WO2017216728A1 - Palladium diesel oxidation catalyst - Google Patents

Palladium diesel oxidation catalyst Download PDF

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Publication number
WO2017216728A1
WO2017216728A1 PCT/IB2017/053514 IB2017053514W WO2017216728A1 WO 2017216728 A1 WO2017216728 A1 WO 2017216728A1 IB 2017053514 W IB2017053514 W IB 2017053514W WO 2017216728 A1 WO2017216728 A1 WO 2017216728A1
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WO
WIPO (PCT)
Prior art keywords
component
layer
impregnated
oxygen storage
catalyst
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/IB2017/053514
Other languages
English (en)
French (fr)
Inventor
Shiang Sung
Patrick William MCCANTY
Markus Koegel
Susanne Stiebels
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BASF Corp
Original Assignee
BASF Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to CA3027822A priority Critical patent/CA3027822A1/en
Priority to KR1020197001523A priority patent/KR102427507B1/ko
Priority to BR112018076199-0A priority patent/BR112018076199A2/pt
Priority to EP17812854.2A priority patent/EP3471877A4/en
Priority to RU2019100972A priority patent/RU2019100972A/ru
Priority to US16/310,327 priority patent/US11248505B2/en
Application filed by BASF Corp filed Critical BASF Corp
Priority to JP2018566205A priority patent/JP6932149B2/ja
Priority to MX2018015865A priority patent/MX2018015865A/es
Priority to CN201780050401.XA priority patent/CN109641196B/zh
Publication of WO2017216728A1 publication Critical patent/WO2017216728A1/en
Anticipated expiration legal-status Critical
Priority to US17/569,628 priority patent/US11982218B2/en
Ceased 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
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/103—Oxidation catalysts for HC and CO only
    • 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
    • B01D53/944—Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts
    • 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
    • B01J23/02—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the alkali- or alkaline earth metals or beryllium
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
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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
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion
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    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion
    • F01N3/206—Adding periodically or continuously substances to exhaust gases for promoting purification, e.g. catalytic material in liquid form, NOx reducing agents
    • F01N3/2066—Selective catalytic reduction [SCR]
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    • F01N2330/00—Structure of catalyst support or particle filter
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    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • F01N2510/00—Surface coverings
    • F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction
    • F01N2510/068—Surface coverings for exhaust purification, e.g. catalytic reaction characterised by the distribution of the catalytic coatings
    • F01N2510/0684—Surface coverings for exhaust purification, e.g. catalytic reaction characterised by the distribution of the catalytic coatings having more than one coating layer, e.g. multi-layered coatings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
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    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the present invention relates to a diesel oxidation catalyst composition
  • a diesel oxidation catalyst composition comprising a porous oxygen storage component impregnated with a palladium (Pd) component and at least one second component, methods for the preparation and use of such catalyst compositions, and catalyst articles and systems employing such catalyst compositions.
  • Pd palladium
  • Embodiment 8 An oxidation catalyst composite of any preceding or subsequent embodiment, wherein the first layer is an under layer coated on the carrier substrate, and the first layer is coated only on a zone of the carrier substrate.
  • Embodiment 12 An oxidation catalyst composite of any preceding or subsequent embodiment, wherein the palladium component impregnated in the first oxygen storage component is present in an amount in the range of about 1 g/fr to 200 g/fr.
  • Embodiment 14 An oxidation catalyst composite of any preceding or subsequent embodiment, wherein the second component comprises magnesium (Mg), and wherein magnesium is present in an amount in the range of about 0.1 to about 5 weight percent, based on the total weight of the impregnated first oxygen storage component.
  • Mg magnesium
  • Embodiment 16 An oxidation catalyst composite of any preceding or subsequent embodiment, wherein the second component comprises rhodium, and wherein the rhodium is present in an amount in the range of about 1 g/fr to about 200 g/fr.
  • Embodiment 20 An oxidation catalyst composite of any preceding or subsequent embodiment, wherein the first oxygen storage component is further impregnated with a metal selected from the group consisting of praseodymium (Pr), iron (Fe), yttrium (Y), lithium (Li), indium (In), tin (Sn), niobium (Nb), gallium (Ga), zirconium (Zr), iridium (Ir), silver (Ag), neodymium (Nd), tungsten (W), copper (Cu), zinc (Zn), molybdenum (Mo), cobalt (Co), and combinations thereof.
  • a metal selected from the group consisting of praseodymium (Pr), iron (Fe), yttrium (Y), lithium (Li), indium (In), tin (Sn), niobium (Nb), gallium (Ga), zirconium (Zr), iridium (Ir), silver (Ag), ne
  • Embodiment 35 A catalyst article of any preceding or subsequent embodiment, wherein the catalyst composition comprises a first layer and a second layer, wherein the first layer comprises the porous oxygen storage component impregnated with the palladium (Pd) component and the second component, wherein the second component comprises a magnesium (Mg) component, and wherein the second layer comprises a second porous oxygen storage component impregnated with a rhodium (Rh) component.
  • the catalyst composition comprises a first layer and a second layer, wherein the first layer comprises the porous oxygen storage component impregnated with the palladium (Pd) component and the second component, wherein the second component comprises a magnesium (Mg) component, and wherein the second layer comprises a second porous oxygen storage component impregnated with a rhodium (Rh) component.
  • Embodiment 36 A catalyst article of any preceding or subsequent embodiment, wherein Pd component is present in amount of about 1-10% by weight, based on the total weight of impregnated oxygen storage component.
  • Embodiment 37 A catalyst article of any preceding or subsequent embodiment, further comprising a metal impregnated within the oxygen storage component, the metal selected from the group consisting of praseodymium (Pr), iron (Fe), yttrium (Y), lithium (Li), indium (In), tin (Sn), niobium (Nb), gallium (Ga), zirconium (Zr), iridium (Ir), silver (Ag), neodymium (Nd), tungsten (W), copper (Cu), zinc (Zn), molybdenum (Mo), cobalt (Co), and combinations thereof.
  • the metal selected from the group consisting of praseodymium (Pr), iron (Fe), yttrium (Y), lithium (Li), indium (In), tin (Sn), niobium (Nb), gallium (Ga), zirconium (Zr), iridium (Ir), silver (Ag), neodymium
  • Embodiment 42 An emission treatment system of any preceding or subsequent embodiment, wherein the SCR catalyst comprises a molecular sieve having a double six ring (d6r) unit.
  • Embodiment 47 The method of any preceding or subsequent embodiment, wherein the SCR catalyst is disposed on a wall flow filter monolith.
  • FIG. IB is a partial cross-sectional view enlarged relative to FIG. 1A and taken along a plane parallel to the end faces of the carrier of FIG. 1 A, which shows an enlarged view of a plurality of the gas flow passages shown in FIG. 1A;
  • FIG. 5 is a graph illustrating CO light-off temperatures for diesel oxidation catalysts comprising ceria impregnated with 2 weight percent palladium (Pd) and 0.5 weight percent of different dopants;
  • FIG. 9 is a graph showing CO light-off temperatures for different loading levels of Mg in ceria.
  • FIG. 10 is a graph illustrating CO light-off temperatures for fresh samples of several catalysts of the present invention.
  • High surface area refractory oxide supports such as alumina support materials, also referred to as "gamma alumina” or “activated alumina,” typically exhibit a BET surface area in excess of 60 m 2 /g, often up to about 200 m 2 /g or higher.
  • gamma alumina alumina support materials
  • 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.
  • “BET surface area” has its usual meaning of referring to the Brunauer, Emmett, Teller method for determining surface area by N 2 adsorption.
  • the active alumina has a specific surface area of 60 to 350 m 2 /g, and typically 90 to 250 m 2 /g.
  • the DOC catalyst composition can comprise a dopant useful in lowering the light-off temperature of the catalyst composition and/or stabilizing the PGM component. It was surprisingly discovered that certain metals can be useful in lowering the CO and HC light-off temperatures of a catalyst composition, as compared to catalyst compositions that do not include the metal dopant component.
  • An exemplary calcination process involves heat treatment in air at a temperature of about 400-550°C for 1-3 hours. The above process can be repeated as needed to reach the desired level of impregnation. The resulting material can be stored as a dry powder or in slurry form.
  • the second component can comprise platinum.
  • the platinum can be present in an amount in the range of about 1 g/ft 3 to 200 g/ft 3 .
  • the weight ratio of palladium to platinum can be in the range of about 0: 10 to about 10:0 (e.g., 1 : 1, 2: 1, 4: 1, 1:2, 1:4, 1: 10 etc.), based on the total weight of the impregnated oxygen storage component.
  • the first layer can be an under layer situated on the carrier substrate and the second layer can be a zoned upper layer situated on at least a portion of the under layer.
  • the second layer can be situated on the outlet end of the carrier substrate and over the first layer which covers the entire carrier substrate as an under layer. As such, only the first layer would be present at the inlet end of the carrier substrate.
  • the second layer can be situated on the inlet end of the carrier substrate and over the first layer which covers the entire carrier substrate as an under layer. As such, only the first layer would be present at the outlet end of the carrier substrate.
  • the first and second layer can be oriented in any zone configuration as desired for the catalyst composite.
  • the substrate for the DOC composition may be constructed of any material typically used for preparing automotive catalysts and will typically comprise a metal or ceramic honeycomb structure.
  • the substrate typically provides a plurality of wall surfaces upon which the DOC washcoat composition is applied and adhered, thereby acting as a carrier for the catalyst composition.
  • the catalyst composition can be used in the form of a packed bed of powder, beads, or extruded granules. However, in certain advantageous embodiments, the catalyst composition is coated on a substrate.
  • the catalyst composition can be mixed with water (if in dried form) to form a slurry for purposes of coating a catalyst substrate.
  • the slurry may optionally contain alumina as a binder, associative thickeners, and/or surfactants (including anionic, cationic, non-ionic or amphoteric surfactants).
  • the pH of the slurry can be adjusted, e.g., to an acidic pH of about 3 to about 5.
  • the substrate is dipped one or more times in the slurry or otherwise coated with the slurry. Thereafter, the coated substrate is dried at an elevated temperature (e.g., 100-150°C) for a period of time (e.g., 1-3 hours) and then calcined by heating, e.g., at 400-600° C, typically for about 10 minutes to about 3 hours. Following drying and calcining, the final washcoat coating layer can be viewed as essentially solvent-free.
  • an elevated temperature e.g., 100-150°C
  • a period of time e.g., 1-3 hours
  • heating e.g., at 400-600° C, typically for about 10 minutes to about 3 hours.
  • the catalyst loading can be determined through calculation of the difference in coated and uncoated weights of the substrate. As will be apparent to those of skill in the art, the catalyst loading can be modified by altering the slurry rheology. In addition, the coating/drying/calcining process can be repeated as needed to build the coating to the desired loading level or thickness.
  • the Pd impregnated alumina powder is mixed with enough deionized water to form a slurry having a targeted solid content of 30 weight percent and the pH of the slurry is reduced to 4 to 4.5 by addition of nitric acid.
  • the slurry is then milled to a particle size with D 90 less than 15 ⁇ , using a ball mill.
  • the milled slurry is dried by stirring and calcined at 500°C for 1 hour in air.
  • Example 2 Preparation of ceria impregnated with Pd High surface area ceria support having a BET surface area of about 140 to 160 m 2 /g and a pore volume between 0.3 to 0.5 cc/g is provided.
  • the ceria is impregnated with a Pd nitrate solution, with a targeted Pd concentration of 2 weight percent, based on the total weight of the impregnated ceria support.
  • the ceria impregnated with Pd is then dried at 120°C for 1 hour.
  • the dried ceria/Pd mixture is then calcined for 1 hour at 500°C.
  • the calcined sample is cooled in air until it reaches room temperature.
  • the Pd impregnated ceria powder is mixed with enough deionized water to form a slurry having a targeted solid content of 30 weight percent and the pH of the slurry is reduced to 4 to 4.5 by addition of nitric acid.
  • the slurry is then milled to a particle size with D 90 less than 15 ⁇ using a ball mill.
  • the milled slurry is dried by stirring and calcined at 500°C for 1 hour in air.
  • the light-off temperatures of aged catalyst powders were also measured under the same parameters as for the fresh catalyst powders. Aging was done in air with 10% steam for 20 hours at 800°C.
  • a measured amount of Pd-Nitrate solution is diluted with an amount of deionized water suitable for incipient wetness impregnation, thereby forming a Pd/Di-H 2 0 solution.
  • the Pd/Di-H 2 0 solution is added dropwise to a measured amount of the calcined Ce/Mg mixture from step 1 while stirring.
  • the targeted Pd concentration is 2 weight percent, based on the total weight of the impregnated ceria.
  • the Pd impregnated Ce/Mg powder was then dried at 120°C for 4 hours.
  • the dried Pd/Mg/Ce mixture is then calcined for 1 hour at 500°C to form a catalyst composition.
  • a number of coated catalyst powders were prepared according to Example 4 above, the catalyst powders comprising ceria impregnated with 2 wt. % palladium and 0.5 wt. % of a dopant selected from the group consisting of magnesium (Mg), praseodymium (Pr), iron (Fe), yttrium (Y), lithium (Li), indium (In), tin (Sn), niobium (Nb), gallium (Ga), zirconium (Zr), iridium (Ir), silver (Ag), neodymium (Nd), tungsten (W), copper (Cu), zinc (Zn), rhodium (Rh), molybdenum (Mo), and cobalt (Co).
  • the catalyst mass was 100 mg per sample.
  • the light-off temperatures of fresh calcined catalytic powders were measured with a powder testing unit. Measurement time was a 3 minute equilibration time plus a 30 second sampling time. Measurements were taken at 125°C, 135°C, 150°C, 165°C, 180°C, 195°C, 210°C, 225°C, 250°C, 300°C, and 350°C.
  • the exhaust feed composition was 700 ppm CO, 80 ppm C 3 H 6 (Q basis), 340 ppm decane/toluene (2/1 ratio, on Ci basis), 70 ppm NO, 10% 0 2 , 10% C0 2 , and 5% H 2 0.
  • Fig. 5 illustrates the CO light-off temperatures for fresh, SO x aged, and regenerated catalyst powders comprising ceria impregnated with 2 wt. % Pd and 0.5 wt. % dopant.
  • fresh catalyst powders all samples showed lower CO light-off temperatures compared to reference N01 (no dopant), with the exception of the Li doped sample.
  • the Mg doped sample showed a good CO light-off temperature after SO x aging and it was the only catalyst that showed a lower light-off temperature after the lean regeneration at 600°C, as compared to the fresh N01 reference sample (before sulfur exposure).
  • Other promising dopants with improved CO light-off temperatures after SO x aging include Cu (N26), Zn (N27), Nb (N18), and Rh (N28).
  • Mg was incorporated into the ceria using the process described in Example 4 above.
  • the CO light-off temperatures of fresh, S-aged and regenerated catalyst samples were measured using the testing conditions described in Example 5 above.
  • Example 8 Comparison of Pd/ceria, Pd/(Mg + ceria), and (Pd + Mg)/ceria light-off temperatures
  • honeycomb substrates as used in commercial vehicles, were coated with various catalyst samples and tested. Three core samples were prepared. An incipient wetness impregnation procedure was used to prepare each sample as follows.
  • the Pd/Ce calcined powder is mixed well with deionized water to form a slurry having a solid content of about 30 weight percent.
  • the pH of the slurry is adjusted to about 4.5 to about 5.0 with HNO 3
  • the Pd/ Mg/Ce calcined powder is mixed well with deionized water to form a slurry having a solid content of about 30 weight percent.
  • the pH of the slurry is adjusted to about 4.5 to about 5.0 with HN(3 ⁇ 4 (concentrated HN(3 ⁇ 4 is diluted 1: 1 with deionized water).
  • the slurry is then milled to a particle size with D 90 less than 15 ⁇ using a ball mill.
  • Alumina binder is added to the slurry and mixed well.
  • a substrate is coated with the slurry.
  • a 1 inch diameter by 3 inch length core is cut from a ceramic substrate.
  • the substrate has 400 cells per square inch.
  • the entire ceramic core is submerged into the slurry until no air bubbles remain in the substrate channels.
  • the core is then removed from the slurry and shaken to remove excess slurry out of the core.
  • An air knife can be used to blow remaining excess slurry out of the channels until all are clear and the core is at the desired weight (determined by solids concentration of the slurry and H 2 0 adsorption by the substrate).
  • the core is then dried until no moisture remains.
  • the dried core is then calcined at 500°C for one hour. This coating process can be repeated as necessary to achieve the desired loading layer.
  • a substrate is coated with the slurry.
  • a 1 inch diameter by 3 inch length core is cut from a ceramic substrate.
  • the substrate has 400 cells per square inch.
  • the entire ceramic core is submerged into the slurry until no air bubbles remain in the substrate channels.
  • the core is then removed from the slurry and shaken to remove excess slurry out of the core.
  • An air knife can be used to blow remaining excess slurry out of the channels until all are clear and the core is at the desired weight (determined by solids concentration of the slurry and H 2 0 adsorption by the substrate).
  • the core is then dried until no moisture remains.
  • the dried core is then calcined at 500°C for one hour. This coating process can be repeated as necessary to achieve the desired loading layer.
  • FIG. 11 is a graph illustrating CO light-off temperatures for aged samples of catalysts A, B, and C.
  • Sample C mixing Pd and Mg first before impregnating the ceria, offered the best CO light-off performance after aging.
  • Example 9 Comparison of additional components useful for minimizing sulfur poisoning

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EP17812854.2A EP3471877A4 (en) 2016-06-17 2017-06-13 DIESEL OXIDATION CATALYST WITH PALLADIUM
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US16/310,327 US11248505B2 (en) 2016-06-17 2017-06-13 Palladium diesel oxidation catalyst
MX2018015865A MX2018015865A (es) 2016-06-17 2017-06-13 Catalizador de oxidacion diesel de paladio.
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MX2018015865A (es) 2019-04-22
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KR20190009421A (ko) 2019-01-28
CN109641196A (zh) 2019-04-16
RU2019100972A (ru) 2020-07-17
US20220127987A1 (en) 2022-04-28
JP6932149B2 (ja) 2021-09-08
US20190331013A1 (en) 2019-10-31
EP3471877A4 (en) 2020-07-29
KR102427507B1 (ko) 2022-08-01
US11982218B2 (en) 2024-05-14
BR112018076199A2 (pt) 2019-03-26
EP3471877A1 (en) 2019-04-24
CN109641196B (zh) 2022-04-05
US11248505B2 (en) 2022-02-15

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