Exhaust system without a DOC having an ASC acting as a DOC in a system with an SCR catalyst before the ASC

Patent metadata

Field	Value
Publication number	US-10589261-B2
Application number	US-201815947112-A
Country	US
Kind code	B2
Filing date	Apr 6, 2018
Priority date	Jun 18, 2015
Publication date	Mar 17, 2020
Grant date	Mar 17, 2020

Abstract

Catalyst articles having a first zone containing a first SCR catalyst and a second zone containing an ammonia slip catalyst (ASC), where the ammonia slip catalyst contains a second SCR catalyst and an oxidation catalyst, and the ASC has DOC functionality, where the first zone is located on the inlet side of the substrate and the second zone is located in the outlet side of the substrate are disclosed. The catalytic articles are useful for selective catalytic reduction (SCR) of NOx in exhaust gases, in reducing the amount of ammonia slip and in oxidizing organic residues. Exhaust systems containing the catalyst articles and methods of using the catalytic articles in an SCR process, where the amount of ammonia slip is reduced and hydrocarbon are oxidized by the ASC catalyst, are also described.

First claim

I claim:

1. An exhaust system comprising:
a. a catalyst article comprising a substrate comprising an inlet end and an outlet, a first zone comprising a first SCR catalyst and a second zone comprising an ammonia slip catalyst (ASC), wherein the ammonia slip catalyst comprises a second SCR catalyst and an oxidation catalyst, wherein the first zone is located on the inlet side of the substrate and the second zone is located in the outlet side of the substrate; and
b. a first means for forming NH 3 in the exhaust gas or introducing NH 3 into an exhaust stream, where the first means for forming NH 3 in the exhaust stream or introducing NH 3 into the exhaust stream is located before the catalytic article.

2. The exhaust system of claim 1 , further comprising a CSF or an SCRF, where the CSF or SCRF are positioned downstream of the catalyst article and, when the system comprises an SCRF, a second means for forming NH 3 in the exhaust stream or introducing NH 3 into the exhaust stream is located between the catalyst article and the SCRF.

3. The exhaust system of claim 2 , wherein the CSF comprises a high PGM loading in the front of the CSF.

4. The exhaust system of claim 1 , wherein the first zone and the second zone are located on the same substrate and the first zone is located on the inlet side of the substrate and the second zone is located on the outlet side of the substrate.

5. The exhaust system of claim 1 , further comprising a second substrate, where the first zone is located on a first substrate and the second zone is located on the second substrate and the first substrate is located upstream of the second substrate.

6. The exhaust system of claim 1 , wherein the ASC is a bi-layer with a bottom layer comprising the oxidation catalyst and a top, overlayer, comprising the second SCR catalyst.

7. The exhaust system of claim 1 , wherein the second zone comprises a blend of the oxidation catalyst and the second SCR catalyst.

8. The exhaust system of claim 1 , wherein the oxidation catalyst comprises a platinum group metal.

9. The exhaust system of claim 1 , wherein the oxidation catalyst comprises platinum or palladium or mixtures thereof.

10. The exhaust system of claim 1 , wherein the first SCR catalyst is a base metal, an oxide of a base metal, a molecular sieve, a metal exchanged molecular sieve or a mixture thereof.

11. The exhaust system of claim 1 , wherein the second SCR catalyst is a Cu-SCR catalyst, an Fe-SCR catalyst, a base metal, an oxide of a base metal or a mixed oxide or a vanadium catalyst.

12. The exhaust system of claim 1 , wherein the oxidation catalyst comprises platinum on a support with low ammonia storage.

13. The exhaust system of claim 12 , wherein the catalyst article provides an improvement in N 2 yield from ammonia at a temperature from about 250° C. to about 350° C. compared to a catalyst comprising a comparable formulation in which the first SCR catalyst is present as a first coating and the platinum on a support with low ammonia storage is present in a second coating and gas comprising NH 3 passes through the first coating before passing through the second coating.

14. The exhaust system of claim 12 , wherein the catalyst article provides at least one of:
(a) an improvement in N 2 yield from ammonia at a temperature from about 350° C. to about 450° C., and (b) a reduction in NOx formation at a temperature from about 350° C. to about 450° C., compared to a catalyst comprising a comparable formulation in which the first SCR catalyst is present as a first coating and the supported platinum is present in a second coating and gas comprising NH 3 passes through the first coating before passing through the second coating.

15. The exhaust system of claim 12 , wherein the catalyst article provides reduced N 2 O formation from NH 3 compared to a catalyst comprising a comparable formulation in which the first SCR catalyst is present as a first coating and the supported platinum is present in a second coating and gas comprising NH 3 passes through the first coating before passing through the second coating.

16. The exhaust system of claim 12 , wherein the catalyst article generates an exotherm.

17. A method of controlling NOx emissions in an exhaust gas, the method comprising contacting an exhaust gas comprising NOx or NH 3 with an exhaust system of claim 1 .

Assignees

• Johnson Matthey Plc

Inventors

• Larsson Mikael

Classifications

• B01D53/9436

  Ammonia · CPC title

• F01N3/2066

  Selective catalytic reduction [SCR] · CPC title

• B01J37/0244

  Coatings comprising several layers · CPC title

• F01N13/0097

  the purifying devices are arranged in a single housing · CPC title

• B01D53/9418 Primary

  for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas · CPC title