Catalytic composites comprising Nb2O5/CeO2 SCR component

Patent metadata

Field	Value
Publication number	US-11167273-B2
Application number	US-201816652875-A
Country	US
Kind code	B2
Filing date	Oct 2, 2018
Priority date	Oct 3, 2017
Publication date	Nov 9, 2021
Grant date	Nov 9, 2021

Abstract

The present disclosure provides SCR catalyst compositions, catalyst articles, and catalyst systems, as well as methods of reducing the amount of NOx present in an engine exhaust gas, particularly exhaust from a gasoline engine. The catalyst compositions particularly can comprise a doped ceria substrate, particularly a ceria support doped with at least a niobia component, and optionally further doped with a further material, particularly a base metal oxide (BMO).

First claim

The invention claimed is:

1. An SCR catalyst composition, comprising a ceria support comprising a first dopant that is niobia and a second dopant that is a base metal oxide, wherein the composition is non-zeolitic.

2. The SCR catalyst composition of claim 1 , wherein the base metal oxide is chosen from lanthanum oxide, praseodymium oxide, neodymium oxide, yttrium oxide, titanium dioxide, tungsten oxide, iron oxide, copper oxide, manganese oxide, nickel oxide, magnesium oxide, barium oxide, and combinations thereof.

3. The SCR catalyst composition of claim 2 , wherein the base metal oxide is chosen from lanthanum oxide, praseodymium oxide, neodymium oxide, yttrium oxide, tungsten oxide, and combinations thereof.

4. The SCR catalyst composition of claim 1 , wherein the niobia constitutes about 0.1 to about 20% by weight of the SCR catalyst composition.

5. The SCR catalyst composition of claim 1 , wherein the second dopant constitutes about 0.1 to about 20% by weight of the SCR catalyst composition.

6. The SCR catalyst composition of claim 1 , wherein the ceria support comprises at least 99% by weight ceria.

7. The SCR catalyst composition of claim 1 , wherein the ceria support comprises about 10% to about 95% by weight ceria and about 5% to about 90% by weight of a further metal oxide, optionally wherein the further metal oxide is aluminum oxide.

8. A catalyst article, comprising a catalyst substrate having a plurality of channels adapted for gas flow, each channel having a wall surface in adherence to a catalytic coating comprising the catalyst composition of claim 1 .

9. The catalyst article of claim 8 , wherein the catalyst substrate is a honeycomb comprising a wall flow filter substrate or a flow through substrate.

10. The catalyst article of claim 8 , wherein the catalytic coating is present on the catalyst substrate with a loading of at least about 1.0 g/in 3 .

11. The catalyst article of claim 8 , further comprising a platinum group metal.

12. An emission treatment system for treatment of an exhaust gas stream, the emission treatment system comprising:
i. an engine which produces an exhaust gas stream;
ii. a three-way catalyst positioned downstream from the engine and in fluid communication with the exhaust gas stream; and
iii. an SCR catalyst article positioned downstream from the three-way catalyst and in fluid communication with the exhaust gas stream, the SCR catalyst article comprising a catalyst substrate having a plurality of channels adapted for gas flow, each channel having a wall surface in adherence to a catalytic coating comprising a ceria support doped with niobia, and wherein the catalyst article is non-zeolitic.

13. The emission treatment system of claim 12 , wherein the SCR catalyst article is substantially free of platinum group metal.

14. The emission treatment system of claim 12 , wherein the SCR catalyst article comprises a platinum group metal.

15. The emission treatment system of claim 14 , wherein the platinum group metal is present on the catalyst substrate with a loading of at least about 0.5 g/ft 3 .

16. The emission treatment system of claim 14 , wherein the platinum group metal is present on the catalyst substrate with a loading of about 0.5 g/ft3 to about 20 g/ft 3 .

17. The emission treatment system of claim 12 , wherein the catalytic coating further comprises boehmite.

18. The emission treatment system of claim 12 , wherein the ceria support of the catalytic coating of the SCR catalyst article comprises at least 99% by weight ceria.

19. The emission treatment system of claim 12 , wherein the ceria support of the catalytic coating of the SCR catalyst article comprises about 10% to about 95% by weight ceria and about 5% to about 90% by weight of a further metal oxide.

20. The emission treatment system of claim 19 , wherein the further metal oxide is aluminum oxide.

21. The emission treatment system of claim 12 , wherein the catalytic coating of the SCR catalyst article comprises a further dopant that is a base metal oxide.

22. The emission treatment system of claim 21 , wherein the base metal oxide is chosen from lanthanum oxide, praseodymium oxide, neodymium oxide, yttrium oxide, titanium dioxide, tungsten oxide, iron oxide, copper oxide, manganese oxide, nickel oxide, magnesium oxide, barium oxide, and combinations thereof.

23. The emission treatment system of claim 22 , wherein the base metal oxide is chosen from lanthanum oxide, praseodymium oxide, neodymium oxide, yttrium oxide, tungsten oxide, and combinations thereof.

24. The emission treatment system of claim 12 , wherein the catalytic coating comprising the ceria support doped with niobia is in a first coating layer, and wherein the catalyst substrate of the SCR catalyst article comprises a second catalytic coating layer.

25. The emission treatment system of claim 24 , wherein the second catalytic coating layer comprises a base metal oxide.

26. The emission treatment system of claim 24 , wherein the second catalytic coating layer comprises a platinum group metal.

27. The emission treatment system of claim 26 , wherein the platinum group metal is present on the catalyst substrate with a loading of at least about 0.5 g/ft 3 .

28. The emission treatment system of claim 26 , wherein the platinum group metal is present on the catalyst substrate with a loading of about 0.5 g/ft 3 to about 20 g/ft 3 .

29. The emission treatment system of claim 24 , wherein the first coating layer is a top layer.

30. The emission treatment system of claim 24 , wherein the first coating layer is a bottom layer.

31. An SCR catalyst composition, comprising
a ceria support comprising a first dopant that is niobia and, optionally, a second dopant that is a base metal oxide,
wherein the ceria support comprises about 10% to about 95% by weight ceria and about 5% to about 90% by weight of a further metal oxide, and wherein the composition is non-zeolitic.

32. The SCR catalyst composition of claim 31 , wherein the further metal oxide is aluminum oxide.

Assignees

• Basf Corp

Inventors

• Zheng Xiaolai
• Burk Patrick

Classifications

• Y02T10/12

  Improving ICE efficiencies · CPC title

• Y02A50/20

  Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters · CPC title

• B01J35/56

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

• F01N3/101

  Three-way catalysts · CPC title

• F01N3/2066

  Selective catalytic reduction [SCR] · CPC title