DURABLE COPPER-SCR CATALYST

Abstract

A catalyst composition for selective catalytic reduction of NO.sub.x by ammonia or compounds, such as urea, generating ammonia under exhaust gas conditions. The composition includes a) a copper ion exchanged zeolite particles having a Si/Al.sub.2 molar ratio (SAR) of 15 or less and a copper content sufficiently high to perform the catalytic reduction, b) a nanocrystalline aluminium compound in an amount sufficient for stabilizing the zeolite, and c) a zirconium compound in an amount sufficient to improve hydrothermal durability of the catalyst composition.

Claims

1-28. (Canceled)

29. A catalyst composition for selective catalytic reduction of NO.sub.x by ammonia or compounds generating ammonia under exhaust gas conditions, the composition comprising: a) a copper ion exchanged zeolite particle having a Si/Al2 molar ratio (SAR) of 15 or less and a copper ion content sufficiently high to perform the catalytic reduction, b) a nanocrystalline aluminium compound in an amount sufficient for stabilizing the zeolite by reducing the dealumination rate from the zeolite, and c) a zirconium compound in an amount sufficient to improve hydrothermal durability of the catalyst composition.

30. The catalyst composition of claim 29, wherein the zeolite is selected from a framework group consisting of chabazite (CHA), AEI, AFX, LEV, Beta or mixtures thereof.

31. The catalyst composition of claim 29, having a SAR from 2-14.9, such as 5-14.9, such as from 10-14.9.

32. The catalyst composition of claim 29, wherein the copper ion content, measured as CuO, in the zeolite is from 1-10 wt %, such as 2-7 wt %, preferably 4-7 wt %, based on the total zeolite weight.

33. The catalyst composition of claim 29, wherein the amount of the nanocrystalline aluminium compound, such as Al.sub.2O.sub.3 , in the catalyst composition is from 0.5 to 25 wt %, such as from 1-20 wt %, such as 5-15 wt-%, typically 7.8-10 wt-% based on total weight of the catalyst composition.

34. The catalyst composition of claim 31, having a SAR from 10-14.9, wherein the amount of the nanocrystalline aluminium compound, such as Al.sub.2O.sub.3, in the catalyst composition is from 0.5 to 25 wt %, such as from 1-20 wt %, such as 5-15 wt-%, typically 7.8-10 wt-% based on total weight of the catalyst composition.

35. The catalyst composition of claim 29, wherein the molar ratio of Cu/Al in the zeolite is from 0.02 to 0.4, preferable from 0.05 to 0.25.

36. The catalyst composition of claim 29, wherein the total copper ion content measured as CuO in the catalyst composition is from 2-6 wt % based on total weight of the catalyst composition.

37. The catalyst composition of claim 29, wherein the copper ion exchanged zeolite particles comprises a size as d.sub.50 from 1-10 micron, such as from 2-5 micron.

38. The catalyst composition of claim 29, wherein the zirconium compound comprises zirconium oxides.

39. The catalyst composition of claim 29, wherein the content of the zirconium compound in the catalyst composition is as ZrO.sub.2 from 1 to 10 wt %, such as from 2-7 wt % based on total weight of the catalyst composition.

40. The catalyst composition of claim 29, wherein the nanocrystalline aluminium compound is aluminium oxide, such as Al.sub.2O.sub.3.

41. The catalyst composition of claim 29, wherein the nanocrystalline Al.sub.2O.sub.3 comprises a crystalline size as d50 from 1-8 nm, such as 3-7 nm, typically from 3-5 nm.

42. The catalyst composition of claim 29, wherein the nanocrystalline Al.sub.2O.sub.3 comprises a dispersed particle size as d.sub.50 from 5-80 nm, such as 10-65 nm, typically from 10-30 nm.

43. The catalyst composition of claim 29, comprising large particle (LP), such as Al.sub.2O.sub.3 based large particles, comprising a particle size by d.sub.50 from 3-200 micron, preferably from 5-40 micron.

44. The catalyst composition of claim 29, comprising an additive selected from oxides of La, Y, Hf, Nd, and mixtures thereof.

45. The catalyst composition of claim 29, comprising Si, Ti and mixtures thereof as a form of stable oxides.

46. The catalyst composition of claim 45, wherein the Si and/or Ti is attached to the large particle (LP).

47. The catalyst composition of claim 29, having a total SAR (TSAR) of less than 10, wherein TSAR is defined as the molar Si/Al.sub.2 ratio between Si in the zeolite and total Ale in the zeolite and nanocrystalline aluminium compound.

48. A support structure for use in an exhaust gas system comprising a catalyst composition of claim 29.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0051] FIG. 1 illustrates schematically the copper SCR catalyst composition on a substrate according to this invention. The catalyst consists of a substrate (100) which forms open flow channels (110) for exhaust gas and on its substrate walls the catalyst coating is located. The coating is formed by the mixture of Cu-zeolite (200, e.g. Cu-CHA), Al compound (300), ZrO.sub.2 (400), additive (Add, 600) and large particles (LP, 500) and Ti and/or Si (700).

[0052] FIG. 2 shows a diagram with the NO.sub.x conversion as tested in a synthetic gas bench with 40% NO.sub.2 and 60% NO (both in respect to total NO.sub.x) in the feed gas at a SV of 71.000 h.sup.−1 for the example 1a, 2 (REF 1), 3 (REF 2) and 4 (REF 3). All the samples have been hydrothermally been aged at 800° C. for 20 hours. The comparison shows the influence of the Al-compound with a small crystalline size (example 1a) in respect to an Al-compound with larger Al.sub.2O.sub.3 crystalline sizes (example 2, REF 1) and a comparison with a reference state-of-art Cu-CHA catalyst (example 3, REF 2) and a second reference sample prepared according to example 1a but with a zeolite with a SAR of 23 (example 4, REF 3).

[0053] FIGS. 3a and 3b illustrate in two diagrams the improvement of the thermal ageing stability of a Cu-CHA with a SAR of 11 in combination with Al-1 either by adding a zirconium compound or lanthanum oxide as an additive or both. The diagram in 3a shows the NO.sub.x conversion as tested in a synthetic gas bench with NO only in the feed gas at a SV of 50.000 h.sup.−1 for example 1b (Cu-CHA with SAR of 11 with Al-1), example 5 (Cu-CHA with SAR of 11 with Al-1 and 6% ZrO.sub.2 as thermal stabilizer), example 6 (Cu-CHA with SAR of 11 with Al-1 and 3% La.sub.2O.sub.3 as thermal stabilizer), and example 7 (Cu-CHA with SAR of 11 with Al-1 and 3% ZrO.sub.2 plus 3% La.sub.2O.sub.3 as thermal stabilizers). All samples have been hydrothermally aged at 850° C. for 20 hours. 3b shows in a diagram the NO.sub.x conversion for the same set of samples as tested in a synthetic gas bench with 40% NO.sub.2 and 60% NO (both in respect to total NO.sub.x) in the feed gas at a SV of 50.000 h.sup.−1

[0054] FIGS. 4a and 4b illustrate in two diagrams the improvement of the thermal ageing stability of a Cu-CHA with a SAR of 11 in combination with Al-1 and the addition of Large Particles (LP). The diagram in 4a shows the NO.sub.x conversion as tested in a synthetic gas bench with NO only in the feed gas at a SV of 50.000 h.sup.−1 for example 1b (Cu-CHA with SAR of 11 with Al-1, total loading 140 g/l), example 8a (Cu-CHA with SAR of 11 with Al-1 at 140 g/l and Large Particles comprising Al.sub.2O.sub.3 as the main oxide and 3% of La.sub.2O.sub.3 at 40 g/l), example 8b (Cu-CHA with SAR of 11 with Al-1 at 140 g/l and Large Particles comprising Al.sub.2O.sub.3 as the main oxide and 20% of SiO.sub.2 at 40 g/l), and example 8c (Cu-CHA with SAR of 11 with Al-1 at 140 g/l and Large Particles comprising Al.sub.2O.sub.3 as the main oxide and 15% of ZrO.sub.2 and 20% of SiO.sub.2 at 40 g/l). All samples have been hydrothermally aged at 850° C. for 20 hours. 4b shows in a diagram the NO.sub.x conversion for the same set of samples as tested in a synthetic gas bench with 40% NO.sub.2 and 60% NO (both in respect to total NO.sub.x) in the feed gas at a SV of 50.000 h.sup.−1.

[0055] FIGS. 5a and 5b illustrate in two diagrams the improvement of the thermal ageing stability of a Cu-CHA with a SAR of 11 in combination with Al-3 and the addition of a zirconium compound and/or Lanthanum oxide as an additive and the addition of Large Particles (LP). The diagram in 5a shows the NO.sub.x conversion as tested in a synthetic gas bench with NO only in the feed gas at a SV of 50.000 h.sup.−1 for example 1b (Cu-CHA with SAR of 11 with Al-1, total loading 140 g/l), example 9 (Cu-CHA with SAR of 11 with Al-3 and 6% ZrO.sub.2 as thermal stabilizer at 140 g/l and Large Particles comprising Al.sub.2O.sub.3 as the main oxide and 3% of La.sub.2O.sub.3 at 40 g/l), example 10 (Cu-CHA with SAR of 11 with Al-3 and 6% ZrO.sub.2 as thermal stabilizer at 140 g/l and Large Particles comprising Al.sub.2O.sub.3 as the main oxide and 20% of SiO.sub.2 and 20% of TiO.sub.2 at 40 g/l), and example 11 (Cu-CHA with SAR of 11 with Al-3 and 3% ZrO.sub.2 plus 3% La.sub.2O.sub.3 as thermal stabilizers at 140 g/l and Large Particles comprising Al.sub.2O.sub.3 as the main oxide and 20% of SiO.sub.2 and 20% of TiO.sub.2 at 40 g/l). All samples have been hydrothermally aged at 850° C. for 20 hours. 5b shows in a diagram the NO.sub.x conversion for the same set of samples as tested in a synthetic gas bench with 40% NO.sub.2 and 60% NO (both in respect to total NO.sub.x ) in the feed gas at a SV of 50.000 h.sup.−1.

[0056] FIG. 6 illustrates in a diagram the improvement of the thermal ageing stability of a Cu-CHA with a SAR of 11 in combination with an Al compound utilizing all possible additives according to this invention. The diagram shows the comparison of the NO.sub.x conversion as tested in a synthetic gas bench with 40% NO.sub.2 and 60% NO (both in respect to total NO.sub.x ) in the feed gas at a SV of 50.000 h.sup.−1 for example 3, which is a reference state-of-art Cu-CHA catalyst with high SAR and a high low temperature DeNOx activity, with example 11, which represents a fully developed Cu-zeolite SCR catalyst composition according to this invention consisting of a Cu-CHA with SAR of 11 with Al-compounds Al-3 and 3% ZrO.sub.2 plus 3% La.sub.2O.sub.3 as thermal stabilizers at 140 g/l and Large Particles comprising Al.sub.2O.sub.3 as the main oxide and 20% of SiO.sub.2 and 20% of TiO.sub.2 at 40 g/l. Both samples have been hydrothermally aged at 850° C. for 20 hours.

DESCRIPTION

[0057] There are many advantages of the present invention in a broad context as well as further even more advantages aspects of the embodiments.

[0058] The SCR catalyst is composed of the defined materials according to the above aspects and/or embodiments of the present invention, which catalyst composition is coated on a carrier structure, such as a ceramic or metallic substrate or particulate filter (carrier). The total coating amount is varied in the range of 20-400 g/L depending on application or carrier type (cell density, ceramic/metallic, flow-through/wall-flow). In a preferred embodiment the total coating amount is in the range of 60-200 g/L.

[0059] The term “copper ion exchanged zeolite” is used interchangeably with “Cu-zeolite”, and for instance “Cu-CHA” means “copper ion exchanged chabazite”.

[0060] The SCR catalyst composition of the present invention is an active microporous zeolite. Cu exchanged zeolite is preferably in the CHA (chabazite) form with a SAR in the range of 2-14.9, preferably in the range of 5-14.9, such as in the range of 10-14.9. The copper loading is measured as CuO typically in the range of 2-7 wt-%, such as in the range of 4-7 wt-%, typically in the range of 4-5 wt-% in zeolite and about 2-6 wt-% in the catalyst including all the catalyst compounds. The surface area of the copper ion exchanged zeolite, preferably Cu-CHA, is in the range of 450-700 m.sup.2/g as fresh (calcined at 550° C./3 h, before aging). Preferably, the mean particle size (d.sub.50) of Cu-zeolite (such as Cu-CHA) is about 2-5 μm in the catalyst coating.

[0061] An important element of the catalyst composition of the present invention is the nanocrystalline Al compound (Al-compound). It is known that SAR has been a variable in zeolite compositions. It has been seen that free Al can exist in zeolites so that not all Al is in the framework (so called non-framework Al). Usually in the known technology it has been a target to minimize non-framework

[0062] Al in zeolite to prevent possible negative effects like dealumination. However, when Al is applied as nanocrystalljne Al-compound to the zeolite-based catalyst of the present invention, it is created in purpose a lot of Al.sub.2O.sub.3 crystals/particles which have very close contact to zeolite structure, preventing dealumination and stabilizing the Al in zeolite framework. The use of an Al-compound with very small crystal size (as Al.sub.2O.sub.3) in the catalyst composition of the present invention has shown to improve the activity, stability, adhesion and cohesion of the catalyst. For these reasons different Al.sub.2O.sub.3 precursors can be used in the washcoat. The Al.sub.2O.sub.3 source can be a dispersion of Al.sub.2O.sub.3 itself, a sol of boehmite or other precursor or even a partly solved aluminium salt as Al(NO.sub.3).sub.3, matching to the ranges of defined crystal size and dispersed particle size of Al compound. Combinations of the mentioned sources are also possible.

[0063] Three different types Al compound candidates were examined in the examples. Al-1, Al-2 (REF 1) and Al-3 were studied as Al compounds in the experiments. Al-1 has a dispersed particle size in water media 20 nm, crystalline size 4.5 nm and initial BET surface area of 260 m.sup.2/g as calcined at 550° C./3 h. Al-2 has these parameters of 90 nm, 9 nm and 200 m.sup.2/g. Al-3 has the parameters of 60 nm, 6 nm and 230 m.sup.2/g. These small crystalline and particle size of Al compound were seen to promote the activity. The small dispersed particle size is also a key variable to keep the Al-compound amount as low together with improved adhesion and cohesion on substrate walls. Higher relative weight amount is needed to reach the same coating layer strength with larger Al-compound or Al binder particles. In addition, a small amount of nitrate can be present in aqua coating media (slurry) or on the Al-compound precursor, which is important for the formation of small Al.sub.2O.sub.3 crystal in chemical and mechanical dispersing process. These surface nitrates are decomposed in final heat treatments leaving ready nanoscale Al.sub.2O.sub.3 particles in the catalyst structure. The ready Al.sub.2O.sub.3 surface has still acidity on oxide and hydroxyl groups after calcination in dry conditions.

[0064] The particle size of Al-compound (Al.sub.2O.sub.3) as dispersed in water is in the range of 5-80 nm, typically in the range of 10-65 nm, such as in the range of 10-30 nm, and crystalline size is in the range of 1-8 nm, typically in the range of 3-7 nm, such as in the range of 3-5 nm. BET surface area is above 200 m.sup.2/g as calcined at 550° C./3 h.

[0065] A nanocrystalline aluminium compound is forming in water a dispersed particle size of 5-80 nm, preferably of 10-65 nm and crystalline size of 1-8 nm, preferably of 3-7 nm for stabilizing the zeolite by reducing the dealumination rate from the zeolite. The small dispersed particle size and crystalline size are the variables to control, which location in zeolite pores the Al compound has an access. The target is to have an access deeper inside zeolite pores than with conventional Al binders but not to disturb Cu in zeolitic sites. Negative effects can be caused, when small soluble ions can be ion exchanged with copper ion which is e.g. added into zeolite before catalyst preparation. The precursors will settle down after drying and calcinations in final dry phase locations, where they have been settled down during the preparation in water media. Therefore, the precursor dimensions in water or other liquid media have a key role where the added promoters are located in final catalyst composition. In addition to water, the wet preparation steps can contain organic additives forming a mixture with water and modifying e.g. surface tension, viscosity and other surface or liquid/sol/slurry properties. Al compound is used as dispersed nanocrystal form with the above particle sizes but not as soluble form, when the ionic radius of Al.sup.3+ is even smaller than that of Cu.sup.2+. Nanocrystalline Al compound has an access in zeolite pores but not as directly as Cu ion on Al sites on zeolite. Because the ionic radius (0.50 Å) of Al.sup.3+ is smaller than that (0.69 Å) of Cu.sup.2+, it is not added as a soluble ionic form but as nanocrystalline particle form in water media. Oppositely,

[0066] Zr compound is added as ionic form, when the ionic radius of Zr.sup.4+ is much larger (0.80 Å) than that of Cu.sup.2+, resulting to intimate promotion in zeolite but not competing with copper in water media.

[0067] Due to the role of nanocrystalline Al-compound, the standard SAR of zeolite is not the only meaningful variable in these zeolite-based Cu-SCR catalysts. Very small aluminium oxide particles have an effect on the stability and dealumination of aluminum-silicate based zeolite catalysts. The nanocrystalline Al.sub.2O.sub.3 present in a close contact to zeolite particles, pores and cages may change the equilibrium of Al compounds (Al in zeolite and Al as Al-compound), which prevent Al diffusion out from zeolite structure (dealumination). Even if a small amount of Cu is present as non-capsulated form (free-Cu) after heavy hydrothermal ageing, Al-compound is a potential stable scavenger for these free Cu/CuO compounds, which oxidation state (Cu, Cu.sup.+, Cu.sup.2+) can be varied by conditions. At high temperatures, Cu on nano-size Al.sub.2O.sub.3 is more stable than Cu on Si-rich silicate (zeolite) surface. In addition, Cu/Al.sub.2O.sub.3 is also quite good SCR catalyst and thus the total SCR functionality of Cu-CHA catalyst is not change too much, if Cu/Al.sub.2O.sub.3 exists and the total free-Cu amount stays low.

[0068] Therefore, the Total SAR (TSAR) was defined, which is calculated as a molar ratio between zeolite Si and Al.sub.2 in zeolite+Al.sub.2 in Al-compound. The possible larger Al.sub.2O.sub.3 particles in binder or LP are excluded in this calculated value, because they have not the same positive interaction and contact with Cu-zeolite and other compounds in composition. TSAR values varied in the range of 5-10 in the studies samples (Table 1). Preferably, TSAR is in the range of 4-8, and even more strictly defined in the range of 5-7. As a combination of these two SAR values, SAR is defined to be as a maximum value of 14.9 and TSAR as a maximum value of 8, which values are reached by the zeolite SAR value and Al-compound amount in the SCR catalyst.

[0069] Based on defined molar SAR and TSAR values and ranges, the Al compound amount as wt-% of Al.sub.2O.sub.3 is known. The main Cu-CHA in examples has SAR of 11 and then the TSAR definition of 4-10 results in 1-18 wt-% of Al compound as Al.sub.2O.sub.3 by the weight of zeolite and Al compound and in 0.9-16.2 wt-% of Al compound as Al.sub.2O.sub.3 by the weight of zeolite, Al compound and maximum Zr compound (10% ZrO.sub.2). Similarly, the Al compound amount is known, when additive, LPs, Si and Ti are added in the composition, diluting the content of copper zeolite, Al compound and Zr compound. According to TSAR of 5-8, Al compound amount as Al.sub.2O.sub.3 is about 4-13 wt-%. According to maximum, defined SAR value of 14.9, Al compound amount is 4.6-21 wt-% as Al.sub.2O.sub.3 by the weight of Cu-zeolite and Al compound and 4.1-18.9 wt-% when including the maximum amount of Zr compound as ZrO.sub.2. Therefore, Zr compound is diluting only slightly the Al compound amount even with the maximum concentrations. As a summary, the Al compound amount by the defined SAR and TSAR results in ranges of 1-21 wt-% as Al.sub.2O.sub.3 by the weight of copper zeolite and Al compound. The dilution by the other added compound can be calculated directly by their contents. In examples, Al compound amount was given in the range of 7.8-10 wt-% as Al.sub.2O.sub.3. In embodiments the amount of the nanocrystalline aluminium compound, such as Al.sub.2O.sub.3 , in the catalyst composition is from 0.5 to 25 wt %, such as from 1-20 wt %, such as 5-15 wt-%, typically 7.8-10 wt-% based on total weight of the catalyst composition. Typically, the aluminium compound is Al.sub.2O.sub.3, such as gamma-Al.sub.2O.sub.3 or theta- Al.sub.2O.sub.3.

[0070] The binder has not completely an inert role for the catalyst activity and durability and the SCR activity is not solely depending on defined zeolite properties. Pure zeolite cannot be tightly bound on substrate walls and some types of binders or additives can decrease the catalytic activity of Cu-zeolite. Therefore, it is important to apply Al-compounds to replace conventional binders.

[0071] A description of zirconium and the additive for enhanced thermal durability: Further the addition of Zr and/or additive (La, Y, Hf, Nb) oxides or dispersed compounds improved the thermal stability. These compounds are added as water soluble or insoluble precursors. The amount of Zr and additive can be varied in the range of 0.1-30 wt-% as stable oxides (e.g. ZrO.sub.2, La.sub.2O.sub.3) of ready calcined coating, preferably in the range of 1-10 wt-%. The Zr together with the additive, such as

[0072] La is also applied to create combinatory promotion effects. For instance, Zr and La are spread evenly on the zeolite surface, zeolite pores, on Al-compound surface or on additional binder materials.

[0073] The ionic size of elements has a crucial role for interactions. The channel size of zeolite pores is size- and shape-limited and small differences in ionic diameter or radius are meaningful, where the metal ions have an access. The pore opening and ionic sizes of planned elements looked to be near in the same range. CHA has 3.8 Å of openings in pore structure. The ionic radius of Cu.sup.2+ is 0.69 Å (Sargent-Welch Scientific Company: Table of periodic properties of the elements, 1968). Therefore, the access of Cu cations to Al sites is partly structure limited in tortuous zeolite channels. La.sup.3+ has ionic radius 1.15 Å, Zr.sup.4+ 0.80 Å, Y.sup.3+ 0.93 Å and Hf .sup.4+ 0.81 Å. Therefore, the defined additive has the larger ionic radius than Cu.sup.2+ ion exchanged in zeolite cages. This is a defined property of the additive according to the invention. Other base metals like Ti.sup.4+ (0.68 Å), Si.sup.4+ (0.41 Å), V, Cr, Mn, Fe. Cr, Co, Ni have as their stable states a smaller ion radius than Cu.sup.2+ and they were not applied as additives, because they could due to the small size cause also negative effects by competing with Cu about zeolitic sites. Al.sup.3+ has ionic radius of 0.50 Å, which is smaller than with Cu.sup.2+. Therefore, the additive has a larger ionic radius than both Cu.sup.2+ and Al.sup.3+ in Al-compound. A larger radius slows down or prevents the access of these ions to the same zeolitic sites where Cu (or Al) are located. It is a target to promote and stabilize the zeolite catalyst but not disturb the state and functionality of Cu sites inside zeolite structured catalyst.

[0074] Description of the large particles (LP): The separate LP particles with promoters act as thermal barriers, which prevent the propagation of thermal sintering from a zeolite particle to another zeolite particle. These large particles have a high local heat capacity and can act as a thermal heat sink representing a thermal barrier to protect the zeolite particles active in SCR. Mechanically strong LP particles improve the coating layer strength and improve the pore diffusion through a thick catalyst layer, because large particles leave more open passages between particles than a structure composing only small particles.

[0075] Preferably, the chemical composition of LP is aluminum oxide with additional promoters like Si or Ti as stable oxides or mixed oxides. The mean particle size (d.sub.50) of LP, thermal barrier, particles is defined to be about 3-200 μm, preferably in the range of 5-40 μm to fit them in common coating layers. Therefore, their mean particle size is larger than zeolite and significantly larger than Al-compound or additives. The particle size (d.sub.50) of LP is larger than for the zeolite (e.g. about 2-5 μm for zeolite and about 5-40 μm for LP). Thus, the LP particles will mechanically strengthen the coating layer. The amount of LP can be varied in the range of 0.5-50 wt-% of total coating amount, preferably in the range of 2-25 wt-%. As the coating amounts are given in g/L this means: an amount of LP of 40 g/L in the total coating amount of 180 g/L equate 22.2 wt-%, 20 g/L in 180 g/L equate 11.1 wt-%, 10 g/L in 140 g/L equate 7.1 wt-%. The studied examples had quite high amount of LP to see better variable effects, but the defined amount can be better applied in the lower range, focusing on thermal and cohesion stabilization with a smaller decrease in the total Cu-zeolite amount. The mean pore sizes (d.sub.50 or d.sub.90) are larger for LP than for Cu-zeolite particles.

[0076] Then BET surface area of LP is about 100-300 m.sup.2/g, when BET surface area of Cu-zeolite is over 450 m.sup.2/g as fresh state (calcined at 550° C./3 h). It is a risk that pure Cu-zeolite with SAR <15 will lose BET surface area down to below 100 m.sup.2/g at 900-1000° C. in air. LP is able to keep a high BET surface area: >200 m.sup.2/g after air ageing at 900° C. and >150 m.sup.2/g after air ageing at 1000° C. for 3 hours. Therefore, these stable, separate LP particles on catalyst composition have a stabilizing effect on zeolite particles. These particles can be added in ready aqua (slurry) media, which is further milled, or they are added after milling keeping the original particle size and a larger difference by the d.sub.50 particle size between zeolite and LP particles in final coating. A dilution of the catalyst composition with thermal barrier particles decreases and dilutes the thermal stress on zeolite particles in the coating layer. It is also possible to add LP only on bottom or top catalyst layers in double-layer coatings, to improve the mechanical strength or gas pore diffusion in coating layers.

[0077] LP can be further stabilized with different Si, Ti, Zr and/or additive oxides as SiO.sub.2, TiO.sub.2, La.sub.2O.sub.3 or ZrO.sub.2. Si, Ti and Zr oxides increase the acidity of LP and prevent the catalyst from sulfation effects on alumina-based structures. The metal oxides are usually added during the Al.sub.2O.sub.3 preparation process itself but can also added later in the process. For this invention both procedures can be used. The added metal oxides can form a mixed oxide or mixture of oxides with Al.sub.2O.sub.3, resulting in very stable LP structure, tailored pore size distribution and a good stability of e.g. Si and/or Ti oxides in the structure. The metal oxides play also a role stabilizing the wide pore size structure of LP, which has a positive effect on pore diffusion and thermal stability.

[0078] Zirconium compound is added as a water-soluble form to improve hydrothermal durability of the catalyst composition. The target is to have an access deeper inside zeolite pores but not to disturb Cu in zeolitic sites. The Zr compound will settle down after drying and calcinations in final dry phase locations, where it has been accessed during the preparation in water media. Zr compound is added as ionic form, when the ionic radius of Zr.sup.4+ is much larger (0.80 Å) than that of Cu.sup.2+, resulting to intimate promotion in zeolite but not competing with copper in water media. Therefore, the fact that the Zr compound precursor is as a soluble form in water media and form dispersed zirconium oxide in heat treatments has a key role that Zr compound is improving the hydrothermal durability of catalyst composition.

[0079] Zr and additives can be added during the catalyst preparation as nitrates, acetates or other water-soluble compounds optionally with acid assistances (nitric or organic acids). The zirconium compound is prepared from the precursors like zirconium oxides, zirconium sulphates, zirconium nitrates, zirconium acetates and zirconium hydroxides, such as ZrO.sub.2, Zr(OH).sub.4, Zr(OH).sub.2.CO.sub.3.ZrO.sub.2, Zr(SO.sub.4).sub.2, zirconia basic carbonate Zr(OH).sub.2.CO.sub.3.ZrO.sub.2, Zirconium acetate Zr(acetate).sub.2 or Zirconium nitrate Zr(NO.sub.3)4.

[0080] Zr, Ti and Si are inert in presence of SO.sub.x, which keeps the sulfation tendency low. Additives La and Y have a higher tendency to form stable sulphates, but they are so stable that are not decomposing or moving in normal exhaust conditions.

[0081] The invented catalyst composition can be coated on ceramic (e.g. cordierite, Al titanate or mullite) or oxidation resistant metallic substrates forming flow-through structure. The same composition can be applied also into particulate filter structures (SiC, cordierite, metallic) with a modified viscosity and solid content in slurry conditions.

[0082] The SCR catalyst composition by the invention can be applied as a SCR unit in ATSs composing DOC, DPF, hydrolysis, SCR and ASC units. The SCR unit can locate before or after DOC+DPF units. This catalyst composition can be integrated also to ASC composition, which is formed by noble metal (e.g. Pt) containing catalyst together with the SCR catalyst by the invention. In the ASC, Pt and SCR catalysts are located in the same zone axially in exhaust gas flow direction to reach a high ASC functionality and selectivity. The catalyst composition by the invention can be also present in the hydrolysis unit, e.g. mixer structures before the SCR unit.

[0083] All references, including publications, patent applications and patents, cited herein are hereby incorporated by reference to the same extent as if each reference was individually and specifically indicated to be incorporated by reference and was set forth in its entirety herein.

[0084] All headings and sub-headings are used herein for convenience only and should not be construed as limiting the invention in any way.

[0085] Any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.

[0086] Recitation of ranges of values herein are merely intended to serve as a short method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. Unless otherwise stated, all exact values provided herein are representative of corresponding approximate values (e.g., all exact exemplary values provided with respect to a particular factor or measurement can be considered to also provide a corresponding approximate measurement, modified by “about”, where appropriate).

[0087] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context.

[0088] The terms “a” and “an” and “the” and similar referents as used in the context of de-scribing the invention are to be construed to insert both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Thus, “a” and “an” and “the” may mean at least one, or one or more.

[0089] The term “and/or” as used herein is intended to mean both alternatives as well as each of the alternatives individually. For instance, expression “xxx and/or yyy” means “the xxx and yyy; the xxx; or the yyy”, all three alternatives are subject to individual embodiments.

[0090] The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise indicated. No language in the specification should be construed as indicating any element is essential to the practice of the invention unless as much is explicitly stated.

[0091] The citation and incorporation of patent documents herein is done for convenience only and does not reflect any view of the validity, patentability and/or enforceability of such patent documents.

[0092] The description herein of any aspect or embodiment of the invention using terms such as “comprising”, “having”, “including” or “containing” with reference to an element or elements is intended to provide support for a similar aspect or embodiment of the invention that “consists of”, “consists essentially of”, or “substantially comprises” that particular element or elements, unless otherwise stated or clearly contradicted by context (e.g., a composition described herein as comprising a particular element should be understood as also describing a composition consisting of that element, unless otherwise stated or clearly contradicted by context).

[0093] This invention includes all modifications and equivalents of the subject matter re-cited in the aspects or claims presented herein to the maximum extent permitted by applicable law.

[0094] The features disclosed in the foregoing description may, both separately and in any combination thereof, be material for realizing the invention in diverse forms thereof.

EXPERIMENTAL

[0095] General preparation description:

[0096] Cu-SCR catalysts were coated by applying a slurry on cordierite substrates with different geometries. The slurry consists of the different materials stated in this invention. A person skilled in the art in this field is able to choose the necessary size, porosity, cell density and other relevant substrate properties by general catalyst design principles. Except for comparison studies copper exchanged synthetic zeolite has been used. The zeolite has a CHA framework, which is defined by its molar Si/Al.sub.2 ratio

[0097] (SAR). Copper has been added to the CHA (SSZ-13 known as synthetic CHA) framework by wet ion exchange methods. The Cu concentrations is about 3-5 wt-% in examples. The molar Cu/Al ratio was in the range of 0.2 to 0.3 in the examples by the invention. The SAR around 11 and CuO concentration of 4.1 wt-% resulted in a low molar Cu/Al (by zeolite Al) ratio of about 0.22, which gives a chance to have a good copper distribution on Al sites inside zeolite (CHA) structure.

[0098] The slurry composition itself and the corresponding preparation vary according to the examined materials. Examples 1 to 11 describe the corresponding catalyst compositions and details in preparation process. The substrates are coated on cordierite flow-through substrates by methods well known in the art of catalyst preparation. Coating was conducted in the presence of a blower and sucking unit to remove excess of water and other volatile compounds. The SCR catalysts in the invention were dried and calcined by standard methods in static air. A ramp increase in temperature is applied for catalyst calcination, to form slowly the final zeolite-metal oxide coating layer with a good adhesion, cohesion and to avoid cracking. Calcination is made in the presence of air or oxygen containing gases at higher temperatures (400-700° C.) to reach the final stable states on the catalyst coating and to decompose the precursors. A calcination temperature around 550-650° C. in air is preferred to form stable zeolite, metal oxide and Cu oxide states. That high temperature guarantees also the stable activity in use conditions.

[0099] In the examples, first Al-compound precursor was added under heavy stirring to deionized water. In this phase the Al.sub.2O.sub.3 source is dispersed forming tiny nanoparticles with small crystalline sizes and dispersed particles, in which process nitrates are enhancing the changes. In the second step, the Cu-containing Cu-CHA was mixed slowly to the mixture and mixing was continued for 2 to 4 hours. Zr and additive (La in examples) were added in the next step. The solid content in the resulting slurry was in the range of 25-39%. Slurry was further milled with a batch ball and a continuous mill for 0.5-4 hours to reach target mean particles sizes (distribution), which are mainly originating from zeolite particles. The LP material is mixed into the slurry after milling but it is also possible to add LP during milling to decrease original particle size of LP particles and improve contacts between particles. The coating was added evenly by dip or dose coating in controlled ways by 1-3 coating rounds to reach the target coating amount. The wet coated substrate was dried in blowing air at 60° C. and calcined before the possible next coating round. The coating amount was calculated by wet slurry basis (solid content known) and finally by the weight of calcined dry coating. The final calcination of samples was conducted at 600° C. in air for 4 hours. The coating uniformity was confirmed by cutting the substrate to two pieces, which quality was checked.

[0100] Activity test conditions: The catalytic activity was investigated by synthetic gas bench (SGB) experiments. The samples were drilled out from a larger substrate (2.5 dm.sup.3 in examples) to a small activity test dimensions (diameter 14 mm, length 40 mm), matching inside the quartz tube reactor. The SCR feed gas composition in the SGB experiments were for NO only: 1000 ppm NH.sub.3, 1000 ppm NO, 8% H.sub.2O, 10% O.sub.2, 82.8% N.sub.2. The gas composition for fast SCR measurement is containing promoting NO.sub.2 (simulates the effect of DOC in SCR systems): 1000 ppm NH.sub.3, 600 ppm NO, 400 ppm NO.sub.2, 8% H.sub.2O, 10% O.sub.2, 82,8% N.sub.2. The space velocity (SV) was about 50.000 or 71.000 h.sup.−1 in the experiments.

[0101] The hydrothermal (HT) ageing was conducted in the presence of air and 10% water at 800 and 850° C. with the SV of 4000 h.sup.−1 over a sample. The high ageing temperature has a target to evaluate the thermal durability of the Cu-CHA catalysts in the presence of water.

[0102] The invention is explained in detail by following examples, figures and schemes. The main catalyst parameters by the invention are shown in FIG. 1.

[0103] The catalyst in the invention consists of substrate (100), which forms open flow channels (110) for exhaust gas and on which substrate walls the catalyst coating was located. The coating is formed by the mixture of Cu-zeolite (200, e.g. Cu-CHA), Al compound (300), ZrO.sub.2 (400), additive (Add, 600) and large particles (LP, 500) and Ti and/or Si (700).

[0104] The catalyst compositions are summarized in Table 1.

TABLE-US-00001 TABLE 1 Catalyst specifications. LP = Large particle component. SAR = Si/Al.sub.2 mol/mol. Total SAR (TSAR, mol/mol) includes Al-compound but excluded Al in LP. Coated on 400 cpsi (cells per in.sup.2) cordierite substrate with 4 mils (101.6 μm) wall thickness. Total SAR TSAR ZrO.sub.2 Add/La.sub.2O.sub.3 CuO CuO LP coating Example Code Si/Al.sub.2 Si/Al.sub.2 wt-% wt-% g/L wt-% g/L Ti, Si g/L  1a Cu- 11 5.9 0 0 7 3.9 0 no 180 CHA-11 + Al-1  1b Cu- 11 5.9 0 0 5 3.9 0 no 140 CHA-11 + Al-1 2 Cu- 11 5.9 0 0 7 3.9 0 no 180 CHA-11 + Al-2 3 Cu-CHA- ~28 na 0 0 ~5 ~3.0 0 no ~180 High SAR REF 4 Cu- 23 8.6 0 0 6 3.3 0 no 180 CHA-23 + Al-1 REF 5 Cu- 11 5.9 6 0 5 3.9 0 no 140 CHA-11 + Al-1 + 6Zr 6 Cu- 11 5.9 0 3 5 3.9 0 no 140 CHA-11 + Al-1 + 3La 7 Cu- 11 5.9 3 3 5 3.9 0 no 140 CHA-11 + Al-1 + 3Zr—3La  8a Cu- 11 5.9* 0 0.6 3% 5 3.0 40 no 180 CHA-11 + in LP Al-1 + LP-AlLa  8b Cu- 11 5.9* 0 0 5 3.0 40 20% SiO.sub.2 180 CHA-11 + in LP Al-1 + LP-AlSi  8c Cu- 11 5.9* 3.3 15% 0 5 3.0 40 20% SiO.sub.2 180 CHA-11 + in LP in LP Al-1 + LP-AlSiZr 9 Cu- 11 5.9* 6 0.6 3% 5 3.0 40 no 180 CHA-11 + in LP Al-3 + 6Zr + LP-AlLa 10  Cu- 11 5.9* 6 0 5 3.0 40 20% SiO.sub.2 + 180 CHA-11 + 20% TiO.sub.2 Al-3 + in LP 6Zr + LP-AlSiTi 11  Cu- 11 5.9* 3 3 5 3.0 40 20% SiO.sub.2 + 180 CHA-11 + 20% TiO.sub.2 Al-3 + in LP 3Zr + 3La + LP-AlSiTi *excluding large particles, SAR and TSAR based on the molar ratio of Si/Al.sub.2. Numbers in codes note compound concentration as oxide. g/L: grams per catalyst volume. wt-% in catalyst composition/coating, Al-compound measured as Al.sub.2O.sub.3 amount about 10% of zeolite + Al-compound in prepared compositions. CHA-11/23: CHA with SAR = 11 or 23 (3.4 wt-% CuO). Add is the abbreviation for Additive.

[0105] The atomic ratio Cu/Al was about 0.22 in zeolite (4.1 wt-% CuO) on the sample with CHA and SAR=11 (#1a, #1b, #5-11). The Cu/Al molar ratio of reference Cu-CHA catalyst #3 was estimated to be about 0.7 by XRF analysis. The Cu/Al molar ratio of reference Cu-CHA catalyst #4 was estimated to be about 0.33 by composition.

EXAMPLE #1: PREPARATION OF A Cu-ZEOLITE CATALYST WITH Al-1

[0106] Copper-exchanged chabazite (Cu-CHA, 4.1 wt-% copper in zeolite, resulting about in 7 g/L of catalyst volume, #1a) with a SAR of 11 (zeolite) and TSAR=5.9 (whole catalyst) was dispersed together with nitrate modified Al-compound Al-1 into deionized water. The Al-1 had a crystallite size of 4.5 nm and a dispersed particle size of 20 nm (d.sub.50). The amount of Al-compound was 10 wt-% as Al.sub.2O.sub.3 in final coating amount (180 g/L) as calcined. Another sample (#1b) with the same composition but a lower coating amount of 140 g/L was also prepared as a comparison to experiments with additional compounds.

EXAMPLE #2: PREPARATION OF A Cu-ZEOLITE CATALYST WITH Al-2

[0107] The same Cu-zeolite (CHA with SAR=11) as in the example 1 was coated also with another Al compound candidate having a crystal size of 9 nm dispersed particle size of 90 nm and this was a reference Al-2 (REF 1) with a larger Al.sub.2O.sub.3 crystal and dispersed particles sizes in water solution or slurry. The amount of Al-compound was 10 wt-% as Al.sub.2O.sub.3 in final coating amount as calcined.

EXAMPLE #3: STATE-OF-ART Cu-CHA CATALYST AS REFERENCE

[0108] A commercial reference Cu-CHA with SAR about 28 was examined as a reference (REF 2) representing the state-of-art Cu-CHA technology. The cell density was 400 cpsi with 4 mils and the coating amount about the same as in #1a.

EXAMPLE #4: PREPARATION OF A Cu-ZEOLITE CATALYST WITH SAR=23 AS REFERENCE

[0109] A Cu-CHA zeolite with a SAR of 23 was used as reference (REF 3) to the samples with Cu-CHA with SAR=11. That Cu-zeolite was coated with Al-compound Al-1. The amount of Al-1 was 10 wt-% as Al.sub.2O.sub.3 in final coating amount after calcination.

EXAMPLE #5: THE USE OF ZIRCONIUM AS THERMAL STABILIZER FOR Cu-CHA CATALYST

[0110] 6% ZrO.sub.2 (#5) (after final calcination) was added as Zr nitrate into Cu-CHA-11 concept with Al-1 as Al-compound. The coating amount was after calcination 140 g/L.

EXAMPLE #6: THE USE OF LANTHANUM AS THERMAL STABILIZER FOR Cu-CHA CATALYST

[0111] 3% La.sub.2O.sub.3 (#6) (after final calcination) was added as water soluble La nitrate into Cu-CHA-11 concept with Al-1 as Al-compound. The coating amount was after calcination 140 g/L.

EXAMPLE #7: THE COMBINATION OF ZIRCONIUM AND LANTHANUM AS THERMAL STABILIZERS FOR Cu-CHA

[0112] 3% La.sub.2O.sub.3 and 3% ZrO.sub.2 (#7) (after final calcination) were added as the water soluble Zr and La nitrates into Cu-CHA concept with Al-1 as Al-compound. The coating amount was after calcination 140 g/L.

EXAMPLE #8a: THE USE OF LP-AlLa IN Cu-CHA CATALYST

[0113] The same Cu-CHA zeolite as in the example 1 was prepared also together with Al-1 and 40 g/L LP, which composed alumina and lanthanum (additive on LP). Lanthanum stabilized Al.sub.2O.sub.3 as LP was added to the pre-milled slurry containing already Cu-zeolite and Al-1. The particle size (d.sub.50) of this LP (noted as LP-AlLa) was 30 μm. The calcined catalyst material contained 70.0% Cu-CHA, 7.8% Al-1 as Al.sub.2O.sub.3 and 22.2% LP-Al-La as oxide form. The total coating amount was after calcination 180 g/L.

EXAMPLE #8b: THE USE OF LP-AlSi PARTICLES IN Cu-CHA CATALYST

[0114] The same Cu-zeolite as in the example 1 was prepared also together with Al-1 and 40 g/L LP, Silica stabilized Al.sub.2O.sub.3 as LP was added to the pre-milled slurry containing already Cu-zeolite and Al-1. The particle size (d50) of this LP (noted as LP-AlSi) was 35 μm. The calcined catalyst material contained 70.0% Cu-CHA, 7.8% Al-1 as Al.sub.2O.sub.3 and 22.2% LP-AlSi as oxide form. The total coating amount was after calcination 180 g/L.

EXAMPLE #8c: THE USE OF LP-AlSiZr PARTICLES IN Cu-CHA CATALYST

[0115] The same Cu-zeolite as in the example 1 was prepared also together with Al-1 and 40 g/L LP, which composed alumina, silica and zirconia. Silica and zirconia stabilized Al.sub.2O.sub.3 as LP was added into the pre-milled slurry containing already Cu-zeolite and Al-1. The particle size (d.sub.50) of this LP (noted as LP-AlSiZr) was 35 μm. Thus, the original large particle size of LP was present in the final coating of #8a-c. The calcined catalyst material contained 70.0% Cu-CHA, 7.8% Al-1 as Al.sub.2O.sub.3 and 22.2% LP-AlSiZr as oxide form. The total coating amount was after calcination 180 g/L.

EXAMPLE #9: THE USE OF Al-3, Zr AND LP-AlLa IN Cu-CHA CATALYST

[0116] The same Cu-zeolite as in the example 1 was prepared together with Al-compound of Al-3, 6% ZrO.sub.2 and 40 g/L LP, which composed of alumina and lanthanum (LP-AlLa, additive included LP). La stabilized Al.sub.2O.sub.3 as LP was added to the slurry containing already Cu-zeolite, Al-3 and 6% ZrO.sub.2 calculated as calcined coating. Nitric acid treated, nanocrystalline Al-3 was an alternative Al-compound to Al-1 and it was applied in these combinatory compound studies with good coating process properties. Water soluble Zr(NO.sub.3).sub.4 is the ZrO.sub.2 source in this slurry. The particle size (d.sub.50) of this LP (LP-AlLa) was 30 μm. The calcined catalyst material contained 67.9% Cu-CHA, 7.6% Al-3 as Al.sub.2O.sub.3, 3.0% ZrO.sub.2 and 21.5% LP-AlLa as oxide form. The total coating amount as coated on ceramic substrate was after calcination 180 g/L.

EXAMPLE #10: ADDITION OF Al-3, Zr AND LP-AlSiTi IN Cu-CHA CATALYST

[0117] The same Cu-zeolite as in the example 1 was prepared with Al-3 together with 6% ZrO.sub.2, 40 g/L LP (22.2 wt-% in final coating), which composed alumina, silica and titanium as stable oxides (LP-AlSiTi). Si-Ti stabilized Al.sub.2O.sub.3 as LP was added to the slurry containing already Cu-zeolite, Al-3 and 6% ZrO.sub.2 as calculated as calcined coating. Nitric acid treated, nanocrystalline Al-3 was an alternative Al-compound to Al-1 and it was applied in these combinatory compound studies. The particle size (d.sub.50) of this LP (LP-AlSiTi) was 30 μm. The calcined catalyst material contained 67.9% Cu-CHA, 7.6% Al-3 as Al.sub.2O.sub.3, 3.0% ZrO.sub.2 and 21.5% LP-AlSiTi as oxide form. The total coating amount as coated on ceramic substrate was after calcination 180 g/L.

EXAMPLE #11: ADDITION OF Al-3, Zr, La and LP-AlSiTi IN Cu-CHA CATALYST

[0118] In this example Cu-CHA with SAR=11 was prepared with Al-3 (Al-compound), 3% ZrO.sub.2, 3% La.sub.2O.sub.3 and LP-AlSiTi, which composed alumina, silica and titanium as stable oxides. Nitric acid treated, nanocrystalline Al-3 applied in these combinatory compound studies. The particle size (d.sub.50) of this LP (LP-AlSiTi) was 30 μm. The weight percent of the calcined material is 65.8% Cu-CHA, 7.3% Al-3 as Al.sub.2O.sub.3, 3.0% ZrO.sub.2, 3.0% La.sub.2O.sub.3 and 20.9% LP-AlSiTi as oxide form. The total coating amount as coated on ceramic substrate was after calcination 180 g/L.

[0119] The functionality of the Al-compound and the effect of the different additives as used in the examples 1-11 are explained in the following by the test results of the NO.sub.x conversion which are shown in FIGS. 2-6.

[0120] FIG. 2: Influence of Al-compound with a small crystalline size and a comparison with a reference state-of-art Cu-CHA catalyst in NO-NO.sub.2 feed gas (40% NO.sub.2, SV 71.000 h.sup.−1) in SGB experiments as HT800/20h aged.

[0121] NO.sub.x conversion in fast SCR was clearly higher with the Cu-CHA sample (example 1a) having SAR of 11, TSAR of 5.9 and Al-1 as Al-compound in comparison to the Cu-CHA with Al-2 (example 2, REF 1) with larger Al.sub.2O.sub.3 crystalline sizes. The state-of-art Cu-CHA (example 3, REF 2) showed a good low and medium temperature activity but also a sharp drop as HT800 aged at high temperatures above 400° C. This is related to excessive high ammonia oxidation, which results in a low conversion of 52% at 570° C. in NO+NO.sub.2 feed gas. The Cu/Al ratio was estimated to be about 0.7 on this high-SAR Cu-CHA, which is probably a reason to free Cu oxides on zeolite and for excessive high ammonia oxidation at high temperature This is a typical property of high-SAR Cu-CHA zeolites in SCR. The use of lower Cu/Al on Cu-CHA with high SAR will decrease the total CuO loading, which is harmful for important low and medium temperature SCR activity. Therefore, a stabilized Cu-CHA with low SAR according to the invention is a solution to keep good SCR functionality at low and high temperatures. The Cu-CHA with SAR=11 was also competitive to Cu-CHA (example 4, REF 3) with SAR=23 prepared with Al-1 additive. The Cu-CHA SCR (SAR=23, example 4) had however a higher SCR activity than the one of example 2 with larger Al.sub.2O.sub.3 crystals. Therefore, it was possible to prepare thermally stable Cu-CHA catalyst with a low SAR like 11 and be competitive to Cu-CHA with higher SAR (>20) by the promotion of nanocrystalline Al-compound.

[0122] FIG. 3: Improved ageing stability of Cu-CHA with Al-1, zirconium and lanthanum as thermal stabilizers in NO only (FIG. 3a) and NO+NO.sub.2 (FIG. 3b) feed gases (50.000 h.sup.−1) in SGB experiments as HT850/20h aged.

[0123] It was further possible to improve the SCR activity on Cu-CHA catalyst with SAR of 11 and Al-1 by adding as dispersed forms 6% ZrO.sub.2 (example 5) or 3% La.sub.2O.sub.3 (example 6). In these thermal stabilizer experiments the ageing temperature was increased up to 850° C. to see the stabilization effects on zeolites. The reactor conditions were slightly changed in comparison to FIG. 2, resulting in SV of 50.000 h.sup.−1 in this and later experiments. In addition, both NO only and NO+NO.sub.2 was applied in feed gases to see the relative NO.sub.2 promotion and dependency in SCR reactions. The improvement due to the added compounds was clear both in NO only and NO+NO.sub.2 feed gases at low and medium temperatures up to 500° C., which temperature range covers the main use and engine mapping conditions in diesel applications.

[0124] Nanocrystalline Al-1 can be also applied with the combinations of 3% ZrO.sub.2 and 3% La.sub.2O.sub.3 (example 7), resulting in improvements at low and high temperature. Therefore, it is possible to enhance the hydrothermal stability of Cu-CHA with low SAR like 11 with Al-1 as Al-compound together with Zr and La as additive.

[0125] FIG. 4: Improved ageing stability of Cu-CHA with Al-1 together with Large Particles (LP) as promoters in NO only (FIG. 4a) and NO+NO.sub.2 (FIG. 4b) feed gases (50.000 h.sup.−1) in SGB experiments as HT850/20h aged.

[0126] The SCR activity of Cu-CHA with low SAR of 11 and Al-1 was further improved by adding LP composing Al.sub.2O.sub.3 as the main oxide but containing also the additives La (in example 8a), Si (in example 8b) or Zr+Si (in example 8c). The addition of LP on Cu-CHA-11 with Al-1 increased NO.sub.x conversions over the whole operation window. LP particles were stabilized preferably with Si or Ti to improve the thermal durability and to increase acidity. Si, Ti or Zr on alumina are also decreasing the sulfur adsorption on LP. The increasing acidity correlates to a lower sulfur adsorption tendency. In addition, Zr and/or additive can be also added on LP particles to improve the stability of LP against sintering. La is a thermal stabilizer but also decreasing acidity and creating basic sites on LP. A role of La is to decrease ammonia adsorption on LP particles in SCR reaction conditions and guide ammonia to adsorb on zeolitic sites near to active copper sites. Then the catalyst composition contains LPs as thermal barriers, which have a minimized ammonia adsorption capacity, which is thus concentrated in zeolite particles with SCR functionality.

[0127] FIG. 5. Improved ageing stability of Cu-CHA with Al-3 as Al-compound, Zr, La as additive and LP with Si+Ti in NO only (FIG. 5a) and NO+NO.sub.2 (FIG. 5b) feed gases (50.000 h.sup.−1) in SGB experiments as HT850/20h aged.

[0128] The combinations of Al-3, Zr, La and LP was applied for the Cu-CHA with SAR=11 catalyst preparation. The stability of LP was promoted with Si+Ti and La (additive). The Cu-CHA amount was the same in all these samples. Therefore, the coating layer was also diluted with LP particles, which have also a preventing effect on sintering propagation in use conditions. The samples with 6% ZrO.sub.2 (example 9 and example 10) showed a high SCR efficiency in NO only and NO+NO.sub.2 feed gases both with LP including La or LP including Si+Ti. The same applies for the sample with 3% ZrO.sub.2 and 3% La.sub.2O.sub.3 with LP including Si+Ti (example 11). The promoters of Zr, La and stabilized LPs in these catalysts improved the low temperature SCR activity. A particular improvement was seen in fast SCR (NO+NO.sub.2), because NO.sub.2 is usually compensating the poor reaction light-off detected in NO only feed. Therefore, LP containing Si and Ti improved the performance of LP in Cu-CHA catalyst. Ti and Si are able to stabilize alumina surface to reduce sulfur oxides' adsorption, which is important in lean exhaust gas applications.

[0129] FIG. 6. The comparison of the Cu-CHA catalyst by the invention to high-SAR Cu-CHA by NO+NO.sub.2 feed gases (50.000 h.sup.−1) in SGB experiments as HT850/20h aged.

[0130] Finally, a developed Cu-zeolite composition containing Al-compound, 3% ZrO.sub.2, 3% La.sub.2O.sub.3 as additive and alumina-based LP with Si+Ti promotion (example 11) was compared to the reference Cu-CHA catalyst (example 3, REF 2) with high SAR of about 28. The invented Cu-CHA composition showed higher NO.sub.x conversion over the whole temperature window and a much higher selectivity at higher temperatures above 400° C. Reference catalyst (REF 2) has a property of excessive high ammonia oxidation, which is harmful for urea consumption and overall NO.sub.x efficiency. A slight drop was also seen after HT850 ageing on example 11 according to this invention but NO.sub.x conversion was still about 90% at 500° C. and about 80% at 600° C. Correspondingly, NO.sub.x conversion was about 80% at 500° C. and about 49% at 600° C. on REF 2 sample (example 3) after HT850 ageing. In the diesel exhaust gas conditions, a high SCR activity at least up to 500° C. is necessary. The low temperature SCR activity was enhanced in the presence of NO.sub.2 by the promotion by Zr, La and LP.

Final Summary and Conclusions

[0131] The SCR activity results with heavily at 800 and 850° C. hydrothermally aged Cu-zeolite catalysts proved the stabilization and promoting effects of claimed catalyst compositions. The use of low-SAR (<15) Cu-zeolite (CHA) enables the use of high Cu loadings with a low molar Cu/Al ratio (<0.4) resulting in a low ammonia oxidation at high temperatures and a high NO.sub.x efficiency with varying NO.sub.2/NO.sub.x ratios over the whole temperature window in lean exhaust gas conditions. Nanocrystalline Al-compound (Al.sub.2O.sub.3) improved the thermal stability with Cu-CHA zeolite with low SAR=11. Two good examples were presented as Al-compound; Al-1 with a crystalline size of 4.5 nm and Al-3 with a crystalline size of 6 nm. Details in coating process play also a role which of the Al-compounds will be used in the combinatory compositions. Zirconium as a stable, dispersed zirconium oxide form showed additional improvements for thermal durability, acidity control and low temperature activity on Cu-zeolite SCR catalyst. Additive (La in examples) showed further stabilization and enhancements at low temperature functionality on Cu-zeolite SCR catalysts. Large particles (LP) with Si and Ti as promoters showed clear improvements in Cu-zeolite catalyst stability. LP have also a key role in the structural and thermal durability of coating layer. The examples showed several variations about the combinations of the promoting compounds. The parameter total SAR (TSAR) was defined which varies for Cu-zeolite SCR catalysts with the amount of nanocrystalline aluminum oxide. The ionic radius of added compounds was also defined by the interaction possibilities. Cu.sup.2+ inside zeolitic cage has a key radius, Al-compound with Al.sup.3+ has a smaller radius, Zr.sup.4+ and additive ions a larger radius and Ti.sup.4+/Si.sup.4+ a smaller radius than Cu.sup.2+.

[0132] In addition, Si and Ti have near to the same radius as Al ions in the main stable ionic states.

[0133] The same promoting effect can be applied also for other zeolite catalysts with low SAR (<20, even lower like <15). AEI, AFX, LEV or Beta microporous zeolite structures can be used instead of CHA as the microporous zeolite carrying at least copper or iron as the active metal.