Catalyst for gasoline lean burn engines with improved NO oxidation activity

• US 9,242,242 B2
• Filed: 09/02/2011
• Issued: 01/26/2016
• Est. Priority Date: 09/02/2010
• Status: Active Grant

• Current Assignee: BASF SE
• Original Assignee: BASF SE
• Inventors: Hilgendorff, Marcus
• Primary Examiner(s): Bogue, Jesse
• Application Number:
  US13/224,665
• Publication Number:
  US 20120055141A1
• Time in Patent Office: 1,607 Days
• Field of Search: 602/74, 602/82, 602/99, 603/01, 603/11, 502100-103, 502/300, 502/306, 502/313, 502/317, 502/339, 423/402, 423/437.1
• US Class Current: 1/1
• CPC Class Codes: B01D 2255/1021 Platinum
• CPC Class Codes: B01D 2255/1023 Palladium
• CPC Class Codes: B01D 2255/1025 Rhodium
• CPC Class Codes: B01D 2255/202 Alkali metals
• CPC Class Codes: B01D 2255/2042 Barium
• CPC Class Codes: B01D 2255/2047 Magnesium
• CPC Class Codes: B01D 2255/2063 Lanthanum
• CPC Class Codes: B01D 2255/2065 Cerium
• CPC Class Codes: B01D 2255/20715 Zirconium
• CPC Class Codes: B01D 2255/9025 Three layers
• CPC Class Codes: B01D 2255/908 O2-storage component incorporated in the catalyst
• 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 2258/012 Diesel engines and lean burn gasoline engines
• 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: 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 23/58 with alkali- or alkaline earth metals
• CPC Class Codes: B01J 23/63 with rare earths or actinides
• CPC Class Codes: B01J 35/40 characterised by dimensions, e.g. grain size in a colloidal state B01J35/23; crystallite size B01J35/77
• CPC Class Codes: B01J 37/0036 : Grinding
• CPC Class Codes: B01J 37/0203 : the impregnation liquid containing organic compounds
• CPC Class Codes: B01J 37/0244 : Coatings comprising several layers
• CPC Class Codes: B01J 37/0248 : Coatings comprising impregnated particles
• CPC Class Codes: F01N 2510/0684 : having more than one coating layer, e.g. multi-layered coatings
• CPC Class Codes: F01N 3/035 : with catalytic reactors , e.g. catalysed diesel particulate filters
• 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 3/0842 : Nitrogen oxides
• CPC Class Codes: F01N 3/0864 : Oxygen
• CPC Class Codes: F01N 3/2066 : Selective catalytic reduction [SCR]
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies

Abstract

Described is a catalyst comprising a substrate and a catalyst coating of two or more layers: (a) a first layer comprising Pt and/or Pd on the substrate; and (b) a second layer comprising Pt on the first layer; these layers each further comprising: one or more particulate support materials; one or more oxygen storage component (OSC) materials; and one or more nitrogen oxide storage materials comprising one or more elements selected from the group of alkali and/or alkaline earth metals, wherein the total amount of alkali and alkaline earth metals ranges from 0.18 to 2.5 g/in³ calculated as the respective alkali metal oxides M₂O and alkaline earth metal oxides MO. Also described is a method for the production of a catalyst, as well as a process for the treatment of a gas stream comprising nitrogen oxide, in particular of an exhaust gas stream resulting from an internal combustion engine.

Claims

1. An oxidation catalyst for the oxidation of NO and hydrocarbons, the catalyst comprising a substrate and a catalyst coating, the catalyst coating comprising two or more layers, said layers comprising:

(a) a first layer provided on the substrate, said first layer comprising Pt and/or Pd; and

(b) a second layer provided on the first layer, said second layer comprising Pt;

the first and second layers each further comprising;

one or more particulate support materials;

one or more oxygen storage component (OSC) materials; and

one or more nitrogen oxide storage materials comprising one or more elements selected from the group of alkali and/or alkaline earth metals,

wherein the total amount of alkali and alkaline earth metals comprised in the one or more nitrogen oxide storage materials contained in the catalyst ranges from 0.18 to 2.5 g/in³ calculated as the respective alkali metal oxides M₂O and alkaline earth metal oxides MO,

wherein Rh is contained in the catalyst in an amount of 1 g/ft³ or less.

2. The catalyst of claim 1, wherein at least part of the one or more platinum group metals is supported on the one or more particulate support materials.

3. The catalyst of claim 1, wherein the second layer contains less than 500 ppm of Ba.

4. The catalyst of claim 1, wherein the first layer comprises less than 500 ppm of Rh,

and/or,

wherein the second layer comprises less than 500 ppm of Rh.

5. The catalyst of claim 1, wherein the one or more particulate support materials comprise metal oxide support particles.

6. The catalyst of claim 1, wherein the one or more OSC materials contained in the catalyst comprise one or more compounds selected from the group consisting of zirconia, ceria, lanthana, praseodymia, neodymia, and mixtures thereof.

7. The catalyst of claim 1, wherein the alkaline and/or alkaline earth metals contained in the catalyst are selected from the group consisting of Li, Na, K, Rb, Cs, Mg, Ca, Sr, and Ba.

8. The catalyst of claim 1, wherein the alkaline and/or alkaline earth metals contained in the catalyst are comprised in the one or more oxygen storage materials as their respective carbonates and/or oxides.

9. The catalyst of claim 1, wherein the catalyst coating comprises Pt and Pd in a Pt:

Pd weight ratio comprised in the range of from 1;

10 to 100;

1.

10. The catalyst of claim 1, wherein the catalyst comprises Pt in a loading of from 5 to 180 g/ft³.

11. The catalyst of claim 1, wherein the catalyst comprises Pd in a loading of from 0.5 to 18 g/ft³.

12. The catalyst of claim 1, wherein Rh is contained in the catalyst in an amount of 500 ppm or less.

13. The catalyst of claim 1, wherein the one or more nitrogen oxide storage materials contained in the catalyst comprise Ba in an amount ranging from 0.18 to 2.0 g/in³ calculated as BaO.

14. The catalyst of claim 1, wherein the catalyst coating comprises Pt and Ba in a weight ratio of platinum to barium calculated as Pt:

BaO which ranges from 0.01 to 1.0.

15. The catalyst of claim 1, wherein the first layer comprises two or more separate layers, said separate layers being provided on one another.

16. The catalyst of claim 1, wherein the catalyst is comprised in an exhaust gas treatment system comprising an internal combustion engine and an exhaust gas conduit in fluid communication with the internal combustion engine, wherein the catalyst is present in the exhaust gas conduit.

17. The catalyst of claim 16, wherein the exhaust gas treatment system further contains a selective catalytic reduction (SCR) catalyst in the exhaust gas conduit.

18. A process for the treatment of a gas stream comprising nitrogen oxide comprising conducting said gas stream over and/or through a catalyst according to claim 1.

19. A method comprising a step of contacting one or more chemical with a catalyst according to claim 1, for catalyzing the oxidation of one or more of the chemical compounds.

20. A method for producing an oxidation catalyst for the oxidation of NO and hydrocarbons, the method comprising the steps of:

(i) providing a substrate;

(ii) impregnating one or more particulate support materials with at least one Pt- and/or at least one Pd-source;

(iii) adding one or more oxygen storage component (OSC) materials, one or more nitrogen oxide storage materials comprising one or more elements selected from the group of alkali and/or alkaline earth metals, and a solvent to the product obtained in step (ii) to obtain a slurry;

(iv) milling the slurry obtained in step (iii);

(v) providing the resulting slurry of step (iv) onto the substrate in one or more coating steps as a layer;

(vi) optionally repeating steps (ii) to (v) one or more times;

(vii) impregnating one or more particulate support materials with at least one Pt-source;

(viii) adding one or more oxygen storage component (OSC) materials, one or more nitrogen oxide storage materials comprising one or more elements selected from the group of alkali and/or alkaline earth metals, and a solvent to the product obtained in step (vii) to obtain a slurry;

(ix) milling the slurry obtained in step (viii);

(x) providing the resulting slurry of step (ix) onto the coated substrate in one or more coating steps as a layer;

wherein the total amount of alkali and alkaline earth metals comprised in the one or more nitrogen oxide storage materials contained in the catalyst ranges from 0.18 to 2.5 g/in³ calculated as the respective alkali metal oxides M₂O and alkaline earth metal oxides MO,

wherein Rh is contained in the catalyst in an amount of 1 g/ft³ or less.