Scr catalyst article and systems for reducing n2o in exhaust gas

Patent metadata

Field	Value
Publication number	US-2024269611-A1
Application number	US-202418437280-A
Country	US
Kind code	A1
Filing date	Feb 9, 2024
Priority date	Feb 10, 2023
Publication date	Aug 15, 2024
Grant date	—

Abstract

Provided is an SCR catalyst article comprising a substrate having thereon a second catalyst composition downstream of a first catalyst composition, wherein the first and second catalyst compositions are different and wherein the first catalyst composition is an SCR catalyst composition and the second catalyst composition comprises an Fe-loaded small- or medium-pore molecular sieve, the small- or medium-pore molecular sieve having a silica-to-alumina ratio (SAR) of from 6 to 19.

First claim

1 . An exhaust gas treatment system comprising a first catalyst article comprising a first catalyst composition and a second catalyst article downstream of the first catalyst article comprising a second catalyst composition, wherein the first and second catalyst compositions are different and wherein the first catalyst composition is an SCR catalyst composition and the second catalyst composition comprises an Fe-loaded small- or medium-pore molecular sieve, the small- or medium-pore molecular sieve having a silica-to-alumina ratio (SAR) of from 6 to 19.

2 . An SCR catalyst article comprising a substrate having thereon a second catalyst composition downstream of a first catalyst composition, wherein the first and second catalyst compositions are different and wherein the first catalyst composition is an SCR catalyst composition and the second catalyst composition comprises an Fe-loaded small- or medium-pore molecular sieve, the small- or medium-pore molecular sieve having a silica-to-alumina ratio (SAR) of from 6 to 19.

3 . The system of claim 1 , wherein the first catalyst composition comprises Cu/CHA or a V-based SCR catalyst.

4 . The system of claim 1 , wherein the small- or medium-pore molecular sieve of the second catalyst composition has a framework defined by a Framework Type Code selected from CHA, FER, MFI, AEI and AEI-CHA intergrowth.

5 . The system of claim 1 , wherein the small- or medium-pore molecular sieve of the second catalyst composition has a SAR of from 6 to 13.

6 . The system of claim 1 , wherein the small- or medium-pore molecular sieve of the second catalyst composition is loaded with at least 0.5 wt. % Fe, based on the total weight of the Fe-loaded small- or medium-pore molecular sieve.

7 . The SCR catalyst article of claim 2 , wherein the SCR catalyst article is a flow-through monolith or a wall-flow filter.

8 . The SCR catalyst article of claim 2 , wherein the first catalyst composition is present in a first zone and the second catalyst composition is present in a second zone, and wherein the first zone forms from 40 to 90% of an axial length of the SCR catalyst article and the second zone forms from 60 to 10% of an axial length of the SCR catalyst article.

9 . The catalyst article of claim 2 , wherein the first catalyst composition is present in a first zone and the second catalyst composition is present in a second zone, and wherein the first zone extends from an inlet end of the SCR catalyst article and the second zone extends from an outlet end of the SCR catalyst article.

10 . The system of claim 1 , further comprising an ammonia slip catalyst (ASC) article located between the first catalyst article and the second catalyst article.

11 . The system of claim 1 , wherein the system is configured to permit injection of a nitrogenous reductant upstream of the second catalyst composition, and optionally upstream of the first catalyst composition.

12 . A fuel combustion and exhaust gas system comprising an engine and the system of claim 1 .

13 . A method of treating an exhaust gas, the method comprising passing an exhaust gas through the exhaust gas treatment system of claim 1 .

14 . The system of claim 11 , wherein the nitrogenous reductant is ammonia, urea, or both.

15 . The system of claim 12 , wherein the engine is a diesel-, hydrogen-, methanol- or nitrogen-containing-fuel-combustion engine.

16 . The method of claim 13 , wherein the engine is a diesel-, hydrogen-, methanol- or nitrogen-containing-fuel-combustion engine.

17 . The SCR catalyst article of claim 2 , wherein the first catalyst composition comprises Cu/CHA or a V-based SCR catalyst.

18 . The SCR catalyst article of claim 2 , wherein the small- or medium-pore molecular sieve of the second catalyst composition has a framework defined by a Framework Type Code selected from CHA, FER, MFI, AEI and AEI-CHA intergrowth.

19 . The SCR catalyst article of claim 2 wherein the small- or medium-pore molecular sieve of the second catalyst composition has a SAR of from 6 to 13.

20 . The SCR catalyst article of claim 2 , wherein the small- or medium-pore molecular sieve of the second catalyst composition is loaded with at least 0.5 wt. % Fe, based on the total weight of the Fe-loaded small- or medium-pore molecular sieve.

Assignees

• Johnson Matthey Plc

Inventors

• Alcove Clave Silvia
• Collier Jillian
• Georgieva Veselina Mihaylova
• Green Alexander Nicholas Michael
• Mantarosie Loredana
• Ruggeri Maria Pia
• Villamaina Roberta

Classifications

• Y02T10/12

  Improving ICE efficiencies · CPC title

• F01N2610/02

  the substance being ammonia or urea · CPC title

• F01N2370/04

  Zeolitic material · CPC title

• F01N3/2803

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

• F01N3/2066

  Selective catalytic reduction [SCR] · CPC title