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WO2009118190A4 - Application of basic exchange os materials for lower temperature catalytic oxidation of particulates - Google Patents

Application of basic exchange os materials for lower temperature catalytic oxidation of particulates Download PDF

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Publication number
WO2009118190A4
WO2009118190A4 PCT/EP2009/002263 EP2009002263W WO2009118190A4 WO 2009118190 A4 WO2009118190 A4 WO 2009118190A4 EP 2009002263 W EP2009002263 W EP 2009002263W WO 2009118190 A4 WO2009118190 A4 WO 2009118190A4
Authority
WO
WIPO (PCT)
Prior art keywords
metal
oxide
particulate filter
solid solution
mixed oxide
Prior art date
Application number
PCT/EP2009/002263
Other languages
French (fr)
Other versions
WO2009118190A2 (en
WO2009118190A3 (en
Inventor
Barry W. L. Southward
Curt Ellis
Original Assignee
Umicore Ag & Co. Kg
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US12/240,170 external-priority patent/US20090246109A1/en
Priority claimed from US12/363,310 external-priority patent/US9403151B2/en
Priority claimed from US12/363,329 external-priority patent/US20100196217A1/en
Application filed by Umicore Ag & Co. Kg filed Critical Umicore Ag & Co. Kg
Priority to BRPI0909386A priority Critical patent/BRPI0909386A2/en
Priority to CN2009801104753A priority patent/CN102112223A/en
Priority to JP2011501155A priority patent/JP2011526198A/en
Priority to EP09724093A priority patent/EP2268395A2/en
Publication of WO2009118190A2 publication Critical patent/WO2009118190A2/en
Publication of WO2009118190A3 publication Critical patent/WO2009118190A3/en
Publication of WO2009118190A4 publication Critical patent/WO2009118190A4/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9445—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
    • B01D53/945—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific catalyst
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9404—Removing only nitrogen compounds
    • B01D53/9409—Nitrogen oxides
    • B01D53/9413—Processes characterised by a specific catalyst
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/944—Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts
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    • B01J23/002—Mixed oxides other than spinels, e.g. perovskite
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    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/54—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/033—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices
    • F01N3/035—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2825—Ceramics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D2255/102—Platinum group metals
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D2255/20—Metals or compounds thereof
    • B01D2255/202—Alkali metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
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    • B01D2255/20—Metals or compounds thereof
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/40—Mixed oxides
    • B01D2255/407—Zr-Ce mixed oxides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/50—Zeolites
    • B01D2255/502—Beta zeolites
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/908—O2-storage component incorporated in the catalyst
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01D2259/4566—Gas separation or purification devices adapted for specific applications for use in transportation means
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    • B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
    • B01J23/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
    • B01J23/83—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36 with rare earths or actinides
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01J23/8933—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with noble metals also combined with metals, or metal oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
    • B01J23/894—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with noble metals also combined with metals, or metal oxides or hydroxides provided for in groups B01J23/02 - B01J23/36 with rare earths or actinides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J29/00—Catalysts comprising molecular sieves
    • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
    • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • B01J29/70—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65
    • B01J29/7007—Zeolite Beta
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
    • B01J37/0027—Powdering
    • B01J37/0036—Grinding
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F01N2330/00—Structure of catalyst support or particle filter
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F01N2570/00—Exhaust treating apparatus eliminating, absorbing or adsorbing specific elements or compounds
    • F01N2570/16—Oxygen
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    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A50/00—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE in human health protection, e.g. against extreme weather
    • Y02A50/20—Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
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  • Chemical & Material Sciences (AREA)
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  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
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  • Health & Medical Sciences (AREA)
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  • Mechanical Engineering (AREA)
  • General Chemical & Material Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Environmental & Geological Engineering (AREA)
  • Biomedical Technology (AREA)
  • Ceramic Engineering (AREA)
  • Toxicology (AREA)
  • Catalysts (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)
  • Inorganic Compounds Of Heavy Metals (AREA)

Abstract

Catalysts for the direct catalytic oxidation of diesel particulate matter are disclosed. The catalysts relate to OIC/OS materials having a stable cubic crystal structure, and most especially to promoted OIC/OS wherein the promotion is achieved by the post-synthetic introduction of non- precious metals via a basic (alkaline) exchange process.

Claims

36AMENDED CLAIMS received by the International Bureau on 18 December 2009 (18.12.2009)
1. The base metal doped mixed oxide / solid solution produced by contacting of redox active material with a precursor solution of dissolved cations under conditions of high pH / low Hydronium Ion (H3O+) / low proton (H+) content, wherein the oxide support is a refractory oxide; wherein the refractory / mixed oxide contains Cerium oxide; further wherein the base metal is introduced into the redox active material by one or more compounds selected from the group consisting of: ammonium hydroxide / ammoniacal complex of the metal cations; organic amine complex of the metal cations; and a hydroxide compound of the metal cations; and wherein the mixed oxide is calcined at a temperature of >35O°C.
2. The base metal doped mixed oxide / solid solution of Claim 1, wherein the Cerium oxide is a solid solution of Cerium and Zirconium Oxide (Ce-Zr Oxide).
3. The base metal doped mixed oxide / solid solution of one or more of the preceding Claims, wherein the Ce-Zr oxide is substantially phase pure solid solution with oxygen ion conducting properties and comprises
a. up to about 95% Zirconium
b. up to about 95% Cerium
c. up to about 20% of a stabiliser selected from the group consisting of rare 37
earths, yttrium and mixtures thereof.
4. The base metal doped mixed oxide / solid solution of one or more of the preceding Claims, wherein the base metal doped mixed oxide / solid solution contains one or more dopant base metal species selected from the group consisting of a transition metal, an alkali metal, an alkaline earth metal, group HIb metal and mixtures thereof.
5. The base metal doped mixed oxide / solid solution of one or more of the preceding Claims, wherein the concentration of metal species introduced is about 0.01 weight % to about 10 weight %.
6. The base metal doped mixed oxide / solid solution of one or more of the preceding Claims, wherein the concentration of metal species introduced is 0.1 wt% to about 2.5 wt %.
7. The base metal doped mixed oxide / solid solution of one or more of the preceding Claims, wherein the resultant product contains metal at high levels of dispersion such that phase analysis by conventional X-Ray diffraction methods retains a substantially phase pure Cubic Fluorite phase (>95%), with bulk metal oxide dopant phase being recorded at <5% and dopant metal oxide particle size, as determined by line- broadening / Scherrer equation method, is about 3θA to about 100A.
8. The base metal doped mixed oxide / solid solution of one or more of the preceding Claims, wherein the resultant product contains metal at high levels of dispersion such that phase analysis by XRD reveals the promoted material maintains at least 95% Cubic Fluorite phase after hydrothermal oxidizing aging at 1100 °C.
9. A particulate filter device for the capture and catalytic oxidative regeneration of solid material produced as a byproduct of an internal combustion engine comprising: a particulate filter comprising a substrate having a redox active material disposed thereon, wherein the redox active material is a base metal doped mixed oxide / solid solution according to one or more of the Claims 1 - 8.
10. The particulate filter device of Claim 9, wherein the particulate filter is a wall flow type filter.
11. A particulate filter device of Claim 9 and/or 10, wherein the temperature of 'regeneration' is about 250 to about 650 °C.
12. A particulate filter device of Claim 9 and/or 10, wherein the temperature of 'regeneration' is about 350 to about 550 0C.
13. A particulate filter device of one or more of the preceding Claims 9 - 12, wherein the particulate filter does not comprise a platinum group metal.
14. A particulate filter device of one or more of the preceding Claims 9 - 12, wherein the particulate filter does additionally comprise a platinum group metal.
15. A particulate filter device of Claim 14, wherein the platinum group metal is selected from the group comprising platinum, palladium, rhodium and mixtures thereof.
16. A method of treating exhaust gas comprising passing an exhaust gas over the particulate filter of one or more of the preceding Claims 9 - 15.
PCT/EP2009/002263 2008-03-27 2009-03-27 Application of basic exchange os materials for lower temperature catalytic oxidation of particulates WO2009118190A2 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
BRPI0909386A BRPI0909386A2 (en) 2008-03-27 2009-03-27 basic material exchange application to lower the temperature of catalytic particle oxidation
CN2009801104753A CN102112223A (en) 2008-03-27 2009-03-27 Application of basic exchange OS materials for lower temperature catalytic oxidation of particulates
JP2011501155A JP2011526198A (en) 2008-03-27 2009-03-27 Application of base exchange OS materials for low temperature catalytic oxidation of fine particles
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US12/363,310 2009-01-30
US12/363,310 US9403151B2 (en) 2009-01-30 2009-01-30 Basic exchange for enhanced redox OS materials for emission control applications
US12/363,329 US20100196217A1 (en) 2009-01-30 2009-01-30 Application of basic exchange os materials for lower temperature catalytic oxidation of particulates
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