CN108367283B - 防止选择性催化还原(scr)催化剂受铂污染的方法 - Google Patents

防止选择性催化还原(scr)催化剂受铂污染的方法 Download PDF

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CN108367283B
CN108367283B CN201680073677.5A CN201680073677A CN108367283B CN 108367283 B CN108367283 B CN 108367283B CN 201680073677 A CN201680073677 A CN 201680073677A CN 108367283 B CN108367283 B CN 108367283B
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platinum group
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CN108367283A (zh
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C·亨斯特
M·洛佩兹
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Umicore Corp And Lianghe Co
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Abstract

本发明涉及一种用于防止排放控制系统中SCR催化剂受到铂族金属污染的方法，所述排放控制系统包括位于所述SCR催化剂上游的含有铂族金属的催化剂，其特征在于含有氧化铝和氧化铈混合物的材料区域位于所述SCR催化剂的上游。

Description

防止选择性催化还原(SCR)催化剂受铂污染的方法
本发明涉及一种防止废气处理系统中SCR催化剂受到来自布置在废气处理系统上游的含铂部件的铂污染的方法。
除了一氧化碳(CO)和氮氧化物(NOx)之外，由柴油发动机驱动的机动车辆的废气含有源自汽缸燃烧室中燃料不完全燃烧的组分。除了残余的烃类(HC)之外，这包括通常以气体形式存在的粒子排放物，并被称为“柴油烟灰”或“烟尘粒子”。
为了清洁这些废气，上述组分必须尽可能完全地转化为无害化合物。这只有在使用合适催化剂的情况下才有可能实现。
这样，一氧化碳(CO)、气态烃(HC)以及(如果适用)粘附到碳烟粒子的有机团聚体(所谓的“挥发性有机馏分”VOF)可使用氧化催化剂以氧化方式去除。氧化催化剂在现有技术中由来已久，并且在大量实施方案中有所描述。在大多数情况下，贵金属铂和/或钯用作氧化-催化活性组分(参见例如US2011/0206584A1)；然而，例如在EP1938893A2中还描述了含金催化剂。
为了去除柴油车废气中的粒子排放物，使用了特殊的粒子过滤器，其可以设置有氧化-催化活性涂层以改善其特性。如在SAE文献SAE 2005-01-1756中详细描述的那样，此类涂层用于减少用于氧基粒子燃烧(烟尘燃烧)的活化能并因此降低过滤器上的烟尘点火温度，通过将废气中含有的一氧化氮氧化成二氧化氮来改善被动再生行为，并抑制烃类和一氧化碳排放物的突破。
柴油发动机废气中的氮氧化物可以例如通过使用氨作为合适的催化剂即SCR催化剂上的还原剂的选择性催化还原(SCR)而转化为无害的氮。还原剂必须通过SCR催化器上游的注射喷嘴从运送附加罐计量进入废气系统。优选地，不运送氨本身，而是运送容易分解成氨的化合物，诸如尿素或氨基甲酸铵。
为了使所讨论的有害废气组分能够被去除到所需程度，上述催化剂或过滤器必须适当地彼此组合成废气处理系统。
在已知废气处理系统中，例如WO99/39809和WO2009/140989中描述的废气处理系统，首先将氧化催化剂，然后是柴油粒子过滤器，最后是SCR催化剂布置在废气的流动方向上。位于柴油粒子过滤器与SCR催化剂之间的是用于计量还原剂的注射设备。根据要求，不使用柴油粒子过滤器的问题解决方案也是可行的。在这些情况下，废气处理系统在废气流动方向上首先包括氧化催化剂，然后是SCR催化剂。在这种情况下，用于计量还原剂的注射设备布置在氧化催化剂与SCR催化剂之间。
当这些系统运行时，据显示在高温下并且取决于λ值，氧化催化剂，特别是当它富含铂时，向气相中排出微量铂，该气相与废气流一起运输到SCR催化剂并污染它。由于铂呈现出高氨氧化活性，因此在约300℃以上的温度下SCR反应没有足够的氨可用，并且氮氧化物的转化降低。此外，还观察到一氧化二氮(N2O)形成的升高，主要在约250℃的温度范围内。这种现象例如在SAE文献SAE 2008-01-2488和SAE 2009-01-0627中有所描述。
为了解决这个问题，US2011/138777A1提出在氧化催化剂下游和SCR催化剂上游的排气系统中布置含有氧化铈或钙钛矿材料作为有效组分的“铂族金属捕集器”。
WO2013/088132A1还提出了在SCR催化剂与含有铂族金属的催化剂之间布置具有能够结合挥发性铂族金属的材料的第三催化剂基底。
然而，上述方法具有的缺点是，废气处理系统必须补充附加部件，考虑到车辆底部的有限空间，这将非常难以实现。另外，这种解决方案将导致更高的成本。
在WO2013/088133A1中还提出了为氧化-催化活性催化剂(即，柴油机氧化催化剂或设置有氧化-催化活性涂层的粒子过滤器)配备能够去除含有在废气流中的铂族金属(尤其是铂)的材料区域。因此，在这种情况下不需要附加部件。提出为“铂族金属捕集器”的是选自由以下各项组成的组的金属氧化物：可能地稳定氧化铝、非晶硅氧化铝、可能地稳定氧化锆、氧化铈、氧化钛、可能地稳定铈/锆混合氧化物以及它们中两者或更多者的混合物。归于与铂具有特殊亲和力的氧化铈是特别优选的。
根据EP2653681A1，提出钯、金或其混合物作为具有氧化-催化活性涂层的柴油粒子过滤器的“铂捕集器”。EP2674584A1也公开了钯、金或其混合物作为“铂捕集器”。
从WO93/10886A1已知的是一种包括催化材料的氧化催化剂，该催化材料基本上由氧化铈和氧化铝的组合组成，各自的BET表面积为至少10m2/g。
令人惊讶的是，由氧化铈和氧化铝组成的混合物是特别活泼的铂族金属捕捉器，特别是铂捕捉器。
因此，本发明涉及一种用于防止废气处理系统中SCR催化剂受到铂族金属污染的方法，所述废气处理系统包括位于SCR催化剂上游的含有铂族金属的催化剂，其特征在于含有氧化铝和氧化铈的混合物的材料区域位于SCR催化剂的上游。
在本发明的上下文中，含有铂族金属的催化剂具体地讲被理解为含有铂族金属的氧化催化剂，或者设置有含铂族金属的氧化-催化活性涂层的粒子过滤器。
在本发明的上下文中，铂族金属具体地讲被理解为铂。
根据本发明并且由氧化铝和氧化铈组成的待使用的混合物包括氧化铝，具体地讲相对于氧化铝和氧化铈的混合物的重量为10至90重量％，诸如30至70或40至60重量％。
如在汽车废气催化领域常规使用的那样，高比表面积氧化铝优选地用作氧化铝。它优选地具有50至200m2/g的比表面积。氧化铝也可以例如利用镧稳定，并且在这种情况下，相对于稳定氧化铝的总重量，含有1至10重量％的氧化镧，优选地3至6重量％。
优选地使用纯氧化铈，即氧化铈含量为80至100重量％的氧化铈作为氧化铈。此类氧化铈对于本领域技术人员而言是已知的并且可商购获得。
根据本发明并且由氧化铝和氧化铈组成的待使用的混合物优选地为物理混合物。它们能够以粉末形式混合，然后掺入到载体涂层中。然而，它们也可以同时或顺序掺入到载体涂层中而无需事先混合。
相对于催化剂基底的体积，由氧化铝和氧化铈组成的混合物特别地以10至300g/L，具体地讲30至200g/L的量使用。
在本发明的上下文中含有铂族金属的催化剂是带有一种或多种涂层形式的氧化-催化活性组分的流通基底或过滤基底，具体地讲壁流式过滤器。它们含有氧化-催化活性组分(尤其是铂)，但它们还可以附加地含有一种或多种其他铂族元素，特别是钯和/或铑，或者例如金。氧化-催化活性组分承载在高比表面积惰性载体材料上的流通或过滤基底上。特别优选的氧化-催化活性涂层含有氧化铝上的铂。
当氧化-催化活性涂层是“富含铂”时，即当它仅含有铂或铂与其他组分(其中铂过量)的混合物作为氧化-催化活性组分时，根据本发明的方法可以被特别有利地使用。
一般来讲，单独使用铂或使用铂和钯的混合物，其中铂与钯的重量比为12:1至4:1。
相对于氧化-催化活性涂层的体积，氧化-催化活性金属的全部装载量优选地为1至3.5g/L(100g/ft3)。
除了氧化-催化活性组分之外，在本发明的上下文中，含有铂族金属的催化剂还可以含有在贫废气条件下(即，富氧条件下)化学结合氮氧化物并且可以在富集废气条件下(即，低氧条件下)释放氮氧化物的组分。此类组分被称为氮氧化物储存组分，并且优选地为碱金属、碱土金属和稀土金属的氧化物、碳酸盐或氢氧化物，其中钡和锶是特别优选的。
特别是对于承载在流通基底上的含有铂族金属的催化剂而言尤其如此。因此，在本发明的上下文中，此类氧化催化剂也可以含有LNT功能(贫NOx捕集器)。
流通或过滤基底可以由金属，具体地讲陶瓷材料组成。优选地，它们由堇青石、碳化硅、莫来石或钛酸铝组成。
优选地，壁流式过滤器基底被用作柴油粒子过滤器。这些是具有流入和流出通道的蜂窝体，它们以气密方式相互密封，由多孔壁界定并彼此分离。进入流入通道的含粒子废气通过位于出口侧上的气密性密封塞被迫穿过多孔壁并且再从壁流过滤器基底穿过在流入侧上密封的出口通道逸出。同时，柴油机烟尘从废气中过滤出来。
文献中经常描述前述流通或过滤基底。
含有氧化铝和氧化铈混合物的材料区域可以承载在位于含铂族金属的催化剂与SCR催化剂之间的单独的催化剂基底上。
然而，有利的是，含有氧化铝和氧化铈混合物的材料区域位于含铂族金属的催化剂上作为附加材料区域。
在这种情况下，这种材料区域能够以各种方式存在。在本发明的一个实施方案中，它作为附加层存在于均匀分布在基底的整个长度上的氧化-催化活性涂层上并且从布置在流出侧的流通或过滤基底的端部开始至少在其整个长度的一部分上覆盖它。在这种情况下，去除废气流中所含的微量铂族金属的材料区域优选地占据过滤基底的整个长度的50至100％，优选地50、60、70、80或90％。
在另一个实施方案中，氧化-催化活性涂层和含有氧化铝和氧化铈混合物的材料区域布置在流通或过滤基底上分开的区域中。与上述实施方案相反，在这种情况下，氧化-催化活性涂层不在基底的整个长度上延伸。
如果基底的总长度为L，则氧化-催化活性区域的长度为L1，并且含有氧化铝和氧化铈的混合物的区域的长度为L2，则L＝L1+L2。
在生产中，可能发生L1+L2不精确地对应于L。例如，L1+L2可能稍大于L。这意味着两个区域L1和L2稍微重叠。另一方面，L1+L2可以略小于L，这意味着未涂布的小间隙位于L1和L2之间。
在本发明的一个优选实施方案中，含有氧化铝和氧化铈混合物的材料区域(L2)占基底总长度的25至67％。因此，氧化-催化活性区域(L1)占基底总长度的33至75％。
含有氧化铝和氧化铈混合物的材料区域总是布置在下游；因此，在废气处理系统中，它指向SCR催化剂的方向。
在根据本发明的方法的优选实施方案中，废气处理系统在废气的流动方向上包括含有铂族金属的流通基底(氧化催化剂)、柴油粒子过滤器和SCR催化剂。就柴油粒子过滤器也设置有氧化-催化活性涂层而言，氧化铝和氧化铈的混合物优选地位于柴油粒子过滤器上。否则，它也可以位于含有铂族金属的流通基底(氧化催化剂)上。
在本发明的实施方案中，SCR催化剂被经常描述并且是本领域技术人员已知的常规产品。它们通常是流通蜂窝体，催化活性组分以涂层的形式施加在所述蜂窝体上。
基于氧化钒或基于无钒混合氧化物以及基于沸石的SCR催化剂都是合适的。基于沸石的SCR催化剂是优选的，特别是与铁和/或铜交换的那些SCR催化剂。此类特别优选的SCR催化剂是菱沸石和插晶菱沸石型的含铜和/或含铁的沸石。
在根据本发明的方法的另一个实施方案中，废气处理系统在废气的流动方向上包括含有铂族金属的流通基底(氧化催化剂)并且包括氧化铝和氧化铈的混合物以及柴油粒子过滤器，其中SCR催化剂以涂层型式施加在柴油粒子过滤器上。在某些情况下，该系统还可以包括位于柴油粒子过滤器下游的另一种SCR催化剂。
最后，还可以想到根据本发明的方法的实施方案，其中废气处理系统在废气流动的方向上包括含铂族金属的流通基底(氧化催化剂)和位于其下游的SCR催化剂，即它不包括柴油粒子过滤器。
根据常规的浸涂方法或泵吸涂层方法和后续的热后处理(煅烧并可能用形成的气体或氢气还原)将催化活性涂层施加到流通蜂窝体和过滤体上，这对于来自现有技术的这些废气净化集料而言是充分已知的。
根据本发明的柴油粒子过滤器非常适用于持续保护SCR催化剂免受铂污染并因此避免活性损失。已经特别表明，根据本发明的方法能够以经济有利的方式有效地防止SCR催化剂受到铂族金属污染。以下示例令人印象深刻。
实施例
如表1所示，在常规流通基底上装载0.7g/L(20g/ft3)氧化铝的常规氧化催化剂与不同的氧化铝/氧化铈混合物组合作为铂捕捉器。为此，分别用对应量的铂捕捉器涂布催化剂并将其置于氧化催化剂的下游。选择氧化催化剂和铂捕捉器的长度，使得氧化催化剂占据总长度的67％，并且将总长度的33％分配给铂捕捉器。
在新鲜状态下，它们在具有等温反应器的常规模型气体系统中在650℃的恒定温度下经受具有以下组分的模型气体18个小时，以确定氧化催化剂的铂迁移：
CO 71ppm
NO 820ppm
O2 6.3体积％
CO2 8.9体积％
H2O 持续18小时的测量中为11体积％，并且持续60小时的测量中为5体积％
N2 余量
离开相应氧化催化剂下游的气体被引导通过长度为5cm(2”)的流通基底并利用铁-β-沸石型SCR催化剂涂布。
然后，测定每种催化剂中结合在SCR催化剂中的铂的量。为此，通过NiS火法试验将催化剂的钻芯在坩埚中熔化，然后通过ICP-OES测定铂。
作为比较，测量了纯氧化铝和纯氧化铈。获得以下结果：
Figure BDA0001696972440000071
氧化铝1是市售的纯氧化铝
氧化铝2是掺杂有来自制造商1的4重量％镧的市售介孔氧化铝
氧化铝3是掺杂有来自制造商2的4重量％镧的市售介孔氧化铝
氧化铈1是来自制造商3的市售纯氧化铈
氧化铈2是来自制造商4的市售纯氧化铈
结果表明，至少高达90重量％的氧化铈可以被更便宜的氧化铝代替而不会使效果恶化。

Claims (10)

1.一种用于防止废气处理系统中SCR催化剂受到铂族金属污染的方法，所述废气处理系统包括位于所述SCR催化剂上游的含铂族金属的催化剂，其特征在于含有氧化铝和氧化铈的混合物的材料区域位于所述SCR催化剂的上游。
2.根据权利要求1所述的方法，其特征在于所述含铂族金属的催化剂是含铂族金属的氧化催化剂或设置有含铂族金属的氧化-催化活性涂层的粒子过滤器。
3.根据权利要求1或2所述的方法，其特征在于所述铂族金属是铂。
4.根据权利要求1所述的方法，其特征在于所述氧化铝和氧化铈的混合物包括相对于所述氧化铝和氧化铈的混合物的重量的10至90重量％的氧化铝。
5.根据权利要求1所述的方法，其特征在于所述氧化铝和氧化铈的混合物是物理混合物。
6.根据权利要求1所述的方法，其特征在于含有氧化铝和氧化铈混合物的材料区域承载在位于所述含铂族金属的催化剂与所述SCR催化剂之间的催化剂基底上。
7.根据权利要求1所述的方法，其特征在于含有氧化铝和氧化铈混合物的材料区域位于所述含铂族金属的催化剂上作为附加材料区域。
8.根据权利要求6所述的方法，其特征在于含有氧化铝和氧化铈混合物的材料区域作为附加层存在于均匀分布在所述基底的整个长度上的氧化-催化活性涂层上并且从布置在下游的含铂族金属的催化剂的端部开始至少在其整个长度的一部分上覆盖它。
9.根据权利要求2所述的方法，其特征在于所述氧化-催化活性涂层和含有氧化铝和氧化铈混合物的材料区域存在于含铂族金属的催化剂上的分开的区域中。
10.根据权利要求9所述的方法，其特征在于含有氧化铝和氧化铈混合物的材料区域占含铂族金属的催化剂的总长度的25至67％。
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