SYSTEM FOR THE TREATMENT OF AN EXHAUST GAS OF A DIESEL COMBUSTION ENGINE

Abstract

The present invention relates to a system for the treatment of an exhaust gas of a diesel combustion engine, a process for preparation of such a system, and a use thereof. In particular, said system comprises a NOx adsorber component and a lean NOx trap component, wherein the NOx adsorber component is comprised in a first catalyst comprising a first substrate and a first coating comprising a platinum group metal supported on a zeolitic material; and wherein the lean NOx trap component is comprised in a second catalyst comprising a second substrate and a second coating comprising Pt and Pd both supported on a specific first non-zeolitic oxidic support material, wherein in said system the NOx adsorber component is arranged upstream of the lean NOx trap component.

Claims

1. A system for the treatment of an exhaust gas of a diesel combustion engine, the system comprising a NOx adsorber component and a lean NOx trap component, wherein the NOx adsorber component is comprised in (a) a first catalyst comprising (a.1) a first substrate comprising an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end of the first substrate, and a plurality of passages defined by internal walls of the first substrate extending therethrough; (a.2) a first coating being said NOx adsorber component, said coating being disposed on a surface of the internal walls of the first substrate over at least 50% of the substrate axial length of the first substrate, the first coating comprising a platinum group metal supported on a zeolitic material; and wherein the lean NOx trap component is comprised in (b) a second catalyst comprising (b.1) a second substrate comprising an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end of the second substrate, and a plurality of passages defined by internal walls of the second substrate extending therethrough; (b.2) a second coating being said lean NOx trap component, said coating being disposed on the surface of the internal walls of the second substrate over at least 50% of the substrate axial length of the second substrate, the second coating comprising a first non-zeolitic oxidic support material, Pt and Pd, wherein Pt and Pd are both supported on the first non-zeolitic oxidic support material; wherein the first non-zeolitic oxidic support material comprises CeO.sub.2 and Al.sub.2O.sub.3, wherein at least 45 weight-% of the first non-zeolitic oxidic support material consist of Al.sub.2O.sub.3, calculated as Al.sub.2O.sub.3, wherein at least 10 weight-% of the first non-zeolitic oxidic support material consist of CeO.sub.2, calculated as CeO.sub.2, wherein in said system the NOx adsorber component is arranged upstream of the lean NOx trap component.

2. The system of claim 1, wherein the zeolitic material according to (a.2) comprises a 10-membered ring pore zeolitic material.

3. The system of claim 1, wherein the zeolitic material according to (a.2) has a framework type selected from the group consisting of FER, TON, MTT, SZR, MFI, MWW, AEL, HEU, AFO, a mixture of two or more thereof and a mixed type of two or more thereof.

4. The system of claim 1, wherein from 45 to 90 weight-% of the first non-zeolitic oxidic support material consist of Al.sub.2O.sub.3, calculated as Al.sub.2O.sub.3.

5. The system of claim 1, wherein the second coating according to (b.2) further comprises Rh and a second non-zeolitic oxidic support material, wherein Rh is supported on the second non-zeolitic oxidic support material.

6. The system of claim 5, wherein the second coating according to (b.2) exhibits a ratio of the weight of Pt, calculated as elemental Pt, to the weight of Rh, calculated as elemental Rh, in the range of from 5:1 to 50:1.

7. The system of claim 1, wherein the system further comprises at least one reductant injector, wherein each reductant injector is arranged between the NOx adsorber component and the lean NOx trap component.

8. The system of claim 1, further comprising (c) a gas heating component wherein the gas heating component is arranged downstream of the NOx adsorber component and upstream of the lean NOx trap component.

9. The system of claim 1, wherein the first substrate according to (a.1) and the second substrate according to (b.1) together form one single substrate which comprises an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end of the single substrate, and a plurality of passages defined by internal walls of the single substrate extending therethrough, wherein the first coating according to (a.2) is disposed on the surface of the internal walls of the single substrate over at least 25% of the substrate axial length of the single substrate and the second coating according to (b.2) is disposed on the surface of the internal walls of the single substrate, the surface of the internal walls of the single substrate being at least partially coated with the first coating according to (a.2), over at least 25% of the substrate axial length of the single substrate.

10. The system of claim 9, wherein the single substrate comprises one or more cavities, wherein each cavity extends from an outer position, wherein the outer position is located at an outer surface of the single substrate, to an inner position, wherein the inner position is located within the single substrate.

11. The system of claim 10, wherein the system further comprises at least one reductant injector, and wherein each reductant injector is located in a cavity.

12. A process for preparing a system for the treatment of an exhaust gas of a diesel combustion engine according to claim 1, said process comprising (1) providing a NOx adsorber component and a lean NOx trap component wherein the NOx adsorber component is comprised in (i) a first catalyst comprising (i.1) a first substrate comprising an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end of the first substrate, and a plurality of passages defined by internal walls of the first substrate extending therethrough; (i.2) a first coating being said NOx adsorber component, said coating being disposed on the surface of the internal walls of the first substrate over at least 50% of the substrate axial length of the first substrate, the first coating comprising a platinum group metal supported on a zeolitic material; and wherein the lean NOx trap component is comprised in (ii) a second catalyst comprising (ii.1) a second substrate comprising an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end of the second substrate, and a plurality of passages defined by internal walls of the second substrate extending therethrough; (ii.2) a second coating being said lean NOx trap component, said coating being disposed on the surface of the internal walls of the second substrate over at least 50% of the substrate axial length of the second substrate, the second coating comprising Pt, Pd, and a first non-zeolitic oxidic support material, wherein Pt and Pd are both supported on the first non-zeolitic oxidic support material, wherein the first non-zeolitic oxidic support material comprises CeO.sub.2 and Al.sub.2O.sub.3, wherein at least 45 weight-% of the first non-zeolitic oxidic support material consist of Al.sub.2O.sub.3, calculated as Al.sub.2O.sub.3, and wherein at least 10 weight-% of the first non-zeolitic oxidic support material consist of CeO.sub.2, calculated as CeO.sub.2; (2) arranging the NOx adsorber component upstream of the lean NOx trap component.

13. A system for the treatment of an exhaust gas of a diesel combustion engine obtainable or obtained by a process according to claim 12.

14. A method for the treatment of an exhaust gas of a diesel combustion engine, comprising providing an exhaust gas from a diesel combustion engine and passing said exhaust gas through a system according to claim 1.

15. (canceled)

Description

DESCRIPTION OF THE FIGURES

[0547] FIG. 1 shows the NOx adsorption for a simulated city cycle evaluation for the systems of Comparative Example 1, Comparative Example 2, and Example 3. On the abscissa, the time in s is given, on the left ordinate the NOx emission in g is given and on the right ordinate the speed in km/h and also the temperature in ? C. is given.

[0548] FIG. 2 shows the NOx emissions during the cold start phase in a worldwide harmonized light vehicle test cycle (WLTC) for the system according to Comparative Example 2 after oven aging and additional DeSOx aging, for the system according to Example 3 after oven aging, and for the system according to Example 3 after DeSOx aging. On the abscissa, the time in s is given, on the left ordinate the NOx emission in g is given and on the right ordinate the speed in km/h and also the temperature in ? C. is given.

[0549] FIG. 3A: shows a system according to an embodiment of the present invention, wherein the first substrate (a.1) is coated with the first coating (a.2) over the total length of the first substrate and the second substrate (b.1) is coated with the second coating (b.2) over the total length of the second substrate, and wherein the first substrate and the second substrate are arranged in directly consecutive order.

[0550] FIG. 3B: shows a system according to an embodiment of the present invention, wherein the first substrate (a.1) is coated with the first coating (a.2) over at least 50% of its length from its inlet end and the second substrate (b.1) is coated with the second coating (b.2) over at least 50% of its length from its outlet end, and wherein the first substrate and the second substrate are arranged in directly consecutive order.

[0551] FIG. 4A: shows a system according to an embodiment of the present invention, wherein the first substrate (a.1) and the second substrate (b.1) form a single substrate, wherein the first substrate (a.1) is coated with the first coating (a.2) over the total length of the first substrate and the second substrate (b.1) is coated with the second coating (b.2) over the total length of the second substrate, and wherein a cavity is located in the single substrate.

[0552] FIG. 4B: shows a system according to an embodiment of the present invention, wherein the first substrate (a.1) and the second substrate (b.1) form a single substrate, wherein the first substrate (a.1) is coated with the first coating (a.2) over at least 50% of its length from its inlet end and the second substrate (b.1) is coated with the second coating (b.2) over at least 50% of its length from its outlet end, and wherein a cavity is located in the single substrate.

[0553] FIG. 5A: shows a system according to an embodiment of the present invention, wherein the first substrate (a.1) is coated with the first coating (a.2) over the total length of the first substrate and the second substrate (b.1) is coated with the second coating (b.2) over the total length of the second substrate, and wherein a gas heating component or a reductant injector is located between the first substrate and the second substrate.

[0554] FIG. 5B: shows a system according to an embodiment of the present invention, wherein the first substrate (a.1) is coated with the first coating (a.2) over at least 50% of its length from its inlet end and the second substrate (b.1) is coated with the second coating (b.2) over at least 50% of its length from its outlet end, and wherein a gas heating component or a reductant injector is located between the first substrate and the second substrate.

[0555] FIG. 6: shows the SO.sub.2 emissions of the system according to Example 7 from the sulfation/desulfation testing according to Example 8. On the left ordinate, the temperature in ? C., and the SO.sub.2 emission in ppm is given, and on the right ordinate the lambda is given. On the abscissa, the time in s is given for the sulfation/desulfation procedure according to Example 8.

[0556] FIG. 7: shows the NOx emissions during the cold start phase in a worldwide harmonized light vehicle test cycle (WLTC) for the system according to Example 7 after SOx/DeSOx aging according to Example 8. On the abscissa, the time in s is given, on the left ordinate the NOx emission in g is given and on the right ordinate the speed in km/h and also the temperature in ? C. is given.

CITED LITERATURE

[0557] U.S. Pat. No. 10,005,075 B2 [0558] WO 2018/183688 A1 [0559] US 2018/0085707 A1 [0560] US 2017/0096922 A1 [0561] US 2015/075140 A1