CN111271157B - 从发动机废气中除去颗粒物和有害化合物的系统 - Google Patents

从发动机废气中除去颗粒物和有害化合物的系统 Download PDF

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CN111271157B
CN111271157B CN202010184653.5A CN202010184653A CN111271157B CN 111271157 B CN111271157 B CN 111271157B CN 202010184653 A CN202010184653 A CN 202010184653A CN 111271157 B CN111271157 B CN 111271157B
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catalyst
way catalyst
alumina
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vanadium
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CN111271157A (zh
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K·约翰森
T·V·W·詹森斯
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Umicore AG and Co KG
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Abstract

用于从压燃式发动机的废气中除去挥发性有害化合物和颗粒物的系统，其包括具有NH3‑SCR活性、氨氧化活性和对上游SCR活性催化剂挥发出的挥发性钒和钨化合物的吸附能力的三效催化剂单元。

Description

从发动机废气中除去颗粒物和有害化合物的系统
本申请是原始中国专利申请号201680040419.7，申请日2016年7月6日，发明名称“从发动机废气中除去颗粒物和有害化合物的系统”的分案申请。
技术领域
本发明涉及用于从压燃式发动机的废气中除去挥发性有机化合物、颗粒物和氮氧化物(NOx)的系统。
背景技术
具有稀燃发动机的现代交通工具的排气系统典型地配备有氧化催化剂、颗粒物过滤器和用于在还原剂存在下选择性还原NOx(SCR)的催化剂。
在氧化挥发性有机化合物和一氧化碳方面呈活性的氧化催化剂和SCR催化剂在本领域是已知的并且在许多出版物中公开。
在柴油废气清洁系统中典型使用的颗粒物过滤器(DPF)是具有多个入口和出口通道的壁流式过滤器。入口通道在它们的出口侧封闭并且出口通道在它们的入口侧封闭，从而通过限定通道的多孔壁迫使气体流入过滤器，由此将颗粒物滤出气体。
为了满足对柴油乘用车和卡车的未来的排放法规，需要使用柴油颗粒物过滤器(DPF)技术和NOx还原催化剂二者。由于其潜在的燃料优化和NOx除去方面的高效率，使用氨作为还原剂的选择性催化还原(NH3-SCR)目前是用于NOx还原的优选的技术。
可以将SCR催化剂布置为在DPF上游和/或下游的单独的单元。本领域中还已建议提供具有SCR催化剂的DPF，以获得更紧凑的清洁系统。
用于氨SCR中的催化剂是本领域中公知的。这些之中，基于负载在TiO2载体上的V2O5和WO3的催化剂提供了借助采用氨的选择性催化还原(SCR)有效减少来自柴油燃料的交通工具的NOx排放的根本解决方案。与NOx排放控制的替代性策略如废气再循环(EGR)和沸石基催化剂相比，钒基SCR催化剂的一大优势在于它们的SCR效率、对硫的稳定性和它们的价格。
当运行具有DPF的清洁系统时，过滤器中捕获的颗粒物必须不时地形成或连续除去，从而避免过滤器上的压降。增加的压降的代价是燃料经济性的缺陷。因此，必须将在过滤器的入口侧处聚集在过滤器壁上的颗粒物通过活性再生或通过非催化被动再生而除去，在所述活性再生中，将颗粒物与负载在过滤器壁上的氧化催化剂接触与废气中的氧气组合在升高的废气温度以催化方式烧除。
在被动碳烟再生中，在低于550℃的温度用在上游DOC上通过氧化NO产生的NO2再生DPF。应当避免用废气中的氧气再生，从而控制温度低于550℃。如果过滤器不受控地用氧气再生，则温度可能上升到高于550℃。
尽管是有效的SCR催化剂，但是氧化钒基催化剂包含V2O5作为必要组分，其是有毒的。文献中的报道表明大体积的V2O5在与催化剂运行相关的温度具有明显蒸气压，并且V和W化合物与水反应形成具有增加的蒸气压的物质。
首先在600℃的高于大约这些系统的最高可应用工作温度的温度释放可测量的量的钒。
因此，尤其在一体化至DPF中时存在V和W挥发性化合物可能从V2O5/WO3/TiO2 SCR催化剂中蒸发的风险。V-SCR催化的DPF中的温度具有被暴露至超过600℃的温度的最高可能性，但是在严重的情况下，V-SCR催化剂中的温度还可能升高至高于600℃并且引发这些化合物的蒸发。
除了将钒和钨化合物排放至大气中的风险以外，还要考虑来自SCR反应的氨泄漏。为了获得最大的NOx转化率，典型地将氨以超化学计量量添加至废气中并且将未反应的氨排放至大气。
发明内容
本发明寻求通过组合钒和钨吸附剂与氨氧化催化剂，解决在用于从发动机废气中除去颗粒物和有害化合物(包括氮氧化物)的系统中，由在SCR反应中使用钒和钨氧化物作为有效的氨SCR催化剂和超化学计量量的氨还原剂导致的上述问题。
因此，本发明在其最宽泛的方面为用于从压燃式发动机的废气中除去挥发性有机化合物、颗粒物和氮氧化物的系统，包括：
(a)具有催化剂的氧化单元，所述催化剂在将挥发性有机化合物和一氧化碳氧化成二氧化碳和水以及将一氧化氮氧化成二氧化氮方面是活性的；
(b)用于将尿素溶液引入来自单元(a)的废气的机构；
(c)下游的催化壁流式颗粒物过滤器，其由被气体可渗透的多孔分隔壁分开的多个纵向入口流动通道和出口流动通道组成，每个入口流动通道具有开放的入口端和封闭的出口端，和每个出口流动通道具有封闭的入口端和开放的出口端，将壁流式过滤器用布置在壁流式颗粒物过滤器的气体可渗透的多孔分隔壁内和/或在多个入口和/或出口通道上的包括钒和钨氧化物的NH3-SCR活性催化剂催化；
(d)下游三效催化剂单元，其具有NH3-SCR活性、氨氧化活性和对从颗粒物过滤器(c)的SCR活性催化剂挥发出的挥发性钒和钨化合物的吸附能力，所述三效催化剂包括选自高表面积的金属氧化物、沸石、二氧化硅、非沸石型二氧化硅氧化铝及其混合物的高表面积化合物。
若干氧化物具有吸附蒸发的钒和钨的化合物的性质，与高表面积的氧化铈、氧化铝、二氧化硅、氧化锆、非沸石型二氧化硅氧化铝和沸石的至少一种混合的钒、钨和钛的氧化物已显示作为有用的V和W化合物吸附剂并且同时在SCR反应方面是活性的。优选将这些吸附剂与氨泄漏催化剂(ASC)组合。
典型的ASC制剂由基于任选与在氧化铝或二氧化钛载体上的钯组合的铂的氨氧化功能和SCR活性催化剂组成。在用于本发明的优选制剂中，将V、W吸附剂与SCR催化剂一起作为顶层施加至具有氨氧化催化剂的底层上。两个层都可以包含如具有V、W吸附能力的氧化铝、二氧化钛、二氧化硅-氧化铝的氧化物陶瓷的结合相。
在本发明的具体实施方案中，三效催化剂包括底层和顶层，所述底层包括涂覆在基材上或部分或完全形成基材的铂、氧化铝和/或二氧化钛和任选的钯，所述顶层包括与高表面积的氧化铈、氧化铝、二氧化硅、氧化锆、非沸石型二氧化硅氧化铝和沸石的至少一种混合的钒、钨和钛的氧化物。
因为将三效催化剂布置在排气系统中最冷的位置处，所以在交通工具上的排气系统的寿命期间在三效催化剂上捕获任何可能蒸发的V和W化合物。
在三效催化剂中采用相对厚的顶层实现高的钒和钨吸附效率。
因此，在优选的实施方案中，顶层具有介于40μm和250μm之间的层厚度。
在另一优选的实施方案中，底层具有介于5μm和80μm之间的层厚度。当底层本身部分或完全形成基材时，层厚度为至多450μm。
为了确保氨从顶层至底层的足够的渗透性，顶层必须是相对多孔的。
因此，在另一优选的实施方案中，顶层具有介于20％和80％之间的孔隙率。
优选地，将三效催化剂布置在具有流通式整料形状的基材上。
当涂覆在流通式整料形式的基材上时，三效催化剂中的顶层的量按每升流通式整料计为介于50和500g之间。
三效催化剂中的底层的量按每升流通式整料计优选为介于5和255g之间，所述量取决于是否将底层涂覆在整料基材的表面上或部分或全部形成整料基材。
当三效催化剂的底层按每升流通式整料计包含0.0018g-0.35g铂和/或钯时，获得三效催化剂的高的氨氧化活性。
三效催化剂的顶层按每升流通式整料计优选包括1.0g-20g五氧化二钒、3g-40g氧化钨、40g-460g二氧化钛和0g-86g二氧化硅、0g-86g氧化铈、0g-86g氧化铝、0g-86g非沸石型二氧化硅氧化铝和0g-86g沸石。
以此确保将挥发性钒和钨化合物基本上吸附在二氧化钛和二氧化硅的表面上和将来自上游单元的剩余量的NOx通过SCR反应选择性还原成氮气和水。
在本发明的上述实施方案中优选的是，在DPF上游的单元(a)中的氧化催化剂包括以1:0至1:1的铂比钯的重量比负载在二氧化硅-氧化铝和/或氧化铝和/或二氧化钛上的铂和钯。
氧化催化剂中的铂和/或钯的含量按每升催化剂计优选为0.1g和2g。
在又一实施方案中，可以优选的是系统包括另外的SCR催化剂单元，其用于通过与包括钒、钨和钛的氧化物的SCR活性催化剂接触与氨反应降低来自过滤器(c)的废气中的剩余量的NOx，所述催化剂布置在过滤器(c)和三效催化剂(d)之间。
附图说明
图1显示了NOx转化率，连同NOx、N2O和N2的出口浓度。NH3-SCR中的在这些条件下的性能通过以低产率的N2O和高产率的N2在感兴趣的温度范围(250-400℃)内约50-60％的转化率来记录。图1显示了使用在100000h-1空速的氮气中的250ppm NOx、300ppm NH3、12％O2和4％水的进料的NH3-SCR的NOx转化率和Pt/V-W氧化物基整料三效催化剂的NOx、N2和N2O的出口浓度。
图2显示了在氨的选择性氧化中氨的转化率和对N2、NOx、N2O的选择性。在感兴趣的温度范围(250-400℃)内，将氨几乎完全转化并且反应产物主要由氮气组成。图2显示了使用在100000h-1空速的氮气中的200ppm NH3、12％O2和4％水的进料，对于Pt/V-W氧化物基整料三效催化剂而言，对于氨的选择性氧化，NH3转化率和对NOx、N2和N2O的选择性。
具体实施方式
实施例1
该实施例证实了三效催化剂的NH3-SCR方面的性能。所述催化剂由浸渍在用TiO2强化的玻璃纤维纸基整料上的Pt组成，在所述整料的顶部施加包含钒和钨、二氧化钛和二氧化硅的具有NH3-SCR活性的载体涂层(washcoat layer)。催化剂中的Pt含量为88mg/l。SCR活性载体涂层的含量为197g/l，其中5％为二氧化硅。将催化剂在性能测试前在550℃熟化1小时。反应器进料气体由在氮气中的250ppm NOx(其中少于5％以NO2存在)、300ppm NH3、12％O2和4％水组成。将流速调节至达到基于整料体积计100000h-1的空速。
实施例2
该实施例显示了如实施例1所表征的三效催化剂对于选择性氧化氨以降低胺泄漏的性能。将催化剂在550℃熟化1小时。用于该测量的进料气体为在氮气中的200ppm NH3、12％O2和4％水。将流动调节至达到基于整料体积计100000h-1的空速。

Claims (13)

1.用于从压燃式发动机的废气中除去挥发性有机化合物、颗粒物和氮氧化物的系统，包括：
(a)具有催化剂的氧化单元，所述催化剂在将挥发性有机化合物和一氧化碳氧化成二氧化碳和水以及将一氧化氮氧化成二氧化氮方面是活性的；
(b)下游的催化壁流式颗粒物过滤器，其由被气体可渗透的多孔分隔壁分开的多个纵向入口流动通道和出口流动通道组成，每个入口流动通道具有开放的入口端和封闭的出口端，和每个出口流动通道具有封闭的入口端和开放的出口端；
(c)用于将尿素溶液引入来自单元(b)的废气的机构；
(d)下游SCR活性催化剂，其包含钒和钨的氧化物，其特征在于，如果还包含
(e)下游三效催化剂单元，其具有NH3-SCR活性、氨氧化活性和对从SCR活性催化剂(d)挥发出的挥发性钒和钨化合物的吸附能力，所述三效催化剂包括选自高表面积的金属氧化物、沸石、二氧化硅、非沸石型二氧化硅氧化铝及其混合物的高表面积化合物。
2.根据权利要求1所述的系统，其中所述三效催化剂包括底层和顶层，所述底层包括涂覆在基材上的包括铂、氧化铝和/或二氧化钛和任选的钯，所述顶层包括与高表面积的氧化铈、氧化铝、二氧化硅、氧化锆、非沸石型二氧化硅氧化铝和沸石的至少一种混合的钒、钨和钛的氧化物。
3.根据权利要求2所述的系统，其中所述顶层具有介于40μm和250μm之间的层厚度。
4.根据权利要求2所述的系统，其中所述底层具有介于5μm和450μm之间的层厚度。
5.根据权利要求2所述的系统，其中所述顶层具有介于20％和80％之间的孔隙率。
6.根据权利要求1所述的系统，其中将所述三效催化剂涂覆在具有流通式整料形状的基材上。
7.根据权利要求1所述的系统，其中所述SCR活性催化剂(d)进一步包括二氧化钛。
8.根据权利要求2所述的系统，其中所述三效催化剂中的顶层的量按每升基材计为介于50至500g之间。
9.根据权利要求2所述的系统，其中所述三效催化剂中的底层的量按每升基材计为介于5和255g之间。
10.根据权利要求2所述的系统，其中所述三效催化剂的底层按每升基材计包含0.0018g-0.35g铂和/或钯。
11.根据权利要求2所述的系统，其中所述三效催化剂的顶层按每升流通式整料计包括1.0g-20g五氧化二钒、3g-40g氧化钨、40g-460g二氧化钛，和
0g-86g二氧化硅、0g-86g氧化铈、0g-86g氧化铝、0g-86g非沸石型二氧化硅氧化铝和0g-86g沸石。
12.根据权利要求1所述的系统，其中氧化单元(a)中的氧化催化剂包括以1:0至1:1的铂比钯的重量比负载在二氧化硅-氧化铝和/或氧化铝和/或二氧化钛上的铂和/或钯。
13.根据权利要求12所述的系统，其中铂和/或钯的含量按每升催化剂计为介于0.1g和2g之间。
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