CN109070000A - 排气系统 - Google Patents

排气系统 Download PDF

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Publication number
CN109070000A
CN109070000A CN201780026384.6A CN201780026384A CN109070000A CN 109070000 A CN109070000 A CN 109070000A CN 201780026384 A CN201780026384 A CN 201780026384A CN 109070000 A CN109070000 A CN 109070000A
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CN
China
Prior art keywords
exhaust system
area
oxidation catalysis
wall flow
wall
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201780026384.6A
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English (en)
Inventor
G·布朗
A·奇菲
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Johnson Matthey PLC
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Johnson Matthey PLC
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Publication date
Application filed by Johnson Matthey PLC filed Critical Johnson Matthey PLC
Publication of CN109070000A publication Critical patent/CN109070000A/zh
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • F01N13/00Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
    • F01N13/16Selection of particular materials
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/54Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
    • B01J23/56Platinum group metals
    • B01J23/60Platinum group metals with zinc, cadmium or mercury
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D53/00Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/92Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
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    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/92Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/944Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B01D53/92Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9459Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts
    • B01D53/9477Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts with catalysts positioned on separate bricks, e.g. exhaust systems
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    • B01J29/42Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively containing iron group metals, noble metals or copper
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    • B01J29/60Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the type L, as exemplified by patent document US3216789
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    • B01J29/63Iron group metals or copper
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    • B01J29/65Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the ferrierite type, e.g. types ZSM-21, ZSM-35 or ZSM-38, as exemplified by patent documents US4046859, US4016245 and US4046859, respectively
    • B01J29/66Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the ferrierite type, e.g. types ZSM-21, ZSM-35 or ZSM-38, as exemplified by patent documents US4046859, US4016245 and US4046859, respectively containing iron group metals, noble metals or copper
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Abstract

用于内燃发动机的排气系统,该排气系统包含:贫NOx阱,和壁流式整料基底,其具有40%或更高的预涂覆孔隙率并包含氧化催化区,该氧化催化区包含负载在第一载体上的铂族金属,第一载体包含至少一种无机氧化物和锌化合物。

Description

排气系统
本发明涉及用于内燃(IC)发动机的排气系统,涉及用在这样的排气系统中的催化整料基底,涉及制造这样的催化型整料基底的方法,和涉及处理废气的方法。
内燃发动机是污染物的潜在来源。希望减少来自内燃发动机的污染物排放。在经济体如欧盟、美国和全世界,已经实施了越来越严格的环境法规,并计划了进一步的法规,以减少污染物从各种来源,特别是内燃发动机排放到大气中。
关注的污染物包括NOx、一氧化碳、颗粒物质、烃、硫化氢和氨气。已经提出多种方法用于减少来自内燃发动机的排放。
WO-A-2010/004320公开了用于贫燃内燃发动机的排气系统,其包含第一基底整料,第一基底整料包含用于氧化一氧化氮(NO)的催化剂,下游是具有入口通道和出口通道的壁流式过滤器,其中该入口通道包含NOx吸收剂催化剂,该出口通道包含用于用含氮还原剂对氮氧化物进行选择性催化还原的催化剂。
WO-A-2012/175948公开了一种用于内燃发动机、用于处理一系列污染物的排气系统,其具有贫NOx阱和催化型基底。该催化型基底具有第一区和第二区,其中第一区包含负载在载体上的铂族金属,第二区包含负载在沸石上的铜或铁。第一区或第二区另外包含负载在无机氧化物上的贱金属氧化物或贱金属。
WO-A-2005/014146公开了使用单个整料的催化剂布置,和净化操作在贫条件下的内燃发动机的废气的方法。将薄壁、多孔的载体涂覆在具有氮氧化物储存催化剂的一侧上和在具有SCR催化剂的另一侧上。
例如当空气中的氮气与氧气在IC发动机内反应时,会产生氮氧化物(NOx)。这样的氮氧化物可以包含一氧化氮和/或二氧化氮。
一种减少NOx排放的催化方法是具有氧化催化剂的贫NOx阱,其将内燃发动机中产生的NOx有效地转化为氮气,不过废气中的一些NOx会在该阱变得饱和时泄漏。一些关注的副产物还可以由贫NOx阱产生,例如非选择性还原路径可以导致产生氨气。
已经研发了多种选择性催化还原(SCR)方法,以期通过将NOx转化为氮气和水来减少NOx排放。主动SCR使用还原剂(例如,含氮还原剂如氨气或尿素),该还原剂被添加到废气流中,吸附到催化剂上。通常,该含氮还原剂转化为氨气,并且在SCR催化剂存在发生多种反应,结果是NOx转化为单质氮和水。
WO-A-2015/036797公开了一种使用主动选择性催化还原来处理来自内燃发动机的废气的排气系统,和用于处理这种废气的方法。
被动SCR不需要单独的装置来将还原剂添加到废气流,可以使用贫NOx吸附剂阱(LNT)和/或选择性催化还原催化剂。当在贫条件中(低燃料/氧气比)产生废气时,NOx吸附在LNT上。LNT可以通过将它与富(高燃料/氧气比)废气间歇接触来再生,该富废气可以在发动机管理系统的控制下产生。这样的富化促进吸附的NOx的解吸和NOx在LNT中存在的还原催化剂上的还原。富废气还由NOx产生氨气(NH3)。该氨气可以吸附在下游SCR催化剂上,然后可用于还原在贫废气条件中从LNT泄漏的NOx。SCR催化剂的效率取决于NO2/NOx比和温度。
NOx阱可以在标准操作期间储存高浓度的硫。该硫需要被定期除去以保持NOx阱的性能。使用高温贫/富循环来使催化剂脱硫。但是,该方法使H2S释放到环境中。虽然H2S目前不是受管制的污染物,但是提供减少硫化氢排放的手段是有利的。
WO-A-2014/080220公开了一种在整料基底上的分区催化剂,其用于控制脱硫期间在贫NOx阱中形成的硫化氢气体。
但是,难以在减少H2S释放的同时保持催化剂良好的氧化性能和保持对颗粒物质的良好过滤。
US-A-2011/0014099公开了一种催化活性颗粒物质过滤器,其具有硫化氢阻塞功能。
US-A-2008/214390公开了一种用于净化废气的催化剂,其能够抑制硫化氢排放。
US-A-2009/082199公开了一种适于净化来自IC发动机的废气的催化剂,特别是其能够减少硫化氢排放。在该文献中,铂族金属催化剂和氧化物被描述为是分开的,以避免PGM催化剂的劣化/中毒。
在用在过滤器基底上的催化剂载体涂层(washcoat)中,H2S还原性材料和PGM分开会导致该过滤器基底的孔隙率显著降低,因为多层或厚的催化剂容易堵塞过滤器基底中的通道和孔。孔隙率降低容易使过滤器基底作为颗粒过滤器的有效性降低。
存在持续的需求,要减少H2S排放,同时还不降低催化除去其他污染物如颗粒物质、烃和CO的有效性,特别是因为新法规降低了IC发动机排放的可接受水平。
本发明的目的是解决这些问题。
因此,在第一方面中,本发明提供一种用于内燃发动机的排气系统,其中该排气系统包含贫NOx阱和壁流式整料基底,该壁流式整料基底具有40%或更高的预涂覆孔隙率(优选具有40%-75%的预涂覆孔隙率),其中该基底包含氧化催化区,该氧化催化区包含负载在第一载体上的铂族金属,其中第一载体包含至少一种无机氧化物和锌化合物。
这是非常有利的,因为这样的排气系统实现NOx、H2S、颗粒物质、CO和烃排放的减少。
在第一载体中使用锌化合物实现H2S泄漏的大幅减少,同时令人惊讶地保持对CO和烃(HC)的有效氧化,甚至当该锌化合物与PGM载体涂层中的PGM合并时。令人惊讶地,锌不毒化PGM。所以,使用Zn允许氧化催化剂在一个载体涂层中(即不分区)被施用到壁流式过滤器,而没有不可接受地增加背压。所以,锌化合物可以用在过滤器中的任何适当位置。这是非常有利的,因为它允许使用具有相对高孔隙率的壁流式整料基底来提供有效的氧化催化活性以及良好的颗粒物质过滤,甚至是对于更具挑战性的新近的用于车辆IC发动机的驾驶测试周期。另外,使用锌化合物是有益的,因为它与其他金属化合物(例如Mn)相比,为HC和CO氧化提供更低的起燃(light off)温度。
锌化合物的特别适合的例子是氧化锌、硝酸锌、碳酸锌和氢氧化锌或其两种或更多种的混合物。
第一载体的无机氧化物可以包含铈化合物,优选二氧化铈或铈和锆的混合氧化物。所以,第一载体的无机氧化物可以包含二氧化铈-氧化锆混合氧化物,其通常比单独的二氧化铈更加热稳定。
替代地或另外地,第一载体可以包含氧化铝和/或铝酸盐。
优选的第一载体包含氧化铝和二氧化铈-氧化锆混合氧化物(优选研磨到d90粒度<25μm,更优选<15μm)。
可用于第一载体中的其他合适的无机氧化物的例子包括尖晶石、二氧化硅-氧化铝、二氧化钛、氧化锆、氧化铝-氧化锆及其组合。无机氧化物可以包括铝酸盐,例如铝酸镁。
第一载体的一种或多种无机氧化物通常包含粒状无机氧化物,优选粒度(例如d90粒度)为1μm-25μm,更优选2μm-20μm,甚至更优选2μm-15μm,或者2μm-12μm,最优选4μm-10μm。
第一载体可以以5-500g/ft3,优选50-400g/ft3,更优选100-350g/ft3,最优选150-300g/ft3的负载量包含锌化合物,基于锌的重量计。
铂族金属可以选自铂、钯和铑或其混合物。优选的铂族金属可以包含铂和钯的混合物,Pt:Pd重量比为0.5:1-7:1,优选1:1-6:1,更优选1:1-4:1,最优选1:1-3:1。这可以为氧化催化区提供有效的催化剂。
优选氧化催化区中的总铂族金属负载量为5-100g/ft3,优选5-50g/ft3,更优选5-40g/ft3,甚至更优选5-25g/ft3,最优选7-15g/ft3
通常,壁流式整料基底的预涂覆孔隙率为40%或更高,41%或更高,42%或更高,优选43%或更高。也可以使用更高的孔隙率47%或更高,49%或更高,51%或更高,55%或更高,59%或更高,60%或更高,61%或更高,或者62%或更高。通常,壁流式整料基底的预涂覆孔隙率为75%或更低,通常70%或更低,优选65%或更低,更优选60%或更低,甚至更优选55%或更低,最优选49%或更低。壁流式整料基底的预涂覆孔隙率可以为40%-60%,41%-55%,42%-50%,或者42%-45%。
这是有利的,因为这样相对高的孔隙率使得废气良好地流过整料基底中的通道壁,有效地强化氧化催化区与废气之间的相互作用和由此强化转化,但是由于含锌氧化催化剂的有利属性,并不会不可接受地增加背压。
如果氧化催化区还包含至少一种碱土金属化合物,会是有用的。更优选地,碱土金属化合物包含钡化合物。该或各碱土金属化合物可以包括镁、钙、锶或钡的氧化物、碳酸盐和/或氢氧化物或者这些化合物的任意两种或更多种的混合物。
虽然在制备催化剂期间,在空气或贫发动机废气的存在下,碱土金属物类可以以氧化物的形式存在,但是碱土金属物类的一些或大部分,例如钡,可以为氧化物、碳酸盐和/或氢氧化物的形式。
通常,当存在时,第一载体可以以90-200g/ft3的负载量包含碱土金属(优选钡)。
有利地,氧化催化区可以作为单层施用,以减少壁流式过滤器中催化层的厚度,由此降低高孔隙率壁流式过滤器中的背压。
氧化催化区的载体涂层负载量可以为0.05-3.0g/in3,优选0.1-2.0g/in3
有利的是,本发明的排气系统在整料基底上还包含选择性催化还原区,其中该选择性催化还原区包含负载在第二载体上的铜或铁,并且第二载体包含分子筛。
分子筛可以选自β沸石(BEA),八面沸石(FAU)(例如X-沸石或Y-沸石,包括NaY和USY),L-沸石,菱沸石,ZSM沸石(例如ZSM-5(MFI)、ZSM-48(MRE)),具有8个四面体原子的最大开孔的所谓小孔分子筛,优选CHA、ERI或AEI,SSZ-沸石(例如SSZ-13(CHA)、SSZ-41、SSZ-33、SSZ-39),镁碱沸石(FER),丝光沸石(MOR),钾沸石(OFF),斜发沸石(HEU),硅质岩,铝磷酸盐分子筛(包括金属铝磷酸盐如SAPO-34(CHA)),中孔沸石(例如MCM-41、MCM-49、SBA-15),或者其混合物;更优选地,该沸石是β沸石(BEA),镁碱沸石(FER),或者选自CHA、ERI和AEI的小孔分子筛;最优选铝硅酸盐CHA或AEI。
如果存在,选择性催化还原区的载体涂层负载量可以为0.5-3.0g/in3(基于沸石和Cu(或Fe)的重量计)。在选择性催化还原区中,优选Cu。
氧化催化区和选择性催化还原区(如果存在)可以各自在同一壁流式整料基底的不同部分上。在例如车辆的排气系统中空间有限的情况中,这是特别有利的,允许提供紧凑和不那么复杂的系统。
使用壁流式整料的巨大优势是,该整料充当非常有效地减少颗粒物质排放的过滤器基底。壁流式整料基底通常包含入口端、出口端和由该壁流式基底的内壁限定的多个通道,该基底具有在该入口端和该出口端之间延伸的轴长。该壁流式过滤器的通道从入口端或出口端交替封闭,因此该通道包含具有开放的入口端和封闭的出口端的入口通道,和具有封闭的入口端和开放的出口端的出口通道。这确保了废气流从入口端进入通道,流过多孔通道壁,并从导向出口端的不同通道离开过滤器。废气流中的颗粒物质被有效地捕集在过滤器中。
氧化催化区可以位于壁流式整料基底从其一端开始的通道中,选择性催化还原区可以位于壁流式整料基底从其另一端开始的通道中。
在氧化催化区和选择性催化还原区在同一壁流式整料基底的部分上的情况中,该氧化催化区可以在该整料基底的轴长的10%-90%上延伸,该选择性催化还原区在90%-10%上延伸。
氧化催化区的轴长与选择性催化还原区的轴长可以重叠整料基底的总轴长的20%或更少。
整料基底的轴长上氧化催化区的末尾与选择性催化还原区的起始之间可以有间距。
优选地,壁流式整料基底包含具有入口通道的入口端,和具有出口通道的出口端,并且氧化催化区位于该整料基底的入口端的入口通道的壁上和/或壁内,和/或该整料基底的出口端的出口通道的壁内。
氧化催化区可以位于选择性催化区的上游或下游,但是优选上游。氧化催化区通常存在于壁流式整料基底的入口端的入口通道上,选择性催化还原区存在于壁流式整料基底的出口端的出口通道上。优选这种取向,尤其是在较高温度的排气系统中,因为SCR区位于比氧化催化区更冷的位置是有利的。在这样相对冷的条件下,SCR区对于减少氨气泄漏更加有效。
优选壁流式整料基底的孔具有9μm-25μm的直径(平均孔径,MPS)。这个范围的孔径适于载体涂层,借此催化剂和载体可以施用到通道的壁,允许用于催化活性的相对高的表面积,而不会不可接受地增加背压。MPS可以用水银孔率法来测定。
在第二方面中,本发明提供一种催化壁流式整料基底,该壁流式整料基底在其上具有氧化催化区,该壁流式整料基底具有40%或更高的预涂覆孔隙率,该氧化催化区包含负载在第一载体上的铂族金属,第一载体包含至少一种无机氧化物和锌化合物。
本发明第二方面的任选和优选的特征对应于第一方面的那些任选和优选的特征。
通常,这些区可以使用载体涂覆(washcoat)程序置于基底上。使用载体涂覆程序来制备整料基底的通用方法如下所述。
载体涂覆优选如下来进行:将构成载体的固体颗粒制浆(例如在水中),以使它们具有平均直径(例如d90)小于20μm的粒度。浆料优选含有4-40重量%的固体,更优选6-30重量%的固体。还可以在浆料中引入另外的组分如稳定剂或促进剂,形成水溶性或水分散性化合物或络合物的混合物。然后可以用浆料涂覆基底一次或多次,由此在该基底上沉积所需负载量的催化材料。
可以通过任何已知手段将铂族金属添加到涂覆有载体的基底整料,手段包括铂化合物(例如硝酸铂)的浸渍、吸附或离子交换,但是常规上将该铂族金属作为一种或多种可溶性铂族金属盐添加到载体涂料浆料中。
在第三方面中,本发明因此提供一种制造催化型整料基底的方法,该方法包括提供壁流式整料基底,该壁流式整料基底具有40%或更高的预涂覆孔隙率,制备氧化催化区载体涂料,该载体涂料包含铂族金属源、含有至少一种无机氧化物和锌化合物源的第一载体,和将该氧化催化区载体涂料施用到该整料基底的第一部分。
在第四方面中,本发明提供一种处理来自内燃发动机的废气的方法,该方法包括使该废气流过根据第一方面的排气系统,其中该废气包含间歇变富化的贫废气。
术语“贫”和“富”相对于发动机中燃料燃烧的化学计量点,即燃料完美地燃烧使烃加氧气转化为二氧化碳和水的空气与燃料的重量比。空气超过该化学计量点时形成贫废气,燃料过量时形成富废气。
在第五方面中,本发明提供装有根据第一方面的排气系统的压燃式发动机。
在第六方面中,本发明提供一种车辆,其包含压燃式发动机和根据第五方面的排气系统。
本发明的上述和其他特性、特征和优点将由以下详细描述,并结合附图和实施例而变得清楚,它们示例地说明了本发明的原理。
本说明书全篇提及“方面”是指结合该方面描述的特定特征、结构或特性被包括在本发明的至少一个方面中。所以,本说明书全篇多个位置出现的表述“在某方面中”不必然全都指同一方面,而是可以指不同方面。并且,本发明任何方面的特定特征、结构或特性可以在一个或多个方面中以任何适当方式组合,如本领域技术人员由本发明内容而显见的。
在这里提供的说明书中,记载了诸多具体的细节。但是,可以理解,本发明可以不需这些具体的细节来实施。在其他实例中,详细地显示了公知的方法、结构和技术,以避免对本说明书的模糊理解。
为了更好地理解本发明,参考附图,其中:
图1示意性地图示了根据本发明的第一排气系统。
图2示意性地图示了根据本发明的第二排气系统。
图3显示了CO转化率作为根据实施例的氧化催化剂的入口温度的函数的图表。
图4是HC转化率作为根据实施例的氧化催化剂的入口温度的函数的图表。
图1示意性地显示了本发明的第一排气系统2。排气系统2包含第一整料基底4,其形成贫NOx阱(LNT)催化剂。来自发动机(未示出)的废气在第一整料基底/贫NOx阱4的上游通过入口10进入第一整料基底4,通过管道8离开第一整料基底4。废气然后进入第二整料基底6,然后通过出口12离开。出口12的下游可以有其他催化区,或者废气可以释放到大气。
第二整料基底6是2.5升体积的SiC壁流式过滤器基底,其具有300个孔腔/平方英寸,10密耳(千分之英寸)的壁厚,和42%的孔隙率。壁流式基底具有蜂窝体结构,该结构具有许多小的平行薄壁通道轴向穿过该基底,该壁流式基底的通道交替封闭,这允许废气流从入口进入通道,然后流过多孔通道壁,再从导向出口的不同通道离开过滤器。第二整料基底6含有铂族金属的氧化催化区,和研磨到d90粒度<15μm的氧化铝和二氧化铈-氧化锆混合氧化物和氧化锌的载体,提供在第二整料基底6的入口端的入口通道的壁上和第二整料基底6的出口端的出口通道的壁上。图1的排气系统可以使用壁流式整料氧化催化剂来生产,该催化剂如下面实施例2所述来生产。
图2示意性地显示了本发明的第二排气系统13。排气系统13包含第一整料基底14,其形成贫NOx阱催化剂。如图1中所示,来自发动机(未示出)的废气在第一整料基底/贫NOx阱14的上游通过入口20进入第一整料基底14,通过管道18离开第一整料基底14。废气然后进入第二整料基底16,之后通过管道19离开到第三整料基底17,然后通过出口22离开。出口22的下游可以有其他催化区,或者废气可以释放到大气。
第二整料基底16是过滤器壁流式整料基底,其具有提供通道的壁上的氧化催化区。第三整料基底17是流通式整料基底,其具有遍及选择性催化还原区的均匀涂层。
以仅示例的方式提供以下实施例。
比较例1
使用研磨到d90粒度<15μm的氧化铝和二氧化铈-氧化锆混合氧化物来制备浆料。添加合适量的可溶性Pt和Pd盐以提供10g/ft3的最终涂覆催化剂负载量,Pt:Pd重量比为2:1,搅拌混合物以均化。将涂料浆料施用到总体积2.5升的SiC壁流式过滤器基底,其具有300个孔腔/平方英寸,10密耳(千分之英寸)的壁厚,和42%的孔隙率。使用强迫空气流干燥涂层,并在500℃煅烧。
实施例2(ZnO)
使用研磨到d90粒度<15μm的氧化铝和二氧化铈-氧化锆混合氧化物来制备浆料。添加合适量的可溶性Pt和Pd盐以提供10g/ft3的最终涂覆催化剂负载量,Pt:Pd重量比为2:1。将氧化Zn添加到浆料,搅拌混合物以均化。将涂料浆料施用到总体积2.5升的SiC壁流式过滤器基底,其具有300个孔腔/平方英寸,10密耳(千分之英寸)的壁厚,和42%的孔隙率。使用强迫空气流干燥涂层,并在500℃煅烧。涂覆的过滤器具有250g/ft3的锌负载量。
比较例3(MnO2)
使用研磨到d90粒度<15μm的氧化铝和二氧化铈-氧化锆混合氧化物来制备浆料。添加合适量的可溶性Pt和Pd盐以提供10g/ft3的最终涂覆催化剂负载量,Pt:Pd重量比为2:1。将氧化Mn添加到浆料,搅拌混合物以均化。将涂料浆料施用到总体积2.5升的SiC壁流式过滤器基底,其具有300个孔腔/平方英寸,10密耳(千分之英寸)的壁厚,和42%的孔隙率。使用强迫空气流干燥涂层,并在500℃煅烧。涂覆的过滤器具有250g/ft3的锰负载量。
比较例4(Mn(NO3)2)
使用研磨到d90粒度<15μm的氧化铝和二氧化铈-氧化锆混合氧化物来制备浆料。添加合适量的可溶性Pt和Pd盐以提供10g/ft3的最终涂覆催化剂负载量,Pt:Pd重量比为2:1。将硝酸锰添加到浆料,搅拌混合物以均化。将涂料浆料施用到总体积2.5升的SiC壁流式过滤器基底,其具有300个孔腔/平方英寸,10密耳(千分之英寸)的壁厚,和42%的孔隙率。使用强迫空气流干燥涂层,并在500℃煅烧。涂覆的过滤器具有250g/ft3的锰负载量。
H2S模拟催化剂活性测试(SCAT)程序
使用实验室反应器和模拟废气来测定涂覆的过滤器H2S控制性能。使用贫和富废气混合物来代表贫NOx阱脱硫过程中产生的那些。所有样品预先在800℃的水热条件下老化16小时。在实验室反应器上取核样品并测试。将反应器加热到第一评价温度,并使贫气体混合物穿过样品20秒。然后将气体混合物切换到富气体混合物20秒。在测试期间重复这种交替贫和富气体混合物的循环。气体混合物浓度提供在表1中,余量是氮气。
表1
贫气体混合物 富气体混合物
CO<sub>2</sub> 14% 14%
HC 120ppm(C<sub>1</sub>) 2000ppm(C<sub>1</sub>)
O<sub>2</sub> 1.7% 0
H<sub>2</sub>O 5% 5%
H<sub>2</sub> 0 0.07%
CO 0 0.24%
H<sub>2</sub>S 0 500ppm
连续测量过滤器样品下游的H2S浓度,并测定H2S的峰浓度。将该值称为H2S泄漏。对于每个催化剂,将5个贫/富操作周期测量的平均H2S泄漏示于表2中,作为入口温度的函数。
HC/CO氧化SCAT程序
测试实施例1、实施例2、实施例3和实施例4的催化型基底整料的CO和HC氧化性能。在模拟催化剂活性测试(SCAT)气体设备中测试老化的核,使用表3中所示的入口气体混合物,余量是氮气。每个实施例的测试结果示于图3和4中。
表2
表3
气体组分 入口气体混合物组成中的量
CO 1500ppm
HC(作为C<sub>1</sub>) 430ppm
NO 100ppm
CO<sub>2</sub> 4%
H<sub>2</sub>O 4%
O<sub>2</sub> 14%
空速 55000/小时
实施例1、实施例2、实施例3和实施例4对于HC和CO氧化的起燃温度示于下面表4中。
表4
HC T50 CO T50
实施例1 211℃ 206℃
实施例2(ZnO) 224℃ 220℃
实施例3(MnO<sub>2</sub>) 281℃ 246℃
实施例4(Mn(NO<sub>3</sub>)<sub>2</sub>) 321℃ 289℃

Claims (33)

1.用于内燃发动机的排气系统,该排气系统包含:
a.贫NOx阱,和
b.壁流式整料基底,其具有40%或更高的预涂覆孔隙率并包含氧化催化区,该氧化催化区包含负载在第一载体上的铂族金属,第一载体包含至少一种无机氧化物和锌化合物。
2.根据权利要求1所述的排气系统,其中该锌化合物选自氧化锌、硝酸锌、碳酸锌、氢氧化锌或者其两种或更多种的混合物。
3.根据权利要求1或2所述的排气系统,其中该无机氧化物包括二氧化铈。
4.根据前述权利要求中任一项所述的排气系统,其中第一载体还包含氧化铝和/或铝酸盐。
5.根据前述权利要求中任一项所述的排气系统,其中第一载体包含氧化铝和二氧化铈-氧化锆混合氧化物。
6.根据前述权利要求中任一项所述的排气系统,其中该锌化合物具有1-25μm的根据d90的粒度。
7.根据前述权利要求中任一项所述的排气系统,其中第一载体包含负载量5-500g/ft3的该锌化合物。
8.根据前述权利要求中任一项所述的排气系统,其中该铂族金属选自铂、钯、铑及其任意两种或更多种的混合物。
9.根据权利要求8所述的排气系统,其中该铂族金属包含Pt:Pd重量比0.5:1-7:1,优选1:1-6:1的铂和钯的混合物。
10.根据前述权利要求中任一项所述的排气系统,其中该氧化催化区中的总铂族金属负载量为5-100g/ft3
11.根据前述权利要求中任一项所述的排气系统,其中该壁流式整料基底的预涂覆孔隙率为41%或更高,优选42%或更高,更优选43%或更高。
12.根据前述权利要求中任一项所述的排气系统,其中该氧化催化区还包含至少一种碱土金属化合物。
13.根据权利要求12所述的排气系统,其中该或各碱土金属化合物包括镁、钙、锶或钡的氧化物、碳酸盐和/或氢氧化物或者这些化合物的任意两种或更多种的混合物。
14.根据权利要求12或13所述的排气系统,其中第一载体包含负载量90-200g/ft3的该碱土金属。
15.根据前述权利要求中任一项所述的排气系统,其中该氧化催化区以单层施用。
16.根据前述权利要求中任一项所述的排气系统,其中该氧化催化区的载体涂层负载量为0.05-3.0g/in3,优选0.1-2.0g/in3
17.根据前述权利要求中任一项所述的排气系统,还包含整料基底上的选择性催化还原区,该选择性催化还原区包含负载在第二载体上的铜或铁,第二载体包含分子筛。
18.根据权利要求17所述的排气系统,其中该分子筛选自β沸石(BEA),八面沸石(FAU),L-沸石,菱沸石,ZSM沸石,具有8个四面体原子的最大开孔的小孔分子筛,优选CHA、ERI或AEI,SSZ-沸石,镁碱沸石(FER),丝光沸石(MOR),钾沸石(OFF),斜发沸石(HEU),硅质岩,铝磷酸盐分子筛,中孔沸石和/或其任意两种或更多种的混合物。
19.根据权利要求17或18所述的排气系统,其中该选择性催化区的载体涂层负载量为0.5-3.0g/in3
20.根据权利要求17-19中任一项所述的排气系统,其中该氧化催化区在第一壁流式整料基底上,该选择性催化还原区在第二整料基底上。
21.根据权利要求17-19中任一项所述的排气系统,其中该氧化催化区和该选择性催化还原区各自在同一壁流式整料基底的部分上。
22.根据权利要求21所述的排气系统,其中该氧化催化区位于该壁流式整料基底从其一端开始的通道中,该选择性催化还原区位于该壁流式整料基底从其另一端开始的通道中。
23.根据权利要求22所述的排气系统,其中该氧化催化区在该整料基底的轴长的10%-90%上延伸,该选择性催化还原区在该整料基底的轴长的90%-10%上延伸。
24.根据权利要求23所述的排气系统,其中该氧化催化区的轴长与该选择性催化还原区的轴长重叠该整料基底的总轴长的20%或更少。
25.根据前述权利要求中任一项所述的排气系统,其中该壁流式整料基底包含具有直径的孔,该壁流式整料基底的孔具有9μm-25μm的直径。
26.根据前述权利要求中任一项所述的排气系统,其中该壁流式整料基底包含具有入口通道的入口端,和具有出口通道的出口端,并且该氧化催化区位于该整料基底的入口端的入口通道的壁上和/或壁内,和/或该整料基底的出口端的出口通道的壁内。
27.催化型壁流式整料基底,该壁流式整料基底在其上具有氧化催化区,该壁流式整料基底具有40%或更高的预涂覆孔隙率,该氧化催化区包含负载在第一载体上的铂族金属,第一载体包含至少一种无机氧化物和锌化合物。
28.根据权利要求27所述的催化型壁流式整料,其中该无机氧化物包括二氧化铈。
29.制造催化型整料基底的方法,该方法包括:
a.提供壁流式整料基底,该壁流式整料基底具有40%或更高的预涂覆孔隙率,
b.制备氧化催化区载体涂料,该载体涂料包含铂族金属源、含有至少一种无机氧化物和锌化合物源的第一载体,和
c.将该氧化催化区载体涂料施用到该整料基底的第一部分。
30.根据权利要求29所述的方法,其步骤b中的该无机氧化物包括二氧化铈。
31.处理来自内燃发动机的废气的方法,该方法包括使该废气流过根据权利要求1-26中任一项所述的排气系统,其中该废气包含间歇变富化的贫废气。
32.装有根据权利要求1-26中任一项所述的排气系统的压燃式发动机。
33.车辆,其包含根据权利要求32所述的压燃式发动机和排气系统。
CN201780026384.6A 2016-04-29 2017-04-28 排气系统 Pending CN109070000A (zh)

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US20170314448A1 (en) 2017-11-02
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