the first washcoat layer and the third washcoat layer, and a downstream zone comprising the second washcoat layer. 37. The catalyst of any of embodiments 27-36, wherein the first washcoat layer and the second washcoat layer are adjacent to each other. 38. The catalyst of any one of embodiments 27-37, wherein the second washcoat layer and the third washcoat layer are adjacent to each other. 39. The catalyst of any of embodiments 27-38, wherein a portion of the second washcoat layer overlaps at least a portion of the first washcoat layer, and preferably the second washcoat layer overlaps the first washcoat layer over a portion in the range of 5 to 100% of the axial length of the substrate, preferably 10 to 100%, more preferably 15 to 80%, more preferably 20 to 50% of the axial length of the first washcoat layer. 40. The catalyst of any of embodiments 27-39, wherein a portion of the first washcoat layer overlaps at least a portion of the second washcoat layer, and preferably the first washcoat layer overlaps the second washcoat layer over a portion in the range of 5 to 100% of the axial length of the substrate, preferably 10 to 100%, more preferably 15 to 80%, more preferably 20 to 50% of the axial length of the second washcoat layer. 41. The catalyst of any of embodiments 27-40, wherein a portion of the third washcoat layer overlaps at least a portion of the first washcoat layer, and preferably the third washcoat layer overlaps the first washcoat layer over a portion in the range of 10 to 100%, more preferably 15 to 80%, more preferably 20 to 50% of the axial length of the first washcoat layer. 42. The catalyst of any of embodiments 1-23, wherein the catalyst comprises a second washcoat layer, the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer, the second washcoat layer being disposed on the substrate along its entire length, the first washcoat layer being disposed on the second washcoat layer along its axial length starting from the outlet end of the substrate, the length of the first washcoat layer being less than the axial length of the substrate so as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and the one or more platinum group metals being at least partially contained in the second washcoat layer. 43. The catalyst of any of embodiments 1-23, wherein the catalyst comprises a second washcoat layer, the catalyst exhibits a zoned arrangement of the first washcoat layer and the second washcoat layer, the second washcoat layer being disposed on the substrate along its entire length, the first washcoat layer being disposed on the second washcoat layer along its axial length starting from the inlet end of the substrate, the length of the first washcoat layer being less than the axial length of the substrate so as to create an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and the one or more platinum group metals being at least partially contained in the second washcoat layer. 44. The catalyst of embodiment 42 or 43, wherein the length of the first washcoat layer is in the range of 10 to 90%, preferably 30 to 80%, and more preferably 50 to 70% of the axial length of the substrate. 45. The catalyst of any of embodiments 1-23, wherein the catalyst comprises a second washcoat layer, the catalyst exhibiting a zoned arrangement of the first washcoat layer and the second washcoat layer, the first washcoat layer being disposed on the substrate along its entire length, the second washcoat layer being disposed on the first washcoat layer along its axial length starting from the inlet end of the substrate, the length of the second washcoat layer being less than the axial length of the substrate so as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and the one or more platinum group metals being at least partially contained in the second washcoat layer. 46. ​​The catalyst of embodiment 45, wherein the catalyst comprises a third washcoat layer, the third washcoat layer being disposed on the first layer, the catalyst exhibiting a zoned arrangement of the second washcoat layer and the third washcoat layer, the second washcoat layer being disposed on the first washcoat layer along the axial length of the substrate starting from the inlet end of the substrate, and the third washcoat layer being disposed on the first washcoat layer along the axial length of the substrate starting from the outlet end of the substrate, and the length of the third washcoat layer is less than the axial length of the substrate so as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the third washcoat layer. 47. The catalyst of any of embodiments 1-23, wherein the catalyst comprises a second washcoat layer, the catalyst exhibiting a zoned arrangement of the first washcoat layer and the second washcoat layer, the first washcoat layer being disposed on the substrate along its entire length, the second washcoat layer being disposed on the first washcoat layer along its axial length starting from the outlet end of the substrate, the length of the second washcoat layer being less than the axial length of the substrate so as to create an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and the one or more platinum group metals being at least partially contained in the second washcoat layer. 48. The catalyst of embodiment 47, wherein the catalyst comprises a third washcoat layer, the third washcoat layer being disposed on the first layer, the catalyst exhibiting a zoned arrangement of the second and third washcoat layers, the third washcoat layer being disposed on the first washcoat layer along the axial length of the substrate starting from an inlet end of the substrate, and the second washcoat layer being disposed on the first washcoat layer along the axial length of the substrate starting from an outlet end of the substrate, and the length of the third washcoat layer is less than the axial length of the substrate so as to create an upstream zone comprising the third washcoat layer and a downstream zone comprising the second washcoat layer. 49. The catalyst of embodiment 47 or 48, wherein the second washcoat layer and the third washcoat layer are adjacent to each other. 50. The catalyst of embodiments 1-49, wherein the length of the first washcoat layer is in the range of 5-100% of the axial length of the substrate, preferably 10-90% of the axial length of the substrate, preferably 15-75%, more preferably 20-60%, more preferably 25-50%, more preferably 35-45%. 51. The catalyst of embodiments 24-50, wherein the length of the second washcoat layer is in the range of 5 to 100% of the axial length of the substrate, preferably 10 to 90% of the axial length of the substrate, more preferably 15 to 75%, more preferably 20 to 60%, more preferably 25 to 50%, more preferably 35 to 45%. 52. The catalyst of embodiments 27-51, wherein the length of the third washcoat layer is in the range of 5-100% of the axial length of the substrate, preferably 10-90% of the axial length of the substrate, preferably 15-75%, more preferably 20-60%, more preferably 25-50%, more preferably 35-45%. 53. The catalyst of any of embodiments 27-52, wherein the third washcoat layer is substantially free of sulfur trapping material, preferably, the third washcoat layer is free of sulfur trapping material. 54. The third layer comprises a hydrocarbon trap material, the hydrocarbon trap material comprising a molecular sieve, preferably a zeolite, more preferably a zeolite having a maximum pore size of 12-membered rings, more preferably zeolite beta, the molecular sieve, preferably the zeolite, preferably comprising SiO2 and Al2O3, the molecular sieve, preferably the zeolite, more preferably having a pore ratio of 10:1 to 500:1, more preferably 10:1 to 100:1, more preferably 10:1 to 40:1, more preferably ... 54. The catalyst of any of embodiments 27-53, preferably having a molar ratio of SiO2 to Al2O3 in the range of 15:1 to 30:1, more preferably 20:1 to 25:1, and wherein the molecular sieve, preferably zeolite, preferably contains Fe, and the molecular sieve, preferably zeolite, more preferably contains Fe in an amount in the range of 1.0 to 7.0 wt. %, more preferably 3.0 to 5.0 wt. %, more preferably 4.0 to 4.5 wt. %, calculated as Fe2O3, based on the weight of the molecular sieve. 55. The loading of hydrocarbon trap material in the third washcoat layer is 0.01 to 2.0 g / in 3 in the range of 0.05 to 1.0 g / in 3 in the range of 0.05 to 0.3 g / in 3 55. The catalyst of embodiment 54, wherein 56. The catalyst of any of embodiments 27-55, wherein the one or more platinum group metals are at least partially contained in the third washcoat layer. 57. The catalyst of embodiment 56, wherein the one or more platinum group metals are supported on a particulate support material, more preferably selected from the group consisting of AI2O3, SiO2, TiO2, SiO2-doped AI2O3, Mn-oxide-doped AI2O3, and mixtures of two or more thereof, and preferably the one or more platinum group metals are supported on AI2O3, and / or SiO2-doped AI2O3, and / or Mn-oxide-doped AI2O3, more preferably SiO2-doped AI2O3, or AI2O3, or Mn-oxide-doped AI2O3, and the Mn-oxide-doped AI2O3 preferably contains 1 to 10 wt. %, more preferably 4 to 6 wt. %, of Mn oxide, calculated as MnO2, based on 100 wt. % of the Mn-oxide-doped AI2O3. 58. The catalyst of any of embodiments 27-57, wherein the catalyst comprises a second washcoat layer and a third washcoat layer, wherein the one or more platinum group metals are completely contained in the second washcoat layer and the third washcoat layer, wherein the weight ratio of the one or more platinum group metals in the second washcoat layer to the one or more platinum group metals in the third washcoat layer is in the range of 0.5:1 to 5.0:1, more preferably 1.0:1 to 2.0:1, more preferably 1.4:1 to 1.6:1, wherein the one or more platinum group metals in the second washcoat layer preferably comprise, more preferably consist of, Pt and Pd, and wherein the one or more platinum group metals in the third washcoat layer preferably comprise, more preferably consist of, Pt and Pd. 59. The loading of Mn, calculated as element, in the zone of the catalyst containing the first washcoat layer is 0.01 to 1 g / in, based on the volume of the zone of the catalyst containing the first washcoat layer. 3 , preferably 0.05 to 0.5 g / in 3 , more preferably 0.08 to 0.35 g / in 3 , more preferably 0.1 to 0.25 g / in 3 , more preferably 0.13 to 0.2 g / in 3 , more preferably 0.15 to 0.18 g / in 3 59. The catalyst of any of embodiments 27 to 58, wherein 60. The Cu loading, calculated as elemental Cu, in the zone of the catalyst containing the first washcoat layer is 0.01 to 1.5 g / in, based on the volume of the zone of the catalyst containing the first washcoat layer. 3 , preferably 0.05 to 1 g / in 3 , more preferably 0.1 to 0.5 g / in 3 , more preferably 0.13 to 0.35 g / in 3 , more preferably 0.15 to 0.25 g / in 3 , more preferably 0.17 to 0.22 g / in 3 60. The catalyst of any of embodiments 27 to 59, wherein 61. The catalyst of any of embodiments 1-60, wherein the one or more platinum group metals are contained entirely in the second washcoat layer, or in the second washcoat layer and the third washcoat layer. 62. The catalyst of any of embodiments 1-60, wherein the one or more platinum group metals are at least partially contained in the first washcoat layer. 63. The catalyst of any of embodiments 1-62, wherein the substrate is a metallic substrate or a ceramic substrate, preferably the substrate is a ceramic substrate, more preferably the substrate comprises cordierite and / or SiC, preferably cordierite, more preferably the substrate consists of cordierite and / or SiC, preferably cordierite. 64. The catalyst of any of embodiments 27 to 63, wherein the substrate consists of two separate monoliths, the first monolith being provided upstream of the second monolith, and wherein the upstream zone washcoat layer or layers are contained on the first monolith and the downstream zone washcoat layer or layers are contained on the second monolith, preferably the first monolith containing the upstream zone washcoat layer or layers and the second monolith containing the downstream zone washcoat layer or layers are obtained or obtainable by compartmentalizing the catalyst according to any of embodiments 27 to 63 into two separate monoliths, wherein the upstream zone washcoat layer or layers are contained on the first monolith and the downstream zone washcoat layer or layers are contained on the second monolith. 65. The catalyst of any of embodiments 1-64, wherein the exhaust gas stream contains hydrocarbons, preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons. 66. An exhaust gas treatment system comprising an internal combustion engine and an exhaust gas conduit for exhaust gases from the internal combustion engine, wherein the exhaust gas conduit contains one or more catalysts according to any of embodiments 1 to 65, preferably one, two, three, or four catalysts according to any of embodiments 1 to 65. 67. The exhaust gas treatment system of embodiment 66, wherein the internal combustion engine is a compression ignition engine, preferably a diesel engine. 68. The exhaust gas treatment system of embodiment 66 or 67, wherein the internal combustion engine is a lean gasoline engine. 69. The exhaust gas treatment system of embodiment 68, wherein the internal combustion engine is powered by an oxygenated fuel, and the oxygenated fuel preferably comprises one or more of methanol and biofuel. 70. The exhaust gas treatment system of any of embodiments 66-69, wherein the system includes one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on a filter (SCRoF), and a diesel exothermic catalyst (DEC). 71. The exhaust gas treatment system of embodiment 70, comprising, in sequential order in the direction of exhaust gas, optionally an electric heater or fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 65, a catalyst according to any of embodiments 1 to 65, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a diesel exothermic catalyst (DEC), a catalyzed soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst. 72. The exhaust gas treatment system of embodiment 70, comprising, in sequential order in the direction of exhaust gas, optionally an electric heater or fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 65, a catalyst according to any of embodiments 1 to 65, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a diesel exothermic catalyst (DEC), a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst. 73. The exhaust gas treatment system of embodiment 70, comprising, in sequential order in the direction of exhaust gas, optionally an electric heater or fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 65, a catalyst according to any of embodiments 1 to 65, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a diesel exothermic catalyst (DEC), a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst. 74. The exhaust gas treatment system of embodiment 70, comprising, in sequential order in the direction of the exhaust gas, optionally an electric heater or fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 65, a catalyst according to any of embodiments 1 to 65, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of embodiments 1 to 65, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst. 75. The exhaust gas treatment system of embodiment 70, comprising, in sequential order in the direction of the exhaust gas, optionally an electric heater or fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 65, a catalyst according to any of embodiments 1 to 65, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of embodiments 1 to 65, a catalyst according to any of embodiments 1 to 65, and wherein the substrate is a wall-flow substrate, a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst. 76. The exhaust gas treatment system of embodiment 70, optionally comprising, in sequential order in the direction of the exhaust gas, an electric heater or fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 65, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a catalyzed soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst. 77. The exhaust gas treatment system of embodiment 70, optionally comprising, in sequential order in the direction of the exhaust gas, an electric heater or fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 65, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a catalyzed soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst. 78. The exhaust gas treatment system of embodiment 70, comprising, in sequential order in the direction of the exhaust gas, optionally an electric heater or fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 65, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of embodiments 1 to 65, and wherein the substrate is a wall-flow substrate, a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst. 79. The exhaust gas treatment system of embodiment 70, optionally comprising, in sequential order in the direction of the exhaust gas, an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 65, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction catalyst on a filter (SCRoF), and an ammonia oxidation (AMOX) catalyst. 80. The exhaust gas treatment system of embodiment 70, comprising, in sequential order in the direction of the exhaust gas, optionally an electric heater or fuel burner and / or a fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of embodiments 1 to 65, a selective catalytic reduction catalyst on a filter (SCRoF), and an ammonia oxidation (AMOX) catalyst. 81. The exhaust gas treatment system of embodiment 70, comprising, in sequential order in the direction of the exhaust gas, optionally an electric heater or fuel burner and / or a fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of embodiments 1 to 65, a catalyzed soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst. 82. The exhaust gas treatment system of embodiment 70, comprising, in sequential order in the direction of the exhaust gas, optionally an electric heater or fuel burner and / or a fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of embodiments 1 to 65, a catalyst according to any of embodiments 1 to 65, and wherein the substrate is a wall-flow substrate, a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst. 83. The exhaust gas treatment system of embodiment 70, optionally comprising, in sequential order in the direction of exhaust gas, an electric heater or fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 65, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst. 84. The exhaust gas treatment system of embodiment 70, optionally comprising, in sequential order in the direction of the exhaust gas, an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 65, a selective catalytic reduction catalyst on a filter (SCRoF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst. 85. The exhaust gas treatment system of embodiment 70, optionally comprising, in sequential order in the direction of the exhaust gas, an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 65, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction catalyst on a filter (SCRoF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst. 86. A method for the treatment of an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons, the method comprising: (A) providing an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons; (B) directing the exhaust gas stream provided in (A) through a catalyst according to any of embodiments 1-65. 87. The method of embodiment 86, wherein the exhaust gas stream provided in (A) comprises one or more sulfur-containing compounds, preferably SO2 and / or SO3. 88.(A) The exhaust gas flow provided by NO x 88. The method of embodiment 86 or 87, comprising: 89. The method of any of embodiments 86-88, wherein the exhaust gas stream provided in (A) comprises CO. 90. The method of any of embodiments 86-89, wherein the exhaust gas stream provided in (A) comprises formaldehyde. 91. The method of any of embodiments 86-89, wherein the exhaust gas stream provided in (A) comprises hydrocarbons, preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons. 92. Use of a catalyst according to any of embodiments 1-65 for the oxidation of one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons, preferably for the oxidation of one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons in an exhaust gas stream, more preferably for the oxidation of one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons in the exhaust gas stream of an internal combustion engine, more preferably for the oxidation of one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons in the exhaust gas stream of a compression ignition engine, more preferably for the oxidation of one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons in the exhaust gas stream of a diesel engine. [Example]

[0107] The present invention is further illustrated by the following examples and comparative examples.

[0108] Experimental Section Comparative Example 1: Preparation of a DOC catalyst for the treatment of exhaust gas streams containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons Prior art catalysts were prepared by separately coating platinum group metal (PGM)-containing front zone segments and base metal oxide (BMO)-containing rear zone segments onto 1-inch diameter cordierite honeycomb substrates, then combining the coated cores consecutively for subsequent S-aging and testing. First, approximately 150 m of Pt, Pd, beta zeolite, and 5 wt. % silica were coated using techniques known in the art. 2 / g and a BET surface area of ​​approximately 0.6 cm 3The anterior zone segment was prepared by combining a commercially available alumina support powder with a pore volume of 10 ... 3 The BMO-containing rear zone segment was prepared as follows: 9 wt. % La2O3, approximately 75 m 2 / g BET surface area and approximately 0.5 cm 3 Commercially available zirconia support powder with a pore volume of 1.8 g / g was mixed with deionized water (Di) to form a slurry. The resulting mixture was ground to a particle size suitable for coating, after which a boehmite alumina binder was added. The resulting slurry was then coated onto a 1-inch diameter x 1.8-inch long cordierite substrate, which was dried and then fired at 590°C for 1 hour. The total washcoat loading was 1.8 g / in of monolith volume. 3 It was.

[0109] Comparative Example 2: Preparation of a DOC catalyst for the treatment of exhaust gas streams containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons A catalyst according to the prior art was prepared in the same manner as described in Comparative Example 1, except that the rear zone slurry contained Mn nitrate and Ce nitrate. The resulting rear zone catalyst had a mass of 1.7 g / in of monolith volume. 3 and the washcoat Mn and Ce concentrations are each about 10 wt %.

[0110] Example 3: Preparation of a catalyst for the treatment of exhaust gas streams containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons A catalyst was prepared in the same manner as described in Comparative Example 2, except that the rear zone slurry contained Cu nitrate but no Ce. The resulting rear zone catalyst had a concentration of 1.7 g / in of monolith volume. 3 and the washcoat Mn and Cu concentrations are each about 10 wt %.

[0111] Comparative Example 4: Preparation of a DOC catalyst for the treatment of exhaust gas streams containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons A catalyst according to the prior art was prepared in the same manner as described in Comparative Example 2, except that the rear zone slurry contained Mn nitrate, Ce nitrate, and Cu nitrate. The resulting rear zone catalyst had a mass of 1.8 g / in of monolith volume. 3 and the washcoat Mn, Ce, and Cu concentrations are each about 10 wt %.

[0112] Comparative Example 5: Preparation of a DOC catalyst for the treatment of exhaust gas streams containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons A catalyst according to the prior art was prepared in the same manner as described in Comparative Example 4, except that the rear zone contained two layers. The washcoat loading was 1.0 g / in of monolith volume. 3 The underlayer was the same as in Comparative Example 4, except that the underlayer was 0.01 g / in. The additional topcoat contained CuO (17 wt.%) on an Al2O3 compound (1.0 g / in 3 The resulting rear zone catalyst was approximately 2.0 g / in of monolith volume. 3 The washcoat loading was 0.01g.

[0113] Example 6: Preparation of a catalyst for the treatment of exhaust gas streams containing one or more of formaldehyde, nitrogen oxides (NO), and one or more hydrocarbons A catalyst according to the present invention was prepared in the same manner as described in Comparative Example 5, except that the rear zone had a different topcoat. The bottom layer was the same as that described in Comparative Example 5, and therefore the washcoat loading was 1.0 g / in of monolith volume. 3 An additional topcoat was CuO (17%) (0.9 g / in) on an Al2O3 compound. 3 ), and additional manganese oxide (0.1 g / in 3 The resulting rear zone catalyst contained approximately 2.0 g / in of monolith volume. 3 The washcoat loading was 0.01g.

[0114] Example 7: Catalytic testing The catalysts of Example 3 and Comparative Examples 1, 2, and 4 were subjected to sulfur aging (S-aging). The S-aging was achieved in a laboratory reactor at 300°C in a feed containing 15 ppm SO, 150 ppm NO, 10% O, and 5% HO. The flow through the catalyst, measured as space velocity, was 35,000 / hr. The exposure time was 88 minutes, corresponding to a target S exposure of 1 g(S) / L of monolith volume. Desulfation was achieved at 700°C under isothermal conditions in a feed containing 10% O and 5% HO for 30 minutes. The flow through the catalyst, measured by space velocity, was 32,000 / hr.

[0115] After sulfation and desulfation, 180 ppm NO, 1000 ppm CO, 25 ppm HCHO, 100 ppm C1 from C2H4, C 10 H 22 The samples were tested for HCHO light-off performance using a feed containing 190 ppm Cl, 10% O, 10% HO, and 10% CO from a catalyst. The flow through the catalyst, as measured by space velocity, was 50,000 / hr. The samples were placed in a reactor and first equilibrated in flowing air at 80°C. The formaldehyde-containing feed was then introduced, and a temperature ramp to 300°C was initiated at a rate of 15°C / min. Formaldehyde concentration was monitored by FTIR during the light-off ramp, and conversion performance versus temperature was then calculated from these measurements.

[0116] The results for HCHO performance of Comparative Examples 1, 2, and 4, and Example 3 for virgin samples are shown in Figure 1. Further results for HCHO performance for samples of catalysts according to Comparative Examples 1, 2, and 4, and Example 3, each subjected to S-aging as described above, are shown in Figure 2, respectively.

[0117] As shown in FIG. 1, the catalysts according to Example 3 and Comparative Examples 2 and 4 provide good low-temperature HCHO conversion performance, and in particular, the examples exhibit relatively better low-temperature performance than the catalyst of Comparative Example 1.

[0118] After the sulfur exposure followed by a sulfur removal step (Figure 2), the catalyst of Example 3 showed the best performance, especially in the temperature range of about 110 to 220°C. The above results indicate that the catalyst of Example 3 (Cu+Mn sample) is the most S-tolerant catalyst.

[0119] The results for the hydrocarbon conversion performance of the catalysts of Comparative Examples 1, 2, and 4, and Example 3 for samples exposed to sulfur and then subjected to a desulfation step are shown in FIG.

[0120] Again, as shown in Figure 3, the catalyst of Example 3 (Cu+Mn sample) is the most S-tolerant catalyst for HC conversion, especially in the temperature range of about 160-300°C.

[0121] The results for the CO conversion performance of the catalysts of Comparative Examples 1, 2, and 4, and Example 3 for samples exposed to sulfur and then subjected to a desulfation step are shown in FIG.

[0122] As shown in FIG. 4, the catalyst of Example 3 (Cu+Mn sample) is the most S-tolerant catalyst for CO conversion.

[0123] Similar results can be observed for the catalysts of Comparative Example 5 and Example 6, as shown in Figures 5 and 6. In particular, the figures show that the catalyst of Example 6 (which includes a washcoat layer containing Cu+Mn and no Ce) provides better S resistance than that of Comparative Example 5. [Brief explanation of the drawings]

[0124] [Figure 1] Figure 1 shows the HCHO conversion performance of virgin samples of the catalysts of Comparative Examples 1, 2, and 4, and Example 3. All samples contained a front zone of 2:1 Pt-Pd at 75 g / ft3, but the rear zone was different. [Figure 2] Figure 1 shows the HCHO conversion performance after sulfated and 700°C desulfated (total S exposure approx. 1 g / L catalyst) of the catalysts of Comparative Examples 1, 2, and 4, and Example 3. All samples contained a front zone of 2:1 Pt-Pd at 75 g / ft3, but the rear zone was different. [Figure 3] Figure 1 shows the HC conversion performance after sulfated and 700°C desulfated (total S exposure approx. 1 g / L catalyst) of the catalysts of Comparative Examples 1, 2, and 4, and Example 3. All samples contained a front zone of 2:1 Pt-Pd at 75 g / ft3, but the rear zone was different. [Figure 4] Figure 1 shows the CO conversion performance after sulfated and 700°C desulfated (total S exposure approx. 1 g / L catalyst) of the catalysts of Comparative Examples 1, 2, and 4, and Example 3. All samples contained a front zone of 2:1 Pt-Pd at 75 g / ft3, but the rear zone was different. [Figure 5] Figure 1 shows the HCHO conversion performance after sulfation (1 g / L S exposure) at 300°C for the catalysts of Comparative Example 5 and Example 6. Both samples contained a front zone of 2:1 Pt-Pd at 75 g / ft, but each sample contained a different rear zone containing two coats. [Figure 6]Figure 1 shows the HCHO conversion performance of the catalysts of Comparative Example 5 and Example 6 after sulfation at 300°C (1 g / L S exposure) and desulfation at 700°C. Both samples contained a front zone of 2:1 Pt-Pd at 75 g / ft3, but each sample contained a different rear zone containing two coats.

[0125] References -International Publication No. 2022 / 047132(A1) -US Patent No. 10,598,061(B2) -US Patent No. 10,392,980(B2) -International Publication No. 2020 / 089043(A1)

Claims

1. 1. A catalyst for the treatment of an exhaust gas stream containing one or more of formaldehyde, nitrogen oxides (NO), and hydrocarbons, said catalyst comprising: a first washcoat layer containing Mn and Cu, the first washcoat layer being substantially free of Ce; A substrate, the substrate having an inlet end through which the exhaust gas flow can enter the catalyst and an outlet end through which the exhaust gas flow can exit the catalyst; the catalyst further comprises one or more platinum group metals comprising Pt, Pd, or Pt and Pd, the one or more platinum group metals being: (a) the first washcoat layer, and (b) an optional second washcoat layer; or (c) a catalyst at least partially contained in one or more of the optional second and third washcoat layers.

2. 2. The catalyst of claim 1, wherein the loading of Mn in the first washcoat layer, calculated as element, ranges from 1 to 50 wt %, based on 100 wt % of the first washcoat layer.

3. 3. The catalyst of claim 1 or 2, wherein the loading of Cu in the first washcoat layer, calculated as element, is in the range of 1 to 50 wt %, based on 100 wt % of the first washcoat layer.

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

5. The catalyst has a viscosity of 2 to 250 g / ft, calculated as element. ３ 5. The catalyst of claim 1, comprising a Pt loading in the range of

6. The catalyst has a viscosity of 5 to 100 g / ft, calculated as element. ３ 6. The catalyst of claim 1, comprising a Pd loading in the range of

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

8. 8. The catalyst of claim 1, wherein the catalyst comprises a second washcoat layer, and the one or more platinum group metals are at least partially contained in the second washcoat layer.

9. The catalyst of any one of claims 1 to 8, wherein the second washcoat layer comprises a hydrocarbon trapping material, the hydrocarbon trapping material comprising a molecular sieve.

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

11. the catalyst comprises a second washcoat layer, the catalyst exhibiting a zoned arrangement of the first washcoat layer and the second washcoat layer; 10. The catalyst of claim 1, wherein the second washcoat layer is disposed on the substrate along its axial length beginning at the inlet end of the substrate, the first washcoat layer is disposed on the substrate along its axial length beginning at the outlet end of the substrate, the length of the first washcoat layer being less than the axial length of the substrate to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and the one or more platinum group metals are at least partially contained in the second washcoat layer.

12. the catalyst comprises a second washcoat layer, the catalyst exhibiting a zoned arrangement of the first washcoat layer and the second washcoat layer; 10. The catalyst of any one of claims 1 to 9, wherein the second washcoat layer is disposed on the substrate along its entire length, the first washcoat layer is disposed on the second washcoat layer along its axial length beginning at the outlet end of the substrate, the length of the first washcoat layer being less than the axial length of the substrate to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and the one or more platinum group metals are at least partially contained in the second washcoat layer.

13. 13. An exhaust gas treatment system comprising an internal combustion engine and an exhaust gas conduit for exhaust gases from said internal combustion engine, said exhaust gas conduit containing a catalyst according to any one of claims 1 to 12.

14. 14. The exhaust gas treatment system of 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 catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on a filter (SCRoF), and a diesel exothermic catalyst (DEC).

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

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

Images