EP0721368A1 - CATALYSEURS A METAUX NOBLES ABAISSANT LA TENEUR EN NO x? DE GAZ D'ECHAPPEMENT DE MOTEURS A COMBUSTION INTERNE CONTENANT UN EXCEDENT D'OXYGENE - Google Patents
CATALYSEURS A METAUX NOBLES ABAISSANT LA TENEUR EN NO x? DE GAZ D'ECHAPPEMENT DE MOTEURS A COMBUSTION INTERNE CONTENANT UN EXCEDENT D'OXYGENEInfo
- Publication number
- EP0721368A1 EP0721368A1 EP94929929A EP94929929A EP0721368A1 EP 0721368 A1 EP0721368 A1 EP 0721368A1 EP 94929929 A EP94929929 A EP 94929929A EP 94929929 A EP94929929 A EP 94929929A EP 0721368 A1 EP0721368 A1 EP 0721368A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- oxygen
- catalyst
- temperature
- reduction
- catalysts
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 239000003054 catalyst Substances 0.000 title claims abstract description 131
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 title claims abstract description 37
- 239000007789 gas Substances 0.000 title claims abstract description 37
- 239000001301 oxygen Substances 0.000 title claims abstract description 37
- 229910052760 oxygen Inorganic materials 0.000 title claims abstract description 37
- 230000009467 reduction Effects 0.000 title claims abstract description 33
- 238000002485 combustion reaction Methods 0.000 title claims description 9
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 claims abstract description 129
- 239000000203 mixture Substances 0.000 claims abstract description 30
- 229910000510 noble metal Inorganic materials 0.000 claims abstract description 28
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 claims abstract description 16
- 229910002091 carbon monoxide Inorganic materials 0.000 claims abstract description 16
- 229930195733 hydrocarbon Natural products 0.000 claims abstract description 14
- 150000002430 hydrocarbons Chemical class 0.000 claims abstract description 14
- 239000011261 inert gas Substances 0.000 claims abstract description 14
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims description 32
- IJGRMHOSHXDMSA-UHFFFAOYSA-N nitrogen Substances N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 27
- 238000000034 method Methods 0.000 claims description 20
- 230000001965 increasing effect Effects 0.000 claims description 16
- 239000010948 rhodium Substances 0.000 claims description 16
- 230000008569 process Effects 0.000 claims description 15
- 229910052757 nitrogen Inorganic materials 0.000 claims description 14
- 229910052697 platinum Inorganic materials 0.000 claims description 12
- 229910052751 metal Inorganic materials 0.000 claims description 11
- 239000002184 metal Substances 0.000 claims description 11
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 10
- 238000011282 treatment Methods 0.000 claims description 10
- 229910052703 rhodium Inorganic materials 0.000 claims description 9
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 claims description 5
- 229910052878 cordierite Inorganic materials 0.000 claims description 4
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 claims description 4
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 claims description 4
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 claims description 3
- 150000001341 alkaline earth metal compounds Chemical class 0.000 claims description 2
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 claims description 2
- 229910001404 rare earth metal oxide Inorganic materials 0.000 claims description 2
- 230000003647 oxidation Effects 0.000 abstract description 7
- 238000007254 oxidation reaction Methods 0.000 abstract description 7
- 238000006722 reduction reaction Methods 0.000 description 24
- 238000006243 chemical reaction Methods 0.000 description 21
- 239000000463 material Substances 0.000 description 19
- 239000000446 fuel Substances 0.000 description 12
- 230000001590 oxidative effect Effects 0.000 description 11
- 239000002253 acid Substances 0.000 description 9
- 230000000694 effects Effects 0.000 description 9
- 239000007864 aqueous solution Substances 0.000 description 8
- 239000010953 base metal Substances 0.000 description 8
- 239000002131 composite material Substances 0.000 description 7
- SONJTKJMTWTJCT-UHFFFAOYSA-K rhodium(iii) chloride Chemical compound [Cl-].[Cl-].[Cl-].[Rh+3] SONJTKJMTWTJCT-UHFFFAOYSA-K 0.000 description 7
- 239000003638 chemical reducing agent Substances 0.000 description 6
- 150000002736 metal compounds Chemical class 0.000 description 6
- 239000000243 solution Substances 0.000 description 6
- 239000010457 zeolite Substances 0.000 description 6
- 229910021536 Zeolite Inorganic materials 0.000 description 5
- 150000002739 metals Chemical class 0.000 description 5
- 239000002002 slurry Substances 0.000 description 5
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 4
- QQONPFPTGQHPMA-UHFFFAOYSA-N Propene Chemical compound CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 4
- 238000005275 alloying Methods 0.000 description 4
- 230000003197 catalytic effect Effects 0.000 description 4
- 239000010949 copper Substances 0.000 description 4
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 4
- 239000008187 granular material Substances 0.000 description 4
- 229910052739 hydrogen Inorganic materials 0.000 description 4
- 239000001257 hydrogen Substances 0.000 description 4
- -1 oxide Chemical compound 0.000 description 4
- 238000005245 sintering Methods 0.000 description 4
- 229910052802 copper Inorganic materials 0.000 description 3
- 229910052593 corundum Inorganic materials 0.000 description 3
- 238000007598 dipping method Methods 0.000 description 3
- 230000000737 periodic effect Effects 0.000 description 3
- AAIMUHANAAXZIF-UHFFFAOYSA-L platinum(2+);sulfite Chemical compound [Pt+2].[O-]S([O-])=O AAIMUHANAAXZIF-UHFFFAOYSA-L 0.000 description 3
- 229910052594 sapphire Inorganic materials 0.000 description 3
- 229910052719 titanium Inorganic materials 0.000 description 3
- 229910001845 yogo sapphire Inorganic materials 0.000 description 3
- 229910052726 zirconium Inorganic materials 0.000 description 3
- 241000640882 Condea Species 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 2
- 150000001242 acetic acid derivatives Chemical class 0.000 description 2
- 230000032683 aging Effects 0.000 description 2
- IXSUHTFXKKBBJP-UHFFFAOYSA-L azanide;platinum(2+);dinitrite Chemical compound [NH2-].[NH2-].[Pt+2].[O-]N=O.[O-]N=O IXSUHTFXKKBBJP-UHFFFAOYSA-L 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000018109 developmental process Effects 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 238000005470 impregnation Methods 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 150000002823 nitrates Chemical class 0.000 description 2
- 229910017604 nitric acid Inorganic materials 0.000 description 2
- 229910052763 palladium Inorganic materials 0.000 description 2
- KDLHZDBZIXYQEI-UHFFFAOYSA-N palladium Substances [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 229910052761 rare earth metal Inorganic materials 0.000 description 2
- 150000002910 rare earth metals Chemical class 0.000 description 2
- 230000002441 reversible effect Effects 0.000 description 2
- VXNYVYJABGOSBX-UHFFFAOYSA-N rhodium(3+);trinitrate Chemical class [Rh+3].[O-][N+]([O-])=O.[O-][N+]([O-])=O.[O-][N+]([O-])=O VXNYVYJABGOSBX-UHFFFAOYSA-N 0.000 description 2
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 229910052718 tin Inorganic materials 0.000 description 2
- 229910052723 transition metal Inorganic materials 0.000 description 2
- 150000003624 transition metals Chemical class 0.000 description 2
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 1
- 229910052684 Cerium Inorganic materials 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 1
- OLBVUFHMDRJKTK-UHFFFAOYSA-N [N].[O] Chemical compound [N].[O] OLBVUFHMDRJKTK-UHFFFAOYSA-N 0.000 description 1
- CIMPUKITDIGFOL-UHFFFAOYSA-L [Pt+2].S(=O)(OO)OS(=O)[O-].OOS(=O)OS(=O)[O-] Chemical compound [Pt+2].S(=O)(OO)OS(=O)[O-].OOS(=O)OS(=O)[O-] CIMPUKITDIGFOL-UHFFFAOYSA-L 0.000 description 1
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 1
- 150000001342 alkaline earth metals Chemical class 0.000 description 1
- 150000004645 aluminates Chemical class 0.000 description 1
- 229910052788 barium Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 239000012018 catalyst precursor Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 229910001882 dioxygen Inorganic materials 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 230000001815 facial effect Effects 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 229910052735 hafnium Inorganic materials 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 description 1
- 229910052741 iridium Inorganic materials 0.000 description 1
- 229910052745 lead Inorganic materials 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 230000001473 noxious effect Effects 0.000 description 1
- 229910052762 osmium Inorganic materials 0.000 description 1
- QNEIVTNMGMUAEX-UHFFFAOYSA-H oxalate rhodium(3+) Chemical compound [Rh+3].[Rh+3].[O-]C(=O)C([O-])=O.[O-]C(=O)C([O-])=O.[O-]C(=O)C([O-])=O QNEIVTNMGMUAEX-UHFFFAOYSA-H 0.000 description 1
- HNKLPNDFOVJIFG-UHFFFAOYSA-N oxalic acid;platinum Chemical compound [Pt].OC(=O)C(O)=O HNKLPNDFOVJIFG-UHFFFAOYSA-N 0.000 description 1
- 235000021317 phosphate Nutrition 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- PXXKQOPKNFECSZ-UHFFFAOYSA-N platinum rhodium Chemical compound [Rh].[Pt] PXXKQOPKNFECSZ-UHFFFAOYSA-N 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000010970 precious metal Substances 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- SVOOVMQUISJERI-UHFFFAOYSA-K rhodium(3+);triacetate Chemical compound [Rh+3].CC([O-])=O.CC([O-])=O.CC([O-])=O SVOOVMQUISJERI-UHFFFAOYSA-K 0.000 description 1
- PJRGNVSDUQPLCM-UHFFFAOYSA-H rhodium(3+);trisulfite Chemical compound [Rh+3].[Rh+3].[O-]S([O-])=O.[O-]S([O-])=O.[O-]S([O-])=O PJRGNVSDUQPLCM-UHFFFAOYSA-H 0.000 description 1
- 229910052707 ruthenium Inorganic materials 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- 229910052712 strontium Inorganic materials 0.000 description 1
- LSNNMFCWUKXFEE-UHFFFAOYSA-L sulfite Chemical class [O-]S([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-L 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/9445—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
- B01D53/945—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific catalyst
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/12—Oxidising
- B01J37/14—Oxidising with gases containing free oxygen
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
- F02B3/00—Engines characterised by air compression and subsequent fuel addition
- F02B3/06—Engines characterised by air compression and subsequent fuel addition with compression ignition
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
Definitions
- the invention relates generally to the control of hydrocarbons (HC) , carbon monoxide (CO) , and nitrogen oxides (NO ⁇ ) in the exhaust of internal combustion engines. More particularly, the invention relates to the removal of NO ⁇ when the exhaust gases include oxygen in excess of that needed for combustion of the fuel. This is typically the case with lean-burn engines, diesel engines, and other engines currently under development which produce such exhaust gases. In recent years three-way catalysts have been used to remove all of the three principal noxious components in auto exhaust gases. The engines are run with stoichiometric air/fuel ratios and the catalysts are able to remove all three components at the same time, that is, a single catalyst is sufficient over the range of engine operating temperatures.
- lean-burn engines operate with air-fuel ratios which are far from the typical stoichiometric conditions.
- the lean- burn engine may operate with air-fuel ratios above 18/1, up to about 22-24/1, or even higher ratios for diesel engines.
- the exhaust from a lean-burn engine will include more hydrocarbons, less carbon monoxide, and less, but still excessive nitrogen oxides.
- the nitrogen oxides can be decomposed to diatomic nitrogen and diatomic oxygen. This reaction is ther odynamically favored, but catalysts which are able to carry out this reaction under the highly oxidizing conditions and high temperatures found in engine exhaust gases have not yet been found.
- the second route is the chemical reduction of nitrogen oxides using reducing agents present in the exhaust, such as carbon monoxide, hydrocarbons, and hydrogen. This is considered to be the mechanism of the three-way catalysts used in the exhaust from an engine operating with a stoichiometric air-fuel ratio which contains little oxygen. When a large excess of oxygen is present, as in a lean-burn or diesel engine, the oxygen can preferentially react with the hydrocarbons, carbon monoxide, and hydrogen thus removing the reducing agents needed to remove nitrogen oxides.
- the NO ⁇ removal catalysts are defined as phosphates, sulfates, or aluminates of transition metals of the 4th period of the Periodic table (e.g. Cr, Mn, Fe, Co, Ni, Cu, Zn) .
- the oxidation catalyst is generally described as a noble metal, a base metal or a perovskite on a support.
- the invention is a process for removing carbon monoxide, hydrocarbons, and nitrogen oxides from the exhaust gases produced by an engine which is operated with an excess of air relative to that required for stoichiometric combustion of the fuel, such as lean-burn, diesel, and the like.
- Noble metal catalysts are used which are treated in an oxygen-inert gas mixture at a temperature of at least 400"C, preferably 600" up to 1200 * C, to adjust the temperature window for nitrogen oxide conversion to a desired value by varying the oxygen partial pressure. More than one catalyst may be used, each having been treated so that in combination they are able to reduce nitrogen oxides over the full range of engine exhaust gas temperatures.
- the reducing agents such as carbon monoxide, hydrocarbons and hydrogen can also be oxidized while the nitrogen oxides are reduced.
- the noble metals are selected from the group of platinum, and rhodium, particularly platinum-rhodium and platinum alone.
- the noble metals typically will be supported, preferably on an alumina or an alumina containing a rare earth metal oxide, particularly ceria, or an alkaline earth metal compound such as a sulfate, oxide, carbonate, or hydroxide.
- Other supports may be used, such as the oxides of Zr, Si, Ti and Sn, and cordierite or silicon carbide.
- Steam is generally included in the gas mixture at about 0 to 30 vol.%, the amount of oxygen is greater than zero and up to 21 vol.%, and the remainder of the treating gas is nitrogen or other inert gas.
- Increasing the oxygen content of the mixture increases the temperature window for nitrogen oxide reduction so that the most active catalyst is produced by exposing the catalyst to inert gas containing substantially no oxygen with lesser activity being obtained by increasing the amount of oxygen.
- the catalysts are disposed to contact the exhaust gases in order of increasing activity for NO ⁇ reduction.
- the invention is at least one catalyst treated as described above.
- Figure 1 is a plot of NO conversion versus temperature for Pt/Rh catalysts, showing the effect of varying oxygen content.
- Figure 2 is a plot of NO conversion versus temperature for a composite catalyst of the invention showing a wide conversion window for NO.
- Figure 3 is a plot of NO conversion versus temperature comparing the effect of inert gas versus air treatment.
- Figure 4 is a plot of NO conversion versus temperature for Pt catalysts showing the effect of varying oxygen content.
- Figure 5 is a plot of NO conversion versus temperature for various catalysts treated at varying temperatures in the absence of oxygen.
- catalysts may function differently depending upon the operating conditions and that each catalyst has a temperature range within which it is capable of destroying nitrogen oxides. We will refer to this temperature range as a "window" within which nitrogen oxides are converted. This is generally contrary to the experience with three-way catalysts which become active ("light-off") at a temperature of about 250" to 350"C and thereafter are able to oxidize hydrocarbons and carbon monoxide while reducing nitrogen oxides over the usual range of operating temperatures, say about 300° to 800*C. It should be noted here that auto exhaust changes its composition and its temperature as driving conditions change. Consequently, tests of auto exhaust catalysts require that a car be operated over a range of conditions which represents typical driving.
- each catalyst has a temperature range within which it is effective and outside that range the conversion of nitrogen oxides is minimal. At the same time it is still necessary to remove the reducing agents including residual hydrocarbons, hydrogen, and carbon monoxide.
- Multiple catalysts may be employed, each capable of reducing nitrogen oxides within a particular temperature range. However, in the present invention it is possible to use a single catalyst composition but modify its performance so that it can reduce nitrogen oxides over a wider range of temperatures, thereby obtaining the effect previously achieved by combining catalysts of differing compositions.
- the noble metals of Group VIII include Pt, Pd, Rh, Ru, Os, and Ir (Groups 8-10 IUPAC). Generally, only Pt, Pd, and Rh are used in automobile exhaust catalysts. Preferred are Pt alone and Pt plus Rh in atomic proportions of 1/1 to 30/1.
- the catalysts may contain base metals.
- the base metals of Group VIII namely Co, Ni and Fe, and metals of Groups IVa and IVb (Groups 4 and 14 IUPAC) such as Sn, Zr, Ti, and Pb may be included.
- Rare earth metals such as Ce may also be included, as well as the alkaline earth metals such as Ba, Sr, and Ca.
- Representative concentrations of the noble metals will be about 0.01 to 5.0 g/L, preferably 0.7 to 3.6 g/L, most preferably 1.0 to 2.5 g/L, when disposed on a typical monolithic carrier.
- the base metals if present, will be about 0.01 to 40 g/L, preferably 0.1 to 15 g/L, most preferably 0.5 to 13 g/L, when disposed on a typical monolithic carrier.
- the noble metals and any base metal promoters are deposited on supports, either before or after such supports are placed on the surface of ceramic or metal monolithic carriers.
- the supports typically are aluminas of the various structures known in the art (e.g. gamma, delta, theta, alpha, etc.), but the supports may also be other metal oxides such as Zn0 2 , Si0 2 , Ti0 2 , Sn0 2 , cordierite, etc. or Sic.
- Addition of the noble metals may be done by impregnation techniques familiar to those skilled in the art. Generally, these involve contacting the support with an aqueous solution of the metal (or metals) compound to be deposited and subsequently drying and heating the impregnated support to decompose the metal compounds. The concentration of the metal compounds in solution will be adjusted to provide the amount of metals in the finished catalyst.
- the noble metal compounds may be those used in the past, such as halogenated compounds (e.g. chloroplatinic acid, rhodium chloride) , nitrates (e.g. rhodium nitrates) , acetates (e.g.
- rhodium acetate e.g. platinum sulfite acid i.e., hydroxy disulfite platinum (II) acid
- Preferred noble metal compounds include rhodium chloride, rhodium nitrate, rhodium sulfite, rhodium oxalate, chloroplatinic acid, platinum oxalate, platinum ammine nitrite, and platinum sulfite.
- the base metals are preferably applied by impregnation of the support with an aqueous solution of a base metal compound, such as the nitrates, acetates, sulfates, etc.
- a conventionally prepared noble metal catalyst will have a temperature "window" for nitrogen oxide reduction which is at a relatively low temperature and which has a peak performance centered about say 250" to 300 ⁇ C.
- an oxygen-nitrogen mixture at temperatures of at least 400"C, preferably at least 600°C to about 1200"C, the temperature range of the window is increased.
- the most active catalyst is obtained when the treatment is carried out with only an inert gas, that is, substantially in the absence of oxygen.
- the activity of the catalysts is reduced and the window moves to higher temperatures as oxygen is added to the inert gas.
- the catalyst temperature window may be increased by 100° to 150°C.
- the catalysts could be mixed together after treating. Preferably, they could be arranged in a sequence, with the catalyst having the highest temperature window (i.e. the least active) contacting the exhaust gases first and being disposed upstream of a catalyst having an overlapping temperature window but a lower peak temperature (i.e. more active) .
- the catalysts are arrayed in order of increasing catalytic activity for NO ⁇ reduction.
- the treatment of the invention may be carried out with gas compositions in the range of 0-30 vol.% steam, greater than zero up to 21 vol.% oxygen, and the remainder nitrogen or other inert gas.
- the temperature will be in the general range of 400* to 1200 ⁇ C and the treatment will be carried out for a sufficient period of time to adjust the temperature window for nitrogen oxide reduction to the desired range.
- Catalyst samples used for pretreatment in steam/nitrogen mixtures of varying oxygen content and subsequent performance measurements were removed from ceramic monoliths on which had been deposited Pt, Rh, Ce0 2 , BaS0 , and A1 2 0 3 .
- Cylindrical cores measuring 4.75 inches in length and 1.5 inches in diameter (120 x 38 mm) were initially removed from the full size pieces, then cut in half longitudinally and subsequently aged at 1060"C for 6 hours in steam/nitrogen mixtures of varying oxygen content. After aging, smaller cylindrical shaped cores having dimensions of 0.5 inches (12.7 mm) in length and 0.876 inches (22.2 mm) in diameter were removed from the aged larger cores and were evaluated in a synthetic lean burn exhaust gas mixture. The nominal space velocity for the tests used was 60K hr *1 .
- the catalyst was prepared by conventional preparation procedures, of the type described below. Initially a slurry is prepared by combining a Ce0 2 /Al 2 0 3 (24 wt.%Ce) finely divided powder with a dilute nitric acid solution which also contains BaS0 A . The slurry is subsequently ball milled and pH adjusted with nitric acid to give a final pH of 3.75. An oval shaped cordierite monolith with a minor axis of 8 cm and a major axis of 16.8 cm, a length of 15.2 cm and having 400 square channels per square inch of facial area is dipped into the slurry. The geometric volume of the monolith is 1517 cm 3 .
- the slurry coated monolith is calcined in a gas-fired oven for about 1 hour at 540 ⁇ C.
- platinum and rhodium are added to the monolith by dipping into an aqueous solution containing platinum in the form of chloroplatinic acid and rhodium in the form of rhodium chloride.
- the excess solution is blown out with an air gun, and the monolith is dried and calcined for about an hour at 540"C.
- the final catalyst has a total washcoat loading of 0.165 g/cm 3 (2.7 g/in 3 ) .
- the catalyst of Example 1 was treated by exposure to a mixture of 10 vol.% steam, up to 90 vol.% nitrogen and varying amounts of oxygen at a temperature of 1060°C for 6 hours.
- the treated catalysts were tested by exposure to a synthetic exhaust gas containing 1200 ppmv NO ⁇ , 3000 ppmv CO, 1000 ppmv H 2 , 1600 ppmv propene, 20 ppmv S0 2 , and 3.2 vol.% 0 2 , remainder nitrogen and 10 vol.% steam.
- the temperature was gradually increased up to a maximum of 800*C (rise 1) , held at 800 ⁇ C for one hour, and then cooled to 50*C and repeated (rise 2) .
- the performance of the catalyst is shown in Figure 1 for rise 1.
- Example 3 Two composite catalysts were prepared using four individual catalyst samples as in Example 1 that had been pretreated at 1040*C in steam/nitrogen mixtures of varying oxygen content and combined sequentially to give a composite catalyst.
- the least active catalyst was placed at the exhaust gas inlet (i.e., the sample treated with the highest oxygen concentration) and the most active sample (i.e., the sample treated with the lowest oxygen concentration) at the exhaust gas outlet.
- Composite catalyst A consisted of four portions of a Pt,Rh,Ce0 2 ,BaS0 4 ,Al 2 0 3 catalyst as described in Example 1 which had been pretreated with 0.02 vol.% 0 2 , 0.06 vol.% 0 2 , 1.26 vol.% 0 2 and 5.0 vol.% 0 2 and arrayed in the reverse order, that is, with the samples treated with 5 vol.% 0 2 first and the sample 0.02 vol.% 0 2 last.
- Composite catalyst B consisted of the same catalyst but the four portions had been pretreated at 1040 ⁇ C in steam-nitrogen mixtures containing 0 vol.% O z , 1.26 vol.% 0 2 : , 5 vol.% 0 2 , and 21 vol.% 0 2 and again arrayed in the reverse order. The test procedures of Example 2 were repeated with these composite catalysts. It is seen from the results in Figure 2 that the NO reduction performance of these composite catalysts is effective over a temperature range that covers 200° - 500 ⁇ C.
- a catalyst was prepared by impregnating an aqueous solution of chloroplatinic acid and rhodium chloride onto a ceria-alumina granular support.
- the Pt content was about 3300 ppm by weight; the Rh content about 700 ppm by weight.
- the catalyst was dried and calcined in air at 600°C for 6 hr. The catalyst in this state is considered to be untreated. A portion of this material was treated at 1140°C in N 2 with 10% steam; this material is considered to be treated. NO reduction performance was determined using the same synthetic gas mixture and the same temperature program as used in Example 2. Performance of the two catalysts is shown in Figure 3.
- the panel labelled A shows performance during an initial temperature increase.
- panel B pertains to results obtained after aging the catalyst in the synthetic gas mixture which is, overall, an oxidizing gas mixture, at 800°C.
- the treated catalyst is seen to possess NO conversion activity that is markedly superior to the untreated catalyst.
- treatment at high temperature in N 2 and steam is shown to improve NO reduction performance for this catalyst compared to a conventional preparation method.
- NO conversion and NO reduction are used synonymously since NO conversion is detected with a chemiluminescent NO ⁇ analyzer that detects both NO and N0 2 .
- NO oxidation to more highly oxidized oxides of nitrogen are not counted as converted NO.
- the high temperature treatment in N 2 and steam is believed to cause substantial sintering of the precious metal.
- a platinum (II) sulfite acid solution was used to impregnate 80.0 g of ⁇ -Al 2 0 3 .
- the water was evaporated and the catalyst divided into portions.
- the Pt content was 2.5 wt.%.
- One portion was treated with 85% N 2 , 5% 0 2 , and 10% steam at 1060°C for 6 hr.
- Another portion was treated with 90% N 2 and 10% steam at 1060°C for 6 hr.
- Catalytic performance of these two materials were determined using a synthetic exhaust gas designed to model emissions from an engine operating at an air-to- fuel ratio of 22/1.
- This gas mixture is comprised of 3300 ppmv propene, 1000 ppmv CO, 330 ppmv H 2 , 700 ppmv NO, 7.5% 0 2 , 10% C0 2 , and 10% steam.
- the temperature was gradually increased to 800°C and held at 800°C for an hour.
- the temperature was then lowered and then increased a second time to 800°C.
- NO reduction performance during the second temperature increase is shown in Figure 4. Performance was similar during the first temperature increase. It can be seen that the Pt/ ⁇ -Al 2 0 3 catalyst treated with 5% 0 2 reduces NO at somewhat higher temperatures compared to the Pt/ ⁇ -Al 2 0 3 catalyst treated with only N 2 and steam.
- this catalyst is defined as 5B.
- a second material was made using granules of a delta alumina manufactured by Condea. This second material was impregnated with an aqueous solution containing chloroplatinic acid and rhodium chloride sufficient to yield a material containing 1.33 wt.% Pt and 670 ppm by weight Rh. After the aqueous solution was evaporated, the granular material was recovered and dried. Twenty grams of this second material was treated with 90% N 2 and 10% steam at 800°C for 6 hr: this catalyst is defined as 5C.
- this catalyst was treated with 90% N 2 and 10% steam at 1000°C for 6 hr: this catalyst is defined as 5D.
- An additional twenty grams of this second material was initially calcined in air at 600°C for 6 hr and subsequently treated with 90% N 2 and 10% steam at 1000°C for 6 hr: this catalyst is defined as 5E.
- a third material was made by impregnating a granular ⁇ -Al 2 0 3 with a solution of chloroplatinic acid and rhodium chloride to provide a third solid material containing 0.175 wt.% Rh and 0.876 wt.% Pt.
- this third material was treated in N 2 in the absence of steam at 1100°C for 6 hr: this material is defined as 5F.
- Catalytic performance of these 6 materials was evaluated using the gas mixture and temperature program used in Example 2.
- Figure 5 shows NO reduction performance during the second temperature increase. It is apparent that all six of these materials are able to reduce NO in the oxidizing environment used in these experiments.
- catalyst precursors in N 2 with or without steam Treatment of catalyst precursors in N 2 with or without steam is sufficient to create materials with the desired catalytic properties for NO reduction under oxidizing conditions.
- a variety of precursors and support materials may be employed.
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Health & Medical Sciences (AREA)
- Organic Chemistry (AREA)
- Combustion & Propulsion (AREA)
- Materials Engineering (AREA)
- Biomedical Technology (AREA)
- Environmental & Geological Engineering (AREA)
- Analytical Chemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Catalysts (AREA)
- Exhaust Gas Treatment By Means Of Catalyst (AREA)
Abstract
On obtient l'élimination du monoxyde de carbone, les hydrocarbures et des oxydes d'azote présents dans les gaz d'échappement de moteurs à mélange pauvre, ou diesel notamment, gaz qui contiennent un excédent d'oxygène, en utilisant des catalyseurs à métaux nobles supportés traités par exposition à des mélanges gaz inertes-oxygène pour abaisser la teneur en oxydes d'azote de ces gaz d'échappement dans une fourchette donnée de températures. On obtient aussi une oxydation des gaz réducteurs restants.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US13034093A | 1993-10-01 | 1993-10-01 | |
| US130340 | 1993-10-01 | ||
| PCT/US1994/011014 WO1995009687A1 (fr) | 1993-10-01 | 1994-09-29 | CATALYSEURS A METAUX NOBLES ABAISSANT LA TENEUR EN NOx DE GAZ D'ECHAPPEMENT DE MOTEURS A COMBUSTION INTERNE CONTENANT UN EXCEDENT D'OXYGENE |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| EP0721368A1 true EP0721368A1 (fr) | 1996-07-17 |
Family
ID=22444227
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP94929929A Withdrawn EP0721368A1 (fr) | 1993-10-01 | 1994-09-29 | CATALYSEURS A METAUX NOBLES ABAISSANT LA TENEUR EN NO x? DE GAZ D'ECHAPPEMENT DE MOTEURS A COMBUSTION INTERNE CONTENANT UN EXCEDENT D'OXYGENE |
Country Status (2)
| Country | Link |
|---|---|
| EP (1) | EP0721368A1 (fr) |
| WO (1) | WO1995009687A1 (fr) |
Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0762926B1 (fr) * | 1994-06-01 | 2000-06-28 | ASEC Manufacturing Company | PROCEDE DE PREPARATION DE CATALYSEURS A BASE DE METAUX ALLIES DESTINES A REDUIRE LA TENEUR EN NO x DE GAZ D'ECHAPPEMENT DE MOTEURS A COMBUSTION INTERNE RENFERMANT UN EXCES D'OXYGENE |
| FR2744038B1 (fr) * | 1996-01-26 | 1998-03-06 | Pechiney Recherche | Supports de catalyseur en mousse de sic revetue de cerine et systemes catalytiques correspondants |
| DE19847008A1 (de) * | 1998-10-13 | 2000-04-20 | Degussa | Stickoxid-Speicherkatalysator |
| US8835346B2 (en) * | 2012-07-27 | 2014-09-16 | Basf Corporation | Catalyst materials |
| CN106540688B (zh) * | 2016-12-06 | 2020-07-10 | 绍兴正开智能设备有限公司 | 一种三元复合贵金属催化剂 |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2546078B1 (fr) * | 1983-05-19 | 1987-05-07 | Pro Catalyse | Procede de fabrication de catalyseurs pour le traitement des gaz d'echappement des moteurs a combustion interne |
| DE3624934A1 (de) * | 1986-07-23 | 1988-01-28 | Dynamit Nobel Ag | Bei hohen temperaturen bestaendige katalysator-formkoerper und verfahren zu deren herstellung |
| DE3902913A1 (de) * | 1989-02-01 | 1990-08-09 | Degussa | Traegermaterial fuer platingruppenmetall-haltige dreiweg-katalysatoren mit verringerter neigung zur h(pfeil abwaerts)2(pfeil abwaerts)s-emission |
| US5010051A (en) * | 1989-11-08 | 1991-04-23 | Engelhard Corporation | Staged three-way conversion catalyst and method of using the same |
-
1994
- 1994-09-29 EP EP94929929A patent/EP0721368A1/fr not_active Withdrawn
- 1994-09-29 WO PCT/US1994/011014 patent/WO1995009687A1/fr not_active Ceased
Non-Patent Citations (1)
| Title |
|---|
| See references of WO9509687A1 * |
Also Published As
| Publication number | Publication date |
|---|---|
| WO1995009687A1 (fr) | 1995-04-13 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| EP1008378B1 (fr) | Catalyseur pour la purification de gaz d'échappement | |
| US6365118B1 (en) | Reduction of NOx in the exhaust from leanOx internal combustion engines | |
| US4157316A (en) | Polyfunctional catalysts | |
| US5073532A (en) | Catalyst for purifying exhaust gases from internal combustion engines and method of making the catalyst | |
| US5958828A (en) | Catalyst for purifying exhaust gas | |
| EP0963951B1 (fr) | Oxyde mixte de cerium et de zirconium, procédé pour sa préparation et materiau catalytique pour la purification de gaz d'échappement | |
| US5977012A (en) | Alloyed metal catalysts for the reduction of NOx in the exhaust gases from internal combustion engines containing excess oxygen | |
| US4957896A (en) | Catalyst for purification of exhaust gases | |
| US4675308A (en) | Three-way catalyst for lean operating engines | |
| CA1335279C (fr) | Catalyseur pour purifier les gaz d'echappement de moteurs a combustion interne tout en reduisant les emissions de sulfure d'hydrogene produit par ledit catalyseur et methode d'utilisation dudit catalyseur | |
| EP0764460B1 (fr) | Séparateurs pour oxyde d'azote | |
| CA1328653C (fr) | Catalyseurs | |
| EP0562516B1 (fr) | Méthode pour la purification de gaz d'échappement | |
| US5286699A (en) | Exhaust gas purifying catalyst suppressing the generation of hydrogen sulfide and method of making the catalyst | |
| US6191061B1 (en) | Method of purifying exhaust gas and catalyst for purifying exhaust gas | |
| US4500650A (en) | Three-way catalysts for purification of exhaust gas and method for the preparation of the catalysts | |
| US4552733A (en) | Polyfunctional catalysts and method of use | |
| US4140655A (en) | Oxidation reduction catalyst for the treatment of combustion gases and method for making the catalyst | |
| US5894068A (en) | Reduction of NOx in the exhaust gases from internal combustion engines containing excess oxygen | |
| EP1053778A1 (fr) | Procédé pour la préparation d'un catalyseur à trois voies | |
| US5972828A (en) | Method of manufacturing catalyst for cleaning exhaust gas released from internal combustion engine, and catalyst for the same | |
| JPH05237390A (ja) | 排気ガス浄化用触媒 | |
| EP0658370B1 (fr) | Procédé de préparation d'un catalyseur pour la purification de gaz d'échappement | |
| EP1850948B9 (fr) | Catalyseur à trois voies pour la purification des gaz d'echappement | |
| EP0721368A1 (fr) | CATALYSEURS A METAUX NOBLES ABAISSANT LA TENEUR EN NO x? DE GAZ D'ECHAPPEMENT DE MOTEURS A COMBUSTION INTERNE CONTENANT UN EXCEDENT D'OXYGENE |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PUAI | Public reference made under article 153(3) epc to a published international application that has entered the european phase |
Free format text: ORIGINAL CODE: 0009012 |
|
| 17P | Request for examination filed |
Effective date: 19960219 |
|
| AK | Designated contracting states |
Kind code of ref document: A1 Designated state(s): AT BE CH DE DK ES FR GB GR IE IT LI LU MC NL PT SE |
|
| RIN1 | Information on inventor provided before grant (corrected) |
Inventor name: ROBOTA, HEINZ JUERGEN Inventor name: KHARAS, KARL, C., C. Inventor name: NUNAN, JOHN, GERARD |
|
| STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: THE APPLICATION HAS BEEN WITHDRAWN |
|
| 18W | Application withdrawn |
Withdrawal date: 19961125 |