CN105683518B - 具有改性贫燃NOx阱的排气系统和方法 - Google Patents
具有改性贫燃NOx阱的排气系统和方法 Download PDFInfo
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Abstract
公开了用于处理来自内燃机的排气气体的排气系统。系统包括改性贫燃NOx阱(LNT)、尿素注射系统和氨‑选择性催化还原(NH3‑SCR)催化剂。改性LNT包含铂、钯、钡和含二氧化铈的材料,并且铂:钯摩尔比为至少3:1。改性LNT在低于约200℃的温度下储存NOx并且在高于约200℃的温度下释放储存的NOx。尿素注射系统在高于约180℃的温度下注射尿素。还公开了用于处理来自内燃机的排气气体的方法。
Description
技术领域
本发明涉及用于处理来自内燃机的排气气体的排气系统,和用于处理来自内燃机的排气气体的方法。
背景技术
内燃机产生包含各种污染物的排气气体,所述污染物包括氮氧化物(“NOx”)、一氧化碳和未燃烧的烃,其是政府立法的对象。排放物控制系统广泛用于降低排放到大气中的这些污染物的量,并且一旦它们达到其操作温度(通常,200℃以上),其通常实现非常高的效率。然而,这些系统在低于其操作温度(“冷启动”时期)时相对低效。
例如,实施来满足Euro 6b排放的现有的尿素系选择性催化还原 (SCR)应用要求在尿素可以定量加入并且用于转化NOx之前,在尿素定量加入位置处的温度高于约180℃。低于180℃时使用现有的系统难以实现NOx转化,并且未来的欧洲和美国立法将强调低温NOx储存和转化。目前,这是通过加热策略实现的,但是这具有CO2排放物的有害影响。
因为日益严格的国家和地区立法降低了可以从柴油或汽油发动机排放的污染物的量,在冷启动时期期间减少排放物变成很大的挑战。因此,持续探索了用于降低冷启动条件期间释放的NOx水平的方法。
例如,PCT国际申请WO2008/047170公开了这样的系统,其中来自贫燃排气气体的NOx在低于200℃的温度下吸附并且随后在高于 200℃时热解吸。据教导,NOx吸附剂由以下组成:钯和铈氧化物或包含铈和至少一种其它过渡金属的混合氧化物或复合氧化物。
美国申请公开号2011/0005200教导了这样的催化剂系统,其通过将氨-选择性催化还原(“NH3-SCR”)催化剂配制物放置在贫燃NOx阱下游,同时除去氨并且提高净NOx转化率。据教导,NH3-SCR催化剂吸附在贫燃NOx阱中的富燃脉冲期间产生的氨。然后使储存的氨与从上游贫燃NOx阱释放的NOx反应,其增加了NOx转化率,同时耗尽储存的氨。
PCT国际申请WO2004/076829公开了排气-气体纯化系统,其包括布置在SCR催化剂上游的NOx储存催化剂。NOx储存催化剂包括至少一种碱金属、碱土金属或稀土金属,其使用至少一种铂族金属(Pt、 Pd、Rh或Ir)涂覆或活化。特别优选的是,据教导,NOx储存催化剂包括涂覆有铂的铈氧化物和作为基于氧化铝的载体上的氧化催化剂的另外的铂。EP1027919公开了NOx吸附剂材料,其包含多孔载体材料,例如氧化铝、沸石、二氧化锆、二氧化钛和/或氧化镧,和至少0.1wt%的贵金属(Pt、Pd和/或Rh)。例示了氧化铝上负载的铂。
与任何汽车系统和方法类似,期望获得排气气体处理系统的更加进一步的改进,特别是在冷启动条件下。我们已经发现了可以在冷启动时期期间降低NOx排放的系统,同时维持良好的CO氧化活性并且显示出对由硫酸盐化(sulfation)导致的减活的耐受性。
发明内容
本发明是用于处理来自内燃机的排气气体的排气系统。该系统包括改性贫燃NOx阱(LNT)、尿素注射系统和氨-选择性催化还原 (NH3-SCR)催化剂。改性LNT包含铂、钯、钡和含二氧化铈的材料,并且铂:钯摩尔比为至少3:1。改性LNT在低于约200℃的温度下储存NOx并且在高于约200℃的温度下释放储存的NOx。
具体实施方式
本发明为用于处理来自内燃机的排气气体的排气系统。系统包括改性贫燃NOx阱(LNT)。贫燃NOx阱在本领域是公知的。贫燃NOx阱通常设计为在贫燃排气条件下吸附NOx,在富燃条件下释放吸附的NOx,并且还原释放的NOx以形成N2。
LNT通常包括NOx-储存组分、氧化组分和还原组分。NOx-储存组分优选包含碱土金属(例如,钡、钙、锶和镁)、碱金属(例如,钾、钠、锂和铯)、稀土金属(例如,镧、钇、镨和钕)或其组合。这些金属通常见于氧化物形式。通常,包括铂来进行氧化功能并且包括铑来进行还原功能。这些组分包含在一种或多种载体上。
氧化/还原催化剂和NOx-储存组分优选负载在载体材料(例如,无机氧化物)上,以形成用于排气系统的LNT。
本发明的改性LNT设计为具有不同于已知的LNT的功能,不同之处在于它们设计为在低于约200℃的温度下储存NOx并且在高于约 200℃的温度下释放储存的NOx。改性LNT包含铂、钯、钡和含二氧化铈的材料。含二氧化铈的材料优选为二氧化铈、二氧化铈-二氧化锆、二氧化铈-二氧化锆-氧化铝或其混合物。更优选地,含二氧化铈的材料为二氧化铈。
改性LNT的铂:钯摩尔比为至少3:1,更优选大于4:1。
改性LNT还包含钡。可以通过任何已知的方式将钡添加至改性 LNT。例如,可以通过任何已知的方式将钡化合物负载至含二氧化铈的材料或载体材料上,认为添加的方式并不特别关键。例如,可以通过浸渍、吸附、离子交换、初湿含浸法或沉淀等将钡化合物(例如,乙酸钡)添加至含二氧化铈的材料或载体材料上。优选地,改性LNT包含至少150g/ft3的负载量的钡,并且在一些情况下,改性LNT可以包含至少400g/ft3的负载量的钡。
优选地,改性LNT还包含载体。载体优选为无机氧化物,和更优选包括第2、3、4、5、13和14族元素的氧化物。最优选地,载体为氧化铝、二氧化硅、二氧化钛、二氧化锆、氧化镁、氧化铌、钽氧化物、钼氧化物、钨氧化物、其任何两者或更多者的混合氧化物或复合氧化物(例如,二氧化硅-氧化铝、氧化镁-氧化铝),及其混合物。载体也可以优选包含铈。有用的载体优选具有10-1500m2/g的表面积, 0.1-4mL/g的孔体积,和约10-1000埃的孔径。具有大于80m2/g的表面积的高表面积载体是特别优选的。
本发明的改性LNT在低于约200℃的温度下储存NOx并且在高于约200℃的温度下释放储存的NOx。
改性LNT优选涂覆在基材上。基材优选为陶瓷基材或金属基材。陶瓷基材可以由任何适合的耐火材料制备,所述耐火材料为例如,氧化铝、二氧化硅、二氧化钛、二氧化铈、二氧化锆、氧化镁、沸石、氮化硅、碳化硅、锆的硅酸盐、镁的硅酸盐、铝硅酸盐和金属铝硅酸盐(例如、堇青石和锂辉石)或其任何两者或更多者的混合物或混合氧化物。堇青石、铝硅酸镁和碳化硅是特别优选的。
金属基材可以由任何适合的金属,并且特别是耐热性金属和金属合金(例如钛和不锈钢以及除其他痕量金属之外包含铁、镍、铬和/或铝的铁素体合金)组成。
基材可以为过滤式基材或流通式基材,并且最优选为流通式基材,尤其是蜂窝状整料。基材通常设计为提供多个通道,其中通过汽车排气。通道的表面负载有三元催化剂。
可以通过任何已知的方式将改性LNT添加至基材。例如,优选可以使改性LNT材料作为载体涂层施用并且结合至基材,所述载体涂层为结合至基材表面的多孔高表面积层。载体涂层通常由水基浆料施用至基材,然后在高温下干燥和煅烧。优选地,将改性LNT作为单一的层添加至基材,尽管可以使用另外的层。
本发明的排气系统还包括氨-选择性催化还原(NH3-SCR)催化剂。 NH3-SCR催化剂可以包含任何已知的NH3-SCR催化剂,其在本领域是公知的。NH3-SCR催化剂是通过与氮化合物(例如,氨或尿素)的反应将NOx还原成N2的催化剂。
优选地,NH3-SCR催化剂包含氧化钒-二氧化钛催化剂、氧化钒- 氧化钨-二氧化钛催化剂或金属/沸石。金属/沸石催化剂包含金属和沸石。优选金属包括铁和铜。沸石优选为β沸石、八面沸石(例如,X- 沸石或Y-沸石,包括NaY和USY)、L-沸石、ZSM沸石(例如,ZSM-5、ZSM-48)、SSZ-沸石(例如,SSZ-13、SSZ-41、SSZ-33)、镁碱沸石、丝光沸石、菱沸石、菱钾沸石、毛沸石、斜发沸石、硅质岩、磷酸铝沸石(包括金属铝磷酸盐,例如SAPO-34)、中孔沸石(例如,MCM-41、 MCM-49、SBA-15)或其混合物;更优选地,沸石为β沸石、镁碱沸石或菱沸石。
NH3-SCR催化剂优选涂覆在陶瓷或金属基材上,如上所述。基材通常设计为提供多个管道,其中通过车辆排气,并且通道表面优选涂覆有NH3-SCR催化剂。
用于NH3-SCR催化剂的基材可以为过滤式基材或流通式基材。优选地,NH3-SCR催化剂涂覆在过滤器上,其称为氨-选择性催化还原过滤器(NH3-SCRF)。SCRF为单一基材装置,其组合了NH3-SCR和颗粒过滤器的功能。它们用于减少来自内燃机的NOx和颗粒排放物。
本发明的系统进一步包括尿素注射系统。尿素注射系统优选包括尿素注射器,其将尿素注射至NH3-SCR催化剂上游和改性LNT下游的排气气体物流中。尿素注射系统优选由喷嘴组成,以生产明确限定的尿素溶液液滴。液滴尺寸优选小于500微米,以允许快速蒸发和尿素分解。注射器压力和泵速率是这样的,其允许排气气体物流中的有效混合。
尿素注射系统还优选由以下组成:尿素罐、输送管线和可能的加热系统,以避免尿素溶液的冷冻。
优选地,尿素注射系统在高于约180℃的温度下注射尿素。通常,尿素注射系统构造为在高于约180℃的温度下注射尿素。例如,尿素注射系统可以进一步包括构造为在高于约180℃的温度下注射尿素的处理器,其中处理器电连接至温度传感器。
本发明还包括用于处理来自内燃机的排气气体的方法。该方法包括将排气气体传送在上述改性LNT上。改性LNT在低于约200℃的温度下从排气气体除去氮氧化物(NOx),并且在高于约200℃的温度下释放NOx。在高于约180℃的温度下,将尿素注射至改性LNT下游的排气气体,和包含从改性LNT释放的NOx的排气气体中并且将尿素传送在NH3-SCR催化剂上。释放的NOx通过在NH3-SCR催化剂上氨 (产生自尿素)与NOx的反应转化成氮。释放的NOx是在低温下储存在改性LNT上并且然后在较高温度下释放的NOx,并且还包括传送在 NH3-SCR催化剂上而没有储存的NOx。
优选地,改性LNT周期性地经受富燃脱硫酸盐化(desulfation)步骤。燃料中硫化合物的存在可能有害于改性LNT,因为硫化合物的氧化在排气气体中产生硫氧化物。在LNT中,二氧化硫可以在铂族金属上氧化成三氧化硫并且在LNT表面上形成表面硫酸盐(例如,氧化物钡或碳酸钡与三氧化硫反应从而形成硫酸钡)。这些硫酸盐比硝酸盐更稳定并且要求更高的温度(>500℃)来脱硫酸盐化。
在富燃脱硫酸盐化中,改性LNT通常在富燃空气:燃料比环境中在经受高于约500℃的温度以实现硫的去除。脱硫酸盐化优选通过增加排气温度通过燃料的后注射进行。脱硫酸盐化策略可以包括单一、连续富燃时期,或串联的短富燃空气:燃料比脉冲。
以下实施例仅仅说明了本发明。本领域技术人员将认识到多种变型可以在本发明的精神和权利要求的范围内。
实施例1:改性LNT的制备
改性LNT 1A(Pt:Pd比=5:1):
用NOx吸收剂催化剂配制物涂覆400个孔/平方英寸的(cpsi)流通式堇青石基材整料,所述NOx吸收剂催化剂配制物包含单层,所述单层包含1.5g/in3的Ce/铝酸镁尖晶石、3g/in3的颗粒二氧化铈、94g/ft3的Pt和19g/ft3的Pd。使用WO99/47260中公开的方法将载体涂层涂覆在未经涂覆的基材整料上,随后在强制空气干燥器中在100℃下干燥30分钟并且然后在500℃下锻烧2小时。
对比LNT 1B:(Pt:Pd比=2:1)
根据用于改性LNT 1A的流程制备对比LNT 1B,除了NOx吸收剂催化剂配制物包含单层,所述单层包含53.3g/ft3的Pt和26.6g/ft3的Pd。
实施例2:NOx储存测试
LNT 1A(1.6L催化剂体积)在800℃下水热老化5小时,并且然后在NEDC驱动循环上对1.6升发动机采用低压排气气体再循环(EGR) 进行测试。在测试期间没有采用富燃吹扫。
结果显示改性LNT 1A在最高约200℃下储存约0.5g的NOx,随后在200-300℃下接近完全热释放储存的NOx,显示出本发明的改性 LNT能够用于NH3-SCR系统。
实施例3:脱硫酸盐化测试
LNT 1A和对比LNT 1B经受富燃脱硫酸盐化再生以测试对CO转化率的影响。在重复的贫燃NEDC驱动循环上对1.6升发动机采用低压排气气体再循环(EGR)测试在800℃下水热老化5小时的对比LNT 1B(1.6升催化剂体积)。完成重复的贫燃NEDC循环以评估在延长的贫燃操作情况下的循环CO转化率的劣化。结果显示在表1中。在十个NEDC循环的期间,排气管CO排放从1.3g的CO增加至4.7g的 CO。在第十个贫燃循环之后,使用3秒富燃吹扫对100kph巡航进行串联的三个NEDC循环以再活化催化剂。分析显示一个3秒富燃吹扫足以再活化催化剂,因为排气管CO排放降低至1.8g的CO。再次在 CO减活之后完成进一步的10个仅贫燃NEDC循环,并且在第十个循环时,排气管CO排放增加至5.6g的CO。在第二个NEDC循环之后,以0.95的λ进行500-550℃入口温度脱硫酸盐化10分钟,并且进行第三10-循环NEDC测试。结果显示高温脱硫酸盐化使该LNT对CO转化减活。在第三NEDC循环之后,完成10分钟贫燃DPF再生(在含氧气氛中600℃)。结果显示初始的CO转化率在该再生时未恢复。
相反,本发明的改性LNT 1A在富燃脱硫酸盐化之后显示出良好的CO转化率,其中比较LNT 1B在富燃脱硫酸盐化之后损失了CO 转化率。
表1:排气管CO排放
Claims (12)
1.用于处理来自内燃机的排气气体的排气系统,包括:
(a)改性贫燃NOx阱(LNT),其中改性贫燃NOx阱包含铂、钯、钡和含二氧化铈的材料并且改性贫燃NOx阱的铂:钯摩尔比为至少3:1,和其中该改性贫燃NOx阱作为单一的层存在于基材上;
(b)尿素注射系统;和
(c)氨-选择性催化还原(NH3-SCR)催化剂,
其中改性贫燃NOx阱在低于约200℃的温度下储存NOx并且在高于约200℃的温度下释放储存的NOx;和
其中所述NH3-SCR催化剂是金属/沸石,其中所述金属/沸石包含:选自铁或铜的金属;和选自β沸石、八面沸石、L-沸石、ZSM沸石、SSZ-沸石、镁碱沸石、丝光沸石、菱沸石、菱钾沸石、毛沸石、斜发沸石、硅质岩、磷酸铝沸石和中孔沸石的沸石。
2.根据权利要求1的排气系统,其中所述尿素注射系统在高于约180℃的温度下注射尿素。
3.根据权利要求1或权利要求2的排气系统,其中所述改性贫燃NOx阱的铂:钯摩尔比为至少4:1。
4.根据权利要求1或权利要求2的排气系统,其中所述改性贫燃NOx阱的钡负载量大于150g/ft3。
5.根据权利要求1或权利要求2的排气系统,其中所述改性贫燃NOx阱的钡负载量大于400g/ft3。
6.根据权利要求1或权利要求2的排气系统,其中所述NH3-SCR催化剂为氨-选择性催化还原过滤器(NH3-SCRF)。
7.根据权利要求6的排气系统,其中所述氨-选择性催化还原过滤器包括过滤器,所述过滤器具有选自氧化钒-二氧化钛催化剂、氧化钒-氧化钨-二氧化钛催化剂和金属/沸石的NH3-SCR催化剂。
8.用于处理来自车辆的内燃机的排气气体的方法,包括:
(a)将排气气体传送在改性贫燃NOx阱(LNT)上以在低于约200℃的温度下从排气气体中除去氮氧化物(NOx)并且在高于约200℃的温度下释放NOx,其中改性贫燃NOx阱包含铂、钯、钡和含二氧化铈的材料并且所述改性贫燃NOx阱的铂:钯摩尔比为至少3:1,和其中该改性贫燃NOx阱作为单一的层存在于基材上;
(b)在高于约180℃的温度下将尿素注射至改性贫燃NOx阱下游的排气气体中;和
(c)将包含从改性贫燃NOx阱释放的NOx的排气气体和尿素传送在NH3-SCR催化剂上以将NOx转化成氮;
其中所述NH3-SCR催化剂是金属/沸石,其中所述金属/沸石包含:选自铁或铜的金属;和选自β沸石、八面沸石、L-沸石、ZSM沸石、SSZ-沸石、镁碱沸石、丝光沸石、菱沸石、菱钾沸石、毛沸石、斜发沸石、硅质岩、磷酸铝沸石和中孔沸石的沸石。
9.根据权利要求8的方法,进一步包括在富燃空气:燃料比环境中周期性地使所述改性贫燃NOx阱经受高于约500℃的温度以除去累积在所述改性贫燃NOx阱上的硫。
10.根据权利要求8或权利要求9的方法,其中所述改性贫燃NOx阱的铂:钯摩尔比为至少4:1。
11.根据权利要求8或权利要求9的方法,其中所述改性贫燃NOx阱的钡负载量大于150g/ft3。
12.根据权利要求8或权利要求9的方法,其中所述改性贫燃NOx阱的钡负载量大于400g/ft3。
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US20190063287A1 (en) | 2019-02-28 |
BR112016005657A2 (zh) | 2017-08-01 |
RU2016114527A (ru) | 2017-10-23 |
KR102277783B1 (ko) | 2021-07-15 |
WO2015036797A1 (en) | 2015-03-19 |
US20150075140A1 (en) | 2015-03-19 |
RU2016114527A3 (zh) | 2018-05-03 |
US10119445B2 (en) | 2018-11-06 |
GB2520148B (en) | 2017-10-18 |
BR112016005657B1 (pt) | 2022-03-29 |
CN105683518A (zh) | 2016-06-15 |
DE102014113304A1 (de) | 2015-03-19 |
DE102014113304B4 (de) | 2017-06-29 |
JP2016535203A (ja) | 2016-11-10 |
EP3572633A1 (en) | 2019-11-27 |
KR20160055244A (ko) | 2016-05-17 |
EP3047121B1 (en) | 2019-07-17 |
GB201416300D0 (en) | 2014-10-29 |
GB2520148A (en) | 2015-05-13 |
EP3047121A1 (en) | 2016-07-27 |
RU2660722C2 (ru) | 2018-07-09 |
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