# US 12,005,426 B2 · Three-way conversion catalyst in gasoline-natural gas applications

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- Number: US 12,005,426 B2
- Document ID: US12005426B2
- Status: Granted
- Kind: B2
- Application number: 17/250,794
- Filed: 2019-09-12
- Published: 2021-11-04
- Granted: 2024-06-11
- Earliest claimed: 2018-09-13
- Assignees: BASF SE
- Applicants: BASF Corporation
- Inventors: Karifala Dumbuya; Thomas Schmitz; Florian Waltz; Stephan Siemund
- Web page: https://patentgrep.com/patent/US12005426B2

## CPC

- B01J 23/6562: {Manganese}
- B01D 53/9454: {characterised by a specific device}
- B01J 21/04: Alumina
- B01J 23/58: with alkali- or alkaline earth metals
- B01J 23/8892: {Manganese}
- 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 37/0244: {Coatings comprising several layers}
- F01N 3/035: with catalytic reactors
- F01N 3/101: {Three-way catalysts}
- B01D 2255/1021: Platinum
- B01D 2255/1023: Palladium
- B01D 2255/1025: Rhodium
- B01D 2255/2042: Barium
- B01D 2255/2061: Yttrium
- B01D 2255/2063: Lanthanum
- B01D 2255/2065: Cerium
- B01D 2255/2066: Praseodymium
- B01D 2255/2068: Neodymium
- B01D 2255/20715: Zirconium
- B01D 2255/2073: Manganese
- B01D 2255/407: Zr-Ce mixed oxides
- B01D 2255/9022: Two layers
- B01D 2255/908: O2-storage component incorporated in the catalyst
- B01D 2255/9205: Porosity
- B01D 2255/9207: Specific surface
- F01N 3/0835: {Hydrocarbons}
- F01N 3/0842: {Nitrogen oxides}
- F01N 3/0857: {Carbon oxides}
- 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

The disclosure relates to a three-way conversion catalyst for the treatment of an exhaust gas comprising nitrogen monoxide, carbon monoxide, and hydrocarbon, wherein the catalyst comprises: (i) a substrate; (ii) a first coating comprising rhodium supported on a first oxidic component; (iii) a second coating comprising palladium supported on a non-zeolitic oxidic material, wherein the non-zeolitic oxidic material comprises manganese and a second oxidic component, wherein the second coating consists of 0 weight-% to 0.001 weight-% of platinum; wherein the first coating is disposed on the substrate over x % of the axial length, with x ranging from 80 to 100; wherein the second coating extends over y % of the axial length from the inlet end to the outlet end and is disposed on the first coating, with y ranging from 20 to x.

## Claims

### Claim 1

A three-way conversion catalyst for the treatment of an exhaust gas comprising nitrogen monoxide, carbon monoxide and hydrocarbon, wherein the catalyst comprises:
(i) a substrate comprising an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end and a plurality of passages defined by internal walls of the substrate extending therethrough;
(ii) a first coating comprising rhodium supported on a first oxidic component; and
(iii) a second coating comprising palladium supported on a non-zeolitic oxidic material, wherein the non-zeolitic oxidic material comprises manganese and a second oxidic component, wherein from 0 weight-% to 0.001 weight-% of the second coating consists of platinum;
wherein the first coating is disposed on the surface of the internal walls of the substrate over x % of the substrate axial length and x ranging from 80 to 100;
wherein the second coating extends over y % of the substrate axial length from the inlet end to the outlet end and is disposed on the first coating and y ranging from 20 to x.

### Claim 2 (depends on 1)

The three-way conversion catalyst of claim 1, wherein x ranges from 90 to 100 and wherein y ranges from 80 to x.

### Claim 3 (depends on 1)

The three-way conversion catalyst of claim 1, wherein the first oxidic component, in the first coating, is chosen from alumina, ceria, silica, zirconia, titania, a mixture of two or more thereof, and a mixed oxide of two or more thereof.

### Claim 4 (depends on 1)

The three-way conversion catalyst of claim 1, wherein the first coating further comprises a platinum group metal other than rhodium.

### Claim 5 (depends on 4)

The three-way conversion catalyst of claim 4, wherein the platinum group metal other than rhodium is supported on a third oxidic component.

### Claim 6 (depends on 5)

The three-way conversion catalyst of claim 5, wherein the platinum group metal other than rhodium is further supported on a first oxygen storage compound.

### Claim 7 (depends on 1)

The three-way conversion catalyst of claim 1, wherein the first coating consists of from 0 weight-% to 0.001 weight-% of manganese.

### Claim 8 (depends on 1)

The three-way conversion catalyst of claim 1, wherein the second coating comprises manganese an amount ranging from 1 weight-% to 10 weight-%, calculated as MnO2 and based on the weight of the non-zeolitic oxidic material.

### Claim 9 (depends on 1)

The three-way conversion catalyst of claim 1, wherein the second oxidic component, in the non-zeolitic oxidic material of the second coating, is chosen from alumina, silica, ceria, zirconia, titania, a mixture of two or more thereof, and a mixed oxide of two or more thereof.

### Claim 10 (depends on 1)

The three-way conversion catalyst of claim 1, wherein the second coating comprises palladium, calculated as elemental palladium, at a loading ranging from 20 g/ft3 to 200 g/ft3.

### Claim 11 (depends on 1)

The three-way conversion catalyst of claim 1, wherein the second coating further comprises a second oxygen storage compound.

### Claim 12 (depends on 1)

The three-way conversion catalyst of claim 1, wherein the substrate according to (i) is a flow-through substrate.

### Claim 13 (depends on 1)

An exhaust gas treatment system downstream of and in fluid communication with an engine, the system comprising a three-way conversion catalyst according to claim 1.

### Claim 14 (depends on 1)

A method of treating an exhaust gas comprising hydrocarbon, carbon monoxide, and nitrogen monoxide from a gasoline engine or a combined gasoline-natural gas engine comprising using the three-way conversion catalyst according to claim 1 for the treatment.

### Claim 15

A process for preparing a three-way conversion catalyst comprising:
(a) providing a substrate comprising an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end and a plurality of passages defined by internal walls of the substrate extending therethrough;
(b) preparing a slurry comprising rhodium, a first oxidic component and water; disposing the slurry on the surface of the internal walls of the substrate over x % of the substrate axial length, from the inlet end to the outlet end of the substrate, or from the outlet end to the inlet end of the substrate, with x ranging from 80 to 100; calcining the obtained slurry-treated substrate, obtaining a substrate coated with a first coating;
(c) preparing a slurry comprising water, palladium and a non-zeolitic oxidic material, comprising manganese and a second oxidic component; disposing the slurry on the first coating of the coated substrate obtained in (b) over y % of the substrate axial length from the inlet end to the outlet end of the substrate, with y ranging from 20 to x; calcining the obtained slurry-treated substrate, obtaining a substrate coated with a first coating and a second coating, wherein the second coating consist of 0 weight-% to 0.001 weight-% of platinum.