Catalytic filter having a soot catalyst and an SCR catalyst

Patent metadata

Field	Value
Publication number	US-9849421-B2
Application number	US-201615279511-A
Country	US
Kind code	B2
Filing date	Sep 29, 2016
Priority date	Sep 29, 2015
Publication date	Dec 26, 2017
Grant date	Dec 26, 2017

Abstract

A catalytic filter is provided having a mixture of an SCR catalyst and soot oxidation catalyst where the soot oxidation catalyst is a copper doped ceria, iron doped ceria or manganese doped ceria. The mixture of an SCR catalyst and soot oxidation catalyst provides for a lowering of the peak oxidation temperature for soot removal from the filter. The use of the filter allows for improved soot combustion and reduces the susceptibility of an SCR catalyst contained on a filter to deterioration. The soot oxidation catalyst also improves the resistance of the SCR catalyst to poisoning and subsequent deterioration of SCR performance.

First claim

The invention claimed is:

1. A composition comprising a mixture of an SCR catalyst and a soot catalyst comprising copper doped ceria, iron doped ceria or manganese doped ceria, wherein the composition is formulated for application to a filter.

2. The composition of claim 1 , wherein the copper doped ceria, iron doped ceria or manganese doped ceria is doped with: (a) zirconia, (b) zirconia and praseodymium, (c) zirconia and neodymium, or (d) zirconia, praseodymium and neodymium.

3. The composition of claim 1 , wherein the soot catalyst and the SCR catalyst are present in an amount having a weight ratio of soot catalyst:SCR catalyst of 5:95 to 95:5.

4. The composition of claim 1 , wherein copper or manganese is present at from 0.5 to 15% by weight relative to the weight of ceria, or iron is present at from 0.5 to 10% by weight relative to the weight of ceria.

5. The composition of claim 1 , wherein the composition further comprises one or more additional metal oxides.

6. The composition of claim 5 , where the one or more additional metal oxides comprises an oxide of zirconium, praseodymium or neodymium, or combinations of two or more of the oxides.

7. The composition of claim 1 , wherein the soot catalyst and the SCR catalyst are present in an amount having a weight ratio of soot catalyst:SCR catalyst of 5:95 to 50:50.

8. The composition of claim 1 , wherein the soot catalyst and the SCR catalyst are present in an amount having a weight ratio of soot catalyst:SCR catalyst of 10:90 to 30:70.

9. A filter comprising an SCR catalyst and a soot catalyst comprising copper doped ceria, iron doped ceria or manganese doped ceria, where the SCR catalyst and the soot catalyst are present on the filter as a mixture.

10. The filter of claim 9 , wherein the copper doped ceria, iron doped ceria or manganese doped ceria is doped with: (a) zirconia, (b) zirconia and praseodymium, (c) zirconia and neodymium, or (d) zirconia, praseodymium and neodymium.

11. The filter of claim 9 , wherein the soot catalyst and the SCR catalyst are present in an amount having a weight ratio of soot catalyst:SCR catalyst of 5:95 to 95:5.

12. The filter of claim 9 , wherein copper or manganese is present at from 0.5 to 15% by weight relative to the weight of ceria, or iron is present at from 0.5 to 10% by weight relative to the weight of ceria.

13. The filter of claim 9 , wherein the filter further comprises one or more additional metal oxides.

14. The filter of claim 13 , where the one or more additional metal oxides comprises an oxide of zirconium, praseodymium or neodymium, or combinations of two or more of the oxides.

15. The filter of claim 9 , wherein the amount of SCR catalyst in the filter is reduced compared to a similar filter without copper doped ceria, iron doped ceria or manganese doped ceria.

16. The filter of claim 9 , wherein the SCR catalyst is less susceptible to poisoning relative to comparable filters that do not comprise copper doped ceria, iron doped ceria or manganese doped ceria.

17. The filter of claim 9 , wherein the soot catalyst and the SCR catalyst are present in an amount having a weight ratio of soot catalyst:SCR catalyst of 5:95 to 50:50.

18. The filter of claim 9 , wherein the soot catalyst and the SCR catalyst are present in an amount having a weight ratio of soot catalyst:SCR catalyst of 10:90 to 30:70.

19. A system for treating a lean burn exhaust gas comprising: (a) a nitrogenous reducing agent injector; and (b) a catalytic filter comprising (i) an SCR catalyst and (ii) a soot catalyst comprising copper doped ceria, iron doped ceria or manganese doped ceria, where the SCR catalyst and the soot catalyst are present on the filter as a mixture and the injector is disposed upstream of, and is in fluid communication with, the catalytic filter.

20. A method for treating a lean burn exhaust gas comprising (a) flowing a lean burn exhaust gas stream comprising soot, NOx, and a nitrogenous reducing agent through a catalytic filter comprising (i) an SCR catalyst and (ii) a soot catalyst comprising copper doped ceria, iron doped ceria or manganese doped ceria, where the SCR catalyst and the soot catalyst are present on the filter as a mixture, (b) oxidizing at least a portion of the soot on the catalytic filter; and (c) reducing at least a portion of the NOx.

21. The method of claim 20 , wherein the copper doped ceria, iron doped ceria or manganese doped ceria is doped with: (a) zirconia, (b) zirconia and praseodymium, (c) zirconia and neodymium, or (d) zirconia, praseodymium and neodymium.

22. The method of claim 20 , wherein the soot catalyst and the SCR catalyst are present in an amount having a weight ratio of soot catalyst:SCR catalyst of 5:95 to 95:5.

23. The method of claim 20 , wherein copper or manganese is present at from 0.5 to 15% by weight relative to the weight of ceria, or iron is present at from 0.5 to 10% by weight relative to the weight of ceria.

24. The method of claim 20 , wherein the composition further comprises one or more additional metal oxides.

25. The method of claim 24 , where the one or more additional metal oxides comprises an oxide of zirconium, praseodymium or neodymium, or combinations of two or more of the oxides.

26. The method of claim 20 , wherein the soot catalyst and the SCR catalyst are present in an amount having a weight ratio of soot catalyst:SCR catalyst of 5:95 to 50:50.

27. The method of claim 20 , wherein the soot catalyst and the SCR catalyst are present in an amount having a weight ratio of soot catalyst:SCR catalyst of 10:90 to 30:70.

28. A method for trapping particulate matter from exhaust gas emitted from an engine, the method comprising: contacting the exhaust gas containing the particulate matter with a filter comprising a mixture of an SCR catalyst and a soot oxidation catalyst comprising copper doped ceria, iron doped ceria or a manganese doped ceria.

Assignees

• Johnson Matthey Plc

Inventors

• Chandler Guy Richard
• Phillips Paul Richard

Classifications

• B01D2255/2068

  Neodymium · CPC title

• F01N3/20

  specially adapted for catalytic conversion (F01N3/22 takes precedence) · CPC title

• B01J37/0246

  Coatings comprising a zeolite · CPC title

• B01D2255/915

  Catalyst supported on particulate filters · CPC title

• B01J29/763

  CHA-type, e.g. Chabazite, LZ-218 · CPC title