# US 10,369,548 B2 · Catalyzed soot filter

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- Number: US 10,369,548 B2
- Document ID: US10369548B2
- Status: Granted
- Kind: B2
- Application number: 15/124,146
- Filed: 2015-03-11
- Published: 2017-01-26
- Granted: 2019-08-06
- Earliest claimed: 2014-03-12
- Assignees: BASF SE
- Applicants: BASF SE; BASF Corporation
- Inventors: Gerd Grubert; Alfred H. Punke; Torsten Neubauer; Marcus Hilgendorff; Chung-Zong Wan; Yuejin Li; Matthew Caudle
- Web page: https://patentgrep.com/patent/US10369548B2

## CPC

- B01J 23/72: Copper
- B01D 53/944: {Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts (three-way-catalysts [TWC] B01D53/9445)}
- B01D 53/9459: {Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts (layered catalysts with only one function B01D53/9413, B01D53/944 or B01D53/945)}
- B01D 53/9468: {in different layers}
- B01J 21/12: Silica and alumina
- B01J 23/42: Platinum
- B01J 23/44: Palladium
- B01J 23/8926: {Copper and noble metals}
- B01J 27/224: Silicon carbide
- B01J 35/19: {Catalysts containing parts with different compositions}
- B01J 35/56: Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths
- B01J 35/612: {less than 10 m2/g}
- B01J 37/0244: {Coatings comprising several layers}
- F01N 3/035: with catalytic reactors
- F01N 13/10: of exhaust manifolds {(with cooling jacket F01N3/046)}
- B01D 53/9431: {Processes characterised by a specific device}
- B01D 2255/1021: Platinum
- B01D 2255/1023: Palladium
- B01D 2255/2073: Manganese
- B01D 2255/20738: Iron
- B01D 2255/20753: Nickel
- B01D 2255/20761: Copper
- B01D 2255/9032: Two zones
- B01D 2255/9155: Wall flow filters
- B01D 2255/9202: Linear dimensions
- B01D 2255/9207: Specific surface
- B01D 2257/304: Hydrogen sulfide
- B01D 2258/012: Diesel engines and lean burn gasoline engines
- B01J 35/60: characterised by their surface properties or porosity
- B01J 35/657: {larger than 1000 nm}
- B01J 37/0219: {the coating containing organic compounds}
- B01J 37/0234: {Impregnation and coating simultaneously}
- B01J 37/0248: {Coatings comprising impregnated particles}
- F01N 3/0814: {combined with catalytic converters, e.g. NOx absorption/storage reduction catalysts}
- F01N 3/0842: {Nitrogen oxides}
- F01N 3/103: {Oxidation catalysts for HC and CO only}
- F01N 3/2066: {Selective catalytic reduction [SCR]}
- F01N 2570/10: Carbon or carbon oxides
- Y02A 50/20: Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- F01N: GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES (arrangements in connection with gas exhaust of propulsion units in vehicles B60K13/00; combustion-air intake silencers specially adapted for, or arranged on, internal-combustion engines F02M35/00; protecting against, or damping, noise in general G10K11/16)
- Y02A: TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE

## Abstract

A catalyzed soot filter, in particular for the treatment of Diesel engine exhaust, comprises a coating design which ensures soot particulates filtration, assists the oxidation of carbon monoxide (CO), and produces low H2S emissions during normal engine operations and regeneration events.

## Claims

### Claim 1

A catalyzed soot filter, comprising
a wall flow substrate comprising an inlet end, an outlet end, a substrate axial length extending between the inlet end and the outlet end, and a plurality of passages defined by internal walls of the wall flow filter substrate;
wherein the plurality of passages comprise inlet passages having an open inlet end and a closed outlet end, and outlet passages having a closed inlet end and an open outlet end;
wherein the internal walls of the inlet passages comprise an inlet coating comprising at least one layer, and the inlet coating extends from the inlet end to an inlet coating end, thereby defining an inlet coating length, wherein the inlet coating length is x % of the substrate axial length, wherein x is from 25 to 100; and
wherein the internal walls of the outlet passages comprise an outlet coating comprising at least one layer, and the outlet coating extends from the outlet end to an outlet coating end, thereby defining an outlet coating length, wherein the outlet coating length is y % of the substrate axial length, wherein y is from 25 to 100;
wherein the inlet coating length defines an upstream zone of the catalyzed soot filter and the outlet coating length defines a downstream zone of the catalyzed soot filter;
wherein the wall flow substrate comprises at least one layer comprising at least one oxidation catalyst and at least one layer comprising at least one H2S suppressing material, wherein the H2S suppressing material comprises CuO in the tenorite phase;
wherein
the at least one oxidation catalyst and the at least one H2S suppressing material are separated by the internal walls of the wall flow filter substrate;
the total coating length is x+y, and x+y is greater than or equal to 150 and
wherein the inlet coating comprises the H2S suppressing material, and the outlet coating comprises the at least one oxidation catalyst.

### Claim 2 (depends on 1)

The catalyzed soot filter of claim 1, wherein x+y is greater than 175.

### Claim 3 (depends on 1)

The catalyzed soot filter of claim 1, wherein x is from 50 to 100.

### Claim 4 (depends on 1)

The catalyzed soot filter of claim 1, wherein y is from 50 to 100.

### Claim 5 (depends on 1)

The catalyzed soot filter of claim 1, wherein the H2S suppressing material is supported on a support material not containing alumina (Al2O3).

### Claim 6 (depends on 1)

The catalyzed soot filter of claim 1, wherein the H2S suppressing material further comprises a metal selected from the group consisting of Mn, Fe, Ni and mixtures thereof.

### Claim 7 (depends on 1)

The catalyzed soot filter of claim 1, wherein an average crystallite size of the CuO is at least 30 nm.

### Claim 8 (depends on 1)

The catalyzed soot filter of claim 1, wherein a BET surface area of the CuO in the tenorite phase is less than 5 m2/g.

### Claim 9 (depends on 1)

The catalyzed soot filter of claim 1, wherein the wall flow substrate is a porous wall flow substrate, and the at least one oxidation catalyst and/or the at least one H2S suppressing material have been introduced into the porous walls of the porous wall flow substrate.

### Claim 10 (depends on 1)

The catalyzed soot filter of claim 1, wherein in the coating containing the at least one oxidation catalyst, the oxidation catalyst comprises:
(a) Pt, but no Pd; or
(b) Pd, but no Pt; or
(c) Pt and Pd, provided that the weight ratio of Pt:Pd is in the range of from 20:1 to 1:1.

### Claim 11 (depends on 1)

A system for treating a diesel engine exhaust stream, the system comprising an exhaust conduit in fluid communication with the diesel engine via an exhaust manifold; the catalyzed soot filter of claim 1; and one or more of the following in fluid communication with the catalyzed soot filter: a diesel oxidation catalyst (DOC), a selective catalytic reduction (SCR) article, a NOx storage and reduction (NSR) catalytic article, a lean NOx trap (LINT) article.

### Claim 12 (depends on 1)

A method of treating a diesel engine exhaust stream, the exhaust stream containing soot particles, said method comprising contacting the exhaust stream with the catalyzed soot filter of claim 1.

### Claim 13 (depends on 12)

The method of treating a diesel engine exhaust stream according to claim 12, wherein the catalyzed soot filter is arranged downstream of an article that produces H2S.

### Claim 14 (depends on 12)

The method of treating a diesel engine exhaust stream of claim 12, wherein an average crystallite size of the CuO in the tenorite phase is at least 30 nm.

### Claim 15 (depends on 1)

The catalyzed soot filter of claim 1, wherein the H2S suppressing material is not supported on a support material.

### Claim 16 (depends on 11)

The system of claim 11, wherein the catalyzed soot filter is arranged downstream of an article that produces H2S.

### Claim 17

A process for manufacturing a catalyzed soot filter comprising:
(i) providing a wall flow substrate comprising an inlet end, and outlet end, a substrate axial length extending between the inlet end and the outlet end, and a plurality of passages defined by the internal walls of the wall flow substrate;
wherein the plurality of passages comprise inlet passages having an open inlet end and a closed outlet end, and outlet passages having a closed inlet end and an open outlet end;
wherein a given inlet passage, an adjacent outlet passage, and the internal wall between said inlet and said outlet passage define an overall passage;
(ii) applying a first coating to at least part of the internal walls of at least 25% of the overall passages such that the first coating extends from the inlet end to a first coating end whereby an inlet coating length is defined, wherein the inlet coating length is x % of the substrate axial length, with 25≤x≤100, said first coating comprising at least one oxidation catalyst or at least one H2S suppressing material;
(iii) applying a second coating to at least part of the internal walls of at least 25% of the overall passages such that the second coating extends from the outlet end to a second coating end whereby an outlet coating length is defined, wherein the outlet coating length is y % of the substrate axial length, with 25≤y≤100, said second coating comprising at least one oxidation catalyst or at least one H2S suppressing material;
wherein the outlet coating comprises the at least one oxidation catalyst, and the inlet coating comprises the at least one H2S suppressing material, and the at least one oxidation catalyst and the at least one H2S suppressing material are separated by the internal walls of the wall flow filter substrate, and the total coating length is x+y, and x+y is greater than or equal to 150, and
wherein the H2S suppressing material comprises CuO in the tenorite phase.

### Claim 18 (depends on 17)

The process for manufacturing a catalyzed soot filter of claim 17, wherein the wall flow substrate has a porosity in the range of from 38 to 75, determined according to mercury porosimetry measurement according to DIN 66133 and wherein the wall flow substrate is a cordierite substrate, an aluminum titanate substrate, or a silicon carbide substrate.