NOx Adsorber Catalyst with Superior Low Temperature Performance

• US 20090320457A1
• Filed: 06/23/2009
• Published: 12/31/2009
• Est. Priority Date: 06/27/2008
• Status: Active Grant

• Current Assignee: BASF Corporation (BASF SE)
• Original Assignee: BASF Catalysts LLC (BASF SE)
• Inventors: Wan, Chung Z.
• Granted Patent: US 8,475,752 B2
• Time in Patent Office: Days
• US Class Current: 60/299
• CPC Class Codes: B01D 2255/102 Platinum group metals
• CPC Class Codes: B01D 2255/202 Alkali metals
• CPC Class Codes: B01D 2255/204 Alkaline earth metals
• CPC Class Codes: B01D 2255/206 Rare earth metals
• CPC Class Codes: B01D 2255/9022 Two layers
• CPC Class Codes: B01D 2255/91 NOx-storage component incorporated in the catalyst
• CPC Class Codes: B01D 2257/404 Nitrogen oxides other than dinitrogen oxide
• CPC Class Codes: B01D 2257/502 Carbon monoxide
• CPC Class Codes: B01D 2257/702 Hydrocarbons
• CPC Class Codes: B01D 2258/012 Diesel engines and lean burn gasoline engines
• CPC Class Codes: B01D 53/9422 for removing nitrogen oxides by NOx storage or reduction by cyclic switching between lean and rich exhaust gases (LNT, NSC, NSR)
• CPC Class Codes: B01D 53/9477 with catalysts positioned on separate bricks, e.g. exhaust systems
• CPC Class Codes: B01J 23/63 with rare earths or actinides
• CPC Class Codes: B01J 37/0244 Coatings comprising several layers
• CPC Class Codes: B01J 37/0246 Coatings comprising a zeolite
• CPC Class Codes: F01N 2330/60 Discontinuous, uneven properties of filter material, e.g. different material thickness along the longitudinal direction; Higher filter capacity upstream than downstream in same housing
• CPC Class Codes: F01N 3/0814 combined with catalytic converters, e.g. NOx absorption/storage reduction catalysts
• CPC Class Codes: F01N 3/0821 combined with particulate filters catalysed diesel particulate filters F01N3/035
• CPC Class Codes: F01N 3/0835 Hydrocarbons
• CPC Class Codes: F01N 3/0842 Nitrogen oxides
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

The lean NOx trap catalyst composition of the present invention comprises distinct layers, or zone configuration or multi-brick arrangement. The top layer, front zone or front brick is free of any alkali or alkaline earth NOx trapping components. The under layer, rear zone or rear brick may contain any desirable NOx trapping component in contact with a precious metals group catalyst (e.g., Pt). Catalysts of this invention show wide temperature operation window with superior low temperature performance.

Claims

1. A combined lean NOx trap/catalyst system for treatment of exhaust gas emissions, comprising:

a. a carrier substrate;

b. an undercoat washcoat layer comprising a support material, one or more precious metals and one or more NOx trapping components, wherein said undercoat layer is coated on said carrier substrate; and

c. a top washcoat layer comprising a support material, one or more precious metals, and ceria, said top washcoat layer being devoid of alkali or alkaline earth components, and wherein said top washcoat layer is coated on said carrier substrate.

2. The lean NOx trap/catalyst of claim 1, wherein said undercoat washcoat layer is coated over the entire axial length of said substrate and said top washcoat layer is coated over said undercoat washcoat layer.

3. The lean NOx trap/catalyst of claim 1, wherein said top washcoat layer is coated over an upstream portion of said substrate and said undercoat washcoat layer is coated over a downstream portion of said substrate.

4. The lean NOx trap/catalyst of claim 3, wherein said top washcoat layer is coated over about 5 to about 70% of the upstream length of said substrate and wherein said undercoat washcoat layer is coated over the remaining downstream portion of the substrate.

5. The NOx trap/catalyst of claim 1, wherein said support material is a refractory oxide support.

6. The NOx trap/catalyst of claim 1, wherein said NOx trapping component in said undercoat washcoat layer comprises an oxide, hydroxide, and/or carbonates of alkali earth metals, alkaline earth metals, lanthanum group metals, ceria or a combination thereof.

7. The NOx trap/catalyst of claim 6, wherein said NOx trapping component is an oxide of an alkali or alkaline earth metal.

8. An exhaust gas treatment system for treating exhaust gas emissions from a lean burn engine comprising:

a. a multiple-brick arrangement comprising at least two bricks;

b. wherein said first brick contains a washcoat layer comprising a support material, one or more precious metals, ceria and is devoid of any alkali or alkaline earth components; and

c. wherein said second brick contains a support material, one or more precious metals and one or more NOx trapping components.

9. The exhaust gas treatment system of claim 8, wherein said first brick is located upstream of said second brick.

10. The exhaust gas treatment system of claim 8, wherein said second brick is located upstream of said first brick.

12. The exhaust gas treatment system of claim 8, wherein said support material is a refractory oxide support.

13. The exhaust gas treatment system of claim 8, wherein said NOx trapping component in said second brick comprises an oxide, hydroxide, and/or carbonates of alkali earth metals, alkaline earth metals, lanthanum group metals, ceria or a combination thereof.

14. The exhaust gas treatment system of claim 8, wherein said NOx trapping component is an oxide of an alkali or alkaline earth metal.

11. The exhaust gas treatment system of claim 11, wherein one of said first brick or said second brick further comprises a particulate filter.

15. A method for treating exhaust gas emissions from lean burn engine, said method comprising the steps of:

a. providing a combined NOx trap/catalyst component, comprising;

i. a carrier substrate;

ii. an undercoat washcoat layer comprising a support material, one or more precious metals and one or more NOx trapping components, wherein said undercoat washcoat layer is coated on said carrier substrate; and

iii. a top washcoat layer comprising a support material, one or more precious metals, and ceria, said top washcoat layer being devoid of alkali or alkaline earth components, and wherein said top washcoat layer is coated on said carrier substrate.

b. passing an exhaust gas stream comprising unburned hydrocarbons, carbon monoxides and nitrogen oxides, from a lean burn engine across said carrier substrate;

c. wherein under lean burn conditions said undercoat washcoat layer is capable of simultaneously storing nitrogen oxides (NOx) and catalyzing the conversion of hydrocarbons (HC) and carbon monoxides (CO), and said top washcoat layer is capable of oxidizing nitrogen oxides (NOx) and catalyzing the conversion of hydrocarbons and carbon monoxides (CO); and

d. wherein under rich burn conditions both of said top and undercoat washcoat layers are capable of releasing and oxidizing nitrogen oxides (NOx) and catalyzing the conversion of hydrocarbons and carbon monoxide.

16. The method of claim 15, wherein said NOx trap/catalyst component is capable of treating exhaust gas emissions at a temperature of from about 100°

C. to about 500°

C.

17. The method of claim 15, wherein said top washcoat layer is capable of oxidizing NOx at temperatures below 350°

C.

18. The method of claim 15, wherein said undercoat washcoat layer is coated over the entire axial length of said substrate and said top washcoat layer is coated over said undercoat washcoat layer.

19. The method of claim 15, wherein said top washcoat layer is coated over an upstream portion of said substrate and said undercoat washcoat layer is coated over a downstream portion of said substrate.

20. The method of claim 15, wherein said top washcoat layer and said undercoat washcoat layer are coated on separate bricks of a multiple-brick emission treatment system.