A CATALYST FOR THE SELECTIVE CATALYTIC REDUCTION OF NOX AND FOR THE CRACKING AND CONVERSION OF A HYDROCARBON

Abstract

The present invention relates to a catalyst for the selective catalytic reduction of NOx and for the cracking and conversion of a hydrocarbon, comprising a substrate comprising an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end and a plurality of passages defined by internal walls of the substrate extending therethrough: a coating disposed on the surface of the internal walls of the substrate, said coating comprising a platinum group metal, an 8-membered ring pore zeolitic material comprising one or more of copper and iron, and further comprising a 10- or more membered ring pore zeolitic material.

Claims

1. A catalyst for the selective catalytic reduction of NOx and for the cracking and conversion of a hydrocarbon, comprising (i) a substrate comprising an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end and a plurality of passages defined by internal walls of the substrate extending therethrough; (ii) a coating disposed on the surface of the internal walls of the substrate, said coating comprising a platinum group metal, an 8-membered ring pore zeolitic material comprising one or more of copper and iron, and further comprising a 10- or more membered ring pore zeolitic material.

2. The catalyst of claim 1, wherein the coating (ii) further comprises a non-zeolitic oxidic material comprising one or more of alumina, zirconia, silica, titania and ceria.

3. The catalyst of claim 1, wherein the 8-membered ring pore zeolitic material comprised in the coating (ii) has a framework type selected from the group consisting of CHA, AEI, RTH, LEV, DDR, KFI, ERI, AFX, a mixture of two or more thereof and a mixed type of two or more thereof, preferably selected from the group consisting of CHA, AEI, RTH, AFX, a mixture of two or more thereof and a mixed type of two or more thereof.

4. The catalyst of claim 1, wherein the 10- or more membered ring pore zeolitic material comprised in the coating (ii) is a zeolitic material having a framework type selected from the group consisting of FER, MFI, BEA, MWW, AFI, MOR, OFF, MFS, MTT, FAU, LTL, MEI, MOR, a mixture of two or more thereof and a mixed type of two or more thereof.

5. The catalyst of claim 1, wherein the platinum group metal comprised in the coating (ii) is palladium.

6. The catalyst of claim 1, wherein in the framework structure of the 10- or more membered ring pore zeolitic material comprised in the coating (ii), the molar ratio of Si to Al, calculated as molar SiO.sub.2:Al.sub.2O.sub.3, is in the range of from 2:1 to 60:1.

7. The catalyst of claim 1, wherein the 10- or more membered ring pore zeolitic material comprised in the coating (ii) is a zeolitic material having a framework type BEA, and wherein in the framework structure of said zeolitic material, the molar ratio of Si to Al, calculated as molar SiO.sub.2:Al.sub.2O.sub.3, is in the range of from 4:1 to 20:1; or wherein the 10- or more membered ring pore zeolitic material comprised in the coating (ii) is a zeolitic material having a framework type FER, and wherein in the framework structure of said zeolitic material, the molar ratio of Si to Al, calculated as molar SiO.sub.2:Al.sub.2O.sub.3, is in the range of from 10:1 to 30:1.

8. The catalyst of claim 1, wherein the 10- or more membered ring pore zeolitic material comprised in the coating (ii) is a zeolitic material having a framework type FAU, and wherein, in the framework structure of said zeolitic material, the molar ratio of Si to Al, calculated as molar SiO.sub.2:Al.sub.2O.sub.3, is in the range of from 3:1 to 15:1; or wherein the 10- or more membered ring pore zeolitic material comprised in the coating (ii) is a zeolitic material having a framework type MFI, and wherein in the framework structure of said zeolitic material, the molar ratio of Si to Al, calculated as molar SiO.sub.2:Al.sub.2O.sub.3, is in the range of from 10:1 to 35:1.

9. The catalyst of claim 1, wherein the 10- or more membered ring pore zeolitic material comprised in the coating (ii) comprises one or more of iron, copper and a rare earth element component.

10. The catalyst of claim 1, wherein the coating according to (ii) comprises (ii.1) an inlet coat comprising the platinum group metal and the 10- or more membered ring pore zeolitic material; and (ii.2) an outlet coat comprising the platinum group metal, a non-zeolitic oxidic material, and the 8-membered ring pore zeolitic material comprising one or more of copper and iron; wherein the inlet coat (ii.1) extends over x % of the substrate axial length from the inlet end towards the outlet end of the substrate according to (i), wherein x ranges from 20 to 80, and wherein the outlet coat (ii.2) extends over y % of the substrate axial length from the outlet end towards the inlet end of the substrate according to (i), wherein y ranges from 20 to 80.

11. The catalyst of claim 10, wherein the platinum group metal in the inlet coat (ii.1) is palladium and the 10- or more membered ring pore zeolitic material in the inlet coat (ii.1) is a zeolitic material having a framework type BEA; or wherein the platinum group metal in the inlet coat (ii.1) is palladium and the 10- or more membered ring pore zeolitic material in the inlet coat (ii.1) is a zeolitic material having a framework type FAU; or wherein the platinum group metal of the inlet coat (ii.1) is palladium and the 10- or more membered ring pore zeolitic material in the inlet coat (ii.1) is a zeolitic material having a framework type MFI.

12. The catalyst of claim 10, wherein in the framework structure of the 8-membered ring pore zeolitic material of the outlet coat (ii.2), the molar ratio of Si to Al, calculated as molar SiO2:Al2O3, is in the range of from 15:1 to 33:1.

13. The catalyst of claim 1, wherein the coating (ii) is a single coat.

14. The catalyst of claim 13, wherein in the framework structure of the 8-membered ring pore zeolitic material of the coating (ii), the molar ratio of Si to Al, calculated as molar SiO2:Al.sub.2O.sub.3, is in the range of from 15:1 to 20:1.

15. The catalyst of claim 13, wherein the weight ratio of the 8-membered ring pore zeolitic material of the coating (ii) relative to the 10- or more membered ring pore zeolitic material of the coating (ii) is in the range of from 2:1 to 15:1.

16. The catalyst of claim 13, wherein the 8-membered ring pore zeolitic material of the coating (ii) has a framework type CHA and the 10- or more membered ring pore zeolitic material of the coating (ii) has a framework type BEA and comprises iron; or wherein the 8-membered ring pore zeolitic material of the coating (ii) has a framework type CHA and the 10- or more membered ring pore zeolitic material of the coating (ii) has a framework type FAU and comprises a rare earth element component.

17. The catalyst of claim 14, wherein the 8-membered ring pore zeolitic material of the coating (ii) has a framework type CHA and the 10- or more membered ring pore zeolitic material of the coating (ii) has a framework type MFI and comprises iron; or wherein the 8-membered ring pore zeolitic material of the coating (ii) has a framework type CHA and the 10- or more membered ring pore zeolitic material of the coating (ii) has a framework type FER.

18. (canceled)

19. 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 (a) a first catalyst having an inlet end and an outlet end, wherein said catalyst is a catalyst according to claim 1; (b) 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 a non-zeolitic 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 (a) 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 (b) is located downstream of the first catalyst according to (a) and wherein the inlet end of the second catalyst is arranged upstream of the outlet end of the second catalyst.

20. A catalyst for the selective catalytic reduction of NOx, for the cracking and conversion of a hydrocarbon, and for the oxidation of ammonia, comprising a substrate comprising an inlet end, an outlet end, a substrate axial length extending from the inlet end to the outlet end and a plurality of passages defined by internal walls of the substrate extending therethrough; a first coating disposed on the surface of the internal walls of the substrate, said coating comprising a platinum group metal supported on a non-zeolitic 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; a second coating disposed on the first coating, said coating comprising a platinum group metal, an 8-membered ring pore zeolitic material comprising one or more of copper and iron, and further comprising a 10- or more membered ring pore zeolitic material.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0528] FIGS. 1 to 3 show the testing conditions of the two exhaust gas treatment systems.

[0529] FIGS. 4 and 6 show the different temperatures obtained at the outlet end of Catalyst 1 and Catalyst 2 of the comparative system as well as the HC slip at the outlet end of Catalyst 1 and Catalyst 2, when applying Catalyst 1 inlet temperatures of 305, 325 and 350? C.

[0530] FIGS. 5 and 7 show the different temperatures obtained at the outlet end of Catalyst 1 and Catalyst 2 of the inventive system as well as the HC slip at the outlet end of Catalyst 1 and Catalyst 2, when applying Catalyst 1 inlet temperatures of 305, 325 and 350? C.

[0531] FIG. 8 shows the DeNOx measured for the catalysts of Examples 10 and 12-15 at low and high temperatures.

[0532] FIG. 9 show the N.sub.2O formation measured for the catalysts of Examples 10 and 12-15 at low and high temperatures.

[0533] FIG. 10 show the NH.sub.3 slip measured for the catalysts of Examples 10 and 12-15 at low and high temperatures.

CITED LITERATURE

[0534] WO 2018/224651 A2 [0535] U.S. Pat. No. 10,589,261 B2 [0536] U.S. Pat. No. 5,788,834 B