SCR catalyst and exhaust gas cleaning system

Patent metadata

Field	Value
Publication number	US-10898889-B2
Application number	US-201815877691-A
Country	US
Kind code	B2
Filing date	Jan 23, 2018
Priority date	Jan 23, 2018
Publication date	Jan 26, 2021
Grant date	Jan 26, 2021

Abstract

The present invention relates to a SCR catalyst comprising a carrier substrate of the length L, which is a flow-through substrate, and a coating A which comprises a small pore zeolite, copper and palladium.

First claim

The invention claimed is:

1. SCR catalyst comprising
a carrier substrate of the length L, which is a flow-through substrate, and
a coating A which comprises a small pore zeolite, copper, and palladium, and wherein coating A comprises palladium in an amount of 0.003 to 0.1% by weight based on the weight of the small pore zeolite and calculated as palladium metal,
wherein coating A extends only to a part of the length L. and
a coating B which comprises a small-pore zeolite and copper but is free from palladium, and
wherein coating A extends starting from one end of the carrier substrate to 10 to 80% of the length L. and coating B extends starting from the other end of the carrier substrate to 20 to 90% of the length L,
and wherein L is L A +L B wherein La is the length of coating A and L B is the length of coating B.

2. SCR catalyst according to claim 1 , wherein the small pore zeolite belongs to a framework type having the framework type code AEI, AFX, CHA, ERI, KFI or LEV.

3. SCR catalyst according to claim 1 , wherein coating A comprises copper in an amount of 1 to 20% by weight based on the weight of the small pore zeolite and calculated as CuO.

4. SCR catalyst according to claim 1 , wherein coating A comprises palladium in an amount of 0.04 to 0.1% by weight based on the weight of the small pore zeolite and calculated as palladium metal.

5. SCR catalyst according to claim 1 , wherein coating A comprises cerium or cerium/zirconium mixed oxide in an amount of 10 to 80 g/L, respectively, based on the volume of the carrier substrate.

6. SCR catalyst according to claim 1 , wherein coating A is present in an amount of 50 to 300 g/L, based on the volume of the carrier substrate.

7. SCR catalyst according to claim 1 , wherein coating A comprises palladium in an amount of 0.06 to 0.08 wt % by weight based on the weight of the small pore zeolite and calculated as palladium metal.

8. SCR catalyst according to claim 1 , wherein the small pore zeolite is SSZ-13.

9. SCR catalyst according to claim 1 , wherein coating A comprises copper in an amount of 2 to 6% by weight based on the weight of the small pore zeolite and calculated as CuO.

10. SCR catalyst according to claim 1 , wherein coating A and B only differ in the absence of palladium in coating B.

11. SCR catalyst according to claim 4 , wherein the small pore zeolite belongs to a framework type having the framework type code AEI, AFX, CHA, ERI, KFI or LEV and has a SAR value of 5 to 50.

12. System comprising a SCR catalyst comprising
a carrier substrate of the length L, which is a flow-through substrate, and
a coating A which comprises a small pore zeolite, copper, and palladium in an amount of 0.003 to 0.1% by weight based on the weight of the small pore zeolite and calculated as palladium metal;
wherein coating A extends only to a part of the length L, and
a coating B which comprises a small-pore zeolite and copper but is free from palladium, and
wherein coating A extends starting from one end of the carrier substrate to 10 to 80% of the length L, and coating B extends starting from the other end of the carrier substrate to 20 to 90% of the length L,

and wherein L is L A +L B wherein La is the length of coating A and L B is the length of coating B, and wherein coating A is arranged upstream and coating B is arranged downstream; and a dosing unit for reductant supply to the SCR catalyst.

13. Exhaust gas cleaning system comprising in the following order
a first dosing unit for reductant,
a first SCR catalyst comprising,
a carrier substrate of the length L, which is a flow-through substrate, and
a coating A which comprises a small pore zeolite, copper, and palladium in an amount of 0.003 to 0.1% by weight based on the weight of the small pore zeolite and calculated as palladium metal,
wherein coating A extends only to a part of the length L, and
a coating B which comprises a small-pore zeolite and copper but is free from palladium, and
wherein coating A extends starting from one end of the carrier substrate to 10 to 80% of the length L, and coating B extends starting from the other end of the carrier substrate to 20 to 90% of the length L.
and wherein L is L A +L B wherein La is the length of coating A and L B is the length of coating B,
and wherein coating A is arranged upstream and coating B is arranged downstream,
a second dosing unit for reductant and a second SCR catalyst.

14. Exhaust gas cleaning system according to claim 13 , further comprising a combined oxidation catalyst and particulate filter which combination forms a catalyzed particulate filter (cDPF) that is positioned between the first SCR catalyst and the second dosing unit.

15. Exhaust gas cleaning system according to claim 13 , further comprising an oxidation catalyst upstream of the second dosing unit and wherein the second SCR catalyst is in the form of an SDPF.

16. Process for cleaning exhaust gas emitted from a lean burn engine and containing nitrogen oxides, which process comprises passing the exhaust gas stream through an exhaust gas cleaning system comprising in the following order
a first dosing unit for reductant,
the SCR catalyst of claim 1 as a first SCR catalyst,
an oxidation catalyst,
a particulate filter,
a second dosing unit for reductant and
a second SCR catalyst.
wherein the first dosing unit for reductant and the first SCR catalyst are arranged close coupled and wherein the oxidation catalyst, the particulate filter, the second dosing unit for reductant and the second SCR catalyst are arranged underfloor and
wherein the exhaust gas enters the exhaust gas cleaning system before the first dosing unit for reductant and leaves it after the second SCR catalyst.

17. Exhaust gas cleaning system comprising in the following order
a first dosing unit for reductant,
a first SCR catalyst according to claim 1
an oxidation catalyst,
a particulate filter,
a second dosing unit for reductant and
a second SCR catalyst.

18. System according to claim 17 , wherein coating A comprises copper in an amount of 2 to 6% by weight based on the weight of the small pore zeolite and calculated as CuO, and the palladium is in an amount of 0.04 to 0.1%.

19. SCR catalyst comprising
a carrier substrate of the length L, which is a flow-through substrate, and a coating A which comprises a small pore zeolite, copper and palladium, and wherein coating A comprises palladium in an amount of 0.003 to 0.1% by weight based on the weight of the small pore zeolite and calculated as palladium metal, wherein the carrier substrate comprises catalytically active coating B which comprises a small pore zeolite and copper and is free of palladium, and SCR, wherein coating A and coating B are the same but for coating B being free of palladium.

Assignees

• Umicore Ag & Co Kg

Inventors

• Price Kenneth Sherwood
• Schuler Anke
• Seyler Michael
• Schütze Frank-Walter
• Pfeifer Marcus

Classifications

• Y02T10/12

  Improving ICE efficiencies · CPC title

• B01D2251/2067

  Urea · CPC title

• B01D2279/30

  for treatment of exhaust gases from IC Engines · CPC title

• F01N3/035

  with catalytic reactors · CPC title

• B01D2255/1023

  Palladium · CPC title