# US 11,110,436 B2 · Phosphorus compound-containing exhaust gas purifying catalyst

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- Number: US 11,110,436 B2
- Document ID: US11110436B2
- Status: Granted
- Kind: B2
- Application number: 16/767,213
- Filed: 2018-12-26
- Published: 2020-12-10
- Granted: 2021-09-07
- Earliest claimed: 2017-12-28
- Assignees: Umicore Shokubai Japan Co., Ltd.
- Applicants: Umicore Shokubai Japan Co., Ltd.
- Inventors: Hirotaka Kuno; Masashi Nakashima; Kimihiro Nakama
- Web page: https://patentgrep.com/patent/US11110436B2

## CPC

- B01J 23/464: {Rhodium}
- B01D 53/945: {characterised by a specific catalyst}
- B01D 53/9468: {in different layers}
- B01D 53/9472: {in different zones}
- B01J 21/04: Alumina
- B01J 21/066: {Zirconium or hafnium; Oxides or hydroxides thereof}
- B01J 23/10: of rare earths
- B01J 23/44: Palladium
- B01J 23/63: with rare earths or actinides
- 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 37/0215: {Coating}
- B01J 37/0228: {in several steps}
- B01J 37/0236: {Drying, e.g. preparing a suspension, adding a soluble salt and drying}
- B01J 37/0244: {Coatings comprising several layers}
- B01J 37/0248: {Coatings comprising impregnated particles}
- B01J 37/031: {Precipitation}
- B01J 37/086: {Decomposition of an organometallic compound, a metal complex or a metal salt of a carboxylic acid}
- B01J 37/28: Phosphorising
- F01N 3/10: by thermal or catalytic conversion of noxious components of exhaust
- F01N 3/101: {Three-way catalysts}
- B01D 2255/1023: Palladium
- B01D 2255/1025: Rhodium
- B01D 2255/2042: Barium
- B01D 2255/2063: Lanthanum
- B01D 2255/2065: Cerium
- B01D 2255/20715: Zirconium
- B01D 2255/2092: Aluminium
- B01D 2255/407: Zr-Ce mixed oxides
- B01D 2255/9022: Two layers
- B01D 2255/9032: Two zones
- B01D 2255/904: Multiple catalysts
- B01D 2255/905: Catalysts having a gradually changing coating
- B01D 2255/908: O2-storage component incorporated in the catalyst
- B01D 2255/9202: Linear dimensions
- B01D 2257/55: Compounds of silicon, phosphorus, germanium or arsenic
- F01N 2510/0682: having a discontinuous, uneven or partially overlapping coating of catalytic material, e.g. higher amount of material upstream than downstream or vice versa
- F01N 2510/0684: having more than one coating layer, e.g. multi-layered coatings
- Y02T 10/12: Improving ICE efficiencies
- 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)
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

A phosphorus compound-containing exhaust gas purifying catalyst includes: a refractory three-dimensional structure extending from a gas inflow side end surface to a gas outflow side end surface, the refractory three-dimensional structure having cell walls that define and form multiple gas flow paths, the gas flow paths running from the gas inflow side end surface to the gas outflow side end surface; a lower catalyst layer that contains Pd and is formed continuously from the gas inflow side end surface on the cell walls; a gas inflow side upper catalyst layer that contains Rh and is located as an uppermost layer on the cell walls; and a gas outflow side upper catalyst layer that contains Rh and is located as an uppermost layer on the cell walls.

## Claims

### Claim 1

A phosphorus compound-containing exhaust gas purifying catalyst, comprising:
a refractory three-dimensional structure extending from a gas inflow side end surface to a gas outflow side end surface, the refractory three-dimensional structure having cell walls that define and form multiple gas flow paths, the gas flow paths running from the gas inflow side end surface to the gas outflow side end surface;
a lower catalyst layer that contains Pd and is formed continuously from the gas inflow side end surface on the cell walls;
a gas inflow side upper catalyst layer that contains Rh and is located on an uppermost layer on the cell walls, the gas inflow side upper catalyst layer being formed continuously from the gas inflow side end surface; and
a gas outflow side upper catalyst layer that contains Rh and is located on an uppermost layer on the cell walls, the gas outflow side upper catalyst layer being formed continuously from the gas outflow side end surface, wherein
the gas inflow side upper catalyst layer and the gas outflow side upper catalyst layer are disposed so as to be separated from one another along the gas flow path direction, and
the lower catalyst layer has a length along the gas flow path direction of 15 mm or more, and a length ratio is 18% or more and less than 100% of the total length of the gas flow paths.

### Claim 2 (depends on 1)

The phosphorus compound-containing exhaust gas purifying catalyst according to claim 1, wherein
a total thickness of the catalyst layers at a gas inflow side end of the gas outflow side upper catalyst layer is greater than a total thickness of the catalyst layers at a gas outflow side end of the gas outflow side upper catalyst layer.

### Claim 3 (depends on 1)

The phosphorus compound-containing exhaust gas purifying catalyst according to claim 1, wherein
a separation distance between the gas inflow side upper catalyst layer and the gas outflow side upper catalyst layer is 5 mm or more and 30 mm or less.

### Claim 4 (depends on 1)

The phosphorus compound-containing exhaust gas purifying catalyst according to claim 1, wherein
the gas inflow side upper catalyst layer has a length along the gas flow path direction of 10 mm or greater, and a length ratio is 12% or greater and 57% or less to the total length of the gas flow paths.

### Claim 5 (depends on 1)

The phosphorus compound-containing exhaust gas purifying catalyst according to claim 1, wherein
the gas outflow side upper catalyst layer has a length along the gas flow path direction of 25 mm or greater, and a length ratios is 31% or greater and less than 88% to the total length of the gas flow paths.

### Claim 6 (depends on 1)

The phosphorus compound-containing exhaust gas purifying catalyst according to claim 1, wherein
the gas inflow side upper catalyst layer has a length along the gas flow path direction equal to or less than the length of the lower catalyst layer.

### Claim 7 (depends on 1)

The phosphorus compound-containing exhaust gas purifying catalyst according to claim 1, wherein
the gas inflow side upper catalyst layer has a higher Rh concentration than the Rh concentration of the gas outflow side upper catalyst layer.

### Claim 8 (depends on 1)

The phosphorus compound-containing exhaust gas purifying catalyst according to claim 1, wherein
the lower catalyst layer has a lower Rh concentration than the gas outflow side upper catalyst layer.

### Claim 9 (depends on 1)

The phosphorus compound-containing exhaust gas purifying catalyst according to claim 1, wherein
at least one layer among the lower catalyst layer, the gas inflow side upper catalyst layer, and the gas outflow side upper catalyst layer contains a composite oxide containing CeO2 and ZrO2.

### Claim 10 (depends on 1)

The phosphorus compound-containing exhaust gas purifying catalyst according to claim 1, wherein
the refractory three-dimensional structure has a length in the gas flow path direction of greater than 15 mm and 1000 mm or less.

### Claim 11 (depends on 1)

A method of manufacturing the phosphorus compound-containing exhaust gas purifying catalyst according to claim 1, comprising:
applying, drying, and calcining a slurry for the lower catalyst layer containing Pd continuously from the gas inflow side end surface to form the lower catalyst layer on the cell walls of the refractory three-dimensional structure, the three-dimensional structure extending along the gas inflow side end surface to the gas outflow side end surface, the refractory three-dimensional structure having the cell walls that define and form multiple gas flow paths running from the gas inflow side end surface to the gas outflow side end surface; and
after forming the lower catalyst layer, applying a slurry for the gas inflow side upper catalyst layer containing Rh continuously from the gas inflow side end surface and a slurry for gas outflow side catalyst layer containing Rh continuously from the gas outflow side end surface on the cell walls such that the slurries do not contact one another, subsequently drying and calcining the slurries to form the gas inflow side upper catalyst layer and the gas outflow side upper catalyst layer.

### Claim 12 (depends on 1)

A method of purifying phosphorus compound-containing exhaust gas comprising
bringing the phosphorus compound-containing exhaust gas purifying catalyst according claim 1 into contact with phosphorus compound-containing exhaust gas.