Cu/LTA catalyst and exhaust system, and manufacturing method of cu/LTA catalyst
10799854 ยท 2020-10-13
Assignee
Inventors
Cpc classification
B01J29/80
PERFORMING OPERATIONS; TRANSPORTING
B01D53/9418
PERFORMING OPERATIONS; TRANSPORTING
F01N2370/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B01D2255/915
PERFORMING OPERATIONS; TRANSPORTING
F01N3/035
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B01J37/0246
PERFORMING OPERATIONS; TRANSPORTING
B01D53/9413
PERFORMING OPERATIONS; TRANSPORTING
F01N3/2066
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B01J35/56
PERFORMING OPERATIONS; TRANSPORTING
B01J29/763
PERFORMING OPERATIONS; TRANSPORTING
B01J35/19
PERFORMING OPERATIONS; TRANSPORTING
C01B39/145
CHEMISTRY; METALLURGY
B01D2258/012
PERFORMING OPERATIONS; TRANSPORTING
International classification
B01J29/80
PERFORMING OPERATIONS; TRANSPORTING
B01J37/02
PERFORMING OPERATIONS; TRANSPORTING
B01J35/00
PERFORMING OPERATIONS; TRANSPORTING
F01N3/035
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01N3/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Provided herein is an exhaust system comprising a diesel particulate filter coated with a selective catalytic reduction (SDPF) wherein the SCR is coated with a Cu/LTA catalyst comprising a LTA zeolite that includes copper ions and the SCR is coated on a high pore diesel particulate matter filter, wherein a ratio of copper and aluminum is from about 0.14 to about 0.48, and wherein the Si/Al ratio of the LTA zeolite is from about 8 to about 100.
Claims
1. An exhaust system comprising a diesel particulate filter coated with a selective catalytic reduction (SCR) (SDPF), wherein said SCR is coated with a Cu/LTA catalyst consisting essentially of a LTA zeolite and copper ions included in the LTA zeolite and said SCR is coated on a high pore diesel particulate matter filter, wherein a ratio of copper and aluminum in the Cu type of LTA zeolite is from about 0.14 to about 0.48, wherein the Si/Al ratio of the LTA zeolite is from about 11 to about 16, wherein the Cu/LTA catalyst with high temperature catalytic performance is coated on the rear end of the SPDF, and a Cu/CHA catalyst with low temperature catalytic performance is coated on the front end of the SPDF, and wherein a content of copper with respect to the total weight of the Cu/LTA catalyst is from about 1.5 wt % to about 3 wt %.
2. The exhaust system of claim 1, wherein: the ratio of copper and aluminum is from about 0.32 to about 0.48.
3. The exhaust system of claim 1, wherein: the Cu/LTA catalyst is coated on the surface of the SDPF with range of 40% to 60% of entire length of the SDPF.
4. The exhaust system of claim 1, further comprising: a composite catalyst unit SCR on which the Cu/CHA catalyst is coated and is at a rear end of the SDPF.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
DESCRIPTION OF SYMBOLS
(11) 100: SCR 200, 300: SDPF 400: composite catalyst unit
DETAILED DESCRIPTION OF THE EMBODIMENTS
(12) Hereinafter, the present invention will be described more fully with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention.
(13) Further, in exemplary embodiments, since like reference numerals designate like elements having the same configuration, a first exemplary embodiment is representatively described, and in other exemplary embodiments, only configurations different from the first exemplary embodiment will be described.
(14) The drawings are schematic, and are not illustrated in accordance with a scale. Relative dimensions and ratios of portions in the drawings are illustrated to be exaggerated or reduced in size for clarity and convenience, and the dimensions are just exemplified and are not limiting. In addition, same structures, elements, or components illustrated in two or more drawings use same reference numerals for showing similar features. It will be understood that when an element such as a layer, film, region, or substrate is referred to as being on another element, it can be directly on the other element or intervening elements may also be present.
(15) The exemplary embodiment of the present invention shows an exemplary embodiment of the present invention in detail. As a result, various modifications of the drawings will be expected. Therefore, the exemplary embodiment is not limited to a specific aspect of the illustrated region, and for example, includes modifications of an aspect by manufacturing.
(16) A Cu/LTA catalyst according to an exemplary embodiment of the present invention includes a LTA zeolite that includes copper ions, and a ratio of copper and aluminum is from about 0.14 to about 0.48 (e.g., about 0.14, 0.16, 0.18, 0.20, 0.22, 0.24, 0.26, 0.28, 0.30, 0.32, 0.34, 0.36, 0.38, 0.40, 0.42, 0.44, 0.46, or about 0.48), and the Si/Al ratio of the LTA zeolite is from about 8 to about 100 (e.g., about 8, 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58, 60, 62, 64, 66, 68, 70, 72, 74, 76, 78, 80, 82, 84, 86 ,88, 90, 92, 94, 96, 98, or about 100). Further, more preferably, the ratio of copper and aluminum may be from about 0.32 to about 0.48 (e.g., about 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.40, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, or about 0.48).
(17) However, this is not restrictive, and a ratio of copper and aluminum may be adjusted depending on an environment where the catalyst is used according to another exemplary embodiment.
(18) In addition, when a content of copper is indicated using wt % with respect to the total weight of the catalyst, a content of copper with respect to the total weight of catalyst may be from about 0.5 wt % to about 5 wt % (e.g., about 0.5 wt %, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, or about 5.0 wt %). Further, more preferably, the content of copper may be from about 1.5 wt % to about 3 wt % (e.g., about 1.5 wt %, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or about 3 wt %).
(19) Further, more preferably, the Si/Al ratio of the LTA zeolite may be from about 11 to about 16 (e.g., about 11, 12, 13, 14, 15, or about 16).
(20) Now, a performance of the Cu/LTA catalyst according to an exemplary embodiment of the present invention will be described with reference to
(21)
(22) Referring to
(23)
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(25)
(26) Referring to
(27)
(28) Referring to
(29) Also, as shown in
(30) Also, as shown in
(31) The Cu/CHA catalyst may include SSZ-13 zeolite including copper ions, and the SSZ-13 zeolite is an aluminosilicate zeolite having micro pores of 0.380.38 nm and expressed as Q.sub.xNa.sub.yAl.sub.2.4Si.sub.33.6O.sub.72zH.sub.2O, and x is 1.4 to 27, y is 0.7 to 4.3, and z is 1 to 7. The Q may be N,N,N-1-trimethyladamantammonium. The copper type SSZ-13 zeolite has a high catalytic performance in a low temperature. Accordingly, when the copper type LTA zeolite and the copper type SSZ-13 zeolite are used by mixing, excellent catalytic performance can be maintained in a low temperature to a high temperature.
(32) Further, as shown in
(33) The SDPF 200 may be an SDPF that SCR on which the Cu/LTA catalyst as illustrated in
(34)
(35)
(36) Referring to
(37) In order to prepare the LTA zeolite, an LTA seed may be mixed in a mixture of aluminum hydroxide (Al(OH).sub.3) and tetraethyl orthosilicate (Si(OC.sub.2H.sub.5).sub.4).
(38) Specifically, a 1,2-dimethyl-3-(4-methylbenzyl)imidazolium hydroxide aqueous solution and aluminum hydroxide (Al(OH).sub.3) are mixed and the mixture is primarily stirred, and then tetramethylammonium hydroxide pentahydrate is additionally mixed and then secondarily stirred so as to prepare a first mixture.
(39) Here, with respect to the total weight of the first mixture, 2035 wt % (e.g., from about 20 wt % to about 35 wt %, about 20 wt %, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, or about 35 wt %) of 1,2-dimethyl-3-(4-methylbenzyl)imidazolium hydroxide, 12 wt % (e.g., from about 1 wt % to about 2 wt %, about 1 wt %, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or about 2 wt %) of aluminum hydroxide (Al(OH).sub.3), 15 wt % (e.g., from about 1 wt % to about 5 wt %, about 1 wt %, 2, 3, 4, or about 5 wt %), of tetramethylammonium hydroxide pentahydrate, and a residual quantity of water are mixed, and the primary stirring and the secondary stirring may be respectively performed for about 0.5 to 1.5 h (e.g., about 0.5 h, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, or about 1.5 h).
(40) Tetraethyl orthosilicate (TEOS) (Si(OC.sub.2H.sub.5).sub.4) is mixed into the first mixture and then third stirring is performed, and then the LTA seed is mixed and fourth stirring is performed so as to prepare a second mixture.
(41) 3035 wt % (e.g., from about 30 wt % to about 35 wt %, about 30 wt %, 31, 32, 33, 34, or about 35 wt %) of TEOS may be mixed with respect to the total weight of the second mixture, and the amount of LTA seed may be 26 wt % (e.g., from about 2 wt % to about 6 wt %, about 2 wt %, 3, 4, 5, or about 6 wt %) with respect to the total weight of the entire silicon included in LTA zeolite.
(42) In addition, the third stirring may be performed for about 2 to 4 h (e.g., about 2, 2.5, 3, 3.4, or about 4 h), and the fourth stirring may be performed for about 20 to 28 h (e.g., about 20, 21, 22, 23, 24, 25, 26, 27, or about 28 h).
(43) Next, the second mixture is sufficiently heated to cause hydrolysis of the TEOS, and ethanol and water generated from the hydrolysis of TEOS are evaporated such that a third mixture is prepared.
(44) The second mixture may be heated at a temperature between from about 70 C. and about 90 C. (e.g., about 70 C., 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, or about 90 C.).
(45) Next, a hydrofluoric aqueous solution is mixed in the third mixture, and a fourth mixture is prepared through heating, cleansing, and drying processes.
(46) Here, the third mixture may be heated for a constant time period at a temperature of from about 150 C. to about 200 C. (e.g., about 150 C., 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199, or about 200 C.), the cleansing process may be iteratively performed, and the drying process may be performed at room temperature.
(47) Next, heat treatment is additionally performed to remove an organic material from the fourth mixture such that the LTA zeolite for manufacturing the zeolite catalyst according to the exemplary embodiment of the present invention is manufactured.
(48) When the LTA zeolite is manufactured without using a seed, the following method may be used. In a plastic beaker, 0.1 to 1.0 mole of aluminium hydroxide and 0.0 to 0.2 mole of tetramethylammonium hydroxide (hereinafter, referred to as TMAOH) are added to 0.1 to 0.2 mole of 2-Dimethyl-3-(4-methylbenzyl) imidazolium hydroxide (hereinafter, referred to as 12DM3 (4MB) IOH), which is an organic structure directing agent, and then sufficiently stirred. Next, with respect to the content of the reactant, tetraethyl orthosilicate (hereinafter, referred to as TEOS) is mixed to be a ratio of 1 mole and then sufficiently stirred.
(49) Next, the solution is sufficiently heated at 60 to 100 C. to completely remove ethanol generated from the hydrolysis of TEOS and at the same time to make the amount of water generated from the hydrolysis of TEOS become 0 to 10 mole. Then, 0.1 to 1.0 mole of hydrogen fluoride (HF) is added and then sufficiently stirred such that a reaction mixture having a composition of Chemical Formula 1 is acquired.
1 SiO.sub.2:0.0-0.2 Al(OH).sub.3:0.0-0.2 TMAOH:0.1-1.0 R:0.1-1.0 HF:0-10 H.sub.2O[Chemical Formula 1]
(50) wherein R is 12DM3 (4MB)IOH.
(51) The reaction mixture is moved to a teflon reactor and received in a container that is made of stainless steel, and then heated at 100 to 200 C. for 0.1 to 14 days such that a LTA zeolite can be manufactured. A ratio of Si/Al of the LTA zeolite manufactured through above-stated method may also be 5 to 50. However, the method for manufacturing the LTA zeolite is not limited to the above-stated method.
(52) Next, a LTA zeolite that includes ions is manufactured using the LTA zeolite S1002.
(53) First, the LTA zeolite is put into ammonium salt and refluxed, and then cleansing and drying processes are performed to prepare an LTA zeolite including NH.sub.4.sup.+ ions (i.e., NH.sub.4 type of LTA zeolite). Here, the ammonium salt may be ammonium nitrate (NH.sub.4NO.sub.3). The reflux process may be performed at a temperature between 60 C. and 100 C. for about 5 to 7 h. In the present exemplary embodiment, ions are exemplarily described as ammonium ions, but this is not restrictive. That is, use of other ions and ion salt is also included in the scope of the present invention.
(54) Next, a Cu type of LTA zeolite is manufactured by performing copper ion exchange on the LTA zeolite including ions S1003. In the Cu type of LTA zeolite manufactured in the present step, a ratio of copper and aluminum may be from about 0.14 to about 0.48 (e.g., about 0.14, 0.16, 0.18, 0.20, 0.22, 0.24, 0.26, 0.28, 0.30, 0.32, 0.34, 0.36, 0.38, 0.40, 0.42, 0.44, 0.46, or about 0.48). However, the ratio is not limited thereto, and can be appropriately adjusted according to an environmental condition where the catalyst is used.
(55) In addition, when a content of copper is indicated by using wt %, a content of copper may be from about 0.5 wt % to about 5 wt % (e.g., about 0.5 wt %, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, or about 5.0 wt %). More preferably, the content of copper may be 1.5 wt % to 3 wt % (e.g., about 1.5 wt %, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or about 3 wt %).
(56) In a previous step, a dried NH.sub.4 type of LTA zeolite including NH.sub.4.sup.+ ions undergoes copper (Cu) ion exchange such that a Cu type of LTA zeolite including copper ions may be prepared.
(57) For the copper ion exchange, the dried NH.sub.4 type of LTA zeolite including NH.sub.4.sup.+ ions is injected into a copper precursor solution such as copper acetate monohydrate, copper nitride, copper nitrate, copper sulfate, and the like, and stirred, and then cleansing and drying processes are performed such that the Cu type of LTA zeolite can be prepared.
(58) Next, the Cu type of LTA zeolite is heated in an oven with a gradually increasing temperature, and then a heat treatment process is performed such that the catalyst according to the exemplary embodiment of the present invention is manufactured S1004.
(59) Here, for the heat temperature of the Cu type of LTA zeolite, the temperature may be increased to about 400 to about 750 C. (e.g., about 400 C., 405, 410, 415, 420, 425, 430, 435, 440, 445, 450, 455, 460, 465, 470, 475, 480, 485, 490, 495, 500, 505, 510, 515, 520, 525, 530, 535, 540, 545, 550, 555, 560, 565, 570, 575, 580, 585, 590, 595, 600, 605, 610, 615, 620, 625, 630, 635, 640, 645, 650, 655, 660, 665, 670, 675, 680, 685, 690, 695, 700, 705, 710, 715, 720, 725, 730, 735, 740, 745, or about 750 C.) at a rate of about 1 to about 30 C./min (e.g., about 1 C./min, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or about 30 C./min), and then the heat treatment may be performed to about 1 to about 24 h (e.g., about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, or about 24 h).
(60) In the Cu type of LTA zeolite manufactured in the present step, a ratio of copper and aluminum may be from about 0.14 to about 0.48 (e.g., about 0.14, 0.16, 0.18, 0.20, 0.22, 0.24, 0.26, 0.28, 0.30, 0.32, 0.34, 0.36, 0.38, 0.40, 0.42, 0.44, 0.46, or about 0.48). More preferably, the ratio may be from about 0.32 to about 0.48 (e.g., about 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.40, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, or about 0.48).
(61) Such a ratio of copper and aluminum is a ratio for excellent NOx purification performance while maintaining thermal stability.
(62) Like this, according to an exemplary embodiment of the present invention, deterioration may be prevented and purification performance of the nitrogen oxide may be improved by applying Cu/LTA catalyst having improved heat resistance.
(63) Also, hydrothermal stability of the Cu/LTA catalyst is excellent to be applied to SCR or SDPF.
(64) Also, regeneration period may be increased by improved heat resistance, and fuel consumption efficiency can be improved since the amount of soot loading may be increased.
(65) Also, temperature of the SDPF may be increased by improving heat resistance to improve efficiency of eliminating the soot.
(66) While this invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. On the contrary, it is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.