Oxidation catalysts containing platinum group metals and base metal oxides
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- BASF MOBILE EMISSIONS CATALYSTS LLC
- Filing Date
- 2026-03-03
- Publication Date
- 2026-06-16
AI Technical Summary
【0043】 本開示のこれら及び他の特徴、態様、及び利点は、以下に簡単に説明する添付図面と共に以下の詳細な説明を読むことにより明らかになるであろう。本開示は、上述の実施形態の2つ、3つ、4つ、又はそれ以上の任意の組み合わせ、並びに本開示に規定される任意の2つ、3つ、4つ、又はそれ以上の特徴又は要素の組み合わせを含み、その特徴又は要素が本明細書の特定の実施形態の説明において明示的に組み合わされるかどうかに関係なく、本開示は、そのような組み合わせも含む。本開示は、その様々な態様及び実施形態のいずれかにおける開示された主題の任意の分離可能な特徴又は要素が、文脈によって明確に指示されない限り、組み合わせ可能であることを意図していると見なされるべきであるように、全体的に読まれることを意図している。本開示の他の態様及び利点は、以下から明らかになるであろう。
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Figure 2026097926000020 
Figure 2026097926000021
Abstract
Claims
1. Platinum group metal (PGM) components including palladium, platinum, or combinations thereof, Manganese component, and Zirconia-containing first refractory metal oxide support material An oxidation catalyst composition containing the following:
2. The oxidation catalyst composition according to claim 1, comprising about 0.1% by mass to about 90% by mass of manganese on an oxide basis, based on the mass of the first refractory metal oxide support material.
3. The oxidation catalyst composition according to claim 1, wherein the manganese component is supported on the first refractory metal oxide support material.
4. The oxidation catalyst composition according to claim 1, wherein the first refractory metal oxide support material contains zirconia in an amount of about 1% by mass to about 99% by mass.
5. The oxidation catalyst composition according to claim 1, wherein the first refractory metal oxide support material further comprises alumina, silica, ceria, titanium oxide, silica-doped alumina, silica-titania, silica-zirconia, yttrium-zirconium, manganese-zirconia, tungsten-titania, zirconia-titania, zirconia-ceria, zirconia-alumina, manganese-alumina, lanthanum-zirconia, lanthanum-zirconia-alumina, magnesium oxide-alumina, and combinations thereof.
6. The oxidation catalyst composition according to claim 1, wherein the zirconia in the first refractory metal oxide support material is doped with lanthanum in an amount of about 1% by mass to about 40% by mass on an oxide basis, based on the mass of the zirconia.
7. The oxidation catalyst composition according to claim 1, further comprising a base metal oxide selected from oxides of cerium, iron, cobalt, zinc, chromium, molybdenum, nickel, tungsten, copper, magnesium, antimony, tin, lead, yttrium, and combinations thereof.
8. The oxidation catalyst composition according to claim 7, wherein the base metal oxide is supported on the first refractory metal oxide support material.
9. The base metal oxide is ceria oxide, The oxidation catalyst composition according to claim 7, wherein the ceria is present in an amount of about 99% by mass or less based on the mass of the first refractory metal oxide support material.
10. Based on the mass of the first refractory metal oxide support material, manganese in an amount of about 1% to about 60% by mass on an oxide basis; and Based on the mass of the first refractory metal oxide support material, ceria in an amount of about 1% to about 99% by mass. The oxidation catalyst composition according to claim 1, comprising:
11. The palladium is supported on the first refractory metal oxide support in an amount of about 0% to about 10% by mass, based on the mass of the first refractory metal oxide support. The platinum is supported on the first refractory metal oxide carrier in an amount of about 0% to about 10% by mass, based on the mass of the first refractory metal oxide carrier. The oxidation catalyst composition according to claim 1, wherein at least one of the platinum or palladium is present in an amount of about 0.1% by mass or more based on the mass of the first refractory metal oxide support.
12. The oxidation catalyst composition according to claim 1, wherein the PGM component includes a combination of platinum and palladium.
13. The oxidation catalyst composition according to claim 12, wherein the mass ratio of palladium to platinum is about 100 to about 0.
01.
14. The oxidation catalyst composition according to claim 12, wherein the mass ratio of palladium to platinum is about 1 to about 0.
01.
15. The oxidation catalyst composition according to claim 1, further comprising a second refractory metal oxide support material.
16. The oxidation catalyst composition according to claim 15, wherein the second refractory metal oxide support material includes alumina, silica, zirconia, titania, ceria, silica-doped alumina, silica-titania, silica-zirconia, yttrium-zirconia, manganese-zirconia, tungsten-titania, zirconia-titania, zirconia-ceria, zirconia-alumina, manganese-alumina, lanthanum-zirconia, lanthanum-zirconia-alumina, magnesium oxide-alumina, or a combination thereof.
17. The oxidation catalyst composition according to claim 15, wherein the second refractory metal oxide support material comprises a base metal oxide selected from oxides of cerium, iron, cobalt, zinc, chromium, molybdenum, nickel, tungsten, copper, magnesium, antimony, tin, lead, yttrium, and combinations thereof.
18. The oxidation catalyst composition according to claim 15, wherein the PGM component is supported on the second refractory metal oxide support material in an amount of about 0.1% by mass to about 10% by mass, based on the mass of the second refractory metal oxide support material.
19. The oxidation catalyst composition according to claim 15, wherein the second refractory metal oxide support material comprises alumina or zirconia.
20. The oxidation catalyst composition according to claim 19, wherein the zirconia in the second refractory metal oxide support material is doped with lanthanum in an amount of about 0.1% by mass to about 40% by mass, based on the mass of the zirconia and on an oxide basis.
21. The oxidation catalyst composition according to claim 15, wherein the second refractory metal oxide support material substantially contains lanthanum.
22. The oxidation catalyst composition according to claim 15, wherein the second refractory metal oxide support material contains manganese.
23. The oxidation catalyst composition according to claim 15, wherein the manganese component is supported on the first refractory metal oxide support material, and the PGM component is supported on the second refractory metal oxide support material.
24. The oxidation catalyst composition according to claim 23, wherein the PGM component is supported on the second refractory metal oxide support material in an amount of about 0.1% by mass to about 10% by mass, based on the mass of the second refractory metal oxide support material.
25. The manganese component is manganese oxide, and is supported on the first refractory metal oxide carrier material in an amount of approximately 0.1% by mass to approximately 40% by mass, based on the mass of the first refractory metal oxide carrier material. The oxidation catalyst composition according to claim 15, wherein the PGM component is supported on the second refractory metal oxide support material, and the second refractory metal oxide support material is selected from alumina, silica-doped alumina, titania, titania-doped alumina, zirconium-doped alumina, zirconia, and zirconia doped with about 1% to about 40% by mass of lantana based on the mass of the zirconia.
26. The oxidation catalyst composition according to claim 25, wherein the first refractory metal oxide support material further comprises ceria in an amount of about 1% by mass to about 50% by mass, based on the mass of the first refractory metal oxide support material.
27. An oxidation catalyst composition according to any one of claims 1 to 25, which is substantially free of copper.
28. A catalyst article comprising a substrate having an inlet end and an outlet end defining the overall length, and a catalyst coating disposed on at least a portion thereof, wherein the catalyst coating includes a first wash coat and a second wash coat, The first wash coat comprises a first refractory metal oxide carrier material containing a manganese component and zirconia, wherein the manganese component is supported on the first refractory metal oxide carrier material as manganese oxide or a mixed oxide. A catalyst article wherein the second wash coat comprises a platinum group metal (PGM) component including palladium, platinum, or a combination thereof, and a second refractory metal oxide support material, the PGM component being supported on the second refractory metal oxide support material.
29. The catalyst article according to claim 28, comprising manganese in an amount of about 0.1% by mass to about 40% by mass, based on the mass of the first refractory metal oxide support material, on an oxide basis.
30. The catalyst article according to claim 28, further comprising a base metal oxide supported on the first refractory metal oxide support material, wherein the base metal oxide is selected from oxides of cerium, iron, cobalt, zinc, chromium, molybdenum, nickel, tungsten, copper, and combinations thereof.
31. The catalyst article according to claim 28, further comprising a base metal oxide supported on the first refractory metal oxide support material, wherein the base metal oxide is selected from oxides of cerium, iron, cobalt, zinc, chromium, molybdenum, nickel, tungsten, magnesium, antimony, tin, lead, yttrium, and combinations thereof.
32. The catalyst article according to claim 30, wherein the base metal oxide is ceria, and the ceria is present in an amount of about 30% by mass or less based on the mass of the first refractory metal oxide support material.
33. Based on the mass of the first refractory metal oxide support material, manganese in an amount of about 1% by mass to about 30% by mass on an oxide basis; and Based on the mass of the first refractory metal oxide support material, an amount of ceria of about 1% to about 30% by mass is used. The catalyst article according to claim 32, including the following:
34. The catalyst article according to claim 28, wherein the zirconia in the first refractory metal oxide support material is doped with about 1% to about 40% by mass of lanthanum oxide, based on the total mass of the zirconia.
35. The catalyst article according to claim 28, wherein the second refractory metal oxide support material comprises alumina, silica, zirconia, titania, ceria, or a combination thereof.
36. The catalyst article according to claim 28, wherein the second refractory metal oxide support material contains alumina.
37. The catalyst article according to claim 28, wherein the second refractory metal oxide support material comprises zirconia.
38. The catalyst article according to claim 37, wherein the zirconia in the second refractory metal oxide support material is doped with about 1% by mass to about 40% by mass of lanthanum oxide, based on the total mass of the zirconia.
39. The catalyst article according to claim 28, wherein the second refractory metal oxide support material is selected from alumina, silica-doped alumina, titania, titania-doped alumina, zirconium-doped alumina, zirconia, and zirconia doped with about 1% to about 40% by mass of lantana based on the mass of the zirconia.
40. The catalyst article according to claim 28, wherein the PGM component includes a combination of platinum and palladium.
41. The catalyst article according to claim 40, wherein the mass ratio of palladium to platinum is about 100 to about 0.
01.
42. The catalyst article according to claim 40, wherein the mass ratio of palladium to platinum is about 1 to about 0.
01.
43. The catalyst article according to claim 28, wherein the total amount of the PGM component supported on the catalyst article is about 5 g / ft³ to about 200 g / ft³.
44. The catalyst article according to claim 28, wherein the PGM is supported on the second refractory metal oxide support material in an amount of about 0.5% by mass to about 10% by mass, based on the mass of the second refractory metal oxide support material.
45. The manganese component is manganese oxide, supported on the first refractory metal oxide carrier material in an amount of about 1% to about 30% by mass, based on the mass of the first refractory metal oxide carrier material, and the first refractory metal oxide carrier material contains alumina or zirconia, and the zirconia is doped with about 1% to about 40% by mass of lantana, based on the mass of the zirconia; The first refractory metal oxide support material further contains ceria in an amount of about 1% by mass to about 50% by mass, based on the mass of the first refractory metal oxide support material; The catalyst article according to claim 28, wherein the PGM component is supported on the second refractory metal oxide support material, and the second refractory metal oxide support material is selected from alumina, silica-doped alumina, titania, titania-doped alumina, zirconium-doped alumina, zirconia, and zirconia doped with about 1% to about 40% by mass of lantana based on the mass of the zirconia.
46. The catalyst article according to any one of claims 28 to 45, wherein the first wash coat and the second wash coat are substantially copper-free.
47. The catalyst article according to any one of claims 28 to 45, wherein the first wash coat is disposed directly on the substrate and the second wash coat is disposed on at least a portion of the first wash coat.
48. The catalyst article according to any one of claims 28 to 45, wherein the second wash coat is disposed directly on the substrate and the first wash coat is disposed on at least a portion of the second wash coat.
49. The catalyst article according to any one of claims 28 to 45, wherein the catalyst article has a zone configuration, the first wash coat is directly placed on the substrate for a length of about 20% to about 100% of the total length from the outlet end, and the second wash coat is placed on the substrate for a length of about 20% to about 100% of the total length from the inlet end.
50. The catalyst article according to any one of claims 28 to 45, wherein the catalyst article has a zone configuration, the second wash coat is directly placed on the substrate for a length of about 20% to about 100% of the total length from the outlet end, and the first wash coat is placed on the substrate for a length of about 20% to about 100% of the total length from the inlet end.
51. A catalyst article comprising a substrate having an inlet end and an outlet end defining the overall length, and a catalyst coating disposed on at least a portion thereof, wherein the catalyst coating includes a first wash coat, a second wash coat, and a third wash coat. The first wash coat comprises a first refractory metal oxide carrier material containing a manganese component and zirconia, wherein the manganese component is supported on the first refractory metal oxide carrier material as manganese oxide or a mixed oxide. The second wash coat comprises a base metal oxide component including ceria, manganese oxide, zirconia, lanthanum oxide, copper oxide, or a combination thereof, and a second refractory metal oxide support material, wherein the base metal oxide component is supported on the second refractory metal oxide support material. A catalyst article wherein the third wash coat comprises a platinum group metal (PGM) component including palladium, platinum, or a combination thereof, and a third refractory metal oxide support material, the PGM component being supported on the third refractory metal oxide support material.
52. The catalyst article according to claim 51, wherein the zirconia in the first refractory metal oxide support material is doped with about 1% to about 40% by mass of lanthanum oxide, based on the total mass of the zirconia.
53. The catalyst article according to claim 51, wherein the second refractory metal oxide support material includes alumina, silica, zirconia, titania, ceria, silica-doped alumina, titania, titania-doped alumina, zirconium-doped alumina, zirconia, silica-titania, silica-zirconia, yttrium-zirconia, manganese-zirconia, tungsten-titania, zirconia-titania, zirconia-ceria, zirconia-alumina, manganese-alumina, lanthanum-zirconia, lanthanum-zirconia-alumina, magnesium oxide-alumina, or a combination thereof.
54. The catalyst article according to claim 51, wherein the second refractory metal oxide support material contains alumina.
55. The catalyst article according to claim 51, wherein the second refractory metal oxide support material comprises silica-doped alumina.
56. The catalyst article according to claim 51, wherein the second refractory metal oxide support material contains zirconia.
57. The catalyst article according to claim 56, wherein the zirconia in the second refractory metal oxide support material is doped with about 0.1% by mass to about 40% by mass of lanthanum oxide, based on the total mass of the zirconia.
58. The catalyst article according to claim 51, wherein the third refractory metal oxide support material includes alumina, silica, zirconia, titania, ceria, silica-doped alumina, titania, titania-doped alumina, zirconium-doped alumina, zirconia, silica-titania, silica-zirconia, tungsten-titania, zirconia-titania, zirconia-ceria, zirconia-alumina, lanthanum-zirconia, lanthanum-zirconia-alumina, magnesium oxide-alumina, or a combination thereof.
59. The catalyst article according to claim 51, wherein the PGM component includes a combination of platinum and palladium.
60. The catalyst article according to any one of claims 51 to 59, wherein the first wash coat is disposed directly on the substrate and the second wash coat is disposed on at least a portion of the first wash coat.
61. The catalyst article according to any one of claims 51 to 59, wherein the second wash coat is disposed directly on the substrate and the first wash coat is disposed on at least a portion of the second wash coat.
62. The catalyst article according to any one of claims 51 to 59, wherein the first wash coat is disposed directly on the substrate, the second wash coat is disposed on at least a portion of the first wash coat, and the third wash coat is disposed on at least a portion of the second wash coat.
63. The catalyst article according to any one of claims 51 to 59, wherein the third wash coat is disposed directly on the substrate, the second wash coat is disposed on at least a portion of the third wash coat, and the first wash coat is disposed on at least a portion of the second wash coat.
64. The catalyst article according to any one of claims 51 to 59, wherein the first wash coat is disposed directly on the substrate, the third wash coat is disposed on at least a portion of the first wash coat, and the second wash coat is disposed on at least a portion of the third wash coat.
65. The catalyst article according to any one of claims 51 to 59, wherein the second wash coat is disposed directly on the substrate, the third wash coat is disposed on at least a portion of the second wash coat, and the first wash coat is disposed on at least a portion of the third wash coat.
66. The catalyst article according to any one of claims 51 to 59, wherein the second wash coat is disposed directly on the substrate, the first wash coat is disposed on at least a portion of the second wash coat, and the third wash coat is disposed on at least a portion of the first wash coat.
67. The catalyst article has a zone configuration, The first wash coat is placed directly on the substrate for a length of approximately 20% to approximately 100% of the total length from the outlet end. The second wash coat is placed on the substrate for a length of approximately 20% to approximately 100% of the total length from the entrance end. The catalyst article according to any one of claims 51 to 59, wherein the third wash coat is disposed on the substrate for a length of about 20% to about 100% of the total length from the inlet end.
68. An exhaust gas treatment system comprising a catalytic article according to any one of claims 28 to 67, wherein the catalytic article is located downstream of a compression ignition internal combustion engine and is in fluid communication with it.
69. A method for treating an exhaust gas stream containing hydrocarbons and / or carbon monoxide and / or NOx, comprising contacting the exhaust gas stream with a catalyst article according to any one of claims 28 to 67, or an exhaust gas treatment system according to claim 68.
70. Refractory metal oxide support material containing zirconia, Based on the mass of the aforementioned refractory metal oxide support material, manganese in an amount of about 1% to about 30% by mass on an oxide basis; and Based on the mass of the aforementioned fire-resistant metal oxide carrier material, ceria is added in an amount of approximately 0% to approximately 30% by mass. Including, A formaldehyde oxidation catalyst composition that is substantially free of copper.
71. The formaldehyde oxidation catalyst composition according to claim 70, wherein the manganese is disposed on the refractory metal oxide support material.
72. The formaldehyde oxidation catalyst composition according to claim 70, wherein the ceria is disposed on the refractory metal oxide support material.
73. The formaldehyde oxidation catalyst composition according to claim 70, wherein the zirconia in the refractory metal oxide support material is doped with about 0.1% to about 40% by mass of lanthanum oxide, based on the total mass of the zirconia.