US20120275977A1 - CATALYSTS FOR TREATING TRANSIENT NOx EMISSIONS - Google Patents

CATALYSTS FOR TREATING TRANSIENT NOx EMISSIONS Download PDF

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Publication number
US20120275977A1
US20120275977A1 US13/477,305 US201213477305A US2012275977A1 US 20120275977 A1 US20120275977 A1 US 20120275977A1 US 201213477305 A US201213477305 A US 201213477305A US 2012275977 A1 US2012275977 A1 US 2012275977A1
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Prior art keywords
canceled
catalyst
molecular sieve
zeolites
exhaust gas
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Abandoned
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US13/477,305
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English (en)
Inventor
Guy Richard Chandler
Alexander Nicholas Michael Green
Joanne Elizabeth Melville
Paul Richard Phillips
Stuart David Reid
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Johnson Matthey PLC
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Johnson Matthey PLC
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Assigned to JOHNSON MATTHEY PUBLIC LIMITED COMPANY reassignment JOHNSON MATTHEY PUBLIC LIMITED COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MELVILLE, Joanne Elizabeth, REID, STUART DAVID, CHANDLER, GUY RICHARD, GREEN, ALEXANDER NICHOLAS MICHAEL, PHILLIPS, PAUL RICHARD
Assigned to JOHNSON MATTHEY PLC reassignment JOHNSON MATTHEY PLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CHANDLER, GUY RICHARD, GREEN, ALEXANDER NICHOLAS MICHAEL, MELVILLE, Joanne Elizabeth, PHILLIPS, PAUL RICHARD, REID, STUART DAVID
Publication of US20120275977A1 publication Critical patent/US20120275977A1/en
Priority to US13/746,074 priority Critical patent/US9616420B2/en
Priority to US15/482,966 priority patent/US9815048B2/en
Abandoned legal-status Critical Current

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    • 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
    • F01N3/0807—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents
    • F01N3/0814—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by using absorbents or adsorbents combined with catalytic converters, e.g. NOx absorption/storage reduction catalysts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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Definitions

  • the present invention relates to a selective catalytic reduction catalyst comprising an optionally metal-promoted molecular sieve component for converting oxides of nitrogen (NO x ) present in exhaust gas emitted from a mobile source, such as a vehicular lean-burn internal-combustion engine, in the presence of a nitrogenous reductant.
  • a mobile source such as a vehicular lean-burn internal-combustion engine
  • SCR selective catalytic reduction
  • N 2 nitrogen to dinitrogen
  • SCR is known from treating NO x emissions from industrial stationary source applications, such as thermal power plants. More recently the SCR technique has been developed for treating NO x emissions from mobile source applications, such as passenger cars, trucks and buses.
  • a difficulty in treating NO x from mobile source applications is that the quantity of NO x present in the exhaust gas is transient, i.e. it varies with driving conditions, such as acceleration, deceleration and cruising at various speeds.
  • the transient nature of the NO x component in the mobile application exhaust gas presents a number of technical challenges, including correct metering of nitrogenous reductant to reduce sufficient NO x without waste or emission of nitrogenous reductant to atmosphere.
  • SCR catalysts can adsorb (or store) nitrogenous reductant, thus providing a buffer to the appropriate supply of available reductant. Technologists use this phenomenon to calibrate appropriate nitrogenous reductant injection to exhaust gas.
  • SCR catalysts for mobile source applications broadly perform three functions: (i) convert NO x using e.g. ammonia (NH 3 ) as nitrogenous reductant; (ii) store the NH 3 when there is excess NH 3 in the gas feed; and (iii) utilise the stored NH 3 under conditions where there is not sufficient NH 3 present in the gas feed to achieve the required conversion.
  • NH 3 ammonia
  • a desirable SCR catalyst has sufficient NH 3 storage capacity at a given temperature (to ensure any excess NH 3 is not “slipped” past the catalyst and to allow conversion to continue if NH 3 is not present in the feed) and high activity independent of the fraction of NH 3 fill level (fill level is defined relative to a saturated NH 3 storage capacity).
  • the NH 3 fill level can be expressed as the amount of NH 3 (for example in grams) present on the complete catalyst (for example in litres) relative to a maximum fill level at a given set of conditions.
  • NH 3 adsorption can be determined according to methods known in the art, such as Langmuir absorption. It will be understood that the fill level of all SCR catalysts is not directly proportional to the maximal NO x conversion activity of the SCR catalyst, i.e. it does not follow that NO x conversion activity increases to a maximum at 100% ammonia fill level. In fact, specific SCR catalysts can show maximal NO x conversion rates at a fill level of ⁇ 100%, such as ⁇ 90%, ⁇ 80%, ⁇ 50% or ⁇ 30%.
  • the activity of a SCR catalyst can depend on the amount of NH 3 to which the entire catalyst monolith has been exposed.
  • Molecular sieve-based SCR catalysts can store ammonia, and the amount of storage capacity depends, among others, on the temperature of the gas stream and the catalyst, the feed gas composition, the space velocity, particularly the NO:NO 2 ratio etc.
  • the catalyst activity at the onset of exposure of the catalyst to NH 3 can be substantially lower than the activity when the catalyst has a relatively high exposure or saturated exposure to NH 3 . For practical vehicle applications, this means the catalyst needs to be pre-loaded with an appropriate NH 3 loading to ensure good activity. However, this requirement presents some significant problems.
  • SCR catalysts for use on mobile applications such as automotive are required to operate at low temperature whilst also being tolerant to hydrocarbons.
  • Low temperature operation usually means that there is very little NO 2 in the feed gas, which favours the use of copper-based SCR catalysts.
  • iron-based SCR catalysts are typically very good at treating approximately 50:50 NO:NO 2 gas feeds and are also good under high temperature conditions that may be experienced should an exhaust system contain a catalysed soot filter (CSF) and the system is arranged so that the CSF is regenerated (i.e. collected particulate matter is combusted) periodically by engineering forced high temperature conditions.
  • CSF catalysed soot filter
  • WO 2008/132452 discloses a method of converting nitrogen oxides in a gas, such as an exhaust gas of a vehicular lean-burn internal combustion engine, to nitrogen by contacting the nitrogen oxides with a nitrogenous reducing agent in the presence of a molecular sieve catalyst containing at least one transition metal, wherein the molecular sieve is a small pore zeolite containing a maximum ring size of eight tetrahedral atoms, wherein the at least one metal is selected from the group consisting of Cr, Mn, Fe, Co, Ce, Ni, Cu, Zn, Ga, Mo, Ru, Rh, Pd, Ag, In, Sn, Re, Jr and Pt.
  • Suitable small pore molecular sieves include (using the three-letter code recognised by the Structure Commission of the International Zeolite Association) CHA, including SSZ-13 and SAPO-34; LEV, such as Nu-3; DDR e.g. Sigma-1; and ERI, including ZSM-34.
  • SCR catalysts for use in the method of WO 2008/132452 show a maximum NO x conversion at relatively high fill level.
  • WO '452 explains certain drawbacks to using ZSM-5 and Beta zeolites for converting NO x in exhaust gases emitted by mobile sources, such as vehicles, including that they are susceptible to dealumination during high temperature hydrothermal ageing resulting in a loss of acidity, especially with Cu/Beta and Cu/ZSM-5 catalysts; both Beta- and ZSM-5-based catalysts are also affected by hydrocarbons which become adsorbed on the catalysts at relatively low temperatures (known as “coking”) which hydrocarbons can be oxidised subsequently as the temperature of the catalytic system is raised generating a significant exotherm, which can thermally damage the catalyst. This problem is particularly acute in vehicular diesel applications where significant quantities of hydrocarbon can be adsorbed on the catalyst during cold-start. Coking can also reduce catalytic activity because active catalyst sites can become blocked.
  • transition metal-containing small pore molecular sieve-based SCR catalysts demonstrate significantly improved NO x reduction activity than the equivalent transition metal-containing medium, large or meso-pore molecular sieve catalysts, transition metal-containing small pore molecular sieve catalysts, especially at low temperatures. They also exhibit high selectivity to N 2 (e.g. low N 2 O formation) and good hydrothermal stability. Furthermore, small pore molecular sieves containing at least one transition metal are more resistant to hydrocarbon inhibition than larger pore molecular sieves.
  • SAE 2008-01-1185 discloses a selective catalytic reduction catalyst comprising separate iron zeolite and copper zeolite catalysts arranged in zones coated one behind the other on a flow-through substrate monolith with the iron zeolite zone disposed upstream of the copper zeolite zone. No details are given regarding the zeolites used. Results for transient response (shown in FIG. 17 ) for the combined iron zeolite/copper zeolite catalyst compared unfavourably to the use of copper zeolite alone.
  • transition metal/molecular sieve e.g. zeolite
  • catalysts are more active for NO x conversion but also have relatively fast transient response.
  • iron molecular sieve catalysts can give good activity as well as being hydrocarbon tolerant.
  • the invention provides a heterogeneous catalyst article comprising (a) a catalytic component comprising a combination of a first molecular sieve having a medium pore, large pore, or meso-pore crystal structure and optionally containing about 0.01 to about 20 weight percent of a first metal, and a second molecular sieve having a small pore crystal structure and optionally containing about 0.01 to about 20 weight percent of a second metal, wherein said first and second metals are exchanged or free with respect to the molecular sieve's crystalline frame work and are independently selected from the group consisting of Cr, Mn, Fe, Co, Ce, Ni, Cu, Zn, Ga, Mo, Ru, Rh, Pd, Pt, Ag, In, Sn, Re, and Ir; and (b) a monolith substrate onto or within which said catalytic component is incorporated, wherein said combination of the first and second molecular sieves is selected from the group consisting of a blends, a plurality of layers,
  • Types of combinations of catalysts that are useful in the present invention include blends of two or more catalysts, a plurality of layers wherein each layer consisting of a single catalyst, and a plurality of zones, wherein each zone consists of a single catalyst.
  • the combinations are characterized by properties that are not obtainable by any of their constituent parts acting independently of the combination.
  • FIGS. 4 a - 4 d shown are certain embodiments of different combinations according to the present invention.
  • FIG. 4 a shows of a blend 100 comprising a blend of two molecular sieves 104 coated on a substrate 102 .
  • the term “blend”, with respect to molecular sieves means a volume of two or more molecular sieves having approximately the same proportions relative to one another throughout the volume. Also shown is an embodiment of a plurality of zones 110 comprising a first zone consisting of a first molecular sieve 116 and a second zone comprising a second molecular sieve 118 , wherein the first and second zones are coated on a substrate 102 and are adjacent to each other and to said monolith substrate. The direction 114 of exhaust gas flow is also shown. In FIG.
  • FIG. 4 c shown is an embodiment of a plurality of layers 120 comprising first layer 116 and a second layer 118 , wherein the second layer is adjacent to both said first layer and the substrate and is between the first layer and the substrate.
  • FIG. 4 d shows two combinations 130 , wherein the first combination is two zones (molecular sieve 116 and blend 104 ) and the second combination is blend 104 .
  • the molecular sieves for each combination are independently selected.
  • other multiple combinations are within the scope of the invention as well.
  • an arrangement similar to that of FIG. 4 d but instead of a blend, the second combination could be a plurality of layers.
  • multiple combinations include the use of a blend as one or more layers; the use of layers as one or more zones; and the like.
  • the order of combinations with respect to exhaust gas flow through the catalyst component is not particularly limited. However, it is highly preferred that at least one medium, large, or meso-pore molecular sieve always be disposed upstream of any small pore molecular sieves.
  • combination comprises the first molecular sieve and the second molecular sieve in a first molecular sieve: second molecular sieve weight ratio of about 0.1 (i.e., 1:10) to about 1 (i.e., (1:1).
  • the weight ratio of first molecular sieve to second molecular sieve is about 0.25 to about 0.50. In certain embodiments, the weight ratio of first molecular sieve to second molecular sieve is about 0.3 to about 0.4.
  • a catalyst for selectively catalysing the conversion of oxides of nitrogen using a nitrogenous reductant in a feed gas whose composition, flow rate and temperature are each changeable temporally which catalyst comprising a combination of a first molecular sieve component and a second molecular sieve component, wherein in a direct comparison tested on the Federal Test Procedure (FTP) 75 cycle the catalyst has a higher cumulative conversion of NO x at equal or lower NH 3 slip than either molecular sieve component taken alone.
  • FTP Federal Test Procedure
  • a synergic relationship between the first molecular sieve component and the second molecular sieve component which can be used to improve a transient response to NO x conversion of a SCR catalyst comprising molecular sieve, e.g. a small pore molecular sieve while retaining the advantages of using the small pore molecular sieve as a component in a SCR catalyst.
  • a “catalyst for selectively catalysing the reduction of oxides of nitrogen in a feed gas with a nitrogenous reductant” shall be referred to herein as a “selective catalytic reduction” (or “SCR”) catalyst.
  • SCR catalysts containing combinations of three or more molecular sieves fall within the scope of the present invention.
  • the catalyst has a higher cumulative conversion of NO x at equal or lower NH 3 slip than either molecular sieve component taken alone where the cumulative molar NO:NO 2 ratio in feed gas entering said catalyst is equal to or less than 1.
  • the NO:NO 2 ratio in feed exhaust gas stream is about 0.8 to about 1.2.
  • the NO:NO 2 ratio in feed exhaust gas stream is less than about 0.3, while in other preferred embodiments, the ratio is greater than about 3.
  • the catalyst has a higher cumulative conversion of NO x to dinitrogen at equal or lower NH 3 slip than either molecular sieve component taken alone.
  • This invention significantly improves catalyst activity so that higher activity is obtained at lower NH 3 exposures (low exposure relative to the saturated storage capacity of the catalyst) compared to current state-of-the-art SCR catalysts.
  • the rate of increase of activity from zero ammonia exposure to saturated ammonia exposure is referred to as the ‘transient response’.
  • the first molecular sieve component achieves the maximum NO x conversion at a lower NH 3 fill level for the conditions selected than the second molecular sieve component.
  • the ammonia fill level of the first molecular sieve component can be in the range of 10-80%, such as 20-60% or 30-50%.
  • the first and second molecular sieves can be selected independently from zeolites and non-zeolite molecular sieves.
  • “Zeolite” according to the International Zeolite Association, is generally considered to be an alumino-silicate, whereas a “non-zeolite molecular sieve” can be a molecular sieve of the same Framework Type (or crystal structure) as the corresponding zeolite, but having one or more non-aluminium/non-silicon cations present in its crystal lattice, e.g. phosphorus, both cobalt and phosphorus, copper or iron.
  • SSZ-13 is a zeolite of Framework Type Code CHA
  • SAPO-34 is a silico-aluminophosphate non-zeolite molecular sieve sharing the same CHA Framework Type Code.
  • iron-containing aluminosilicate zeolites such as Fe-containing ZSM5, Beta, CHA or FER disclosed for example in WO2009/023202 and EP2072128A1, which are hydrothermally stable and have relatively high SCR activity.
  • catalysts comprising these iron-containing aluminosilicate zeolites produce little or no ammonium nitrate, and exhibit relatively high selectivity, e.g. low N 2 O.
  • Typical SiO 2 /Al 2 O 3 mole ratios for such materials are 30 to 100 and SiO 2 /Fe 2 O 3 of 20 to 300 such as 20 to 100.
  • the first (zeolitic or non-zeolitic) molecular sieve component can be a small pore molecular sieve containing a maximum ring size of eight (8) tetrahedral atoms, optionally selected from any set out in Table 1.
  • the second (zeolitic or non-zeolitic) molecular sieve component also can be a small pore molecular sieve containing a maximum ring size of eight (8) tetrahedral atoms and can be selected independently of the first molecular sieve component from any set out in Table 1.
  • the small pore molecular sieves can be selected from the group of Framework Type Codes consisting of: ACO, AEI, AEN, AFN, AFT, AFX, ANA, APC, APD, ATT, CDO, CHA, DDR, DFT, EAB, EDI, EPI, ERI, GIS, GOO, IHW, ITE, ITW, LEV, KFI, MER, MON, NSI, OWE, PAU, PHI, RHO, RTH, SAT, SAV, SIV, THO, TSC, UEI, UFI, VNI, YUG and ZON.
  • Framework Type Codes consisting of: ACO, AEI, AEN, AFN, AFT, AFX, ANA, APC, APD, ATT, CDO, CHA, DDR, DFT, EAB, EDI, EPI, ERI, GIS, GOO, IHW, ITE, ITW, LEV, KFI, MER,
  • Small pore molecular sieves with particular application for treating NO x in exhaust gases of lean-burn internal combustion engines, e.g. vehicular exhaust gases are set out in Table 2.
  • the second molecular sieve (either a zeolite or a non-zeolite molecular sieve) component can be a medium pore, large pore or meso-pore size molecular sieve.
  • the first molecular sieve is a CuCHA material and the second molecular sieve is a FeBEA, FeFER, FeCHA or FeMFI (e.g. ZSM-5) wherein the Fe is impregnated, ion-exchanged and/or present within the crystal lattice of the molecular sieve.
  • medium pore herein we mean a molecular sieve containing a maximum ring size of ten (10) and by “large pore” herein we mean containing a maximum ring size of twelve (12) tetrahedral atoms.
  • Meso-pore molecular sieves have a maximum ring size of >12.
  • Suitable medium pore molecular sieves for use as second molecular sieves in the present invention include ZSM-5 (MFI), MCM-22 (MWW), ALPO-11 and SAPO-11 (AEL), AlPO-41 and SAPO-41 (AFO), ferrierite (FER), Heulandite or Clinoptilolite (HEU).
  • Large pore molecular sieves for use in the present invention include zeolite Y, such as ultrastable-Y (or USY), faujasite or SAPO-37 (FAU), AlPO-5 and SAPO-5 (AFI), SAPO-40 (AFR), AlPO-31 and SAPO-31 (ATO), Beta (BEA), Gmelinite (GME), mordenite (MOR) and Offretite (OFF).
  • zeolite Y such as ultrastable-Y (or USY), faujasite or SAPO-37 (FAU), AlPO-5 and SAPO-5 (AFI), SAPO-40 (AFR), AlPO-31 and SAPO-31 (ATO), Beta (BEA), Gmelinite (GME), mordenite (MOR) and Offretite (OFF).
  • a small pore molecular sieve is combined with a medium, large or meso-pore molecular sieve that the presence of the small pore molecular sieve reduces the coking on the medium, large or meso-pore molecular sieve.
  • Another benefit of this arrangement is that a ratio of NO:NO 2 in feed gas contacting the catalyst can be adjusted to improve total NO x conversion on the SCR catalyst.
  • Molecular sieves for use in the present invention can be independently selected from one-dimensional, two-dimensional and three-dimensional molecular sieves.
  • Molecular sieves showing three-dimensional dimensionality have a pore structure, which is interconnected in all three crystallographic dimensions, whereas a molecular sieve having two-dimensional dimensionality has pores which are interconnected in two crystallographic dimensions only.
  • a molecular sieve having one-dimensional dimensionality has no pores that are interconnected from a second crystallographic dimension.
  • Small pore molecular sieves particularly aluminosilicate zeolites, for use in the present invention can have a silica-to-alumina ratio (SAR) of from 2 to 300, optionally 4 to 200 such as 8 to 150 e.g. 15 to 50 or 25 to 40.
  • SAR silica-to-alumina ratio
  • higher SARs are preferred to improve thermal stability (especially high catalytic activity at a low temperature after hydrothermal ageing) but this may negatively affect transition metal exchange. Therefore, in selecting preferred materials consideration can be given to SAR so that a balance may be struck between these two properties.
  • SAR for iron-in-framework molecular sieves is discussed elsewhere in this description.
  • the first molecular sieve, the second molecular sieve or both the first and second molecular sieves contain one or more metal selected independently from the group consisting of Cr, Mn, Fe, Co, Ce, Ni, Cu, Zn, Ga, Mo, Ru, Rh, Pd, Ag, In, Sn, Re, Jr and Pt.
  • the metal contained in the first molecular sieve can be the same or different from that of the second molecular sieve. So for example, the first molecular sieve can contain copper and the second molecular sieve can contain iron. In one embodiment, the two molecular sieves can be ion-exchanged together.
  • molecular sieves containing one or more transition metal herein we intend to cover molecular sieves wherein elements other than aluminium and silicon are substituted into the framework of the molecular sieve.
  • Such molecular sieves are known as “non-zeolitic molecular sieves” and include “SAPO”, “MeAPO”, “FeAPO”, “AlPO 4 ”, “TAPO”, “ELAPO”, “MeAPSO” and “MeAlPO” which are substituted with one or more metals.
  • Suitable substituent metals include one or more of, without limitation, As, B, Be, Co, Fe, Ga, Ge, Li, Mg, Mn, Ti, Zn and Zr.
  • Such non-zeolitic molecular sieves can in turn be impregnated by suitable metals listed hereinabove, i.e. Cr, Mn, Fe, Co etc.
  • One or both of the first and second molecular sieves can contain substituent framework metals. Where both the first and the second molecular sieves contain substituent framework metals, the or each substituent metal is selected independently from the above list.
  • the small pore zeolites and non-zeolite molecular sieves for use in the present invention can be selected from the group consisting of aluminosilicate zeolites, metal-substituted aluminosilicate molecular sieves, such as the preferred iron-containing aluminosilicate zeolites and aluminophosphate molecular sieves.
  • Aluminophosphate molecular sieves with application in the present invention include aluminophosphate (AlPO 4 ) molecular sieves, metal substituted aluminophosphate molecular sieves (MeAlPO), silico-aluminophosphate (SAPO) molecular sieves and metal substituted silico-aluminophosphate (MeAPSO) molecular sieves.
  • AlPO 4 aluminophosphate
  • MeAlPO metal substituted aluminophosphate molecular sieves
  • SAPO silico-aluminophosphate
  • MeAPSO metal substituted silico-aluminophosphate
  • a particularly interesting group of molecular sieve components for use either as a first or a second molecular sieve component are iron substituted aluminosilicates, i.e. where iron is present in the framework of the molecular sieve.
  • iron-substituted aluminosilicates are particularly interesting because they produce relatively low or no N 2 O, which is a powerful “greenhouse” gas.
  • the at least one transition metal is selected from the group consisting of Cr, Ce, Mn, Fe, Co, Ni and Cu. In a preferred embodiment, the at least one transition metal is selected from the group consisting of Cu, Fe and Ce. In a particular embodiment, the at least one transition metal consists of Cu. In another particular embodiment, the at least one transition metal consists of Fe. In a further particular embodiment, the at least one transition metal is Cu and/or Fe.
  • the total of the at least one transition metal that can be included in the at least one transition metal-containing molecular sieve can be from 0.01 to 20.00 wt %, based on the total weight of the molecular sieve catalyst containing at least one transition metal. In one embodiment, the total of the at least one transition metal that can be included can be from 0.1 to 10.0 wt %. In a particular embodiment, the total of the at least one transition metal that can be included is from 0.5 to 5.0 wt %. In preferred embodiments, the transition metal loading is from 2.0 to 4.0 wt % and the SAR is 25 to 50 or >40 or >60 e.g.
  • the SiO 2 /Fe 2 O 3 ratio is met (where present the SiO 2 /Fe 2 O 3 is 50 to 200, preferably 50 to 100).
  • Transition metals may be incorporated into the molecular sieves for use in the present invention using techniques well known in the art, including liquid-phase exchange or solid-ion exchange or by an incipient wetness process.
  • liquid-phase exchange or solid-ion exchange or by an incipient wetness process.
  • the catalytic component comprises or consists of a combination of a first molecular sieve that is a large pore molecular sieve and a second molecular sieve that is a small pore molecular sieve.
  • the small pore molecular sieve has a CHA framework, more preferably a SSZ-13 framework, and contains copper.
  • this small pore molecular sieve is combined with a large pore molecular sieve having a BEA framework.
  • the BEA framework contains either exchanged or free iron or is an iron isomorphous BEA molecular structure (also referred to as BEA-type ferrosilicate), with iron isomorphous BEA molecular structure being particularly preferred.
  • the iron isomorphous BEA molecular structure is crystalline silicate having (1) an iron-containing BEA-framework structure that has a SiO 2 /Fe 2 O 3 mol ratio of about 20 to about 300, and (2) at least 80% of the contained iron is isolated iron ions Fe 3+ in a fresh state and/or log(SiO 2 /Al 2 O 3 ) by mol is at least about 2.
  • Preferred BEA-type ferrosilicates useful in the present invention have a composition represented by following formula:
  • n is an atomic value of cation M
  • iron-containing BEA-framework structure that has a SiO 2 /Fe 2 O 3 mol ratio of about 25 to about 300, about 20 to about 150, about 24 to about 150, about 25 to about 100, or about 50 to about 80.
  • the upper limit of log(SiO 2 /Al 2 O 3 ) by mol is not particularly limited, provided that the log(SiO 2 /Al 2 O 3 ) by mol is at least 2 (i.e., the SiO 2 /Al 2 O 3 ratio by mol is at least 100).
  • the log(SiO 2 /Al 2 O 3 ) by mol is preferably at least 2.5 (i.e., the SiO 2 /Al 2 O 3 ratio by mol is at least 310), more preferably at least 3 (i.e., the SiO 2 /Al 2 O 3 ratio by mol is at least 1,000).
  • the log(SiO 2 /Al 2 O 3 ) by mol exceeds 4 (i.e., the SiO 2 /Al 2 O 3 ratio by mol becomes at least 10,000)
  • the performance for nitrogen oxide reduction is constant at the highest level.
  • the CHA molecular sieve is characterized as having a mean crystal size of greater than about 1 microns, preferably about 1 to about 5 microns, with about 2 to about 4 microns being most preferred.
  • the iron ingredient most prominently exhibiting a catalytic activity for the reduction of nitrogen oxides is not agglomerated as Fe 2 O 3 but is dispersed as isolated iron ion Fe 3+ in the framework structure (i.e., isolated and dispersed in the silicate frame structure or ion exchange sites).
  • isolated iron ion Fe3+ can be detected by the electron spin resonance measurement.
  • the SiO 2 /Fe 2 O 3 ratio by mol as used for defining the composition of the BEA-type ferrosilicate is an expedient expression for defining the whole iron content including isolated iron ion Fe +3 in the BEA-type ferrosilicate.
  • Zoned and layered SCR catalysts offer further improvements, particularly when the exhaust gas has about a 50/50 ratio of NO to NO 2 . This catalyst reduces the N 2 O emissions by approximately 75% over the blended equivalent whilst retaining excellent transient response and good conversion in low NO/NO 2 gas mixes.
  • the Fe-BEA material is preferably aged at 600-900° C., preferably 650-850° C., more preferably 700-800° C., and even more preferably 725-775° C., for 3-8 hours, preferably 4-6 hours, more preferably from 4.5-5.5 hours, and even more preferably from 4.75-5.25 hours.
  • Embodiments using copper exchanged SSZ-13/pre-aged Fe-BEA combinations are advantageous in applications in which the formation of N 2 O is undesirable.
  • ratios of Cu:SSZ-13 to pre-aged Fe-BEA similar to those of Cu:SSZ-13 to Fe-BEA and Cu:SSZ-13 to BEA-Ferrosilicate are also included within the scope of the invention.
  • combinations of Cu:SSZ-13 to pre-aged Fe-BEA similar to those of Cu:SSZ-13 to Fe-BEA and Cu:SSZ-13 to BEA-Ferrosilicate.
  • Both the first and second molecular sieves can be present in the same catalyst coating, i.e. coated in a washcoat onto a suitable substrate monolith or each of the first and second molecular sieve components may be separated in washcoat layers one above the other, with either the first molecular sieve component in a layer above the second molecular sieve component or vice versa.
  • both the first and second molecular sieves can be combined in a composition for forming substrate monoliths of the extruded-type.
  • the extruded monolith can be further coated with a washcoat containing one or both of the first and second molecular sieve component(s).
  • an extruded substrate monolith comprising one, but not both, of the first and second molecular sieve components and coating the extruded substrate monolith with a washcoat containing the other molecular sieve component not present in the extrudate, or the washcoat can contain both the first and second molecular sieves.
  • the first molecular sieve component can be the same in both the extrudate and the coating, or different.
  • the washcoat can contain SSZ-13 zeolite and the extrudate can contain SAPO-34.
  • the second molecular sieve component e.g. the washcoat can contain ZSM-5 zeolite and the extrudate can contain Beta zeolite.
  • Washcoat compositions containing the molecular sieves for use in the present invention for coating onto the monolith substrate or for manufacturing extruded type substrate monoliths can comprise a binder selected from the group consisting of alumina, silica, (non zeolite) silica-alumina, naturally occurring clays, TiO 2 , ZrO 2 , and SnO 2 .
  • Suitable substrate monoliths include so-called flow-through substrate monoliths (i.e. a honeycomb monolithic catalyst support structure with many small, parallel channels running axially through the entire part) made of ceramic materials such as cordierite; or metal substrates made e.g. of fecralloy.
  • Substrate monoliths can be filters including wall-flow filters made from cordierite, aluminium titanate, silicon carbide or mullite; ceramic foams; sintered metal filters or so-called partial filters such as those disclosed in EP 1057519 or WO 01/080978.
  • the invention provides an exhaust system for treating a flowing exhaust gas containing oxides of nitrogen from a mobile source of such exhaust gas, which system comprising a source of nitrogenous reducing agent arranged upstream in a flow direction from a SCR catalyst according to the invention.
  • the source of nitrogenous reducing agent can comprise a suitable injector means operated under control of e.g. a suitably programmed electronic control unit to deliver an appropriate quantity of reducing agent or a precursor thereof (held in a suitable vessel or tank) for converting NO x to a desired degree.
  • Liquid or solid ammonia precursor can be urea ((NH 2 ) 2 CO), ammonium carbonate, ammonium carbamate, ammonium hydrogen carbonate or ammonium formate, for example. Alternatively, ammonia per se or hydrazine can be used.
  • the source of nitrogenous reducing agent is a NO x absorber (also known as a NO x trap, lean NO x trap or NO x absorber catalyst (NAC)) in combination with an engine that is configured so that at least one engine cylinder can operate richer than normal operating conditions, e.g. in the remaining engine cylinders, e.g. to produce exhaust gas having a stoichiometrically balanced redox composition, or a rich redox composition and/or a separate hydrocarbon injector means arranged upstream of the NO x absorber for injecting hydrocarbons into a flowing exhaust gas.
  • NO x absorbed on the NO x absorber is reduced to ammonia through contacting adsorbed NO x with the reducing environment.
  • ammonia produced in situ can be utilised for NO x reduction on the SCR catalyst when the NO x absorber is being regenerated by contacting the NO x absorber with e.g. richer exhaust gas generated by the engine.
  • the source of nitrogenous reducing agent can be a separate catalyst e.g. a NO x trap or a reforming catalyst located in an exhaust manifold of each of at least one engine cylinder which is configured to operate, either intermittently or continuously, richer than normal.
  • a separate catalyst e.g. a NO x trap or a reforming catalyst located in an exhaust manifold of each of at least one engine cylinder which is configured to operate, either intermittently or continuously, richer than normal.
  • an oxidation catalyst for oxidising nitrogen monoxide in the exhaust gas to nitrogen dioxide can be located upstream of a point of metering the nitrogenous reductant into the exhaust gas and the SCR catalyst.
  • the oxidation catalyst can include at least one precious metal, preferably a platinum group metal (or some combination of these), such as platinum, palladium or rhodium, coated on a flow-through monolith substrate.
  • the at least one precious metal is platinum, palladium or a combination of both platinum and palladium or an alloy of Pd—Au, optionally in combination with Pt—Pd.
  • the precious metal can be supported on a high surface area washcoat component such as alumina, an aluminosilicate zeolite, silica, non-zeolite silica alumina, ceria, zirconia, titania or a mixed or composite oxide containing both ceria and zirconia.
  • a suitable filter substrate is located between the oxidation catalyst and the catalyst according to the invention.
  • Filter substrates can be selected from any of those mentioned above, e.g. wall flow filters.
  • the filter is catalysed, e.g. with an oxidation catalyst of the kind discussed above, preferably the point of metering nitrogenous reductant is located between the filter and the catalyst according to the invention. It will be appreciated that this arrangement is disclosed in WO 99/39809.
  • the means for metering nitrogenous reductant can be located between the oxidation catalyst and the filter.
  • the SCR catalyst for use in the present invention is coated on a filter or is in the form of an extruded-type catalyst located downstream of the oxidation catalyst.
  • the filter includes the SCR catalyst for use in the present invention, the point of metering the nitrogenous reductant is preferably located between the oxidation catalyst and the filter.
  • the invention provides a lean-burn internal combustion engine comprising an exhaust system according to the invention.
  • the engine can be a compression ignition engine or a positive ignition engine.
  • Positive ignition engines can be fuelled using a variety of fuels including gasoline fuel, gasoline fuel blended with oxygenates including methanol and/or ethanol, liquid petroleum gas or compressed natural gas.
  • Compression ignition engines can be fuelled using diesel fuel, diesel fuel blended with non-diesel hydrocarbons including synthetic hydrocarbons produced by gas-to-liquid methods or bio-derived components.
  • the invention provides a vehicle comprising a lean-burn internal combustion engine according to the invention.
  • the invention provides a method of converting oxides of nitrogen (NO x ) in an exhaust gas of a mobile source whose composition, flow rate and temperature of which exhaust gas are each changeable temporally, which method comprising the step of by contacting the NO x with a nitrogenous reducing agent in the presence of a selective catalytic reduction catalyst comprising a combination of a first molecular sieve component and a second molecular sieve component, wherein in a direct comparison tested on the Federal Test Procedure (FTP) 75 cycle the catalyst has a higher cumulative conversion of NO x at equal or lower NH 3 slip than either molecular sieve component taken alone.
  • FTP Federal Test Procedure
  • the catalyst has a higher cumulative conversion of NO x at equal or lower NH 3 slip than either molecular sieve component taken alone where the cumulative molar NO:NO 2 ratio in feed gas entering said catalyst is equal to, or less than 1.
  • the catalyst has a higher cumulative conversion of NO x to dinitrogen at equal or lower NH 3 slip than either molecular sieve component taken alone.
  • the nitrogen oxides are reduced with the nitrogenous reducing agent at a temperature of at least 100° C. In another embodiment, the nitrogen oxides are reduced with the reducing agent at a temperature from about 150° C. to 750° C.
  • the latter embodiment is particularly useful for treating exhaust gases from heavy and light duty diesel engines, particularly engines comprising exhaust systems comprising (optionally catalysed) diesel particulate filters which are regenerated actively, e.g. by injecting hydrocarbon into the exhaust system upstream of the filter, wherein the catalyst according to the present invention is located downstream of the filter.
  • the temperature range is from 175 to 550° C. In another embodiment, the temperature range is from 175 to 400° C.
  • the nitrogen oxides reduction is carried out in the presence of oxygen. In an alternative embodiment, the nitrogen oxides reduction is carried out in the absence of oxygen.
  • the gas containing the nitrogen oxides can contact the catalyst according to the invention at a gas hourly space velocity of from 5,000 hr ⁇ 1 to 500,000 hr ⁇ 1 , optionally from 10,000 hr ⁇ 1 to 200,000 hr ⁇ 1 .
  • the metering of the nitrogenous reducing agent contacting the SCR catalyst can be arranged such that 60% to 200% of theoretical ammonia is present in exhaust gas entering the SCR catalyst calculated at 1:1 NH 3 /NO and 4:3 NH 3 /NO 2 .
  • a step of oxidising nitrogen monoxide in the exhaust gas to nitrogen dioxide can be performed prior to introduction of any nitrogenous reducing agent. Suitable, such NO oxidation step can be done using a suitable oxidation catalyst.
  • the oxidation catalyst is adapted to yield a gas stream entering the SCR catalyst having a ratio of NO to NO 2 of from about 4:1 to about 1:3 by volume, e.g. at an exhaust gas temperature at oxidation catalyst inlet of 250° C. to 450° C.
  • FIG. 1 is a schematic drawing of an exhaust system embodiment according to the invention
  • FIG. 2 is a schematic drawing of a further exhaust system embodiment according to the invention.
  • FIG. 3 is a graph showing the results of NO x conversion activity tests described in Example 3 on fresh catalysts prepared according to Examples 1, 2 and 3.
  • FIGS. 4 a - 4 d shows different types of combinations of a first molecular sieve and a second molecular sieve on a substrate.
  • FIGS. 5 , 6 a , 6 b , 7 , and 8 a - 8 c are graphs showing data associated with certain embodiments of the invention.
  • FIG. 1 an apparatus 10 comprising a light-duty diesel engine 12 and an exhaust system 14 comprising a conduit for conveying exhaust gas emitted from the engine to atmosphere 15 disposed in which conduit is a metal substrate monolith coated with a NO x Absorber Catalyst ((NAC)) also known as a NO x trap or lean NO x trap) 16 followed in the flow direction by a wall-flow filter 18 coated with a SCR catalyst according to the invention (Cu/SSZ-13 blended with an iron-in-zeolite framework BEA also ion-exchanged with additional ion-exchanged iron).
  • a clean-up catalyst 24 comprising a relatively low loading of Pt on alumina is disposed downstream of wall-flow filter 18 .
  • the engine runs lean of stoichiometric, wherein NO x is absorbed in the NAC. Intermittently, the engine is run rich to desorb and reduce NO x . During rich running operation, some NO x is reduced to NH 3 and is stored on the downstream SCR catalyst for further NO x reduction. The SCR catalyst also treats NO x during intermittent rich events. NO oxidised to NO 2 on the NAC is used to combust soot trapped on the filter 18 passively. The NAC is also used to combust additional hydrocarbon during occasional forced (active) regenerations of the filter.
  • FIG. 2 shows an alternative apparatus 11 according to the invention comprising a diesel engine 12 and an exhaust system 13 therefor.
  • Exhaust system 13 comprises a conduit 17 linking catalytic aftertreatment components, namely a 2Au-0.5Pd/Al 2 O 3 catalyst coated onto an inert ceramic flow-through substrate 19 disposed close to the exhaust manifold of the engine (the so-called close coupled position).
  • an flow-through catalyst 22 of the extruded type comprising a mixture of an aluminosilicate CHA ion-exchanged with Cu and FeCHA, having Fe present in the molecular sieve framework structure.
  • a source of nitrogenous reductant (urea) is provided in tank 28 , which is injected into the exhaust gas conduit 17 between catalysts 19 and 22 .
  • urea nitrogenous reductant
  • a catalyst for selectively catalysing the conversion of oxides of nitrogen using a nitrogenous reductant in a feed gas whose composition, flow rate and temperature are each changeable temporally which catalyst comprising a combination of a first molecular sieve component and a second molecular sieve component, wherein in a direct comparison tested on the Federal Test Procedure (FTP) 75 cycle the catalyst has a higher cumulative conversion of NO x at equal or lower NH 3 slip than either molecular sieve component taken alone.
  • FTP Federal Test Procedure
  • the catalyst has a higher cumulative conversion of NO x , preferably to elemental nitrogen, at equal or lower NH 3 slip than either molecular sieve component taken alone where the cumulative molar NO:NO 2 ratio in feed gas entering said catalyst is equal to, or less than 1.
  • the SCR catalyst has the first molecular sieve component achieves the maximum NO x conversion at a lower NH 3 fill level for the conditions selected than the second molecular sieve component.
  • the lower NH 3 fill level of the first molecular sieve component is in the range of 10-80%.
  • the first and second molecular sieves can be selected independently from zeolites and non-zeolite molecular sieves.
  • one of the molecular sieve components is a small pore molecular sieve containing a maximum ring size of eight (8) tetrahedral atoms, preferably selected from the group of Framework Type Codes consisting of: ACO, AEI, AEN, AFN, AFT, AFX, ANA, APC, APD, ATT, CDO, CHA, DDR, DFT, EAB, EDI, EPI, ERI, GIS, GOO, IHW, ITE, ITW, LEV, KFI, MER, MON, NSI, OWE, PAU, PHI, RHO, RTH, SAT, SAV, SIV, THO, TSC, UEI, UFI, VNI, YUG and ZON, with CHA, LEV, ERI, DDR, KFI
  • the other molecular sieve component is selected from a small pore, medium pore, large pore or meso-pore size molecular sieve.
  • Preferred medium pore molecular sieve include MFI, MWW, AEL, AFO, FER and HEU.
  • Preferred large pore molecular sieve include FAU, AFI, AFR, ATO, BEA, GME, MOR and OFF.
  • one or both of the first and second molecular sieves contains a substituent framework metal selected from the group consisting of As, B, Be, Co, Fe, Ga, Ge, Li, Mg, Mn, Ti, Zn and Zr.
  • one or both of the first molecular sieve component and the second molecular sieve component contain one or more metal selected independently from the group consisting of Cr, Mn, Fe, Co, Ce, Ni, Cu, Zn, Ga, Mo, Ru, Rh, Pd, Ag, In, Sn, Re, Ir and Pt, preferably Cr, Ce, Mn, Fe, Co, Ni and Cu.
  • an exhaust system for treating a flowing exhaust gas containing oxides of nitrogen from a mobile source of such exhaust gas, which system comprising a source of nitrogenous reducing agent arranged upstream in a flow direction from a selective catalytic reduction catalyst described herein.
  • the system further comprises an oxidation catalyst disposed upstream of the source of nitrogenous reducing agent and the SCR catalyst.
  • the system further comprises a filter disposed between the oxidation catalyst and the source of nitrogenous reducing agent.
  • a lean-burn internal combustion engine such as a compression ignition engine or a positive ignition engine, comprising an exhaust system described herein.
  • the engine comprises a NO x absorber which functions, at least in part, as the source of a nitrogenous reducing agent.
  • a vehicle comprising a lean-burn internal combustion engine described herein.
  • a method for converting oxides of nitrogen (NO x ) in an exhaust gas of a mobile source the composition, flow rate and temperature of which exhaust gas are each changeable temporally comprising the step of contacting the NO x with a nitrogenous reducing agent in the presence of a selective catalytic reduction catalyst comprising a combination of a first molecular sieve component and a second molecular sieve component, wherein in a direct comparison tested on the Federal Test Procedure (FTP) 75 cycle the catalyst has a higher cumulative conversion of NO x at equal or lower NH 3 slip than either molecular sieve component taken alone.
  • FTP Federal Test Procedure
  • the catalyst has a higher cumulative conversion of NO x , preferably to dinitrogen, at equal or lower NH 3 slip than either molecular sieve component taken alone where the cumulative molar NO:NO 2 ratio in feed gas entering said catalyst is equal to, or less than 1.
  • the NO x is converted at a temperature of at least 100° C., preferably from about 150° C. to 750° C.
  • the gas containing the NO x contacts the SCR catalyst at a gas hourly space velocity of from 5,000 hr ⁇ 1 to 500,000 hr ⁇ 1 .
  • the NO:NO 2 ratio in gas contacting the SCR catalyst is from about 4:1 to about 1:3 by volume.
  • Beta zeolite was NH 4 + ion exchanged in a solution of NH 4 NO 3 , then filtered. The resulting material was added to an aqueous solution of Fe(NO 3 ) 3 with stirring. The slurry was filtered, then washed and dried. The procedure can be repeated to achieve a desired metal loading. The final product was calcined.
  • the materials prepared according to this Example are referred to herein as “fresh”.
  • the activity of the fresh powder samples prepared according to Examples 1, 2 and 3 were tested at 250° C. in a laboratory apparatus using the following gas mixture: 125 ppm NO, 375 ppm NO 2 750 ppm NH 3 , 14% O 2 , 4.5% H 2 O, 4.5% CO 2 , N 2 balance at a space velocity of 60,000 hr ⁇ 1 .
  • the test is stopped when 20 ppm NH 3 is detected downstream of the sample. The results are shown in FIG. 3 .
  • the Fe/Beta sample has a fast transient response, but limited maximum conversion. It also slips NH 3 early on in the test compared with the Cu/SSZ-13 and Fe/Beta+Cu/SSZ-13 blend. Transient response is defined as the rate at which NOx conversion increases as the level of NH 3 fill on the catalyst increases.
  • the Cu/SSZ-13 has better, higher maximum conversion but a slower transient response.
  • the combination of Fe/Beta and Cu/SSZ-13 gives fast transient response, higher maximum conversion, but also has higher conversion than the individual components at intermediate NH 3 fill levels, which is evidence of synergy. Pre-aged 1:3 Fe/Beta:Cu/SSZ-13 will provide improved results as well.
  • a samples of a 1:3 (by weight) FeBEA:CuSSZ-13 combination and three samples of a 1:3 (by weight) BEA-Ferrosilicate:CuSSZ-13 combination were prepared and separately coated on substrates.
  • the FeBEA:CuSSZ-13 combination was coated as a blend, whereas the samples of BEA-Ferrosilicate:CuSSZ-13 combination were separately coated as a blend, zones, and layers.
  • Each of the samples were exposed to a simulated diesel gas exhaust combined with NH 3 dosing (20 ppm slip). The average N 2 O formation during exposure was recorded and is shown in FIGS. 6 a and 6 b.
  • the FeBEA:CuSSZ-13 blend produces significant N 2 O resulting in an apparent reduction in maximum conversion and ‘N 2 selective’ transient response. This reduction in conversion also outweighs that observed for the two components evaluated independently.
  • the BEA-Ferrosilicate:CuSSZ-13 blend produces substantially less N 2 O than that observed for any other CuSSZ-13/zeolite blend.
  • layers and zones of BEA-Ferrosilicate:CuSSZ-13 maintain the low N 2 O make observed for the blend, but also show improved transient response under different NO 2 levels (see FIG. 7 ).
  • Samples of FeBEA, CuSSZ-13, and BEA-Ferrosilicate were prepared can combined in the indicated combinations and multiple combinations shown in FIGS. 8 a - 8 c .
  • the ratios are give by weight, blends are shown in parenthesises, and zones are indicated by “//”, with the first named component disposed upstream with respect to gas flow past the catalyst.
  • Each of the combinations and multiple combinations were exposed to a simulated diesel gas exhaust gas stream containing an NH 3 reductant.
  • the NO:NO 2 ratio in the exhaust gas was varied from only NO, 50:50 NO:NO 2 (by weight), and 75% NO 2 (by weight), to test the catalyst at different conditions.
  • Each combination or multiple combination was evaluated for NO x conversion (corrected for N 2 O formation) as a function of NH 3 fill level.

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