Monolith washcoat having optimum pore structure and optimum method of designing the washcoat

Claim 2

An optimum washcoated monolith catalyst for treating automotive exhaust gases where the monolith is either ceramic or metal comprising a washcoat having a thickness in the range of 30-80 microns, a total pore volume in the range of 0.60-1.80 cm 3 /g washcoat, a micropore volume in the range of 0.35-0.60 cm 3 /g washcoat, a micropore radius below 60 Angstrom units, and a surface area between 125-250 m 2 /g washcoat.

Claim 3

A washcoated monolith catalyst according to claim 1 wherein the micropore radius is above 30 Angstrom units.

Claim 4

A washcoated monolith catalyst according to claim 1, having optimum thickness between lines A and B in FIG. 2 depending on the desired service length of the converter where lines A and B are based on the following data points ______________________________________ Service Length Optimal Washcoat Thickness (accumulated miles) (microns) ______________________________________ 50,000 40-50 100,000 70-80 ______________________________________

Claim 5

Process for making a washcoated ceramic or metal monolith for treating automotive exhaust gases comprising the steps: (a) specifying (i) the reactant of CO, HC and NO x and poisons so that the effective diffusion coefficient and mass transfer coefficients can be determined, (ii) the process conditions including the volumetric flow rate, the temperature, and concentration of poisons, and (iii) desired time on stream in terms of desired catalyst life in hours; (b) determining from the parameters in step (a) the optimum pore size distribution and thickness of the washcoat to maximize alpha in the equation ##EQU8## where y is obtained from the following equations ##EQU9## where C p ,g is the gas phase poison concentration, x is the axial distance down the monolith, t is the time of operation of the catalyst, k m ,p is the mass transfer coefficient for the poison, D e ,p is the effective diffusion coefficient of the poison into the washcoat layer, y is the thickness of the poisoned layer within the washcoat, b is the size of the cross-section of the square honeycomb, w is the washcoat thickness, C p ,inf. is the saturation concentration of the poison on the support, Q is the volumetric flow rate of the inlet gas at reaction conditions, R is the radius of the monolith catalyst, and a is the thickness of the walls separating the channels; (c) preparing a washcoat catalyst with an alumina washcoat having the desired pore size distribution; and (d) applying the prepared alumina washcoat catalyst to the ceramic or metal monolith to produce a finished automotive exhaust gas catalyst where the washcoat on the catalyst has a thickness in the range of 30-80 microns, a total pore volume in the range of 0.60-1.80 cm 3 /g washcoat, a micropore volume in the range of 0.35-0.60 cm 3 /g washcoat, a micropore radius below 60 Angstrom units, and a surface area between 125-250 m 2 /g washcoat.

Claim 6

Process for making a washcoated ceramic or metal monolith for treating automotive exhaust gases comprising the steps: (a) specifying (i) the reactant of CO, HC and NO x and poisons so that the effective diffusion coefficient and mass transfer coefficients can be determined, (ii) the process conditions including the volumetric flow rate, the temperature, and concentration of poisons, and (iii) desired time on stream in terms of desired catalyst life in hours; (b) determining from the parameters in step (a) the optimum pore size distribution and thickness of the washcoat to maximize alpha in the equation ##EQU8## where y is obtained from the following equations ##EQU9## where C p ,g is the gas phase poison concentration, x is the axial distance down the monolith, t is the time of operation of the catalyst, k m ,p is the mass transfer coefficient for the poison, D e ,p is the effective diffusion coefficient of the poison into the washcoat layer, y is the thickness of the poisoned layer within the washcoat, b is the size of the cross-section of the square honeycomb, w is the washcoat thickness, C p ,inf. is the saturation concentration of the poison on the support, Q is the volumetric flow rate of the inlet gas at reaction conditions, R is the radius of the monolith catalyst, and a is the thickness of the walls separating the channels; (c) preparing a washcoat catalyst with an alumina washcoat having the desired pore size distribution; and (d) applying the prepared alumina washcoat catalyst to the ceramic or metal monolith to produce a finished automotive exhaust gas catalyst where the washcoat on the catalyst has a thickness in the range of 30-80 microns, a total pore volume in the range of 0.60-1.80 cm 3 /g washcoat, a micropore volume in the range of 0.35-0.60 cm 3 /g washcoat, a micropore radius below 60 Angstrom units, and a surface area between 125-250 m 2 /g washcoat.