# US 9,040,003 B2 · Three way catalyst comprising extruded solid body > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,040,003 B2 - Document ID: US9040003B2 - Status: Granted - Kind: B2 - Application number: 14/079,210 - Filed: 2013-11-13 - Published: 2014-03-06 - Granted: 2015-05-26 - Earliest claimed: 2010-02-01 - Assignees: Johnson Matthey Public Limited Company - Applicants: Johnson Matthey Public Limited Company - Inventors: Paul Joseph Andersen; Ralf Dotzel; Kwangmo Koo; Rainer Leppelt; Jörg Werner Münch; Jeffery Scott Rieck; Hubert Schedel; Duncan John William Winterborn; Todd Howard Ballinger; Julian Peter Cox - Web page: https://patentgrep.com/patent/US9040003B2 ## CPC - B01J 23/30: Tungsten - B01D 53/9413: {Processes characterised by a specific catalyst} - B01D 53/945: {characterised by a specific catalyst} - B01J 23/83: with rare earths or actinides - B01J 23/888: Tungsten - B01J 29/7415: {Zeolite Beta} - B01J 29/7815: {Zeolite Beta} - B01J 35/56: Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths - B01J 37/0009: {Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst} - C04B 35/50: based on rare-earth compounds {(non-oxide rare earth compounds C04B35/5156)} - C04B 35/63488: {Polyethers, e.g. alkylphenol polyglycolether, polyethylene glycol [PEG], polyethylene oxide [PEO]} - C04B 35/6365: {Cellulose or derivatives thereof} - C04B 35/80: Fibres, filaments, whiskers, platelets, or the like - C04B 35/82: Asbestos; Glass; Fused silica - C04B 38/0006: {Honeycomb structures (from one or more corrugated sheets by winding or stacking C04B38/0083)} - F01N 3/035: with catalytic reactors - B01D 53/9418: {for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas} - B01D 2255/20738: Iron - B01D 2255/20776: Tungsten - B01D 2255/9155: Wall flow filters - C04B 2111/00793: {as filters or diaphragms} - C04B 2111/0081: {as catalysts or catalyst carriers} - C04B 2235/3218: Aluminium (oxy)hydroxides, e.g. boehmite, gibbsite, alumina sol - C04B 2235/322: Transition aluminas, e.g. delta or gamma aluminas - C04B 2235/3229: Cerium oxides or oxide-forming salts thereof - C04B 2235/6021: Extrusion moulding - C04B 2235/606: Drying - Y02A 50/20: Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters - Y02T 10/12: Improving ICE efficiencies - Y10S 55/30: Exhaust treatment - Y10T 29/49345: Catalytic device making - 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) - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - 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 - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION - Y10S: TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A three way catalyst includes an extruded solid body having by weight: 10-100% of at least one binder/matrix component; 5-90% of a zeolitic molecular sieve, a non-zeolitic molecular sieve or a mixture of any two or more thereof; and 0-80% optionally stabilised ceria. The catalyst also includes at least one precious metal and optionally at least one non-precious metal, wherein: (i) the at least one precious metal is carried in one or more coating layer(s) on the body surface; (ii) at least one metal is present throughout the body and at least one precious metal is carried in one or more coating layer(s) on a body surface; or (iii) at least one metal is present throughout the body, is present in a higher concentration at a body surface, and at least one precious metal is carried in one or more coating layer(s) on the body surface. ## Claims ### Claim 1 A three-way catalyst comprising an extruded solid body comprising: 10-95% by weight of at least one binder/matrix component; 5-90% by weight of an aluminosilicate zeolite having a silica-to-alumina ratio of 10 to 150; and 0-80% by weight optionally stabilised ceria, which catalyst comprising at least two precious metals selected from the group consisting of Pd, Ag, and Rh and optionally at least one non-precious metal, wherein: (i) Pd and Rh are carried in one or more coating layer(s) on a surface of the extruded solid body; (ii) at least one of Pd and Ag is present throughout the extruded solid body and Pd and Rh are carried in one or more coating layer(s) on a surface of the extruded solid body; or (iii) at least one of Pd and Ag is present throughout the extruded solid body, at least one of Pd and Ag is present in a higher concentration at a surface of the extruded solid body and Pd and Rh are carried in one or more coating layer(s) on the surface of the extruded solid body. ### Claim 2 (depends on 1) A catalyst according to claim 1, wherein the at least one of Pd and Ag is present throughout the extruded solid body and is associated with the aluminosilicate zeolite. ### Claim 3 (depends on 2) A catalyst according to claim 2, wherein the extruded solid body further comprises at least one metal that is not associated with the aluminosilicate zeolite. ### Claim 4 (depends on 1) A three-way catalyst according to claim 1, wherein: the at least one binder/matrix component is selected from the group consisting of cordierite, nitrides, carbides, borides, intermetallics, lithium aluminosilicate, an optionally doped alumina, a silica source, titania, zirconia, titania-zirconia, zircon and mixtures of any two or more thereof; and the aluminosilicate zeolite optionally contains one or more metal; and the extruded solid body further comprises: 0-80% by weight of spinel; and 0-25% by weight inorganic fibres. ### Claim 5 (depends on 1) A three-way catalyst according to claim 1, wherein the extruded solid body consists essentially of: the at least one binder/matrix component; the aluminosilicate zeolite in an amount of 50-90% by weight; and 0-25% by weight of inorganic fibres, wherein the at least one binder/matrix component is selected from the group consisting of cordierite, nitrides, carbides, borides, intermetallics, lithium aluminosilicate, a spinel, an optionally doped alumina, a source of silica, titania, zirconia, titania-zirconia, zircon and mixtures of any two or more thereof; the aluminosilicate zeolite optionally contains one or more metal. ### Claim 6 (depends on 1) A three-way catalyst according to claim 1, wherein the extruded solid body consists essentially of: the at least one binder/matrix component; the aluminosilicate zeolite in an amount of 5-50% by weight; the optionally stabilised ceria in an amount of 20-80% by weight; and 0-25% by weight of inorganic fibres, wherein the at least one binder/matrix component is selected from the group consisting of a cordierite, nitrides, carbides, borides, intermetallics, lithium aluminosilicate, an optionally doped alumina, a spinel, a silica source, titania, zirconia, titania-zirconia, zircon and mixtures of any two or more thereof; the zeolitic molecular sieve, the aluminosilicate zeolite optionally contains one or more metal. ### Claim 7 (depends on 1) A three-way catalyst according to claim 1 in the form of a wall-flow filter. ### Claim 8 (depends on 1) A three-way catalyst according to claim 1 comprising the extruded solid body in the flow-through configuration, wherein the extruded solid body consists essentially of: the at least one binder/matrix component; the aluminosilicate zeolite in an amount of 50-81% by weight; and 0-20% by weight of inorganic fibres, wherein the at least one binder/matrix component comprises 15-30% by weight of cordierite, nitrides, carbides, borides, intermetallics, lithium aluminosilicate, a spinel, an optionally doped alumina, titania, zirconia, titania-zirconia, zircon and mixtures of any two or more thereof and 0-20% by weight of a source of silica; the aluminosilicate zeolite optionally contains one or more metal; and the extruded solid catalyst body is coated with a single layer comprising a mixture of γ-alumina and a stabilised ceria supporting Pd and Rh. ### Claim 9 (depends on 1) A three-way catalyst according to claim 1, wherein the aluminosilicate zeolite is selected from the group consisting of ZSM-5, beta, ferrierite and mixtures of any two or more thereof. ### Claim 10 (depends on 1) A three-way catalyst according to claim 1, wherein the catalyst comprises the at least one non-precious metal and the at least one non-precious metal is associated with the aluminosilicate zeolite. ### Claim 11 (depends on 10) A three-way catalyst according to claim 10, wherein the or each at least one non-precious metal associated with the aluminosilicate zeolite is selected from the group consisting of a transition metal, a lanthanide or a mixture of any two or more thereof. ### Claim 12 (depends on 11) A three-way catalyst according to claim 11, wherein the at least one non-precious metal is Cu. ### Claim 13 A three-way catalysed soot filter comprising an extruded solid body in the wall-flow filter configuration, the extruded solid catalyst body consisting essentially of: 15-70% by weight of cordierite, nitrides, carbides, borides, intermetallics, lithium aluminosilicate, a spinel, an optionally doped alumina, titania, zirconia, titania-zirconia, zircon and mixtures of any two or more thereof; 0-20% by weight of a source of silica; 5-50% by weight of an aluminosilicate zeolite having a silica-to-alumina ratio of 10 to 150, optionally containing one or more metal; 20-80% by weight optionally stabilised ceria; and 0-20% by weight of inorganic fibres, the extruded solid catalyst body being coated with one or more layer(s) comprising supported Pd and Rh. ### Claim 14 (depends on 1) A method of treating exhaust gas emissions from internal combustion engines from a stationary source or a vehicle, wherein said exhaust gas has HC, CO, and NOX, which method comprising oxidizing the HC and CO and reducing the NO by contacting the exhaust gas with a three-way catalyst according to claim 1. ### Claim 15 (depends on 1) An exhaust system for an internal combustion engine, which exhaust system comprising a three-way catalyst according to claim 1. ### Claim 16 A three-way catalyst comprising: an extruded solid body comprising 10-95% by weight of at least one binder/matrix component; 5-90% by weight of an aluminosilicate zeolite having a silica-to-alumina ratio of 10 to 150; and 0-80% by weight optionally stabilised ceria, and one or more coating layers on a surface of the extruded solid body, the one or more coating layers comprising Pd and Rh. ### Claim 17 (depends on 16) The three-way catalyst of claim 16, wherein the extruded solid body further comprises Pd throughout the extruded solid body. ### Claim 18 (depends on 17) The three-way catalyst of claim 17, wherein the extruded solid body further comprises Ag throughout the extruded solid body. ### Claim 19 (depends on 18) The three-way catalyst of claim 18, wherein at least one of the Pd and Ag is present in a higher concentration at a surface of the extruded solid body. ### Claim 20 (depends on 16) The three-way catalyst of claim 16, wherein the extruded solid body further comprises Ag throughout the extruded solid body. ### Claim 21 (depends on 20) The three-way catalyst of claim 20, wherein the Ag is present in a higher concentration at a surface of the extruded solid body. ### Claim 22 (depends on 16) The three-way catalyst of claim 16, wherein the one or more coating layer(s) further comprises a mixed oxide of ceria-zirconia for supporting the Pd and Rh.