CN114072223A - Catalyst system for treating motor vehicle exhaust gases and method for producing same - Google Patents

Catalyst system for treating motor vehicle exhaust gases and method for producing same Download PDF

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Publication number
CN114072223A
CN114072223A CN202080032316.2A CN202080032316A CN114072223A CN 114072223 A CN114072223 A CN 114072223A CN 202080032316 A CN202080032316 A CN 202080032316A CN 114072223 A CN114072223 A CN 114072223A
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China
Prior art keywords
module
washcoat
substrate
catalyst system
catalyst
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CN202080032316.2A
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Chinese (zh)
Inventor
刘欣竹
H·黄
S-L·F·陈
A·库马尔
S·K·潘迪
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Basf Catalyst Shanghai Co ltd
Shangyinuo Motorcycle Co ltd
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Basf Catalyst Shanghai Co ltd
Shangyinuo Motorcycle Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation 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
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9445—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
    • B01D53/945—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific catalyst
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B01J23/46—Ruthenium, rhodium, osmium or iridium
    • B01J23/464—Rhodium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/54—Catalysts 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
    • B01J23/56—Platinum group metals
    • B01J23/63—Platinum group metals with rare earths or actinides
    • B01J35/19—
    • B01J35/56—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
    • B01J37/0018—Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat)
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/0215—Coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/0236—Drying, e.g. preparing a suspension, adding a soluble salt and drying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/024—Multiple impregnation or coating
    • B01J37/0244—Coatings comprising several layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/024—Multiple impregnation or coating
    • B01J37/0248—Coatings comprising impregnated particles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/10—Noble metals or compounds thereof
    • B01D2255/102—Platinum group metals
    • B01D2255/1021—Platinum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/10—Noble metals or compounds thereof
    • B01D2255/102—Platinum group metals
    • B01D2255/1023—Palladium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/10—Noble metals or compounds thereof
    • B01D2255/102—Platinum group metals
    • B01D2255/1025—Rhodium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/40—Mixed oxides
    • B01D2255/407—Zr-Ce mixed oxides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/902—Multilayered catalyst
    • B01D2255/9022—Two layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/903—Multi-zoned catalysts
    • B01D2255/9032—Two zones
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/904—Multiple catalysts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/908—O2-storage component incorporated in the catalyst
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2258/00—Sources of waste gases
    • B01D2258/01—Engine exhaust gases
    • B01D2258/014—Stoichiometric gasoline engines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2510/00—Surface coverings
    • F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction
    • F01N2510/068—Surface coverings for exhaust purification, e.g. catalytic reaction characterised by the distribution of the catalytic coatings
    • F01N2510/0682—Surface coverings for exhaust purification, e.g. catalytic reaction characterised by the distribution of the catalytic coatings having a discontinuous, uneven or partially overlapping coating of catalytic material, e.g. higher amount of material upstream than downstream or vice versa
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2510/00—Surface coverings
    • F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction
    • F01N2510/068—Surface coverings for exhaust purification, e.g. catalytic reaction characterised by the distribution of the catalytic coatings
    • F01N2510/0684—Surface coverings for exhaust purification, e.g. catalytic reaction characterised by the distribution of the catalytic coatings having more than one coating layer, e.g. multi-layered coatings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A50/00—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE in human health protection, e.g. against extreme weather
    • Y02A50/20—Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Abstract

The invention relates to a catalyst system for the aftertreatment of motor vehicle exhaust gases. The invention also relates to an exhaust gas treatment system comprising said catalyst unit. The invention also relates to an exhaust gas treatment method for treating motorcycle exhaust gas. The exhaust gas needs to meet various specifications before being discharged into the atmosphere. The catalyst system of the present invention effectively reduces harmful Hydrocarbons (HC), carbon monoxide (CO) and nitrogen oxides (NOx) to less harmful components to meet emission specifications. The catalyst system has the advantages of economy and high efficiency, reduced back pressure while meeting emission specifications, optimal utilization of precious metals in the catalyst resulting in cost reduction.

Description

Catalyst system for treating motor vehicle exhaust gases and method for producing same
Technical Field
The present invention relates to a catalyst system for treating motor vehicle exhaust gases. In particular, the present invention relates to a catalyst system for reducing hydrocarbons, carbon monoxide and nitrogen oxides in motorcycle exhaust. The invention also relates to a method for preparing said catalyst. The exhaust gas needs to meet various specifications before being discharged into the atmosphere. The invention also relates to an exhaust gas treatment system comprising said catalyst unit. The invention also relates to an exhaust gas treatment method for treating motorcycle exhaust gas.
Background
Motor vehicles containing internal combustion engines are widely used for transportation throughout the world. Products or exhaust gases from internal combustion engines have many different components. The product may contain partially converted feed (hydrocarbons), carbon dioxide, carbon monoxide, nitrogen oxides, and the like. The wider use of automobiles has led to a wider range of these products.
Exhaust gas from an automotive engine typically contains emissions such as Hydrocarbons (HC), carbon monoxide (CO) and Nitrogen Oxides (NO)x). Such emissions are relatively harmful and require pre-treatment prior to discharge into the atmosphere. Furthermore, emission treatment specifications have become more stringent year by year. Recently, stricter emission standards have been or will be required in many countries to further limit emissions such as HC, CO, NOxTo improve the environmental conditions.
Vehicles such as motorcycles or scooters are generally equipped with an exhaust emission purification device such as a catalyst that purifies exhaust gas emitted from an engine. The purified exhaust gas from the exhaust gas purification device is then discharged into the atmosphere in a harmless state. In one example, a catalyst unit is used as the exhaust gas purification apparatus. The catalyst unit is disposed within the muffler or intermediate an exhaust pipe connected at one end to the engine and at the other end to the muffler. The catalyst unit is used to reduce tailpipe emission levels. Typically, the catalyst units are constructed in a honeycomb or pellet geometry to expose the exhaust to large surfaces made of one or more precious metals, such as platinum group metals, including platinum, palladium, rhodium. The catalyst unit consists essentially of a substrate, a washcoat and one or more layers of precious metals, such as platinum, palladium and rhodium.
It is well known in the art that various catalysts and exhaust gas purification systems have been developed and used in motor vehicles to address challenging emission control issues. However, there is always room for improvement and advancement in catalyst systems.
Reference is made to CN patent application CN105664939A, which discloses a catalytic converter consisting of a support and a washcoat for treating motorcycle exhaust gases. The washcoat layer is comprised of alumina or an oxygen storage material and a noble metal comprising platinum, palladium, and rhodium. First, the high cost of such catalysts remains a critical factor for the use of such catalysts, since noble metals are extremely expensive. Furthermore, it is important for such catalysts to treat the exhaust gas in the largest possible manner, for example three-way conversion (TWC) catalysts. Accordingly, it is desirable to develop catalyst systems that use limited precious metals while meeting increasingly stringent regulations.
Further reference is made to US patent application US20120128558 Al, which discloses TWC catalysts consisting of at least two front layers and two rear layers together with a substrate. This document discloses that all layers comprise a platinum group metal component and that the rear substrate is substantially free of a ceria-containing oxygen storage component. Although such catalyst systems may meet emission specifications, there is still a need to reduce hydrocarbons in the exhaust. In addition, there is a need to develop catalysts with improved reactant exhaust conversion.
While the prior art discloses various catalyst systems to treat the exhaust stream, the known systems are either unsatisfactory or very expensive. Accordingly, there remains a need for a cost-effective, well-designed catalyst system for post-treatment of motorcycle exhaust.
In view of the above, the inventors of the present disclosure have recognized a need to develop a cost effective catalyst system that overcomes all of the problems of the prior art. There is a particular need to improve the efficiency of the catalyst, i.e. the conversion of hydrocarbons. The present invention provides an improved catalyst system and exhaust gas treatment method for converting harmful components of exhaust gas into less harmful components that can be exhausted into the atmosphere. The improved catalyst is effective in reducing emissions, particularly hydrocarbons present in the exhaust. The catalyst system not only produces economic benefits, but also solves environmental problems and meets emission specifications.
It is an object of the present invention to provide an effective catalyst for the catalysis of HC, CO and NO from motorcycle exhaustxReduced catalyst of (a).
Another object of the invention is to effectively reduce emissions in the exhaust gases from a motorcycle.
Yet another object of the present invention relates to a cost effective catalyst system.
It is a further object of the present invention to provide an exhaust gas treatment system for effectively treating motor vehicle exhaust gases.
Summary of The Invention
The invention relates to a catalyst system for the aftertreatment of motor vehicle exhaust gases. In particular, the present invention relates to a catalyst system for reducing hydrocarbons, carbon monoxide and nitrogen oxides in motorcycle exhaust. The exhaust gas needs to meet various specifications before being discharged into the atmosphere. The invention also relates to an exhaust gas treatment system comprising said catalyst unit. The invention also relates to an exhaust gas treatment method for treating motorcycle exhaust gas.
In one aspect of the disclosure, the invention relates to the effective catalysis of HC, CO and NO from motorcycle exhaustxReduced catalyst system of (2). The catalyst system for the aftertreatment of motorcycle exhaust gases comprises two modules (fricks) 1 and 2 in sequence. Located upstream is a module 1 comprising a washcoat 1 and a washcoat 2 coated on a substrate 1. Located downstream is a module 2 comprising a washcoat 3 coated on a substrate 2. All washcoat layers 1, 2 and 3 contained the noble metals Pt, Pd and Rh. The substrate 1 and/or the substrate 2 has a composition comprising an oxygen storage component and a refractory metal oxideIncluding the longitudinal structure. The thickness ratio of the washcoat layers of module 1 and module 2 is 1.25 to 1.35. The total average precious metal of the catalyst system is 35 to 40g/ft3. PGM loading was 45 to 50g/ft in Module 1325 to 30g/ft in module 23。
The inventors of the present invention have surprisingly found that by providing a catalyst comprising various features in addition to the thickness ratio of the washcoat of modules 1 and 2, a cost effective catalyst system effective in reducing emissions in exhaust gases can be obtained.
In another aspect of the disclosure, the present invention relates to an exhaust gas treatment system comprising the catalyst system or unit of the present invention. The exhaust treatment system may have a catalyst unit as well as other units for effective treatment.
In another aspect of the disclosure, the present disclosure is directed to a method of treating exhaust gas with a catalyst system.
Brief Description of Drawings
The invention itself, as well as further features and attendant advantages, will become more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings. One or more embodiments of the present invention will now be described, by way of example only, with like reference numerals representing like elements and wherein:
FIG. 1 illustrates a schematic diagram of a catalyst according to one embodiment of the present invention;
FIG. 2 illustrates a schematic diagram of a catalyst according to an embodiment of the present invention;
FIG. 3 illustrates a schematic diagram of a catalyst according to an embodiment of the invention;
FIG. 4 illustrates a schematic diagram of a catalyst according to an embodiment of the invention;
FIG. 5 shows Total HC (THC) emissions on GVS for examples 1-4;
FIG. 6 shows the cumulative THC emissions of examples 2 and 3;
FIG. 7 shows cumulative NO's for examples 2 and 3xDischarging;
FIG. 8 shows the cumulative THC emissions of examples 5 and 6;
FIG. 9 shows the cumulative hydrocarbon emissions for examples 7 and 8;
the drawings referred to in the description should not be understood as being drawn to scale and as being merely exemplary, if not explicitly stated.
Detailed Description
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that there is no intention to limit the invention to the specific forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.
The terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a device, structure, or method that comprises a list of elements or steps does not include only those elements or steps but may include other elements or steps not expressly listed or inherent to such device, structure, or method. In other words, one or more elements of a system or apparatus that "comprises" does not preclude the presence of other elements or additional elements in the system or apparatus, if not more limited.
For a better understanding of the present invention, reference is now made to the embodiments illustrated in the drawings and described in the following description, in which like reference numerals are used to designate like components in the various views.
Although the present invention is described with respect to a vehicle, the exhaust system and aspects and features thereof may be used with other types of vehicles. The terms "vehicle", "two-wheeled vehicle" and "motorcycle" are used interchangeably throughout the specification. The term "vehicle" encompasses vehicles such as motorcycles, scooters, bicycles, mopeds, scooter type vehicles (scooters type vehicles), All Terrain Vehicles (ATVs), and the like.
Furthermore, it is to be understood that the invention is not limited to the details of construction or method steps set forth in the following description. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
The following terms used in the present specification and appended claims have the following definitions:
the words "a", "an" and "the" when used in reference to a term include both the plural and singular forms of that term.
All percentages and ratios are by weight unless otherwise indicated.
In one aspect of the invention, a catalyst system for treating motor vehicle exhaust is provided comprising one or more substrates and two or more washcoat layers on the substrates forming one or more modules, wherein
A first module positioned upstream comprises a first washcoat layer and a second washcoat layer coated on a first substrate,
the downstream second module comprises a third washcoat layer coated on a second substrate,
wherein the washcoat comprises a noble metal selected from the group consisting of Pt, Pd, and Rh, the first substrate and/or the second substrate has a metal substrate comprising an oxygen storage component and a refractory metal oxide,
characterized in that the thickness ratio of the first module to the second module is 1.25 to 1.35.
In one embodiment of the present invention, a catalyst system is disclosed wherein the noble metal has 35 to 40g/ft in the catalyst system3Total average loading of.
In another embodiment of the invention, a catalyst system is disclosed wherein the precious metal loading in the first module is 45 to 50g/ft325 to 30g/ft in the second module3。
Yet another embodiment of the present invention is directed to the catalyst system, wherein the Pd/Rh weight ratio in the first module is from 2.5 to 2.8; and the Pd/Rh weight ratio in the second module is 1/5 to 1/3.
Yet another embodiment of the invention is directed to a catalyst system wherein the two module systems are together 50mm from the engine pipe in motorcycle BS-VI applications.
Yet another embodiment of the present invention is directed to a catalyst system wherein the metal substrate is a longitudinal structured monolith.
Yet another embodiment of the present invention is directed to a catalyst system wherein the washcoat layer is applied to a single substrate.
Yet another embodiment of the invention is directed to a catalyst system wherein the substrate has a ceria oxygen storage component and the refractory metal oxide component is one or more of niobium, molybdenum, tantalum, tungsten, and rhenium.
In one embodiment of the invention, a method of preparing a catalyst system for aftertreatment of motor vehicle exhaust gases includes the steps of
Preparing and applying one or more wash coats on one or more substrates to form two or more modules comprising
a. The soluble noble metal solution is diluted with water to incipient wetness (incipient wetness),
b. impregnating alumina, cerium and zirconium oxide particles on the noble metal solution,
c. adding water and another soluble noble metal solution to form slurry,
d. the slurry is applied to a metal substrate,
e. drying and calcining at a temperature of from 500 ℃ to 600 ℃ for at least 2 hours,
wherein the slurry for the first and second washcoat zones has a solids content of at least 40%, the slurry for the third washcoat zone has a solids content of at least 30%,
a first module located upstream comprises a first washcoat layer and a second washcoat layer,
the second module located downstream contains a third washcoat,
characterized in that the thickness ratio of the first module to the second module is 1.25 to 1.35.
In another embodiment of the invention, a method of making a catalyst system wherein the precious metal loading in the first module is 45 to 50g/ft325 to 30g/ft in the second module3。
Yet another embodiment of the invention is directed to a method of preparing a catalyst system, wherein the Pd/Rh weight ratio in the first module is from 2.5 to 2.8; and the Pd/Rh weight ratio in the second module is 1/5 to 1/3.
Yet another embodiment of the invention relates to a method of making a catalyst system wherein the two-module system is together 50mm from the engine pipe in a motorcycle BS-VI application.
Yet another embodiment of the present invention is directed to a method of making a catalyst system wherein the metal substrate is a longitudinal structured monolith.
In one embodiment of the present invention, an exhaust gas treatment system for treating motor vehicle exhaust gas comprises one or more catalyst systems
The catalyst system comprises one or more substrates and one or more washcoats on the substrates forming two or more modules, wherein
A first module positioned upstream comprises a first washcoat layer and a second washcoat layer coated on a first substrate,
the downstream second module comprises a third washcoat layer coated on a second substrate,
wherein the washcoat comprises a noble metal selected from the group consisting of Pt, Pd, and Rh, the first substrate and/or the second substrate has a metal substrate comprising an oxygen storage component and a refractory metal oxide,
characterized in that the thickness ratio of the first module to the second module is 1.25 to 1.35.
In one embodiment of the present invention, an exhaust gas treatment method for treating an exhaust gas of a motor vehicle includes the steps of
Exhaust gas from an automotive engine is directed to an exhaust treatment system to convert harmful Hydrocarbons (HC), carbon monoxide (CO) and nitrogen oxides (NOx) into less harmful components to meet emission specifications,
wherein the exhaust gas treatment system is the system as claimed in claim 14.
In one embodiment of the invention, the use of a catalyst system as claimed in claim 1 for aftertreatment of motor vehicle exhaust gases.
In one embodiment of the present invention, the use of a catalyst system as claimed in claim 16 with reduced back pressure and optimal utilization of precious metals.
A catalyst system for purifying the exhaust gas of an internal combustion engine comprises at least one substrate; a first washcoat zone disposed on an upstream side of the at least one substrate, wherein the first washcoat zone comprises a first Platinum Group Metal (PGM); a second washcoat zone disposed adjacent/sequentially to the first washcoat zone on the substrate, wherein the second washcoat zone comprises a second Platinum Group Metal (PGM); a third washcoat zone disposed on the first washcoat zone on an upstream side of the substrate, wherein the third washcoat zone comprises a third Platinum Group Metal (PGM); wherein the first PGM, the second PGM, and the third PGM are selected from the group consisting of platinum, palladium, and rhodium. The total loading/density of the second PGM is greater than the total loading/density of the first PGM, and the total loading/densities of the first and third PGMs together are greater than the total loading/density of the second PGM. Further, the ratio of the thickness of the first washcoat layer to the second washcoat layer is 1.25 to 1.35.
The terms "rear/back/rear (rear/back)", "up/upper/top", "down/lower/down, bottom", "left/left", "right/right" as used herein represent directions seen by a straddling vehicle driver and these directions are represented in the drawings by arrows Fr, Rr, U, Lr, L, R.
Fig. 1 illustrates a schematic diagram of a catalyst according to one embodiment of the present invention.
The catalyst (100) of the present invention comprises a first substrate (101), a second substrate (102), a first washcoat zone (201), a second washcoat zone (202), a third washcoat zone (203). The second substrate (102) is arranged adjacent to the first substrate (101) along a downstream of the first substrate (101).
In another embodiment, as shown in fig. 4, the second substrate (102) is disposed adjacent to the first substrate (101) with a predetermined spatial gap 'x' along the downstream of the first substrate (101). A first washcoat zone (201) is disposed on the first substrate (101). A second washcoat zone (202). A first washcoat zone (201) is disposed on the first substrate (101). The first washcoat zone (201) includes a first Platinum Group Metal (PGM) selected from platinum, palladium, and rhodium. In one embodiment, the palladium/rhodium weight ratio in the first substrate is from 2.5 to 2.8. Further, a second washcoat zone (202) is disposed on a second substrate (102) adjacent to the first substrate (101) and in a downstream direction of the first substrate (101).
In one embodiment of the invention, the palladium/rhodium weight ratio in the second substrate is from 1/5 to 1/3. The second washcoat zone (202) includes a second platinum group metal selected from platinum, palladium, and rhodium. Further, a third washcoat zone (203) is disposed on the first washcoat zone (201) on the first substrate (101). The third washcoat zone (203) comprises a first platinum group metal selected from platinum, palladium, and rhodium. In one embodiment, the ratio of the thickness of the total thickness of the first and third washcoat zones in the first substrate to the thickness of the second washcoat zone in the second substrate is from 1.25 to 1.35. In one embodiment, the total loading of the first and third PGMs is 45 to 50g/ft3. In one embodiment the loading of the third PGM is 25 to 30g/ft3. The first substrate (101) and the second substrate (102) are equal in length in one embodiment.
In another embodiment, as shown in fig. 3, the first substrate (101) and the second substrate (102) are a unitary substrate (103). In one embodiment, as shown in fig. 4, a spatial gap 'x' is provided between the first substrates (101) and (102). Such a spatial gap 'x' between the first substrate (101) and the second substrate (102) is provided to improve the flow uniformity index and to maintain turbulence in the second substrate (102) to bring about a better purification efficiency of the catalyst system (100). In one embodiment, the spatial gap is in the range of 10mm to 20 mm.
In another aspect of the invention, the substrate is a metal substrate (including longitudinal structures) comprising an oxygen storage component and a refractory metal oxide. Oxygen storage components which are frequently used are cerium oxides or cerium-containing mixed oxides, for example cerium oxide-zirconium oxide mixed oxides. The refractory metal oxide is selected from the group consisting of alumina, silica, zirconia, titania, ceria and mixtures thereof.
In a preferred embodiment, the catalyst system comprises different Pd/Rh ratios in different modules of the catalyst. Preferably, the Pd/Rh weight ratio in module 1 is from 2.5 to 2.8; and the Pd/Rh weight ratio in module 2 is 1/5 to 1/3.
Another aspect of the invention provides a catalyst system applied on a two-module system that together are 50mm from the engine pipe in motorcycle BS-VI applications.
The invention itself, as well as further features and attendant advantages, will become more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings. One or more embodiments of the present invention will now be described, by way of example only, with like reference numerals representing like elements and wherein:
examples
Many variations and combinations may be made based on the present disclosure to make a catalyst system for aftertreatment of motorcycle exhaust without departing from the spirit of the present disclosure. The following examples and embodiments are given by way of illustration only and should not be construed to limit the present invention.
The noble metal coating on the substrate and the placement on the substrate play an important role in the overall performance of the engine. If the precious metal coating on the substrate is very thick, it may increase the backpressure in the exhaust system, affecting the performance of the engine. In addition, precious metal coatings can increase costs. Therefore, the precious metal coating on the substrate must be made in an optimized manner so that it does not affect engine performance and also meets the vehicle's emission specifications. At the same time, the noble metal coating should be cost effective for the catalyst. The preparation methods described below were used to prepare the catalyst systems of the invention in examples 1 to 8:
step 1: preparation and application of washcoat 1
The soluble rhodium solution was diluted with water to achieve incipient wetness of the impregnated alumina, cerium and zirconium oxide particles. The impregnated sample was then mixed with water, a soluble platinum solution, to form a slurry with-40 wt% solids content. The above mixture was applied to a metal substrate (40X 60mm D X L, cell density of 200cpsi), dried and calcined at 550 ℃ for 2 hours.
Step 2: preparation and application of washcoat 2
The soluble palladium and rhodium solutions were diluted with water to enable incipient wetness of the alumina and cerium and zirconium oxides. The impregnated sample was then mixed with water to form a slurry with-30% by weight solids content. The mixture was applied to washcoat 1, dried and calcined at 550 ℃ for 2 hours.
And step 3: preparation and application of the washcoat 3
The soluble palladium and rhodium solutions were diluted with water to enable incipient wetness of the alumina and cerium and zirconium oxide particles. The impregnated sample was then mixed with water and a soluble platinum solution to form a slurry with-40 wt% solids content. The above mixture was applied to a metal substrate (40X 60mm D X L, cell density of 200cpsi), dried and calcined at 550 ℃ for 2 hours.
Example 1:
the catalyst system was prepared using the above preparation method, and the washcoat loading in washcoat 1 of the resulting catalyst system was 1.4g/in3Washcoat loading in washcoat 2 of 1.0g/in3And washcoat loading in washcoat 3 of 3g/in3. The thickness ratio of module 1 to module 2 was 1.26.
Example 2:
the catalyst system was prepared using the above preparation method, and the washcoat loading in washcoat 1 of the resulting catalyst system was 2.0g/in3Washcoat loading in washcoat 2 of 1.0g/in3And washcoat loading in washcoat 3 of 3g/in3. The thickness ratio of module 1 to module 2 is 1.25 to 1.35.
Example 3:
the catalyst system was prepared using the above preparation method, and the washcoat loading in washcoat 1 of the resulting catalyst system was 2.0g/in3Washcoat loading in washcoat 2 of 1.0g/in3And washcoat loading in washcoat 3 of 2.4g/in3. The thickness ratio of module 1 to module 2 is 1.25 to 1.35.
Example 4:
the catalyst system was prepared using the above preparation method, and the washcoat loading in washcoat 1 of the resulting catalyst was 2.0g/in3Washcoat loading in washcoat 2 of 1.0g/in3And washcoat loading in washcoat 3 of 2.0g/in3. The thickness ratio of module 1 to module 2 is 1.25 to 1.35.
Example 5:
the catalyst system was prepared using the above preparation method, and the Pd/Rh ratio in module 1 and the Pd/Rh ratio in module 2 of the resulting catalyst system were 2.7 and 0.4, respectively. The thickness ratio of module 1 to module 2 is 1.25 to 1.35.
Example 6:
the catalyst system was prepared using the above preparation method, and the Pd/Rh ratio in module 1 and the Pd/Rh ratio in module 2 of the resulting catalyst system were 1.7 and 0.4, respectively. The thickness ratio of module 1 to module 2 is 1.25 to 1.35.
Example 7:
the catalyst system was prepared using the above preparation method, and the Pd/Rh ratio in module 1 and the Pd/Rh ratio in module 2 of the resulting catalyst system were 2.7 and 0.25, respectively. The thickness ratio of module 1 to module 2 is 1.25 to 1.35.
Example 8:
the catalyst system was prepared using the above preparation method, and the Pd/Rh ratio in module 1 and the Pd/Rh ratio in module 2 of the resulting catalyst system were 2.7 and 4.0. The thickness ratio of module 1 to module 2 is 1.25 to 1.35.
Comparative example 1:
the catalyst of comparative example 1 was the same as the catalyst of example 1 of the present invention except that the thickness ratio of module 1 to module 2 was 0.8.
Comparative example 2:
the catalyst of comparative example 1 was the same as the catalyst of example 1 of the present invention except that the thickness ratio of module 1 to module 2 was 1.
Comparative example 3:
the catalyst of comparative example 1 was the same as the catalyst of example 1 of the present invention except that the thickness ratio of module 1 to module 2 was 1.5.
Test of THC (Total Hydrocarbon) Properties of example 1 and comparative examples 1, 2 and 3：
The catalyst was aged in air at 550 ℃ for 24 hours and coated on a core substrate (1 inch D × 1 inch L × 2). Tests were performed on a GVS (gasoline vehicle simulator) and the space velocity was dynamic, reaching a maximum of 85,000h-1And λ oscillates between 0.80 and 1.20; HC of 0-20,000ppm, CO of 0-35,000ppm and NOx(NO/NO2) 0 to 8,000ppm, H2O＝10％，CO/NOx/O2Based on lambda. By TCD, FID andFTIR Infrared Spectroscopy for THC/CO/NOxAmount of the compound (A). The results are shown in fig. 5.
As shown in fig. 5, when the thickness ratio of module 1 to module 2 is between the claimed ranges, THC (total hydrocarbons) is effectively reduced (example 1). On the other hand, if the thickness ratio of module 1 to module 2 is outside the claimed range (comparative examples 1 to 3), the desired reduction in THC is not obtained. Thus, the tests of example 1 and comparative examples 1 to 3 clearly show the enhanced performance of the catalyst system of the present invention.
xTesting of THC and NO Performance for examples 2 and 3：
Use of the catalysts of examples 2 and 3 of the invention for NOxFurther study of the properties. The Test was carried out on a motor vehicle using the World Motorcycle Test Cycle (WMTC). The WMTC cycle is a standard cycle in which the catalyst is tested by varying the speed, time. The catalyst was coated on a full-size substrate (40mm D × 60mm L × 2) and assembled on an automotive muffler. THC/CO/NO determination by TCD, FID and FTIR Infrared SpectroscopyxAmount of the compound (A). The results are shown in fig. 6 and 7. Grey indicates the actual speed of the engine. P8 (yellow) indicates example 3 and P8OH (blue) indicates example 2. It can be seen that the washcoat loading of example 3 provides better emissions control (THC and NO) than the washcoat loading of example 2xDecrease).
Testing of THC Performance for examples 5 and 6：
The catalysts of examples 5 and 6 of the invention were used for further studies of THC performance. The Test was carried out on a motor vehicle using the World Motorcycle Test Cycle (WMTC). The WMTC cycle is a standard cycle in which the catalyst is tested by varying the speed, time.
The catalyst was aged in air at 550 ℃ for 24 hours and coated on a core substrate (1 inch D × 1 inch L × 2). Tests were performed on a GVS (gasoline vehicle simulator) and the space velocity was dynamic, reaching a maximum of 85,000h-1And λ oscillates between 0.80 and 1.20; HC of 0-20,000ppm, CO of 0-35,000ppm and NOx(NO/NO2) 0 to 8,000ppm, H2O＝10％，CO/NOx/O2Based on lambda. THC/CO/NO determination by TCD, FID and FTIR Infrared SpectroscopyxAmount of the compound (A). The results are shown in fig. 8. Example 5 is indicated by 2.7 (red) and example 6 by 1.7 (blue). It can be seen that the example 5 washcoat loading provides better emissions control (THC reduction) than the example 6 washcoat loading.
Testing of THC Performance for examples 7 and 8：
The catalysts of examples 7 and 8 of the invention were used for further investigation of THC performance.
The test was carried out on a motorcycle using the WMTC cycle. The catalyst was coated on a full size substrate (40mm D × 90mm L × 2) and assembled on a motorcycle muffler. THC/CO/NO determination by TCD, FID and FTIR Infrared SpectroscopyxAmount of the compound (A). The results are shown in fig. 9. Grey indicates the actual speed of the engine. Example 8 is indicated by 4 (green) and example 7 is indicated by 0.25 (magenta). It can be seen that the example 7 washcoat loading provides better emissions control (cumulative hydrocarbon) than the example 8 washcoat loading.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It will be apparent to those skilled in the art that various modifications and variations can be made in the method and apparatus of the present invention without departing from the spirit and scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
The advantages are that:
the catalyst unit and emission treatment system of the present invention have the following advantages:
economic and efficient
Effective reduction of Hydrocarbons (HC), carbon monoxide (CO) and nitrogen oxides (NOx) from motor vehicle exhaust
Reduced back pressure while meeting emission specifications
Optimal utilization of the noble metals in the catalyst, resulting in a cost reduction.

Claims (17)

1. A catalyst system for treating motor vehicle exhaust comprising one or more substrates and one or more washcoat layers on the substrates forming two or more modules, wherein
A first module positioned upstream comprises a first washcoat layer and a second washcoat layer coated on a first substrate,
the downstream second module comprises a third washcoat layer coated on a second substrate,
wherein the washcoat comprises a noble metal selected from the group consisting of Pt, Pd, and Rh, the first substrate and/or the second substrate has a metal substrate comprising an oxygen storage component and a refractory metal oxide,
characterized in that the washcoat thickness ratio of the first module to the second module is from 1.25 to 1.35.
2. The catalyst system of claim 1, wherein the noble metal in the catalyst system has 35 to 40g/ft3Total average loading of.
3. The catalyst system as recited in claim 1 or 2, wherein the precious metal loading in the first module is 45 to 50g/ft325 to 30g/ft in the second module3。
4. The catalyst system as claimed in claim 1, wherein the Pd/Rh weight ratio in the first module is in the range of 2.5 to 2.8; and the Pd/Rh weight ratio in the second module is in the range of 1/5 to 1/3.
5. A catalyst system as claimed in any one of claims 1 to 4, wherein the two module systems together are 50mm in the exhaust pipe from the exhaust of the motor vehicle engine.
6. The catalyst system of claim 1, wherein the metal substrate is a longitudinal structured monolith.
7. A catalyst system as claimed in claim 1 or 6, wherein the washcoat is applied on a single substrate.
8. A catalyst system as claimed in claim 1 or 6, wherein the substrate has a ceria oxygen storage component and the refractory metal oxide component is one or more of niobium, molybdenum, tantalum, tungsten and rhenium.
9. A method of preparing a catalyst for aftertreatment of motor vehicle exhaust gases comprising the steps of:
preparing and applying one or more wash coats on one or more substrates to form two or more modules comprising
a. Diluting the soluble noble metal solution with water to achieve incipient wetness,
b. impregnating alumina, cerium and zirconium oxide particles on the noble metal solution,
c. adding water and another soluble noble metal solution to form slurry,
d. the slurry is applied to a metal substrate,
e. drying and calcining at a temperature of from 500 ℃ to 600 ℃ for at least 2 hours,
wherein the slurry for the first and second washcoat zones has a solids content of at least 40%, the slurry for the third washcoat zone has a solids content of at least 30%,
a first module located upstream comprises a first washcoat layer and a second washcoat layer,
the second module located downstream contains a third washcoat,
characterized in that the washcoat thickness ratio of the first module to the second module is from 1.25 to 1.35.
10. The process as set forth in claim 9 wherein the precious metal loading in the first module is from 45 to 50g/ft325 to 30g/ft in the second module3。
11. A method as claimed in claim 9 or 10, wherein the Pd/Rh weight ratio in the first module is in the range of 2.5 to 2.8; and the Pd/Rh weight ratio in the second module is in the range of 1/5 to 1/3.
12. The method as claimed in any one of claims 9 to 11, wherein the two module systems together are 50mm from an engine pipe in a motorcycle.
13. The method as recited in claim 9 wherein the metal substrate is a longitudinal structured monolith.
14. An exhaust gas treatment system for treating motor vehicle exhaust comprising one or more catalyst systems comprising one or more substrates and one or more washcoats on the substrates forming two or more modules, wherein
A first module positioned upstream comprises a first washcoat layer and a second washcoat layer coated on a first substrate,
the downstream second module comprises a third washcoat layer coated on a second substrate,
wherein the washcoat comprises a noble metal selected from the group consisting of Pt, Pd, and Rh, the first substrate and/or the second substrate has a metal substrate comprising an oxygen storage component and a refractory metal oxide,
characterized in that the washcoat thickness ratio of the first module to the second module is from 1.25 to 1.35.
15. An exhaust gas treatment method for treating exhaust gas of a motor vehicle, comprising the steps of
Exhaust gas from an engine of a motor vehicle is directed to an exhaust gas treatment system to convert harmful Hydrocarbons (HC), carbon monoxide (CO) and nitrogen oxides (NOx) into less harmful components to meet emission specifications, wherein the exhaust gas treatment system is a system as claimed in claim 14.
16. Use of a catalyst system as claimed in claim 1 for aftertreatment of motor vehicle exhaust gases.
17. Use of a catalyst system as claimed in claim 16 with reduced back pressure and optimum utilization of precious metals.
CN202080032316.2A 2019-03-11 2020-03-11 Catalyst system for treating motor vehicle exhaust gases and method for producing same Pending CN114072223A (en)

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