Johnson Matthey Patente

The present invention provides a method of manufacturing a catalyst article, the method comprising: providing a substrate;providing a washcoat slurry, the washcoat slurry comprising a solvent, a support material, platinum group metal (PGM) ions, e.g. palladium, barium ions and a chelating agent of formula (1);coating the substrate with the washcoat slurry to provide a coated substrate; andheating the coated substrate to calcine the washcoat slurry;wherein formula (1) is defined by:wherein R is CH₂OH, COOH orwherein R' is CH₂OH or COOH.

The present invention provides a catalyst article for the treatment of exhaust gas, the catalyst article comprising:a wall-flow filter substrate having porous walls and having a first face and a second face defining a longitudinal direction therebetween from an inlet end to an outlet end of the catalyst article and first and second pluralities of channels extending in the longitudinal direction, wherein the first plurality of channels is open at the first face and closed at the second face, and wherein the second plurality of channels is open at the second face and closed at the first face, wherein the first plurality of channels provide a first plurality of inner surfaces and wherein the second plurality of channels provide a second plurality of inner surfaces;a first coating disposed on the first plurality of inner surfaces and/or within the porous walls, and extending from the first face; anda second coating disposed on the second plurality of inner surfaces and/or within the porous walls, and extending from the second face;wherein the first coating comprises an Fe-loaded molecular sieve having an FER Framework Type and the second coating comprises a Cu-loaded molecular sieve having a CHA Framework Type and/or a Cu-loaded molecular sieve having an AEI Framework Type. The catalyst article is able to provide a good balance of high NO₂ conversion, high overall NO_x conversion and low NH₃ slip, while having good N₂O selectivity, at both low and high temperatures.

The present invention provides a selective catalytic reduction (SCR) catalyst, for treating a gas mixture comprising NOx, the SCR catalyst comprising 50 to 90 wt% of a metal loaded zeolite and > 5 to 35 wt% of a binder in the form of titanium dioxide or silica-stabilised titanium dioxide.

The present invention provides an all-active, extruded selective catalytic reduction (SCR) catalyst, comprising a metal-loaded zeolite and a binder in the form of silica-alumina, wherein the silica content of the silica-alumina is in the range of about 1% to 20% by weight. The invention further provides a method of preparing such an SCR catalyst comprising (a) forming a plastic mixture having a solids content of greater than 50 % by weight by mixing together a metal-loaded zeolite or a zeolite in an H+ or NH4+ form and an active metal precursor; an inorganic matrix component comprising silica-containing boehmite, wherein the silica content of the silica-boehmite is in the range about 1% to 20% by weight; an organic auxiliary agent, an aqueous solvent and optionally inorganic fibres; (b) moulding the plastic mixture into a shaped article; and (c) calcining the shaped article to form a solid catalyst body.

This invention relates to a method for making a selective catalytic reduction catalyst, a catalyst article made according to the method and the use of the catalyst article in the selective catalytic reduction of NO<x>. The invention specifically relates to a method for producing a catalyst for the selective catalytic reduction of NO<x> in a gas mixture, the method comprising the steps of preparing a slurry comprising vanadium (V), antimony (Sb) and a reactive media, such as a hydrogen peroxide solution, to form a colloidal sol of VSbO<4>; combining the colloidal sol of VSbO<4> with a catalyst support material, such as titania, to form a mixture; and optionally drying and calcining the resulting mixture.

A catalytic article for treating exhaust gas from gasoline engines comprising: a substrate comprising an inlet end and an outlet end with an axial length L, a first catalytic region comprising a first platinum group metal (PGM) component and a first metal component, wherein the first PGM component is platinum or palladium; wherein the first metal component is Fe; wherein when the first PGM component is platinum, the molar ratio between the first metal component and the first PGM component in the first catalytic region is from 35:1 to 8:1; wherein when the first PGM component is palladium, the molar ratio between the first metal component and the first PGM component in the first catalytic region is from 10:1 to 1:5; and wherein the first catalytic region further comprises a first oxygen storage capacity (OSC) material and a first inorganic oxide. The invention also relates to a catalytic article comprising a first catalytic region comprising Fe and Pd, wherein the molar ratio of Fe to Pd is 120:1 to 1:5. The invention also relates to a catalytic article comprising a first catalytic region comprising no more than 2wt.% of Zn based on element.

A method of quantifying a content of an insoluble metal compound in an aqueous suspension comprising an insoluble metal compound and a metal ion-exchanged molecular sieve is disclosed, The method comprises: treating the aqueous suspension of the insoluble metal compound and the metal ion-exchanged molecular sieve with a selective solubilising agent for the insoluble metal compound, thus producing a treated mixture comprising a metal solution comprising a dissolved metal from the insoluble metal compound and undissolved metal ion-exchanged molecular sieve; and quantifying a dissolved metal content of the treated mixture using a suitable analytical technique.

Provided is a catalytic gasoline particulate filter (GPF) for the treatment of exhaust gas from a gasoline engine, the catalytic GPF comprising:a wall-flow filter substrate; anda first coating disposed on the wall-flow filter substrate, wherein the first coating comprises:an inorganic oxide support;an oxygen storage capacity (OSC) material;a platinum group metal (PGM) component; andan Fe component;wherein the first coating comprises from 0.05 to 1.5 wt.% of the Fe component, calculated based on the total weight of Fe in the Fe component relative to the total weight of the inorganic oxide support and OSC material. The first coating is able to provide an excellent balance of improved oxygen storage capacity and catalytic activity, even after ageing, without significantly increasing the backpressure caused by the catalytic GPF in use.

Exhaust systems (2) and methods for hydrogen internal combustion engines (ICE) (1). A valve (11) is used to direct exhaust gas through either a primary (8) or secondary channel (9) of the exhaust system (2) dependent on whether a switching condition is met. The primary channel (8) provides fluid communication for the exhaust gas to flow from an inlet (5), through a substrate (6) comprising a catalyst, and then to an outlet (7). The secondary channel (9) provides fluid communication for the exhaust gas to flow from the inlet (5) to the outlet (7) without passing through the substrate (6) comprising the catalyst.

An apparatus for determining an exotherm characteristic of a substrate comprising an oxidation catalyst having a substrate inlet face and a substrate outlet face comprises: a non-engine-based heat source (7) configured to generate and output a heated gas flow through a gas outlet; a flow conduit (11) coupled with the gas outlet to receive the heated gas flow, the flow conduit (11) comprising an oxidation catalyst station (15) configured to hold a substrate (2) comprising an oxidation catalyst; a fuel injector (13) configured to inject fuel into the heated gas flow in the flow conduit (11) upstream of the oxidation catalyst station (15); and one or more temperature sensors, the one or more temperature sensors including one or more inlet face temperature sensors (18) configured to measure the temperature of the heated gas flow at an inlet face of a substrate comprising an oxidation catalyst (2) installed in the oxidation catalyst station (15) and one or more outlet face temperature sensors (20) configured to measure the temperature of the heated gas flow at an outlet face of said substrate comprising an oxidation catalyst (2) installed in the oxidation catalyst station (15).

Exhaust systems (2) and methods for hydrogen internal combustion engines (ICE) (1). A valve arrangement (11) is used to direct exhaust gas through either a primary (8) or secondary channel (9) of the exhaust system (2) based on one or more switching variables. The secondary channel (9) comprises a water separator (10) configured to reduce a water content of the exhaust gas prior to the exhaust gas reaching and contacting a downstream substrate (6) comprising a catalyst. The switching variables relate to a water content and/or temperature of the exhaust gas, a time period elapsed from a start-up event, and/or a temperature of one or more components of the hydrogen ICE (1); and/or a temperature of one or more substrate.

An oxidation catalyst article (20) for treating an exhaust gas produced by a compression ignition engine comprises a flow-through honeycomb substrate (5) having an inlet end and an outlet end and a longitudinal length (10) extending therebetween and comprising an array of channels each defined by a channel wall; a first washcoat (35) extending a first length from the inlet end which is up to 40% of the longitudinal length of the substrate and comprising a first platinum group metal composition on a first alumina support, the first washcoat (35) having a total combined loading of Pt and Pd of X g/ft<3>; a second washcoat (25) extending a second length from the inlet end which is up to 85% of the longitudinal length of the substrate and entirely overlying the first washcoat (35), the second washcoat (25) comprising a second platinum group metal composition on a second alumina support, the second washcoat (25) having a total combined loading of Pt and Pd of Y g/ft<3>; a third washcoat (30) extending a third length from the outlet end and comprising a third platinum group metal composition on a third alumina support, the third washcoat having a total combined loading of Pt and Pd of Z g/ft<3>, wherein the third platinum group metal composition is platinum only or both platinum and palladium; and a fourth washcoat (40) extending a fourth length from the outlet end which is 40% or less of the longitudinal length of the substrate, overlying the third washcoat (30) and comprising a capture material, wherein the capture material comprises a Pt-alloying metal supported on a refractory oxide; wherein 2Z<X>1.5Y; wherein a sum of the first length and the third length is less than 120% of the longitudinal length (10); and wherein a sum of the second length and the fourth length is from 100% to 120% of the longitudinal length (10).

Provided is a method for the manufacture of a catalytic gasoline particulate filter (GPF) for the treatment of exhaust gas from a gasoline engine, the method comprising:(i) providing a wall-flow filter substrate having porous walls and having a first face and a second face defining a longitudinal direction therebetween and first and second pluralities of channels extending in the longitudinal direction, wherein the first plurality of channels is open at the first face and closed at the second face, and wherein the second plurality of channels is open at the second face and closed at the first face, wherein the first plurality of channels provide a first plurality of inner surfaces and wherein the second plurality of channels provide a second plurality of inner surfaces;(ii) providing a first washcoat slurry comprising: (a) a polyacrylate, (b) a first platinum group metal selected from the group consisting of Pt, Pd, Rh and mixtures thereof, (c) a first oxygen storage capacity (OSC) material, and (d) a first inorganic oxide support;(iii) providing a second washcoat slurry comprising: (a) an organic pore former, (b) optionally a second platinum group metal selected from the group consisting of Pt, Pd, Rh and mixtures thereof, (c) optionally a second oxygen storage capacity (OSC) material, and (d) optionally a second inorganic oxide support;(iv) coating the wall-flow filter substrate with the first washcoat slurry from the second face to form a first coating disposed within the porous walls and extending from the second face for at least 50% of a length of the second plurality of channels;(v) coating the wall-flow filter substrate with the second washcoat slurry from the first face to form a second coating disposed on the first plurality of inner surfaces and extending from the first face for at least 70% of a length of the first plurality of channels; and(vi) calcining the first coating and the second coating to form the catalytic GPF.

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The specification describes a method of retrofitting a chemical plant which initially comprises a hydrotreating section and a steam reforming section, the method involving introducing a tail-gas treatment which is arranged to accept tail-gas from the steam reforming section and generate a crude H2 stream which is used at least in part to provide fuel for the fired reformer within the steam reforming section. The specification also describes an integrated hydrogen and hydrotreatment plant which incorporates a tail-gas treatment unit, and a process for producing hydrogen and carrying our hydrotreatment using the plant.

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According to various aspects of this disclosure, there is provided a method of backpressure testing manufactured parts, the method comprising: obtaining one or more reference parts and determining a reference backpressure measurement for each reference part indicative of the backpressure of that reference part when or if tested on a reference testing unit; calibrating one or more testing positions of a backpressure testing unit using the one or more reference parts; setting an upper backpressure limit and a lower backpressure limit for each of the one or more testing positions; and thereafter using the one or more testing positions to assess the backpressure of one or more manufactured parts.

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