CN109475843A - 三区柴油机氧化催化剂 - Google Patents

三区柴油机氧化催化剂 Download PDF

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CN109475843A
CN109475843A CN201780026882.0A CN201780026882A CN109475843A CN 109475843 A CN109475843 A CN 109475843A CN 201780026882 A CN201780026882 A CN 201780026882A CN 109475843 A CN109475843 A CN 109475843A
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material sections
oxidation catalyst
diesel oxidation
diesel
carrier element
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CN109475843B (zh
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C·亨斯特
F·多恩豪斯
M·施菲尔
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Umicore AG and Co KG
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Umicore AG and Co KG
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Abstract

本发明涉及一种柴油机氧化催化剂，该柴油机氧化催化剂具有在第一端面a和第二端面b之间延伸的长度L的支撑主体，和布置在所述支撑主体上的催化活性材料区A、B和C，其中‑材料区A包含钯或者重量比为Pt∶Pd≤1的铂和钯以及碱土金属，并且从端面a开始在长度L的20％至80％上延伸，材料区B包含氧化铈(ceroxide)，不含铂，并且从端面b开始在长度L的20％至80％上延伸，材料区C包含铂或重量比为Pt∶Pd≥5的铂和钯，并且无论材料区A还是材料区C均不布置在材料区B上。

Description

三区柴油机氧化催化剂
技术领域
本发明涉及用于净化柴油机发动机的废气的氧化催化剂。
背景技术
除了一氧化碳CO、烃HC和氮氧化物NOx之外，柴油机发动机的原始废气包含最多至15体积％的相对高氧含量。此外，包含微粒排放物，其主要由烟灰残余物，并且在一些情况下有机附聚物组成，并且由气缸中燃料的部分不完全燃烧造成。
虽然具有和不具有催化活性涂涂料的柴油机微粒过滤器适用于移除颗粒排放物，并且氮氧化物可例如通过在所谓的SCR催化剂中选择性催化还原(SCR)而转化为氮气，但通过在适宜氧化催化剂中氧化使一氧化碳和烃变得无害。
氧化催化剂在文献中广泛地描述。这些例如是由陶瓷或金属材料制成的所谓的流通式基底，其在高表面积、多孔、高熔点氧化物，例如氧化铝上承载作为主要催化活性成分的贵金属，诸如铂和钯。
还描述了已分区的氧化催化剂，其在废气的流动方向上具有不同组合物的材料区，废气与其进行连续接触。
因此.US2010/257843、US2011/099975、WO2006/021337 A1和WO2012/079598 A1描述了包含铂和钯的分区氧化催化剂。WO 2011/057649还描述了氧化催化剂，其中它们可用于分层和分区的实施方案中。在分区的实施方案的情况下，第二区，即流出的废气与其直接接触的区具有比与进入废气直接接触的前区更高的贵金属含量。根据WO2011/057649的氧化催化剂具有设置废气侧SCR催化剂的NO对NO2的最佳比率的特殊任务。
EP2000639A1描述了氧化催化剂，其除了铂之外，包含选自镁、碱土金属和碱金属的金属的氧化物。催化剂的功能是在燃料喷射期间增加废气温度。
WO 2013/088133描述了一种分区催化剂，其包含在上游区中的铂以及在下游区中的能够结合挥发性铂的金属氧化物。所述催化剂应抵消SAE2009-01-0627中所述的现象，根据所述现象，含铂催化剂可在高温下将少量铂物质递送到气相中，这继而不利地影响下游SCR催化剂的有效性。作为金属氧化物，公开了稳定化氧化铝、无定形铝/硅氧化物、任选的稳定化氧化锆、氧化铈、氧化钛、任选地稳定化铈/锆混合氧化物以及所提及材料的混合物。其用量为6.1g/L至305g/L(0.1g/in3至5g/in3)。
由于节约燃料以降低CO2排放，废气立法欧洲5，6和6+的当前和未来柴油机发动机的废气温度正在逐渐降低。更重要的是具有柴油机氧化催化剂，其在低废气温度下具有足够CO点火。迄今为止已知的柴油机氧化催化剂不充分满足该条件，因此需要相应的进一步发展。
现在已经发现，下文描述并定义的柴油机氧化催化剂符合这些条件。
发明内容
本发明涉及一种柴油机氧化催化剂，该柴油机氧化催化剂包含：
载体主体，所述载体主体具有在第一端面a和第二端面b之间延伸的长度L，和
催化活性材料区A、B和C，该催化活性材料区A、B和C被布置在所述载体主体上，其中
-材料区A包含钯或重量比为Pt∶Pd≤1的铂和钯以及碱土金属，并且从端面a延伸至长度L的20％至80％，
-材料区B包含氧化铈并且不含铂并且从端面b延伸至长度L的20％至80％，并且
-材料区C包含铂或重量比为Pt∶Pd≥5的铂和钯，并且
无论材料区A还是材料区C均不布置在材料区B上方。
如果铂和钯存在于材料区A中，则重量比Pt∶Pd≤1。在本发明的实施方案中，材料区A中的重量比Pt∶Pd例如为1∶1至1∶15。
如果铂和钯存在于材料区C中，则重量比Pt∶Pd≥5。在本发明的实施方案中，材料区C中的重量比Pt∶Pd例如为5∶1至12∶1。
具体实施方式
在根据本发明的氧化催化剂的实施方案中，在一种或多种载体氧化物上的材料区A和C中施用钯、铂或者铂和钯。这些载体氧化物有利地为高熔点的，即其熔点足够高于在根据本发明的氧化催化剂的预期操作期间出现的温度。所述载体氧化物还有利地具有高表面积并且优选地具有50m2/g至200m2/g的比表面积。
材料区A和C中的载体氧化物可以相同或不同。
合适的载体氧化物选自由下列组成的系列：氧化铝、掺杂的氧化铝、氧化硅、二氧化钛以及它们中一种或多种的混合氧化物。
掺杂的氧化铝为例如掺杂有氧化锆和/或氧化钛的氧化铝。有利地使用镧稳定的氧化铝，其中镧的用量为1重量％至10重量％，优选地3重量％至6重量％，其各自按La2O3并且相对于稳定化氧化铝的重量计算。
在根据本发明的氧化催化剂的实施方案中，镁、钙、锶、钡或这些金属中至少两种的混合物用作材料区A中的碱土金属。优选地使用锶或钡。
碱土金属有利地以相对于材料区A的重量的0.5重量％至5重量％的量使用。
当使用锶时，其特别优选地以相对于材料区A的重量的1重量％至3重量％的量存在。
相比之下，如果使用钡，则其特别优选地以相对于材料区A的重量的2.5重量％至4.5重量％的量存在。
在根据本发明的氧化催化剂的实施方案中，在材料区B中氧化铈部分地被氧化铝替代。可使用氧化铈和氧化铝的混合物，其包含相对于氧化铝和氧化铈的混合物的重量的量为10重量％至90重量％的氧化铝。
优选地将纯氧化铈，即具有80重量％至100重量％的氧化铈含量的氧化铈用作所述氧化铈。
普通高表面积氧化铝，诸如在材料层A和C中也用作载体氧化物，可用作氧化铝。
在根据本发明的氧化催化剂的其它实施方案中，材料区B包含钯。优选的钯含量为相对于所述材料区B的重量的0.01重量％至5重量％，优选地2重量％至4重量％。
特别地，钯承载于材料区B中存在的氧化铈上。然而其也可完全或部分地承载于在标准载体氧化物上，其中特别地考虑上文对于材料区A和C中的铂和钯所述的载体氧化物，特别地还考虑氧化铝。
在根据本发明的氧化催化剂的实施方案中，材料区A和C彼此独立地以相对于载体主体的体积的50g/L至150g/L的量存在。材料区B优选地以相对于载体主体的体积的50g/L至150g/L的量存在。
在本发明的氧化催化剂的实施方案中，材料区A的长度为载体主体的总体长度L的20％至70％，40％至60％，或45％至50％。
在根据本发明的氧化催化剂的另一实施方案中，材料区B的长度为载体主体的总体长度L的20％至70％，40％至60％或45％至50％。
在根据本发明的氧化催化剂的实施方案中，材料区C在载体主体的整个长度L上延伸。然而，其还可仅在载体主体的总体长度L的一部分上延伸，例如载体主体的总体长度L的20％至70％，40％至60％或45％至50％。
在根据本发明的氧化催化剂的实施方案中，材料区A和B布置在材料区C上。材料区C优选地在载体主体的整个长度L上延伸，然而材料区A和B各自在载体主体的总体长度L的40至60％上延伸。材料区A和B的长度的总和对应于或小于载体主体的总体长度L。
在这些实施方案中，材料区A和B在每种情况下特别优选地延伸至载体主体的长度L的50％，并且材料区C延伸至载体主体的长度L的100％。
在根据本发明的氧化催化剂的实施方案中，材料区C布置在材料区A上并且材料区B布置在材料区C上。在这种情况下，材料区C优选地也在载体主体的整个长度L上延伸，然而材料A和B各自在载体主体的总体长度L的40％至60％上延伸。材料区A和B的长度的总和对应于或小于载体主体的总体长度L。
在这些实施方案中，材料区A和B在每种情况下特别优选地延伸至载体主体的长度L的50％，并且材料区C延伸至载体主体的长度L的100％。
根据本发明的氧化催化剂可通过以本身已知的方式使用涂料悬浮液(所谓的修补基面涂料)涂覆适宜的载体主体来制备。为了制备用于制备材料区A或C的涂料悬浮液，例如将所选的载体氧化物悬浮于水中。然后在搅拌下将铂和/或钯以适宜的水溶性前体化合物(例如诸如硝酸钯或六羟基铂酸)的形式添加到悬浮液中，并任选地通过设定pH和/或通过添加辅助试剂固定在载体材料上。
另选地，还可以与EP 1,101,528 A2中所述的方法类似的方式，将贵金属施用到载体材料中。
然后通过标准涂覆方法中的一种将以这种方式获得的悬浮液研磨并施用到载体主体。在每个涂覆步骤后，经涂覆的部件在热空气流中干燥并在一些情况下煅烧。
前述前体和辅助试剂是本领域技术人员熟知的。
由陶瓷，特别地堇青石，或由金属制成的所谓的蜂窝主体特别适合作为载体主体。优选地使用所谓的流通式蜂窝主体。然而，也可设想其中将壁流式过滤器用作载体主体的实施方案。
根据本发明的柴油机氧化催化剂适用于净化柴油机发动机的废气，特别是关于一氧化碳和烃。
因此，本发明还涉及一种用于处理柴油机废气的方法，其特征在于将柴油机废气引导通过如上所述和定义的柴油机氧化催化剂，其中所述柴油机废气在端面a处流入载体主体中并且在端面b处从载体主体流出。
根据本发明的柴油机氧化催化剂特别地用作废气净化系统的组分。除了根据本发明的柴油机氧化催化剂之外，对应的废气净化系统包括例如柴油机微粒过滤器和/或用于选择性催化还原氮氧化物的催化剂，其中柴油机微粒过滤器和SCR催化剂通常被布置在根据本发明的柴油机氧化催化剂的下游，即在流出侧上。在排放控制系统的一个实施方案中，将SCR催化剂布置在柴油机微粒过滤器上。
图1示出了实施例1至3和比较例1至3的加热行为的比较。
实施例1
a)用修补基面涂料涂覆尺寸为14.38cm×10.16cm(5.66″×4.00″)且孔密度为62孔每平方厘米(400cpsi)并且壁厚为0.16mm(6.5密耳)的可商购获得的圆形流通式堇青石基底的整个长度，所述修补基面涂料包含49.23g/L的镧掺杂的中孔氧化铝、0.60540g/L的标准水溶性Pt化合物、以及0.10090g/L的标准水溶性Pd化合物。Pt∶Pd重量比为6∶1。
b)用修补基面涂料将根据a)获得的经涂覆的基底从一端(下文所述测试中的入口侧)涂覆至其长度的50％，所述修补基面涂料包含48.23g/L的可商购获得的镧掺杂的氧化铝、1.00g/L氧化锶(ex Sr(OH)2)、0.47086g/L的标准水溶性Pd化合物、以及0.23543g/L的标准水溶性Pt化合物。Pt∶Pd重量比为1∶2。
c)在另一个步骤中，用修补基面涂料将根据b)获得的基底从另一端(在下文所述测试中的出口侧上)开始涂覆至其长度的50％，所述修补基面涂料包含45g/L的可商购获得的氧化铝，和5g/L的可商购获得的氧化铈。
比较例1
重复实施例1，不同之处在于省略步骤c)。
比较例2
重复实施例1，不同之处在于省略步骤b)。
比较例3
a)用修补基面涂料涂覆尺寸为14.38cm×10.16cm(5.66″×4.00″)且孔密度为62孔每平方厘米(400cpsi)并且壁厚为0.16mm(6.5密耳)的可商购获得的流通式堇青石基底的整个长度，所述修补基面涂料包含73.85g/L的镧掺杂的中孔氧化铝、0.90810g/L的标准水溶性Pt化合物、以及0.15135g/L的标准水溶性Pd化合物。Pt∶Pd重量比为6∶1。
b)在另一个步骤中，用修补基面涂料将根据a)获得的基底从一端(在下文所述测试中的出口侧)涂覆至其长度的50％，所述修补基面涂料包含45g/L的可商购获得的氧化铝，和5g/L的可商购获得的氧化铈。
实施例2
a)用修补基面涂料从一端(在下文所述的测试中的入口侧上)涂覆尺寸为14.38cm×10.16cm(5.66″×4.00″)且孔密度为62孔每平方厘米(400cpsi)并且壁厚为0.16mm(6.5密耳)的可商购获得的流通式堇青石基底的长度的50％，所述修补基面涂料包含48.23g/L的可商购获得的镧掺杂的氧化铝、1.00g/L氧化锶(ex Sr(OH)2)、0.47086g/L的标准水溶性Pd化合物、以及0.23543g/L的标准水溶性Pt化合物。Pt∶Pd重量比为1∶2。
b)用修补基面涂料涂覆根据a)获得的经涂覆的基底的整个长度(即，在根据a的区上的入口侧上)，所述修补基面涂料包含49.23g/L的可商购获得的镧掺杂的氧化铝、1.00g/L氧化锶(ex Sr(OH)2)、0.47086g/L的标准水溶性Pd化合物、以及0.23543g/L的标准水溶性Pt化合物。Pt∶Pd重量比为1∶2。
c)在另一个步骤中，用修补基面涂料将根据b)获得的基底从另一端(在下文所述测试中的出口侧上)开始涂覆至其长度的50％，即，在根据a)的区上，所述修补基面涂料包含45g/L的可商购获得的氧化铝和5g/L的可商购获得的氧化铈。
实施例3
将尺寸为14.38cm×10.16cm(5.66″×4.00″)且孔密度为62孔每平方厘米(400cpsi)并且壁厚为0.16mm(6.5密耳)的可商购获得的流通式堇青石基底锯成等长的三个部分。
三个部分各自用实施例1a)、b)和c)中提及的修补基面涂料材料涂覆其整个长度。
就下述测试而言，按照以下顺序在废气流动的方向上将三个基底部分接合在一起：
根据实施例1b)用修补基面涂料涂覆第1部分
根据实施例1a)用修补基面涂料涂覆第2部分
根据实施例1c)用修补基面涂料涂覆第3部分
进行比较测试
a)水热炉老化
将根据实施例1至3和比较例1至3的催化剂在750℃下老化16小时。除非另外指明，否则下文所述的比较测试用以这种方式老化的催化剂进行。
b)在模型气体中确定NO2形成和CO转化率；就所有测量而言，以下项目施用：
空速＝37,5001/h
孔芯尺寸2.54cm×10.16cm(1″×4″)(从根据实施例1至3和比较例1至3的基底钻孔)
研究的温度范围：75℃至500℃，其中温度200℃、250℃和300℃下的值记录于下表中。
升温/加热速率＝15K/min
用三种不同的气体组合物进行测试：
测试条件： 1 2 3
单位 [ppm] [ppm] [ppm]
CO 350 250 500
H2 116 0 167
丙烯作为C3 60 0 200
丙烷作为C3 30 0 67
甲苯作为C7 0 0 8.6
正癸烷作为C10 0 0 14
无 270 750 150
单位 [％] [％] [％]
O2 6 10 13
H2O 5 7.5 10
CO2 10.7 7 5
N2 静止 静止 静止
获得以下结果：
表1：在测试条件1下的T50CO和NO2形成
表2：在测试条件2下的T50CO和NO2形成
表3：在测试条件3下的T50CO知NO2形成
c)确定发动机点火测试中的NO2形成和CO转化率：
通过在发动机的恒定转速下提高扭矩，实现预催化剂温度的增加；测试从低温到高温运行，类似于模型气体程序。
污染物的转化率通过AMA线测量并计算；使用CLD确定NO2形成。
获得以下结果：
表4：发动机上的T50CO和NO2形成
d)在发动机测试中确定加热行为(3点加热测试)：
通过扭矩和转速的适当组合来接近静态发动机操作点。将其保持恒定并持续一定时间；然后经由二级/外部喷射器将柴油机燃料以精细雾化状态喷射到催化剂上游，其然后将燃料转化，从而产生一定放热/热，所述放热/热使用安装在催化剂中的热电偶来测量。
该测试从高温至低温运行；所述温度为：
1)280℃预催化剂温度
2)270℃预催化剂温度
3)260℃预催化剂温度
结果示于图1中。
e)测定铂迁移
在650℃的恒温下，在具有等温反应器的标准合成气体装置中，使实施例1至3和比较例1至3中使用的催化剂在新鲜状态下经受以下组成的模型气体并持续18小时：
CO 71ppm
NO 820ppm
O2 6.3体积％
CO2 8.9体积％
H2O 测量持续18小时时为11体积％，并且测量持续60小时时为5体积％
N2 余量
将离开相应催化剂下游的气体引导穿过流通式基底，所述基底具有5.08cm(2″)长度并且涂覆有铁-β-沸石型的SCR催化剂。
然后测定每种催化剂的在SCR催化剂中结合的铂量。为此，使用NiS火法化验将催化剂的钻芯在坩埚中熔融，然后使用ICP-OES测定铂。
获得以下结果：
铂量[ppm]
实施例1 1.2
比较例1 3.0
比较例2 0.3
比较例3 0.9
实施例2 0.4
实施例3 0.4

Claims (14)

1.一种柴油机氧化催化剂，所述柴油机氧化催化剂包含：
载体主体，所述载体主体具有在第一端面a和第二端面b之间延伸的长度L，和
催化活性材料区A、B和C，所述催化活性材料区A、B和C被布置在所述载体主体上，其中
-材料区A包含钯或重量比为Pt：Pd≤1的铂和钯以及碱土金属，并且从端面a延伸至长度L的20％至80％，
-材料区B包含氧化铈并且不含铂并且从端面b延伸至长度L的20％至80％，并且
-材料区C包含铂或重量比为Pt：Pd≥5的铂和钯，并且无论材料区A还是材料区C均不布置在材料区B上方。
2.根据权利要求1所述的柴油机氧化催化剂，其特征在于在所述材料区A和C中，钯、铂或者铂和钯存在于载体氧化物上。
3.根据权利要求1和/或2所述的柴油机氧化催化剂，其特征在于，材料区A和C中的所述载体氧化物彼此相同或不同，并且选自氧化铝、掺杂的氧化铝、氧化硅、二氧化钛以及它们中的一者或多者的混合氧化物。
4.根据权利要求1至3中任一项或多项所述的柴油机氧化催化剂，其特征在于材料区A中的所述碱土金属相对于所述材料区A的重量以0.5重量％至5重量％的量存在。
5.根据权利要求1至4中任一项或多项所述的柴油机氧化催化剂，其特征在于材料区A中的所述碱土金属为锶或钡或者锶和钡。
6.根据权利要求1至5中任一项或多项所述的柴油机氧化催化剂，其特征在于材料区B包含钯。
7.根据权利要求6所述的柴油机氧化催化剂，其特征在于材料区B包含相对于材料区B的重量的量为0.01重量％至5重量％的钯。
8.根据权利要求1至7中任一项或多项所述的柴油机氧化催化剂，其特征在于材料区C在所述载体主体的整个长度L上延伸。
9.根据权利要求1至8中任一项或多项所述的柴油机氧化催化剂，其特征在于材料区A和B布置在材料区C上。
10.根据权利要求1至8中任一项或多项所述的柴油机氧化催化剂，其特征在于材料区C布置在材料区A上并且材料区B布置在材料区C上。
11.根据权利要求1至10中任一项或多项所述的柴油机氧化催化剂，其特征在于材料区A和B各自延伸至所述载体主体的所述长度L的50％，并且材料区C延伸至所述载体主体的长度L的100％。
12.一种用于处理柴油机废气的方法，其特征在于将所述柴油机废气引导通过根据权利要求1至11中任一项或多项所述的柴油机氧化催化剂，其中所述柴油机废气在端面a处流入所述载体主体中并且在所述端面b处流出所述载体主体。
13.一种装置，所述装置用于净化来自柴油机发动机的废气，所述柴油机发动机具有根据权利要求1至11中任一项所述的柴油机氧化催化剂。
14.根据权利要求13所述的装置，其特征在于将根据权利要求1至11中任一项所述的柴油机氧化催化剂布置在柴油机颗粒过滤器和/或催化剂的上游以用于选择性催化还原氮氧化物。
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