Catalyst comprising an integrated sulfur-trap material for the treatment of an exhaust gas stream containing one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons
A catalyst with a Mn-containing washcoat and sulfur-trap material addresses thermal instability and sulfur resistance issues, enhancing conversion of exhaust gases and reducing platinum group metal usage for efficient emissions treatment.
Patent Information
- Application Number
- PCT/EP2025/065451
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2024-06-05
- Filing Date
- 2025-06-04
- Publication Date
- 2025-12-11
AI Technical Summary
Existing catalysts for treating exhaust gases containing formaldehyde, nitrogen oxides, and hydrocarbons face challenges in thermal stability and sulfur resistance, leading to inefficient conversion and high platinum group metal usage, which is costly and environmentally impactful.
A catalyst comprising a first washcoat layer with Mn and a sulfur-trap material, supported on a substrate, with optional platinum group metals, that can reversibly bind sulfur and maintain effective conversion of formaldehyde, nitrogen oxides, and hydrocarbons under sulfation and de-sulfation conditions.
The catalyst achieves enhanced conversion of formaldehyde, nitrogen oxides, and hydrocarbons while reducing platinum group metal usage, meeting stringent emissions standards and lowering production costs and environmental impact.
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Abstract
Description
[0001] Catalyst comprising an integrated sulfur-trap material for the treatment of an exhaust gas stream containing one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons
[0002] TECHNICAL FIELD
[0003] The present invention relates to a catalyst for the treatment of an exhaust gas stream containing one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons, an exhaust gas treatment system comprising said catalyst, a method for the treatment of an exhaust gas stream containing one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons using said catalyst, and use of said catalyst for the oxidation of one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons.
[0004] INTRODUCTION
[0005] The present invention relates to the use of a diesel oxidation catalyst (DOC) with enhanced oxidation function, in particular with enhanced oxidation function of one or more of formaldehyde (HCHO), nitrogen oxide (NO), and hydrocarbons (including diesel fuel). It is known that formaldehyde is a toxic material that is coming under increasing regulation within indoor air spaces due to its release from various building materials used in the construction industry. Tighter regulations are also being implemented for formaldehyde emissions from the engine exhaust of passenger and delivery vehicles. Generally, manganese oxides (e.g., MnO2) are known to be active for destroying formaldehyde under ambient conditions, but they do not have the required thermal stability to survive in a typical engine exhaust environment. In particular, phase transitions at high temperature (e.g., higher than 400 °C) cause the structure of MnC>2 to collapse such that the surface area and pore volume are so low as to be catalytically ineffective. One way to improve the stability of the Mn oxide at high temperature (as well as other catalytically useful base metal oxides such as copper, ceria and iron) can be to support them on refractory oxide materials which themselves have high stability when exposed to high temperatures in the engine exhaust. Materials such as aluminum oxide (AI2O3) and zirconium oxide (ZrO2) can be useful in this regard.
[0006] The key challenge for inclusion of Mn-containing base metal oxide (BMO) catalysts in technology for abatement of exhaust emissions from diesel vehicles can be seen in the intrinsically poor S resistance of Mn reflected in the high desulfation temperature of manganese sulfate. As described in the literature, significant desulfation of MnSC does not occur at temperatures typical for filter regeneration or de-sulfation (de-SOx) on a diesel engine (about 650-700 °C). In flowing nitrogen, 800 °C is typically required, while in flowing air, the temperature is even about 30 °C higher (Figure 1). It is known that Pt and Pd supported on a high temperature resistant refractory metal oxide support provides efficient oxidation of CO and HC pollutants emitted from diesel engines. Such DOC compositions are needed by vehicle manufacturers to meet ever more stringent worldwide CO and HC exhaust emission requirements. An additional function of the DOC composition when placed in the exhaust of a diesel vehicle is to oxidize diesel fuel injected into the exhaust upstream of the DOC in order to create a high temperature exotherm that is used to thermally oxidize soot that has accumulated on a diesel particulate filter (DPF) or a catalyzed soot filter (CSF) located downstream of the DOC composition. Alternatively, the hydrocarbon concentration in the exhaust stream can be increased for exotherm generation by adjusting the combustion process through various post-injection methods or the like. Temperatures greater 600 °C at the DPF or CSF inlet are preferred to provide efficient oxidation of the retained soot. The concentration of diesel fuel injected into the exhaust stream needed to provide the desired exotherm is quite high, approximately 1 % (10,000 ppm) on a C1 basis or more. The temperature at which the DOC composition can oxidize (“light-off’) the injected fuel needs to be as low as possible, preferably less than 300 °C. In addition, the amount of hydrocarbon slip bypassing the DOC catalyst during exotherm generation needs to be as low as possible, preferably less than 3,000 ppm, 2,000 ppm or even 1 ,000 ppm.
[0007] WO 2022 / 047132 A1 relates to an oxidation catalyst composition for catalytic articles, and exhaust gas treatment systems for reducing formaldehyde levels in engine exhaust emissions. In particular, an oxidation catalyst is disclosed in claim 1 comprising a platinum group metal (PGM) component comprising Pd, Pt, or a combination thereof, a manganese component, and a first refractory metal oxide support material comprising zirconia.
[0008] US 10,598,061 B2 relates to methods and systems for a diesel oxidation catalyst. In particular, a method is disclosed in claim 1 comprising: generating NO2 in a catalyst comprising a washcoat with zirconium, one or more base metal oxides, and a palladium oxide, with an exhaust gas flow rate being between lower and upper threshold flow rates; and facilitating a regeneration of a particulate filter located downstream of the catalyst via NO2 when an exhaust gas temperature is greater than a threshold temperature where the palladium oxide is contained in an upstream portion of the catalyst relative to a direction of exhaust gas flow; and the one or more base metal oxides are contained in a downstream portion of the catalyst relative to the direction of exhaust gas flow.
[0009] US 10,392,980 B2 relates to methods and systems for a diesel oxidation catalyst. In particular, a method is disclosed in claim 1 comprising: passing diesel combustion exhaust gas over a diesel oxidation catalyst having a washcoat comprising zirconium oxide, palladium oxide, and at least one base metal oxide, the washcoat coated on a surface of a substrate with the at least one base metal oxide coated to a downstream portion of the substrate in a greater amount than coated to an upstream portion and the palladium oxide coated to the upstream portion of the substrate in a greater amount than coated to the downstream portion, downstream referring to an axial direction of exhaust gas flow, and where the palladium oxide is 0.5-3 weight percent of the washcoat. US 2015 / 352493 A1 relates to a catalytic article comprising a first catalytic coating comprising a platinum group metal, wherein the first catalytic coating is substantially free of Cu, Ni, Fe, Mn, V, Co, Ga, Mo, Mg, Cr and Zn; a second catalytic coating comprising a non-PGM metal, wherein the second catalytic coating is substantially free of a platinum group metal; and one or more substrates, wherein the first catalytic coating is separated from the second catalytic coating.
[0010] US 2022 / 152589 A1 relates to a composite oxidation catalyst for use in an exhaust system for treating an exhaust gas produced by a vehicular compression ignition internal combustion engine and upstream of a particulate matter filter in the exhaust system.
[0011] CN 112 805 089 A discloses a three-way catalyst composition comprising alumina doped with a transition metal. The transition metal comprises Ti, Mn, Fe, Cu, Zn, Ni, or a combination thereof.
[0012] US 2015 / 352493 A1 relates to catalytic articles containing platinum group metals and non-plati- num group metals and methods of making and using same. In the examples, a catalysts is disclosed particularly comprising a substrate, a lower layer comprising at least Cu and Mn supported on ceria, wherein an upper layer may comprise Pt supported on ceria and / or Pd supported on ceria-zirconia.
[0013] US 2023 / 321636 A1 relates to an oxidation catalyst comprising a platinum group metal and a base metal or metalloid oxide. In particular, oxidation catalyst compositions are disclosed in said document particularly comprising a platinum group metal (PGM) component comprising palladium, platinum, or a combination thereof; a first oxide chosen from oxides of cerium, silicon, iron, cobalt, zinc, chromium, molybdenum, nickel, tungsten, magnesium, antimony, tin, lead, yttrium, and combinations thereof; and a first refractory metal oxide support material; catalytic articles; and exhaust gas treatment systems, as well as methods of making and using such oxidation catalyst compositions.
[0014] US 2018 / 318805 A1 relates to a diesel oxidation catalyst combining platinum group metal with base metal oxide. According to claim 1 of said document, a diesel oxidation catalyst composition particularly comprises at least one platinum group metal impregnated onto a porous refractory oxide material in particulate form and at least one base metal oxide impregnated onto a porous refractory oxide material in particulate form, wherein the porous refractory oxide material impregnated with at least one platinum group metal and the porous refractory oxide material impregnated with at least one base metal oxide are in the form of a mixture or wherein the at least one platinum group metal and the at least one base metal oxide are impregnated on the same porous refractory oxide material.
[0015] US 2015 / 252708 A1 relates to a zoned catalyzed substrate monolith. Further, an exhaust system for an internal combustion engine is disclosed therein, the system particularly comprising a lean NOx trap and a zoned catalyst substrate monolith. In Example 1 , a zoned catalyst is dis- closed comprising a wall-flow substrate coated with an inlet coating comprising Pt and Pd supported on alumina-ceria mixed oxide, beta zeolite and manganese dioxide, and an outlet coating comprising Pt and Pd supported on alumina-ceria mixed oxide, beta zeolite and iron oxide.
[0016] Therefore, it was an object of the present invention to provide a catalyst having an improved performance with respect to the conversion of one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons, in particular after being exposed to a sulfation and de-sulfation treatment.
[0017] DETAILED DESCRIPTION
[0018] It has surprisingly been found that an improved catalyst can be provided for the conversion of one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons in an exhaust gas. In particular, it has been surprisingly found that a catalyst can be provided showing an improved performance with respect to the conversion of one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons after being exposed to a sulfation and de-sulfation treatment as encountered in a typical application. Furthermore, it has been surprisingly found that the catalyst according to the present invention shows enhanced hydrocarbon (HO) and nitrogen oxide (NO) oxidation function. In particular, it has surprisingly been found that the benefit of using BMO-containing catalyst to reduce platinum group metal in diesel exhaust treatment systems is not limited only to HCHO oxidation, but also to hydrocarbon and NO oxidation. This enables vehicle manufacturers to meet ever tightening vehicle emissions standards while also reducing overall PGM usage and costs. It has also been surprisingly found that use of a diesel oxidation catalyst (DOC) comprising both a platinum group metal (PGM) and a base metal oxide (BMO) catalyst leads to a catalyst having enhanced fuel burning function. Furthermore, it can be expected that the catalyst of the present invention is able to oxidize soot accumulation on a substrate, in particular on a wall-flow substrate, especially since the Mn-containing washcoat layer can generate NO2 which oxidizes soot. Additionally, the catalyst of the present invention can enable a comparatively lower N2O production, in particular due to its comparatively lower content of platinum group metals.
[0019] Therefore, the present invention relates to a catalyst for the treatment of an exhaust gas stream containing one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons, the catalyst comprising a first washcoat layer comprising Mn and a sulfur-trap material, wherein the sulfur-trap material may be desulfated, and a substrate, wherein the substrate has an inlet end through which the exhaust gas stream may enter the catalyst, and an outlet end through which the exhaust gas stream may exit the catalyst, wherein the catalyst further comprises one or more platinum group metals comprising Pt, Pd, or Pt and Pd, wherein the one or more platinum group metals are at least in part contained in one or more of: (a) the first washcoat layer, and
[0020] (b) an optional second washcoat layer, or
[0021] (c) optional second and third washcoat layers.
[0022] Within the meaning of the present invention, the sulfur-trap material may reversibly bind sulfur in the form of a sulfate and / or sulfite, wherein the regeneration of the material leads to the release of sulfur, in particular as SO2 and / or SO3 in a process which is designated as desulfation.
[0023] It is preferred that the sulfur-trap material is substantially free of Mn, wherein more preferably the sulfur-trap material is free of Mn.
[0024] Within the meaning of the present invention, the sulfur-trap material is substantially free of Mn when the sulfur-trap material contains Mn in an amount of 1 wt.-% or less calculated as the element and based on 100 wt.-% of the sulfur-trap material, more preferably in an amount of 0.5 wt.-% or less, more preferably of 0.1 wt.-% or less, more preferably of 0.05 wt.-% or less, more preferably of 0.01 wt.-% or less, more preferably of 0.005 wt.-% or less, more preferably of 0.001 wt.-% or less.
[0025] It is preferred that the catalyst comprises a second washcoat layer, and wherein the first washcoat layer is substantially free of the one or more platinum group metals, wherein more preferably the first washcoat layer is free of the one or more platinum group metals.
[0026] Within the meaning of the present invention, a washcoat layer is substantially free of an element or compound(s) when the washcoat layer contains said element or compound(s) in an amount of 1 wt.-% or less calculated as the element or compound(s) and based on 100 wt.-% of the wash-coat layer, preferably in an amount of 0.5 wt.-% or less, more preferably of 0.1 wt.-% or less, more preferably of 0.05 wt.-% or less, more preferably of 0.01 wt.-% or less, more preferably of 0.005 wt.-% or less, more preferably of 0.001 wt.-% or less.
[0027] It is preferred that the optional second washcoat layer is substantially free of Mn, wherein more preferably the optional second washcoat layer is free of Mn.
[0028] It is preferred that the content of Mn, calculated as the element, in the first washcoat layer is in the range of from 1 to 50 wt.-% based on 100 wt.-% of the first washcoat layer, more preferably from 2 to 20 wt.-%, more preferably from 5 to 12 wt.-%, more preferably from 7 to 11 wt.-%, more preferably from 8 to 10 wt.-%.
[0029] It is preferred that Mn is present in the form of one or more cations of Mn, wherein Mn is more preferably contained in the first washcoat layer as one or more oxides, wherein Mn is more preferably contained in the first washcoat layer as one or more oxides of Mn(ll), Mn(lll), Mn(ll / lll), and Mn(IV), more preferably as one or more oxides selected from the group consisting of MnO, Mn2O3, MnsC , MnC>2, Mn(O)OH, and Mn-Zr mixed oxides, including mixtures of two or more thereof, wherein the Mn-Zr mixed oxides are preferably contained in the first washcoat layer as a solid solution.
[0030] It is preferred that the first washcoat layer comprises a particulate support material, wherein Mn is supported on the particulate support material, wherein the particulate support material is more preferably selected from the group consisting of ZrC>2, AI2O3, SiC>2, TiC>2, La2O3-doped ZrC>2, CeO2-ZrC>2 mixed oxide, La2C>3-doped CeO2-ZrO2 mixed oxide, Nd2Os-doped CeO2-ZrO2 mixed oxide, Y2C>3-doped CeO2-ZrO2 mixed oxide, praseodymium oxide-doped CeO2-ZrO2 mixed oxide, ZrC>2-doped AI2O3, ZrC>2-doped SiC>2, SiC>2-doped AI2O3, CUO-AI2O3 mixed oxide, and mixtures of two or more thereof, more preferably from the group consisting of ZrC>2, La2C>3-doped ZrC>2, CeO2-ZrC>2 mixed oxide, La2C>3-doped CeO2-ZrO2 mixed oxide, Nd2Os-doped CeO2-ZrO2 mixed oxide, Y2Os-doped CeO2-ZrO2 mixed oxide, P^Os-doped CeO2-ZrO2 mixed oxide, PreOn- doped CeO2-ZrC>2 mixed oxide, PrC>2-doped CeO2-ZrO2 mixed oxide, ZrC>2-doped AI2O3, ZrC>2- doped SiC>2, and mixtures of two or more thereof, more preferably from the group consisting of ZrC>2, La2C>3-doped ZrC>2, CeO2-ZrO2 mixed oxide, La2C>3-doped CeO2-ZrO2 mixed oxide, Nd20s- doped CeO2-ZrC>2 mixed oxide, Y2Os-doped CeO2-ZrO2 mixed oxide, P^Os-doped CeO2-ZrO2 mixed oxide, P^On-doped CeO2-ZrO2 mixed oxide, and mixtures of two or more thereof, wherein more preferably Mn is supported on particulate La2C>3-doped ZrC>2, wherein more preferably Mn is supported on ZrO2doped with La20s in an amount ranging from 1 to 50 wt.% calculated as La2C>3 and based on 100 wt.-% of ZrO2and La20s, preferably from 3 to 30 wt.-%, more preferably from 5 to 15 wt.-%, more preferably from 8 to 10 wt.-%.
[0031] It is preferred that the first washcoat layer comprises Ce, wherein Ce is more preferably contained in the first washcoat layer as CeC>2 and / or Ce2Os.
[0032] In the case wherein the first washcoat layer comprises Ce, it is preferred that the content of Ce, calculated as the element, in the first washcoat layer is in the range of from 1 to 50 wt.-% based on 100 wt.-% of the first washcoat layer, more preferably from 2 to 20 wt.-%, more preferably from 5 to 12 wt.-%, more preferably from 7 to 11 wt.-%, more preferably from 8 to 10 wt.-%.
[0033] Further in the case wherein the first washcoat layer comprises Ce, it is preferred that Ce is supported on a particulate support material, wherein the particulate support material is more preferably selected from the group consisting of ZrO2, AI2O3, SiO2, TiO2, La2O3-doped ZrO2, CeO2- ZrO2mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, praseodymium oxide-doped CeO2-ZrO2 mixed oxide, ZrO2-doped AI2O3, ZrO2-doped SiO2, SiO2-doped AI2O3, CUO-AI2O3 mixed oxide, and mixtures of two or more thereof, more preferably from the group consisting of ZrO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, P^Os-doped CeO2-ZrO2 mixed oxide, P^On-doped CeO2-ZrC>2 mixed oxide, PrC>2-doped CeO2-ZrO2 mixed oxide, ZrC>2-doped AI2O3, ZrC>2-doped SiC>2, and mixtures of two or more thereof, more preferably from the group consisting of ZrC>2, La2C>3-doped ZrC>2, CeO2-ZrO2 mixed oxide, La2C>3-doped CeO2-ZrO2 mixed oxide, Nd2Os-doped CeO2-ZrC>2 mixed oxide, Y2Os-doped CeO2-ZrO2 mixed oxide, P^Os-doped CeO2-ZrO2 mixed oxide, PreOn-doped CeO2-ZrO2 mixed oxide, and mixtures of two or more thereof, wherein more preferably Ce is supported on particulate La2C>3-doped ZrC>2, wherein more preferably Ce is supported on ZrO2doped with La20s in an amount ranging from 1 to 50 wt.% calculated as La2C>3 and based on 100 wt.-% of ZrO2and La20s, preferably from 3 to 30 wt.-%, more preferably from 5 to 15 wt.-%, more preferably from 8 to 10 wt.-%.
[0034] It is preferred that the first washcoat layer is substantially free of Ce, wherein more preferably the first washcoat layer is free of Ce.
[0035] In the case wherein the first washcoat layer is substantially free of Ce, it is preferred that the catalyst is substantially free of Ce, wherein more preferably the catalyst is free of Ce.
[0036] Within the meaning of the present invention, the catalyst is substantially free of an element or compound(s) when the catalyst contains said element or compound(s) in an amount of 1 wt.-% or less calculated as the element or compound(s) and based on 100 wt.-% of the catalyst, preferably in an amount of 0.5 wt.-% or less, more preferably of 0.1 wt.-% or less, more preferably of 0.05 wt.-% or less, more preferably of 0.01 wt.-% or less, more preferably of 0.005 wt.-% or less, more preferably of 0.001 wt.-% or less.
[0037] It is preferred that the first washcoat layer comprises Cu, wherein the first washcoat layer more preferably comprises CuO, CU2O, or CuO and CU2O, more preferably CuO.
[0038] In the case wherein the first washcoat layer comprises Cu, it is preferred that the content of Cu, calculated as the element, in the first washcoat layer is in the range of from 1 to 50 wt.-% based on 100 wt.-% of the first washcoat layer, more preferably from 2 to 30 wt.-%, more preferably from 5 to 20 wt.-%, more preferably from 8 to 12 wt.-%.
[0039] Further in the case wherein the first washcoat layer comprises Cu, it is preferred that Cu is supported on a particulate support material, wherein the particulate support material is more preferably selected from the group consisting of ZrO2, AI2O3, SiO2, TiO2, La2O3-doped ZrO2, CeO2- ZrO2mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, praseodymium oxide-doped CeO2-ZrO2 mixed oxide, ZrO2-doped AI2O3, ZrO2-doped SiO2, SiO2-doped AI2O3, CUO-AI2O3 mixed oxide, and mixtures of two or more thereof, more preferably from the group consisting of ZrO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, P^Os-doped CeO2-ZrO2 mixed oxide, P^On-doped CeO2-ZrC>2 mixed oxide, PrC>2-doped CeO2-ZrO2 mixed oxide, ZrC>2-doped AI2O3, ZrC>2-doped SiC>2, and mixtures of two or more thereof, more preferably from the group consisting of ZrC>2, La2C>3-doped ZrC>2, CeO2-ZrO2 mixed oxide, La2C>3-doped CeO2-ZrO2 mixed oxide, Nd2Os-doped CeO2-ZrC>2 mixed oxide, Y2Os-doped CeO2-ZrO2 mixed oxide, P^Os-doped CeO2-ZrO2 mixed oxide, PreOn-doped CeO2-ZrO2 mixed oxide, and mixtures of two or more thereof, wherein more preferably Cu is supported on particulate La2C>3-doped ZrC>2.
[0040] It is preferred that the content of the sulfur-trap material in the first washcoat layer is in the range of from 5 to 75 wt.-% based on 100 wt.-% of the second washcoat layer, more preferably from 10 to 50 wt.-%, more preferably from 15 to 40 wt.-%, more preferably from 20 to 30 wt.-%.
[0041] It is preferred that the sulfur-trap material comprises one or more metal oxides which react with SO2 and / or SO3 to form corresponding metal sulfites and / or sulfates, wherein more preferably the sulfur-trap material consists of the one or more metal oxides.
[0042] In the case wherein the sulfur-trap material comprises one or more metal oxides which react with SO2 and / or SO3 to form corresponding metal sulfites and / or sulfates, it is preferred that each of the one or more metal oxides, which react with SO2 and / or SO3 to form corresponding metal sulfite and / or sulfate, displays a desulfation temperature T50, at which 50% of the respective metal sulfite and / or metal sulfate has decomposed to the metal oxide and SO2 and / or SO3, which is lower than the desulfation temperature T50 of MnSC , wherein more preferably, each of the one or more metal oxides displays a desulfation temperature T50 which is at least 10°C lower than the desulfation temperature T50 of MnSC , preferably at least 20°C lower, more preferably at least 50°C lower, more preferably at least 80°C lower, more preferably at least 100°C lower, more preferably at least 150°C lower.
[0043] Further in the case wherein the sulfur-trap material comprises one or more metal oxides which react with SO2 and / or SO3 to form corresponding metal sulfites and / or sulfates, it is preferred that the one or more metal oxides are selected from the group consisting of oxides of Cu, Ni, Co, Fe, and Sn, including mixtures of two or more thereof, more preferably from the group consisting of oxides of Cu, Fe, and Sn, including mixtures of two or more thereof, wherein more preferably the one or more metal oxides comprise, preferably consist of, oxides of Fe.
[0044] In the case wherein the one or more metal oxides are selected from the group consisting of oxides of Cu, Ni, Co, Fe, and Sn, including mixtures of two or more thereof, it is preferred that the one or more metal oxides are selected from the group consisting of Fe20s, CuO, SnO, and SnO2, including mixtures of two or more thereof, wherein more preferably the one or more metal oxides comprise, preferably consist of Fe20s. Further in the case wherein the one or more metal oxides are selected from the group consisting of oxides of Cu, Ni, Co, Fe, and Sn, including mixtures of two or more thereof, it is preferred that the one or more metal oxides comprise, more preferably consist of, oxides of Fe, wherein more preferably the one or more metal oxides comprise, more preferably consist of, Fe20s and / or Fe2Os-doped AI2O3, more preferably comprise, more preferably consist of, Fe20s.
[0045] In the case wherein the one or more metal oxides comprise oxides of Fe, it is preferred that the content of the one or more oxides of Fe in the first washcoat layer, calculated as Fe20s and based on 100 wt.-% of the first washcoat layer, is in the range of from 1 to 100 wt.-%, more preferably from 5 to 75 wt.-%, more preferably from 10 to 50 wt.-%, more preferably from 15 to 40 wt.-%, more preferably from 20 to 30 wt.-%.
[0046] Further in the case wherein the one or more metal oxides comprise oxides of Fe, it is preferred that the one or more oxides of Fe display an average particle size D50 of 20 pm or less, more preferably of 10 pm or less, more preferably of 5 pm or less, more preferably of 1 pm or less, wherein the average particle size is preferably determined according to ISO 13320:2020.
[0047] Further in the case wherein the one or more metal oxides are selected from the group consisting of oxides of Cu, Ni, Co, Fe, and Sn, including mixtures of two or more thereof, it is preferred that the one or more metal oxides of Fe are supported on a particulate support material, wherein the particulate support material is more preferably selected from the group consisting of ZrO2, AI2O3, SiO2, TiO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, praseodymium oxide-doped CeO2-ZrO2 mixed oxide, ZrO2-doped AI2O3, ZrO2-doped SiO2, SiO2- doped AI2O3, CUO-AI2O3 mixed oxide, and mixtures of two or more thereof, more preferably from the group consisting of ZrO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3-doped CeO2-ZrO2 mixed oxide, Pr2O3-doped CeO2-ZrO2 mixed oxide, P^On-doped CeO2-ZrO2 mixed oxide, PrO2-doped CeO2-ZrO2 mixed oxide, ZrO2-doped AI2O3, ZrO2-doped SiO2, and mixtures of two or more thereof, more preferably from the group consisting of ZrO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2O3-doped CeO2-ZrO2 mixed oxide, Y2O3- doped CeO2-ZrO2 mixed oxide, P^Os-doped CeO2-ZrO2 mixed oxide, P^On-doped CeO2-ZrO2 mixed oxide, and mixtures of two or more thereof, wherein more preferably Fe is supported on particulate La2O3-doped ZrO2.
[0048] Further in the case wherein the one or more metal oxides are selected from the group consisting of oxides of Cu, Ni, Co, Fe, and Sn, including mixtures of two or more thereof, it is preferred that the one or more metal oxides comprise, more preferably consist of, oxides of Sn, more preferably of SnO, SnO2, or SnO and SnO2. In the case wherein the one or more metal oxides comprise oxides of Sn, it is preferred that the oxides of Sn are supported on a particulate support material, wherein the particulate support material is more preferably selected from the group consisting of ZrC>2, AI2O3, SiC>2, TiC>2, La20s- doped ZrC>2, CeO2-ZrO2 mixed oxide, La2C>3-doped CeO2-ZrO2 mixed oxide, Nd2Os-doped CeO2-ZrC>2 mixed oxide, Y2Os-doped CeO2-ZrO2 mixed oxide, praseodymium oxide-doped CeO2-ZrC>2 mixed oxide, ZrC>2-doped AI2O3, ZrC>2-doped SiC>2, SiC>2-doped AI2O3, CUO-AI2O3 mixed oxide, and mixtures of two or more thereof, more preferably from the group consisting of ZrC>2, La2C>3-doped ZrC>2, CeO2-ZrO2 mixed oxide, La2C>3-doped CeO2-ZrO2 mixed oxide, Nd20s- doped CeO2-ZrC>2 mixed oxide, Y2Os-doped CeO2-ZrO2 mixed oxide, P^Os-doped CeO2-ZrO2 mixed oxide, P^On-doped CeO2-ZrO2 mixed oxide, PrC>2-doped CeO2-ZrO2 mixed oxide, ZrC>2- doped AI2O3, ZrC>2-doped SiC>2, and mixtures of two or more thereof, more preferably from the group consisting of ZrC>2, La2C>3-doped ZrC>2, CeO2-ZrO2 mixed oxide, La2C>3-doped CeO2-ZrO2 mixed oxide, Nd2Os-doped CeO2-ZrO2 mixed oxide, Y2Os-doped CeO2-ZrO2 mixed oxide, P^Os- doped CeO2-ZrC>2 mixed oxide, P^On-doped CeO2-ZrO2 mixed oxide, and mixtures of two or more thereof, wherein more preferably Sn is supported on particulate La2C>3-doped ZrC>2.
[0049] It is preferred that the substrate is a wall-flow substrate or a flow-through substrate, more preferably a honeycomb wall-flow substrate or a honeycomb flow-through substrate, more preferably a honeycomb flow-through substrate, wherein the flow-through substrate is more preferably a flow-through substrate with high porosity walls.
[0050] It is preferred that the loading of the first washcoat layer is in the range of from 0.5 to 6 g / in3, more preferably of from 1 to 5 g / in3, more preferably of from 1.5 to 4.5 g / in3, more preferably of from 2 to 4 g / in3, more preferably of from 2.5 to 3.5 g / in3.
[0051] Within the meaning of the present invention, the loading of a washcoat layer in the catalyst refers to the loading of said washcoat layer based on the volume of the catalyst in which said washcoat layer is contained. Accordingly, within the meaning of the present invention, the loading of a washcoat layer only contained in a certain portion or zone of the catalyst is based on the volume of that portion or zone of the catalyst. Thus, by means of examples, if a washcoat layer is provided over 50% of the axial length of a honeycomb substrate, its loading is calculated based on 50% of the total volume of the honeycomb substrate.
[0052] It is preferred that the loading of the second washcoat layer is in the range of from 0.25 to 6 g / in3, more preferably of from 0.3 to 5.5 g / in3, more preferably of from 1 to 4.8 g / in3, more preferably of from 1 .5 to 4.2 g / in3, more preferably of from 2 to 3.8 g / in3, more preferably of from 2.2 to 3.5 g / in3, more preferably of from 2.5 to 3.3 g / in3, more preferably of from 2.8 to 3 g / in3.
[0053] It is preferred that the catalyst comprises one or more platinum group metals consisting of Pt, Pd, or Pt and Pd, wherein more preferably the catalyst comprises Pt, or Pt and Pd as the one or more platinum group metals, wherein more preferably the catalyst comprises Pt and Pd as the one or more platinum group metals.
[0054] It is preferred that the catalyst comprises Pt, calculated as the element, at a loading in the range of from 2 to 250 g / ft3, more preferably of from 5 to 150 g / ft3, more preferably of from 10 to 125 g / ft3, more preferably of from 20 to 100 g / ft3, more preferably of from 25 to 85 g / ft3, more preferably of from 30 to 80 g / ft3, more preferably of from 40 to 60 g / ft3.
[0055] Within the meaning of the present invention, the loading of Pt, Pd, or Pt and Pd in the catalyst refers to the loading of Pt, Pd, or Pt and Pd based on the volume of the catalyst in which Pt, Pd, or Pt and Pd is contained. In the event that Pt, Pd, or Pt and Pd is contained in one or more zones of the catalyst, it is preferred within the meaning of the present invention, that the loading of Pt, Pd, or Pt and Pd is based on the volume of the catalyst in which the one or more Pt, Pd, or Pt and Pd zones are contained. Thus, by means of examples, if Pt, Pd, or Pt and Pd is provided in a zone extending over 50% of the axial length of a honeycomb substrate, its loading is calculated based on 50% of the total volume of the honeycomb substrate.
[0056] It is preferred that the catalyst comprises Pd, calculated as the element, at a loading in the range of from 1 to 80 g / ft3, more preferably of from 5 to 60 g / ft3, more preferably of from 10 to 50 g / ft3, more preferably of from 15 to 40 g / ft3, more preferably of from 20 to 30 g / ft3.
[0057] It is preferred that the catalyst comprises Pt and Pd, calculated as the respective element, at a total Pt and Pd loading in the range of from 2 to 250 g / ft3, more preferably of from 5 to 200 g / ft3, more preferably of from 10 to 150 g / ft3, more preferably of from 20 to 130 g / ft3, more preferably of from 30 to 125 g / ft3, more preferably of from 40 to 110 g / ft3, more preferably of from 50 to 100 g / ft3, more preferably of from 60 to 90 g / ft3, more preferably of from 70 to 80 g / ft3.
[0058] It is preferred that the catalyst comprises Pt and Pd at a Pt : Pd weight ratio in the range of from 30:70 to 90:10, more preferably of from 50:50 to 80:20, more preferably of from 60:40 to 75:25, more preferably of from 65:35 to 70:30.
[0059] It is preferred that the one or more platinum group metals are supported on a particulate support material, wherein the particulate support material is more preferably selected from the group consisting of AI2O3, SiC>2, TiC>2, SiC>2-doped AI2O3, Mn oxide-doped AI2O3, and mixtures of two or more thereof, wherein preferably the one or more platinum group metals are supported on AI2O3 and / or SiC>2-doped AI2O3 and / or Mn oxide-doped AI2O3, more preferably SiC>2-doped AI2O3 or AI2O3 or Mn oxide-doped AI2O3, more preferably SiC>2-doped AI2O3, wherein the Mn oxide-doped AI2O3 preferably comprises from 1 to 10 weight-%, more preferably from 4 to 6 weight-%, of Mn oxide, calculated as MnC>2, based on 100 weight-% of the Mn oxide-doped AI2O3, and wherein the SiC>2-doped AI2O3 preferably comprises from 1 to 10 weight-%, more preferably from 4 to 6 weight-%, of SiC>2, based on 100 weight-% of the SiC>2-doped AI2O3.
[0060] It is preferred that the first washcoat layer comprises a hydrocarbon trap material, wherein the hydrocarbon trap material comprises a molecular sieve, more preferably a zeolite, more preferably a zeolite having a maximum pore size of 12-membered rings, more preferably zeolite beta.
[0061] In the case wherein the first washcoat layer comprises a hydrocarbon trap material, wherein the hydrocarbon trap material comprises a molecular sieve, it is preferred that the molecular sieve, more preferably the zeolite, comprises SiC>2 and AI2O3, wherein the molecular sieve, more preferably the zeolite, more preferably has a molar ratio of SiC>2 to AI2O3 in the range of from 10:1 to 500:1 , more preferably of from 10:1 to 100:1 , more preferably of from 10:1 to 40:1 , more preferably of from 15:1 to 30:1 , more preferably of from 20:1 to 25:1.
[0062] Further in the case wherein the first washcoat layer comprises a hydrocarbon trap material, wherein the hydrocarbon trap material comprises a molecular sieve, more preferably a zeolite, it is preferred that the molecular sieve, more preferably the zeolite, comprises Fe, wherein the molecular sieve, more preferably the zeolite, more preferably comprises Fe, calculated as Fe2C>3, in an amount in the range of from 1 .0 to 7.0 weight-%, more preferably of from 3.0 to 5.0 weight-%, more preferably of from 4.0 to 4.5 weight-%, based on the weight of the molecular sieve.
[0063] Further in the case wherein the first washcoat layer comprises a hydrocarbon trap material, wherein the hydrocarbon trap material comprises a molecular sieve, it is preferred that the loading of the hydrocarbon trap material in the first washcoat layer is in the range of from 0.01 to 5.0 g / in3, more preferably in the range of from 0.05 to 3.0 g / in3, more preferably in the range of from 0.1 to 2.0 g / in3, more preferably in the range of from 0.15 to 1 .0 g / in3, more preferably in the range of from 0.2 to 0.5 g / in3, more preferably in the range of from 0.22 to 0.3 g / in3, more preferably in the range of from 0.25 to 0.27 g / in3.
[0064] It is preferred that the catalyst comprises a second washcoat layer, wherein the one or more platinum group metals are at least in part contained in the second washcoat layer, wherein more preferably the one or more platinum group metals are entirely contained in the second washcoat layer.
[0065] It is preferred that the second washcoat layer comprises a hydrocarbon trap material, wherein the hydrocarbon trap material comprises a molecular sieve, more preferably a zeolite, more preferably a zeolite having a maximum pore size of 12-membered rings, more preferably zeolite beta. In the case wherein the second washcoat layer comprises a hydrocarbon trap material, wherein the hydrocarbon trap material comprises a molecular sieve, more preferably a zeolite, it is preferred that the molecular sieve, more preferably the zeolite, comprises SiC>2 and AI2O3, wherein the molecular sieve, preferably the zeolite, preferably has a molar ratio of SiC>2 to AI2O3 in the range of from 10:1 to 500:1 , more preferably of from 10:1 to 100:1 , more preferably of from 10:1 to 40:1 , more preferably of from 15:1 to 30:1 , more preferably of from 20:1 to 25:1.
[0066] Further in the case wherein the second washcoat layer comprises a hydrocarbon trap material, wherein the hydrocarbon trap material comprises a molecular sieve, more preferably a zeolite, it is preferred that the molecular sieve, more preferably the zeolite, comprises Fe, wherein the molecular sieve, more preferably the zeolite, more preferably comprises Fe, calculated as Fe2C>3, in an amount in the range of from 1 .0 to 7.0 weight-%, more preferably of from 3.0 to 5.0 weight-%, more preferably of from 4.0 to 4.5 weight-%, based on the weight of the molecular sieve.
[0067] Further in the case wherein the second washcoat layer comprises a hydrocarbon trap material, wherein the hydrocarbon trap material comprises a molecular sieve, more preferably a zeolite, it is preferred that the loading of the hydrocarbon trap material in the second washcoat layer is in the range of from 0.01 to 5.0 g / in3, more preferably in the range of from 0.05 to 3.0 g / in3, more preferably in the range of from 0.1 to 2.0 g / in3, more preferably in the range of from 0.15 to 1 .0 g / in3, more preferably in the range of from 0.2 to 0.5 g / in3, more preferably in the range of from 0.22 to 0.3 g / in3, more preferably in the range of from 0.25 to 0.27 g / in3.
[0068] According to a first alternative, it is preferred that the catalyst comprises a second washcoat layer, wherein the catalyst displays a layered arrangement of the first and second washcoat layers, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer.
[0069] In the case wherein the catalyst comprises a second washcoat layer, wherein the catalyst displays a layered arrangement of the first and second washcoat layers, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer, in accordance with the first alternative, it is preferred according to an alternative that the first washcoat layer is provided on the substrate, and the second washcoat layer is provided on the first washcoat layer.
[0070] Further in the case wherein the catalyst comprises a second washcoat layer, wherein the catalyst displays a layered arrangement of the first and second washcoat layers, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer, in accordance with the first alternative, it is preferred according to a further alternative that the second washcoat layer is provided on the substrate, and the first washcoat layer is provided on the second washcoat layer. Further in the case wherein the catalyst comprises a second washcoat layer, wherein the catalyst displays a layered arrangement of the first and second washcoat layers, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer, in accordance with the first alternative, wherein the first washcoat layer is preferably provided on the substrate, and the second washcoat layer is preferably provided on the first washcoat layer, it is preferred according to a further alternative that the catalyst comprises a third washcoat layer, wherein the catalyst displays a zoned arrangement of the first, second, and third washcoat layers, wherein the third washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate and wherein the first washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate, and wherein the second washcoat layer is provided on and entirely covers the first washcoat layer, wherein the length of the first washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the third washcoat layer and a downstream zone comprising the first and second washcoat layers, and wherein the one or more platinum group metals are at least in part contained in the third washcoat layer.
[0071] Further in the case wherein the catalyst comprises a second washcoat layer, wherein the catalyst displays a layered arrangement of the first and second washcoat layers, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer, in accordance with the first alternative, wherein the second washcoat layer is preferably provided on the substrate, and the first washcoat layer is preferably provided on the second washcoat layer, it is preferred according to a further alternative that the catalyst comprises a third washcoat layer, wherein the catalyst displays a zoned arrangement of the first, second, and third washcoat layers, wherein the third washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate and wherein the second washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate, and wherein the first washcoat layer is provided on and entirely covers the second washcoat layer, wherein the length of the second washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the third washcoat layer and a downstream zone comprising the first and second washcoat layers, and wherein the one or more platinum group metals are at least in part contained in the third washcoat layer.
[0072] Further in the case wherein the catalyst comprises a second washcoat layer, wherein the catalyst displays a layered arrangement of the first and second washcoat layers, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer, in accordance with the first alternative, wherein the first washcoat layer is preferably provided on the substrate, and the second washcoat layer is preferably provided on the first washcoat layer, it is preferred according to a further alternative that the catalyst comprises a third washcoat layer, wherein the catalyst displays a zoned arrangement of the first, second, and third washcoat layers, wherein the third washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate and wherein the first washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate, and wherein the second washcoat layer is provided on and entirely covers the first washcoat layer, wherein the length of the first washcoat layer is less than the axial length of the substrate such as to create a downstream zone comprising the third washcoat layer and an upstream zone comprising the first and second washcoat layers, and wherein the one or more platinum group metals are at least in part contained in the third washcoat layer.
[0073] Further in the case wherein the catalyst comprises a second washcoat layer, wherein the catalyst displays a layered arrangement of the first and second washcoat layers, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer, in accordance with the first alternative, wherein the second washcoat layer is preferably provided on the substrate, and the first washcoat layer is preferably provided on the second washcoat layer, it is preferred according to a further alternative that the catalyst comprises a third washcoat layer, wherein the catalyst displays a zoned arrangement of the first, second, and third washcoat layers, wherein the third washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate and wherein the second washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate, and wherein the first washcoat layer is provided on and entirely covers the second washcoat layer, wherein the length of the second washcoat layer is less than the axial length of the substrate such as to create a downstream zone comprising the third washcoat layer and an upstream zone comprising the first and second washcoat layers, and wherein the one or more platinum group metals are at least in part contained in the third washcoat layer.
[0074] According to a second alternative, it is preferred that the catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the second washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate, and wherein the first washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer.
[0075] According to a third alternative, it is preferred that catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the first washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate, and wherein the second washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer. According to a fourth alternative, it is preferred that the catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the second washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate, and wherein the first washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer.
[0076] According to a fifth alternative, it is preferred that the catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the first washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate, and wherein the second washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer.
[0077] In the case wherein the catalyst comprises optional second and third washcoat layers according to the second or fourth alternative as defined herein, it is preferred that the catalyst comprises a third washcoat layer, wherein the third washcoat layer is provided on the first washcoat layer, wherein the catalyst displays a zoned arrangement of the second and third washcoat layers, wherein the second washcoat layer is provided on the substrate along the axial length of the substrate starting from the inlet end of the substrate, and wherein the third washcoat layer is provided on the first washcoat layer along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the third washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first and third washcoat layers.
[0078] In the case wherein the catalyst comprises optional second and third washcoat layers according to the second or fourth alternative as defined herein, it is preferred that the catalyst comprises a third washcoat layer, wherein the third washcoat layer is provided on the first washcoat layer, wherein the catalyst displays a zoned arrangement of the second and third washcoat layers, wherein the third washcoat layer is provided on the first washcoat layer along the axial length of the substrate starting from the inlet end of the substrate, and wherein the second washcoat layer is provided on the substrate along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the third washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the first and third washcoat layers and a downstream zone comprising the second washcoat layer. In the case wherein the catalyst comprises optional second and third washcoat layers according to the second, third, fourth or fifth alternative as defined herein, it is preferred that the first and second washcoat layers are adjacent to one another.
[0079] In the case wherein the catalyst comprises optional second and third washcoat layers according to the first alternative as defined herein, it is preferred that the first and third washcoat layers are adjacent to one another.
[0080] In the case wherein the catalyst comprises optional second and third washcoat layers according to the first, second, third, fourth or fifth alternative as defined herein, it is preferred that the second and third washcoat layers are adjacent to one another.
[0081] In the case wherein the catalyst comprises optional second and third washcoat layers according to the second, third, fourth or fifth alternative as defined herein, it is preferred that a portion of the second washcoat layer overlaps at least a portion of the first washcoat layer, wherein preferably the second washcoat layer overlaps the first washcoat layer over a portion ranging from 10 to 100% of the axial length of the first washcoat layer, more preferably from 15 to 80%, more preferably from 20 to 50%.
[0082] In the case wherein the catalyst comprises optional second and third washcoat layers according to the second, third, fourth or fifth alternative as defined herein, it is preferred that a portion of the first washcoat layer overlaps at least a portion of the second washcoat layer, wherein more preferably the first washcoat layer overlaps the second washcoat layer over a portion ranging from 10 to 100% of the axial length of the second washcoat layer, more preferably from 15 to 80%, more preferably from 20 to 50%.
[0083] In the case wherein the catalyst comprises optional second and third washcoat layers according to the first, second, third, fourth or fifth alternative as defined herein, wherein the catalyst comprises a third washcoat layer, it is preferred that a portion of the third washcoat layer overlaps at least a portion of the first washcoat layer, wherein more preferably the third washcoat layer overlaps the first washcoat layer over a portion ranging from 10 to 100% of the axial length of the first washcoat layer, more preferably from 15 to 80%, more preferably from 20 to 50%.
[0084] According to a sixth alternative, it is preferred that the catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the second washcoat layer is provided on the substrate along its entire length, and wherein the first washcoat layer is provided on the second washcoat layer along its axial length starting from the outlet end of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer.
[0085] According to a seventh alternative, it is preferred that the catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the second washcoat layer is provided on the substrate along its entire length, and wherein the first washcoat layer is provided on the second washcoat layer along its axial length starting from the inlet end of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer.
[0086] In the case wherein the catalyst comprises optional second washcoat layer according to the sixth or seventh alternative as defined herein, it is preferred that the length of the first washcoat layer ranges from 10 to 90% of the axial length of the substrate, more preferably from 30 to 80%, more preferably from 50 to 70%.
[0087] According to an eighth alternative, it is preferred that the catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the first washcoat layer is provided on the substrate along its entire length, and wherein the second washcoat layer is provided on the first washcoat layer along its axial length starting from the inlet end of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer.
[0088] In the case wherein the catalyst comprises a second washcoat layer according to the eighth alternative as defined herein, it is preferred that the catalyst comprises a third washcoat layer, wherein the third washcoat layer is provided on the first washcoat layer, wherein the catalyst displays a zoned arrangement of the second and third washcoat layers, wherein the second washcoat layer is provided on the first washcoat layer along the axial length of the substrate starting from the inlet end of the substrate, and wherein the third washcoat layer is provided on the first washcoat layer along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the third washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the third washcoat layer. According to a ninth alternative, it is preferred that the catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the first washcoat layer is provided on the substrate along its entire length, and wherein the second washcoat layer is provided on the first washcoat layer along its axial length starting from the outlet end of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer.
[0089] In the case wherein the catalyst comprises a second washcoat layer according to the ninth alternative as defined herein, it is preferred that the catalyst comprises a third washcoat layer, wherein the third washcoat layer is provided on the first washcoat layer, wherein the catalyst displays a zoned arrangement of the second and third washcoat layers, wherein the third washcoat layer is provided on the first washcoat layer along the axial length of the substrate starting from the inlet end of the substrate, and wherein the second washcoat layer is provided on the first washcoat layer along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the third washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the third washcoat layer and a downstream zone comprising the second washcoat layer.
[0090] In the case wherein the catalyst comprises second and third washcoat layers according to the eighth or ninth alternative as defined herein, it is preferred that the second and third washcoat layers are adjacent to one another.
[0091] According to a tenth alternative, wherein the catalyst comprises second and third washcoat layers, wherein the catalyst preferably displays a layered arrangement of the first and second washcoat layers, and wherein the one or more platinum group metals are preferably at least in part contained in the second washcoat layer, in accordance with the first alternative as defined herein, it is preferred that the first washcoat layer is provided on the substrate, wherein the second washcoat layer is at least partially, preferably completely, provided on the first washcoat layer, and wherein the third washcoat layer is at least partially, preferably completely, provided on the second washcoat layer.
[0092] According to an eleventh alternative, wherein the catalyst comprises second and third washcoat layers, wherein the catalyst preferably displays a layered arrangement of the first and second washcoat layers, and wherein the one or more platinum group metals are preferably at least in part contained in the second washcoat layer, in accordance with the first alternative as defined herein, it is preferred that the first washcoat layer is provided on the substrate, wherein the third washcoat layer is at least partially, preferably completely, provided on the first washcoat layer, and wherein the second washcoat layer is at least partially, preferably completely, provided on the third washcoat layer.
[0093] It is preferred that the length of the first washcoat layer ranges from 5 to 100% of the axial length of the substrate, more preferably from 10 to 90% of the axial length of the substrate, preferably from 15 to 75%, more preferably from 20 to 60%, more preferably from 25 to 50%, more preferably from 35 to 45%.
[0094] In the case wherein the catalyst comprises a second washcoat layer, it is preferred that the length of the second washcoat layer ranges from 5 to 100% of the axial length of the substrate, more preferably from 10 to 90% of the axial length of the substrate, more preferably from 15 to 75%, more preferably from 20 to 60%, more preferably from 25 to 50%, more preferably from 35 to 45%.
[0095] In the case wherein the catalyst comprises a third washcoat layer, it is preferred that the length of the third washcoat layer ranges from 5 to 100% of the axial length of the substrate, more preferably from 10 to 90% of the axial length of the substrate, preferably from 15 to 75%, more preferably from 20 to 60%, more preferably from 25 to 50%, more preferably from 35 to 45%.
[0096] Further in the case wherein the catalyst comprises a third washcoat layer, it is preferred that the third washcoat layer comprises a hydrocarbon trap material, wherein the hydrocarbon trap material comprises a molecular sieve, more preferably a zeolite, more preferably a zeolite having a maximum pore size of 12-membered rings, more preferably zeolite beta.
[0097] In the case wherein the third washcoat layer comprises a hydrocarbon trap material, wherein the hydrocarbon trap material comprises a molecular sieve, more preferably a zeolite, it is preferred that the molecular sieve, more preferably the zeolite, comprises SiC>2 and AI2O3, wherein the molecular sieve, more preferably the zeolite, more preferably has a molar ratio of SiC>2 to AI2O3 in the range of from 10:1 to 500:1 , more preferably of from 10:1 to 100:1 , more preferably of from 10:1 to 40:1 , more preferably of from 15:1 to 30:1 , more preferably of from 20:1 to 25:1.
[0098] Further in the case wherein the third washcoat layer comprises a hydrocarbon trap material, wherein the hydrocarbon trap material comprises a molecular sieve, more preferably a zeolite, it is preferred that the molecular sieve, more preferably the zeolite, comprises Fe, wherein the molecular sieve, more preferably the zeolite, more preferably comprises Fe, calculated as Fe2C>3, in an amount in the range of from 1 .0 to 7.0 weight-%, more preferably of from 3.0 to 5.0 weight-%, more preferably of from 4.0 to 4.5 weight-%, based on the weight of the molecular sieve. Further in the case wherein the third washcoat layer comprises a hydrocarbon trap material, wherein the hydrocarbon trap material comprises a molecular sieve, more preferably a zeolite, it is preferred that the loading of the hydrocarbon trap material in the third washcoat layer is in the range of from 0.01 to 5.0 g / in3, more preferably in the range of from 0.05 to 3.0 g / in3, more preferably in the range of from 0.1 to 2.0 g / in3, more preferably in the range of from 0.15 to 1 .0 g / in3, more preferably in the range of from 0.2 to 0.5 g / in3, more preferably in the range of from 0.22 to 0.3 g / in3, more preferably in the range of from 0.25 to 0.27 g / in3.
[0099] Further in the case wherein the catalyst comprises a third washcoat layer, it is preferred that the one or more platinum group metals are at least in part contained in the third washcoat layer.
[0100] In the case wherein the one or more platinum group metals are at least in part contained in the third washcoat layer, it is preferred that the one or more platinum group metals contained in the third washcoat layer are supported on a particulate support material, wherein the particulate support material is more preferably selected from the group consisting of AI2O3, SiC>2, TiC>2, SiC>2-doped AI2O3, Mn oxide-doped AI2O3, and mixtures of two or more thereof, wherein more preferably the one or more platinum group metals are supported on AI2O3 and / or SiC>2-doped AI2O3 and / or Mn oxide-doped AI2O3, more preferably SiC>2-doped AI2O3 or AI2O3 or Mn oxidedoped AI2O3, more preferably SiC>2-doped AI2O3, wherein the Mn oxide-doped AI2O3 preferably comprises from 1 to 10 weight-%, more preferably from 4 to 6 weight-%, of Mn oxide, calculated as MnC>2, based on 100 weight-% of the Mn oxide-doped AI2O3, and wherein the SiC>2-doped AI2O3 preferably comprises from 1 to 10 weight-%, more preferably from 4 to 6 weight-%, of SiC>2, based on 100 weight-% of the SiC>2-doped AI2O3.
[0101] In the case wherein the catalyst comprises second and third washcoat layers, in particular in accordance with the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, or eleventh alternative, it is preferred that the one or more platinum group metals are entirely contained in the second and third washcoat layers.
[0102] In the case wherein the one or more platinum group metals are entirely contained in the second and third washcoat layers, it is preferred that the weight ratio of the one or more platinum group metals comprised in the second washcoat layer to the one or more platinum group metals comprised in the third washcoat layer is in the range of from 0.5:1 to 5.0:1 , more preferably of from 1.0:1 to 2.0:1 , more preferably in the range of from 1.4:1 to 1.6:1.
[0103] Further in the case wherein the one or more platinum group metals are entirely contained in the second and third washcoat layers, it is preferred that the one or more platinum group metals comprised in the second washcoat layer comprise, more preferably consist of, Pt and Pd, wherein the one or more platinum group metals comprised in the third washcoat layer more preferably comprise, more preferably consist of, Pt and Pd. In the case wherein the catalyst comprises a second washcoat layer or second and third washcoat layers, it is preferred that the one or more platinum group metals are entirely contained in the second washcoat layer or in the second and third washcoat layers.
[0104] In the case wherein the catalyst comprises a second washcoat layer or second and third washcoat layers, it is preferred that the one or more platinum group metals are at least in part contained in the first washcoat layer.
[0105] It is preferred that the substrate is a metallic substrate or a ceramic substrate, wherein more preferably the substrate is a ceramic substrate, wherein more preferably the substrate comprises cordierite and / or SiC, more preferably cordierite, wherein more preferably, the substrate consists of cordierite and / or SiC, more preferably of cordierite.
[0106] In the case wherein the catalyst comprises a second washcoat layer and optionally a third washcoat layer, in accordance with the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, or eleventh alternative, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, of the second and third washcoat layers, and / or of the first and third washcoat layers, it is preferred that the substrate consists of two separate monoliths, wherein the first monolith is provided upstream of the second monolith, wherein the washcoat layer or washcoat layers of the upstream zone are contained on the first monolith, and the washcoat layer or washcoat layers of the downstream zone are contained on the second monolith, wherein preferably the first monolith containing the washcoat layer or washcoat layers of the upstream zone and the second monolith containing the washcoat layer or washcoat layers of the downstream zone are obtained or obtainable by sectioning of a catalyst according to any of embodiments 48 to 88 into two separate monoliths, wherein the washcoat layer or washcoat layers of the upstream zone are contained on the first monolith, and the washcoat layer or washcoat layers of the downstream zone are contained on the second monolith.
[0107] It is preferred that the exhaust gas stream contains hydrocarbons, preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons.
[0108] Further, the present invention relates to an exhaust gas treatment system comprising an internal combustion engine and an exhaust gas conduit for exhaust gas from the internal combustion engine, wherein the exhaust gas conduit comprises one or more catalysts according to any one of the embodiments defined herein, preferably one, two, three or four catalysts according to any one of the embodiments defined herein.
[0109] According to a first alternative, it is preferred that the internal combustion engine is a compression ignition engine, more preferably a diesel engine. According to a second alternative, wherein the internal combustion engine optionally is a compression ignition engine, optionally a diesel engine, according to the first alternative, it is preferred that the internal combustion engine is a lean gasoline engine.
[0110] According to a third alternative, it is preferred that the internal combustion engine is powered by an oxygenated fuel, wherein the oxygenated fuel more preferably comprises one or more of methanol and biofuel.
[0111] It is preferred that the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC).
[0112] According to a first alternative for the exhaust gas treatment system, in the case wherein the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC), it is preferred that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments defined herein, a catalyst according to any of the embodiments defined herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a diesel exotherm catalyst (DEC), a catalyzed soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst.
[0113] According to a second alternative for the exhaust gas treatment system, in the case wherein the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC), it is preferred that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments defined herein, a catalyst according to any of the embodiments defined herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a diesel exotherm catalyst (DEC), a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst.
[0114] According to a third alternative for the exhaust gas treatment system, in the case wherein the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC), it is preferred that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments defined herein, a catalyst according to any of the embodiments defined herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a diesel exotherm catalyst (DEC), a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.
[0115] According to a fourth alternative for the exhaust gas treatment system, in the case wherein the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC), it is preferred that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments defined herein, a catalyst according to any of the embodiments defined herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of the embodiments defined herein, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst.
[0116] According to a fifth alternative for the exhaust gas treatment system, in the case wherein the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC), it is preferred that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments defined herein, a catalyst according to any of the embodiments defined herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of the embodiments defined herein, a catalyst according to any of the embodiments defined herein, wherein the substrate is a wall-flow substrate, a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.
[0117] According to a sixth alternative for the exhaust gas treatment system, in the case wherein the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC), it is preferred that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments defined herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a catalyzed soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst.
[0118] According to a seventh alternative for the exhaust gas treatment system, in the case wherein the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC), it is preferred that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments defined herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a catalyzed soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.
[0119] According to an eighth alternative for the exhaust gas treatment system, in the case wherein the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC), it is preferred that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments defined herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of the embodiments defined herein, wherein the substrate is a wall-flow substrate, a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.
[0120] According to a ninth alternative for the exhaust gas treatment system, in the case wherein the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC), it is preferred that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments defined herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction catalyst on filter (SCRoF), and an ammonia oxidation (AMOX) catalyst.
[0121] According to a tenth alternative for the exhaust gas treatment system, in the case wherein the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC), it is preferred that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of the embodiments defined herein, a selective catalytic reduction catalyst on filter (SCRoF), and an ammonia oxidation (AMOX) catalyst.
[0122] According to an eleventh alternative for the exhaust gas treatment system, in the case wherein the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC), it is preferred that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of the embodiments defined herein, a catalyzed soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.
[0123] According to a twelfth alternative for the exhaust gas treatment system, in the case wherein the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC), it is preferred that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of the embodiments defined herein, a catalyst according to any of the embodiments defined herein, wherein the substrate is a wall-flow substrate, a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.
[0124] According to a thirteenth alternative for the exhaust gas treatment system, in the case wherein the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC), it is preferred that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 85, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.
[0125] According to a fourteenth alternative for the exhaust gas treatment system, in the case wherein the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC), it is preferred that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments defined herein, a selective catalytic reduction catalyst on filter (SCRoF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.
[0126] According to a fifteenth alternative for the exhaust gas treatment system, in the case wherein the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC), it is preferred that the exhaust gas treatment system comprises in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of the embodiments defined herein, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction catalyst on filter (SCRoF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.
[0127] Yet further, the present invention relates to a method for the treatment of an exhaust gas stream containing one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons, the method comprising
[0128] (A) providing an exhaust gas stream comprising one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons;
[0129] (B) directing the exhaust gas stream provided in (A) through a catalyst according to any of the embodiments defined herein.
[0130] It is preferred that the exhaust gas stream provided in (A) comprises one or more sulfur-containing compounds, more preferably SO2 and / or SO3.
[0131] It is preferred that the exhaust gas stream provided in (A) comprises NOX.
[0132] It is preferred that the exhaust gas stream provided in (A) comprises CO.
[0133] It is preferred that the exhaust gas stream provided in (A) comprises hydrocarbons, more preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons.
[0134] Yet further, the present invention relates to use of a catalyst according to any of the embodiments defined herein for the oxidation of one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons, preferably for the oxidation of one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons in an exhaust gas stream, more preferably for the oxidation of one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons in the exhaust gas stream of an internal combustion engine, more preferably for the oxidation of one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons in the exhaust gas stream of a compression ignition engine, more preferably for the oxidation of one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons in the exhaust gas stream of a diesel engine.
[0135] The present invention is further illustrated by the following set of embodiments and combinations of embodiments resulting from the dependencies and back-references as indicated. In particular, it is noted that in each instance where a range of embodiments is mentioned, for example in the context of a term such as "The catalyst of any one of embodiments 1 to 4", every embodiment in this range is meant to be explicitly disclosed for the skilled person, i.e. the wording of this term is to be understood by the skilled person as being synonymous to "The catalyst of any one of embodiments 1 , 2, 3, and 4". Further, it is explicitly noted that the following set of embodiments represents a suitably structured part of the general description directed to preferred aspects of the present invention, and, thus, suitably supports, but does not represent the claims of the present invention.
[0136] 1 . A catalyst for the treatment of an exhaust gas stream containing one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons, the catalyst comprising a first washcoat layer comprising Mn and a sulfur-trap material, wherein the sulfur- trap material may be desulfated, and a substrate, wherein the substrate has an inlet end through which the exhaust gas stream may enter the catalyst, and an outlet end through which the exhaust gas stream may exit the catalyst, wherein the catalyst further comprises one or more platinum group metals comprising Pt, Pd, or Pt and Pd, wherein the one or more platinum group metals are at least in part contained in one or more of:
[0137] (a) the first washcoat layer, and
[0138] (b) an optional second washcoat layer, or
[0139] (c) optional second and third washcoat layers.
[0140] 2. The catalyst of embodiment 1 , wherein the sulfur-trap material is substantially free of Mn, wherein preferably the sulfur-trap material is free of Mn.
[0141] 3. The catalyst of embodiment 1 or 2, wherein the catalyst comprises a second washcoat layer, and wherein the first washcoat layer is substantially free of the one or more platinum group metals, wherein preferably the first washcoat layer is free of the one or more platinum group metals. 4. The catalyst of any of embodiments 1 to 3, wherein the optional second washcoat layer is substantially free of Mn, wherein preferably the optional second washcoat layer is free of Mn.
[0142] 5. The catalyst of any of embodiments 1 to 4, wherein the content of Mn, calculated as the element, in the first washcoat layer is in the range of from 1 to 50 wt.-% based on 100 wt.- % of the first washcoat layer, preferably from 2 to 20 wt.-%, more preferably from 5 to 12 wt.-%, more preferably from 7 to 11 wt.-%, more preferably from 8 to 10 wt.-%.
[0143] 6. The catalyst of any of embodiments 1 to 5, wherein Mn is present in the form of one or more cations of Mn, wherein Mn is preferably contained in the first washcoat layer as one or more oxides, wherein Mn is more preferably contained in the first washcoat layer as one or more oxides of Mn(ll), Mn(lll), Mn(l l / l II), and Mn(IV), more preferably as one or more oxides selected from the group consisting of MnO, Mn2O3, MnsC , MnO2, Mn(O)OH, and Mn-Zr mixed oxides, including mixtures of two or more thereof, wherein the Mn-Zr mixed oxides are preferably contained in the first washcoat layer as a solid solution.
[0144] 7. The catalyst of any of embodiments 1 to 6, wherein the first washcoat layer comprises a particulate support material, wherein Mn is supported on the particulate support material, wherein the particulate support material is preferably selected from the group consisting of ZrO2, AI2C>3, SiO2, TiO2, Lae-doped ZrO2, CeO2-ZrO2mixed oxide, Lae-doped CeO2- ZrO2mixed oxide, Nd2Os-doped CeO2-ZrO2mixed oxide, Y2Os-doped CeO2-ZrO2mixed oxide, praseodymium oxide-doped CeO2-ZrO2mixed oxide, ZrO2-doped AI2C>3, ZrO2- doped SiO2, SiO2-doped AI2C>3, CuO-AI2Os mixed oxide, and mixtures of two or more thereof, more preferably from the group consisting of ZrO2, Lae-doped ZrO2, CeO2-ZrO2mixed oxide, Lae-doped CeO2-ZrO2mixed oxide, Nd2Os-doped CeO2-ZrO2mixed oxide, Ye-doped CeO2-ZrO2mixed oxide, Pr2Os-doped CeO2-ZrO2mixed oxide, P^On-doped CeO2-ZrO2mixed oxide, PrO2-doped CeO2-ZrO2mixed oxide, ZrO2-doped AI2C>3, ZrO2- doped SiO2, and mixtures of two or more thereof, more preferably from the group consisting of ZrO2, Lae-doped ZrO2, CeO2-ZrO2mixed oxide, Lae-doped CeO2-ZrO2mixed oxide, Nde-doped CeO2-ZrO2mixed oxide, Y2Os-doped CeO2-ZrO2mixed oxide, Predoped CeO2-ZrO2mixed oxide, P^On-doped CeO2-ZrO2mixed oxide, and mixtures of two or more thereof, wherein more preferably Mn is supported on particulate Lae-doped ZrO2, wherein more preferably Mn is supported on ZrO2doped with Lae in an amount ranging from 1 to 50 wt.% calculated as Lae and based on 100 wt.-% of ZrO2and Lae, preferably from 3 to 30 wt.-%, more preferably from 5 to 15 wt.-%, more preferably from 8 to 10 wt.-%.
[0145] 8. The catalyst of any of embodiments 1 to 7, wherein the first washcoat layer comprises Ce, wherein Ce is preferably contained in the first washcoat layer as CeO2and / or Cee. 9. The catalyst of embodiment 8, wherein the content of Ce, calculated as the element, in the first washcoat layer is in the range of from 1 to 50 wt.-% based on 100 wt.-% of the first washcoat layer, preferably from 2 to 20 wt.-%, more preferably from 5 to 12 wt.-%, more preferably from 7 to 11 wt.-%, more preferably from 8 to 10 wt.-%.
[0146] 10. The catalyst of embodiment 8 or 9, wherein Ce is supported on a particulate support material, wherein the particulate support material is preferably selected from the group consisting of ZrC>2, AI2O3, SiC>2, TiC>2, La2O3-doped ZrC>2, CeO2-ZrO2 mixed oxide, La2Os- doped CeO2-ZrC>2 mixed oxide, Nd2Os-doped CeO2-ZrO2 mixed oxide, Y2Os-doped CeC>2- ZrC>2 mixed oxide, praseodymium oxide-doped CeO2-ZrO2 mixed oxide, ZrC>2-doped AI2O3, ZrC>2-doped SiC>2, SiC>2-doped AI2O3, CUO-AI2O3 mixed oxide, and mixtures of two or more thereof, more preferably from the group consisting of ZrC>2, La2C>3-doped ZrC>2, CeO2-ZrC>2 mixed oxide, La2C>3-doped CeO2-ZrO2 mixed oxide, Nd2Os-doped CeO2-ZrO2 mixed oxide, Y2Os-doped CeO2-ZrO2 mixed oxide, P^Os-doped CeO2-ZrO2 mixed oxide, PreOn-doped CeO2-ZrO2 mixed oxide, PrC>2-doped CeO2-ZrO2 mixed oxide, ZrC>2-doped AI2O3, ZrC>2-doped SiC>2, and mixtures of two or more thereof, more preferably from the group consisting of ZrC>2, La2C>3-doped ZrC>2, CeO2-ZrO2 mixed oxide, La2C>3-doped CeC>2- ZrC>2 mixed oxide, Nd2Os-doped CeO2-ZrO2 mixed oxide, Y2Os-doped CeO2-ZrO2 mixed oxide, Pr2Os-doped CeO2-ZrO2 mixed oxide, P^On-doped CeO2-ZrO2 mixed oxide, and mixtures of two or more thereof, wherein more preferably Ce is supported on particulate La2O3-doped ZrO2, wherein more preferably Ce is supported on Zr©2 doped with La20s in an amount ranging from 1 to 50 wt.% calculated as La20s and based on 100 wt.-% of ZrO2and La20s, preferably from 3 to 30 wt.-%, more preferably from 5 to 15 wt.-%, more preferably from 8 to 10 wt.-%.
[0147] 11 . The catalyst of any of embodiments 1 to 10, wherein the first washcoat layer is substantially free of Ce, wherein preferably the first washcoat layer is free of Ce.
[0148] 12. The catalyst of embodiment 11 , wherein the catalyst is substantially free of Ce, wherein preferably the catalyst is free of Ce.
[0149] 13. The catalyst of any of embodiments 1 to 12, wherein the first washcoat layer comprises Cu, wherein the first washcoat layer preferably comprises CuO, CU2O, or CuO and CU2O, more preferably CuO.
[0150] 14. The catalyst of embodiment 13, wherein the content of Cu, calculated as the element, in the first washcoat layer is in the range of from 1 to 50 wt.-% based on 100 wt.-% of the first washcoat layer, preferably from 2 to 30 wt.-%, more preferably from 5 to 20 wt.-%, more preferably from 8 to 12 wt.-%. 15. The catalyst of embodiment 13 or 14, wherein Cu is supported on a particulate support material, wherein the particulate support material is preferably selected from the group consisting of ZrC>2, AI2O3, SiC>2, TiC>2, La2O3-doped ZrC>2, CeO2-ZrO2 mixed oxide, La2Os- doped CeO2-ZrC>2 mixed oxide, Nd2Os-doped CeO2-ZrO2 mixed oxide, Y2Os-doped CeC>2- ZrO2mixed oxide, praseodymium oxide-doped CeO2-ZrO2 mixed oxide, ZrC>2-doped AI2O3, ZrC>2-doped SiC>2, SiC>2-doped AI2O3, CUO-AI2O3 mixed oxide, and mixtures of two or more thereof, more preferably from the group consisting of ZrC>2, La2C>3-doped ZrC>2, CeO2-ZrC>2 mixed oxide, La2C>3-doped CeO2-ZrO2 mixed oxide, Nd2Os-doped CeO2-ZrO2 mixed oxide, Y2Os-doped CeO2-ZrO2 mixed oxide, P^Os-doped CeO2-ZrO2 mixed oxide, PreOn-doped CeO2-ZrO2 mixed oxide, PrC>2-doped CeO2-ZrO2 mixed oxide, ZrC>2-doped AI2O3, ZrC>2-doped SiC>2, and mixtures of two or more thereof, more preferably from the group consisting of ZrC>2, La2C>3-doped ZrC>2, CeO2-ZrO2 mixed oxide, La2C>3-doped CeC>2- ZrO2mixed oxide, Nd2Os-doped CeO2-ZrO2 mixed oxide, Y2Os-doped CeO2-ZrO2 mixed oxide, Pr2Os-doped CeO2-ZrO2 mixed oxide, P^On-doped CeO2-ZrO2 mixed oxide, and mixtures of two or more thereof, wherein more preferably Cu is supported on particulate La2C>3-doped ZrC>2.
[0151] 16. The catalyst of any of embodiments 1 to 15, wherein the content of the sulfur-trap material in the first washcoat layer is in the range of from 5 to 75 wt.-% based on 100 wt.-% of the second washcoat layer, preferably from 10 to 50 wt.-%, more preferably from 15 to 40 wt.- %, more preferably from 20 to 30 wt.-%.
[0152] 17. The catalyst of any of embodiments 1 to 16, wherein the sulfur-trap material comprises one or more metal oxides which react with SO2 and / or SO3 to form corresponding metal sulfites and / or sulfates, wherein preferably the sulfur-trap material consists of the one or more metal oxides.
[0153] 18. The catalyst of embodiment 17, wherein each of the one or more metal oxides, which react with SO2 and / or SO3 to form corresponding metal sulfite and / or sulfate, displays a desulfation temperature T50, at which 50% of the respective metal sulfite and / or metal sulfate has decomposed to the metal oxide and SO2 and / or SO3, which is lower than the desulfation temperature T50 of MnSC , wherein preferably, each of the one or more metal oxides displays a desulfation temperature T50 which is at least 10°C lower than the desulfation temperature T50 of MnSC , preferably at least 20°C lower, more preferably at least 50°C lower, more preferably at least 80°C lower, more preferably at least 100°C lower, more preferably at least 150°C lower.
[0154] 19. The catalyst of embodiment 17 or 18, wherein the one or more metal oxides are selected from the group consisting of oxides of Cu, Ni, Co, Fe, and Sn, including mixtures of two or more thereof, preferably from the group consisting of oxides of Cu, Fe, and Sn, including mixtures of two or more thereof, wherein more preferably the one or more metal oxides comprise, preferably consist of, oxides of Fe.
[0155] 20. The catalyst of embodiment 19, wherein the one or more metal oxides are selected from the group consisting of Fe20s, CuO, SnO, and SnC>2, including mixtures of two or more thereof, wherein more preferably the one or more metal oxides comprise, preferably consist of Fe2C>3.
[0156] 21 . The catalyst of embodiment 19 or 20, wherein the one or more metal oxides comprise, preferably consist of, oxides of Fe, wherein preferably the one or more metal oxides comprise, preferably consist of, Fe20s and / or Fe2Os-doped AI2O3, more preferably comprise, preferably consist of, Fe20s.
[0157] 22. The catalyst of embodiment 21 , wherein the content of the one or more oxides of Fe in the first washcoat layer, calculated as Fe20s and based on 100 wt.-% of the first washcoat layer, is in the range of from 1 to 100 wt.-%, preferably from 5 to 75 wt.-%, more preferably from 10 to 50 wt.-%, more preferably from 15 to 40 wt.-%, more preferably from 20 to 30 wt.-%.
[0158] 23. The catalyst of embodiment 21 or 22, wherein the one or more oxides of Fe display an average particle size D50 of 20 pm or less, preferably of 10 pm or less, more preferably of 5 pm or less, more preferably of 1 pm or less, wherein the average particle size is preferably determined according to ISO 13320:2020.
[0159] 24. The catalyst of any of embodiments 19 to 23, wherein the one or more metal oxides of Fe are supported on a particulate support material, wherein the particulate support material is preferably selected from the group consisting of ZrO2, AI2O3, SiO2, TiO2, La2O3-doped ZrO2, CeO2-ZrO2 mixed oxide, La2O3-doped CeO2-ZrO2 mixed oxide, Nd2Os-doped CeO2- Zr©2 mixed oxide, Y2Os-doped CeO2-ZrO2 mixed oxide, praseodymium oxide-doped CeO2-ZrO2 mixed oxide, ZrC>2-doped AI2O3, ZrC>2-doped SiC>2, SiC>2-doped AI2O3, CuO- AI2O3 mixed oxide, and mixtures of two or more thereof, more preferably from the group consisting of ZrC>2, La2C>3-doped ZrC>2, CeO2-ZrO2 mixed oxide, La2C>3-doped CeO2-ZrO2 mixed oxide, Nd2Os-doped CeO2-ZrO2 mixed oxide, Y2Os-doped CeO2-ZrO2 mixed oxide, Pr2O3-doped CeO2-ZrO2 mixed oxide, P^On-doped CeO2-ZrO2 mixed oxide, PrC>2-doped CeO2-ZrC>2 mixed oxide, ZrC>2-doped AI2O3, ZrC>2-doped SiC>2, and mixtures of two or more thereof, more preferably from the group consisting of ZrC>2, La2C>3-doped ZrC>2, CeO2-ZrO2 mixed oxide, La2C>3-doped CeO2-ZrO2 mixed oxide, Nd2Os-doped CeO2-ZrO2 mixed oxide, Y2C>3-doped CeO2-ZrO2 mixed oxide, P^Os-doped CeO2-ZrO2 mixed oxide, P^On-doped CeO2-ZrC>2 mixed oxide, and mixtures of two or more thereof, wherein more preferably Fe is supported on particulate La2C>3-doped ZrC>2. The catalyst of embodiment 19, wherein the one or more metal oxides comprise, preferably consist of, oxides of Sn, preferably of SnO, SnC>2, or SnO and SnC>2. The catalyst of embodiment 26, wherein the oxides of Sn are supported on a particulate support material, wherein the particulate support material is preferably selected from the group consisting of ZrC>2, AI2O3, SiC>2, TiC>2, La2O3-doped ZrC>2, CeO2-ZrO2 mixed oxide, La2C>3-doped CeO2-ZrO2 mixed oxide, Nd2Os-doped CeO2-ZrO2 mixed oxide, Y2Os-doped CeO2-ZrC>2 mixed oxide, praseodymium oxide-doped CeO2-ZrO2 mixed oxide, ZrC>2-doped AI2O3, ZrC>2-doped SiC>2, SiC>2-doped AI2O3, CUO-AI2O3 mixed oxide, and mixtures of two or more thereof, more preferably from the group consisting of ZrC>2, La2C>3-doped ZrC>2, CeO2-ZrC>2 mixed oxide, La2C>3-doped CeO2-ZrO2 mixed oxide, Nd2Os-doped CeO2-ZrO2 mixed oxide, Y2Os-doped CeO2-ZrO2 mixed oxide, P^Os-doped CeO2-ZrO2 mixed oxide, PreOn-doped CeO2-ZrO2 mixed oxide, PrC>2-doped CeO2-ZrO2 mixed oxide, ZrC>2-doped AI2O3, ZrC>2-doped SiC>2, and mixtures of two or more thereof, more preferably from the group consisting of ZrC>2, La2C>3-doped ZrC>2, CeO2-ZrO2 mixed oxide, La2C>3-doped CeC>2- ZrC>2 mixed oxide, Nd2Os-doped CeO2-ZrO2 mixed oxide, Y2Os-doped CeO2-ZrO2 mixed oxide, Pr2Os-doped CeO2-ZrO2 mixed oxide, P^On-doped CeO2-ZrO2 mixed oxide, and mixtures of two or more thereof, wherein more preferably Sn is supported on particulate La2C>3-doped ZrC>2. The catalyst of any of embodiments 1 to 26, wherein the substrate is a wall-flow substrate or a flow-through substrate, preferably a honeycomb wall-flow substrate or a honeycomb flow-through substrate, more preferably a honeycomb flow-through substrate, wherein the flow-through substrate is more preferably a flow-through substrate with high porosity walls. The catalyst of any of embodiments 1 to 27, wherein the loading of the first washcoat layer is in the range of from 0.5 to 6 g / in3, preferably of from 1 to 5 g / in3, more preferably of from 1.5 to 4.5 g / in3, more preferably of from 2 to 4 g / in3, more preferably of from 2.5 to 3.5 g / in3. The catalyst of any of embodiments 1 to 28, wherein the loading of the second washcoat layer is in the range of from 0.25 to 6 g / in3, preferably of from 0.3 to 5.5 g / in3, more preferably of from 1 to 4.8 g / in3, more preferably of from 1.5 to 4.2 g / in3, more preferably of from 2 to 3.8 g / in3, more preferably of from 2.2 to 3.5 g / in3, more preferably of from 2.5 to 3.3 g / in3, more preferably of from 2.8 to 3 g / in3. The catalyst of any of embodiments 1 to 29, wherein the catalyst comprises one or more platinum group metals consisting of Pt, Pd, or Pt and Pd, wherein preferably the catalyst comprises Pt, or Pt and Pd as the one or more platinum group metals, wherein more preferably the catalyst comprises Pt and Pd as the one or more platinum group metals. 31 . The catalyst of any of embodiments 1 to 30, wherein the catalyst comprises Pt, calculated as the element, at a loading in the range of from 2 to 250 g / ft3, preferably of from 5 to 150 g / ft3, more preferably of from 10 to 125 g / ft3, more preferably of from 20 to 100 g / ft3, more preferably of from 25 to 85 g / ft3, more preferably of from 30 to 80 g / ft3, more preferably of from 40 to 60 g / ft3.
[0160] 32. The catalyst of any of embodiments 1 to 31 , wherein the catalyst comprises Pd, calculated as the element, at a loading in the range of from 1 to 80 g / ft3, preferably of from 5 to 60 g / ft3, more preferably of from 10 to 50 g / ft3, more preferably of from 15 to 40 g / ft3, more preferably of from 20 to 30 g / ft3.
[0161] 33. The catalyst of any of embodiments 1 to 32, wherein the catalyst comprises Pt and Pd, calculated as the respective element, at a total Pt and Pd loading in the range of from 2 to 250 g / ft3, preferably of from 5 to 200 g / ft3, more preferably of from 10 to 150 g / ft3, more preferably of from 20 to 130 g / ft3, more preferably of from 30 to 125 g / ft3, more preferably of from 40 to 110 g / ft3, more preferably of from 50 to 100 g / ft3, more preferably of from 60 to 90 g / ft3, more preferably of from 70 to 80 g / ft3.
[0162] 34. The catalyst of any of embodiments 1 to 33, wherein the catalyst comprises Pt and Pd at a Pt : Pd weight ratio in the range of from 30:70 to 90:10, preferably of from 50:50 to 80:20, more preferably of from 60:40 to 75:25, more preferably of from 65:35 to 70:30.
[0163] 35. The catalyst of any of embodiments 1 to 34, wherein the one or more platinum group metals are supported on a particulate support material, wherein the particulate support material is preferably selected from the group consisting of AI2O3, SiC>2, TiC>2, SiC>2-doped AI2O3, Mn oxide-doped AI2O3, and mixtures of two or more thereof, wherein preferably the one or more platinum group metals are supported on AI2O3 and / or SiC>2-doped AI2O3 and / or Mn oxide-doped AI2O3, more preferably SiC>2-doped AI2O3 or AI2O3 or Mn oxidedoped AI2O3, more preferably SiC>2-doped AI2O3, wherein the Mn oxide-doped AI2O3 preferably comprises from 1 to 10 weight-%, more preferably from 4 to 6 weight-%, of Mn oxide, calculated as MnC>2, based on 100 weight-% of the Mn oxide-doped AI2O3, and wherein the SiC>2-doped AI2O3 preferably comprises from 1 to 10 weight-%, more preferably from 4 to 6 weight-%, of SiC>2, based on 100 weight-% of the SiC>2-doped AI2O3.
[0164] 36. The catalyst of any of embodiments 1 to 35, wherein the first washcoat layer comprises a hydrocarbon trap material, wherein the hydrocarbon trap material comprises a molecular sieve, preferably a zeolite, more preferably a zeolite having a maximum pore size of 12- membered rings, more preferably zeolite beta. 37. The catalyst of embodiment 36, wherein the molecular sieve, preferably the zeolite, comprises SiC>2 and AI2O3, wherein the molecular sieve, preferably the zeolite, preferably has a molar ratio of SiC>2 to AI2O3 in the range of from 10:1 to 500:1 , more preferably of from 10:1 to 100:1 , more preferably of from 10:1 to 40:1 , more preferably of from 15:1 to 30:1 , more preferably of from 20:1 to 25:1 .
[0165] 38. The catalyst of embodiment 36 or 37, wherein the molecular sieve, preferably the zeolite, comprises Fe, wherein the molecular sieve, preferably the zeolite, preferably comprises Fe, calculated as Fe2Os, in an amount in the range of from 1 .0 to 7.0 weight-%, more preferably of from 3.0 to 5.0 weight-%, more preferably of from 4.0 to 4.5 weight-%, based on the weight of the molecular sieve.
[0166] 39. The catalyst of any of embodiments 36 to 38, wherein the loading of the hydrocarbon trap material in the first washcoat layer is in the range of from 0.01 to 5.0 g / in3, preferably in the range of from 0.05 to 3.0 g / in3, more preferably in the range of from 0.1 to 2.0 g / in3, more preferably in the range of from 0.15 to 1 .0 g / in3, more preferably in the range of from 0.2 to 0.5 g / in3, more preferably in the range of from 0.22 to 0.3 g / in3, more preferably in the range of from 0.25 to 0.27 g / in3.
[0167] 40. The catalyst of any of embodiments 1 to 39, wherein the catalyst comprises a second washcoat layer, wherein the one or more platinum group metals are at least in part contained in the second washcoat layer, wherein preferably the one or more platinum group metals are entirely contained in the second washcoat layer.
[0168] 41 . The catalyst of any of embodiments 1 to 40, wherein the second washcoat layer comprises a hydrocarbon trap material, wherein the hydrocarbon trap material comprises a molecular sieve, preferably a zeolite, more preferably a zeolite having a maximum pore size of 12-membered rings, more preferably zeolite beta.
[0169] 42. The catalyst of embodiment 41 , wherein the molecular sieve, preferably the zeolite, comprises SiC>2 and AI2O3, wherein the molecular sieve, preferably the zeolite, preferably has a molar ratio of SiC>2 to AI2O3 in the range of from 10:1 to 500:1 , more preferably of from 10:1 to 100:1 , more preferably of from 10:1 to 40:1 , more preferably of from 15:1 to 30:1 , more preferably of from 20:1 to 25:1 .
[0170] 43. The catalyst of embodiment 41 or 42, wherein the molecular sieve, preferably the zeolite, comprises Fe, wherein the molecular sieve, preferably the zeolite, preferably comprises Fe, calculated as Fe2Os, in an amount in the range of from 1 .0 to 7.0 weight-%, more preferably of from 3.0 to 5.0 weight-%, more preferably of from 4.0 to 4.5 weight-%, based on the weight of the molecular sieve. 44. The catalyst of any of embodiments 41 to 43, wherein the loading of the hydrocarbon trap material in the second washcoat layer is in the range of from 0.01 to 5.0 g / in3, preferably in the range of from 0.05 to 3.0 g / in3, more preferably in the range of from 0.1 to 2.0 g / in3, more preferably in the range of from 0.15 to 1 .0 g / in3, more preferably in the range of from 0.2 to 0.5 g / in3, more preferably in the range of from 0.22 to 0.3 g / in3, more preferably in the range of from 0.25 to 0.27 g / in3.
[0171] 45. The catalyst of any of embodiments 1 to 44, wherein the catalyst comprises a second washcoat layer, wherein the catalyst displays a layered arrangement of the first and second washcoat layers, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer.
[0172] 46. The catalyst of embodiment 45, wherein the first washcoat layer is provided on the substrate, and the second washcoat layer is provided on the first washcoat layer.
[0173] 47. The catalyst of embodiment 45 or 46, wherein the second washcoat layer is provided on the substrate, and the first washcoat layer is provided on the second washcoat layer.
[0174] 48. The catalyst of embodiment 45 or 46, wherein the catalyst comprises a third washcoat layer, wherein the catalyst displays a zoned arrangement of the first, second, and third washcoat layers, wherein the third washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate and wherein the first washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate, and wherein the second washcoat layer is provided on and entirely covers the first washcoat layer, wherein the length of the first washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the third washcoat layer and a downstream zone comprising the first and second washcoat layers, and wherein the one or more platinum group metals are at least in part contained in the third washcoat layer.
[0175] 49. The catalyst of embodiment 45 or 47, wherein the catalyst comprises a third washcoat layer, wherein the catalyst displays a zoned arrangement of the first, second, and third washcoat layers, wherein the third washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate and wherein the second washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate, and wherein the first washcoat layer is provided on and entirely covers the second washcoat layer, wherein the length of the second washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the third washcoat layer and a downstream zone comprising the first and second washcoat layers, and wherein the one or more platinum group metals are at least in part contained in the third washcoat layer. The catalyst of embodiment 45 or 46, wherein the catalyst comprises a third washcoat layer, wherein the catalyst displays a zoned arrangement of the first, second, and third washcoat layers, wherein the third washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate and wherein the first washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate, and wherein the second washcoat layer is provided on and entirely covers the first washcoat layer, wherein the length of the first washcoat layer is less than the axial length of the substrate such as to create a downstream zone comprising the third washcoat layer and an upstream zone comprising the first and second washcoat layers, and wherein the one or more platinum group metals are at least in part contained in the third washcoat layer. The catalyst of embodiment 45 or 47, wherein the catalyst comprises a third washcoat layer, wherein the catalyst displays a zoned arrangement of the first, second, and third washcoat layers, wherein the third washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate and wherein the second washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate, and wherein the first washcoat layer is provided on and entirely covers the second washcoat layer, wherein the length of the second washcoat layer is less than the axial length of the substrate such as to create a downstream zone comprising the third washcoat layer and an upstream zone comprising the first and second washcoat layers, and wherein the one or more platinum group metals are at least in part contained in the third washcoat layer. The catalyst of any of embodiments 1 to 44, wherein the catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the second washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate, and wherein the first washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer. The catalyst of any of embodiments 1 to 44, wherein the catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the first washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate, and wherein the second washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer. The catalyst of any of embodiments 1 to 44, wherein the catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the second washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate, and wherein the first washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer. The catalyst of any of embodiments 1 to 44, wherein the catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the first washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate, and wherein the second washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer. The catalyst of embodiment 52 or 54, wherein the catalyst comprises a third washcoat layer, wherein the third washcoat layer is provided on the first washcoat layer, wherein the catalyst displays a zoned arrangement of the second and third washcoat layers, wherein the second washcoat layer is provided on the substrate along the axial length of the substrate starting from the inlet end of the substrate, and wherein the third washcoat layer is provided on the first washcoat layer along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the third washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first and third washcoat layers. The catalyst of embodiment 53 or 55, wherein the catalyst comprises a third washcoat layer, wherein the third washcoat layer is provided on the first washcoat layer, wherein the catalyst displays a zoned arrangement of the second and third washcoat layers, wherein the third washcoat layer is provided on the first washcoat layer along the axial length of the substrate starting from the inlet end of the substrate, and wherein the second washcoat layer is provided on the substrate along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the third washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the first and third washcoat layers and a downstream zone comprising the second washcoat layer.
[0176] 58. The catalyst of any of embodiments 52 to 57, wherein the first and second washcoat layers are adjacent to one another.
[0177] 59. The catalyst of any of embodiments 48 to 51 , wherein the first and third washcoat layers are adjacent to one another.
[0178] 60. The catalyst of any of embodiments 48 to 51 and 56 to 57, wherein the second and third washcoat layers are adjacent to one another.
[0179] 61 . The catalyst of any of embodiments 52 to 57, wherein a portion of the second washcoat layer overlaps at least a portion of the first washcoat layer, wherein preferably the second washcoat layer overlaps the first washcoat layer over a portion ranging from 10 to 100% of the axial length of the first washcoat layer, more preferably from 15 to 80%, more preferably from 20 to 50%.
[0180] 62. The catalyst of any of embodiments 52 to 57, wherein a portion of the first washcoat layer overlaps at least a portion of the second washcoat layer, wherein preferably the first washcoat layer overlaps the second washcoat layer over a portion ranging from 10 to 100% of the axial length of the second washcoat layer, more preferably from 15 to 80%, more preferably from 20 to 50%.
[0181] 63. The catalyst of any of embodiments 48 to 51 and 56 to 58 and 60 to 62, wherein a portion of the third washcoat layer overlaps at least a portion of the first washcoat layer, wherein preferably the third washcoat layer overlaps the first washcoat layer over a portion ranging from 10 to 100% of the axial length of the first washcoat layer, more preferably from 15 to 80%, more preferably from 20 to 50%.
[0182] 64. The catalyst of any of embodiments 1 to 44, wherein the catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the second washcoat layer is provided on the substrate along its entire length, and wherein the first washcoat layer is provided on the second washcoat layer along its axial length starting from the outlet end of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer. The catalyst of any of embodiments 1 to 44, wherein the catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the second washcoat layer is provided on the substrate along its entire length, and wherein the first washcoat layer is provided on the second washcoat layer along its axial length starting from the inlet end of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer. The catalyst of embodiment 64 or 65, wherein the length of the first washcoat layer ranges from 10 to 90% of the axial length of the substrate, preferably from 30 to 80%, more preferably from 50 to 70%. The catalyst of any of embodiments 1 to 44, wherein the catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the first washcoat layer is provided on the substrate along its entire length, and wherein the second washcoat layer is provided on the first washcoat layer along its axial length starting from the inlet end of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer. The catalyst of embodiment 67, wherein the catalyst comprises a third washcoat layer, wherein the third washcoat layer is provided on the first washcoat layer, wherein the catalyst displays a zoned arrangement of the second and third washcoat layers, wherein the second washcoat layer is provided on the first washcoat layer along the axial length of the substrate starting from the inlet end of the substrate, and wherein the third washcoat layer is provided on the first washcoat layer along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the third washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the third washcoat layer. The catalyst of any of embodiments 1 to 44, wherein the catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the first washcoat layer is provided on the substrate along its entire length, and wherein the second washcoat layer is provided on the first washcoat layer along its axial length starting from the outlet end of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate such as to ere- ate an upstream zone comprising the first washcoat layer and a downstream zone comprising the second washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer.
[0183] 70. The catalyst of embodiment 69, wherein the catalyst comprises a third washcoat layer, wherein the third washcoat layer is provided on the first washcoat layer, wherein the catalyst displays a zoned arrangement of the second and third washcoat layers, wherein the third washcoat layer is provided on the first washcoat layer along the axial length of the substrate starting from the inlet end of the substrate, and wherein the second washcoat layer is provided on the first washcoat layer along the axial length of the substrate starting from the outlet end of the substrate, wherein the length of the third washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the third washcoat layer and a downstream zone comprising the second washcoat layer.
[0184] 71 . The catalyst of embodiment 68 or 70, wherein the second and third washcoat layers are adjacent to one another.
[0185] 72. The catalyst of any one of embodiments 1 to 45, wherein the first washcoat layer is provided on the substrate, wherein the second washcoat layer is at least partially, preferably completely, provided on the first washcoat layer, and wherein the third washcoat layer is at least partially, preferably completely, provided on the second washcoat layer.
[0186] 73. The catalyst of any one of embodiments 1 to 45, wherein the first washcoat layer is provided on the substrate, wherein the third washcoat layer is at least partially, preferably completely, provided on the first washcoat layer, and wherein the second washcoat layer is at least partially, preferably completely, provided on the third washcoat layer.
[0187] 74. The catalyst of any of embodiments 1 to 73, wherein the length of the first washcoat layer ranges from 5 to 100% of the axial length of the substrate, preferably from 10 to 90% of the axial length of the substrate, preferably from 15 to 75%, more preferably from 20 to 60%, more preferably from 25 to 50%, more preferably from 35 to 45%.
[0188] 75. The catalyst of any of embodiments 45 to 74, wherein the length of the second washcoat layer ranges from 5 to 100% of the axial length of the substrate, preferably from 10 10 to 90% of the axial length of the substrate, more preferably from 15 to 75%, more preferably from 20 to 60%, more preferably from 25 to 50%, more preferably from 35 to 45%.
[0189] 76. The catalyst of any of embodiments 48 to 51 and 56 to 57 and 59 to 60 and 68 and 70, wherein the length of the third washcoat layer ranges from 5 to 100% of the axial length of the substrate, preferably from 10 to 90% of the axial length of the substrate, preferably from 15 to 75%, more preferably from 20 to 60%, more preferably from 25 to 50%, more preferably from 35 to 45%. The catalyst of any of embodiments 48 to 51 and 56 to 57 and 59 to 60 and 68 and 70, wherein the third washcoat layer comprises a hydrocarbon trap material, wherein the hydrocarbon trap material comprises a molecular sieve, preferably a zeolite, more preferably a zeolite having a maximum pore size of 12-membered rings, more preferably zeolite beta. The catalyst of embodiment 77, wherein the molecular sieve, preferably the zeolite, comprises SiC>2 and AI2O3, wherein the molecular sieve, preferably the zeolite, preferably has a molar ratio of SiC>2 to AI2O3 in the range of from 10:1 to 500:1 , more preferably of from 10:1 to 100:1 , more preferably of from 10:1 to 40:1 , more preferably of from 15:1 to 30:1 , more preferably of from 20:1 to 25:1 . The catalyst of embodiment 77 or 78, wherein the molecular sieve, preferably the zeolite, comprises Fe, wherein the molecular sieve, preferably the zeolite, preferably comprises Fe, calculated as Fe2Os, in an amount in the range of from 1 .0 to 7.0 weight-%, more preferably of from 3.0 to 5.0 weight-%, more preferably of from 4.0 to 4.5 weight-%, based on the weight of the molecular sieve. The catalyst of any of embodiments 77 to 79, wherein the loading of the hydrocarbon trap material in the third washcoat layer is in the range of from 0.01 to 5.0 g / in3, preferably in the range of from 0.05 to 3.0 g / in3, more preferably in the range of from 0.1 to 2.0 g / in3, more preferably in the range of from 0.15 to 1 .0 g / in3, more preferably in the range of from 0.2 to 0.5 g / in3, more preferably in the range of from 0.22 to 0.3 g / in3, more preferably in the range of from 0.25 to 0.27 g / in3. The catalyst of any of embodiments 48 to 51 , 56 to 57, 59 to 60, 63, 68, 70 to 73, 76 to 77 and 80, wherein the one or more platinum group metals are at least in part contained in the third washcoat layer. The catalyst of embodiment 81 , wherein the one or more platinum group metals are supported on a particulate support material, wherein the particulate support material is preferably selected from the group consisting of AI2O3, SiC>2, TiC>2, SiC>2-doped AI2O3, Mn oxidedoped AI2O3, and mixtures of two or more thereof, wherein preferably the one or more platinum group metals are supported on AI2O3 and / or SiC>2-doped AI2O3 and / or Mn oxidedoped AI2O3, more preferably SiC>2-doped AI2O3 or AI2O3 or Mn oxide-doped AI2O3, more preferably SiC>2-doped AI2O3, wherein the Mn oxide-doped AI2O3 preferably comprises from 1 to 10 weight-%, more preferably from 4 to 6 weight-%, of Mn oxide, calculated as MnC>2, based on 100 weight-% of the Mn oxide-doped AI2O3, and wherein the SiC>2-doped AI2O3 preferably comprises from 1 to 10 weight-%, more preferably from 4 to 6 weight-%, of SiO2, based on 100 weight-% of the SiC>2-doped AI2O3.
[0190] 83. The catalyst of any of embodiments 48 to 82, wherein the catalyst comprises second and third washcoat layers, wherein the one or more platinum group metals are entirely contained in the second and third washcoat layers.
[0191] 84. The catalyst of embodiment 83, wherein the weight ratio of the one or more platinum group metals comprised in the second washcoat layer to the one or more platinum group metals comprised in the third washcoat layer is in the range of from 0.5:1 to 5.0:1 , preferably of from 1.0:1 to 2.0:1 , more preferably in the range of from 1.4:1 to 1.6:1.
[0192] 85. The catalyst of embodiment 83 or 84, wherein the one or more platinum group metals comprised in the second washcoat layer comprise, preferably consist of, Pt and Pd, wherein the one or more platinum group metals comprised in the third washcoat layer preferably comprise, more preferably consist of, Pt and Pd.
[0193] 86. The catalyst of any of embodiments 1 to 85, preferably of any of embodiments 45 to 85, wherein the one or more platinum group metals are entirely contained in the second washcoat layer or in the second and third washcoat layers.
[0194] 87. The catalyst of any of embodiments 1 to 85, preferably of any of embodiments 45 to 85, wherein the one or more platinum group metals are at least in part contained in the first washcoat layer.
[0195] 88. The catalyst of any of embodiments 1 to 87, wherein the substrate is a metallic substrate or a ceramic substrate, wherein preferably the substrate is a ceramic substrate, wherein more preferably the substrate comprises cordierite and / or SiC, preferably cordierite, wherein more preferably, the substrate consists of cordierite and / or SiC, preferably of cordierite.
[0196] 89. The catalyst of any of embodiments 48 to 88, wherein the substrate consists of two separate monoliths, wherein the first monolith is provided upstream of the second monolith, wherein the washcoat layer or washcoat layers of the upstream zone are contained on the first monolith, and the washcoat layer or washcoat layers of the downstream zone are contained on the second monolith, wherein preferably the first monolith containing the washcoat layer or washcoat layers of the upstream zone and the second monolith containing the washcoat layer or washcoat layers of the downstream zone are obtained or obtainable by sectioning of a catalyst according to any of embodiments 48 to 88 into two separate monoliths, wherein the washcoat layer or washcoat layers of the upstream zone are contained on the first monolith, and the washcoat layer or washcoat layers of the downstream zone are contained on the second monolith.
[0197] 90. The catalyst of any of embodiments 1 to 89, wherein the exhaust gas stream contains hydrocarbons, preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons.
[0198] 91 . Exhaust gas treatment system comprising an internal combustion engine and an exhaust gas conduit for exhaust gas from the internal combustion engine, wherein the exhaust gas conduit comprises one or more catalysts according to any of embodiments 1 to 90, preferably one, two, three or four catalysts according to any of embodiments 1 to 90.
[0199] 92. The exhaust gas treatment system of embodiment 91 , wherein the internal combustion engine is a compression ignition engine, preferably a diesel engine.
[0200] 93. The exhaust gas treatment system of embodiment 91 or 92, wherein the internal combustion engine is a lean gasoline engine.
[0201] 94. The exhaust gas treatment system of embodiment 91 , wherein the internal combustion engine is powered by an oxygenated fuel, wherein the oxygenated fuel preferably comprises one or more of methanol and biofuel.
[0202] 95. The exhaust gas treatment system of any of embodiments 91 to 94, wherein the system comprises one or more of an electric heater, a fuel burner, a fuel injector, a selective catalytic reduction (SCR) catalyst, an ammonia oxidation (AMOX) catalyst, a catalyzed soot filter (CSF), a diesel particulate filter (DPF), a selective catalytic reduction catalyst on filter (SCRoF), and a diesel exotherm catalyst (DEC).
[0203] 96. The exhaust gas treatment system of embodiment 95, comprising in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 90, a catalyst according to any of embodiments 1 to 90, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a diesel exotherm catalyst (DEC), a catalyzed soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst.
[0204] 97. The exhaust gas treatment system of embodiment 95, comprising in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 90, a catalyst according to any of embodiments 1 to 90, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a diesel exotherm catalyst (DEC), a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst.
[0205] 98. The exhaust gas treatment system of embodiment 95, comprising in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 90, a catalyst according to any of embodiments 1 to 90, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a diesel exotherm catalyst (DEC), a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.
[0206] 99. The exhaust gas treatment system of embodiment 95, comprising in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 90, a catalyst according to any of embodiments 1 to 90, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of embodiments 1 to 90, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst.
[0207] 100. The exhaust gas treatment system of embodiment 95, comprising in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 90, a catalyst according to any of embodiments 1 to 90, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of embodiments 1 to 90, a catalyst according to any of embodiments 1 to 90, wherein the substrate is a wall-flow substrate, a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.
[0208] 101 . The exhaust gas treatment system of embodiment 95, comprising in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 90, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a catalyzed soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and a selective catalytic reduction (SCR) catalyst.
[0209] 102. The exhaust gas treatment system of embodiment 95, comprising in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 90, a selective catalytic re- duction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a catalyzed soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AM OX) catalyst. The exhaust gas treatment system of embodiment 95, comprising in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 90, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of embodiments 1 to 90, wherein the substrate is a wallflow substrate, a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AM OX) catalyst. The exhaust gas treatment system of embodiment 95, comprising in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 90, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction catalyst on filter (SCRoF), and an ammonia oxidation (AMOX) catalyst. The exhaust gas treatment system of embodiment 95, comprising in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of embodiments 1 to 90, a selective catalytic reduction catalyst on filter (SCRoF), and an ammonia oxidation (AMOX) catalyst. The exhaust gas treatment system of embodiment 95, comprising in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of embodiments 1 to 90, a catalyzed soot filter (CSF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst. The exhaust gas treatment system of embodiment 95, comprising in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a selective catalytic reduction (SCR) catalyst, an optional fuel injector, a catalyst according to any of embodiments 1 to 90, a catalyst according to any of embodiments 1 to 90, wherein the substrate is a wall-flow substrate, a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst. The exhaust gas treatment system of embodiment 95, comprising in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 90, a diesel particulate filter (DPF), a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AM OX) catalyst.
[0210] 109. The exhaust gas treatment system of embodiment 95, comprising in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 90, a selective catalytic reduction catalyst on filter (SCRoF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.
[0211] 110. The exhaust gas treatment system of embodiment 95, comprising in consecutive order in the direction of the exhaust gas: optionally an electric heater or a fuel burner and / or a fuel injector, a catalyst according to any of embodiments 1 to 90, a selective catalytic reduction (SCR) catalyst, a selective catalytic reduction catalyst on filter (SCRoF), a selective catalytic reduction (SCR) catalyst, and an ammonia oxidation (AMOX) catalyst.
[0212] 111. Method for the treatment of an exhaust gas stream containing one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons, the method comprising
[0213] (A) providing an exhaust gas stream comprising one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons;
[0214] (B) directing the exhaust gas stream provided in (A) through a catalyst according to any of embodiments 1 to 90.
[0215] 112. The method of embodiment 111 , wherein the exhaust gas stream provided in (A) comprises one or more sulfur-containing compounds, preferably SO2 and / or SO3.
[0216] 113. The method of embodiment 111 or 112, wherein the exhaust gas stream provided in (A) comprises NOX.
[0217] 114. The method of any of embodiments 111 to 113, wherein the exhaust gas stream provided in (A) comprises CO.
[0218] 115. The method of any of embodiments 111 to 114, wherein the exhaust gas stream provided in (A) comprises hydrocarbons, preferably C1 to C20 hydrocarbons, more preferably C2 to C10 hydrocarbons.
[0219] 116. Use of a catalyst according to any of embodiments 1 to 90 for the oxidation of one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons, preferably for the oxidation of one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons in an exhaust gas stream, more preferably for the oxidation of one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons in the exhaust gas stream of an internal combustion engine, more preferably for the oxidation of one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons in the exhaust gas stream of a compression ignition engine, more preferably for the oxidation of one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons in the exhaust gas stream of a diesel engine.
[0220] The present invention is further illustrated by the following examples and comparative examples.
[0221] EXPERIMENTAL SECTION
[0222] Comparative Example 1 : Preparation of a catalyst for the treatment of an exhaust gas stream containing one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons
[0223] A catalyst was prepared by coating platinum group metal (PGM)-containing front zone and base metal oxide (BMO)-containing rear zone segments separately on 1 ” diameter cordierite honeycomb substrates and then combining the coated cores sequentially for subsequent S aging and testing. The front zone segment was prepared by first combining Pt (using an aqueous solution containing an ammine stabilized hydroxo Pt(IV) complex, said solution having a Pt content in the range of from 10 to 20 weight-%), Pd (using Pd nitrate), Beta zeolite and a commercial alumina support powder comprising 5 wt.-% silica and having a BET surface area of approximately 150 m2 / g and a pore volume of about 0.6 cm3 / g in an aqueous slurry composition using techniques commonly known in the art. After coating the slurry onto a cordierite substrate followed by drying and calcination at 590 °C, a 1 ” diameter by 1 .2” long core was subsequently cut from the monolith to be used as the front zone segment. Pt-Pd weight ratio was 2:1 , and total Pt-Pd loading was 75 g / ft3of monolith volume. The washcoat loading of the PGM-containing layer was 2.9 g / in3, containing about 91 wt.-% alumina and about 9 wt.-% Beta zeolite. The BMO-contain- ing rear zone segment was prepared by first combining a commercial zirconia support powder comprising 9 wt.-% La20s and having a BET surface area of approximately 75 m2 / g with solutions of Mn nitrate and Ce nitrate in de-ionized (Di) water. After milling the resulting mixture to a particle size suitable for coating, boehmite alumina binder was added. The resulting slurry was then coated onto a 1” diameter by 1.8” long cordierite substrate which was dried and subsequently calcined at 590 °C for 1 h. The total washcoat loading of the BMO-containing layer was 2.3 g / in3of monolith volume comprising 9.2 % by weight Mn, 9.2 % by weight Ce, 3 % by weight alumina binder and balance La2C>3-stabilized ZrC>2.
[0224] Example 2: Preparation of a catalyst for the treatment of an exhaust gas stream containing one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons
[0225] A zoned catalyst sample was prepared in the same manner as described in Comparative Example 1 except that Fe2Os was combined in a single layer in the rear zone with the 9.2% Mn and 9.2% Ce-containing BMO catalyst supported on 9% La2C>3-stabilized ZrC>2. The total washcoat loading of the BMO-containing layer was 3.0 g / in3of monolith volume comprising 24 wt.% of Fe2C>3 and 76 wt.% of 9.2 % by weight Mn, 9.2 % by weight Ce, 3 % by weight alumina binder and balance 9% La2C>3-stabilized ZrC>2.
[0226] Example 3: Catalyst aging and catalytic testing
[0227] Sulfur aging (S aging) of the catalysts of Comparative Example 1 as well as of Example 2 was accomplished by exposing the catalysts to the exhaust of a diesel engine operating with fuel containing 325 ppm S by weight. 1”x3” catalyst core samples were loaded into a ceramic monolith holder and placed in the flow of the engine exhaust downstream of a burner DOC used to raise the exhaust temperature for periodic desulfation events. During sulfation, the exhaust temperature at the inlet to the catalyst core samples was maintained at 315 °C, and flow through the catalyst measured as space velocity was 61 ,000 / h. The exposure time at this condition was 180 minutes corresponding to a target S exposure amount of 2 g (S) / L of monolith volume. Desulfation was accomplished by raising the temperature in front of the catalyst core samples to 700 °C for 30 minutes by injecting diesel fuel in front of the burner DOC upstream of the catalysts. Overall, 5 complete sulfation and desulfation cycles were accomplished.
[0228] After sulfation and desulfation, samples were tested for formaldehyde (HCHO) light-off performance using a feed comprising 180 ppm NO, 1000 ppm CO, 25 ppm HCHO, 100 ppm-C1 from C2H4, 190 ppm-C1 from C10H22, 10 % O2, 10 % H2O and 10 % CO2. The flow through the catalyst as measured by space velocity was 50,000 / h. The samples were placed in the reactor and first equilibrated at 80 °C in flowing air. The formaldehyde-containing feed was then introduced, and temperature ramping initiated to 300 °C at a ramp rate of 15 °C / min. Formaldehyde concentration was monitored by FTIR during the light-off ramp and conversion performance vs. temperature was subsequently calculated from these measurements.
[0229] The results after 700 °C desulfation for the catalysts of Comparative Example 1 and Example 2 are shown in Figure 3. Formaldehyde oxidation performance was substantially higher after sul- fation / desulfation for the catalyst of Example 2 comprising a mixture of the Mn-based BMO catalyst and the Fe2Os S-adsorbent in the rear zone. As demonstrated by the results, it is clear that inclusion of the BMO catalyst with integrated S-adsorbent layer can allow for a significant reduction in the PGM content of diesel oxidation catalysts.
[0230] DESCRIPTION OF THE FIGURES
[0231] Figure 1 : shows thermogravimetric (TG) curves for sulfates of divalent metals in flowing high purity nitrogen at a heating rate of 2 °C / min (Tagawa, H., Thermochimica Acta,
[0080] , 1984, 23-33). Figure 2: shows thermogravimetric (TG) curves for sulfates of trivalent and tetravalent metals in flowing high purity nitrogen at a heating rate of 2 °C / min (Tagawa, H., Thermochimica Acta,
[0080] , 1984, 23-33).
[0232] Figure 3: shows formaldehyde (HCHO) oxidation performance after sulfation and 700 °C desulfation for the catalysts of Comparative Example 1 and Example 2. Both samples comprised a 2:1 Pt-Pd front zone at 75 g / ft3. The rear zone of Comparative Example 1 further comprised 9.2 wt.-% Mn and 9.2 wt.-% Ce supported on 9 wt.-% La2O3-stabilized ZrO2. On the other hand, the rear zone of Example 2 comprised a mixture of Fe2Os S adsorbent (24 wt%) and 9.2 wt.-% Mn and 9.2 wt.-% Ce supported on 9 wt.-% La2O3-stabilized ZrO2 (76 wt%).
[0233] CITED LITERATURE
[0234] - WO 2022 / 047132 A1
[0235] - US 10,598,061 B2
[0236] - US 10,392,980 B2
[0237] - US 2015 / 352493 A1
[0238] - US 2022 / 152589 A1
[0239] - CN 112 805 089 A
[0240] - US 2015 / 352493 A1
[0241] - US 2023 / 321636 A1
[0242] - US 2018 / 318805 A1
[0243] - US 2015 / 252708 A1
Claims
Claims1 . A catalyst for the treatment of an exhaust gas stream containing one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons, the catalyst comprising a first washcoat layer comprising Mn and a sulfur-trap material, wherein the sulfur- trap material may be desulfated, and a substrate, wherein the substrate has an inlet end through which the exhaust gas stream may enter the catalyst, and an outlet end through which the exhaust gas stream may exit the catalyst, wherein the catalyst further comprises one or more platinum group metals comprising Pt, Pd, or Pt and Pd, wherein the one or more platinum group metals are at least in part contained in one or more of:(a) the first washcoat layer, and(b) an optional second washcoat layer, or(c) optional second and third washcoat layers.
2. The catalyst of claim 1 , wherein the sulfur-trap material is substantially free of Mn.
3. The catalyst of claim 1 or 2, wherein the first washcoat layer comprises a particulate support material, wherein Mn is supported on the particulate support material.
4. The catalyst of any of claims 1 to 3, wherein the first washcoat layer comprises Ce.
5. The catalyst of claim 4, wherein Ce is supported on a particulate support material.
6. The catalyst of any of claims 1 to 5, wherein the sulfur-trap material comprises one or more metal oxides which react with SO2 and / or SO3 to form corresponding metal sulfites and / or sulfates.
7. The catalyst of claim 6, wherein the one or more metal oxides are selected from the group consisting of oxides of Cu, Ni, Co, Fe, and Sn, including mixtures of two or more thereof.
8. The catalyst of any of claims 1 to 7, wherein the one or more platinum group metals are supported on a particulate support material.
9. The catalyst of any of claims 1 to 8, wherein the catalyst comprises a second washcoat layer, wherein the one or more platinum group metals are at least in part contained in the second washcoat layer.
10. The catalyst of any of claims 1 to 9, wherein the second washcoat layer comprises a hydrocarbon trap material, wherein the hydrocarbon trap material comprises a molecular sieve.11 . The catalyst of any of claims 1 to 10, wherein the catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the second washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate, and wherein the first washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate, wherein the length of the first washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer.
12. The catalyst of any of claims 1 to 10, wherein the catalyst comprises a second washcoat layer, wherein the catalyst displays a zoned arrangement of the first and second washcoat layers, wherein the second washcoat layer is provided on the substrate along its axial length starting from the inlet end of the substrate, and wherein the first washcoat layer is provided on the substrate along its axial length starting from the outlet end of the substrate, wherein the length of the second washcoat layer is less than the axial length of the substrate such as to create an upstream zone comprising the second washcoat layer and a downstream zone comprising the first washcoat layer, and wherein the one or more platinum group metals are at least in part contained in the second washcoat layer.
13. Exhaust gas treatment system comprising an internal combustion engine and an exhaust gas conduit for exhaust gas from the internal combustion engine, wherein the exhaust gas conduit comprises one or more catalysts according to any of claims 1 to 12.
14. Method for the treatment of an exhaust gas stream containing one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons, the method comprising(A) providing an exhaust gas stream comprising one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons;(B) directing the exhaust gas stream provided in (A) through a catalyst according to any of claims 1 to 12.
15. Use of a catalyst according to any of claims 1 to 12 for the oxidation of one or more of formaldehyde, nitrogen oxide (NO), and hydrocarbons.
Citation Information
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