WO2006040533A1

WO2006040533A1 - Method of decomposing nitrogen dioxide

Info

Publication number: WO2006040533A1
Application number: PCT/GB2005/003899
Authority: WO
Inventors: Richard Dominic O'sullivan; Peter Werth
Original assignee: Johnson Matthey Public Limited Company
Priority date: 2004-10-12
Filing date: 2005-10-10
Publication date: 2006-04-20
Also published as: CN101072622A; GB0422549D0; BRPI0515989A; BRPI0515989B1; RU2007117750A; RU2386043C2; AU2005293349A1; KR101310651B1; CN101072622B; ZA200702930B; CA2582935C; JP4990781B2; US20080213145A1; PE20060670A1; US7758832B2; NO20071749L; JP2008516152A; EP1799332A1; AU2005293349B2; MX2007004285A

Abstract

A method of decomposing NO2 to NO in an exhaust gas of a lean-bum internal combustion engine comprises the steps of contacting an acidic metal oxide selected from the group consisting of zeolites, tungsten-doped titania, silica-titania, zirconia-titania, gamma-alumina, amorphous silica-alumina and mixtures of any two or more thereof with a gas mixture comprising the exhaust gas, adjusting the composition of the gas mixture, by injecting hydrocarbon therein at a rate that changes over the course of a duty cycle so that, on average over the duty cycle, the Cl hydrocarbon : nitrogen oxides ratio of the gas mixture contacting the acidic metal oxide is from 0.1 to 2.0 and passing the effluent gas directly to atmosphere optionally via first contacting the gas mixture with a hydrocarbon oxidation catalyst.

Description

METHOD OF DECOMPOSING NITROGEN DIOXIDE

The present invention relates to a method of decomposing nitrogen dioxide to nitrogen monoxide in an exhaust gas of a lean-burn internal combustion engine.

Nitrogen oxides (NO_x) comprise nitrogen monoxide (NO) and nitrogen dioxide (NO₂). Reference herein to NO_x is to a mixture of nitrogen oxides including NO and NO₂, and references herein to NO and NO₂ specifically should be interpreted accordingly.

In our International patent application no. PCT/GB2004/001680 (the entire contents of which are incorporated herein by reference) we describe a novel method of decomposing NO₂ to NO in an exhaust gas of a lean-burn internal combustion engine, which method comprising adjusting the Cl hydrocarbon:nitrogen oxides (Cl HC:NO_X) ratio of the exhaust gas to from 0.1 to 2.0 and contacting the gas mixture with an acidic metal oxide selected from the group consisting of zeolites, tungsten- doped titania, silica-titania, zirconia-titania, gamma-alumina, amorphous silica- alumina and mixtures of any two or more thereof, and passing the effluent gas to atmosphere.

One application of such a method is to decompose NO₂ generated over an oxidation catalyst or a catalysed soot filter before the exhaust gas is passed to atmosphere. Such an application is often described as a "clean-up" catalyst. In one embodiment described in PCT/GB2004/001680, the oxidation catalyst is a NO oxidation catalyst in Johnson Matthey's CRT^® system described in EP 0341382 or US patent no. 4,902,487 (both of which are incorporated herein by reference) for oxidising NO to NO₂ for combusting particulate matter (PM) collected on a filter in NO₂ and the clean-up catalyst is located downstream of the filter, or on the downstream end of the filter. The CRT^® filter can also contain a precious metal catalyst to promote PM combustion. In PCT/GB2004/001680 we explain our belief that the HC reductant is forming a coke on the acidic metal oxide and it is the coke that, at least in part, promotes the decomposition OfNO₂ to NO.

EP 0541271 (incorporated herein by reference) discloses a catalyst system for treating NO_x in the exhaust from a lean-burn gasoline-fuelled engine, which system comprising a first stage catalyst containing a transition metal-exchanged zeolite (i.e. Cu-ZSM5), and a second stage catalyst, which is a three-way catalyst, for treating the effluent from the first stage catalyst. The engine is controlled such that the ratio of NO_x to HC in the exhaust gas is in the range of from 1/3 to 3/1 (i.e. minimum C₃H₆ of 250 ppm (or 750 ppm Cl) and a minimum NO_x of 200-400 ppm). EP 0541271. does not disclose the method of PCT/GB2004/001680 because the effluent gas of the first stage catalyst undergoes further treatment in the second stage catalyst, whereas the effluent gas of the method of PCT/GB2004/001680 is passed to atmosphere. Moreover, preferably the method of PCT/GB2004/001680 is for treating exhaust gas from a diesel- fuelled engine.

In our WO 03/033118 (incorporated herein by reference) we disclose an exhaust system for an internal combustion engine comprising a first lean NO_x catalyst (LNC) comprising a metal on a support comprising alumina, titania, zirconia, non- zeolite silica alumina or mixtures or mixed oxides of any two or more thereof and a second, platinum-based LNC disposed with and/or downstream of the first LNC, wherein the exhaust system comprises means for coking the first LNC during normal engine operation. The invention of PCT/GB2004/001680 is novel over this disclosure for similar reasons to EP 0541271.

US 6,202,407 (incorporated herein by reference) describes a method of catalytically reducing NO_x to N₂, i.e. lean NO_x catalysis, using pulsed injection of hydrocarbon reductant. Preferred catalysts are amphoteric and include gamma- alumina, Ga₂O₃ and ZrO₂, all optionally metallised with Cu, Ni or Sn. A problem with the use of oxidation catalysts and catalysed soot filters is that, as exhaust emission legislation tightens, legislative bodies have begun to discuss limiting the amount of NO₂ it is permissible to exhaust to atmosphere. For example, the California Air Resources Board (CARB) has proposed that a maximum of 20% of tailpipe NO_x of the relevant drive cycle is emitted as NO₂ (See California's Diesel Risk Reduction Program, September 2000 and Title 13, California Code of Regulations, Chapter 14, section 2706.). NO₂ is toxic and can cause headaches, dizziness and nausea in low doses. It also has an objectionable smell. In the context of the CRT^®, if there is insufficient PM on the filter to react with NO₂ generated over the oxidation catalyst or the temperature of the exhaust gas is below a preferred range for combustion of PM in NO₂, NO₂ can slip past the filter and be undesirably exhausted to atmosphere.

This problem is particularly acute when internal combustion engines are used in confined spaces, such as mines, where vehicles are used to drill for, load, and transport mined material to the surface. Many mining operations generate PM, and so exhaust aftertreatment systems comprising filters for reducing the levels of PM emitted are being considered. Furthermore, explosives used to blast rock to recover a desired ore can generate NO₂. Accordingly, it would be an advantage to reduce the exhaust gas emissions of both PM and NO₂ to the atmosphere in closed environments to improve the health and safety of miners. Indeed, the US Mine Safety and Health

Administration prevents the use of diesel exhaust systems comprising diesel particulate filter systems that increase NO₂ emissions.

In developing the method of PCT/GB2004/001680 for practical application, we have discovered a way of utilising the observation that coke formation on the acidic metal oxide materials promotes the decomposition OfNO₂ to NO. In particular, we have observed that conversion can be maintained by ensuring that the catalyst remains coked. In effect, the catalyst can be used as a reservoir for a HC reductant, and this has a number of useful advantages for the practical application of the invention. According to a first aspect, the invention provides a method of decomposing nitrogen dioxide (NO₂) to nitrogen monoxide (NO) in an exhaust gas of a lean-burn internal combustion engine, which method comprising the steps of contacting an acidic metal oxide selected from the group consisting of zeolites, tungsten-doped titania, silica-titania, zirconia-titania, gamma-alumina, amorphous silica-alumina and mixtures of any two or more thereof with a gas mixture comprising the exhaust gas, adjusting the composition of the gas mixture by injecting hydrocarbon therein at a rate that changes over the course of a duty cycle so that, on average over the duty cycle, the Cl hydrocarbon : nitrogen oxides (Cl HC:NO_X) ratio of the gas mixture contacting the acidic metal oxide is from 0.1 to 2.0 and passing the effluent gas directly to atmosphere optionally via first contacting the gas mixture with a hydrocarbon oxidation catalyst.

In one embodiment, HC is injected intermittently into the gas mixture over the course of the duty cycle. In another embodiment, HC is injected continuously into the gas mixture in pulses oscillating between a lower rate of injection and a higher rate of injection over the course of the duty cycle.

By averaging the supply of HC reductant over the duty cycle of the engine, it is possible to use higher flow pumps and injectors to deliver HC intermittently or in pulses from lower to higher rates of delivery, relying on the ability of the catalyst to store the HC as coke for use in the method of the invention. This is advantageous because higher rate flow pumps are more readily available and it is possible to use commercially available injectors.

A second advantage is that it is more difficult to deliver low rates of HC injection continuously, so by injecting larger amounts of HC intermittently and using the catalyst to store the HC, the overall accuracy of HC delivery is improved.

A third advantage is that by using the HC storage capability of the catalyst, it is possible to simplify the system to a single injection point, making calibration control cheaper and easier, for example in an at least two segment engine map embodiment discussed below. The ability of the catalyst to store HC reductant as coke reduces or prevents excessive HC emissions to atmosphere, and certainly enables the system to meet the relevant emission standards, even when using an intermittent HC delivery strategy. This can be important in a mining facility.

In one embodiment, the Cl HC:NO_X ratio is adjusted to from 0.1 to 1.5 or from 0.1 to 1.0.

In an embodiment, the acidic metal oxide is non-metallised, but it can also support a metal or metal compound wherein the metal is selected from the group consisting of rhodium, palladium, iron, copper and mixtures of any two or more thereof. In a further embodiment, the sole supported metal or metal compound is palladium.

NO₂ can account for up to about 50% NO_x in the exhaust gas of an internal combustion engine. Therefore, according to one embodiment the Cl HC:NO₂ ratio is adjusted to from 0.05 to 1.00, such as from 0.05 to 0.75 or 0.05 to 0.50 over the course of the duty cycle.

In an embodiment, HC injection is controlled in response to at least one input selected from the group consisting of: exhaust gas temperature; catalyst bed temperature; exhaust gas mass flow; NO₂ in the exhaust gas; manifold vacuum; ignition timing; engine speed; throttle position; lambda value of the exhaust gas composition; quantity of fuel injected in the engine; position of an exhaust gas recirculation valve; turbo-charger boost pressure; HC concentration downstream of the NO₂ decomposition catalyst; and the rate of change of any thereof. In another embodiment, HC injection is controlled by correlation with the at least one input in stored look-up tables or an engine map. Sophisticated modelling can be used to predict engine-out total NO_x and NO₂ downstream of an oxidation catalyst in order to develop an appropriate HC injection strategy.

For example, in one embodiment the at least one input includes engine speed and exhaust gas temperature, there being a correlation between engine speed and engine-out NO_x. In an embodiment where an engine map is used to correlate the at least one input with the rate and/or quantity of HC injection, the engine map can be divided into at least two segments and a quantity of HC can be injected into the exhaust gas whenever a detected input value crosses from one segment into the other. In further embodiments, the engine map can be subdivided into four segments, sixteen segments or two hundred and fifty six segments, for example.

We have found that for the prescribed Cl HC:NO_X ratios, NO₂ conversion is reduced at lower temperatures. In order to meet the proposed CARB threshold of a maximum of 20% NO₂ of NO_x emitted, in one embodiment we prefer that the step of adjusting the Cl HC-NO_x ratio is performed only when the exhaust gas temperature is at 250°C and above. It will be noted that NO₂ conversion is possible at temperatures much below that required for lean NO_x catalysis for a similar catalyst i.e. above 250°C for NO₂ conversion as opposed to about 40O⁰C for lean NO_x catalysis over Fe-

B eta zeolite.

According to a further embodiment, the step of adjusting the Cl HC:NO_X ratio is done when the exhaust gas temperature is in a range that has been pre-determined to produce increased NO₂ in the exhaust system. Such temperature range will usually depend on the engine type and the duty of the vehicle. Illustrative embodiments include city centre buses comprising heavy-duty diesel engines (250 - 300°C); buses in non-city centre locations (up to 400°C); and heavy-duty diesel trucks (up to 500⁰C).

Potentially, the method according to the first aspect of the invention can be used. to treat gas mixtures including NO₂ generated by any chemical, e.g. industrial, process. However, for the purposes of the present invention, the method is for treating an exhaust gas mixture derived from combustion of a hydrocarbon fuel, such as diesel fuel, gasoline fuel, a gas-to-liquid (GTL)-based fuel, natural gas (NG) or liquid petroleum gas (LPG) in an internal combustion engine. According to a second aspect, the invention provides an exhaust system for an internal combustion engine, which system comprising a catalyst for decomposing nitrogen dioxide (NO₂) to nitrogen monoxide (NO) with a hydrocarbon (HC) reductant, and means, in use, for adjusting the composition of an exhaust gas by injecting HC therein at a rate that changes over the course of a duty cycle so that, on average over the duty cycle, the Cl hydrocarbon : nitrogen oxides (Cl HC:NO_X) ratio of the exhaust gas composition contacting the catalyst is from 0.1 to 2.0, wherein the catalyst consists of an acidic metal oxide selected from the group consisting of zeolites, tungsten-doped titania, silica-titania, zirconia-titania, gamma-alumina, amorphous silica-alumina and mixtures of any two or more thereof optionally supporting a metal or a compound thereof, which metal being selected from the group consisting of rhodium, palladium, iron, copper and mixtures of any two or more thereof, wherein effluent gas from the catalyst is passed directly to atmosphere optionally via a hydrocarbon oxidation catalyst.

Control of the adjustment means can be effected, in use, by suitable means for putting the. method steps of the invention into effect comprising, in one embodiment, a processor which in turn can form part of the engine control unit (ECU), if desired.

In one embodiment, the adjustment means controls HC injection so that, on average over the course of the duty cycle, the Cl hydrocarbon : nitrogen dioxide (Cl HCrNO₂) ratio of the exhaust gas composition contacting the catalyst is from 0.05 to 1.00.

In order to control HC injection, it is desirable that the system comprises one or more sensors for inputting the status of one or more of the following conditions in the system: exhaust gas temperature; catalyst bed temperature; exhaust gas mass flow; NO₂ in the exhaust gas, e.g. as detected by a suitable NO₂ sensor; manifold vacuum; ignition timing; engine speed; throttle position; lambda value of the exhaust gas composition; quantity of fuel injected in the engine; position of an exhaust gas circulation valve; turbo-charger boost pressure; HC concentration downstream of the NO₂ decomposition catalyst; and the rate of change of any thereof. It will be understood that the Cl HC:NO_X ratio can be varied according to the or each input received. For example, at lower exhaust gas temperatures a higher Cl HC: NO_x ratio is desirable for a pre-determined NO₂ conversion, whereas a lower Cl HC:NO_X ratio can be used at higher temperatures.

In one embodiment, the NO₂ decomposition catalyst is disposed downstream of an oxidation catalyst comprising at least one PGM, preferably at least one of platinum and palladium, especially platinum only. It is known from EP 0341382 or US patent no. 4,902,487 that such catalysts can oxidise NO in the exhaust gas to NO₂ at temperatures of up to 400°C. However, preferably, where additional HC is introduced into the exhaust system upstream of the NO₂ decomposition catalyst, this is done downstream of the oxidation catalyst. This is because HC can be combusted on the oxidation catalyst before it reaches the NO₂ decomposition catalyst if the exhaust gas composition over the oxidation catalyst is lambda >1. Whilst it is possible to slip HC past the oxidation catalyst for NO₂ decomposition if the exhaust gas composition over the oxidation catalyst is at lambda <1, the amount of HC required is prohibitive and accurate control of HC delivery to the catalyst is complicated. In the CRT^® configuration, HC injection can be effected between the oxidation catalyst and the filter, or between the filter and a downstream NO₂ decomposition catalyst.

According to a further embodiment, the oxidation catalyst is on a diesel particulate filter. Such arrangement is sometimes called a "catalysed soot filter" or CSF. The catalyst can promote the combustion, i.e. reduce the combustion temperature, of PM on the filter. However, the presence of an oxidation catalyst on the filter can also result in increased levels of NO₂ leaving the filter section of the filter relative to the amount of NO₂ entering the filter.

According to a further embodiment, the oxidation catalyst is associated with a NO_x absorbent material. The NO_x absorbent material is typically at least one compound of an alkali metal, e.g. potassium or caesium, at least one compound of an alkaline earth metal, such as barium, strontium or calcium, or at least one compound of a rare earth metal, for example lanthanum or yttrium. Generally, the compounds of the NO_x absorbent materials will be oxides but, in use, the compounds may also be present as hydroxides, carbonates or, following NO_x absorption (as will be described hereinafter), nitrates.

In this arrangement, NO₂ generated over the oxidation catalyst during lambda

> 1 operation can be absorbed in the NO_x absorbent material and stored as the nitrate. Since the NO_x absorbent material has a finite capacity to absorb NO_x, periodically the NO_x absorbent material is regenerated, i.e. to remove the stored NO_x. Generally, this is done in practice by transiently adjusting the lambda composition of the exhaust gas to reduce the concentration of O₂ in the gas, for example by introducing additional HC fuel into the exhaust gas or by allowing less air into the combustion mixture. The nitrate forms of the alkali, alkaline earth and rare earth metals are understood to be unstable in rich exhaust gas, and so NO_x is released, in what is believed to be a mixture of at least NO and NO₂.

Typically, compositions comprising NO_x absorbent materials also comprise rhodium for reducing the NO_x to N₂ in the presence of the reductant. However, the rhodium NO₂ decomposition catalysts of the present invention do not include other PGM's such as platinum and/or palladium commonly used as oxidation catalysts. In one arrangement, for example, the NO₂ decomposition catalyst is on a separate monolith downstream of the filter. In a particular embodiment, however, the NO₂ decomposition catalyst can be disposed on a downstream end of the filter, e.g. in a stripe configuration. For example, in an embodiment featuring the CRT^® system, the NO₂ decomposition catalyst can be disposed, e.g. as a stripe, on the downstream end of the filter and the HC can be injected between the oxidation catalyst and the filter.

In embodiments including the hydrocarbon oxidation catalyst downstream of the NO₂ decomposition catalyst for controlling HC slip to atmosphere, the HC oxidation catalyst can comprise at least one PGM, but in a particular embodiment the PGM consists solely of platinum. The HC oxidation catalyst can be disposed on a separate monolith, or on the monolith comprising the NO₂ decomposition catalyst eg. in a stripe configuration. In an arrangement wherein the NO₂ decomposition catalyst is present as a stripe, the HC oxidation catalyst stripe is downstream thereof. The filter can be any suitable substrate including a wall-flow filter of ceramic material such as silicon carbide or cordierite. Alternatively, it can be the device described in either EP 1057519 or WO 03/038248 (both of which disclosures are incorporated herein by reference).

Examples of suitable zeolite components for the NO₂ decomposition catalysts are ZSM-5, β-zeolite, Y-zeolite or mordenite. Suitable silica to alumina molar ratios for such zeolites are from 25 to 400, optionally 30 to 80.

The silica-titania, zirconia-titania or tungsten-titania can be in the form of true mixed oxides or composite oxides. "Composite oxide" as defined herein means a largely amorphous oxide material comprising oxides of at least two elements which are not true mixed oxides consisting of the at least two elements. In embodiments, suitably the tungsten, silica or zirconia can be present in the tungsten-titania, silica- titania and zirconia-titania respectively in an amount of from 5 to 15 wt% based on the total weight of the acidic metal oxide.

The NO₂ decomposition catalysts supporting metals or compounds thereof can be prepared according to known methods such as wet impregnation of the at least one support material using a suitable metal salt followed by calcination, co-precipitation or by ion exchange.

In one embodiment, the catalyst for use in the exhaust system according to the invention contains from 0.1 to 5.0 wt% rhodium, such as from 0.25 to 2.5 wt% rhodium, based on the total weight of the acidic metal oxide.

In a specific embodiment, the catalyst consists essentially of 0.5 wt% rhodium on gamma-alumina.

In a further embodiment, the NO₂ decomposition catalyst contains from 1 to 10 wt% copper, such as from 2.5 to 7.5 wt% copper, based on the total weight of the acidic metal oxide. Where the acidic metal oxide is a zeolite, the metal can be impregnated, ion exchanged or co-precipitated onto the acidic metal oxide.

In a specific embodiment the catalyst consists essentially of 5 wt% copper on zeolite ZSM-5 and/or β-zeolite.

In a further embodiment, the catalyst contains from 1 to 10 wt% iron, such as from 2.5 to 7.5 wt% iron, based on the total weight of the acidic metal oxide. Where the acidic metal oxide is a zeolite, the metal can be impregnated, ion exchanged or co- precipitated onto the acidic metal oxide.

In a specific embodiment the catalyst consists essentially of 5 wt% iron and the at least one support is zeolite ZSM-5 and/or β-zeolite.

According to a further embodiment, the catalyst contains from 0.1 to 5.0 wt% palladium, such as from 0.25 to 2.5 wt% palladium, based on the total weight of the acidic metal oxide.

In a specific embodiment the catalyst consists essentially of 2 wt% palladium on tungsten-titania.

According to a third aspect, the invention provides an apparatus comprising an internal combustion engine and an exhaust system according to the invention.

The engine of such an apparatus can be fuelled with diesel fuel, gasoline fuel, a gas-to-liquid (GTL)-based fuel, natural gas (NG) or liquid petroleum gas (LPG), preferably diesel fuel. The fuel that powers the engine is normally used as the HC reductant in the method according to the present invention. However, it is envisaged that a different HC reductant from the fuel that powers the engine can be used if a suitable reservoir and delivery means is installed and means are provided for replenishing depleted HC reductant. In order that the invention may be more fully understood the following Examples are provided by way of illustration only and with reference to the accompanying drawing, in which:

Figure 1 is a graph showing NO₂ emissions from an exhaust system before, during and after a period of HC injection.

EXAMPLE 1

Trials were undertaken to investigate the NO₂ decomposition rates achievable over the range of temperatures using a stationary apparatus comprising a Deutz 34 kW diesel engine and an exhaust system comprising a CRT^® followed by an air assisted HC injector and a NO₂ decomposition catalyst consisting of non-metallised beta- zeolite washcoated on a 400 cells per square inch (cpsi (62 cells cm^"2)) 7 Vz inch (19.05 cm) diameter x 3 inch (7.62 cm) long ceramic monolith substrate (clean-up catalyst). The HC injector is connected to an air pump to optimise diesel fuel injection delivery and spray distribution. The engine speed was held at 2900 rpm with CRT^® catalyst inlet temperature at 355°C and the inlet temperature to the NO₂ decomposition catalyst about 25°C lower. The NO₂ concentration in the exhaust gases was increased from 30 ppm to 150 ppm by the CRT^® system. Using a fuel injection rate between the CRT^® catalyst and the NO₂ decomposition catalyst to give a Cl HC:N0₂ ratio of 0.5, tailpipe NO₂ was reduced to 15 ppm, i.e. less than the concentration of NO₂ from the engine (results not shown). The engine speed and load were then reduced to give an inlet temperature to the NO₂ decomposition catalyst of 243°C. The tailpipe NO₂ level rose to 90 ppm but, on increasing the HC injection rate , to give a 1:1 ratio of Cl HC:NO₂, the tailpipe NO₂ was reduced to 10 ppm. This observation is consistent with the bench engine results shown in PCT/GB2004/001680 wherein low temperature conversion of NO₂ could be enhanced at higher Cl HC:NO₂ ratios.

Figure 1 shows results from an experiment using the Deutz compressor to optimise diesel fuel injection rate. The engine was run at a set speed and load and diesel fuel was added upstream of the NO₂ decomposition catalyst to give a Cl HCrNO₂ ratio of 0.75. This gave a very low level of tailpipe NO₂ and so the diesel fuel injection rate was reduced to give a Cl HCrNO₂ of 0.5. The tailpipe NO₂ level increased slightly and after a few minutes the diesel injection was switched off. It can be seen that the tailpipe NO₂ level only increased slowly over several minutes before it reached the same level as the inlet to the NO₂ decomposition catalyst, demonstrating the considerable storage potential of the catalyst in this system.

To determine whether coked HC deposits might build up on the NO₂ decomposition catalyst if the HC level was in excess, back pressure was monitored at several points over a system using a high Cl HC:NO₂ injection ratio of 1.5, i.e. outside the range of the present invention. Back pressure before the CRT^® system and the NO₂ decomposition catalyst remained constant at 30-35 mbar and 6-8 mbar respectively over 10 hours of continuous running at a steady state condition.

Furthermore, tailpipe HC levels were measured with no NO₂ decomposition catalyst in place to ascertain maximal HC emissions and how detected emissions related to current emission standards. A typical engine-out HC concentration for this engine was 5-10 ppm. After the CRT^® catalyst this was reduced to approximately 2 ppm as shown in Figure 1. With fuel injection to give a typical HC to NO₂ ratio of 0.5, the tailpipe HC level was slightly lower than engine-out. Good NO₂ decomposition was observed under this condition.

EXAMPLE 2

A CRT^® system consisting of an oxidation catalyst followed by a particulate filter, followed by a diesel fuel injector and then a beta-zeolite NO₂ decomposition catalyst similar to that described in Example 1, was fitted to an engine in a laboratory. The engine was a 1994 US, turbo-charged, 12 litre, 303 kW Volvo.

The NO₂ decomposition catalyst coated on a ceramic monolith substrate, 7.5 inch (19.05 cm) diameter x 3 inch (7.62 cm) long, with 400 cells per square inch (cpsi (62 cells cm^'2)) was evaluated as described below. The performance was compared to that of a NO₂ decomposition catalyst of the same diameter but 6 inches (15.24 cm) long.

The engine was run at a steady speed of 1200rpm and the load increased to raise the inlet temperature of the oxidation catalyst in the CRT^®. The temperature was increased in approximately 5O⁰C steps from 200 - 475⁰C and the NO₂, HC (ppm) and

Particulate Matter (PM) (g hr ^"J) were measured at each temperature point, before and after the NO₂ decomposition catalyst. Fuel was injected into the NO₂ decomposition catalyst at a number of ratios of CIrNO₂ to determine the maximum NO₂ conversion (minimum slip). The results show data generated with Cl :NO₂ ratios of 1.0 and 1.5 at three temperature points and are summarised in Table 1.

From the data shown in Table 1, it can be seen that the NO₂ conversion of the NO₂ decomposition catalyst increases with increasing temperature and, for the smaller catalyst, increases with the higher Cl: NO₂ ratio. With the larger, 6 inch catalyst the NO₂ conversion is higher at all temperature points and is unaffected by the additional HC injected at the C 1:1.5 HC to NO₂ ratio. From 315⁰C greater than 90% conversion ofNO₂ is achieved. Although there is increased HC slip at the higher injection ratio, under all operating conditions, the post decomposition catalyst HC is much less with the larger catalyst volume. PM conversion is greater than 85% under all conditions irrespective of HC injection ratio except for the larger 6 inch catalyst at the highest temperature. TABLEl

EXAMPLE 3

A second set of tests was conducted, using the system described in Example 2, to evaluate the effect of coating the rear end of the 6 inch (15.24 cm) long beta-zeolite NO₂ decomposition catalyst with a "stripe" of Pt catalyst. These second set of tests were designed to investigate the possibility of removing HC slip without re-oxidising NO to NO₂. Three samples of catalyst were coated with a 1 inch (25.4 cm) stripe of Pt at the rear of the decomposition catalyst at Pt loadings of 1, 5 and 10 g ft^"3 Pt.

The engine was run at a steady speed of 1200rpm and the same test procedure used as in Example 2, PM was only measured at one test point (37O⁰C) and fuel injection to the decomposition catalyst was conducted with a Cl: NO₂ ratio of 1.0 only. The HC slip and NO₂ conversions at three temperature points are summarised in Table 2, from which it can be seen that the addition of the Pt stripe to the decomposition catalyst improves overall PM conversion, compared with the arrangement wherein no Pt stripe is present, without significantly affecting HC slip or NO₂ conversion. This improvement in conversion efficiency corresponds to a greater than 60% reduction in the PM emissions at the tailpipe, i.e. of gases emitted directly to the atmosphere. This is probably because HC is removed which would contribute to soluble organic fraction (SOF) in the particulate. There is no significant effect of Pt loading of the stripe on performance of the decomposition catalyst.

TABLE 2

EXAMPLE 4

A Liebherr 922, 6 litre, 106 Kilowatt engine fitted to a Track Excavator was equipped with a CRT^® system, similar to that described in Example 2, followed by a diesel fuel injector and then a beta-zeolite NO₂ decomposition catalyst. Two sizes of NO₂ decomposition catalyst were tested, both coated on ceramic substrate containing 400 cpsi (62 cpcm^" ): (i) 7.5 inch (19.05cm) diameter x 3 inch (7.62) cm long, of volume 132.5 in³ (2.17 litre); and (ii) 5.55 inch (14.1cm) diameter x 6 inch (15.24 cm) long, of volume 145in³ (2.37 litre).

The vehicle was maintained in a stationary position during testing and the inlet temperature to the catalyst system was increased by increasing engine speed and applying a load on the engine. In these experiments the engine was operated at 2100 rpm with and without load and HC fuel was injected at 180ml h^" for catalyst (i) and

150 ml h^"1 for catalyst (ii). The NO₂ and HC (ppm) were measured before and after the decomposition catalysts and the results for NO2 and HC measurements taken after the catalyst are summarised in Table 3.

From the results presented in Table 3, it can be seen that the percentage reduction in NO₂ over the decomposition catalyst increases with increasing temperature. With secondary fuel injection, higher levels of NO₂ conversion are achieved. The resulting HC slip shows that the injection of secondary fuel must be regulated to take into account characteristics such as catalyst volume, injector distribution and fuel flow properties to minimise HC slip while maintaining a desired high level of NO₂ removal.

TABLE 3

Claims

CLAIMS:

1. A method of decomposing nitrogen dioxide (NO₂) to nitrogen monoxide (NO) in an exhaust gas of a lean-burn internal combustion engine, which method comprising the steps of contacting an acidic metal oxide selected from the group consisting of zeolites, tungsten-doped titania, silica-titania, zirconia-titania, gamma-alumina, amorphous silica- alumina and mixtures of any two or more thereof with a gas mixture comprising the exhaust gas, adjusting the composition of the gas mixture by injecting hydrocarbon therein at a rate that changes over the course of a duty cycle so that, on average over the duty cycle, the Cl hydrocarbon : nitrogen oxides (Cl HCrNO_x) ratio of the gas mixture contacting the acidic metal oxide is from 0.1 to 2.0 and passing the effluent gas directly to atmosphere optionally via first contacting the gas mixture with a hydrocarbon oxidation catalyst.

2. A method according to claim 1, comprising injecting HC intermittently into the gas mixture over the course of the duty cycle.

3. A method according to claim 1, comprising injecting HC continuously into the gas mixture in pulses oscillating between a lower rate of injection and a higher rate of injection over the course of the duty cycle.

4. A method according to claim 1, 2 or 3, wherein the acidic metal oxide supports a metal or a compound thereof, selected from the group consisting of rhodium, palladium, iron, copper and mixtures of any two or more thereof.

5. A method according to claim 1, 2, 3 or 4, comprising adjusting the CI HC:NO₂ ratio in the gas mixture contacting the acidic metal oxide to, on average, from 0.05 to 1.00 over the course of the duty cycle.

6. A method according to any preceding claim, comprising controlling HC injection in response to at least one input selected from the group consisting of: exhaust gas temperature; catalyst bed temperature; exhaust gas mass flow; NO₂ in the exhaust gas; manifold vacuum; ignition timing; engine speed; throttle position; lambda value of the exhaust gas composition; quantity of fuel injected in the engine; position of an exhaust gas recirculation valve; turbo-charger boost pressure; HC concentration downstream of the NO₂ decomposition catalyst; and the rate of change of any thereof.

7. A method according to claim 6, comprising controlling HC injection by correlation with the at least one input in stored look-up tables or an engine map.

8. A method according to claim 6 or 7, comprising adjusting the Cl HC:NO_X ratio at above 250⁰C.

9. A method according to claim 8, comprising adjusting the Cl HCrNO_x ratio is done at up to 500⁰C.

10. A method according to claim 7, comprising dividing the engine map into at least two segments and injecting a quantity of HC into the exhaust gas whenever a detected input value crosses from one segment to the other.

11. A method according to any preceding claim, wherein the hydrocarbon is diesel fuel, gasoline fuel, a gas-to-liquid (GTL)-based fuel, natural gas (NG) or liquid petroleum gas (LPG), preferably diesel fuel.

12. An exhaust system for an internal combustion engine, which system comprising a catalyst for decomposing nitrogen dioxide (NO₂) to nitrogen monoxide (NO) with a hydrocarbon (HC) reductant, and means, in use, for adjusting the composition of an exhaust gas by injecting HC therein at a rate that changes over the course of a duty cycle so that, on average over the duty cycle, the Cl hydrocarbon : nitrogen oxides (Cl HC:NO_X) ratio of the exhaust gas composition contacting the catalyst is from 0.1 to 2.0, wherein the catalyst consists of an acidic metal oxide selected from the group consisting of zeolites, tungsten-doped titania, silica-titania, zirconia-titania, gamma-alumina, amorphous silica-alumina and mixtures of any two or more thereof optionally supporting a metal or a compound thereof, which metal being selected from the group consisting of rhodium, palladium, iron, copper and mixtures of any two or more thereof, wherein effluent gas from the catalyst is passed directly to atmosphere optionally via a hydrocarbon oxidation catalyst.

13. An exhaust system according to claim 12, wherein the adjusting means, in use, injects HC intermittently into the exhaust gas over the course of the duty cycle.

14. An exhaust system according to claim 12, wherein the adjusting means, in use, injects HC continuously in pulses oscillating between a lower rate of injection and a higher rate of injection over the course of the duty cycle.

15. An exhaust system according to claim 12, 13 or 14, wherein the adjusting means in use, adjusts the composition of the exhaust gas by injecting HC therein so that, on average over the course of the duty cycle, the Cl hydrocarbon : nitrogen dioxide (Cl HC:NO₂) ratio of the exhaust gas composition contacting the catalyst is from 0.05 to 1.00.

16. An exhaust system according to claim 12, 13, 14 or 15, wherein HC injection is controlled, in use, in response to at least one of the inputs selected from the group consisting of: exhaust gas temperature; catalyst bed temperature; exhaust gas mass flow; NO₂ in the exhaust gas; manifold vacuum; ignition timing; engine speed; throttle position; lambda value of the exhaust gas composition; quantity of fuel injected in the engine; position of an exhaust gas recirculation valve; turbo-charger boost pressure; HC concentration downstream of the NO₂ decomposition catalyst; and the rate of change of any thereof.

17. An exhaust system according to claim 16, wherein HC injection is controlled, in use, by correlation with the at least one input in stored look-up tables or an engine map.

18. An exhaust system according to any of claims 16 or 17, wherein the adjustment means is controlled, in use, to operate when the exhaust gas temperature is above 25O⁰C.

19. An exhaust system according to claim 18, wherein the adjustment means is controlled, in use, to operate when the exhaust gas temperature is below 500⁰C.

20. An exhaust system according to claim 17, wherein the engine map is divided into at least two segments and HC injection is controlled, in use, so that a quantity of HC is injected into the exhaust gas whenever a detected input value crosses from one segment to the other.

21. An exhaust system according to any of claims 12 to 20, wherein the adjusting means comprises a processor.

22. An exhaust system according to claim 21, wherein the processor is part of an engine control unit (ECU).

23. An exhaust system according to any of claims 12 to 22, wherein the NO₂ decomposition catalyst is disposed downstream of an oxidation catalyst comprising at least one PGM, preferably at least one of platinum and palladium.

24. An exhaust system according to claim 23, comprising a particulate filter between the oxidation catalyst and the NO₂ decomposition catalyst.

25. An exhaust system according to claim 23, wherein the oxidation catalyst is on a particulate filter.

26. An exhaust system according to claim 23 or 25, wherein the oxidation catalyst is associated with a NO_x absorbent material.

27. An exhaust system according to claim 24 or 25 or claim 26 when appendant to claim 25, wherein the NO₂ decomposition catalyst is disposed on a downstream end of the filter.

28. An exhaust system according to claim 24, 25, 26 or 27, wherein the filter is a wall-flow filter.

29. An exhaust system according to any of claims 23 to 28, when appendant to claim 14, wherein the HC injection means is controlled, in use, to inject the HC into the exhaust system between the oxidation catalyst and the NO₂ decomposition catalyst.

30. An exhaust system according to any of claims 12 to 29, wherein the at least one zeolite is ZSM-5, β-zeolite, Y-zeolite or mordenite.

31. An exhaust system according to any of claims 12 to 30, wherein the silica to alumina molar ratio in the zeolite is from 25 to 400, optionally from 30 to 80.

32. An exhaust system according to any of claims 12 to 31, wherein the tungsten, silica or zirconia is present in the tungsten-titania, silica-titania and zirconia-titania respectively in an amount of from 5 to 15 wt% based on the total weight of the acidic metal oxide.

33. An exhaust system according to any of claims 12 to 32, wherein the acidic metal oxide contains from 0.1 to 5.0 wt%, optionally from 0.25 to 2.5 wt%, rhodium based on the total weight of the acidic metal oxide.

34. An exhaust system according to any of claims 12 to 32, wherein the acidic metal oxide contains from 0.1 to 5.0 wt%, optionally from 0.25 to 2.5 wt%, palladium based on the total weight of the acidic metal oxide.

35. An exhaust system according to any of claims 12 to 32, wherein the acidic metal oxide contains from 1 to 10 wt%, optionally from 2.5 to 7.5 wt%, copper based on the total weight of the acidic metal oxide.

36. An exhaust system according to any of claims 12 to 32, wherein the acidic metal oxide contains from 1 to 10 wt%, optionally from 2.5 to 7.5 wt%, iron based on the total weight of the acidic metal oxide.

37. An exhaust system according to any of claims 12 to 36, wherein the hydrocarbon oxidation catalyst comprises at least one platinum group metal (PGM).

38. An exhaust system according to claim 37, wherein the sole PGM in the hydrocarbon oxidation catalyst is platinum.

39. An apparatus comprising an internal combustion engine and an exhaust system according to any of claims 12 to 38.

40. An apparatus comprising an engine according to claim 39 fuelled with diesel fuel, gasoline fuel, natural gas (NG) or liquid petroleum gas (LPG), preferably diesel fuel.

41. A vehicle, such as mining vehicle, comprising an apparatus according to claim 39 or 40.