# US 9,429,055 B2 · Method for purification of exhaust gas from internal-combustion engine

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- Number: US 9,429,055 B2
- Document ID: US9429055B2
- Status: Granted
- Kind: B2
- Application number: 11/826,365
- Filed: 2007-07-13
- Published: 2008-01-17
- Granted: 2016-08-30
- Earliest claimed: 2006-07-13
- Assignees: Umicore Shokubai USA Inc.; Umicore Shokubai Japan Co., Ltd.
- Applicants: Masanori Ikeda
- Inventors: Masanori Ikeda
- Web page: https://patentgrep.com/patent/US9429055B2

## CPC

- F01N 3/035: with catalytic reactors
- B01D 53/944: {Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts (three-way-catalysts [TWC] B01D53/9445)}
- B01J 23/44: Palladium
- B01J 35/19: {Catalysts containing parts with different compositions}
- B01J 37/0244: {Coatings comprising several layers}
- F01N 3/0253: {adding fuel to exhaust gases}
- F01N 3/0814: {combined with catalytic converters, e.g. NOx absorption/storage reduction catalysts}
- F01N 3/0842: {Nitrogen oxides}
- F01N 13/0097: {the purifying devices are arranged in a single housing}
- B01D 2251/208: Hydrocarbons
- B01D 2255/91: NOx-storage component incorporated in the catalyst
- F01N 3/2033: {using a fuel burner or introducing fuel into exhaust duct}
- 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 2610/03: the substance being hydrocarbons, e.g. engine fuel
- 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 method for extending a temperature range enabling combustion of high concentration hydrocarbon, or for rapidly supplying high temperature gas to a later stage catalyst. Provided is a method for purification of exhaust gas from an internal-combustion engine comprised by: providing a temperature-raising catalyst for exhaust gas from an internal-combustion engine in an exhaust gas passage of the internal-combustion engine, along flow of said exhaust gas, at the upstream side of a purification catalyst for said exhaust gas; and introducing hydrocarbon in an amount of 1,000 to 40,000 ppm, as converted to methane, from the upstream side of the temperature-raising catalyst, wherein said temperature-raising catalyst has catalytically active components supported onto a refractory three-dimensional structure, wherein concentration of said components has a gradient such that said concentration gradually becomes lower from the inflow side toward the outflow side of said exhaust gas.

## Claims

### Claim 1

A method for purification of exhaust gas from an internal-combustion engine comprised by:
providing a temperature-raising catalyst for exhaust gas from an internal-combustion engine in an exhaust gas passage of the internal-combustion engine, along flow of said exhaust gas, at an upstream side of a purification catalyst for said exhaust gas, a temperature of the exhaust gas increasing along the flow of the exhaust gas from an upstream side to a downstream side of the temperature-raising catalyst; and
introducing hydrocarbon in an amount of 1,000 to 15,000 ppm, as converted to methane, at a temperature in the range of 200 to 350° C., from the upstream side of the temperature-raising catalyst, when a gas obtained from the temperature-raising catalyst is fed to the purification catalyst, catalytic activity of the temperature-raising catalyst not decreasing after introducing the hydrocarbon,
wherein said temperature-raising catalyst has catalytically active components (A) supported onto refractory inorganic oxide powders (B) having a three-dimensional structure, wherein concentration of said components has a gradient such that said concentration gradually becomes lower from an inflow side toward an outflow side of said exhaust gas,
wherein the catalytically active components (A) comprise at least one of a noble metal selected from the group consisting of platinum, palladium and rhodium,
wherein a supporting amount of the catalytically active components (A) in said temperature-raising catalyst is 0.2 to 20 g/liter of the catalyst, and a supporting amount of said refractory inorganic oxide powders (B) is 10 to 300 g/liter of the catalyst,
wherein a supporting amount of the catalytically active components (A) of the catalyst component, in said temperature-raising catalyst, in 10 to 66.7% of the total length from the inflow side of said exhausted gas on said refractory three-dimensional structure, is 20 to 80% of total catalytically active components (A), and a supporting amount of the catalytically active components (A) in 50% of the length of the inflow side is more than a supporting amount of the catalytically active components (A) in 50% of the outflow side, and
wherein said gradient is formed stepwise.

### Claim 2 (depends on 1)

The method according to claim 1, wherein an introduction amount of said hydrocarbon is 5,000 to 15,000 ppm, as converted to methane, relative to said exhaust gas.

### Claim 3 (depends on 1)

The method according to claim 1, wherein said exhaust gas temperature-raising catalyst also has capability of exhaust gas purification.

### Claim 4 (depends on 1)

The method according to claim 1, wherein said purification catalyst is at least one selected from the group consisting of a diesel particulate filter, an oxide catalyst and a NOx storage catalyst.

### Claim 5 (depends on 1)

The method according to claim 1, wherein the three-dimensional structure of said purification catalyst is a honeycomb and/or a plug honeycomb or a pellet.

### Claim 6 (depends on 1)

The method according to claim 1, wherein the three-dimensional structure is made of cordierite.

### Claim 7 (depends on 1)

The method according to claim 1, wherein the method is free of poisoning of the temperature-raising catalyst by the hydrocarbon.

### Claim 8 (depends on 1)

The method according to claim 1, wherein said noble metal comprises (a) platinum and (b) palladium or rhodium.

### Claim 9 (depends on 8)

The method according to claim 8, wherein a mass ratio of platinum/palladium or rhodium is in a range of 20/1-1/1.

### Claim 10 (depends on 1)

The method according to claim 1, wherein the hydrocarbon is liquid hydrocarbon.

### Claim 11 (depends on 10)

The method according to claim 10, wherein the liquid hydrocarbon is light oil.

### Claim 12 (depends on 1)

The method according to claim 1, wherein if a value of a temperature sensor located between the temperature-raising catalyst and the purification catalyst exceeds a predetermined value, action of a fuel charging pump stops.

### Claim 13 (depends on 12)

The method according to claim 12, wherein the predetermined value is 700° C.

### Claim 14 (depends on 1)

The method according to claim 1, wherein said noble metal comprises (a) platinum and (b) palladium.

### Claim 15 (depends on 14)

The method according to claim 14, wherein an amount of said catalytically active components (A) is in a range of 1-15 g/liter of the catalyst and an amount of said refractory inorganic oxide powders (B) is in a range of 20-200 g/liter of the catalyst.

### Claim 16 (depends on 14)

The method according to claim 14, wherein a mass ratio of platinum/palladium is in a range of 5/1-2/1.