Co clean-up catalyst, after treatment system and after treatment method

Patent metadata

Field	Value
Publication number	US-11073057-B2
Application number	US-201916263537-A
Country	US
Kind code	B2
Filing date	Jan 31, 2019
Priority date	Jan 31, 2019
Publication date	Jul 27, 2021
Grant date	Jul 27, 2021

Abstract

An after treatment system is disclosed. The after treatment system may include a three-way catalyst (TWC), a selective catalytic reduction (SCR) catalyst, and a CO clean-up catalyst (CUC) on an exhaust pipe through which an exhaust gas flows. The CUC may include a zeolite in which Cu and Fe are ion-exchanged and CeO 2 in which Pt is supported, wherein a weight ratio of the CeO 2 to a total weight of the CUC is 30-70 wt % such that the CUC purifies NH 3 at a lean air/fuel ratio and purifies NH 3 during a delay time at a rich air/fuel ratio.

First claim

What is claimed is:

1. An after treatment system comprising:
an exhaust pipe through which an exhaust gas flows;
a three-way catalyst (TWC) mounted on the exhaust pipe, oxidizing HC and CO contained in the exhaust gas at a lean air/fuel ratio, and generating NH 3 using NOx contained in the exhaust gas at a rich air/fuel ratio;
a selective catalytic reduction (SCR) catalyst mounted on the exhaust pipe at a downstream of the TWC, storing the NH 3 generated in the TWC, and reducing the NOx contained in the exhaust gas using the stored NH 3 , and
a CO clean-up catalyst (CUC) mounted on the exhaust pipe at a downstream of the SCR catalyst, purifying the NH 3 contained in the exhaust gas at the lean air/fuel ratio, purifying the CO slipped from the TWC or contained in the exhaust gas at the rich air/fuel ratio, and purifying the NH 3 contained in the exhaust gas during a delay time at the rich air/fuel ratio,
further comprising an additional TWC or an ammonia production catalyst (APC) disposed between the TWC and the SCR catalyst,
wherein the additional TWC or the APC further generates NH 3 using the NOx contained in the exhaust gas at the rich air/fuel ratio,
wherein the APC includes 0.4-0.9 wt % of Pt, 0.057-0.3 wt % of Pd, 0.03-0.1 wt % of Rh, 5.0-15.0 wt % of Ba, 10-30 wt % of CeO2, 48.7-84.513 wt % of a composite of MgO and Al2O3, and 0-5 wt % of an additive based on a total weight of the APC.

2. The after treatment system of claim 1 , further comprising a particulate filter disposed between the TWC and the SCR catalyst,
wherein the particulate filter traps particulate matter in the exhaust gas.

3. An after treatment system comprising:
an exhaust pipe through which an exhaust gas flows;
a three-way catalyst (TWC) mounted on the exhaust pipe, oxidizing HC and CO contained in the exhaust gas at a lean air/fuel ratio, and generating NH 3 using NOx contained in the exhaust gas at a rich air/fuel ratio;
a selective catalytic reduction (SCR) catalyst mounted on the exhaust pipe at a downstream of the TWC, storing the NH 3 generated in the TWC, and reducing the NOx contained in the exhaust gas using the stored NH 3 ; and
a CO clean-up catalyst (CUC) mounted on the exhaust pipe at a downstream of the SCR catalyst, purifying the NH 3 contained in the exhaust gas at the lean air/fuel ratio, purifying the CO slipped from the TWC or contained in the exhaust gas at the rich air/fuel ratio, and purifying the NH 3 contained in the exhaust gas during a delay time at the rich air/fuel ratio,
further comprising an additional TWC or an ammonia production catalyst (APC) disposed between the TWC and the SCR catalyst,
wherein the additional TWC or the APC further generates NH 3 using the NOx contained in the exhaust gas at the rich air/fuel ratio,
wherein the APC includes 0.4-0.9 wt % of Pt, 0.057-0.3 wt % of Pd, 0.03-0.1 wt % of Rh, 5.0-15.0 wt % of Ba, 10-25 wt % of CeO2, 48.7-79.513 wt % of a composite of MgO and Al 2 O 3 , and 0-10 wt % of an additive based on a total weight of the APC.

4. The after treatment system of claim 3 , wherein a lean NOx trap (LNT) catalyst is further coated in the TWC or the additional TWC, and
wherein the LNT catalyst absorbs the NOx contained in the exhaust gas at the lean air/fuel ratio, and releases and reduces the absorbed NOx into N2 gas or the NH 3 at the rich air/fuel ratio.

5. An after treatment system comprising:
an exhaust pipe through which an exhaust gas flows;
a three-way catalyst (TWC) mounted on the exhaust pipe, oxidizing HC and CO contained in the exhaust gas at a lean air/fuel ratio, and generating NH 3 using NOx contained in the exhaust gas at a rich air/fuel ratio;
a selective catalytic reduction (SCR) catalyst mounted on the exhaust pipe at a downstream of the TWC, storing the NH 3 generated in the TWC, and reducing the NOx contained in the exhaust gas using the stored NH 3 ;
and a CO clean-up catalyst (CUC) mounted on the exhaust pipe at a downstream of the SCR catalyst, purifying the NH 3 contained in the exhaust gas at the lean air/fuel ratio, purifying the CO slipped from the TWC or contained in the exhaust gas at the rich air/fuel ratio, and purifying the NH 3 contained in the exhaust gas during a delay time at the rich air/fuel ratio, wherein the CUC comprises a zeolite in which Cu and Fe are ion-exchanged and CeO2 in which Pt is supported, and
wherein a weight ratio of the CeO2 to a total weight of the CUC is 30-70 wt %.

6. The after treatment system of claim 5 , wherein the CUC comprises 0.04-0.4 wt % of the Pt, 0.2-1 wt % of the Cu, 0.2-1 wt % of the Fe, 20-50 wt % of the zeolite, 30-70 wt % of the CeO2, and 0-20 wt % of an additive based on the total weight of the CUC.

7. The after treatment system of claim 6 , wherein the additive comprises at least one of La, Zr, Mg, and Pr.

8. The after treatment system of claim 5 , wherein the CUC is formed by uniformly mixing the zeolite in which the Cu and the Fe are ion-exchanged and the CeO2 in which the Pt is supported.

9. The after treatment system of claim 5 , wherein the zeolite in which the Cu and the Fe are ion-exchanged is disposed at a front end portion of the CUC and the CeO2 in which the Pt is supported is disposed at a rear end portion of the CUC in a direction to which the exhaust gas flows.

10. The after treatment system of claim 5 , wherein the CUC is formed by stacking up the zeolite in which the Cu and the Fe are ion-exchanged and the CeO2 in which the Pt is supported in a vertical direction to which the exhaust gas flows.

Assignees

• Hyundai Motor Co Ltd
• Kia Motors Corp

Inventors

• Joo Nahm Roh
• Kim Chang Hwan
• Jung Changho

Classifications

• F01N2430/06

  by varying fuel-air ratio, e.g. by enriching fuel-air mixture · CPC title

• F01N3/2066

  Selective catalytic reduction [SCR] · CPC title

• F01N3/101

  Three-way catalysts · CPC title

• B01J29/072 Primary

  Iron group metals or copper · CPC title

• B01J23/42

  Platinum · CPC title