US 12,343,714 B2
Composite, zoned oxidation catalyst for a compression ignition internal combustion engine
Andrew Francis Chiffey, Royston (GB); Kieran Cole, Royston (GB); Oliver Cooper, Royston (GB); Christopher Daly, Royston (GB); Lee Alexander Gilbert, Royston (GB); Robert Hanley, Royston (GB); David Micallef, Royston (GB); Francois Moreau, Royston (GB); Paul Phillips, Royston (GB); and George Platt, Royston (GB)
Assigned to Johnson Matthey Public Limited Company, London (GB)
Appl. No. 17/754,813
Filed by Johnson Matthey Public Limited Company, London (GB)
PCT Filed Oct. 13, 2020, PCT No. PCT/GB2020/052547
§ 371(c)(1), (2) Date Apr. 13, 2022,
PCT Pub. No. WO2021/074605, PCT Pub. Date Apr. 22, 2021.
Claims priority of application No. 19203640 (EP), filed on Oct. 16, 2019; application No. 2004769 (GB), filed on Mar. 31, 2020; and application No. 2009825 (GB), filed on Jun. 26, 2020.
Prior Publication US 2023/0278018 A1, Sep. 7, 2023
Int. Cl. B01D 46/84 (2022.01); B01D 53/94 (2006.01); B01J 21/12 (2006.01); B01J 23/10 (2006.01); B01J 23/34 (2006.01); B01J 23/44 (2006.01); B01J 23/58 (2006.01); B01J 29/76 (2006.01); B01J 35/00 (2006.01); B01J 35/30 (2024.01); B01J 35/39 (2024.01); B01J 35/56 (2024.01); B01J 35/64 (2024.01); F01N 3/02 (2006.01); F01N 3/021 (2006.01); F01N 3/10 (2006.01); F01N 3/28 (2006.01)
CPC B01J 35/19 (2024.01) [B01D 46/84 (2022.01); B01D 53/944 (2013.01); B01D 53/9472 (2013.01); B01J 21/12 (2013.01); B01J 23/10 (2013.01); B01J 23/34 (2013.01); B01J 23/44 (2013.01); B01J 23/58 (2013.01); B01J 29/76 (2013.01); B01J 35/394 (2024.01); B01J 35/56 (2024.01); B01J 35/647 (2024.01); F01N 3/021 (2013.01); F01N 3/103 (2013.01); F01N 3/2828 (2013.01); B01D 2255/1021 (2013.01); B01D 2255/1023 (2013.01); B01D 2255/2042 (2013.01); B01D 2255/2073 (2013.01); B01D 2255/9032 (2013.01); B01D 2255/9155 (2013.01); B01D 2255/9202 (2013.01); B01D 2255/9207 (2013.01); B01D 2258/012 (2013.01); F01N 2330/48 (2013.01); F01N 2370/04 (2013.01); F01N 2510/063 (2013.01)] 16 Claims
OG exemplary drawing
 
1. A compression ignition internal combustion engine (30) for a heavy-duty diesel vehicle comprising an exhaust system (32), which exhaust system comprising a composite oxidation catalyst (12, 42) and a soot filter substrate (44, 50) disposed downstream from the composite oxidation catalyst, which composite oxidation catalyst (12, 42) comprising:
a substrate (5) having a total length (L) and a longitudinal axis and having a substrate surface extending axially between a first substrate end (I) and a second substrate end (O);
two catalyst washcoat zones (1, 2) arranged axially in series on and along the substrate surface, wherein a first catalyst washcoat zone (1) having a length (L1) and comprising a first catalyst washcoat layer (9), wherein (L1) is <50% (L), is defined at one end by the first substrate end (I) and at a second end by a first end (15) of a second catalyst washcoat zone (2) having a length (L2) and comprising a second catalyst washcoat layer (11), wherein (L2)<(L), wherein the second catalyst washcoat zone (2) is defined at a second end thereof by the second substrate end (O), and wherein the first substrate end (I) of the composite oxidation catalyst (12, 42) is oriented to an upstream side and wherein the first catalyst washcoat zone (1) comprises a first refractory metal oxide support material and two or more platinum group metal components supported thereon comprising both platinum and palladium at a weight ratio of platinum to palladium of <1; and the second catalyst washcoat zone (2) comprises a second refractory metal oxide support material and one or more platinum group metal components supported thereon; and
a washcoat overlayer (G) extending axially from the first substrate end (I) for protecting at least part of the underlying first catalyst washcoat zone (1) from phosphorus and/or zinc poisoning when in use, thereby to retain activity of the first catalyst washcoat zone (1) to generate an exotherm from an increased concentration of hydrocarbon fuel present in exhaust gas relative to normal operating conditions for heating the downstream filter, which washcoat overlayer (G) comprising a particulate metal oxide having a loading of >48.8 g/l (>0.8g/in3), wherein the washcoat overlayer extends axially for greater than 100% and up to 150% of the axial length of the underlying first catalyst washcoat layer from the first substrate end (I)
wherein a total platinum group metal loading in the first catalyst washcoat zone (1) defined in grams of platinum group metal per litre of substrate volume (g/l) is greater than a total platinum group metal loading in the second catalyst washcoat zone (2) and wherein the first catalyst washcoat zone (1) comprises one or more first alkaline earth metal components supported on the first refractory metal oxide support material.