WO1992005861A1 - Composition catalytique contenant du rhodium active avec un oxyde metallique basique - Google Patents

Composition catalytique contenant du rhodium active avec un oxyde metallique basique Download PDF

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Publication number
WO1992005861A1
WO1992005861A1 PCT/US1991/006940 US9106940W WO9205861A1 WO 1992005861 A1 WO1992005861 A1 WO 1992005861A1 US 9106940 W US9106940 W US 9106940W WO 9205861 A1 WO9205861 A1 WO 9205861A1
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Prior art keywords
ceria
oxide
weight
metal oxide
catalyst composition
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PCT/US1991/006940
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English (en)
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Samuel J. Tauster
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Engelhard Corporation
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Priority to JP3515927A priority Critical patent/JPH06504940A/ja
Publication of WO1992005861A1 publication Critical patent/WO1992005861A1/fr

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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
    • 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
    • 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
    • B01J23/64—Platinum group metals with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • B01J23/656—Manganese, technetium or rhenium
    • B01J23/6562—Manganese
    • 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 is concerned with catalysts use ⁇ ful for the treatment of gases to reduce contaminants con ⁇ tained therein, such as catalysts of the type generally re ⁇ ferred to as "three-way conversion” or “TWC” catalysts.
  • TWC catalysts are polyfunctional in that they have the capabilitiesi ⁇ ty of substantially simultaneously catalyzing both oxidation and reduction reactions, such as the oxidation of hydrocar ⁇ bons and carbon monoxide and the reduction of nitrogen ox ⁇ ides in a gaseous stream.
  • Such catalysts find utility in a number of fields, including the treatment of the exhaust gases from internal combustion engines, such as automobile and other gasoline-fueled engines.
  • the platinum group metal may comprise platinum or pal ⁇ ladium, preferably including one or more of rhodium, ruthen ⁇ ium and iridium, especially rhodium.
  • the refractory metal oxide support may comprise a high surface area alumina coat ⁇ ing (often referred to as "activated” or "gamma” alumina) carried on a carrier such as a monolithic carrier comprising a refractory ceramic or metal honeycomb structure, as well known in the art.
  • the carrier may also comprise refractory particles such as spheres or short, extruded segments of a refractory material such as alumina.
  • the catalytically active materials dispersed on the activated alumina may contain, in addition to the platinum group metals, one or more base metal oxides, such as oxides of nickel, cobalt, manganese, iron, rhenium, etc., as shown, for example, in CD. Keith et al U.S. Patent 4,552,723.
  • the activated alumina typically exhibits a BET surface area In excess of 60 square meters per gram ("m /g"), often up to 2 about 200 m /g or more.
  • Such activated alumina is usually a mixture of the gamma and delta phases of alumina, but may also contain substantial amounts of eta, kappa and theta alumina phases.
  • the refractory metal oxide supports are subject to thermal degradation from extended exposure to the high tem ⁇ peratures of exhaust gas resulting in a loss of exposed cat ⁇ alyst surface area and a corresponding decrease in catalytic activity. It is a known expedient in the art to stabilize refractory metal oxide supports against such thermal degra- dation by the use of materials such as zirconia, titania, alkaline earth metal oxides such as baria, calcia or stron- tia or, most usually, rare earth metal oxides, for example, ceria, lanthana and mixtures of two or more rare earth metal oxides. For example, see CD. Keith et al U.S. Patent 4,171,288.
  • TWC catalysts are currently formulated with complex washcoat compositions containing stabilized Al p 0_, an oxygen storage component, primarily ceria, and precious metal cata ⁇ lytic components. Such catalysts are designed to be effec- tive over a specific operating range of both lean of, and rich of, stoichiometric conditions.
  • oxygen stor ⁇ age component is used to designate a material which is be- lieved to be capable of being oxidized during oxygen-rich (lean) cycles of the gas being treated, and releasing oxygen during oxygen-poor (rich) cycles.
  • Such TWC catalyst compo ⁇ sitions enable optimization of the conversion of harmful emissions (HC, CO and NO ) to Innocuous substances.
  • rhodium is the most ef ⁇ fective for reducing NO to harmless nitrogen. Unfortunate- ly, rhodium is also the most expensive of these costly mate- rials and, consequently, effective rhodium utilization in automotive exhaust catalysts, such as TWO catalysts, has been extensively studied.
  • U.S. Patent 4,675,308 discloses a meth ⁇ od of effective utilization of rhodium by placing it on alu ⁇ mina which Is segregated from ceria-containing particles, because ceria renders the rhodium less active.
  • Other at ⁇ tempts to segregate rhodium from ceria are disclosed in U.S.
  • Patent 4,806,519 Japanese Patent application 88-326823/46 (J63240947A) of Nissan Motor KK (10.02.87-JP-027383), and in Japanese Patent publication JP63 77,544 (88 77,544).
  • It is known to utilize zirconia as a support for rhodium e.g., U.S. Patent 4,233,189 teaches the use of non-alumina sup ⁇ ports such as zirconia for rhodium.
  • U.S. Patent 4,492,769 discloses palladium and other platinum group met ⁇ als dispersed on a zirconia support together with base met ⁇ als.
  • zir ⁇ conia has certain disadvantages including a lower surface area than gamma alumina and the fact that zirconia itself is not a thermally stable support. Zirconia undergoes a phase transition between its monoclinic crystalline structure and its more stable tetragonal crystalline structure over a wide temperature range; such transition causes drastic sintering of the associated precious metals.
  • the rho ⁇ dium is stated to be supported on the alumina in a high con- centration and in a relatively large rhodium particle size.
  • the zirconia Is stabilized with the ceria (or yttria or cal- cia) by impregnation of zirconia with, for example, a solu ⁇ tion of cerium nitrate, followed by calcination.
  • the rhodi ⁇ um is supported on at least one of the stabilized cerium ox- ide and the refractory inorganic oxide.
  • a catalyst composition comprising a cata- lytic material In which rhodium is dispersed on a ceria- promoted zirconia support, such as a co-formed (as defined below) ceria-zirconia support, with the rhodium being sta- bilized against thermal degradation by a base metal oxide promoter.
  • a catalyst composition comprising a carri- er on which is disposed a washcoat of a catalytic material.
  • the catalytic material comprises a ceria-promoted support, e.g., a co-formed ceria-zirconia support, having dispersed thereon a catalytically effective amount of rhodium and a rhodium-stabilizing amount of a base metal oxide promoter.
  • the ceria content of the ceria-promoted zirconia support (which in all cases described herein optionally may be a co-formed ceria-zirconia support) may comprise, for example, from about 5 to 25% by weight of the weight of the ceria- promoted zirconia support.
  • the base metal oxide promoter dispersed on the ceria-promoted zirconia sup ⁇ port may be present in an amount of from about 1 to 10%, preferably 1 to 5%, by weight of the weight of the ceria- promoted zirconia support, and Is selected from the group consisting of calcium oxide, copper oxide, Iron oxide, lan ⁇ thanum oxide, magnesium oxide, manganese oxide, nickel oxide and tin oxide.
  • the washcoat further comprises a refractory metal ox- ide, e.g., alumina.
  • the base metal oxide comprises one or both of nickel oxide and magne ⁇ sium oxide.
  • the method aspect of the invention provides a method for treating a gas (such as the exhaust gas of a gasoline- fueled automobile engine) containing noxious components comprising one or more of carbon monoxide, hydrocarbons and nitrogen oxides by converting at least some of the noxious components into innocuous substances, the method comprising contacting the gas under conversion conditions, for example, at an Initial temperature of from about 250°C to 500°C, with a catalyst composition comprising a carrier on which is dis- posed a washcoat comprising a catalytic material as de ⁇ scribed above.
  • a gas such as the exhaust gas of a gasoline- fueled automobile engine
  • noxious components comprising one or more of carbon monoxide, hydrocarbons and nitrogen oxides
  • a "rhodium-stabilizing amount" of the base metal oxide promoter means an amount of the promoter which significantly ameliorates the catalytic de-activation which an otherwise identical rhodium-containing catalyst lacking the base metal oxide promoter would sustain under identical conditions of use, due to formation of stable rhodium oxides from the cat ⁇ alytic rhodium metal.
  • innocuous substances refers to the C0 2 and H 0 formed by oxidation of CO and hydrocarbons and the N ? formed by reduction of nitrogen oxides.
  • treat- ment of an automobile engine exhaust gas with a suitable TWC catalyst under conversion conditions will convert at least some of the carbon monoxide ("CO"), nitrogen oxides (“NOx”) and unburned hydrocarbons (“HC”) to innocuous substances, as defined herein.
  • CO carbon monoxide
  • NOx nitrogen oxides
  • HC unburned hydrocarbons
  • ceria-promoted zirconia support means a zir ⁇ conia support material with which ceria is intimately com ⁇ bined, for example, by having a coating of ceria deposited on the zirconia particles, or by impregnating zirconia par ⁇ ticles with a solution or liquid dispersion of a cerium salt or other cerium compound decomposable to the oxide, followed by drying and calcination to convert the cerium compound to ceria.
  • ceria-promoted zirconia support also in ⁇ cludes, as a special case thereof, a co-formed ceria-zircon ⁇ ia support as defined below.
  • co-formed ceria-zirconia support and the term “co-formed” as used with respect to the co-formed ceria-zirconia support material, means that the ceria is distributed substantially throughout the entire matrix of the zirconia particles as will occur, for example, when the cerium oxide and zirconium oxide, or predecessors thereof, are co-precipitated or co-gelled.
  • the defined term is in ⁇ tended to distinguish the material from that obtained in a situation in which ceria Is merely dispersed on or near the surface of the zirconia particles, leaving the core of the particles largely or entirely free of the ceria.
  • references to a component being "dispersed" on a support or re ⁇ ference to "dispersion” or “dispersal” in the same context, means that the component was impregnated onto the support from a solution of the component or of a precursor of the component. This is intended to distinguish the “dispersed” component from the situation in which the component is in ⁇ troduced in "bulk", that is, in fine particulate form.
  • the base metal oxide promoter is nickel oxide
  • it is "dispersed” on the support by impregnating the support with a solution of nickel nitrate and then drying and cal ⁇ cining the support to convert the impregnated nickel salt to nickel oxide.
  • the defined terms thus exclude incorporation of the nickel oxide into the support in the form of fine particles of solid nickel oxide.
  • the present invention provides for the dispersal of a rhodium catalytic component on a zirconia support which Is promoted, e.g., co-formed, with ceria, and therefore is con ⁇ trary to those teachings of the prior art which teach that ceria has a de-activating effect on the performance of rho ⁇ dium when the two are in contact.
  • the invention is accom- pushed by dispersing a base metal oxide promoter together with the dispersed rhodium on a ceria-promoted zirconia sup ⁇ port.
  • the base metal oxide suppresses the rho ⁇ dium sintering which has been known to occur under high tem ⁇ perature oxidizing conditions in the rhodium-containing cat ⁇ alytic materials of the prior art. It is speculated that under such conditions, the base metal oxide forms a complex with the rhodium oxide, thereby “anchoring" the rhodium and preventing the growth of uncomplexed rhodium oxides which destroy the effectiveness of the catalyst.
  • the catalyst compositions of the present in ⁇ vention are free of bulk ceria, at least In amounts which would adversely affect the activity of the rhodium catalyst.
  • the catalyst compositons are substantially free of bulk ceria and, more preferably, are substantially free of ceria either in bulk form (fine particles of ceria) or in dispersed form, except for the ceria used to promote the zirconia support, e.g., the ceria forming part of the co- formed ceria-zirconia support.
  • the promoting ceria e.g., the ceria which is co-formed with the zirconia
  • the present invention embraces ceria-promoted zirconia supports generally, the co-formed ceria-zirconia support is, as indicated above, preferred and the following description will refer thereto. However, it should be understood that except where specifically other ⁇ wise stated the descriptions generally apply to ceria-pro ⁇ moted supports as well.
  • a first catalytic component is prepared by dispersing rhodium metal on a co-formed ceria- zirconia support.
  • the support may be formed by co-precipi- tating or co-gelling zirconia with ceria or by other suit ⁇ able methods to produce a frit in which ceria Is bound in, and distributed substantially throughout, the zirconia com ⁇ ponent.
  • the amount of ceria present in the co-formed sup- port should be limited to between about 1 to 25% by weight of the weight of the co-formed ceria-zirconia support, pre ⁇ ferably from about 5 to 20% by weight, e.g., 12% by weight.
  • the balance of the co-formed support Is substantially or en ⁇ tirely zirconia, which accordingly comprises about 99 to 75% by weight of the co-formed ceria-zirconia support, prefera ⁇ bly about 95 to 80%.
  • cata ⁇ lyst compositions including platinum group metals such as platinum and rhodium dispersed on alumina are admixed with cerium oxide, with the co-formed ceria-zirconia material and optionally with a zirconium compound to form a washcoat slurry.
  • the co-formed ceria-zirconia support of the Japan ⁇ ese application is described as being produced by co-preci ⁇ pitation from a solution of suitable zirconium and cerium compounds.
  • the co-formed ceria-zirconia support produced by coprecipitation is said to retain at high temperatures a quasi-stable cubic crystal structure which is said to have catalytic activity of its own.
  • the co-formed ceria-zir ⁇ conia support is described as having a specific surface area of from about 10 to 150 square meters per gram, preferably from about 50 to 80 square meters per gram.
  • the weight ra ⁇ tio of cerium oxide to zirconium oxide in the co-formed cer ⁇ ia-zirconia support may be from about 1 part ceria to 99 parts zirconia, to about 25 parts ceria to 75 parts zircon- ia. Stated otherwise, the ceria may comprise from about 1% to about 25% by weight of the combined weight of the co- formed ceria-zirconia.
  • rhodium and a base metal cation are dispersed onto the co-formed ceria-zirconia support. This may be accomplished In a conventional manner, for example, by impregnating the co-formed support with a solution of an appropriate rhodium salt, e.g., rhodium nitrate, and with the nitrate salt pre ⁇ cursor of a suitable base metal oxide promoter.
  • a single impregnation solution may contain both a rhodium salt and a base metal salt or separate solutions of a rhodium salt and a base metal salt may be utilized in successive Impregna ⁇ tions.
  • Impregnation is not important and the rhodium salt solution and base metal salt solution may be impregnated onto the co-formed support in any order. How ⁇ ever, it Is more efficient to conduct a single impregnation and single drying and calcining to impregnate both the rho ⁇ dium and base metal precursors, instead of separate impreg ⁇ nation ⁇ ), drying and calcining cycles for each component. To that extent, it is preferred to utilize a single solution containing both a rhodium salt and a base metal salt dis ⁇ solved therein. In any case, the co-formed support, after being impregnated with both the rhodium and base metal oxide precursor salts, is dried and calcined in the conventional manner.
  • Impregnated co-formed support may be dried in air for about 2 to 24 hours at 110°C followed by calcining in air for about 1 to 24 hours at a temperature of about 350 to 550°C Calcining results in the decomposition of the rhodium salt Into rhodium oxide, and of the base met- al salt into the base metal oxide.
  • the resulting calcined composition may then be milled, as well known in the art, so that at least 90% of the particles have a diameter of less than 12 microns.
  • Alumina is preferred as the bulk extender because it also has a binding effect, which helps to secure the washcoat onto the surface of the substrate onto which the washcoat is applied.
  • other extenders in lieu of or in addition to alumina may be used as is known in the art, for example, silica, ti- tania, zirconia and the like.
  • catalytic metals including precious metals such as platinum and/or palladium may be dispersed throughout the washcoat and these, especially platinum or palladium, may conveniently be dispersed on the alumina or other refractory metal oxide em ⁇ ployed as the extender.
  • alumina is preferred and, the alumina used, or the alumina resulting from a final cal ⁇ cining step or from initial use of the catalyst, will pre- ferably be "activated alumina", i.e., a high surface area alumina comprising primarily gamma alumina, although other phases such as theta and eta alumina may be present.
  • the resultant washcoat comprising a mixture of alumina (and/or other extender) and the impregnated co-formed ceria-zirconia particles is coated onto a carrier, such as a cordierite honeycomb, in a manner well known In the art, and is then dried and calcined to provide the finished catalyst.
  • a carrier such as a cordierite honeycomb
  • the co- formed ceria-zirconia support and, optionally, the refracto ⁇ ry metal oxide may be admixed prior to impregnation with the solution or solutions of base metal salts so that both the refractory metal oxide and the co-formed ceria-zirconia sup ⁇ port are impregnated with the base metal compound which is eventually converted into the base metal oxide.
  • an amount of the base metal salt will be used to pro ⁇ vide the desired loading of base metal oxide promoter on the co-formed ceria-zirconia support because, depending on the proportion of refractory metal oxide to co-formed ceria-zir- conia support, a greater or lesser proportion of the base metal solution will be taken up by the refractory metal ox ⁇ ide.
  • the co-formed ceria-zirconia support and, optionally, the refractory metal oxide may be deposited onto a substrate and calcined to form a coating, and the calcined coating is then impregnated with the base metal solution. Conceivably, any of these approaches could also be taken with the rhodium salt solution.
  • the relative concentrations of rhodium salt and base metal salt in the impregnating solution or solutions are se- lected to provide the desired overall loadings of base metal oxide promoter and rhodium in the finished catalyst composi ⁇ tion.
  • the amount of base metal oxide promoter provided is typically from about 1 to 10% by weight of the weight of the co-formed ceria-zirconia support itself (not counting the weight of the promoter, catalytic metals or other components dispersed on the co-formed support), dry basis, with the base metal oxide promoter measured as the oxide.
  • the catalytic material may be prepared by Introducing both the alumina or other extender or binder material as well as the co-formed ceria- zirconia support material into a solution containing a dis- solved base metal salt so that, in the finished catalyst, the base metal oxide is dispersed throughout substantially the entire catalytic material.
  • the preferred amount of base metal oxide promoter that is, 1 to 10% by weight, prefera ⁇ bly 1 to 5% by weight, of the weight of the co-formed ce- ria-zirconia support, is the amount of base metal oxide pro ⁇ moter dispersed on the co-formed ceria-zirconia support it ⁇ self.
  • the amount, if any, of base metal oxide on the aluml- na or other components in the washcoat is not counted to ⁇ wards the preferred 1 to 10% range. It is believed that an excessive amount of the base metal oxide promoter dispersed on the co-formed ceria-zirconia support itself may prevent the reduction of the "anchored" rhodium oxides to rhodium metal and thus be detrimental to catalytic activity.
  • Example 1 A A series of catalyst compositions according to this invention is prepared as follows.
  • a co-formed ceria-zirco ⁇ nia support is obtained by co-precipitating ceria and zir ⁇ conia from a solution of both zirconium and cerium soluble compounds. The result is a co-formed ceria-zirconia support comprising about 12% by weight ceria and about 88% by weight zirconia.
  • each solution used to prepare a catalyst sample exemplary of the present Invention contained both rhodium nitrate and a base metal salt dissolved therein.
  • the metal salt solutions were employed at concentrations to provide the rhodium and base metal loadings set forth in TABLE I.
  • Each of the metal solution-impregnated portions of co-formed support were dried in air at 100°C for 1 hour and then calcined in air for 2 hours at 450°C
  • the dried and calcined rhodium-impregnated co- formed ceria-zirconia compositions obtained from Parts A and 3 respectively are separately milled so that at least 90% of the resulting particles have a diameter of less than 12 mi- crons.
  • Each milled component is separately combined with milled alumina of approximately the same particle size (about 90% of the alumina particles having a diameter of less than 12 microns) in a 1:1 ratio (dry solids weight basis) to form a washcoat slurry.
  • the slurries were coated onto respective cordierite honeycomb cores which were then dried in air at 110°C and calcined at 450°C for 2 hours.
  • the resulting concentration of rhodium in the washcoat was 0.39% by weight of the co-formed ceria-zirconia support.
  • the total washcoat loading was about 1.2 grams per cubic inch of the carrier.
  • the choice (or exclusion) of base met ⁇ al salt and the corresponding base metal oxide and the amount thereof (or lack thereof) in the catalyst composi ⁇ tion, when present, is shown in TABLE I below.
  • the various samples are identified as Samples IA, IB, 1C, 2A, 2B, etc..
  • Catalyst compositions prepared according to Example 1 were loaded into testing chambers and subjected to a 50 hour aging cycle at 900°C inlet gas temperature.
  • the cycle in- eluded a simulated fuel shut-off for five seconds every min ⁇ ute.
  • the fuel shut-off simulation was attained by introduc ⁇ ing air into the exhaust gas ahead of the catalyst to pro ⁇ vide a lean gas to the catalyst.
  • the engine utilized for the aging burned a commercially available normal hydrocarbon gasoline fuel having a lead content of about 3 milligrams Pb per gallon of fuel.
  • compositions were then tested, first by determining the "light-off" temperature (defined below) of the catalysts In a perturbated flow of engine ex ⁇ haust gases generated by combusting a stoichiometric air to fuel ratio combustion mixture, and then under "sweep" test ⁇ ing conditions at + 0.3 A/F Ratio Units, 2 Hz, 450°C, and a space velocity of 80,000 volumes of gas per volume of cata ⁇ lyst per hour. All catalyst composition samples were tested in the exhaust gas generated by an engine burning a commer ⁇ cial unleaded gasoline containing not more than 5 milligrams per gallon Pb. The performance of the various compositions is shown in TABLE I, below.
  • T ⁇ Q light- off temperatures
  • the temperature of the exhaust gas was in ⁇ creased at a rate of approximately 20°C per minute until the light-off temperature was attained.
  • % Prom means the percent by weight of base metal promoter dispersed on the co-formed ceria-zirconia support of the catalyst composition sample and "T,- Q " IS the light-off temperature.
  • % Conversion means the percentage of the pollutant (HC, CO and NOx) in the untreated exhaust gas which is converted to innocuous substances, i.e., COp, HpO and/or N p .
  • the defini ⁇ tion of "Lean” and “Rich” is based on the definition of the stoichiometric air to fuel weight ratio for gasoline as be ⁇ ing 14.65 parts by weight air to parts by weight gasoline.
  • A/F The air to fuel ratio
  • A/F The air to fuel ratio
  • Sample 2B shows a significant reduction in light-off temperature and substantially increased conversion of NOx under rich operating conditions, and of CO under stoichio- metric operating conditions as compared to Comparative Sam ⁇ ple 2A.
  • Sample 3B shows significantly improved activity for CO reduction at stoichi ⁇ ometric conditions.
  • the incorporation of 5 weight percent MgO in Sample 4B shows, as compared to Comparative Sample 4A, slgnficantly lowered light-off temperature and improved conversion of NOx under rich conditions, improved conversion of all three pol ⁇ lutants under stoichiometric conditions, and of HC and CO under lean conditions.
  • significantly decreased ac ⁇ tivity for NOx under lean conditions was observed.
  • Sample 5B shows signifi ⁇ cantly improved conversion of CO at stoichiometric condi ⁇ tions as compared to Comparative Sample 5A.
  • the inclusion of 4 weight percent NiO in Sample 5C did not show a significant improvement in acti ⁇ vity under these particular test conditions.
  • the efficacy of NiO as a base metal oxide promoter in the cata ⁇ lyst compositions of the present invention is amply demon- strated by Samples 9A-C, discussed below, as well as in Sam ⁇ ples IA and IC, as discussed above.
  • Samples 9B and 9C as compared to Comparative Sample 9A shows that the addition of 2 percent NiO signifi ⁇ cantly improves conversion of CO under lean conditions and marginally improves conversion of CO under stoichiometric conditions, while the addition of 1 percent by weight NiO in Sample 9B had the adverse effect of decreasing the conver ⁇ sion of CO under rich conditions.
  • Two catalyst compositions were prepared using tech ⁇ niques similar to those of Example 1 to produce catalyst compositions in which the washcoat is provided as two dis ⁇ crete bottom and top layers on the substrate.
  • the substrates comprising cordierite honeycomb cores were ini- tially coated with a slurry comprising approximately 67% by weight (dry solids basis) of activated alumina and 33% by weight of bulk ceria, I.e., fine particles of cerium oxide.
  • the platinum was impregnated with a platinum hydroxide meth- ylethanolamine solution so that approximately 2% by weight of the combined impregnated alumina and bulk ceria comprised platinum.
  • the coated cordierite substrate was provided with a top coat by being dipped into a slurry prepared as follows. Rhodium ni- trate was utilized to impregnate activated alumina and the impregnated alumina was mixed with a quantity of co-formed ceria-zirconia support in which ceria comprised about 12% by weight of the weight of the co-formed support. The quantity of zirconyl acetate was then Introduced to the slurry of alumina and co-formed ceria-zirconia support particles so that the zirconyl acetate impregnated both the alumina and the co-formed ceria-zirconia particles.
  • Excess slurry was blown om the twice-coated core which was then dried and calcined to provide an outer or top coat layer comprising approximately 38% by weight alumina, approximately 53% by weight of co-formed ceria-zirconia support, approximately 9% by weight zirconia and approximately 0.42% by weight rhodi ⁇ um.
  • the Inner or bottom coat comprises about 68% by weight of the total weight of washcoat (catalytic material) and the top coat comprised about 32% by weight.
  • nickel nitrate is added to the top coat slurry in an amount sufficient so that, if all of the nickel were to migrate to the co-formed ceria-zirconia support, it would amount to
  • the total loading of precious metal (platinum plus rho ⁇ dium) on the catalyst Samples 12A and 12B Is 40 grams per cubic foot, with the platinum and rhodium being present in a weight ratio of 5 parts platinum to 1 part rhodium.
  • Example 3 The catalyst compositions prepared according to Example 3 were loaded into testing chambers and subjected to an aging cycle similar to that described in Example 2 except that an Inlet gas temperature of 850°C and an actual fuel shut-off was utilized, instead of the simulated fuel shut- off employed in Example 2. The fuel shut-off was continued for about five seconds every minute.
  • the abbreviations of TABLE II have the same meaning as those given above for TABLE I.
  • the data of TABLE II shows significant reduction in light-off temperature for the nickel oxide promoted catalyst as compared to the unpromoted catalyst and significantly better conversions of the noxious components to innocuous substances attained.
  • the suitability of ceria-promoted zirconia supports other than co-formed ceria-zirconia supports for the pur ⁇ poses of the present invention is Indicated by tests of com ⁇ parable, but different, catalyst compositions containing platinum and rhodium catalytic components dispersed on ceria-promoted zirconia supports obtained by impregnating zirconia particles with a solution of cerium nitrate. The impregnated particles were then calcined to decompose the cerium nitrate to ceria.
  • the catalyst was aged and tested on the exhaust gas of a stock Nissan GLD engine.
  • the ceria- promoted zirconia support showed good durability and the catalyst showed good activity, indicating that ceria-pro ⁇ moted zirconia supports generally, including those which are not co-formed, are suitable for purposes of the present in ⁇ vention. While the invention has been described in detail with respect to specific embodiments thereof, it will be appreci ⁇ ated that variations to the invention may be made which will nonetheless lie within the sphere and scope of the invention and are intended to be embraced by the appended claims.

Abstract

Composition catalytique comprenant un support monolithique enduit sur l'envers avec un revêtement. Ledit revêtement comprend un matériau catalytique constitué par du rhodium et un activateur d'oxyde métallique basique dispersé sur un support de zircone activé par de l'oxyde cérique, par exemple un support hybride oxyde cérique-zircone. Un oxyde métallique réfractaire, tel que de l'alumine activée, peut être incorporé dans le revêtement afin d'accroître son adhésion au support. La présence d'une quantité stabilisant le rhodium par exemple 1 à 5 ou 10 % en poids du support hybride, de l'activateur d'oxyde métallique basique dispersé avec le rhodium sur le support de zircone activé par de l'oxyde cérique permet de réduire un frittage non voulu du rhodium. La quantité limitée d'oxyde cérique, par exemple de 1 à 25 % en poids du poids, par exemple, du support hybride oxyde cérique-zircone, réduit l'effet nuisible à la santé du rhodium quand il est très profondément dispersé sur un support contenant de l'oxyde cérique. On décrit une méthode utilisant la composition catalytique pour la conversion à trois voies de gaz d'échappement d'un moteur d'automobile.
PCT/US1991/006940 1990-09-27 1991-09-24 Composition catalytique contenant du rhodium active avec un oxyde metallique basique WO1992005861A1 (fr)

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JP3515927A JPH06504940A (ja) 1990-09-27 1991-09-24 ベース金属酸化物助成ロジウム含有触媒組成物

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EP0605274A1 (fr) 1992-12-21 1994-07-06 Rhone-Poulenc Chimie Composition à base d'un oxyde mixte de cérium et de zirconium, préparation et utilisation
EP0614854A1 (fr) 1993-02-10 1994-09-14 Rhone-Poulenc Chimie Procédé de synthèse de compositions à base d'oxydes mixtes de zirconium et de cérium, compositions ainsi obtenues et utilisations de ces dernières
US5474441A (en) * 1989-08-22 1995-12-12 Engelhard Corporation Catalyst configuration for catalytic combustion systems
EP0718239A1 (fr) 1994-12-21 1996-06-26 ENIRISORSE S.p.A. Procédé sol-gel pour l'obtention de sphères d'oxyde de zirconium pur et mixte, microsphères et revêtements, utilisable comme catalyseur ou support de catalyseur
WO1996020787A1 (fr) * 1994-12-30 1996-07-11 Engelhard Corporation Catalyseur d'oxydation catalytique et procede de traitement des rejets organiques halogenes, de voc et de co
EP0781592A1 (fr) * 1995-12-26 1997-07-02 Cosmo Research Institute Purification de gaz d'échappement par réduction des oxydes d'azote
EP1052008A1 (fr) * 1999-05-07 2000-11-15 Daihatsu Motor Co., Ltd. Convertisseur catalytique pour purifier les gaz d'échappement
EP1053779A1 (fr) * 1997-11-20 2000-11-22 Daihatsu Motor Co., Ltd. Convertisseur catalytique pour purifier les gaz d'échappement
WO2003074172A1 (fr) * 2002-03-04 2003-09-12 Hte Aktiengesellschaft The High Throughput Experimentation Company Catalyseurs riches en rhodium dopes d'oxydes des terres rares
US6625976B1 (en) 1996-07-18 2003-09-30 Johnson Matthey Public Limited Company Three-way conversion catalysts and methods for the preparation therefor
US6887455B2 (en) 1998-03-24 2005-05-03 Johnson Matthey Public Limited Company Catalytic generation of hydrogen
EP1541220A1 (fr) * 2003-12-11 2005-06-15 Delphi Technologies, Inc. Dispositif de traitement de gaz d'échappement et procédé de fabrication associé
US6911414B2 (en) * 2000-11-27 2005-06-28 Cataler Corporation Catalyst for purifying exhaust gas
WO2012160437A1 (fr) * 2011-05-26 2012-11-29 Toyota Jidosha Kabushiki Kaisha Système de contrôle de gaz d'échappement, catalyseur de purification de gaz d'échappement et procédé pour la production du catalyseur de purification de gaz d'échappement
US8617496B2 (en) 2011-01-19 2013-12-31 Basf Corporation Three way conversion catalyst with alumina-free rhodium layer
WO2016094399A1 (fr) 2014-12-08 2016-06-16 Basf Corporation Catalyseurs d'élimination d'oxyde nitreux pour systèmes d'échappement
WO2016124943A1 (fr) * 2015-02-05 2016-08-11 Johnson Matthey Public Limited Company Catalyseur à trois voies
CN113272044A (zh) * 2018-12-19 2021-08-17 巴斯夫公司 层状催化剂组合物和催化制品以及其制造和使用方法

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EP0125565A2 (fr) * 1983-05-12 1984-11-21 Nippon Shokubai Kagaku Kogyo Co., Ltd Procédé de fabrication d'un catalyseur en nid d'abeille pour la conversion de gaz d'échappement
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EP0125565A2 (fr) * 1983-05-12 1984-11-21 Nippon Shokubai Kagaku Kogyo Co., Ltd Procédé de fabrication d'un catalyseur en nid d'abeille pour la conversion de gaz d'échappement
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US5474441A (en) * 1989-08-22 1995-12-12 Engelhard Corporation Catalyst configuration for catalytic combustion systems
EP0605274A1 (fr) 1992-12-21 1994-07-06 Rhone-Poulenc Chimie Composition à base d'un oxyde mixte de cérium et de zirconium, préparation et utilisation
EP0614854A1 (fr) 1993-02-10 1994-09-14 Rhone-Poulenc Chimie Procédé de synthèse de compositions à base d'oxydes mixtes de zirconium et de cérium, compositions ainsi obtenues et utilisations de ces dernières
JPH06279027A (ja) * 1993-02-10 1994-10-04 Rhone Poulenc Chim ジルコニウム及びセリウムの混合酸化物を基とする組成物、その合成方法並びに使用方法
EP0718239A1 (fr) 1994-12-21 1996-06-26 ENIRISORSE S.p.A. Procédé sol-gel pour l'obtention de sphères d'oxyde de zirconium pur et mixte, microsphères et revêtements, utilisable comme catalyseur ou support de catalyseur
WO1996020787A1 (fr) * 1994-12-30 1996-07-11 Engelhard Corporation Catalyseur d'oxydation catalytique et procede de traitement des rejets organiques halogenes, de voc et de co
US5578283A (en) * 1994-12-30 1996-11-26 Engelhard Corporation Catalytic oxidation catalyst and method for controlling VOC, CO and halogenated organic emissions
US5653949A (en) * 1994-12-30 1997-08-05 Engelhard Corporation Catalytic oxidation catalyst and method for controlling voc, CO and halogenated organic emissions
CN1090056C (zh) * 1994-12-30 2002-09-04 恩格尔哈德公司 处理气体物流的催化剂和方法
US6399035B1 (en) * 1995-12-26 2002-06-04 Cosmo Research Institute Reduction purification method of nitrogen oxide-containing exhaust gas
EP0781592A1 (fr) * 1995-12-26 1997-07-02 Cosmo Research Institute Purification de gaz d'échappement par réduction des oxydes d'azote
US6030590A (en) * 1995-12-26 2000-02-29 Cosmo Research Institute Reduction purification method of nitrogen oxide-containing exhaust gas
US6625976B1 (en) 1996-07-18 2003-09-30 Johnson Matthey Public Limited Company Three-way conversion catalysts and methods for the preparation therefor
EP1053779A1 (fr) * 1997-11-20 2000-11-22 Daihatsu Motor Co., Ltd. Convertisseur catalytique pour purifier les gaz d'échappement
US6887455B2 (en) 1998-03-24 2005-05-03 Johnson Matthey Public Limited Company Catalytic generation of hydrogen
US6464946B1 (en) 1999-05-07 2002-10-15 Daihatsu Motor Co., Ltd. Catalytic converter for cleaning exhaust gas
EP1052008A1 (fr) * 1999-05-07 2000-11-15 Daihatsu Motor Co., Ltd. Convertisseur catalytique pour purifier les gaz d'échappement
US6911414B2 (en) * 2000-11-27 2005-06-28 Cataler Corporation Catalyst for purifying exhaust gas
WO2003074172A1 (fr) * 2002-03-04 2003-09-12 Hte Aktiengesellschaft The High Throughput Experimentation Company Catalyseurs riches en rhodium dopes d'oxydes des terres rares
EP1541220A1 (fr) * 2003-12-11 2005-06-15 Delphi Technologies, Inc. Dispositif de traitement de gaz d'échappement et procédé de fabrication associé
US8617496B2 (en) 2011-01-19 2013-12-31 Basf Corporation Three way conversion catalyst with alumina-free rhodium layer
WO2012160437A1 (fr) * 2011-05-26 2012-11-29 Toyota Jidosha Kabushiki Kaisha Système de contrôle de gaz d'échappement, catalyseur de purification de gaz d'échappement et procédé pour la production du catalyseur de purification de gaz d'échappement
US11149610B2 (en) 2014-12-08 2021-10-19 Basf Corporation Nitrous oxide removal catalysts for exhaust systems
WO2016094399A1 (fr) 2014-12-08 2016-06-16 Basf Corporation Catalyseurs d'élimination d'oxyde nitreux pour systèmes d'échappement
US11713705B2 (en) 2014-12-08 2023-08-01 Basf Corporation Nitrous oxide removal catalysts for exhaust systems
KR20170093899A (ko) * 2014-12-08 2017-08-16 바스프 코포레이션 배기 시스템용 아산화질소 제거 촉매
EP3244995A4 (fr) * 2014-12-08 2018-09-12 BASF Corporation Catalyseurs d'élimination d'oxyde nitreux pour systèmes d'échappement
US10634030B2 (en) 2014-12-08 2020-04-28 Basf Corporation Nitrous oxide removal catalysts for exhaust systems
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WO2016124943A1 (fr) * 2015-02-05 2016-08-11 Johnson Matthey Public Limited Company Catalyseur à trois voies
US9707545B2 (en) 2015-02-05 2017-07-18 Johnson Matthey Public Limited Company Three-way catalyst
EP3897926A4 (fr) * 2018-12-19 2022-10-26 BASF Corporation Composition de catalyseur multicouche et article catalytique et procédés de fabrication et son utilisation
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