EP3727654A1 - Pot catalytique à trois voies multicouche - Google Patents

Pot catalytique à trois voies multicouche

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Publication number
EP3727654A1
EP3727654A1 EP18826338.8A EP18826338A EP3727654A1 EP 3727654 A1 EP3727654 A1 EP 3727654A1 EP 18826338 A EP18826338 A EP 18826338A EP 3727654 A1 EP3727654 A1 EP 3727654A1
Authority
EP
European Patent Office
Prior art keywords
zirconium
cerium
rare earth
oxide
coating
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
EP18826338.8A
Other languages
German (de)
English (en)
Inventor
Jan Schoenhaber
Martin Roesch
Joerg-Michael Richter
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Umicore AG and Co KG
Original Assignee
Umicore AG and Co KG
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Umicore AG and Co KG filed Critical Umicore AG and Co KG
Publication of EP3727654A1 publication Critical patent/EP3727654A1/fr
Pending legal-status Critical Current

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Classifications

    • 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
    • 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
    • B01D53/9459—Removing 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
    • B01D53/9463—Removing 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 one brick
    • B01D53/9468—Removing 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 one brick in different 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
    • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
    • B01J21/066—Zirconium or hafnium; Oxides or hydroxides thereof
    • 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
    • B01J23/10—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of rare earths
    • 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
    • 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
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/19—Catalysts containing parts with different compositions
    • 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
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
    • B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
    • 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
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/033—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices
    • F01N3/035—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
    • 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
    • F01N3/101—Three-way catalysts
    • 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
    • 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
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2825—Ceramics
    • 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
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/206—Rare earth metals
    • B01D2255/2061—Yttrium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/206—Rare earth metals
    • B01D2255/2063—Lanthanum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/206—Rare earth metals
    • B01D2255/2065—Cerium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/206—Rare earth metals
    • B01D2255/2066—Praseodymium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/207—Transition metals
    • B01D2255/20715—Zirconium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/209—Other metals
    • B01D2255/2092—Aluminium
    • 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
    • B01D2255/908—O2-storage component incorporated in the catalyst
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/915—Catalyst supported on particulate filters
    • B01D2255/9155—Wall flow filters
    • 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
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/06—Ceramic, e.g. monoliths
    • 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
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/30—Honeycomb supports characterised by their structural details
    • 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
    • F01N2370/00—Selection of materials for exhaust purification
    • F01N2370/02—Selection of materials for exhaust purification used in catalytic reactors
    • 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
    • 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
    • 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

Definitions

  • the present invention relates to a three-way catalyst which is particularly suitable for the removal of carbon monoxide, hydrocarbons and nitrogen oxides from the exhaust gas of stoichiometric air / fuel mixture operated internal combustion engines. He is by
  • Gasoline engines are cleaned in conventional processes using three-way catalysts. These are able to absorb the three main gaseous pollutants of the engine, namely hydrocarbons,
  • Combustion air ratio l (A / F ratio, air / fuel ratio) sets the actual air mass m L, tats available for combustion in relation to the stoichiometric air mass m i_, st:
  • platinum group metals in particular platinum, palladium and rhodium are used, which are present for example on g-aluminum oxide as a carrier material.
  • g-aluminum oxide as a carrier material.
  • rhodium is present for example on g-aluminum oxide as a carrier material.
  • Three-Way Catalysts Oxygen storage materials for example
  • Cerium / zirconium mixed oxides In the latter is ceria, a
  • Oxygen storage materials contain additional constituents such as other rare earth metal oxides or alkaline earth metal oxides.
  • Oxygen storage materials are activated by the application of catalytically active materials such as platinum group metals and thus also serve as a carrier material for the
  • the components of a three-way catalyst may be present in a single coating layer on an inert catalyst support. Such catalysts are distinguished from multilayer catalysts by lower coating costs.
  • EP1541220B1 describes a single-layer three-way catalyst in which palladium and rhodium are predominantly in a non-alloyed form.
  • EP1974810B1 describes a single-layer three-way catalyst in which a first cerium / zirconium mixed oxide with rhodium and a second
  • Cerium / zirconium mixed oxide has a higher zirconium oxide content than the second.
  • EP2948653A1 describes a single-layer three-way catalyst in which a temperature-resistant metal oxide and optionally a first cerium / zirconium mixed oxide with rhodium and a second cerium / zirconium mixed oxide with palladium is activated, wherein the proportion of cerium / zirconium mixed oxides in the layer is the same or greater than that of the temperature-resistant metal oxide in the layer.
  • EP1974809A1 discloses three-way, double-layered catalysts containing cerium / zirconium mixed oxides in both layers, the
  • Cerium / zirconium mixed oxide in the upper layer each have a higher content of zirconium than that in the lower layer.
  • EP1726359A1 describes three-way, double-layered catalysts containing in both layers cerium / zirconium / lanthanum / neodymium mixed oxides having a zirconium content of more than 80 mole%, the
  • Cerium / zirconium / lanthanum / neodymium mixed oxide in the upper layer may each have a higher content of zirconium than that in the lower layer.
  • W02008000449A2 also discloses double-layered catalysts which contain cerium / zirconium mixed oxides in both layers and in which, in turn, the mixed oxide in the upper layer has a higher content of zirconium.
  • the cerium / zirconium mixed oxides may also be replaced by cerium / zirconium / lanthanum / neodymium or cerium / zirconium / lanthanum / yttrium mixed oxides.
  • compositions of three-way catalysts are e.g. In
  • EP3045226A1 and EP3247493A1 described. These show at modern
  • the present invention relates to a three-way catalyst having increased oxygen storage capacity and improved emissions, particularly in intake manifold injection vehicles, comprising two layers on an inert catalyst support
  • a layer A at least one active aluminum oxide
  • Alumina a platinum group metal, and at least one
  • Cerium / zirconium / rare earth mixed oxide contains. Surprisingly, it has been shown that a combination
  • coating A is on the walls of the substrate. It is further preferred if the coating A extends over at least 50% of the length L starting from one end of the substrate.
  • the catalytically active coating is located on the walls in the channels of the flow-through substrate. If in the context of the present invention of a coating on the walls is mentioned, then it is meant that only a small proportion of the coating of max. 20% by weight, more preferably max. 15% by weight and most preferably max. 10 wt .-% and most preferably max. 5 wt .-% is present in the walls of the flow-through substrate. This can be determined by graphical analysis of SEM sectional images.
  • the coating extends at least 50% from the first end of the ceramic honeycomb body, preferably at least 70% and most preferably 100% of the length L of the substrate.
  • the coating B is at least partially on the coating A.
  • the coating B covers the coating A to at least 50%, preferably at least 70% and most preferably to 100%.
  • the coating A is catalytically active, especially at
  • Oxygen storage components The oxygen storage components differ with respect to at least one of the contained
  • the coating B is catalytically active, especially at
  • Operating temperatures from 250 ° C to 1100 ° C. It usually contains one or more noble metals, which are fixed on one or more support materials, and at least one oxygen storage component.
  • oxygen storage components are cerium / zirconium / rare earth metal mixed oxides.
  • cerium / zirconium / rare earth metal mixed oxides are particularly suitable oxygen storage components.
  • cerium / zirconium / rare earth mixed oxides are characterized by a substantially homogeneous, three-dimensional crystal structure which is ideally free of phases of pure ceria, zirconia or rare earth oxide. Depending on the manufacturing process but also not completely homogeneous products, but with a homogeneity of> 80 wt .-% arise, which can be used usually without disadvantage.
  • the term rare earth metal or Rare earth metal oxide in the sense of the present invention no cerium or no cerium oxide.
  • rare earth metal oxides in the cerium / zirconium / rare earth metal mixed oxides are lanthanum oxide, yttrium oxide, praseodymium oxide,
  • Neodymium oxide and / or samarium oxide into consideration.
  • Lanthanum oxide, yttrium oxide and / or praseodymium oxide are preferred, and very particular preference is given to lanthanum oxide and yttrium oxide, yttrium oxide and praseodymium oxide, and also lanthanum oxide and praseodymium oxide.
  • the oxygen storage components are preferably free of neodymium oxide.
  • the weight ratio of alumina is the sum of the two
  • Cerium / zirconium / rare earth mixed oxides in the range of 10:90 to 60:40, preferably in the range of 20:80 to 50:50 and more preferably in the range of 25:75 to 35:65.
  • the coatings A and / or B comprise in preferred
  • Cerium / zirconium / rare earth metal mixed oxides in layer A greater than the proportion of cerium / zirconium / rare earth metal mixed oxide in layer B, in each case calculated in wt .-% and based on the total weight of the respective layer.
  • the coating A in embodiments comprises two
  • Cerium / zirconium / rare earth mixed oxide in the range of 4: 1 to 1: 4, preferably in the range of 3: 1 to 1: 3 and more preferably in the range of 2: 1 to 1: 2.
  • the mass ratio of ceria to zirconia in the cerium / zirconium / rare earth mixed oxides of layers A and / or B can vary widely. It is for example 0.1 to 1.5, preferably 0.2 to 1.25 or 0.3 to 1.
  • the coating A comprises a first and a second oxygen storage component, wherein the first oxygen storage component has a higher content of zirconium oxide than the second oxygen storage component. Furthermore, it is preferred if the first oxygen storage component a
  • Other more preferred embodiments include a first oxygen storage component having a weight ratio of ceria to zirconia of 0.6 to 0.2 and a second
  • Oxygen storage component having a weight ratio of ceria to zirconia of from 0.6 to 1.2. Still others very much preferred
  • Embodiments include a first oxygen storage component having a weight ratio of ceria to zirconia of from 0.5 to 0.3, and the second oxygen storage component has a weight ratio of ceria to zirconia of from 0.7 to 1.0.
  • Three-way catalyst designed so that in the coating A, the first cerium / zirconium / rare earth mixed oxide a cerium oxide content of 10% to 40% based on the weight of the first
  • Cerium / zirconium / rare earth mixed oxide more preferably from 15% to 35% and most preferably from 20% to 30% based on the weight of the first cerium / zirconium / rare earth metal composite oxide.
  • the zirconia content in the coating A in the first cerium / zirconium / rare earth mixed oxide is from 40% to 90% based on the weight of the first cerium / zirconium / rare earth metal mixed oxide. It is advantageous if the zirconium oxide content in the first
  • Cerium / zirconium / rare earth mixed oxide between 50% to 75%, from 55% to 65% by weight of the first
  • Cerium / zirconium / rare earth mixed oxide Cerium / zirconium / rare earth mixed oxide.
  • a ceria content of 25% to 60% based on the weight of the second cerium / zirconium / rare earth mixed oxide should be used
  • Cerium / zirconium / rare earth mixed oxide a ceria content of 30% to 55%, more preferably 35% to 50%, based on the weight of the second cerium / zirconium / rare earth metal composite oxide.
  • Cerium / zirconium / rare earth mixed oxide in Coating A has a zirconia content of 20% to 70% based on the weight of the second cerium / zirconium / rare earth mixed oxide.
  • the second cerium / zirconium / rare earth mixed oxide has a zirconia content of from 30% to 60% and most preferably from 40% to 55% by weight of the second
  • Cerium / zirconium / rare earth mixed oxide Cerium / zirconium / rare earth mixed oxide.
  • cerium / zirconium / rare earth metal mixed oxides of layer A it is preferred if both cerium / zirconium / rare earth metal mixed oxides of layer A and optionally also the at least one
  • Cerium / zirconium / rare earth mixed oxide of layer B are doped with lanthanum oxide, so that preferably the content of lanthanum oxide> 0% to 10% based on the weight of the cerium / zirconium / rare earth metal mixed oxide is.
  • These lanthanum oxide-containing oxygen storage components particularly advantageously have a mass ratio of lanthanum oxide to cerium oxide of 0.05 to 0.5.
  • the first cerium / zirconium / rare earth mixed oxide in the coating A is doped with yttria in addition to lanthana.
  • a preferred catalyst has an yttria content in the first
  • Cerium / zirconium / rare earth mixed oxide of 2% to 25% by weight of the first cerium / zirconium / rare earth mixed oxide. More preferably, the yttria content is the first
  • Cerium / zirconium / rare earth mixed oxide between 4% and 20%, more preferably 10% to 15% by weight of the first
  • Cerium / zirconium / rare earth mixed oxide Cerium / zirconium / rare earth mixed oxide.
  • Rare earth metal oxides is doped, preferably with praseodymium.
  • the content of the second rare earth metal in the second cerium / zirconium / rare earth mixed oxide may be from 2% to 15% by weight of the second cerium / zirconium / rare earth mixed oxide. It is more advantageous if the content of the second rare earth metal of the second
  • Cerium / zirconium / rare earth mixed oxide at 3% to 10%, more preferably at 4% to 8% by weight of the second
  • Cerium / zirconium / rare earth mixed oxide Cerium / zirconium / rare earth mixed oxide.
  • Rare earth metal oxides is doped, preferably with praseodymium oxide and / or yttrium oxide. The content of rare earth metal in
  • Cerium / zirconium / rare earth mixed oxide coating B can range from 2% to 15% by weight of the Cerium / zirconium / rare earth mixed oxide lie. It is more advantageous if the content of the rare earth metal of the cerium / zirconium / rare earth metal composite oxide is from 3% to 10%, more preferably from 4% to 8%, based on the weight of the cerium / zirconium / rare earth metal mixed oxide in layer B.
  • the praseodymium content of the respective oxygen storage component is in particular from 2 to 10% by weight, based on the weight of the respective oxygen storage component.
  • the weight ratio of lanthanum oxide to praseodymium oxide is in particular from 0.1 to 2.0, preferably from 0.2 to 1.8, and very preferably from 0.5 to 1.5.
  • the zirconia content of the yttria-containing oxygen storage component is greater than the zirconia content of the zirconia
  • coatings A and B contain noble metals as catalytically active elements.
  • Layer A and Layer B are included as
  • Platinum group metal independently of one another, in particular platinum,
  • layer A contains platinum, palladium or platinum and palladium and layer B comprises palladium, rhodium or palladium and rhodium.
  • layer A contains palladium and layer B rhodium or palladium and rhodium.
  • the noble metals are usually used in amounts of 0.1 g / l to 15 g / l, based on the volume of the ceramic honeycomb body, preferably 0.15 g / L to 10 g / L. In a preferred embodiment the precious metals both on the alumina and on the
  • Suitable support materials for the noble metals in layer A and B are all materials which are familiar to the person skilled in the art for this purpose. Such materials are in particular metal oxides having a BET surface area of from 30 to 250 m 2 / g, preferably from 100 to 200 m 2 / g (determined in accordance with DIN 66132 - latest version on the filing date). As support materials for the
  • Platinum group metals can be used in layer A and / or in layer B the
  • Cerium / zirconium / rare earth metal mixed oxides are used. In addition, they may be supported in layer A and / or in layer B but also completely or partially on active alumina.
  • layer A and layer B contain active alumina. It is particularly preferred if the active aluminum oxide is doped, in particular with
  • Preferred active aluminas contain 1 to 6 wt .-%, in particular 3 to 4 wt .-%, lanthanum oxide (La20 3 ).
  • active aluminum oxide is known to the person skilled in the art and refers in particular to g-aluminum oxide having a surface area of 100 to 200 m 2 / g. Active aluminum oxide has been widely described in the literature and is available on the market.
  • the coating A and / or B contain
  • Oxygen storage components in amounts of 30 to 225 g / l, based on the volume of the honeycomb body, preferably 40 to 200 g / l and particularly preferably 50 to 160 g / L.
  • the mass ratio of carrier materials and oxygen storage components in the coating is usually preferably 0.2 to 1.5, for example 0.3 to 0.8.
  • the mass ratio of carrier materials and oxygen storage components in the coating is usually preferably 0.2 to 1.5, for example 0.3 to 0.8.
  • Coatings A and B one or more alkaline earth compounds such.
  • strontium oxide barium oxide or barium sulfate.
  • the amount of barium sulfate per coating is in particular 2 to 20 g / l volume of the carrier.
  • coating A contains strontium oxide or barium oxide.
  • the coatings A and B contain additives such as rare earth compounds such. B.
  • Lanthan oxide and / or binder such as. B. aluminum compounds. These additives are used in amounts which can vary within wide limits and which the skilled person can determine in a concrete case by simple means.
  • Suitable catalytically inert catalyst carriers are honeycomb bodies made of ceramic or metal with a volume V which have parallel flow channels for the exhaust gases of the internal combustion engine. According to the invention, the catalytically active coating is located on the walls in the channels of a flow-through substrate. Ceramic honeycomb bodies that can be used in accordance with the present invention are known
  • Flow-through substrates and available on the market. They consist for example of silicon carbide, aluminum titanate or cordierite, for example, have a cell density of 200 to 900 cells per square inch (cpsi), and
  • Honeycombs that can be used in accordance with the present invention are known and available on the market.
  • the coating extends from one end of the ceramic honeycomb body
  • the total loading of the substrate with the catalytic coatings is 100 g / l to 350 g / l, based on the volume of the carrier, preferably 125 g / l to 300 g / l and more preferably 150 g / l to 280 g / l.
  • the total loading of the substrate with the catalytic coatings is 100 g / l to 350 g / l, based on the volume of the carrier, preferably 125 g / l to 300 g / l and more preferably 150 g / l to 280 g / l.
  • Coatings A and B do not contain zeolite or molecular sieve.
  • layer A lies directly on the inert catalyst support, i. H. there is no further layer or "undercoat” between the inert catalyst support and layer A.
  • layer B is in direct contact with the exhaust stream, i. H. On layer B there is no further layer or "overcoat".
  • the preparation of the catalyst according to the invention can according to the
  • Coating method is applied to the honeycomb body. Thermal aftertreatment or calcination usually follow.
  • the coated according to the invention with the two catalyst layers A and B.
  • the solids provided for this layer are suspended in water and coated with the coating suspension thus obtained, the catalyst support.
  • the procedure is repeated with a coating suspension containing the solids intended for layer B suspended in water.
  • Both layer A and layer B are preferably coated over the entire length of the inert catalyst support. This means that layer B completely covers layer A, and consequently only layer B comes into direct contact with the exhaust gas flow.
  • the mean particle size of the catalytically active materials has to be matched to the particular ceramic substrate.
  • the catalyst according to the invention is outstandingly suitable for removing carbon monoxide, hydrocarbons and nitrogen oxides from the exhaust gas of stoichiometric air / fuel mixture
  • the present invention thus also relates to a process for removing carbon monoxide, hydrocarbons and nitrogen oxides from the exhaust gas of stoichiometric air / fuel mixture

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Combustion & Propulsion (AREA)
  • Materials Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Toxicology (AREA)
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  • Biomedical Technology (AREA)
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  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Ceramic Engineering (AREA)
  • Catalysts (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)

Abstract

La présente invention concerne un pot catalytique à trois voies pouvant être utilisé en particulier pour éliminer le monoxyde de carbone, les hydrocarbures et les oxydes d'azote présents dans les gaz d'échappement de moteurs à combustion interne fonctionnant avec un mélange air/carburant stœchiométrique. Ce pot catalytique est caractérisé en ce qu'il présente une capacité élevée de stockage d'oxygène après vieillissement et est constitué d'au moins deux couches catalytiquement actives.
EP18826338.8A 2017-12-19 2018-12-19 Pot catalytique à trois voies multicouche Pending EP3727654A1 (fr)

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EP17208615.9A EP3501648B1 (fr) 2017-12-19 2017-12-19 Filtre à particules catalityquement actif
PCT/EP2018/085961 WO2019121994A1 (fr) 2017-12-19 2018-12-19 Pot catalytique à trois voies multicouche

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EP18816073.3A Active EP3727653B1 (fr) 2017-12-19 2018-12-14 Filtre à particules à activité catalytique
EP23212574.0A Pending EP4365421A3 (fr) 2017-12-19 2018-12-14 Filtre à particules à activité catalytique
EP18826338.8A Pending EP3727654A1 (fr) 2017-12-19 2018-12-19 Pot catalytique à trois voies multicouche
EP18826640.7A Pending EP3727655A1 (fr) 2017-12-19 2018-12-19 Pot catalytique à trois voies monocouche

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EP3727653A1 (fr) 2020-10-28
EP3501648A1 (fr) 2019-06-26
CN115990408A (zh) 2023-04-21
US20230285899A1 (en) 2023-09-14
US20210086135A1 (en) 2021-03-25
CN111491715A (zh) 2020-08-04
CN111491715B (zh) 2022-12-27
US11628400B2 (en) 2023-04-18
WO2019121372A1 (fr) 2019-06-27
EP3727655A1 (fr) 2020-10-28
CN111511469B (zh) 2023-07-04
EP4365421A3 (fr) 2024-05-22
US20210079822A1 (en) 2021-03-18
US11185820B2 (en) 2021-11-30
CN111511457A (zh) 2020-08-07
CN111491714A (zh) 2020-08-04
US20210069678A1 (en) 2021-03-11
WO2019121995A1 (fr) 2019-06-27
US20200306693A1 (en) 2020-10-01
WO2019121994A1 (fr) 2019-06-27
US11291952B2 (en) 2022-04-05
US11179676B2 (en) 2021-11-23
EP3727653B1 (fr) 2024-02-14
CN111491714B (zh) 2023-02-10
EP4365421A2 (fr) 2024-05-08
EP3501648B1 (fr) 2023-10-04
WO2019121375A1 (fr) 2019-06-27
CN111511469A (zh) 2020-08-07

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