# US 2018/0021768 A1 · Catalyst binders for filter substrates

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- Number: US 2018/0021768 A1
- Document ID: US20180021768A1
- Status: Published application
- Kind: A1
- Application number: 15/655,933
- Filed: 2017-07-21
- Published: 2018-01-25
- Earliest claimed: 2016-07-22
- Assignees: Johnson Matthey Public Limited Company
- Applicants: Johnson Matthey Public Limited Company
- Inventors: Guy Chandler; Keith Flanagan; Alexander Green; David Marvell; Paul Phillips
- Web page: https://patentgrep.com/patent/US20180021768A1

## CPC

- F01N 3/0222: {the structure being monolithic, e.g. honeycombs}
- B01D 53/00: Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols, (recovery of volatile solvents by condensation B01D5/00; sublimation B01D7/00; cold traps, cold baffles B01D8/00; working-up undefined gaseous mixtures obtained by cracking hydrocarbon oils C10G70/00; cleaning coal gas C10K; working-up of natural gas, or synthetic natural gas, C10L3/10; separation of difficult-to-condense gases or air by liquefaction F25J; for investigating materials G01N30/00)
- B01D 53/9418: {for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas}
- B01D 53/944: {Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts (three-way-catalysts [TWC] B01D53/9445)}
- B01J 21/04: Alumina
- B01J 29/061: {containing metallic elements added to the zeolite}
- B01J 29/064: containing iron group metals, noble metals or copper
- B01J 29/068: Noble metals
- B01J 29/072: Iron group metals or copper
- B01J 29/076: containing arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
- B01J 29/7015: {CHA-type, e.g. Chabazite, LZ-218}
- B01J 29/7049: {containing rare earth elements, titanium, zirconium, hafnium, zinc, cadmium, mercury, gallium, indium, thallium, tin or lead}
- B01J 29/72: containing iron group metals, noble metals or copper
- B01J 29/723: {CHA-type, e.g. Chabazite, LZ-218}
- B01J 29/743: {CHA-type, e.g. Chabazite, LZ-218}
- B01J 29/76: Iron group metals or copper
- B01J 29/763: {CHA-type, e.g. Chabazite, LZ-218}
- B01J 29/783: {CHA-type, e.g. Chabazite, LZ-218}
- B01J 29/85: Silicoaluminophosphates [SAPO compounds]
- B01J 35/19: {Catalysts containing parts with different compositions}
- B01J 35/40: characterised by dimensions, e.g. grain size (in a colloidal state B01J35/23; crystallite size B01J35/77)
- B01J 35/45: Nanoparticles
- B01J 35/57: Honeycombs
- B01J 35/77: Compounds characterised by their crystallite size
- B01J 37/0246: {Coatings comprising a zeolite}
- B01J 37/038: {to form slurries or suspensions, e.g. a washcoat}
- B01J 37/30: Ion-exchange
- F01N 3/035: with catalytic reactors
- F01N 3/2066: {Selective catalytic reduction [SCR]}
- B01D 2255/102: Platinum group metals
- B01D 2255/1021: Platinum
- B01D 2255/1023: Palladium
- B01D 2255/1025: Rhodium
- B01D 2255/1026: Ruthenium
- B01D 2255/2065: Cerium
- B01D 2255/20723: Vanadium
- B01D 2255/20738: Iron
- B01D 2255/20753: Nickel
- B01D 2255/20761: Copper
- B01D 2255/50: Zeolites
- B01D 2255/9155: Wall flow filters
- B01D 2255/9202: Linear dimensions
- B01J 2229/18: to introduce other elements into or onto the molecular sieve itself
- B01J 2229/186: not in framework positions
- B01J 2229/26: to stabilize the total catalyst structure
- F01N 2370/02: used in catalytic reactors
- 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)
- 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)
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS

## Abstract

Provided is a catalyst washcoat comprising (i) a molecular sieve loaded with about 1 to about 10 weight percent of at least non-aluminum promoter metal (wherein the promoter metal weight percent is based on the weight of the molecular sieve); and (ii) about 1 to about 30 weight percent of a binder having a d90 particle size of less than 10 microns (wherein the binder weight percent is based on the total weight of the washcoat). In another aspect of the invention, the catalyst washcoat is applied to a wall-flow filter to form a catalyst article. In another aspect of the invention the catalyst article is part of an exhaust gas treatment system. And in yet another aspect of the invention, provided is a method for treating exhaust gas using the catalyst article.

## Claims

### Claim 1

A catalytic article:
a. a honeycomb wall-flow filter having porous walls;
b. a catalyst washcoat disposed on and/or within at least a portion of the porous walls, wherein the catalyst washcoat comprises (i) a molecular sieve having about 1 to about 10 weight percent of at least one non-aluminum promoter metal, based on the total weight of the molecular sieve; and (ii) about 1 to about 30 weight percent of a binder having a d90 particle size of less than 10 microns, based on the total weight of the washcoat.

### Claim 2 (depends on 1)

The catalyst article of claim 1, wherein the d90 particle size is less than 5 microns.

### Claim 3 (depends on 1)

The catalyst article of claim 1, wherein the d90 particle size is greater than 1 micron.

### Claim 4 (depends on 1)

The catalyst article of claim 1, wherein the binder is selected from the group consisting alumina, silica, ceria, titania, zirconia, or combinations of two or more of these.

### Claim 5 (depends on 1)

The catalyst article of claim 1, wherein the binder is alumina.

### Claim 6 (depends on 5)

The catalyst article of claim 5, wherein the alumina is selected from gamma-alumina and theta alumina.

### Claim 7 (depends on 1)

The catalyst article of claim 1, wherein the honeycomb wall-flow filter is a ceramic monolith.

### Claim 8 (depends on 1)

The catalyst article of claim 1, wherein the filter is constructed of aluminum titanate, cordierite, silicon carbide, silicon nitride, zirconia, mullite, alumina-silica-magnesia, zirconium silicate, ceramic fiber composite, wherein the filter is passivated or unpassivated.

### Claim 9 (depends on 1)

The catalyst article of claim 1, wherein the molecular sieve is an aluminosilicate or a SAPO.

### Claim 10 (depends on 9)

The catalyst article of claim 9, wherein said molecular sieve is an aluminosilicate having a framework selected from CHA, AEI, AFX, AFT, ERI, LEV, or KFI.

### Claim 11 (depends on 10)

The catalyst article of claim 10, wherein the molecular sieve has a silica-to-alumina ratio (SAR) of about 10 to about 50.

### Claim 12 (depends on 11)

The catalyst article of claim 11, wherein the framework is AEI.

### Claim 13 (depends on 12)

The catalyst article of claim 12, wherein the SAR is about 10 to about 20.

### Claim 14 (depends on 10)

The catalyst article of claim 10, wherein the promoter metal is selected from Cu, Fe, V, Ce, Pt, Pd, Ru, Rh, and Ni.

### Claim 15 (depends on 14)

The catalyst article of claim 14, wherein the promoter metal is Cu.