Combined soot filter and urea hydrolysis

Patent metadata

Field	Value
Publication number	US-11033858-B2
Application number	US-201816622921-A
Country	US
Kind code	B2
Filing date	Jun 14, 2018
Priority date	Jun 16, 2017
Publication date	Jun 15, 2021
Grant date	Jun 15, 2021

Abstract

A monolith filter unit for exhaust gas cleaning combines urea hydrolysis with particle filtering.

First claim

The invention claimed is:

1. A catalyst impregnated exhaust gas particulate filter unit for vehicle exhaust gas, the unit comprises
at least one monolith comprising a plurality of channels open at one end and closed at the other end,
a first open end, and
a second open end,
wherein the at least one monolith is divided in two sections, a first section which is not coated or which is coated with a first type of catalyst and a second section which is coated with a second type of catalyst, and
wherein the filter unit has a cylindrical shape and the first section has the shape of a sector or segment of a circle when seen in a cross sectional view of the filter unit.

2. The catalyst impregnated exhaust gas particulate filter unit according to claim 1 , wherein the first type of catalyst is a urea hydrolysis catalyst.

3. The catalyst impregnated exhaust gas particulate filter unit according to claim 2 , wherein the urea hydrolysis catalyst is at least one of ZrO 2 , TiO 2 , Al 2 O 3 , H-ZSM-5, or SiO 2 .

4. The catalyst impregnated exhaust gas particulate filter unit according to claim 1 , wherein the second type of catalyst is a diesel oxidation catalyst.

5. The catalyst impregnated exhaust gas particulate filter unit according to claim 4 , wherein the diesel oxidation catalyst is at least one of Pt/Al 2 O 3 ; (Pt, Pd)/Al 2 O 3 ; Pt/TiO 2 ; or (Pt, Pd)/TiO 2 in an amount of 0-50 g/ft 3 precious metals.

6. A catalyst impregnated exhaust gas particulate filter unit for vehicle exhaust gas, the unit comprises
at least one monolith comprising a plurality of channels open at one end and closed at the other end,
a first open end, and
a second open end,
wherein the at least one monolith is divided in two sections, a first section which is not coated or which is coated with a first type of catalyst and a second section which is coated with a second type of catalyst, and
wherein the unit further comprises a flow guide upstream the first section adapted to guide a part of the exhaust gas stream only to the first section and isolate this part of the exhaust gas stream from the rest of the exhaust gas stream.

7. The catalyst impregnated exhaust gas particulate filter unit according to claim 6 , wherein the first type of catalyst is a urea hydrolysis catalyst.

8. The catalyst impregnated exhaust gas particulate filter unit according to claim 7 , wherein the urea hydrolysis catalyst is at least one of ZrO 2 , TiO 2 , Al 2 O 3 , H-ZSM-5, or SiO 2 .

9. The catalyst impregnated exhaust gas particulate filter unit according to claim 6 , wherein the second type of catalyst is a diesel oxidation catalyst.

10. The catalyst impregnated exhaust gas particulate filter unit according to claim 9 , wherein the diesel oxidation catalyst is at least one of Pt/Al 2 O 3 ; (Pt, Pd)/Al 2 O 3 ; Pt/TiO 2 ; or (Pt, Pd)/TiO 2 in an amount of 0-50 g/ft 3 precious metals.

11. The catalyst impregnated exhaust gas particulate filter unit according to claim 6 , wherein the first section has the shape of a circle or a sector or segment thereof when seen in a cross sectional view of the filter unit.

12. A catalyst impregnated exhaust gas particulate filter unit for vehicle exhaust gas, the unit comprises
at least one monolith comprising a plurality of channels open at one end and closed at the other end,
a first open end, and
a second open end,
wherein the at least one monolith is divided in two sections, a first section which is not coated or which is coated with a first type of catalyst and a second section which is coated with a second type of catalyst, and
wherein the filter unit further comprises a mixer arranged downstream the first and second section adapted to mix the exhaust gas stream from the first section with the exhaust gas stream from the second section.

13. The catalyst impregnated exhaust gas particulate filter unit according to claim 12 , wherein the first type of catalyst is a urea hydrolysis catalyst.

14. The catalyst impregnated exhaust gas particulate filter unit according to claim 13 , wherein the urea hydrolysis catalyst is at least one of ZrO 2 , TiO 2 , Al 2 O 3 , H-ZSM-5, or SiO 2 .

15. The catalyst impregnated exhaust gas particulate filter unit according to claim 12 , wherein the second type of catalyst is a diesel oxidation catalyst.

16. The catalyst impregnated exhaust gas particulate filter unit according to claim 15 , wherein the diesel oxidation catalyst is at least one of Pt/Al 2 O 3 ; (Pt, Pd)/Al 2 O 3 ; Pt/TiO 2 ; or (Pt, Pd)/TiO 2 in an amount of 0-50 g/ft 3 precious metals.

17. The catalyst impregnated exhaust gas particulate filter unit according to claim 12 , wherein the first section has the shape of a circle or a sector or segment thereof when seen in a cross sectional view of the filter unit.

18. A process for vehicle exhaust gas cleaning comprising the steps of
providing a catalyst impregnated exhaust gas particulate filter unit for vehicle exhaust gas comprising at least one monolith comprising a plurality of channels open at one end and closed at the other end, a first open end, a second open end, at least one wall adapted to fit around said at least one monolith, wherein the at least one monolith is divided in two sections, a first section which is not coated or which is coated with a first type of catalyst and a second section which is coated with a second type of catalyst,
providing a vehicle exhaust gas upstream the first open end of the unit,
injecting urea into a partial stream of the vehicle exhaust gas, upstream the first section of the at least one monolith, and
providing a fluid guide upstream the first section of the at least one monolith for the partial stream, adapted to guide the partial stream to the first section of the at least one monolith.

19. The process according to claim 18 , further including the step of providing an SCR unit downstream the filter unit.

20. A process for vehicle exhaust gas cleaning comprising the steps of
providing a catalyst impregnated exhaust gas particulate filter unit for vehicle exhaust gas comprising at least one monolith comprising a plurality of channels open at one end and closed at the other end, a first open end, a second open end, at least one wall adapted to fit around said at least one monolith, wherein the at least one monolith is divided in two sections, a first section which is not coated or which is coated with a first type of catalyst and a second section which is coated with a second type of catalyst,
providing a vehicle exhaust gas upstream the first open end of the unit,
injecting urea into a partial stream of the vehicle exhaust gas, upstream the first section of the at least one monolith, and
providing a mixer downstream the filter unit and mixing the flow of fluids comprising NO 2 and NH 3 exiting the first and the second section of the filter unit.

21. The process according to claim 20 , further including the step of providing an SCR unit downstream the filter unit.

Assignees

• Umicore Ag & Co Kg

Inventors

• Gabrielsson Paer

Classifications

• B01J35/56

  Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths · CPC title

• B01D2255/915

  Catalyst supported on particulate filters · CPC title

• F01N3/2803

  characterised by structure, by material or by manufacturing of catalyst support · CPC title

• B01J21/04

  Alumina · CPC title

• F01N2610/02

  the substance being ammonia or urea · CPC title