Ammonia SCR catalyst and method of using the catalyst

• US 7,527,776 B2
• Filed: 01/09/2007
• Issued: 05/05/2009
• Est. Priority Date: 01/09/2007
• Status: Active Grant

• Current Assignee: Catalyst Health Solutions Incorporated (UnitedHealth Group Incorporated)
• Original Assignee: Catalyst Health Solutions Incorporated (UnitedHealth Group Incorporated)
• Inventors: Iretskaya, Svetlana, Golden, Stephen J.
• Primary Examiner(s): Vanoy; Timothy C
• Application Number:
  US11/651,290
• Publication Number:
  US 20080166282A1
• Time in Patent Office: 847 Days
• Field of Search: 423/239.1, 423/239.2, 402/300, 402/345, 402/319, 402/325, 402/324, 402/353, 402/304, 402/302, 402/340, 402/527.12
• US Class Current: 423/239.1
• CPC Class Codes: B01D 2251/2062 Ammonia
• CPC Class Codes: B01D 2255/2065 Cerium
• 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 2255/407 Zr-Ce mixed oxides
• CPC Class Codes: B01D 2255/50 Zeolites
• CPC Class Codes: B01D 53/9418 for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas
• CPC Class Codes: B01J 23/34 Manganese
• CPC Class Codes: B01J 29/061 containing metallic elements added to the zeolite
• CPC Class Codes: B01J 29/076 containing arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
• CPC Class Codes: B01J 29/48 containing arsenic, antimony, bismuth, vanadium, niobium tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
• CPC Class Codes: B01J 29/7815 Zeolite Beta
• CPC Class Codes: B01J 37/0242 Coating followed by impregnation
• CPC Class Codes: B01J 37/0246 Coatings comprising a zeolite
• CPC Class Codes: Y02A 50/20 Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02T 10/12 Improving ICE efficiencies

Abstract

A catalyst and a method for selectively reducing nitrogen oxides with ammonia are provided. The catalyst includes a first component of copper, chromium, cobalt, nickel, manganese, iron, niobium, or mixtures thereof, a second component of cerium, a lanthanide, a mixture of lanthanides, or mixtures thereof, and a zeolite. The catalyst may also include strontium as an additional second component. The catalyst and the method may have special application to selective reduction of nitrogen oxides in exhaust gas from diesel vehicles, although the catalyst and the method have broad application to a wide range of gas streams that contain nitrogen oxides.

Claims

1. A catalyst for selective catalytic reduction of nitrogen oxides with ammonia, the catalyst comprising:

a first component comprising at least one selected from the group consisting of copper, chromium, cobalt, nickel, manganese, iron, niobium, and mixtures thereof;

a second component comprising at least one selected from the group consisting of cerium, a lanthanide, a mixture of lanthanides, and mixtures thereof;

at least one zeolite and

strontium.

2. A catalyst for selective catalytic reduction of nitrogen oxides with ammonia, the catalyst comprising:

a first component comprising at least one selected from the group consisting of copper, chromium, cobalt, nickel, manganese, iron, niobium, and mixtures thereof;

a second component comprising at least one selected from the group consisting of cerium, a lanthanide, a mixture of lanthanides, and mixtures thereof;

at least one zeolite and

an oxygen storage material.

3. The catalyst of claim 2, wherein the oxygen storage material is selected from the group consisting of Ce_1-aZr_aO₂ and Ce_1-c-dZr_cLan_dO₂, wherein Lan is selected from the group consisting of Y, La, Pr, Nd, Sm, Eu, Gd, Ho, Yb and mixtures thereof.

4. A catalyst for selective catalytic reduction of nitrogen oxides with ammonia, the catalyst comprising:

approximately 1 to approximately 20 weight percent of a first component, said first component comprising at least one selected from the group consisting of copper, chromium, cobalt nickel, manganese, iron, niobium, and mixtures thereof;

approximately 2 to approximately 35 weight percent of a second component, said second component comprising at least one selected from the group consisting of cerium, a lanthanide, a mixture of lanthanides, and mixtures thereof;

approximately 10 to approximately 90 weight % of at least one zeolite, and

approximately 2 to approximately 35 weight percent of strontium, wherein the weight percent of the strontium is on the basis of strontium metal, and wherein the weight percentages of the first component and the second component are on the basis of the metals.

5. A catalyst composition comprising:

a substrate; and

a catalyst for selective catalytic reduction of nitrogen oxides with ammonia, the catalyst comprising;

a first component comprising at least one selected from the group consisting of copper, chromium, cobalt, nickel, manganese, iron, niobium, and mixtures thereof;

a second component comprising at least one selected from the group consisting of cerium, a lanthanide, a mixture of lanthanides, and mixtures thereof;

at least one zeolite, and an oxygen storage material, wherein the catalyst is placed on the substrate.

6. The catalyst composition of claim 5, further comprising at least one inorganic oxide selected from the group consisting of alumina, silica, titania, and silica-alumina solutions, composites, and mixtures thereof, and wherein at least one of the zeolite, the oxygen storage material, and the inorganic oxide is placed on the substrate in a form of a washcoat.

7. A method for selective reduction of nitrogen oxides in a gas stream with ammonia, wherein the gas stream comprises nitrogen oxides, the method comprising:

contacting the gas stream with ammonia in the presence of a catalyst, the catalyst comprising;

a first component comprising at least one selected from the group consisting of copper, chromium, cobalt, nickel, manganese, iron, niobium, and mixtures thereof;

a second component comprising at least one selected from the group consisting of cerium, a lanthanide, a mixture of lanthanides, and mixtures thereof;

at least one zeolite and

strontium.

8. A method for selective reduction of nitrogen oxides in a gas stream with ammonia, wherein the gas stream comprises nitrogen oxides, the method comprising:

contacting the gas stream with ammonia in the presence of a catalyst, the catalyst comprising;

a first component comprising at least one selected from the group consisting of copper, chromium, cobalt, nickel, manganese, iron, niobium, and mixtures thereof;

a second component comprising at least one selected from the group consisting of cerium, a lanthanide, a mixture of lanthanides, and mixtures thereof;

at least one zeolite and

an oxygen storage material.

9. The method of claim 8, wherein the oxygen storage material is selected from the group consisting of Ce_1-aZr_aO₂ and Ce_1-c-dZr_cLan_dO₂, wherein Lan is selected from the group consisting of Y, La, Pr, Nd, Sm, Eu, Gd, Ho, Yb and mixtures thereof.

10. A method for selective reduction of nitrogen oxides in a gas stream with ammonia, wherein the gas stream comprises nitrogen oxides, the method comprising:

contacting the gas stream with ammonia in the presence of a catalyst, the catalyst comprising;

a first component comprising at least one of the group consisting of copper, chromium, cobalt, nickel, manganese, iron, niobium, and mixtures thereof, a second component comprising at least one of the group consisting of cerium, a lanthanide, a mixture of lanthanides, and mixtures thereof, and at least one zeolite, wherein the catalyst comprises approximately 1 to approximately 20 weight percent of the first component, approximately 2 to approximately 35 weight percent of the second component, and approximately 10 to approximately 90 weight % of the at least one zeolite, wherein the weight percentages of the first component and the second component are on the basis of the metals, and approximately 2 to approximately 35 weight percent of strontium, wherein the weight percent of the strontium is on the basis of strontium metal.