CATALYTIC ARTICLE AND EXHAUST GAS TREATMENT SYSTEMS

Abstract

The present invention relates to a catalytic article comprising a substrate having a catalyst composition disposed thereon, wherein the catalyst composition comprises a platinum group metal impregnated onto a porous support and a selective catalytic reduction catalyst, wherein the catalyst composition is substantially free of platinum; and wherein the catalytic article is effective in the abatement of nitrogen oxides (NOx) and hydrocarbons (HCs). The present invention further relates to exhaust gas treatment systems for treating an exhaust gas stream exiting a diesel engine.

Claims

1. 1.A catalytic article comprising: a substrate having a catalyst composition disposed thereon, wherein the catalyst composition comprises a platinum group metal impregnated onto a porous support and a selective catalytic reduction catalyst; wherein the catalyst composition is substantially free of platinum; and wherein the catalytic article is effective in the abatement of nitrogen oxides (NO.sub.x) and hydrocarbons (HCs).

2. The catalytic article of claim 1, wherein the selective catalytic reduction catalyst comprises a mixed metal oxide component, wherein the mixed metal oxide component is selected from FeTiO.sub.3, FeAl.sub.2O.sub.3, MgTiO.sub.3, MgAlO.sub.3, MnO.sub.x/TiO.sub.2, CuTiO.sub.3, CeZrO.sub.2, TiZrO.sub.2, V.sub.2O.sub.5/TiO.sub.2, and mixtures thereof.

3. The catalytic article of claim 1, wherein the platinum group metal impregnated onto a porous support is palladium impregnated onto zirconia and the selective catalytic reduction catalyst comprises one or more of a mixed metal oxide and a zeolite comprising one or more of Cu and Fe.

4. The catalytic article of claim 3, wherein the selective catalytic reduction catalyst comprises a zeolite comprising Cu, preferably a zeolite having a framework structure type CHA.

5. The catalytic article of claim 1, wherein the catalyst composition comprises a first layer and a second layer, wherein the first layer comprises the selective catalytic reduction catalyst and the second layer comprises platinum group metal impregnated onto the porous support; wherein the first layer is preferably disposed directly on the substrate and the second layer is disposed on top of the first layer; or wherein the second layer is preferably disposed directly on the substrate and the first layer is disposed on top of the second layer; or wherein the first layer and the second layer are preferably disposed directly on the substrate in a zoned configuration.

6. The catalytic article of claim 1, wherein the substrate has an inlet end, an outlet end and a substrate length extending from the inlet end to the outlet end of the substrate and comprises a plurality of passages defined by the internal walls of the substrate and wherein the catalyst composition comprises a first layer and a second layer, wherein the first layer comprises platinum group metal impregnated onto the porous support and the second layer comprises the selective catalytic reduction catalyst.

7. The catalytic article of claim 6, wherein the first layer comprises palladium impregnated onto one or more of zirconia and alumina.

8. The catalytic article of claim 6, wherein the selective catalytic reduction catalyst comprises a zeolite comprising Cu, preferably a zeolite having the structure type CHA.

9. The catalytic article of claim 1 wherein the catalyst composition comprises, preferably consists of, a single layer.

10. An emission treatment system for treatment of an exhaust gas stream, the emission treatment system comprising: an engine producing an exhaust gas stream; the catalytic article according to claim 1 positioned downstream from the engine in fluid communication with the exhaust gas stream and adapted for the reduction of NOx and HCs within the exhaust stream to form a treated exhaust gas stream; and an injector adapted for the addition of a reductant to the exhaust gas stream upstream of the catalytic article.

11. An exhaust gas treatment system for treating an exhaust gas stream leaving a diesel engine, said exhaust gas treatment system having an upstream end for introducing said exhaust gas stream into said exhaust gas treatment system, wherein said exhaust gas treatment system comprises the catalytic article according to claim 6, the catalytic article having an inlet end and an outlet end; wherein the catalytic article is the first catalytic article of the exhaust gas treatment system downstream of the upstream end of the exhaust gas treatment system and wherein the inlet end of the catalytic article is arranged upstream of the outlet end of the catalytic article.

12. An exhaust gas treatment system for treating an exhaust gas stream exiting a diesel engine, said exhaust gas treatment system having an upstream end for introducing said exhaust gas stream into said exhaust gas treatment system, wherein said exhaust gas treatment system comprises (i) a first catalyst having an inlet end and an outlet end and comprising a coating disposed on a substrate, wherein the coating comprises palladium supported on an oxidic material comprising zirconium and further comprises one or more of a vanadium oxide and a zeolitic material comprising one or more of copper and iron; or a first catalyst having an inlet end and an outlet end and being the catalytic article according to claim 1; (ii) a second catalyst having an inlet end and an outlet end and comprising a coating disposed on a substrate, wherein the coating comprises a platinum group metal supported on an oxidic material and further comprises one or more of a vanadium oxide, a tungsten oxide and a zeolitic material comprising one or more of copper and iron; wherein the first catalyst according to (i) is the first catalyst of the exhaust gas treatment system downstream of the upstream end of the exhaust gas treatment system and wherein the inlet end of the first catalyst is arranged upstream of the outlet end of the first catalyst; wherein in the exhaust gas treatment system, the second catalyst according to (ii) is located downstream of the first catalyst according to (i) and wherein the inlet end of the second catalyst is arranged upstream of the outlet end of the second catalyst.

13. The exhaust gas treatment system of claim 12, wherein the coating of the first catalyst comprises palladium supported on an oxidic material comprising zirconium, wherein from 99 to 100 weight-% of the oxidic material consist of zirconium and oxygen, preferably zirconia, and comprises a zeolitic material comprising one or more of copper and iron.

14. A catalyst for the selective catalytic reduction of NOx and for the oxidation of a hydrocarbon, comprising a coating disposed on a substrate, wherein the coating comprises palladium supported on an oxidic material comprising zirconium, and further comprises one or more of a vanadium oxide and a zeolitic material comprising one or more of copper and iron, wherein from 0 to 2 weight-% of the oxidic material consist of ceria and alumina.

15. The catalyst of claim 14, wherein from 90 to 100 weight-%, preferably from 95 to 100 weight-%, more preferably from 99 to 100 weight-% of the oxidic material comprised in the coating consist of zirconium and oxygen, preferably of zirconia.

16. The catalyst of claim 14, wherein the coating comprises a zeolitic material comprising one or more of copper and iron, wherein the zeolitic material has preferably a framework structure of the type CHA.

17. A method for preparing a catalyst, preferably the first catalyst comprised in the exhaust gas treatment system according to claim 12, comprising (A) preparing a first mixture comprising palladium, an oxidic material comprising zirconium, and water, (B) preparing a second mixture comprising a solvent and one or more of a vanadium oxide and a zeolitic material comprising one or more of copper and iron, wherein the vanadium oxide is preferably supported on an oxidic material comprising one or more of titanium, silicon, and zirconium, more preferably an oxidic material comprising one or more of titanium and silicon, more preferably an oxidic material comprising one or more of titania and silica, more preferably on titania, wherein titania optionally contains one or more of tungsten and silicon; (C) mixing the first mixture obtained in (A) and the second mixture obtained in (B) obtaining a slurry; (D) disposing the slurry obtained in (C) on a substrate, obtaining a slurry-treated substrate; (E) optionally, drying the slurry-treated substrate obtained in (D), obtaining a substrate having a coating disposed thereon; (F) calcining the slurry-treated substrate obtained in (D), preferably the dried slurry-treated substrate obtained in (E), obtaining a catalyst, preferably the first catalyst comprised in the exhaust gas treatment system.

18. An exhaust gas treatment system for treating an exhaust gas stream leaving a diesel engine, said exhaust gas treatment system having an upstream end for introducing said exhaust gas stream into said exhaust gas treatment system, wherein said exhaust gas treatment system comprises (i) a first catalyst being a diesel oxidation (DOC) catalyst, having an inlet end and an outlet end and consisting of a coating and a substrate wherein the coating is disposed on internal walls of the substrate, wherein the substrate has an inlet end, an outlet end and a substrate length extending from the inlet end to the outlet end of the substrate and comprises a plurality of passages defined by the internal walls of the substrate, wherein the coating comprises palladium supported on an oxidic material comprising one or more of zirconium, silicon, aluminum and titanium, wherein from 99 to 100 weight-% of the coating of the first catalyst consist of palladium supported on an oxidic material comprising one or more of zirconium, silicon, aluminum and titanium; (ii) a second catalyst having an inlet end and an outlet end and comprising a coating and a substrate wherein the coating is disposed on internal walls of the substrate, wherein the substrate has an inlet end, and outlet end and a substrate length extending from the inlet end to the outlet end of the substrate and comprises a plurality of passages defined by the internal walls of the substrate, wherein the coating of the second catalyst comprises one or more of a vanadium oxide and a zeolitic material comprising one or more of copper and iron; or a second catalyst having an inlet end and an outlet end and being the catalytic article according to claim 1; wherein the first catalyst according to (i) is the first catalyst of the exhaust gas treatment system downstream of the upstream end of the exhaust gas treatment system and wherein the inlet end of the first catalyst is arranged upstream of the outlet end of the first catalyst; wherein in the exhaust gas treatment system, the second catalyst according to (ii) is located downstream of the first catalyst according to (i) and wherein the inlet end of the second catalyst is arranged upstream of the outlet end of the second catalyst; wherein the outlet end of the first catalyst according to (i) is in fluid communication with the inlet end of the second catalyst according to (ii) and wherein between the outlet end of the first catalyst according to (i) and the inlet end of the second catalyst according to (ii), no catalyst for treating the exhaust gas stream exiting the first catalyst is located in the exhaust gas treatment system.

19. The exhaust gas treatment system of claim 18, wherein the oxidic material comprised in the coating of the first catalyst according to (i) comprises, preferably consists of, one or more of zirconium and aluminum.

20. The exhaust gas treatment system of claim 18, wherein the coating of the first catalyst comprises palladium at a loading, calculated as elemental palladium, in the range of from 0.18 to 3.53 g/l (5 to 100 g/ft.sup.3), preferably in the range of from 0.71 to 2.82 g/l (20 to 80 g/ft.sup.3), more preferably in the range of from 1.06 to 2.47 g/l (30 to 70 g/ft.sup.3), more preferably in the range of from 1.24 to 1.94 g/l (35 to 55 g/ft.sup.3), more preferably in the range of from 1.41 to 1.77 g/l (40 to 50 g/ft.sup.3).

21. The exhaust gas treatment system of claim 18, wherein the coating of the second catalyst comprises a zeolitic material comprising one or more of copper and iron, wherein the zeolitic material comprised in the coating of the second catalyst has a framework structure of the type AEI, GME, CHA, MFI, BEA, FAU, MOR or mixtures of two or more thereof, preferably a framework structure of the type AEI, CHA, BEA or mixtures of two or more thereof, more preferably a framework structure of the type CHA or AEI, more preferably a framework structure of the type CHA; or wherein the coating of the second catalyst according to (ii) comprises a vanadium oxide; wherein the vanadium oxide is preferably one or more of a vanadium (V) oxide and a vanadium (IV) oxide, wherein the vanadium oxide optionally contains one or more of tungsten, iron and antimony.

22. The exhaust gas treatment system of claim 18, further comprising an ammonia oxidation catalyst located downstream of the second catalyst according to (ii), wherein the ammonia oxidation catalyst has an inlet end and an outlet end, wherein the outlet end of the second catalyst according to (ii) is in fluid communication with the inlet end of the ammonia oxidation catalyst and wherein between the outlet end of the second catalyst according to (ii) and the inlet end of the ammonia oxidation catalyst, no catalyst for treating the exhaust gas exiting the second catalyst is located in the exhaust gas treatment system.

23. A method for the simultaneous selective catalytic reduction of NOx, the oxidation of hydrocarbon, the oxidation of nitrogen monoxide and the oxidation of ammonia, comprising (1) providing an exhaust gas stream from a diesel engine comprising one or more of NOx, ammonia, nitrogen monoxide and a hydrocarbon; (2) passing the exhaust gas stream provided in (1) through the exhaust gas system according to claim 12.

Description

BRIEF DESCRIPTION OF THE FIGURES

[1089] In order to provide an understanding of the invention, reference is made to the appended figures, which are not necessarily drawn to scale, and in which reference numerals refer to components of the invention.

[1090] FIG. 1 shows a perspective view of a honeycomb-type substrate which may comprise a catalytic article (i.e., selective reduction catalyst (SCR)) washcoat composition in accordance with the present invention.

[1091] FIG. 2 shows a partial cross-sectional view enlarged relative to FIG. 1 and taken along a plane parallel to the end faces of the substrate of FIG. 1 representing a monolithic flow-through substrate, which shows an enlarged view of a plurality of the gas flow passages shown in FIG. 1.

[1092] FIG. 3 shows a cutaway view of a section enlarged relative to FIG. 1, wherein the honeycomb-type substrate in FIG. 1 represents a wall flow filter substrate monolith.

[1093] FIG. 4 shows a cross-sectional view of a zoned catalytic article of the present invention.

[1094] FIG. 5 shows a schematic depiction of an embodiment of an emission treatment system in which a catalytic article of the present invention is utilized.

[1095] FIG. 6 is a line graph showing the NOx conversion activity of certain inventive embodiments of the present invention as set forth in the Examples.

[1096] FIG. 7 is a line graph showing the NO.sub.x conversion activity of certain inventive embodiments of the present invention as set forth in the Examples.

[1097] FIG. 8 is a graph showing the NO.sub.2 formation of certain inventive embodiments of the present invention as set forth in the Examples.

[1098] FIG. 9 is a graph showing the CO conversion of certain inventive embodiments of the present invention as set forth in the Examples.

[1099] FIG. 10 is a graph showing the HC oxidation of certain inventive embodiments of the present invention as set forth in the Examples.

[1100] FIG. 11a shows a schematic depiction of an engine coupled with the exhaust gas treatment system according to the present invention and a further catalytic unit. In particular,

[1101] FIG. 11a shows a schematic depiction of an engine coupled with an exhaust gas treatment system according to the present invention and a further catalytic unit. The exhaust gas treatment system 1 according to the present invention is depicted on FIG. 11a, said system comprises a first catalyst 2 as described in the foregoing which is located downstream of the diesel engine and downstream the inlet end of the exhaust gas treatment system 1. Optionally, a fluid injector 4 may be located upstream of the first catalyst 2 and downstream of the inlet end of the exhaust gas treatment system. Further, the system 1 comprises a second catalyst 3 as described in the foregoing which is located downstream of the first catalyst 2. The first catalyst 2 comprises a coating disposed on a substrate, both being not represented on FIG. 11a. The second catalyst 3 comprises a coating disposed on a substrate, both also not represented on FIG. 11a. The substrates of the catalyst 2 and the catalyst 3 are separate substrates, such that the first catalyst 2 and the second catalyst 3l are separated by a pipe or a tube 5. A further catalytic unit 6 may be disposed downstream of the exhaust gas treatment system 1, said unit 6 may be one or more of a diesel oxidation catalyst, a nitrogen oxides reduction catalyst and an ammonia oxidation.

[1102] FIG. 11b shows a schematic depiction of an engine coupled with the exhaust gas treatment system according to the present invention and a further catalytic unit. In particular, FIG. 11b shows a schematic depiction of an engine coupled with an exhaust gas treatment system according to the present invention and a further catalytic unit. The exhaust gas treatment system 11 according to the present invention is depicted on FIG. 11b, said system comprises a first catalyst 12 as described in the foregoing which is located downstream of the diesel engine and downstream the inlet end of the exhaust gas treatment system 1. Optionally, a fluid injector 4 may be located upstream of the first catalyst 12 and downstream of the inlet end of the exhaust gas treatment system. Further, the system 11 comprises a second catalyst 13 as described in the foregoing which is located downstream of the first catalyst 12. The first catalyst 12 comprises a coating disposed on a substrate, both being not represented on FIG. 11a. The second catalyst 13 comprises a coating disposed on a substrate, both also not represented on FIG. 11a. The substrates of the catalyst 12 and the catalyst 13 form a single substrate. For example, the coating of the first catalyst 12 may cover from 48 to 52% of the substrate length from the inlet end to the outlet end of the substrate and the coating of the second catalyst 13 may cover from 48 to 52% of the substrate length from the outlet end to the inlet end of the substrate with no overlap of the coatings. Alternatively, the coatings of the catalysts 12 and 13 may overlap. As a further alternative, a gap between the coatings of the first catalyst 12 and of the second catalyst 13 may be created. These alternatives are not depicted on FIG. 11b. A further catalytic unit 6 may be disposed downstream of the exhaust gas treatment system 1, said unit 6 may be one or more of a diesel oxidation catalyst, a nitrogen oxides reduction catalyst and an ammonia oxidation.

[1103] FIG. 12 shows the HC slip measured at the exit of the AMOX catalyst (HC slip AMO(out)) and the SCR(out) temperatures for the exhaust gas treatment systems of Example 13 and the exhaust gas treatment system of comparative Example 1 at different loadpoints 1 to 7.

[1104] FIG. 13 shows the NOx conversion measured obtained by using the exhaust gas treatment systems of Example 13 and comparative Example 1 at low temperature, namely 225 C.

[1105] FIG. 14 shows the relative amount of reduced NOx measured at 203 C. after HC injection for the exhaust gas treatment system of Example 13 and the exhaust gas treatment system of comparative Example 1.

[1106] FIG. 15 shows the DOC outlet temperatures and the HC slip measured for an exhaust gas treatment system of the present invention (system 1) at different loadpoints 1 to 12.

[1107] FIG. 16 shows the DOC outlet temperatures and the HC slip measured for an exhaust gas treatment system of the present invention (system 2) at different loadpoints 1 to 12.

[1108] FIG. 17 shows the DOC outlet temperatures and the HC slip measured for an exhaust gas treatment system of the present invention (system 3) at different loadpoints 1 to 12.

[1109] FIG. 18 shows the DOC outlet temperatures and the HC slip measured for an exhaust gas treatment system not according to the present invention (system 4) at different loadpoints 1 to 12.

[1110] FIG. 19 shows the DOC outlet temperatures and the HC slip measured for an exhaust gas treatment system not according to the present invention (system 5) at different loadpoints 1 to 12.

[1111] FIG. 20 shows the DeNOx for the exhaust gas treatment systems of Example 20 and of Comparative Example 4 at different temperatures, i.e. 204, 217 and 274 C.

[1112] FIG. 21 shows the HC slip measured at the exit of the AMOX catalyst (HC slip AMOX(out)) and the SCR(out) temperatures for the exhaust gas treatment systems of Example 20 and the exhaust gas treatment system of Comparative Example 4 at different loadpoints 1 to 7.

[1113] FIG. 22 shows the relative amount of reduced NOx measured at 203 C. after HC injection for the exhaust gas treatment system of Example 20 and the exhaust gas treatment system of Comparative Example 4

[1114] FIG. 23 shows the temperatures post SCR and post Pt-DOC for the exhaust gas treatment system of Comparative Example 5 at different temperatures pre catalyst.

[1115] FIG. 24 shows enlargements of FIG. 23.

[1116] FIG. 25 shows the temperatures post SCR and post Pt-DOC for the exhaust gas treatment system of Example 21 at different temperatures pre catalyst.

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