EP0443765A1
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EP
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Catalyst composition containing segregated platinum and rhodium components
Assignee: BASF Catalysts LLC
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Filing: 1991-02-13
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Granted: —
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Expires: 2011-02-13
Abstract
Abstract A catalyst composition suitable for three-way conversion of internal combustion engine, e.g., automobile gasoline engine, exhaust gases includes a catalytic material disposed in two discrete coats on a carrier. The first coat includes a stabilized alumina support on which a first platinum catalytic component is dispersed and bulk ceria, and may also include bulk iron oxide, a metal oxide (such as bulk nickel oxide) which is effective for the suppression of hydrogen sulfide emissions, and one or both of baria and zirconia dispersed throughout the first coat as a thermal stabilizer. The second coat, which may comprise a top coat overlying the first coat, contains a co-formed (e.g., co-precipitated) rare earth oxide-zirconia support on which a first rhodium catalytic component is dispersed, and a second activated alumina support having a second platinum catalytic component dispersed thereon. The second coat may also include a second rhodium catalytic component, and optionally, a third platinum catalytic component, dispersed as an activated alumina support. The present invention also provides a method for treating engine exhaust gases by contacting the gases under conversion conditions with the catalyst composition.
Inventors
- 👤 Chung-Zong Wan
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-11-07 20:39
CPC Classifications
B; B01; B01D; B01D53/00; B01D53/34; B01D53/92; B01D53/94; B01D53/9445; B01D53/945; B01J; B01J23/00; B01J23/38; B01J23/40; B01J23/46; B01J23/54; B01J23/56; B01J23/62; B01J23/622; B01J23/624; B01J23/63; B01J23/64; B01J23/656; B01J23/6562; B01J23/70; B01J23/89; B01J23/8933; B01J23/894; B01J37/00; B01J37/02; B01J37/024; B01J37/0244; B01D2255/00; B01D2255/90; B01D2255/902; Y; Y02; Y02A; Y02A50/00; Y02A50/20; Y02T; Y02T10/00; Y02T10/10; Y02T10/12
Claims Analysis
Total Claims: 52
Claim 1
Independent Claim
109 words
A catalyst composition comprising a carrier on which is disposed a catalytic material, the catalytic material comprising: a first coat carried on the carrier and comprising a first activated alumina support, a catalytically effective amount of a first platinum catalytic component dispersed on the first alumina support, and a catalytically effective amount of bulk ceria; and a second coat carried by the carrier and comprising a co-formed rare earth oxide-zirconia support, a catalytically effective amount of a first rhodium catalytic component dispersed on the co-formed zirconia support, a second activated alumina support, and a catalytically effective amount of a second platinum catalytic component dispersed on the second alumina support.
Claim 2
Dependent Claim
17 words
The catalyst composition of claim 1 wherein the second coat comprises a topcoat overlying the first coat.
Claim 3
Dependent Claim
32 words
The catalyst composition of claim 1 or claim 2 wherein the first coat further includes an effective amount of a metal oxide effective for the suppression of H₂S emissions from the catalyst.
Claim 4
Dependent Claim
34 words
The catalyst composition of claim 3 wherein the metal oxide effective for the suppression of H₂S is selected from the group consisting of one or more of oxides of nickel, copper, manganese and germanium.
Claim 5
Dependent Claim
29 words
The catalyst composition of claim 1 or claim 2 wherein the first coat further includes bulk iron oxide in a catalytically effective amount for promoting the oxidation of CO.
Claim 6
Dependent Claim
14 words
The catalyst composition of claim 5 wherein the bulk iron oxide comprises magnetite (Fe₃O₄).
Claim 7
Dependent Claim
32 words
The catalyst composition of claim 5 wherein the bulk iron oxide is present in an amount of from about 0.05 to 0.3 grams per cubic inch of catalyst composition, calculated as Fe₂O₃.
Claim 8
Dependent Claim
32 words
The catalyst composition of claim 1 or claim 2 wherein the second coat further includes a catalytically effective amount of a second rhodium catalytic component dispersed on the second activated alumina support.
Claim 9
Dependent Claim
37 words
The catalyst composition of claim 1 or claim 2 wherein the second coat further includes a third activated alumina support and a catalytically effective amount of a second rhodium catalytic component dispersed on the third alumina support.
Claim 10
Dependent Claim
19 words
The catalyst composition of claim 9 further including a third platinum catalytic component dispersed on the third alumina support.
Claim 11
Dependent Claim
37 words
The catalyst composition of claim 1 or claim 2 wherein the first coat further includes a thermal stabilizer dispersed therein in an amount sufficient to stabilize the first activated alumina and the bulk ceria against thermal degradation.
Claim 12
Dependent Claim
25 words
The catalyst composition of claim 11 wherein the thermal stabilizer is selected from the group consisting of one or more of ceria, baria and zirconia.
Claim 13
Dependent Claim
20 words
The catalyst composition of claim 11 wherein the thermal stabilizer is selected from the group consisting of baria and zirconia.
Claim 14
Dependent Claim
15 words
The catalyst composition of claim 11 wherein the thermal stabilizer comprises both baria and zirconia.
Claim 15
Dependent Claim
31 words
The catalyst composition of claim 13 wherein the baria and the zirconia are each present in an amount of from about 0.05 to 0.5 grams per cubic inch of catalyst composition.
Claim 16
Dependent Claim
38 words
The catalyst composition of claim 1 or claim 2 wherein the rare earth oxide of the co-formed rare earth oxide-zirconia support is selected from the group consisting of one or more of oxides of cerium, neodymium and yttrium.
Claim 17
Dependent Claim
24 words
The catalyst composition of claim 1 or claim 2 wherein the rare earth oxide of the co-formed rare earth oxide-zirconia support is cerium oxide.
Claim 18
Dependent Claim
47 words
The catalyst composition of claim 1 or claim 2 wherein the first rhodium catalytic component is present in an amount of from about 0.03 to 1.0 weight percent of the combined weight of rhodium plus stabilized zirconia support, the weight of rhodium being calculated as the metal.
Claim 19
Dependent Claim
29 words
The catalyst composition of claim 1 or claim 2 wherein the bulk ceria in the first coat comprises at least about 0.15 grams per cubic inch of catalyst composition.
Claim 20
Dependent Claim
35 words
The catalyst composition of claim 1 or claim 2 wherein the bulk ceria in the first coat is present in an amount of from about 0.15 to 1.5 grams per cubic inch of catalyst composition.
Claim 21
Dependent Claim
39 words
The catalyst composition of claim 3 wherein the metal oxide effective for the suppression of H₂S is present in an amount of from about 0.05 to 0.5 grams per cubic inch of catalyst composition, calculated as the metal oxide.
Claim 22
Dependent Claim
21 words
The catalyst composition of claim 21 wherein the metal oxide comprises bulk nickel oxide and its weight is calculated as NiO.
Claim 23
Dependent Claim
30 words
The catalyst composition of claim 1, claim 2 or claim 20 wherein the bulk ceria comprises at least 90 percent by weight CeO₂, the balance comprising other rare earth oxides.
Claim 24
Dependent Claim
34 words
The catalyst composition of claim 1 or claim 2 wherein the second coat further incudes a thermal stabilizer dispersed therein in an amount sufficient to stabilize the second activated alumina support against thermal degradation.
Claim 25
Dependent Claim
12 words
The catalyst composition of claim 24 wherein the thermal stabilizer comprises zirconia.
Claim 26
Dependent Claim
29 words
The catalyst composition of claim 25 wherein the zirconia for alumina stabilization is present in an amount of about 0.02 to 0.5 grams per cubic inch of catalyst composition.
Claim 27
Dependent Claim
51 words
The catalyst composition of claim 1 or claim 2 wherein the rare earth oxide of the co-formed rare earth oxide-zirconia support comprises ceria and is present in an amount of from about 2 to 30 percent by weight of the combined weight of ceria and zirconia in the co-formed zirconia support.
Claim 28
Dependent Claim
17 words
The catalyst composition of claim 1 or claim 2 wherein the first coat further comprises crushed cordierite.
Claim 29
Dependent Claim
35 words
The catalyst composition of claim 1 or claim 2 wherein the co-formed rare earth oxide-zirconia support is present in an amount of from about 0.05 to 1.0 grams per cubic inch of the catalyst composition.
Claim 30
Dependent Claim
46 words
The catalyst composition of claim 1 or claim 2 wherein the second platinum catalytic component is present in an amount of from about 0.05 to 5.0 weight percent of the combined weight of platinum, measured as the metal, and the activated alumina in the second coat.
Claim 31
Dependent Claim
35 words
The catalyst composition of claim 1 or claim 2 wherein the activated alumina is present in the first coat in an amount of from about 0.1 to 4.0 grams per cubic inch of catalyst composition.
Claim 32
Dependent Claim
36 words
The catalyst composition of claim 1 or claim 2 wherein the activated alumina is present in the second coat in an amount of from about 0.10 to 2.0 grams per cubic inch of the catalyst composition.
Claim 33
Dependent Claim
37 words
The catalyst composition of claim 1 or claim 2 wherein the first platinum catalytic component is present in the first coat in an amount of from about 5 to 100 grams per cubic foot of catalyst composition.
Claim 34
Dependent Claim
37 words
The catalyst composition of claim 1 or claim 2 wherein the second platinum catalytic component is present in the second coat in an amount of from about 1 to 50 grams per cubic foot of catalyst composition.
Claim 35
Dependent Claim
40 words
The catalyst composition of claim 1 or claim 2 wherein the total amount of rhodium catalytic component present in the catalyst composition is present in an amount of from about 0.1 to 15 grams per cubic foot of catalyst composition.
Claim 36
Dependent Claim
32 words
The catalyst composition of claim 1 or claim 2 further including up to 100 grams per cubic foot of palladium catalytic component dispersed on the activated alumina support in the first coat.
Claim 37
Dependent Claim
48 words
The catalyst composition of claim 1 or claim 2 wherein the carrier comprises a refractory body having a plurality of substantially parallel passages extending therethrough, the passages being defined by walls and the catalytic material being coated on the walls as said first coat and said second coat.
Claim 38
Dependent Claim
173 words
A catalyst composition comprising a carrier on which is disposed a catalytic material, the catalytic material comprising: a first coat carried on the carrier and comprising a first activated alumina support, a catalytically effective amount of a first platinum catalytic component dispersed on the first alumina support, a catalytically effective amount of bulk ceria and of bulk iron oxide, a catalytically effective amount of bulk nickel oxide, and baria and zirconia dispersed throughout the first coat in an amount sufficient to stabilize the alumina and the other bulk metal oxides against thermal degradation; and a second coat comprising a topcoat overlying the first coat and carried by the carrier, and comprising a co-formed rare earth oxide-zirconia support, a catalytically effective amount of a first rhodium catalytic component dispersed on the co-formed zirconia support, and a second activated alumina support having a catalytically effective amount of a second platinum catalytic component dispersed thereon, and zirconia dispersed throughout the second coat in an amount sufficient to stabilize the activated alumina support therein against thermal degradation.
Claim 39
Dependent Claim
19 words
The catalytic composition of claim 38 including a second rhodium catalytic component dispersed on the second activated alumina support.
Claim 40
Dependent Claim
32 words
The catalyst composition of claim 38 further including a third activated alumina support on which catalytically effective amounts of a second rhodium catalytic component and a third platinum catalytic component are dispersed.
Claim 41
Independent Claim
147 words
A method for treating a gas containing noxious components comprising one or more of carbon monoxide, hydrocarbons and nitrogen oxides, by converting at least some of the noxious components to innocuous substances, the method comprising contacting the gas under conversion conditions with a catalyst composition comprising a carrier on which is disposed a catalytic material, the catalytic material comprising (i) a first coat carried on the carrier and comprising a first activated alumina support, a catalytically effective amount of a first platinum catalytic component dispersed on the alumina support, and a catalytically effective amount of bulk ceria and (ii) a second coat carried by the carrier and comprising a co-formed rare earth oxide-zirconia support, a catalytically effective amount of a first rhodium catalytic component dispersed on the co-formed zirconia support, and a catalytically effective amount of a second platinum catalytic component dispersed on the second alumina support.
Claim 42
Dependent Claim
69 words
The method of claim 41 wherein the catalyst composition further includes in the first coat a catalytically effective amount of bulk iron oxide, a metal oxide present in an amount sufficient to suppress H₂S emissions, and at least one of baria, ceria and zirconia dispersed throughout the first coat in an amount sufficient to stabilize the activated alumina and other bulk oxides in the first coat against thermal degradation.
Claim 43
Dependent Claim
16 words
The method of claim 42 wherein the metal oxide to suppress H₂S emissions is nickel oxide.
Claim 44
Dependent Claim
32 words
The method of claim 41 wherein the second coat of the catalyst composition further includes a catalytically effective amount of a second rhodium catalytic component dispersed on the second activated alumina support.
Claim 45
Dependent Claim
36 words
The method of claim 41 wherein the second coat of the catalyst composition further includes a third activated alumina support and a catalytically effective amount of a second rhodium component dispersed on the third alumina support.
Claim 46
Dependent Claim
25 words
The method of claim 45 wherein the second coat of the catalyst composition further includes a third platinum component dispersed on the third alumina support.
Claim 47
Independent Claim
54 words
The method of any one of claims 41 or 42 wherein the catalyst composition comprises a refractory body having a plurality of substantially parallel passages extending therethrough, the passages being defined by walls and the catalytic material being coated on the walls with the second coat comprising a top coat overlying the first coat.
Claim 48
Independent Claim
190 words
A method for treating a gas containing noxious components comprising one or more of carbon monoxide, hydrocarbons and nitrogen oxides, by converting at least some of the noxious components to innocuous substances, the method comprising contacting the gas under conversion conditions with a catalyst composition comprising a carrier on which is disposed a catalytic material, the catalytic material comprising (1) a first coat carried on the carrier and comprising a first activated alumina support, a catalytically effective amount of a first platinum catalytic component dispersed on the alumina support, a catalytically effective amount of bulk ceria and of bulk iron oxide, a catalytically effective amount of bulk nickel oxide, and baria and zirconia dispersed throughout the first coat in an amount sufficient to stabilize the alumina and iron oxide against thermal degradation; and (ii) a second coat comprising a topcoat overlying the first coat and carried by the carrier, and comprising a co-formed rare earth oxide-zirconia support, a catalytically effective amount of a first rhodium catalytic component dispersed on the co-formed zirconia support, and a catalytically effective amount of a second platinum catalytic component dispersed on the second alumina support.
Claim 49
Dependent Claim
43 words
The method of claim 48 wherein the second coat of the catalyst composition further includes a catalyticaly effective amount of a second rhodium catalytic component dispersed on at least one of the second activated alumina support and an optional third activated alumina support.
Claim 50
Dependent Claim
40 words
The method of claim 48 or claim 49 wherein the first coat and second coat each include a thermal stabilizer in an amount effective to stabilize the activated alumina and other bulk metal oxides respectively present therein against thermal degradation.
Claim 51
Dependent Claim
38 words
The method of claim 50 wherein the thermal stabilizer in the first coat is selected from the group consisting of one or more of ceria, baria and zirconia and the thermal stabilizer in the second coat comprises zirconia.
Claim 52
Dependent Claim
37 words
The method of claim 50 wherein the thermal stabilizer in the first coat is selected from the group consisting of one or both of baria and zirconia, and the thermal stabilizer in the second coat comprises zirconia.
References Cited (Backward Citations)
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