Multifunctional catalyst for NO oxidation, NH3 oxidation, and selective catalytic reduction of NOx

Abstract

The present invention relates to a catalyst for the oxidation of NO, the oxidation of ammonia, and the selective catalytic reduction of NOx, the catalyst comprising a substrate, a first coating comprising one or more of vanadium oxide and a zeolitic material comprising one or more of copper and iron; and a second coating comprising a platinum group metal component supported on a non-zeolitic oxide material, the second coating further comprising a zeolitic material comprising one or more of copper and iron.

Description

[Technical Field]

[0001] The present invention relates to a catalyst for the oxidation of NO, the oxidation of ammonia and the selective catalytic reduction of NOx, a method for preparing a catalyst for the oxidation of NO, the oxidation of ammonia and the selective catalytic reduction of NOx, and the use of said catalyst. The present invention further relates to an exhaust gas treatment system comprising said catalyst. [Background technology]

[0002] US2018 / 0280876A1 discloses a catalyst article having a first inlet zone including an ammonia slip catalyst (ASC) on a substrate, the first zone including a platinum group metal on a support and a first SCR catalyst, and a second outlet zone including a diesel oxidation catalyst or a diesel exothermic catalyst. Furthermore, US2018 / 0280877A1 discloses a catalyst article and system for NOx conversion and ammonia conversion. The catalysts in these prior art documents are not optimized for NO oxidation, and the potential reduction of nitrous oxide at the outlet of the catalyst article and system is not discussed. Therefore, there remains a need to provide improved catalysts for NO oxidation, ammonia oxidation, and selective catalytic reduction of NOx that exhibit high catalytic activity (NH3 oxidation, NO oxidation, and NOx conversion) while minimizing the formation of nitrous oxide (NO). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] US2018 / 0280876A1 [Patent Document 2] US2018 / 0280877A1 Summary of the Invention [Problem to be solved by the invention]

[0004] It is therefore an object of the present invention to provide a catalyst for the oxidation of NO, oxidation of ammonia and selective catalytic reduction of NO, which exhibits high catalytic activity (NH oxidation, NO oxidation and NO conversion) while minimizing the formation of nitrous oxide (NO). Surprisingly, it has been found that the catalyst for the oxidation of NO, oxidation of ammonia and selective catalytic reduction of NO according to the present invention is capable of obtaining high catalytic activity (NH oxidation, NO oxidation and NO conversion) while reducing the formation of nitrous oxide (NO). [Means for solving the problem]

[0005] The present invention therefore relates to a catalyst for the oxidation of NO, the oxidation of ammonia and the selective catalytic reduction of NOx, said catalyst comprising: (i) a substrate including an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end, and a plurality of passages defined by an interior wall of the substrate extending through the interior of the substrate, wherein an interface between the passages and the interior wall is defined by a surface of the interior wall; (ii) a first coating comprising one or more of vanadium oxide and a zeolite material comprising one or more of copper and iron; (iii) a second coating comprising a platinum group metal component supported on a non-zeolitic oxide material, wherein the platinum group metal component supported on the non-zeolitic oxide material is present in the second coating at a first loading, L1, which is the sum of the loading of the platinum group metal component and the loading of the non-zeolitic oxide material; the second coating further comprises a zeolitic material comprising one or more of copper and iron, the zeolitic material comprising one or more of copper and iron being present in the second coating at a second loading L2, the second loading being the sum of the loading of the zeolitic material and the loading of the one or more of copper and iron; the second coating is disposed on the surface of the inner wall over y% of the axial length of the substrate from the outlet end to the inlet end, where y is in the range of 10 to 90; the first coating extends over x% of the axial length of the substrate from the inlet end to the outlet end and is disposed on the second coating and on the surface of the inner wall, where x is in the range of 95 to 100; The ratio of the first loading in g / l to the second loading in g / l, L1:L2, is at least 1.1:1. [Brief explanation of the drawings]

[0006] [Figure 1] FIG. 1 shows the deNOx performance of the catalysts of Example 1 and Comparative Example 1 at inlet temperatures in the range of 200 to 450° C. and ANR=1.1. [Figure 2] FIG. 2 shows the formation of nitrous oxide for the catalysts of Example 1 and Comparative Example 1 measured at inlet temperatures ranging from 200 to 450° C. and ANR=1.0. [Figure 3] FIG. 3 shows the ammonia slip of the catalysts of Example 1 and Comparative Example 1 at inlet temperatures ranging from 200 to 450°C. [Figure 4] FIG. 4 shows the NO oxidation amounts (NO2 / NOx ratios) of the catalysts of Example 1 and Comparative Example 1 at inlet temperatures in the range of 200 to 450°C and an SV of 100 kJ / h. [Figure 5] FIG. 5 shows a schematic representation of a catalyst according to the invention (a) and a catalyst not according to the invention (b). DETAILED DESCRIPTION OF THE INVENTION

[0007] x is preferably in the range of 98-100, and more preferably in the range of 99-100.

[0008] y is preferably in the range of 20 to 80, more preferably in the range of 40 to 75, more preferably in the range of 50 to 72, and more preferably in the range of 60 to 70. More preferably, x is in the range of 99 to 100, and y is in the range of 50 to 72, and more preferably in the range of 60 to 70.

[0009] Preferably, the first coating (ii) comprises a zeolitic material containing one or more of copper and iron.

[0010] The zeolite material contained in the first coating preferably has a framework type selected from the group consisting of AEI, GME, CHA, MFI, BEA, FAU, MOR, mixtures of two or more thereof, and mixed types of two or more thereof, more preferably selected from the group consisting of AEI, GME, CHA, BEA, FAU, MOR, mixtures of two or more thereof, and mixed types of two or more thereof, more preferably selected from the group consisting of AEI, CHA, BEA, mixtures of two or more thereof, and mixed types of two or more thereof. The zeolite material contained in the first coating has a framework type CHA or AEI, more preferably CHA.

[0011] The present invention therefore preferably relates to a catalyst for the oxidation of NO, the oxidation of ammonia and the selective catalytic reduction of NOx, said catalyst comprising: (i) a substrate including an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end, and a plurality of passages defined by an interior wall of the substrate extending through the interior of the substrate, wherein an interface between the passages and the interior wall is defined by a surface of the interior wall; (ii) a first coating comprising a zeolitic material comprising one or more of copper and iron, the zeolitic material having a framework type CHA or AEI, more preferably CHA; (iii) a second coating comprising a platinum group metal component supported on a non-zeolitic oxide material, wherein the platinum group metal component supported on the non-zeolitic oxide material is present in the second coating at a first loading, L1, which is the sum of the loading of the platinum group metal component and the loading of the non-zeolitic oxide material; the second coating further comprises a zeolitic material comprising one or more of copper and iron, the zeolitic material comprising one or more of copper and iron being present in the second coating at a second loading L2, the second loading being the sum of the loading of the zeolitic material and the loading of the one or more of copper and iron; the second coating is disposed on the surface of the inner wall over y% of the axial length of the substrate from the outlet end to the inlet end, where y is in the range of 10 to 90; the first coating extends over x% of the axial length of the substrate from the inlet end to the outlet end and is disposed on the second coating and on the surface of the inner wall, where x is in the range of 95 to 100; The ratio of the first loading in g / l to the second loading in g / l, L1:L2, is at least 1.1:1.

[0012] In the context of the present invention, it is preferred that 95-100% by weight, more preferably 98-100% by weight, more preferably 99-100% by weight, more preferably 99.5-100% by weight of the framework structure of the zeolitic material comprised in the first coating consists of Si, Al, O and optionally one or more of P and H, wherein in the framework structure the molar ratio of Si to Al, calculated as molar SiO2:Al2O3, is more preferably in the range of 2:1 to 50:1, more preferably in the range of 4:1 to 45:1, more preferably in the range of 10:1 to 40:1, more preferably in the range of 12:1 to 30:1, more preferably in the range of 13:1 to 25:1, more preferably in the range of 15:1 to 21:1.

[0013] The zeolite material contained in the first coating preferably contains copper, and the amount of copper calculated as CuO contained in the zeolite material is more preferably in the range of 1 to 10% by mass, more preferably in the range of 2 to 8% by mass, more preferably in the range of 3 to 6% by mass, more preferably in the range of 4.5 to 6% by mass, based on the total mass of the zeolite material.

[0014] The amount of iron, calculated as Fe2O3, contained in the zeolite material in the first coating is preferably at most 0.01% by mass, more preferably in the range of 0 to 0.001% by mass, and even more preferably in the range of 0 to 0.0001% by mass, based on the total mass of the zeolite material. In other words, the zeolite material in the first coating is preferably substantially free of iron, and even more preferably free of iron.

[0015] Alternatively, the zeolite material in the first coating preferably contains iron, and the amount of iron contained in the zeolite material, calculated as Fe2O3, is preferably in the range of 0.1 to 10.0 mass%, more preferably 1.0 to 7.0 mass%, and more preferably 2.5 to 5.5 mass%, based on the total mass of the zeolite material. More preferably, 95 to 100 mass%, more preferably 98 to 100 mass%, more preferably 99 to 100 mass%, and more preferably 99.5 to 100 mass% of the framework structure of the zeolite material in the first coating is composed of Si, Al, O, and optionally one or more of P and H, and the molar ratio of Si to Al, calculated as SiO2:Al2O3, in the framework structure is preferably in the range of 2:1 to 50:1, more preferably 4:1 to 45:1, more preferably 10:1 to 40:1, more preferably 12:1 to 30:1, more preferably 13:1 to 25:1, and more preferably 15:1 to 21:1.

[0016] The present invention therefore preferably relates to a catalyst for the oxidation of NO, the oxidation of ammonia and the selective catalytic reduction of NOx, said catalyst comprising: (i) a substrate including an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end, and a plurality of passages defined by an interior wall of the substrate extending through the interior of the substrate, wherein an interface between the passages and the interior wall is defined by a surface of the interior wall; (ii) a first coating comprising a copper-containing zeolitic material, the zeolitic material having a framework type CHA or AEI, more preferably CHA, and the amount of copper, calculated as CuO, contained in the zeolitic material is more preferably in the range of 1 to 10 wt. %; (iii) a second coating comprising a platinum group metal component supported on a non-zeolitic oxide material, wherein the platinum group metal component supported on the non-zeolitic oxide material is present in the second coating at a first loading, L1, which is the sum of the loading of the platinum group metal component and the loading of the non-zeolitic oxide material; the second coating further comprises a zeolitic material comprising one or more of copper and iron, the zeolitic material comprising one or more of copper and iron being present in the second coating at a second loading L2, the second loading being the sum of the loading of the zeolitic material and the loading of the one or more of copper and iron; the second coating is disposed on the surface of the inner wall over y% of the axial length of the substrate from the outlet end to the inlet end, where y is in the range of 10 to 90; the first coating extends over x% of the axial length of the substrate from the inlet end to the outlet end and is disposed on the second coating and on the surface of the inner wall, where x is in the range of 95 to 100; The ratio of the first loading in g / l to the second loading in g / l, L1:L2, is at least 1.1:1.

[0017] In the context of the present invention, the first coating (ii) comprises one or more of copper and iron in an amount of 0.5 to 4 g / in 3 in the range of 0.75 to 3.5 g / in 3 in the range of 1 to 3 g / in 3 in the range of 1.5 to 2.5 g / in 3 It is preferred that the zeolite material contains a loading in the range of

[0018] The zeolitic material included in the first coating more preferably has framework type CHA and has an average crystal size as determined via scanning electron microscopy of at least 0.5 micrometers, more preferably in the range of 0.5 to 1.5 micrometers, more preferably in the range of 0.6 to 1.0 micrometers, more preferably in the range of 0.6 to 0.8 micrometers.

[0019] Preferably, the first coating further comprises a first oxide material, more preferably one or more of zirconia, alumina, titania, silica, and mixed oxides comprising two or more of Zr, Al, Ti, and Si, more preferably one or more of alumina and zirconia, more preferably zirconia.

[0020] The first coating preferably comprises the first oxide material in an amount in the range of 0.5 to 10% by mass, more preferably in the range of 1 to 7% by mass, more preferably in the range of 3 to 6% by mass, based on the total mass of the zeolite material contained in the first coating.

[0021] The first coating is 0.01 to 0.2 g / in 3 in the range of 0.02 to 0.15 g / in 3 in the range of 0.03 to 0.10 g / in 3 It is preferred that the first oxide material be present in a loading range of 1000 to 15000.

[0022] Preferably, 95 to 100% by mass of the first coating is made of a zeolite material including a zeolite material containing one or more of copper and iron, more preferably 98 to 100% by mass, more preferably 99 to 100% by mass, and more preferably 99.5 to 100% by mass, of the first coating, more preferably made of the first oxide material defined above.

[0023] In the context of the present invention, it is alternatively preferred that the first coating comprises vanadium oxide, more preferably one or more of vanadium(V) oxide, vanadium(IV) oxide and vanadium(III) oxide, the vanadium oxide optionally comprising one or more of tungsten, iron and antimony.

[0024] More preferably, the vanadium oxide is supported on an oxide support material comprising one or more of titanium, silicon and zirconium, more preferably one or more of titanium and silicon, and the oxide support material is more preferably one or more of titania and silica, more preferably titania and silica, and more preferably 80 to 95 mass % of the oxide support material consists of titania.

[0025] According to said alternative, the first coating contains vanadium oxide, calculated as V2O5, in an amount of 1 to 6 g / in 3 in the range of 2 to 4 g / in 3 It is preferable that the amount of the supported metal is in the range of 100 to 1500.

[0026] According to said alternative, it is preferred that 95 to 100% by weight of the first coating consists of vanadium oxide supported on said oxide support material, more preferably 98 to 100% by weight, more preferably 99 to 100% by weight, more preferably 99.5 to 100% by weight.

[0027] In the context of the present invention, it is preferred that 0 to 0.001% by weight, more preferably 0 to 0.0001% by weight, more preferably 0 to 0.00001% by weight, more preferably 0 to 0.00001% by weight of the first coating consists of platinum, more preferably platinum, palladium and rhodium, more preferably platinum, palladium, rhodium, osmium and iridium, more preferably any precious metal. In other words, it is preferred that the first coating is substantially free of platinum, more preferably platinum, more preferably platinum, palladium and rhodium, more preferably platinum, palladium, rhodium, osmium and iridium, more preferably no precious metal.

[0028] The catalyst is a first coating (ii) of 0.5 to 7 g / in 3 in the range of 1 to 5 g / in 3 in the range of 1.5 to 3 g / in 3 It is preferable that the amount of the supported metal is in the range of 100 to 1500.

[0029] The first coating preferably comprises a nitrogen oxide (NOx) reducing component, and more preferably consists of a nitrogen oxide (NOx) reducing component.

[0030] With respect to the second coating, the platinum group metal component contained in the second coating is preferably one or more of platinum, palladium, and rhodium, more preferably one or more of platinum and palladium, and even more preferably the platinum group metal component is platinum.

[0031] The second coating contains platinum group metal components calculated as platinum group metal elements at a concentration of 2 to 50 g / ft 3 More preferably, in the range of 5 to 30 g / ft 3 in the range of 10 to 15 g / ft 3 Preferably, the second coating contains platinum in a loading range of 2 to 50 g / ft, calculated as elemental platinum. 3 More preferably, in the range of 5 to 30 g / ft 3 in the range of 10 to 15 g / ft 3 It is more preferable that the amount of the supported metal is in the range of 1.

[0032] The second coating preferably comprises a platinum group metal component in an amount in the range of 0.1 to 3 mass %, more preferably in the range of 0.25 to 1.5 mass %, more preferably in the range of 0.5 to 1 mass %, based on the mass of the non-zeolitic oxide material contained in the second coating.

[0033] The non-zeolitic oxide material on which the platinum group metal component of the second coating is supported preferably comprises, and more preferably consists of, one or more of alumina, zirconia, titania, silica, ceria, and mixed oxides comprising two or more of Al, Zr, Ti, Si, and Ce, more preferably one or more of alumina, zirconia, titania, and silica, more preferably one or more of titania and silica.

[0034] The present invention therefore preferably relates to a catalyst for the oxidation of NO, the oxidation of ammonia and the selective catalytic reduction of NOx, said catalyst comprising: (i) a substrate including an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end, and a plurality of passages defined by an interior wall of the substrate extending through the interior of the substrate, wherein an interface between the passages and the interior wall is defined by a surface of the interior wall; (ii) a first coating comprising one or more of vanadium oxide and a zeolite material comprising one or more of copper and iron; (iii) a second coating comprising platinum supported on a non-zeolitic oxide material, the platinum supported on the non-zeolitic oxide material being present in the second coating at a first loading L1, the first loading being the sum of the platinum loading and the non-zeolitic oxide material loading, the non-zeolitic oxide material comprising one or more of alumina, zirconia, titania, silica, ceria, and mixed oxides comprising two or more of Al, Zr, Ti, Si, and Ce; the second coating further comprises a zeolitic material comprising one or more of copper and iron, the zeolitic material comprising one or more of copper and iron being present in the second coating at a second loading L2, the second loading being the sum of the loading of the zeolitic material and the loading of the one or more of copper and iron; the second coating is disposed on the surface of the inner wall over y% of the axial length of the substrate from the outlet end to the inlet end, where y is in the range of 10 to 90; the first coating extends over x% of the axial length of the substrate from the inlet end to the outlet end and is disposed on the second coating and on the surface of the inner wall, where x is in the range of 95 to 100; The ratio of the first loading in g / l to the second loading in g / l, L1:L2, is at least 1.1:1.

[0035] The present invention more preferably relates to a catalyst for the oxidation of NO, the oxidation of ammonia and the selective catalytic reduction of NOx, said catalyst comprising: (i) a substrate including an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end, and a plurality of passages defined by an interior wall of the substrate extending through the interior of the substrate, wherein an interface between the passages and the interior wall is defined by a surface of the interior wall; (ii) a first coating comprising a copper-containing zeolitic material, the zeolitic material having a framework type CHA or AEI, more preferably CHA, and the amount of copper, calculated as CuO, contained in the zeolitic material is more preferably in the range of 1 to 10 wt. %; (iii) a second coating comprising platinum supported on a non-zeolitic oxide material, the platinum supported on the non-zeolitic oxide material being present in the second coating at a first loading L1, the first loading being the sum of the platinum loading and the non-zeolitic oxide material loading, the non-zeolitic oxide material comprising one or more of alumina, zirconia, titania, silica, ceria, and mixed oxides comprising two or more of Al, Zr, Ti, Si, and Ce; the second coating further comprises a zeolitic material comprising one or more of copper and iron, the zeolitic material comprising one or more of copper and iron being present in the second coating at a second loading L2, the second loading being the sum of the loading of the zeolitic material and the loading of the one or more of copper and iron; the second coating is disposed on the surface of the inner wall over y% of the axial length of the substrate from the outlet end to the inlet end, where y is in the range of 10 to 90; the first coating extends over x% of the axial length of the substrate from the inlet end to the outlet end and is disposed on the second coating and on the surface of the inner wall, where x is in the range of 95 to 100; The ratio of the first loading in g / l to the second loading in g / l, L1:L2, is at least 1.1:1.

[0036] In the context of the present invention, with respect to the non-zeolitic oxide material contained in the second coating, preferably 90 to 100%, more preferably 95 to 100%, more preferably 99 to 100%, more preferably 99.5 to 100% by weight of the non-zeolitic oxide material of the second coating consists of titania and optionally silica. More preferably, 60 to 100%, more preferably 80 to 100%, more preferably 85 to 95% by weight of the non-zeolitic oxide material of the second coating consists of titania, and more preferably 0 to 40%, more preferably 0 to 20%, more preferably 5 to 15% by weight of the non-zeolitic oxide material of the second coating consists of silica.

[0037] The second coating is preferably 0.25 to 3 g / in 3 in the range of 0.5 to 2 g / in 3 in the range of 0.75 to 1.5 g / in 3 and non-zeolitic oxide materials at loadings in the range of 0.1 to 1.0.

[0038] Preferably, the zeolitic material in the second coating has a framework type selected from the group consisting of AEI, GME, CHA, MFI, BEA, FAU, MOR, mixtures of two or more thereof, and mixed types of two or more thereof, more preferably, AEI, GME, CHA, BEA, FAU, MOR, mixtures of two or more thereof, and mixed types of two or more thereof, more preferably, AEI, CHA, BEA, mixtures of two or more thereof, and mixed types of two or more thereof. The zeolitic material of the second coating has a framework type CHA or AEI, more preferably CHA.

[0039] The zeolite material contained in the second coating preferably contains copper, and the amount of copper calculated as CuO contained in the zeolite material is more preferably in the range of 1 to 10% by mass, more preferably in the range of 2 to 8% by mass, more preferably in the range of 3 to 6% by mass, more preferably in the range of 4.5 to 6% by mass, based on the total mass of the zeolite material. With regard to the second coating, it is more preferred that the second coating comprises platinum supported on a non-zeolitic oxide material, the platinum supported on the non-zeolitic oxide material being present in the second coating at a first loading L1, the first loading being the sum of the loading of platinum and the loading of the non-zeolitic oxide material, the non-zeolitic oxide material comprising one or more of alumina, zirconia, titania, silica, ceria, and mixed oxides comprising two or more of Al, Zr, Ti, Si, and Ce; it is more preferred that the second coating further comprises a zeolitic material comprising copper, the zeolitic material comprising copper being present in the second coating at a second loading L2, the second loading being the sum of the loading of the zeolitic material and the loading of one or more of copper and iron, the zeolitic material of the second coating having a framework type CHA or AEI, more preferably CHA.

[0040] In the context of the present invention, 95 to 100% by weight, more preferably 98 to 100% by weight, more preferably 99 to 100% by weight, more preferably 99.5 to 100% by weight of the framework structure of the zeolitic material of the second coating consists of one or more of Si, Al, O and optionally H and P, and in the framework structure the molar ratio of Si to Al, calculated as SiO2:Al2O3, is more preferably in the range of 2:1 to 50:1, more preferably in the range of 4:1 to 45:1, more preferably in the range of 10:1 to 40:1, more preferably in the range of 12:1 to 30:1, more preferably in the range of 13:1 to 25:1, more preferably in the range of 15:1 to 21:1.

[0041] The amount of iron, calculated as Fe2O3, contained in the zeolite material in the second coating is preferably at most 0.01% by mass, more preferably 0 to 0.001% by mass, and even more preferably 0 to 0.0001% by mass, based on the total mass of the zeolite material. In other words, the zeolite material in the second coating is substantially free of iron, and even more preferably free of iron.

[0042] Alternatively, the zeolite material in the second coating preferably comprises iron, and the amount of iron, calculated as Fe2O3, in the zeolite material is more preferably in the range of 0.1 to 10.0 mass %, more preferably in the range of 1.0 to 7.0 mass %, more preferably in the range of 2.5 to 5.5 mass %, based on the total mass of the zeolite material. According to said alternative, it is preferred that 95-100% by weight, more preferably 98-100% by weight, more preferably 99-100% by weight, more preferably 99.5-100% by weight of the framework structure of the zeolitic material consists of one or more of Si, Al, O, and optionally H and P, and the molar ratio of Si to Al, calculated as SiO2:Al2O3, in the framework structure is more preferably in the range 2:1 to 50:1, more preferably in the range 4:1 to 45:1, more preferably in the range 10:1 to 40:1, more preferably in the range 12:1 to 30:1, more preferably in the range 13:1 to 25:1, more preferably in the range 15:1 to 21:1.

[0043] In the context of the present invention, the second coating comprises a zeolite material containing one or more of copper and iron at a concentration of 0.05 to 2 g / in 3 range, more preferably 0.08 to 1 g / in 3 in the range of 0.1 to 0.5 g / in 3 The amount of support is in the range of

[0044] The zeolitic material, more preferably having framework type CHA, included in the second coating preferably has an average crystal size as determined via scanning electron microscopy of at least 0.5 micrometers, more preferably in the range of 0.5 to 1.5 micrometers, more preferably in the range of 0.6 to 1.0 micrometers, more preferably in the range of 0.6 to 0.8 micrometers.

[0045] With regard to the second coating, it is preferred that the second coating further comprises a second oxide material, more preferably one or more of silica, alumina, titania, zirconia, and mixed oxides comprising two or more of Si, Al, Ti, and Zr, more preferably one or more of silica and alumina, more preferably silica. It is more preferred that the second coating comprises the second oxide material in an amount in the range of 0.5 to 10% by weight, more preferably in the range of 2 to 8% by weight, more preferably in the range of 4 to 6% by weight, based on the total weight of the zeolite material of the second coating.

[0046] The second coating comprises a second oxide material at a concentration of 0.005 to 0.05 g / in 3 in the range of 0.008 to 0.02 g / in 3 It is preferable that the amount of the supported metal is in the range of 100 to 1500.

[0047] Preferably, 95 to 100% by mass of the second coating is made of a zeolitic material containing one or more of a platinum group metal component, copper, and iron supported on a non-zeolitic oxide material, more preferably 98 to 100% by mass, more preferably 99 to 100% by mass, and more preferably 99.5 to 100% by mass of the second coating.

[0048] The second coating preferably comprises, and more preferably consists of, one or more nitrogen oxide (NOx) reducing components and one or more ammonia oxidizing (AMOx) components.

[0049] The catalyst is applied as a second coating at a concentration of 0.5 to 5 g / in 3 in the range of 0.75 to 3 g / in 3 in the range of 1 to 2.5 g / in 3 It is preferable that the amount of the supported metal is in the range of 100 to 1500.

[0050] In the second coating, the ratio of the first loading in g / l to the second loading in g / l, L1:L2, is preferably in the range of 1.1:1 to 50:1, more preferably in the range of 1.5:1 to 30:1, more preferably in the range of 1.75:1 to 20:1, more preferably in the range of 2:1 to 10:1, more preferably in the range of 2.5:1 to 8:1, more preferably in the range of 3:1 to 6:1, more preferably in the range of 3.5:1 to 5:1.

[0051] Preferably, the substrate for the catalyst is a flow-through substrate or a wall-flow filter substrate, more preferably a flow-through substrate.

[0052] With regard to the catalyst substrate, it is preferred that the catalyst substrate comprises a ceramic material, more preferably consists of a ceramic material, and the ceramic material more preferably comprises or more preferably consists of one or more of alumina, silica, silicate, aluminosilicate, more preferably cordierite or mullite, aluminotitanate, silicon carbide, zirconia, magnesia, more preferably spinel and titania, more preferably one or more of silicon carbide and cordierite, more preferably cordierite.

[0053] Preferably, the catalyst substrate is a flow-through substrate comprising cordierite, more preferably a flow-through substrate consisting of cordierite.

[0054] Alternatively, with regard to the substrate, it is preferred that the substrate comprises, more preferably consists of, a metallic material, and that the metallic material more preferably comprises, more preferably consists of, oxygen and one or more of iron, chromium and aluminum.

[0055] The catalyst of the present invention preferably comprises a substrate (i), a first coating (ii) and a second coating (iii).

[0056] The present invention further relates to a method for preparing a catalyst for the oxidation of NO, the oxidation of ammonia and the selective catalytic reduction of NOx, preferably a catalyst according to the invention, which method comprises the steps of: (a) providing an uncoated substrate, the substrate including an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end, and a plurality of passages defined by an interior wall of the substrate extending through an interior of the substrate, wherein an interface between the passages and the interior wall is defined by a surface of the interior wall; (b) providing a slurry including a solvent, a platinum group metal component, a non-zeolitic oxide material, and a zeolitic material including one or more of copper and iron, disposing the slurry on the surface of the inner wall from the outlet end to the inlet end over y% (y is in the range of 10 to 90) of the axial length of the substrate, and calcining the slurry disposed on the substrate to obtain a second coating disposed on the surface of the inner wall of the substrate; (c) providing a slurry comprising a solvent and one or more zeolite materials comprising one or more of vanadium oxide, copper, and iron, disposing the slurry on the second coating over x% (x is in the range of 95 to 100) of the axial length of the substrate from the inlet end to the outlet end, and calcining the slurry disposed on the substrate to obtain a first coating disposed on the surface of the inner wall of the substrate and on the second coating; Includes:

[0057] Regarding (b), (b) is (b.1) forming a slurry with water, an aqueous mixture of a platinum group metal precursor, more preferably a platinum precursor, a non-zeolitic oxide material, and a zeolitic material, more preferably an aqueous mixture of a zeolitic material having a framework type CHA that includes one or more of copper and iron; (b.2) more preferably adding a precursor of a second oxide material, more preferably a Si-containing precursor, more preferably colloidal silica; (b.3) disposing the slurry obtained in (b.1), more preferably obtained in (b.2), on the surface of the inner wall over y% of the axial length of the substrate from the outlet end to the inlet end of the substrate; (b.4) more preferably, drying the slurry disposed on the substrate obtained in (b.3) to obtain a dried slurry-treated substrate; (b.5) calcining the slurry disposed on said substrate obtained in (b.3), more preferably the dried slurry treated substrate obtained in (b.4), in a gas atmosphere having a temperature preferably in the range of 300-600°C, more preferably in the range of 350-550°C, wherein said gas atmosphere preferably comprises and more preferably is one or more of air, lean air and oxygen, more preferably air; It is preferred that the composition comprises, and more preferably consists of,

[0058] Regarding (b.1), (b.1) is (b.1a) impregnating a non-zeolitic oxide material with a platinum group metal precursor, more preferably a platinum precursor; (b.1b) calcining the impregnated non-zeolitic oxide material obtained according to (b.1a); (b.1c) mixing the platinum group metal supported on the non-zeolitic oxide material obtained according to (b.1b) with water and a zeolitic material, more preferably a zeolitic material having a framework type CHA containing one or more of copper and iron; It is preferred that the compound contains:

[0059] In (b), more preferably in (b.1), and more preferably in (b.1c), it is preferred that the mass ratio of the mass of platinum group metal supported on the non-zeolitic oxide material to the mass of the zeolitic material comprising one or more of copper and iron is at least 1.1:1, more preferably in the range of 1.1:1 to 50:1, more preferably in the range of 1.5:1 to 30:1, more preferably in the range of 1.75:1 to 20:1, more preferably in the range of 2:1 to 10:1, more preferably in the range of 2.5:1 to 8:1, more preferably in the range of 3:1 to 6:1, more preferably in the range of 3.5:1 to 5:1.

[0060] According to (b.4), the drying is preferably carried out in a gas atmosphere having a temperature in the range of 90 to 180°C, the gas atmosphere more preferably comprising, more preferably being, one or more of air, lean air and oxygen, more preferably air.

[0061] According to (b.5), it is preferred that the calcination is carried out in a gas atmosphere having a temperature in the range of 350 to 500° C. The gas atmosphere comprises, and is more preferably, one or more of air, lean air and oxygen, more preferably air.

[0062] Regarding (c), (c) is (c.1) forming a slurry comprising water and a zeolitic material, more preferably a zeolitic material having a framework type CHA comprising one or more of copper and iron, and more preferably a precursor of a first oxide material, more preferably a Zr-containing precursor, more preferably zirconyl acetate; or forming a slurry with water and a source of vanadium oxide, more preferably vanadium oxalate, and adding more preferably the oxide material, more preferably along with a dispersant; (c.2) disposing the slurry obtained in (c.1) on the surface of the inner wall and on the second coating over x% of the axial length of the substrate from the inlet end to the outlet end of the substrate, where x is more preferably in the range of 98-100, more preferably in the range of 99-100; (c.3) optionally drying the slurry disposed on the substrate obtained in (c.2) to obtain a dried slurry-treated substrate; (c.4) calcining the slurry disposed on the substrate obtained in (c.2), or the dried slurry-treated substrate obtained in (c.3), in a gas atmosphere having a temperature preferably in the range of 300-600°C, more preferably in the range of 350-550°C, wherein the gas atmosphere preferably comprises and is one or more of air, lean air, and oxygen, more preferably air; It is preferred that the composition comprises, and more preferably consists of,

[0063] According to (c.3), the drying is preferably carried out in a gas atmosphere having a temperature in the range of 90 to 180°C, the gas atmosphere more preferably comprising, more preferably being, one or more of air, lean air and oxygen, more preferably air.

[0064] According to (c.4), it is preferred that the calcination is carried out in a gas atmosphere having a temperature in the range of 350 to 500° C. More preferably, the gas atmosphere comprises, and more preferably is, one or more of air, lean air and oxygen, more preferably air.

[0065] It is more preferable that y is in the range of 20 to 80, more preferably in the range of 40 to 75, more preferably in the range of 50 to 72, and even more preferably in the range of 60 to 70.

[0066] More preferably, the disposing in one or more of (b) and (c), more preferably (b) and (c), is carried out by spraying the slurry onto the substrate or by immersing the substrate in the slurry, more preferably by immersing the substrate in the slurry.

[0067] The method according to the present invention preferably comprises (a), (b) and (c).

[0068] The present invention further relates to a catalyst for the oxidation of NO, the oxidation of ammonia and the selective catalytic reduction of NOx, preferably according to the invention, i.e. obtainable or obtained by the method according to the invention.

[0069] The invention further relates to the use of the catalyst for NO oxidation, ammonia oxidation and selective catalytic reduction of NOx according to the invention for simultaneous selective catalytic reduction of NOx, oxidation of ammonia and oxidation of NO.

[0070] The present invention further relates to an exhaust gas treatment system for treating an exhaust gas stream emitted from an internal combustion engine, preferably a diesel engine, said exhaust gas treatment system having an upstream end for introducing said exhaust gas stream into said exhaust gas treatment system, said exhaust gas treatment system comprising a catalyst for the oxidation of NO, the oxidation of ammonia and the selective catalytic reduction of NOx according to the present invention and as defined above, and one or more of a selective catalytic reduction catalyst, a hybrid selective catalytic reduction / ammonia oxidation catalyst, a catalyzed soot filter.

[0071] The system preferably includes a catalyst according to the present invention and a selective catalytic reduction catalyst, the selective catalytic reduction catalyst being located upstream of the catalyst according to the present invention. More preferably, the system further includes a first urea injector, the urea injector being located upstream of the selective catalytic reduction catalyst.

[0072] The system further comprises a catalyzed soot filter, which is preferably located downstream of the catalyst according to the present invention.

[0073] More preferably, the system further comprises a hybrid selective catalytic reduction / ammonia oxidation catalyst and a second selective catalytic reduction catalyst, the hybrid selective catalytic reduction / ammonia oxidation catalyst being located downstream of the second selective catalytic reduction catalyst, and the second catalytic reduction catalyst being located upstream of the hybrid selective catalytic reduction / ammonia oxidation catalyst and downstream of the catalyzed soot filter. More preferably, the system further comprises a second urea injector, the second urea injector being located downstream of the catalyzed soot filter and upstream of the second selective catalytic reduction catalyst.

[0074] The present invention further relates to a method for simultaneous selective catalytic reduction of NOx, oxidation of ammonia and oxidation of nitric oxide, the method comprising: (1) providing a gas stream containing one or more of NOx, ammonia, and nitric oxide; (2) contacting the gas stream provided in (1) with a catalyst for the oxidation of NO, the oxidation of ammonia, and the selective catalytic reduction of NOx according to the present invention; Includes:

[0075] The present invention is illustrated by the following series of embodiments and combinations of embodiments resulting from the indicated dependencies and backward references. In particular, where a range of embodiments is mentioned, such as in the context of a term such as "the catalyst of any one of embodiments 1 to 4," it is intended that all embodiments within this range are expressly disclosed to those skilled in the art, i.e., this expression should be understood by those skilled in the art as being synonymous with "the catalyst of any one of embodiments 1, 2, 3, and 4." Furthermore, it is expressly pointed out that the following series of embodiments represent a suitably structured part of the description directed to the general and preferred aspects of the present invention, rather than a series of claims determining the scope of protection.

[0076] Embodiment 1: A catalyst for the oxidation of NO, the oxidation of ammonia and the selective catalytic reduction of NOx, comprising: (i) a substrate including an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end, and a plurality of passages defined by an interior wall of the substrate extending through the interior of the substrate, wherein an interface between the passages and the interior wall is defined by a surface of the interior wall; (ii) a first coating comprising one or more of vanadium oxide and a zeolite material comprising one or more of copper and iron; (iii) a second coating comprising a platinum group metal component supported on a non-zeolitic oxide material, wherein the platinum group metal component supported on the non-zeolitic oxide material is present in the second coating at a first loading, L1, which is the sum of the loading of the platinum group metal component and the loading of the non-zeolitic oxide material; the second coating further comprises a zeolitic material comprising one or more of copper and iron, the zeolitic material comprising one or more of copper and iron being present in the second coating at a second loading L2, the second loading being the sum of the loading of the zeolitic material and the loading of the one or more of copper and iron; the second coating is disposed on the surface of the inner wall over y% of the axial length of the substrate from the outlet end to the inlet end, where y is in the range of 10 to 90; the first coating extends over x% of the axial length of the substrate from the inlet end to the outlet end and is disposed on the second coating and on the surface of the inner wall, where x is in the range of 95 to 100; A catalyst wherein the ratio of the first loading in g / l to the second loading in g / l, L1:L2, is at least 1.1:1.

[0077] Embodiment 2: The catalyst of embodiment 1, wherein x is in the range of 98-100, preferably in the range of 99-100.

[0078] Embodiment 3: The catalyst of embodiment 1 or 2, wherein y is in the range of 20 to 80, preferably in the range of 40 to 75, more preferably in the range of 50 to 72, more preferably in the range of 60 to 70.

[0079] Embodiment 4: The catalyst of any one of embodiments 1-3, wherein the first coating (ii) comprises a zeolitic material comprising one or more of copper and iron.

[0080] Embodiment 5: The catalyst of any one of embodiments 1 to 4, wherein the zeolitic material included in the first coating has a framework type selected from the group consisting of AEI, GME, CHA, MFI, BEA, FAU, MOR, mixtures of two or more thereof, and mixed types of two or more thereof, preferably selected from the group consisting of AEI, GME, CHA, BEA, FAU, MOR, mixtures of two or more thereof, and mixed types of two or more thereof, more preferably selected from the group consisting of AEI, CHA, BEA, mixtures of two or more thereof, and mixed types of two or more thereof, and the zeolitic material included in the first coating more preferably has a framework type CHA or AEI, more preferably CHA.

[0081] Embodiment 6: The catalyst of any one of embodiments 1 to 5, wherein 95 to 100 wt. %, preferably 98 to 100 wt. %, more preferably 99 to 100 wt. %, more preferably 99.5 to 100 wt. % of the framework structure of the zeolitic material in the first coating consists of Si, Al, O, and optionally one or more of P and H, and wherein the molar ratio of Si to Al, calculated as molar SiO:AlO, in the framework structure is preferably in the range of 2:1 to 50:1, more preferably in the range of 4:1 to 45:1, more preferably in the range of 10:1 to 40:1, more preferably in the range of 12:1 to 30:1, more preferably in the range of 13:1 to 25:1, more preferably in the range of 15:1 to 21:1.

[0082] Embodiment 7: The catalyst of any one of embodiments 1 to 6, wherein the zeolitic material in the first coating comprises copper, and the amount of copper, calculated as CuO, in the zeolitic material is preferably in the range of 1 to 10 wt.%, more preferably in the range of 2 to 8 wt.%, more preferably in the range of 3 to 6 wt.%, more preferably in the range of 4.5 to 6 wt.%, based on the total weight of the zeolitic material.

[0083] Embodiment 8: The catalyst of embodiment 7, wherein the amount of iron, calculated as Fe2O3, contained in the zeolitic material in the first coating is at most 0.01 wt%, preferably in the range of 0 to 0.001 wt%, more preferably in the range of 0 to 0.0001 wt%, based on the total weight of the zeolitic material.

[0084] Embodiment 9: The zeolite material in the first coating comprises iron, and the amount of iron in the zeolite material, calculated as Fe2O3, is preferably in the range of 0.1 to 10.0% by weight, more preferably in the range of 1.0 to 7.0% by weight, more preferably in the range of 2.5 to 5.5% by weight, based on the total weight of the zeolite material, and is preferably 95 to 100% by weight, more preferably 98 to 100% by weight, more preferably 99 to 100% by weight of the framework structure of the zeolite material in the first coating. 6. The catalyst of any one of embodiments 1 to 5, wherein, more preferably 99.5 to 100 wt. % consists of Si, Al, O, and optionally one or more of P and H, and wherein the molar ratio of Si to Al, calculated as SiO2:Al2O3, in said framework structure is preferably in the range of 2:1 to 50:1, more preferably in the range of 4:1 to 45:1, more preferably in the range of 10:1 to 40:1, more preferably in the range of 12:1 to 30:1, more preferably in the range of 13:1 to 25:1, more preferably in the range of 15:1 to 21:1.

[0085] Embodiment 10: The first coating (ii) comprises one or more of copper and iron in an amount of 0.5 to 4 g / in 3 in the range of 0.75 to 3.5 g / in 3 in the range of 1 to 3 g / in 3 in the range of 1.5 to 2.5 g / in 3 10. The catalyst of any one of embodiments 1-9, comprising a zeolitic material comprising at a loading in the range of

[0086] Embodiment 11: The catalyst of any one of embodiments 1 to 10, wherein the zeolitic material included in the first coating preferably has framework type CHA and has an average crystallite size as determined via scanning electron microscopy of at least 0.5 micrometers, preferably in the range of 0.5 to 1.5 micrometers, more preferably in the range of 0.6 to 1.0 micrometers, more preferably in the range of 0.6 to 0.8 micrometers.

[0087] Embodiment 12: The catalyst of any one of embodiments 1 to 11, wherein the first coating further comprises a first oxide material, the first oxide material preferably comprising one or more of zirconia, alumina, titania, silica, and mixed oxides comprising two or more of Zr, Al, Ti, and Si, more preferably one or more of alumina and zirconia, more preferably zirconia.

[0088] Embodiment 13: The first coating comprises the first oxide material in an amount ranging from 0.5 to 10% by weight, preferably from 1 to 7% by weight, more preferably from 3 to 6% by weight, based on the total weight of the zeolite material contained in the first coating, and the first coating preferably comprises the first oxide material in an amount ranging from 0.01 to 0.2 g / in 3 in the range of 0.02 to 0.15 g / in 3 in the range of 0.03 to 0.10 g / in 3 13. The catalyst of embodiment 12, comprising a loading in the range of

[0089] Embodiment 14: The catalyst of any one of embodiments 1 to 13, wherein 95 to 100% by weight, preferably 98 to 100% by weight, more preferably 99 to 100% by weight, more preferably 99.5 to 100% by weight of the first coating consists of a zeolitic material comprising one or more of copper and iron, and a first oxide material, preferably as defined in embodiment 13.

[0090] Embodiment 15: The catalyst of any one of embodiments 1 to 3, wherein the first coating comprises vanadium oxide, preferably one or more of vanadium (V) oxide, vanadium (IV) oxide, and vanadium (III) oxide, and the vanadium oxide optionally comprises one or more of tungsten, iron, and antimony.

[0091] Embodiment 16: The catalyst of embodiment 15, wherein the vanadium oxide is supported on an oxide support material comprising one or more of titanium, silicon, and zirconium, preferably one or more of titanium and silicon, and the oxide support material is more preferably one or more of titania and silica, more preferably titania and silica, and preferably 80 to 95 wt. % of the oxide support material consists of titania.

[0092] Embodiment 17: The first coating comprises vanadium oxide, calculated as V2O5, in an amount of 1 to 6 g / in 3 in the range of 2 to 4 g / in 3 17. The catalyst of embodiment 15 or 16, comprising a loading in the range of

[0093] Embodiment 18: The catalyst of any one of embodiments 15 to 17, wherein 95 to 100 wt. % of the first coating consists of vanadium oxide supported on the oxide support material, preferably 98 to 100 wt. %, more preferably 99 to 100 wt. %, more preferably 99.5 to 100 wt. %.

[0094] Embodiment 19: The catalyst of any one of embodiments 1 to 18, wherein 0 to 0.001 wt. %, preferably 0 to 0.0001 wt. %, more preferably 0 to 0.00001 wt. % of the first coating consists of platinum, preferably platinum, palladium, and rhodium, more preferably platinum, palladium, rhodium, osmium, and iridium, more preferably any noble metal.

[0095] Embodiment 20: The catalyst comprises: a first coating (ii) of 0.5 to 7 g / in 3in the range of 1 to 5 g / in 3 in the range of 1.5 to 3 g / in 3 20. The catalyst of any one of embodiments 1-19, comprising a loading in the range of:

[0096] Embodiment 21: The catalyst of any one of embodiments 1 to 20, wherein the first coating comprises, and preferably consists of, a nitrogen oxide (NOx) reducing component.

[0097] Embodiment 22: The catalyst of any one of embodiments 1 to 21, wherein the platinum group metal component included in the second coating is one or more of platinum, palladium, and rhodium, preferably one or more of platinum and palladium, and the platinum group metal component is more preferably platinum.

[0098] Embodiment 23: The second coating contains the platinum group metal component, calculated as platinum group metal elements, in an amount of 2 to 50 g / ft 3 range, preferably 5 to 30 g / ft 3 in the range of 10 to 15 g / ft 3 23. The catalyst of any one of embodiments 1 to 22, comprising a loading in the range of:

[0099] Embodiment 24: The catalyst of any one of embodiments 1 to 23, wherein the second coating comprises a platinum group metal component in an amount in the range of 0.1 to 3 wt. %, preferably in the range of 0.25 to 1.5 wt. %, more preferably in the range of 0.5 to 1 wt. %, based on the weight of the non-zeolitic oxide material included in the second coating.

[0100] Embodiment 25: The catalyst of any one of embodiments 1 to 24, wherein the non-zeolitic oxide material on which the platinum group metal component of the second coating is supported comprises, and preferably consists of, one or more of alumina, zirconia, titania, silica, ceria, and mixed oxides comprising two or more of Al, Zr, Ti, Si, and Ce, preferably comprises, and preferably consists of, one or more of alumina, zirconia, titania, and silica, more preferably comprises, and preferably consists of, one or more of titania and silica.

[0101] Embodiment 26: The catalyst of embodiment 25, wherein 90 to 100%, preferably 95 to 100%, more preferably 99 to 100%, more preferably 99.5 to 100%, by weight of the non-zeolitic oxide materials of the second coating consist of titania and optionally silica; preferably 60 to 100%, more preferably 80 to 100%, more preferably 85 to 95%, by weight of the non-zeolitic oxide materials of the second coating consist of titania; and preferably 0 to 40%, more preferably 0 to 20%, more preferably 5 to 15%, by weight of the non-zeolitic oxide materials of the second coating consist of silica.

[0102] Embodiment 27: The second coating comprises the non-zeolitic oxide material in an amount of 0.25 to 3 g / in 3 range, preferably 0.5 to 2 g / in 3 in the range of 0.75 to 1.5 g / in 3 27. The catalyst of any one of embodiments 1-26, comprising a loading in the range of:

[0103] Embodiment 28: The catalyst of any one of embodiments 1 to 27, wherein the zeolitic material included in the second coating has a framework type selected from the group consisting of AEI, GME, CHA, MFI, BEA, FAU, MOR, mixtures of two or more thereof, and mixed types of two or more thereof, preferably selected from the group consisting of AEI, GME, CHA, BEA, FAU, MOR, mixtures of two or more thereof, and mixed types of two or more thereof, more preferably selected from the group consisting of AEI, CHA, BEA, mixtures of two or more thereof, and mixed types of two or more thereof, and the zeolitic material of the second coating more preferably has framework type CHA or AEI, more preferably CHA.

[0104] Embodiment 29: The catalyst of any one of embodiments 1 to 28, wherein the zeolitic material in the second coating comprises copper, and the amount of copper, calculated as CuO, in the zeolitic material is preferably in the range of 1 to 10% by weight, more preferably in the range of 2 to 8% by weight, more preferably in the range of 3 to 6% by weight, more preferably in the range of 4.5 to 6% by weight, based on the total weight of the zeolitic material.

[0105] Embodiment 30: The catalyst of any one of embodiments 1 to 29, wherein 95 to 100% by weight, preferably 98 to 100% by weight, more preferably 99 to 100% by weight, more preferably 99.5 to 100% by weight of the framework structure of the zeolitic material of the second coating consists of one or more of Si, Al, O, and optionally H and P, and wherein the molar ratio of Si to Al, calculated as SiO2:Al2O3, in the framework structure is preferably in the range of 2:1 to 50:1, more preferably in the range of 4:1 to 45:1, more preferably in the range of 10:1 to 40:1, more preferably in the range of 12:1 to 30:1, more preferably in the range of 13:1 to 25:1, more preferably in the range of 15:1 to 21:1.

[0106] Embodiment 31: The catalyst of embodiment 29 or 30, wherein the amount of iron, calculated as Fe2O3, contained in the zeolitic material in the second coating is at most 0.01 wt.%, preferably 0 to 0.001 wt.%, more preferably 0 to 0.0001 wt.%, based on the total weight of the zeolitic material.

[0107] Embodiment 32: The zeolite material in the second coating comprises iron, and the amount of iron in the zeolite material, calculated as Fe2O3, is preferably in the range of 0.1 to 10.0% by weight, more preferably in the range of 1.0 to 7.0% by weight, more preferably in the range of 2.5 to 5.5% by weight, based on the total weight of the zeolite material, and is preferably 95 to 100% by weight, more preferably 98 to 100% by weight, more preferably 99 to 100% by weight, more preferably 100 to 100% by weight, based on the total weight of the zeolite material. 27. The catalyst of any one of embodiments 1 to 26, wherein 99.5 to 100 wt. % of the framework structure consists of Si, Al, O, and optionally one or more of H and P, and the molar ratio of Si to Al, calculated as SiO2:Al2O3, in the framework structure is preferably in the range of 2:1 to 50:1, more preferably in the range of 4:1 to 45:1, more preferably in the range of 10:1 to 40:1, more preferably in the range of 12:1 to 30:1, more preferably in the range of 13:1 to 25:1, more preferably in the range of 15:1 to 21:1.

[0108] Embodiment 33: The second coating comprises a zeolite material containing one or more of copper and iron in an amount of 0.05 to 2 g / in 3 range, preferably 0.08 to 1 g / in 3 in the range of 0.1 to 0.5 g / in 3 33. The catalyst of any one of embodiments 1-32, comprising a loading in the range of

[0109] Embodiment 34: The catalyst of any one of embodiments 1 to 33, wherein the zeolitic material, preferably having framework type CHA, included in the second coating has an average crystallite size, as determined via scanning electron microscopy, of at least 0.5 micrometers, preferably in the range of 0.5 to 1.5 micrometers, more preferably in the range of 0.6 to 1.0 micrometers, more preferably in the range of 0.6 to 0.8 micrometers.

[0110] Embodiment 35: The second coating further comprises a second oxide material, preferably comprising one or more of silica, alumina, titania, zirconia, and mixed oxides comprising two or more of Si, Al, Ti, and Zr, more preferably one or more of silica and alumina, more preferably silica; the second coating more preferably comprises the second oxide material in an amount in the range of 0.5 to 10% by weight, more preferably in the range of 2 to 8% by weight, more preferably in the range of 4 to 6% by weight, based on the total weight of the zeolitic material of the second coating; The second coating more preferably contains the second oxide material at a concentration of 0.005 to 0.05 g / in 3 in the range of 0.008 to 0.02 g / in 3 35. The catalyst of any one of embodiments 1 to 34, comprising a loading in the range of

[0111] Embodiment 36: The catalyst of any one of embodiments 1 to 35, wherein 95 to 100%, preferably 98 to 100%, more preferably 99 to 100%, more preferably 99.5 to 100%, by weight, of the second coating consists of a zeolitic material comprising one or more of the platinum group metal component, copper, and iron supported on the non-zeolitic oxide material, and a second oxide material, preferably as defined in embodiment 35.

[0112] Embodiment 37: The catalyst of any one of embodiments 1 to 36, wherein the second coating comprises, preferably consists of, one or more nitrogen oxide (NOx) reducing components and one or more ammonia oxidation (AMOx) components.

[0113]

[0042] Embodiment 38: The catalyst is applied to the second coating at a concentration of 0.5 to 5 g / in 3 range, preferably 0.75 to 3 g / in 3 in the range of 1 to 2.5 g / in 3 38. The catalyst of any one of embodiments 1 to 37, comprising a loading in the range of

[0114] Embodiment 39: The catalyst of any one of embodiments 1 to 38, wherein in the second coating, the ratio L1:L2 of the first loading in g / l to the second loading in g / l is in the range of 1.1:1 to 50:1, preferably in the range of 1.5:1 to 30:1, more preferably in the range of 1.75:1 to 20:1, more preferably in the range of 2:1 to 10:1, more preferably in the range of 2.5:1 to 8:1, more preferably in the range of 3:1 to 6:1, more preferably in the range of 3.5:1 to 5:1.

[0115] Embodiment 40: The catalyst of any one of embodiments 1 to 39, wherein the substrate of the catalyst is a flow-through substrate or a wall-flow filter substrate, preferably a flow-through substrate.

[0116] Embodiment 41: The catalyst of any one of embodiments 1 to 40, wherein the substrate of the catalyst comprises, preferably consists of, a ceramic material, the ceramic material preferably comprising, more preferably consisting of, one or more of alumina, silica, silicate, aluminosilicate, preferably cordierite or mullite, aluminotitanate, silicon carbide, zirconia, magnesia, preferably spinel and titania, more preferably one or more of silicon carbide and cordierite, more preferably cordierite; the substrate of the catalyst is preferably a flow-through substrate comprising, more preferably consisting of cordierite.

[0117] Embodiment 42: The catalyst of any one of embodiments 1 to 40, wherein the substrate of the catalyst comprises, preferably consists of, a metal material, and the metal material preferably comprises, more preferably consists of, oxygen and one or more of iron, chromium, and aluminum.

[0118] Embodiment 43: The catalyst of any one of embodiments 1 to 42, comprising the substrate (i), the first coating (ii), and the second coating (iii).

[0119] Embodiment 44: A method for preparing a catalyst for the oxidation of NO, the oxidation of ammonia and the selective catalytic reduction of NOx, preferably according to any one of embodiments 1 to 43, comprising: (a) providing an uncoated substrate, the substrate including an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end, and a plurality of passages defined by an interior wall of the substrate extending through an interior of the substrate, wherein an interface between the passages and the interior wall is defined by a surface of the interior wall; (b) providing a slurry comprising a solvent, a platinum group metal component, a non-zeolitic oxide material, and a zeolitic material comprising one or more of copper and iron, disposing the slurry on a surface of the inner wall over y% of the axial length of the substrate from the outlet end to the inlet end, where y is in the range of 10 to 90, and calcining the slurry disposed on the substrate to obtain a second coating disposed on the surface of the inner wall of the substrate; (c) providing a slurry comprising a solvent and one or more zeolite materials comprising one or more of vanadium oxide, copper, and iron, disposing the slurry on the second coating over x% of the axial length of the substrate from the inlet end to the outlet end, where x is in the range of 95 to 100, and calcining the slurry disposed on the substrate to obtain a first coating disposed on the surface of the inner wall of the substrate and on the second coating; A method comprising:

[0120] Embodiment 45:(b) is (b.1) forming a slurry with water, an aqueous mixture of a platinum group metal precursor, preferably a platinum precursor, a non-zeolitic oxide material, and a zeolitic material, preferably a zeolitic material having a framework type CHA containing one or more of copper and iron; (b.2) preferably adding a precursor of a second oxide material, more preferably a Si-containing precursor, more preferably colloidal silica; (b.3) disposing the slurry obtained in (b.1), preferably obtained in (b.2), on the surface of the inner wall over y% of the axial length of the substrate from the outlet end to the inlet end of the substrate; (b.4) preferably drying the slurry disposed on the substrate obtained in (b.3) to obtain a dried slurry-treated substrate; (b.5) calcining the slurry disposed on the substrate obtained in (b.3), preferably the dried slurry treated substrate obtained in (b.4), in a gas atmosphere preferably having a temperature in the range of 300-600°C, more preferably in the range of 350-550°C, said gas atmosphere preferably comprising and more preferably being one or more of air, lean air and oxygen, more preferably air; 45. The method of embodiment 44, comprising, and preferably consisting of:

[0121] Embodiment 46: The process of embodiment 45, wherein according to (b.4), drying is carried out in a gas atmosphere having a temperature in the range of 90 to 180°C, and the gas atmosphere preferably comprises, and is, one or more of air, lean air and oxygen, more preferably air.

[0122] Embodiment 47: The process of embodiment 45 or 46, wherein, according to (b.5), the calcination is carried out in a gas atmosphere having a temperature in the range of 350 to 500°C.

[0123] Embodiment 48: The method of embodiment 47, wherein the gas atmosphere comprises, and preferably is, one or more of air, lean air, and oxygen, more preferably air.

[0124] Embodiment 49:(c) is (c.1) forming a slurry comprising water and a zeolitic material, preferably a zeolitic material having a framework type CHA comprising one or more of copper and iron, and preferably a precursor of a first oxide material, more preferably a Zr-containing precursor, more preferably zirconyl acetate; or forming a slurry using water and a source of vanadium oxide, preferably vanadium oxalate, and adding preferably the oxide material, more preferably along with a dispersant; (c.2) disposing the slurry obtained in (c.1) on the surface of the inner wall and on the second coating over x% of the axial length of the substrate from the inlet end to the outlet end of the substrate, where x is preferably in the range of 98-100, more preferably in the range of 99-100; (c.3) optionally drying the slurry disposed on the substrate obtained in (c.2) to obtain a dried slurry-treated substrate; (c.4) calcining the slurry disposed on the substrate obtained in (c.2) or the dried slurry-treated substrate obtained in (c.3) in a gas atmosphere having a temperature preferably in the range of 300-600°C, more preferably in the range of 350-550°C, said gas atmosphere preferably comprising and more preferably being one or more of air, lean air and oxygen, more preferably air; 49. The method of any one of embodiments 44 to 48, comprising, preferably consisting of:

[0125] Embodiment 50: The method of embodiment 49, wherein according to (c.3), drying is carried out in a gas atmosphere having a temperature in the range of 90 to 180°C, the gas atmosphere preferably comprising, and more preferably being, one or more of air, lean air and oxygen, more preferably air.

[0126] Embodiment 51: The process of embodiment 49 or 50, wherein, according to (c.4), the calcination is carried out in a gas atmosphere having a temperature in the range of 350 to 500°C.

[0127] Embodiment 52: The method of embodiment 51, wherein the gas atmosphere comprises, and preferably is, one or more of air, lean air, and oxygen, more preferably air.

[0128] Embodiment 53: The method of any one of embodiments 44-52, wherein y is in the range of 20-80, preferably in the range of 40-75, more preferably in the range of 50-72, more preferably in the range of 60-70.

[0129] Embodiment 54: The method of any one of embodiments 44 to 53, wherein the disposing in one or more of (b) and (c), preferably (b) and (c), is carried out by spraying the slurry onto the substrate or by immersing the substrate in the slurry, preferably by immersing the substrate in the slurry.

[0130] Embodiment 55: The method of any one of embodiments 44 to 54, comprising (a), (b), and (c).

[0131] Embodiment 56: A catalyst for the oxidation of NO, the oxidation of ammonia and the selective catalytic reduction of NOx, preferably according to any one of embodiments 1 to 43, wherein the catalyst is obtainable or obtained by a method according to any one of embodiments 44 to 55.

[0132] Embodiment 57: Use of a catalyst for the oxidation of NO, the oxidation of ammonia and the selective catalytic reduction of NOx according to any one of embodiments 1 to 43, 56 for simultaneous selective catalytic reduction of NOx, oxidation of ammonia and oxidation of NO.

[0133] Embodiment 58: An exhaust gas treatment system for treating an exhaust gas stream emitted from an internal combustion engine, preferably a diesel engine, the exhaust gas treatment system having an upstream end for introducing the exhaust gas stream into the exhaust gas treatment system, the exhaust gas treatment system including a catalyst for NO oxidation, ammonia oxidation, and selective catalytic reduction of NOx according to any one of embodiments 1 to 43, 56, and one or more of a selective catalytic reduction catalyst, a hybrid selective catalytic reduction / ammonia oxidation catalyst, and a catalyzed soot filter.

[0134] Embodiment 59: The exhaust gas treatment system of embodiment 58, comprising a catalyst according to any one of embodiments 1 to 43 and 56 and a selective catalytic reduction catalyst, wherein the selective catalytic reduction catalyst is disposed upstream of the catalyst according to any one of embodiments 1 to 43 and 56, and the system preferably further comprises a first urea injector, wherein the urea injector is disposed upstream of the selective catalytic reduction catalyst.

[0135] Embodiment 60: The exhaust gas treatment system of embodiment 58 or 59, further comprising a catalyzed soot filter, wherein the catalyzed soot filter is positioned downstream of the catalyst according to any one of embodiments 1 to 43 and 56.

[0136] Embodiment 61: The exhaust gas treatment system of any one of embodiments 58 to 60, further comprising a hybrid selective catalytic reduction / ammonia oxidation catalyst and a second selective catalytic reduction catalyst, wherein the hybrid selective catalytic reduction / ammonia oxidation catalyst is disposed downstream of the second selective catalytic reduction catalyst, and the second selective catalytic reduction catalyst is disposed upstream of the hybrid selective catalytic reduction / ammonia oxidation catalyst and downstream of the catalyzed soot filter; the system preferably further comprises a second urea injector, wherein the second urea injector is disposed downstream of the catalyzed soot filter and upstream of the second selective catalytic reduction catalyst.

[0137] Embodiment 62: A method for simultaneous selective catalytic reduction of NOx, oxidation of ammonia and oxidation of nitric oxide, comprising: (1) providing a gas stream containing one or more of NOx, ammonia, and nitric oxide; (2) contacting the gas stream provided in (1) with a catalyst for the oxidation of NO, the oxidation of ammonia, and the selective catalytic reduction of NO according to any one of embodiments 1 to 43 and 56; A method comprising:

[0138] In the context of this invention, the "loading of a given component / coating" (g / in 3 or g / ft 3 The term "mass of said component / coating" refers to the mass of said component / coating per volume of substrate, where the volume of the substrate is the volume defined by the product of the cross section of the substrate and the axial length of the substrate on which said component / coating is present. For example, a component / coating extending over x% of the axial length of the substrate and having a mass of X g / in 3 When referring to a loading of a first coating having a loading of 0.01, the loading is measured by the total volume of the substrate (units in 3 ) refers to X grams of first coating per x% of the total.

[0139] Furthermore, in the context of the present invention, the term "X is one or more of A, B, and C" (where X is a given characteristic and A, B, and C each represent a specific realization of that characteristic) should be understood to indicate that X is either A, or B, or C, or A and B, or A and C, or B and C, or A, B, and C. In this regard, it should be noted that a person skilled in the art can translate the above abstract terms into concrete examples, for example, a specific example where X is a chemical element and A, B, and C are specific elements such as Li, Na, and K, or a specific example where X is a temperature and A, B, and C are specific temperatures such as 10°C, 20°C, and 30°C. In this regard, those skilled in the art can expand the above terms to less specific implementations of the feature, for example, "X is one or more of A and B" to indicate "X is either A, or B, or A and B", and to more specific implementations of the feature, for example, "X is one or more of A, B, C and D" to indicate "X is either A, or B, or C, or D, or A and B, or A and C, or A and D, or B and C, or B and D, or C and D, or A and B and C, or A and B and D, or B and C and D, or A and B and C and D".

[0140] Furthermore, in the context of the present invention, the term "internal wall surface" is understood as the "bare" or "exposed" or "blank" surface of the wall, i.e., the surface of the wall in its untreated state consisting of the wall material, except for unavoidable impurities that may contaminate the surface.

[0141] Furthermore, in the context of the present invention, the term "noble metal" encompasses the metals ruthenium, rhodium, palladium, platinum, silver, osmium, iridium, and gold.

[0142] In the context of the present invention, the term "consists of" in relation to weight percent of one or more components refers to the weight percent amount of that component(s) based on 100 weight percent of that entity. For example, the phrase "0-0.001 weight percent of the first coating consists of platinum" indicates that of the 100 weight percent components that the coating comprises, 0-0.001 weight percent is platinum.

[0143] The present invention will be further illustrated by the following Reference Examples, Comparative Examples and Examples. [Example]

[0144] Reference Example 1: Determination of Dv20, Dv50 and Dv90 values Particle size distribution was measured by static light scattering using a Sympatec HELOS instrument, and the optical density of the samples ranged from 5 to 10%.

[0145] Reference Example 2: Measurement of BET specific surface area The BET specific surface area was determined according to DIN 66131 or DIN ISO 9277 using liquid nitrogen.

[0146] Reference Example 3: General coating method To coat a flow-through substrate with one or more coatings, the flow-through substrate was suitably immersed vertically in a portion of a given slurry for a specific length of the substrate equal to the target length of the coating to be applied, in this manner contacting the wall surface of the substrate.

[0147] Comparative Example 1: Preparation of a catalyst not according to the invention (with three coatings) Third Coating (Outlet Bottom Coating): Si-doped titania powder (10% by mass SiO, 200 m 2A platinum ammine solution was added to a Si-titania (BET specific surface area of ​​10.5 mm / g, Dv90 of 20 micrometers) such that the calcined Si-titania had a Pt content of 0.81 wt. % based on the weight of the Si-titania. This material was added to water, and the slurry was milled until the resulting Dv90 was 5.2 microns, determined as described in Example 1. Finally, colloidal silica binder was mixed into the slurry at a level calculated (from the binder) to result in 2.5 wt. % SiO2 after calcination, based on the weight of the Si-titania. The resulting mixture was then applied to an uncoated honeycomb flow-through cordierite monolith substrate (diameter: 26.67 cm (10.5 in) x length: 7.62 cm (3 in), with a 400 / (2.54) per square centimeter coating density, using the coating method described in Example 3. 2 The third coating was applied to a cell (a cylindrical substrate having a wall thickness of 0.1 mm, 4 mils) from the outlet side to the inlet side, extending halfway along the length of the substrate. The coated substrate was then dried and calcined in an oven. The loading of the third coating after calcination was 14 g / ft of the third coating. 3 Including the platinum content of about 1 g / in 3 It was.

[0148] Second coating (inlet bottom coating): Si-doped titania powder (10% by mass SiO, 200 m 2 A platinum ammine solution was added to the Pt / Si-titania (BET specific surface area of ​​0.46 wt. % Pt, based on the weight of the Si-titania) to give a Pt / Si-titania (Dv90 of 20 microns, determined as described in Reference Example 1). After calcination at 590°C, the final Pt / Si-titania had a Pt content of 0.46 wt. % Pt, based on the weight of the Si-titania. This material was added to water and the slurry was milled until the resulting Dv90 was 10 microns, determined as described in Reference Example 1.

[0149] To an aqueous slurry of Cu-CHA zeolite material (5.1 wt.% CuO, 18% SiO:AlO molar ratio), zirconyl acetate solution was added to provide 5 wt.% ZrO after calcination based on the mass of the zeolite material. The Pt-containing slurry was added to the Cu-CHA slurry and stirred to form a final slurry. Using the coating method described in Reference Example 3, the final slurry was then applied over half the length of a honeycomb cordierite monolith substrate coated with a third coating, from the inlet side to the outlet side of the substrate, ensuring that the second coating did not overlap with the third coating. The coated substrate was then dried and calcined in an oven. The calcined second coating loading was 1.67 g / in. 3 Cu-CHA loading, 0.08 g / in 3 ZrO2 loading, 0.25 g / in 3 Si-titania loading of about 2 g / in 3 and 2g / ft 3 The mass ratio of Si-titania to Cu-CHA was approximately 0.15:1.

[0150] First Coating (Full Length Top Coating): To an aqueous slurry of Cu-CHA zeolite material (5.1 wt. % CuO, 18% SiO:AlO molar ratio), zirconyl acetate solution was added to provide 5 wt. % ZrO after calcination, based on the mass of the zeolite material. Using the coating method described in Reference Example 3, the slurry was then applied over the entire length of the honeycomb cordierite monolith substrate coated with the second and third coatings, from the inlet side to the outlet side of the substrate, covering the second and third coatings. The coated substrate was then dried and calcined in an oven. The calcined first coating loading was 1.0 g / in. 3 It was.

[0151] The final catalyst loading (first, second and third coatings) on the calcined catalyst was approximately 2.5 g / in 3 It was.

[0152] Example 1: Preparation of a catalyst according to the invention (with two coatings) Second Coating (Outlet Bottom Coating): Silica-doped titania powder (TiO (90 wt%), 10 wt% SiO, 200 m 2 / g BET specific surface area, Dv90 of 20 μm, 0.6 cm 3 Incipient wetness impregnation of Pt into the titania powder (particle size: 100 μm / g of new pore volume) was performed. The Pt source was a suspension of colloidally stabilized Pt at 2 wt% solids. The volume of the impregnation solution was calculated based on the mass of the titania powder and the corresponding pore volume. The Pt was then heat-set by powder calcining the impregnated silica-doped titania at 590°C for 1 hour. After heat-setting, the impregnated silica-doped titania powder was reslurried with deionized water and tartaric acid to a final slurry solids content of 40 wt% and a pH of the aqueous phase of the slurry of 3.75. The slurry was then milled to a resultant Dv90 of 10 micrometers, as determined as described in Reference Example 1.

[0153] Separately, a zeolite slurry was produced by mixing Cu-CHA zeolite material (5.1 wt% Cu calculated as CuO, SiO2:Al2O3 molar ratio of 18) with deionized water to produce a resulting slurry solids content of 38 wt%. This Cu-CHA slurry was then added to a Pt / silica-doped titania slurry. The mass ratio of Pt / silica-doped titania to Cu-CHA was approximately 4:1. Finally, colloidal silica binder (having a solids content of 34.5 wt%) and deionized water were added to the slurry to produce a final slurry solids content of 38 wt%. The resulting mixture was then coated onto an uncoated honeycomb flow-through cordierite monolith substrate (diameter: 26.67 cm (10.5 in) × length: 7.62 cm (3 in), 400 / (2.54) per square centimeter) using the coating method described in Reference Example 3. 2The second coating was applied to a cylindrical substrate (with a wall thickness of 0.1 mm (4 mils)) from the outlet side to the inlet side, covering 67% of the substrate's length. The coated substrate was then dried and then calcined. The final loading of the second coating after calcination was 0.24 g / in. 3 Cu-CHA loading, 1 g / in 3 of silica-doped titania, 0.012 g / in 3 Including the SiO2 loading (binder), the total is approximately 1.25 g / in 3 The second coating (coated over 67% of the substrate length) had a PGM loading of 12 g / ft 3 The ratio of the first loading in g / l (Pt / silica-doped titania) to the second loading in g / l (Cu-CHA), L1:L2, was about 4:1.

[0154] First Coating (Full Length Top Coating): The aqueous zirconyl acetate solution was diluted with water (3.1 wt. % ZrO in water). The amount of zirconyl acetate was adjusted to give a loading of 0.05 g / in of calcined zirconia (in the first coating), calculated as ZrO. 3 The slurry was calculated to be 0.01g / in. To this, Cu-CHA zeolite (Cu calculated as CuO, 5.1 wt. %, SiO2:Al2O3 molar ratio of 18) was added and mixed. The resulting slurry was 38 wt. % solids. Using the coating method described in Reference Example 3, this slurry was then applied over the second coating and along the entire length of the coated honeycomb flow-through cordierite monolith substrate, from the inlet side to the outlet side of the substrate. The coated substrate was then dried and then calcined. The calcined first coating loading was 1.95 g / in. 3 of Cu-CHA and 0.05g / in 3 of ZrO2, 2g / in 3 It was.

[0155] The final catalyst loading (first and second coatings) on the calcined catalyst was about 2.85 g / in 3 It was.

[0156] Example 2: Testing of Comparative Example 1 and Example 1 Catalysts - DeNOx Performance, N2O Production and NH3 Slip The catalysts were evaluated in a motor test cell equipped with a 6.7 L off-road calibration engine. In all cases, each catalyst was tested alone, without an upstream oxidation catalyst or downstream SCR catalyst. The resulting space velocity was 85 kJ / h for the SCR test (165 kJ / h at the highest temperature point). The SCR test used an ammonia-to-NOx ratio (ANR) sweep test with different stoichiometric ratios between NH3 and NOx. For the data shown in Figures 1-3, NOx conversion was always provided at an ANR of 1.1, while NO production and NH3 slip were provided at an ANR of 1.0. (ANR is the stoichiometric ammonia-to-NOx ratio, allowing the correct amount of urea to be injected to determine the given exhaust mass flow and NOx concentration.) The catalyst of Example 1 was tested by degreening, i.e., heating at 450°C for 2 hours and aging at 550°C for 50 hours in a hydrothermal oven containing 10% HO, while the catalyst of the comparative example was tested by degreening, i.e., heating at 450°C for 2 hours. Five SCR inlet temperatures were selected, and engine conditions were appropriately set to achieve the target space velocity. The catalyst activity was allowed to reach steady-state equilibrium at each engine load (temperature) and ANR step before moving on to the next step. The NOx conversion, N2O production, and NH3 slip shown here were measured in the same test.

[0157] As can be seen from Figure 1, the two catalysts have similar deNOx performance at temperatures between about 250 and 350°C. Meanwhile, at higher temperatures, the catalyst of the present invention (Example 1) exhibits improved NOx conversion by up to about 10%. Without wishing to be bound by any theory, this is believed to be due to the specific design of the catalyst of the present invention, which has a PGM outlet bottom coating and a zeolite top coating. Therefore, this figure demonstrates that the catalyst of the present invention allows for improved deNOx performance compared to a catalyst that does not have the specific design and composition of the catalyst of the present invention. Furthermore, as can be seen from Figure 2, at high temperatures (above 350°C), the NO formation measured for the catalyst of the present invention (Example 1) is very similar to that measured for the comparative catalyst, although the latter exhibits lower deNOx performance. Therefore, this figure demonstrates that the catalyst of the present invention allows for improved deNOx performance without increased nitrous oxide formation compared to a catalyst that does not have the specific design and composition of the catalyst of the present invention. Finally, as can be seen in Figure 3, NH3 slips at temperatures ranging from 200 to 450°C. Without wishing to be bound by any theory, it is believed that this is due to the specific design of the catalyst of the present invention, which has a PGM outlet bottom coating and a zeolite top coating. Thus, this example demonstrates that a catalyst of the present invention containing two catalyst coatings can improve its catalytic performance compared to a catalyst containing the same PGM loading but requiring three catalyst coatings.

[0158] Example 3: Testing of the catalysts of Comparative Example 1 and Example 1 - NO oxidation The catalysts were evaluated in a motor test cell equipped with a 6.7-liter off-road calibration engine. In all cases, each catalyst was tested alone, without an upstream oxidation catalyst or downstream SCR catalyst. The resulting space velocity was 100 kJ / h for the NOx oxidation test. Prior to this test, the catalysts were in-situ degreened, i.e., heated to 450°C for 2 hours. The catalyst of Example 1 was also tested after aging at 500°C for 50 hours in a hydrothermal oven containing 10% HO. For the NO oxidation test, the outlet exhaust temperature was increased and decreased in 25°C steps from 200°C to 500°C and back to 200°C while keeping the space velocity constant. Each step was held for 15 minutes to reach equilibrium catalyst conditions. NO oxidation activity is reported as the ratio of NO2 to total NOx (or NO2 / NOx%).

[0159] As can be seen from Figure 4, at low temperatures (200-250°C), the NO oxidation performance of the two catalysts is very similar. However, above 250°C, the NO oxidation performance of the catalyst of the present invention (Example 1) is improved over that of the catalyst of Comparative Example 1, which is not in accordance with the present invention, ultimately improving by about 5% by 350°C. abs A large NO2 / NOx ratio was reached. Without wishing to be bound by any theory, this is believed to be due to the specific second coating (outlet bottom coating) of the catalyst of the present invention. It should be noted that in all cases the total amount of PGM (g / total volume) is identical between the catalyst of Example 1 and the catalyst of Comparative Example 1. Thus, as shown by Examples 2 and 3 above, the catalyst of the present invention comprising two coatings makes it possible to exhibit excellent catalytic activity (ammonia oxidation, NO oxidation, NOx conversion) while reducing the formation of nitrous oxide.

[0160] BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a graph showing the deNOx performance of the catalysts of Example 1 and Comparative Example 1 at an inlet temperature in the range of 200 to 450° C. and an ANR of 1.1. FIG. 2 shows the formation of nitrous oxide for the catalysts of Example 1 and Comparative Example 1 measured at inlet temperatures ranging from 200 to 450° C. and ANR=1.0. FIG. 3 is a graph showing ammonia slip for the catalysts of Example 1 and Comparative Example 1 at inlet temperatures ranging from 200 to 450°C. FIG. 4 is a diagram showing the NO oxidation amounts (NO2 / NOx ratios) of the catalysts of Example 1 and Comparative Example 1 at an inlet temperature in the range of 200 to 450° C. and an SV of 100 k / h. FIG. 5 is a schematic diagram illustrating a catalyst (a) according to the present invention and a catalyst (b) not according to the present invention, i.e., Comparative Example 1. In particular, the diagram illustrates (a) a catalyst 1 according to the present invention, including a substrate 2, such as a flow-through substrate, on which an outlet coating 3, a second coating according to the present invention, is disposed along 67% of the axial length of the substrate, from the outlet end to the inlet end of the substrate. Catalyst 1 further includes a top coating 4 disposed on the inner wall surface of substrate 2 and on coating 3 (second coating) along the entire length of the substrate. The diagram also illustrates (b) a catalyst 20 according to the present invention, including a substrate 2, such as a flow-through substrate, on which an inlet coating 5, a second coating according to the catalyst of Comparative Example 1, is disposed along 50% of the axial length of the substrate, from the inlet end to the outlet end of the substrate, and an outlet coating 6, a third coating according to the catalyst of Comparative Example 1, is disposed along 50% of the axial length of the substrate, from the outlet end to the inlet end. Catalyst 20 further includes a top coating 7 disposed on coatings 5 ​​and 6 along the entire length of the substrate.

[0161] References -US2018 / 0280876A1 -US2018 / 0280877A1

Claims

1. 1. A catalyst for the oxidation of NO, the oxidation of ammonia and the selective catalytic reduction of NOx, said catalyst comprising: (i) a substrate including an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end, and a plurality of passages defined by an interior wall of the substrate extending through the interior of the substrate, wherein an interface between the passages and the interior wall is defined by a surface of the interior wall; (ii) a first coating comprising one or more of vanadium oxide and a zeolite material comprising one or more of copper and iron; (iii) a second coating comprising a platinum group metal component supported on a non-zeolitic oxide material, wherein the platinum group metal component supported on the non-zeolitic oxide material is present in the second coating in a first loading, L1, which is the sum of the loading of the platinum group metal component and the loading of the non-zeolitic oxide material; the second coating further comprises a zeolite material comprising one or more of copper and iron, the zeolite material comprising one or more of copper and iron being present in the second coating at a second loading amount L2, the second loading amount being the sum of the loading amount of the zeolite material and the loading amount of the one or more of copper and iron; the second coating is disposed on the surface of the inner wall over y % of the axial length of the substrate from the outlet end to the inlet end, where y is in the range of 10 to 90; the first coating extends over x % of the axial length of the substrate from the inlet end to the outlet end and is disposed on the second coating and on the surface of the inner wall, where x is in the range of 95 to 100; the ratio of the first loading in g / l to the second loading in g / l, L1:L2, is at least 1.1:1; and A catalyst wherein the non-zeolitic oxide materials include titania and silica.

2. A catalyst as described in claim 1, wherein 90 to 100 mass % of the non-zeolitic oxide material of the second coating consists of titania and silica, and 5 to 15 mass % of the non-zeolitic oxide material of the second coating consists of silica.

3. 3. The catalyst of claim 1 or 2, wherein the first coating (ii) comprises a zeolitic material containing one or more of copper and iron.

4. 4. The catalyst of claim 1, wherein the zeolite material included in the first coating is selected from the group consisting of AEI, GME, CHA, MFI, BEA, FAU, MOR, a mixture of two or more thereof, and a mixed type of two or more thereof.

5. 5. The catalyst according to claim 1, wherein the zeolite material included in the first coating comprises copper, and the amount of copper, calculated as CuO, included in the zeolite material is in the range of 1 to 10% by weight, based on the total weight of the zeolite material.

6. 6. The catalyst according to claim 1, wherein 0 to 0.001% by mass of the first coating consists of platinum.

7. The catalyst according to any one of claims 1 to 6, wherein the platinum group metal component contained in the second coating is one or more of platinum, palladium and rhodium.

8. The second coating contains the non-zeolitic oxide material at a concentration of 0.25 to 3 g / in ３ The catalyst according to any one of claims 1 to 7, wherein the catalyst comprises a loading in the range of

9. 9. The catalyst of claim 1, wherein the zeolite material included in the second coating is selected from the group consisting of AEI, GME, CHA, MFI, BEA, FAU, MOR, a mixture of two or more thereof, and a mixed type of two or more thereof.

10. 10. The catalyst according to claim 1, wherein the zeolite material included in the second coating comprises copper, and the amount of copper, calculated as CuO, included in the zeolite material is in the range of 3 to 6% by weight, based on the total weight of the zeolite material.

11. 11. The catalyst of claim 1, wherein in the second coating, the ratio L1:L2 of the first loading in g / l to the second loading in g / l is in the range of 1.1:1 to 50:

1.

12. A method for preparing a catalyst according to any one of claims 1 to 11, comprising: (a) providing an uncoated substrate, the substrate including an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end, and a plurality of passages defined by interior walls of the substrate extending through an interior of the substrate, wherein interfaces between the passages and the interior walls are defined by surfaces of the interior walls; (b) providing a slurry comprising a solvent, a platinum group metal component, a non-zeolitic oxide material, and a zeolitic material comprising one or more of copper and iron, disposing the slurry on a surface of the inner wall over y% of the axial length of the substrate from the outlet end to the inlet end, where y is in the range of 10 to 90, and calcining the slurry disposed on the substrate to obtain a second coating disposed on the surface of the inner wall of the substrate; (c) providing a slurry comprising a solvent and one or more zeolite materials comprising one or more of vanadium oxide, copper, and iron, disposing the slurry on the second coating over x% of the axial length of the substrate from the inlet end to the outlet end, where x is in the range of 95 to 100, and calcining the slurry disposed on the substrate to obtain a first coating disposed on the surface of the inner wall of the substrate and on the second coating; A method comprising:

13. (b) is (b.1) forming a slurry with an aqueous mixture of water, a platinum group metal precursor, a non-zeolitic oxide material, and a zeolitic material comprising one or more of copper and iron; (b.2) optionally adding a precursor of a second oxide material; (b.3) disposing the slurry obtained in (b.1) or obtained in (b.2) on the surface of the inner wall over y % of the substrate axial length from the outlet end to the inlet end of the substrate; (b.4) optionally drying the slurry disposed on the substrate obtained in (b.3) to obtain a dried slurry-treated substrate; (b.5) calcining the slurry disposed on the substrate obtained in (b.3) or the dried slurry-treated substrate obtained in (b.4) in a gas atmosphere; 13. The method of claim 12, comprising:

14. Use of a catalyst for the oxidation of NO, the oxidation of ammonia and the selective catalytic reduction of NOx according to any one of claims 1 to 11 for simultaneous selective catalytic reduction of NOx, oxidation of ammonia and oxidation of NO.

15. 12. An exhaust gas treatment system for treating an exhaust gas stream emitted from an internal combustion engine, the exhaust gas treatment system having an upstream end for introducing the exhaust gas stream into the exhaust gas treatment system, the exhaust gas treatment system comprising a catalyst for the oxidation of NO, the oxidation of ammonia and the selective catalytic reduction of NOx according to any one of claims 1 to 11, and one or more of a selective catalytic reduction catalyst, a hybrid selective catalytic reduction / ammonia oxidation catalyst, and a catalyzed soot filter.

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