Method for the preparation of a catalysed particulate filter and catalysed particulate filter

• US 9,346,018 B2
• Filed: 07/01/2011
• Issued: 05/24/2016
• Est. Priority Date: 11/02/2010
• Status: Active Grant

• Current Assignee: Umicore AG & Company KG (Umicore S.A.)
• Original Assignee: Haldor Topsã¸E A/S (Haldor Topsã¸E Holding A/S)
• Inventors: Johansen, Keld
• Primary Examiner(s): McDonough, James
• Application Number:
  US13/880,362
• Publication Number:
  US 20130216441A1
• Time in Patent Office: 1,789 Days
• Field of Search: 502/100, 502/60, 502/208, 502/300
• US Class Current: 1/1
• CPC Class Codes: B01D 2255/1021 Platinum
• CPC Class Codes: B01D 2255/1023 Palladium
• CPC Class Codes: B01D 2255/2065 Cerium
• CPC Class Codes: B01D 2255/20707 Titanium
• CPC Class Codes: B01D 2255/20715 Zirconium
• CPC Class Codes: B01D 2255/20761 Copper
• CPC Class Codes: B01D 2255/20776 Tungsten
• CPC Class Codes: B01D 2255/2092 Aluminium
• CPC Class Codes: B01D 2255/30 Silica
• CPC Class Codes: B01D 2255/502 Beta zeolites
• CPC Class Codes: B01D 2255/9022 Two layers
• 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 53/9436 Ammonia
• 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: B01J 23/44 Palladium
• CPC Class Codes: B01J 29/7615 Zeolite Beta
• CPC Class Codes: B01J 29/85 Silicoaluminophosphates [SAPO compounds]
• CPC Class Codes: B01J 35/19 Catalysts containing parts with different compositions
• 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 37/0244 : Coatings comprising several layers
• 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

Abstract

The invention pertains to a catalyzed particulate filter provided in its entire dispersion side and within its partition walls with a first catalyst being active in selective catalytic reduction of nitrogen oxides, and in its entire permeate side with a second catalyst combination with a catalyst being active in oxidation of ammonia mixed with a catalyst being active in oxidation of carbon monoxide and hydrocarbons and a method for its preparation. The mean particle size of the first catalyst is smaller than the mean pore diameter of the longitudinal porous walls, and the mean particle size of the second catalyst combination is larger than the mean pore diameter of the longitudinal walls. In the example, the first catalyst is a silica aluminum phosphate SAPO-34 promoted with 2% copper and the second catalyst is a mixture of platinum and palladium (molar ratio 3:1) supported on alumina particles and beta zeolite powder with 1.0% copper.

Claims

1. Method for the preparation of a catalysed particulate filter comprising the steps of

a) providing a particulate filter body with longitudinal flow passages being confined by longitudinal porous walls, defining a dispersion side and a permeation side;

b) providing a first catalyst washcoat containing a first catalyst composition being active in selective catalytic reduction of nitrogen oxides,

c) providing a second catalyst washcoat containing a second combined catalyst composition in form of a mixture of a catalyst being active in selective oxidation of ammonia to nitrogen, and a catalyst being active in oxidation of carbon monoxide and hydrocarbons;

d) coating the particulate filter body with the first catalyst washcoat on the entire dispersion side and within partition walls of the filter body, and coating the particulate filter with the second catalyst washcoat on the entire permeate side of the filter body; and

e) drying and heat treating the coated filter to obtain the catalysed particulate filter.

2. The method of claim 1, wherein the first catalyst comprises at least one of a zeolite, a silica aluminum phosphate, an ion exchanged zeolite, a silica aluminum phosphate promoted with iron and/or copper, one or more base metal oxides and a catalyst support of at least one of cerium tungsten oxide on a titania support, an alumina support, a zirconia support, a silica support or mixtures thereof.

3. The method of claim 2, wherein the zeolite is a beta zeolite, a chabazite zeolite or a silica aluminum phosphate with chabazite structure and mixtures thereof.

4. The method of claim 3, wherein the silica aluminum phosphate with chabazite structure is SAPO 34 promoted with copper and/or iron.

5. The method of claim 1, wherein the second catalyst composition comprises a mixture of platinum and palladium supported on at least one of alumina, titania, ceria, zirconia and silica mixed with copper and/or iron containing zeolite or silica alumina phosphate with chabazite structure.

6. The method of claim 5, wherein the zeolite is beta zeolite or a chabazite zeolite.

7. The method according to claim 1, wherein the filter is in form of a wall flow monolith with a plurality of longitudinal passages divided by longitudinal porous walls, dispersion side of the passages having an open inlet end and an outlet end being plugged with plugs, and permeate side of the passages having an inlet end being plugged with plugs and an open outlet end.

8. The method of claim 7, wherein the wall flow monolith is washcoated with the first catalyst washcoat from the inlet end of the dispersion side and with the second washcoat from the outlet end of the permeate side.

9. The method according to claim 1, wherein mode particle size of the first catalyst in the first washcoat is smaller than the mean pore diameter of the longitudinal walls, and wherein mode particle size of the second washcoat is larger than the mean pore diameter of the longitudinal walls.