Catalyst compositions, catalytic articles, systems and processes using large particle molecular sieves

1. A catalyst composition comprising a washcoat including a platinum group metal supported on a refractory metal oxide support and further comprising molecular sieve particles, wherein greater than 90% of the molecular sieve particles have a particle size greater than 1 μm and a d 50 less than 50 microns, wherein the molecular sieve does not have a surface coating.

2. The catalyst composition of claim 1 , wherein a portion of the platinum group metal is supported on the molecular sieve particles.

3. The catalyst composition of claim 1 , wherein greater than 95% of the molecular sieve particles have a particle size greater than 1 μm.

4. The catalyst composition of claim 1 , wherein greater than 96% of the molecular sieve particles have a particle size greater than 1 μm.

5. The catalyst composition of claim 1 , wherein the molecular sieve particles are spray-dried particles mixed with binder.

6. The catalyst composition of claim 1 , wherein the platinum group metal comprises platinum and palladium.

7. The catalyst composition of claim 1 , wherein greater than 90% of the molecular sieve particles comprise primary crystals with sizes greater than 1 μm.

8. The catalyst composition of claim 1 , wherein the molecular sieve particles are agglomerates of primary crystals that maintain physical integrity and remain agglomerated during normal oxidation catalyst slurry preparation.

9. The catalyst composition of claim 8 , further comprising a binder holding the crystals together.

10. The catalyst composition of claim 1 wherein the molecular sieve particle component comprises about 96% particles greater than 1 μm and about 95% of particles greater than 2 μm.

11. The catalyst composition of claim 1 wherein the molecular sieve particle component comprises 96% particles in the range of about 1 μm to 10 μm.

12. The catalyst composition of claim 1 , wherein the molecular sieve particles are zeolites selected from the group consisting of faujasite, chabazite, clinoptilolite, mordenite, silicalite, zeolite X, zeolite Y, ultrastable zeolite Y, ZSM-5, ZSM-12, SSZ-13, SAPO-5, SAPO-37, offretite, Beta zeolite and combinations thereof.

13. The catalyst composition according to claim 12 , wherein the zeolite is H-Beta.

14. The catalyst composition of claim 1 , wherein the zeolite has a particle size distribution that is monomodal.

15. A catalytic article for the treatment of exhaust gas from a lean burn internal combustion engine containing hydrocarbons, carbon monoxide and nitrogen oxides comprising a carrier substrate having a length, an inlet end and an outlet end, an oxidation catalyst material on the carrier, the oxidation catalyst material including the catalyst composition of claim 1 .

16. The catalytic article of claim 15 , wherein the catalytic article utilizes a single washcoat layer.

17. A method of treating exhaust gas from a lean burn engine containing hydrocarbons, carbon monoxide and nitrogen oxides comprising flowing the exhaust gas over a catalytic article in accordance with claim 15 .

18. A catalyst composition comprising a washcoat including a platinum group metal supported on a refractory metal oxide support and further comprising molecular sieve particles, wherein greater than 90% of the molecular sieve particles have a particle size greater than 1 μm and a d 50 less than 50 microns, and further comprising a binder selected from the group consisting of silica, ceria, phosphate, combinations of silica, ceria and phosphate, and an organic binder.

19. The catalyst composition of claim 18 , wherein greater than 95% of the molecular sieve particles have a particle size greater than 1 μm.

20. The catalyst composition of claim 18 , wherein greater than 96% of the molecular sieve particles have a particle size greater than 1 μm.

21. The catalyst composition of claim 18 , wherein the platinum group metal comprises platinum and palladium.

22. The catalyst composition of claim 18 , wherein the molecular sieve particles are agglomerates of primary crystals that maintain physical integrity and remain agglomerated during normal oxidation catalyst slurry preparation.

23. The catalyst composition of claim 18 wherein the molecular sieve particle component comprises about 96% particles greater than 1 μm and about 95% of particles greater than 2 μm.

24. The catalyst composition of claim 18 wherein the molecular sieve particle component comprises 96% particles in the range of about 1 μm to 10 μm.

25. The catalyst composition of claim 18 , wherein the molecular sieve particles are zeolites selected from the group consisting of faujasite, chabazite, clinoptilolite, mordenite, silicalite, zeolite X, zeolite Y, ultrastable zeolite Y, ZSM-5, ZSM-12, SSZ-13, SAPO-5, SAPO-37, offretite, Beta zeolite and combinations thereof.

26. The catalyst composition according to claim 25 , wherein the zeolite is H-Beta.

27. The catalyst composition of claim 18 , wherein the zeolite has a particle size distribution that is monomodal.

28. A catalytic article for the treatment of exhaust gas from a lean burn internal combustion engine containing hydrocarbons, carbon monoxide and nitrogen oxides comprising a carrier substrate having a length, an inlet end and an outlet end, an oxidation catalyst material on the carrier, the oxidation catalyst material including the catalyst composition of claim 18 , wherein the article is a DOC.

29. A catalytic article for the treatment of exhaust gas from a lean burn internal combustion engine containing hydrocarbons, carbon monoxide and nitrogen oxides comprising a carrier substrate having a length, an inlet end and an outlet end, an oxidation catalyst material on the carrier, the oxidation catalyst material including the catalyst composition of claim 18 , wherein the article is a CSF.

30. A catalyst composition comprising a washcoat including a platinum group metal supported on a refractory metal oxide support and further comprising molecular sieve particles, wherein greater than 90% of the molecular sieve particles have a particle size greater than 1 μm and a d 50 less than 50 microns, and further comprising an alkaline earth metal component.

31. The catalyst composition of claim 30 , wherein greater than 95% of the molecular sieve particles have a particle size greater than 1 μm.

32. The catalyst composition of claim 30 , wherein greater than 96% of the molecular sieve particles have a particle size greater than 1 μm.

33. The catalyst composition of claim 30 , wherein the platinum group metal comprises platinum and palladium.

34. The catalyst composition of claim 30 , wherein the molecular sieve particles are agglomerates of primary crystals that maintain physical integrity and remain agglomerated during normal oxidation catalyst slurry preparation.

35. The catalyst composition of claim 30 wherein the molecular sieve particle component comprises about 96% particles greater than 1 μm and about 95% of particles greater than 2 μm.

36. The catalyst composition of claim 30 wherein the molecular sieve particle component comprises 96% particles in the range of about 1 μm to 10 μm.

37. The catalyst composition of claim 30 , wherein the zeolite has a particle size distribution that is monomodal.

38. A catalytic article for the treatment of exhaust gas from a lean burn internal combustion engine containing hydrocarbons, carbon monoxide and nitrogen oxides comprising a carrier substrate having a length, an inlet end and an outlet end, an oxidation catalyst material on the carrier, the oxidation catalyst material including the washcoat catalyst composition of claim 30 , wherein the article is an LNT.

39. A catalyst composition comprising a platinum group metal supported on a refractory metal oxide support and further comprising non-agglomerated molecular sieve particles having a d 50 less than 50 microns, wherein greater than 90% of the molecular sieve particles have a particle size greater than 1 μm.

40. The catalyst composition of claim 39 , wherein greater than 95% of the molecular sieve particles have a particle size greater than 1 μm.

41. The catalyst composition of claim 39 , wherein greater than 96% of the molecular sieve particles have a particle size greater than 1 μm.

42. The catalyst composition of claim 39 , wherein the molecular sieve particles are zeolites selected from the group consisting of faujasite, chabazite, clinoptilolite, mordenite, silicalite, zeolite X, zeolite Y, ultrastable zeolite Y, ZSM-5, ZSM-12, SSZ-13, SAPO-5, SAPO-37, offretite, Beta zeolite and combinations thereof.

43. A catalyst composition comprising a platinum group metal supported on a refractory metal oxide support and further comprising agglomerated particles comprising molecular sieve particles and a binder, the agglomerated particles having a d 50 less than 50 microns and wherein greater than 90% of the molecular sieve particles comprise primary crystals with sizes greater than 1 μm.

44. The catalyst composition of claim 43 , wherein greater than 95% of the molecular sieve particles have a particle size greater than 1 μm.

45. The catalyst composition of claim 43 , wherein greater than 96% of the molecular sieve particles have a particle size greater than 1 μm.