Dual Function Catalytic Filter

• US 20140093442A1
• Filed: 05/31/2012
• Published: 04/03/2014
• Est. Priority Date: 05/31/2011
• Status: Abandoned Application

• Current Assignee: Johnson Matthey PLC
• Original Assignee: Johnson Matthey PLC
• Inventors: Spreitzer, Glen, Chatterjee, Sougato, Rajaram, Raj Rao, Millington, Paul James, Collier, Jillian Elaine, Laroze, Sylvie Cecile
• Application Number:
  US14/122,802
• Publication Number:
  US 20140093442A1
• Time in Patent Office: Days
• US Class Current: 423/239.1
• CPC Class Codes: B01D 2255/2065 Cerium
• CPC Class Codes: B01D 2255/207 Transition metals
• CPC Class Codes: B01D 2255/2073 Manganese
• CPC Class Codes: B01D 2255/20738 Iron
• CPC Class Codes: B01D 2255/20746 Cobalt
• CPC Class Codes: B01D 2255/20753 Nickel
• CPC Class Codes: B01D 2255/20761 Copper
• CPC Class Codes: B01D 2255/20776 Tungsten
• CPC Class Codes: B01D 2255/20784 Chromium
• CPC Class Codes: B01D 2255/407 Zr-Ce mixed oxides
• CPC Class Codes: B01D 2255/915 Catalyst supported on particulate filters
• CPC Class Codes: B01D 53/565 by treating the gases with solids
• CPC Class Codes: B01D 53/944 Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts three-way-catalysts [TWC] B01D53/9445
• CPC Class Codes: B01D 53/9472 in different zones
• CPC Class Codes: F01N 3/035 with catalytic reactors , e.g. catalysed diesel particulate filters
• CPC Class Codes: F01N 3/2066 Selective catalytic reduction [SCR]
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

A dual function catalytic filter is provided having a soot filter with an inlet and an outlet, a soot oxidation layer on the inlet, wherein the soot oxidation layer comprises a soot oxidation catalytic component consisting essentially of at least one transition metal dispersed on a cerium and zirconium mixed and/or composite oxide, wherein the at least one transition metal is selected from the group consisting of W, Cr, Ce, Mn, Fe, Co, Ni, Cu, and combinations thereof, and an SCR layer coated on the outlet, wherein the SCR layer comprises an SCR catalytic component. Also provided are methods for removing NO_x and soot from a lean burn exhaust gas using the dual function catalytic filter.

Claims

1. An article for treating an exhaust gas comprising:

a) a soot filter having an inlet and an outlet,

b) a soot oxidation zone on the inlet, wherein the soot oxidation zone comprises a soot oxidation catalytic component consisting essentially of at least one transition metal dispersed on a cerium and zirconium mixed and/or composite oxide, wherein the at least one transition metal is selected from the group consisting of W, Cr, Ce, Mn, Fe, Co, Ni, Cu, and combinations thereof, and

c) an SCR zone coated on the outlet, wherein the SCR zone comprises an SCR catalytic component.

2. The article of claim 1, wherein the catalytic component is supported on an inert oxide selected from the group consisting of alumina, titania, non-zeolite silica-alumina, ceria, zirconia and mixtures, composite oxides and mixed oxides of any two or more thereof.

3. The article of claim 1, wherein said soot oxidation catalytic component has a formula of M:

Ce_xO₂Zr_1-xO₂, wherein x=0.1-0.9 and M is selected from W, Cr, Ce, Mn, Fe, Co, Ni, Cu, and combinations thereof.

4. The article of claim 3, wherein M is W and x is less than about 0.5.

5. The article of claim 1, wherein the at least one transition metal is present in the soot oxidation catalyst component from 0.5 to 20 wt %, based on the total weight of the soot oxidation catalyst component.

6. The article of claim 1, wherein said soot oxidation zone is coated with a soot oxidation catalyst comprising said soot oxidation component and, optionally, one or more non-catalytic binders or stabilizers.

7. The article of claim 1, wherein said soot oxidation zone comprises said soot oxidation component in an amount of about 0.1 to about 0.5 g/in³.

8. The article of claim 1, wherein said SCR catalyst component comprises at least one metal selected from V, Cr, Ce, Mn, Fe, Co, Ni or Cu, wherein the metal is disposed on a support selected from aluminosilicate molecular sieves, silicoaluminophosphate molecular sieves, alumina, and mixed-oxide base material.

9. The article of claim 1, wherein said SCR catalyst component is a molecular sieve having a CHA framework and extra-framework copper.

10. The article of claim 1, wherein said soot oxidation catalyst component has a formula W:

Ce_xO₂Zr_1-xO₂, wherein x=about 0.1 to about 0.9 and said SCR catalyst component has a formula Fe—

W;

Ce_xO₂Zr_1-x′

O₂, wherein x′

=about 0.1 to about 0.99.

11. The article of claim 10 wherein x is less than about 0.5 and x′

is greater than about 0.5.

12. The article of claim 10 wherein said SCR catalyst component has a W:

Fe ratio of greater than about 0.5.

13. The article of claim 1, wherein said soot oxidation catalyst component and said SCR catalyst component have the same formulation and wherein said soot oxidation catalyst component in the inlet and said SCR catalyst component in the outlet are present in a ratio of about 1:

25 to about 1;

2.

14. The article of claim 1, wherein said SCR catalyst is a small pore aluminosilicate or silicoaluminophosphate molecular sieve having extra-framework copper.

15. The article of claim 1, wherein said soot filter is a wall-flow filter.

16. A system for treating NOx in a lean burn exhaust gas comprising:

a) a nitrogenous reducing agent injector,

b) a dual function catalytic filter comprising

i. a soot filter having an inlet and an outlet,

ii. a soot oxidation zone on the inlet, wherein the soot oxidation zone comprises a soot oxidation catalytic component consisting essentially of at least one transition metal dispersed on a cerium and zirconium mixed and/or composite oxide, wherein the at least one transition metal is selected from the group consisting of W, Cr, Ce, Mn, Fe, Co, Ni, Cu, and combinations thereof, and

iii. an SCR zone coated on the outlet, wherein the SCR zone comprises an SCR catalytic component,

wherein said injector is disposed upstream of, and is in fluid communication with, said dual function catalytic filter.

17. The system of claim 16, wherein said system is free of a filter substrate that is not coated with a soot oxidation catalyst and an SCR catalyst.

18. The system of claim 16, further comprising:

c) at least one flow-through monolith substrate coated with a second SCR catalyst composition disposed downstream of the dual function catalytic filter; and

d) an ammonia slip catalyst disposed downstream of said at least one flow-through monolith substrate coated with said second SCR catalyst composition.

19. The system of claim 16, further comprising:

e) a diesel oxidation catalyst disposed upstream of said nitrogenous reducing agent injector.

20. A method for treating a lean burn exhaust gas comprising:

a) flowing a lean burn exhaust gas stream comprising soot, NOx, and a nitrogenous reducing agent through a dual function catalytic filter comprising

i. a soot filter having an inlet and an outlet,

ii. a soot oxidation zone on the inlet, wherein the soot oxidation zone comprises a soot oxidation catalytic component consisting essentially of at least one transition metal dispersed on a cerium and zirconium mixed and/or composite oxide, wherein the at least one transition metal is selected from the group consisting of W, Cr, Ce, Mn, Fe, Co, Ni, Cu, and combinations thereof, and

iii. an SCR zone coated on the outlet, wherein the SCR zone comprises an SCR catalytic component,

b) oxidizing at least a portion of the soot at the soot oxidation zone; and

c) reducing at least a portion of said NOx at the SCR catalyst zone.