WO2009103549A1 - Scr catalyst with ammonia accumulator function - Google Patents
Scr catalyst with ammonia accumulator function Download PDFInfo
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- WO2009103549A1 WO2009103549A1 PCT/EP2009/001227 EP2009001227W WO2009103549A1 WO 2009103549 A1 WO2009103549 A1 WO 2009103549A1 EP 2009001227 W EP2009001227 W EP 2009001227W WO 2009103549 A1 WO2009103549 A1 WO 2009103549A1
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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
- B01D53/9404—Removing only nitrogen compounds
- B01D53/9409—Nitrogen oxides
- B01D53/9413—Processes characterised by a specific catalyst
- B01D53/9418—Processes characterised by a specific catalyst for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas
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- 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
- B01J29/061—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof containing metallic elements added to the zeolite
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- B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
- B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
- B01J29/40—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
- B01J29/48—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively containing arsenic, antimony, bismuth, vanadium, niobium tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
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- 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
- B01J29/78—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65 containing arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
- B01J29/7815—Zeolite Beta
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
- B01J29/80—Mixtures of different zeolites
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- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/02—Impregnation, coating or precipitation
- B01J37/024—Multiple impregnation or coating
- B01J37/0246—Coatings comprising a zeolite
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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
- F01N3/08—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
- F01N3/18—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 methods of operation; Control
- F01N3/20—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 methods of operation; Control specially adapted for catalytic conversion
- F01N3/206—Adding periodically or continuously substances to exhaust gases for promoting purification, e.g. catalytic material in liquid form, NOx reducing agents
- F01N3/2066—Selective catalytic reduction [SCR]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2251/00—Reactants
- B01D2251/20—Reductants
- B01D2251/206—Ammonium compounds
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- B01D2255/00—Catalysts
- B01D2255/20—Metals or compounds thereof
- B01D2255/207—Transition metals
- B01D2255/20707—Titanium
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- B01D2255/20738—Iron
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- B01D2255/207—Transition metals
- B01D2255/20746—Cobalt
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- B01D2255/20—Metals or compounds thereof
- B01D2255/207—Transition metals
- B01D2255/20761—Copper
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/20—Metals or compounds thereof
- B01D2255/207—Transition metals
- B01D2255/20776—Tungsten
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/50—Zeolites
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/50—Zeolites
- B01D2255/504—ZSM 5 zeolites
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/80—Type of catalytic reaction
- B01D2255/808—Hydrolytic
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- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01D2255/904—Multiple catalysts
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- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/90—Physical characteristics of catalysts
- B01D2255/911—NH3-storage component incorporated in the catalyst
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2258/00—Sources of waste gases
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- B01D2258/012—Diesel engines and lean burn gasoline engines
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01D2258/00—Sources of waste gases
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- 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
- B01J29/40—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
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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
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- 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
- 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
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- 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
Definitions
- the present invention relates to an SCR catalyst which comprises an SCR-active component and an NH 3 storage component, wherein the NH 3 storage component is preferably a zeolite.
- the invention further relates to the use of the SCR catalyst for reducing nitrogen oxides of mobile or stationary incinerators.
- SCR Selective Catalytic Reduction
- NO x nitrogen oxides
- NH 3 ammonia
- precursor compounds of ammonia are usually used, which are decomposed in the exhaust line of the vehicles with ammonia formation.
- AdBlue® which is an approximately 32.5% eutectic solution of urea in water.
- Other ammonia sources are, for example, ammonium carbamate, ammonium formate or urea pellets.
- ammonia must first be formed from urea. This is done in two reaction steps, collectively referred to as a hydrolysis reaction. net. First, NH 3 and isocyanic acid are formed in a thermolysis reaction. Isocyanic acid is then reacted with water to form ammonia and carbon dioxide in the actual hydrolysis reaction.
- NH 3 slip may occur.
- the removal of the NH 3 can be achieved by an additional oxidation catalyst downstream of the SCR catalyst. This barrier catalyst oxidizes the possibly ammonia to N 2 and H 2 O. In addition, careful application of urea dosing is essential.
- feed ratio ⁇ defined as the molar ratio of metered NH 3 to the NO x present in the exhaust gas.
- the dosing strategy is of great importance in high NH 3 storage capacity catalysts because the NH 3 storage capability of prior art SCR catalysts typically decreases with increasing temperature.
- catalysts based on titanium dioxide, vanadium pentoxide and tungsten oxide are predominantly used both in the power plant sector and in the automotive sector. Also, the use of SCR catalysts based on zeolites is known in the art.
- the object of the present invention was thus to provide an improved SCR catalyst with respect to the SCR catalysts known from the prior art, which is also suitable for use in exhaust systems of internal combustion engines.
- the presence of the NH 3 storage component does not require impregnation with a noble metal such as palladium, platinum, etc. on the SCR catalyst. It has also been shown that the existence of the Ammo niak storage component in the SCR catalyst, a further oxidation catalyst behind the SCR catalyst in an exhaust system is unnecessary.
- This barrier catalyst hitherto used in the prior art for removing the NH 3 oxidizes the possibly occurring ammonia to N 2 and H 2 O. Due to the storage of the excess NH 3 , the barrier catalyst can thus surprisingly be dispensed with.
- SCR catalysts comprising a NH 3 storage component with a zeolite containing SiO 2 and Al 2 O 3 in a specific specific ratio and which in a certain percentage based on the amount of the catalytically active composition in the SCR catalyst is present, have particularly advantageous properties. It has been found, in particular, that a zeolite comprising a very specific SiO 2 / Al 2 O 3 molar ratio and used in a certain percentage of the catalytically active composition in an SCR catalyst has an optimized absorption and desorption character - shows characteristic.
- a SCR catalyst designed in this way already releases enough NH 3 during a cold start, so that the SCR-active constituent also has optimum NO x conversion rates in cold start behavior.
- An additional effect here is that at fast Lastwech-, as they are common, for example in the automotive industry, an existing inert urea dosing is relieved, as can be compensated by optimized absorption and desorption the associated concentration peaks.
- the present invention therefore relates, in a first aspect, to an SCR catalyst comprising a catalytically active composition comprising an SCR-active component and an a NH 3 storage component, wherein the SCR active component and the NH 3 storage component are different from each other, and wherein the NH 3 storage component comprises a zeolite having a Si0 2 / Al 2 ⁇ 3 molar ratio of 5: 1 to 150: 1 and the zeolite is contained in an amount of 2 to 30 wt .-% in the catalytically active composition.
- the subject matter of the present invention also includes an exhaust gas purification system for the purification of diesel engine exhaust gases comprising a group of catalyst devices arranged one behind the other, consisting of an oxidation catalyst and an SCR catalyst according to the invention.
- the present invention also relates to the use of the SCR catalyst according to the invention for reducing the nitrogen oxide emission of mobile or stationary combustion devices.
- SCR active component refers to a material that catalyzes the aforementioned SCR reaction.
- NH 3 storage component is understood as meaning a material which is capable of reversibly adsorbing NH 3. It is preferably a porous or particularly preferably a microsoporous material.
- the storage component is a zeolite having a SiO 2 / Al 2 O 3 molar ratio of 5: 1 to 150: 1.
- zeolite generally used in the definition of the International Mineralogical Association (DS Coombs et al., Can. Mineralogist, 35, 1997, 1571) is a crystalline substance. dance from the group of aluminum silicates with spatial network structure of the general formula
- the zeolite structure contains voids and channels characteristic of each zeolite.
- the zeolites are classified according to their topology into different structures (see above).
- the zeolite framework contains open cavities in the form of channels and cages that are normally occupied by water molecules and extra framework cations that can be exchanged.
- An aluminum atom has an excess negative charge which is compensated by these cations.
- the interior of the pore system represents the catalytically active surface. The more aluminum and the less silicon a zeolite contains, the denser the negative charge in its lattice and the more polar its internal surface.
- the pore size and structure are determined by the Si / Al ratio, which determines most of the catalytic character of a zeolite, in addition to the parameters in the preparation (use or type of template, pH, pressure, temperature, presence of seed crystals) , Due to the presence of z. B. 3-valent atoms (eg., Al or Ga), the zeolite receives a negative lattice charge in the form of so-called Anionstellen, in the vicinity of which are the corresponding cation positions. The negative charge is compensated by the incorporation of cations into the pores of the zeolite material.
- the zeolites are distinguished mainly by the geometry of the cavities formed by the rigid network of SiO4 / AlO4 tetrahedra.
- the entrances to the cavities are formed by 8, 10 or 12 "rings" (narrow, medium and large pore zeolites).
- Certain zeolites show a uniform structure structure (eg ZSM-5 with MFI topology) with linear or zigzag running channels, in others close behind the pore openings larger cavities, eg. As in the Y and A zeolites, with the topologies FAU and LTA.
- any zeolite in particular any 10 and 12 "ring" zeolite, which has a SiO 2 / Al 2 O 3 molar ratio of from 5: 1 to 150: 1, can be used in the context of the present invention the topologies AEL, BEA, CHA, EUO, FAO, FAU, FER, KFI, LTA, LTL, MAZ, MOR, MEL, MTW, LEV, OFF, TON and MFI
- AEL, BEA, CHA, EUO, FAO, FAU, FER, KFI, LTA, LTL, MAZ, MOR, MEL, MTW, LEV, OFF, TON and MFI Very particular preference is given to zeolites of the topological structures FAU, MOR, BEA , MFI and MEL.
- ⁇ , ⁇ and ⁇ positions which define the position of the exchange sites (also referred to as “interchangeable locations"). All of these three positions are accessible to reactants during the NH 3 -SCR reaction, especially when using MFI, BEA, FAU, MOR, MTW, and MEL zeolites.
- MFI, BEA, FAU, MOR, MTW, and MEL zeolites Surprisingly, it has been found that the improvement in cold start emissions is dependent on the NH 3 storage capability of the SCR catalyst.
- the NH 3 storage capacity depends on the (BrOnstedt) acidic surface centers of the zeolite preferably used according to the invention. Different zeolite types have different acid sites and thus different adsorption and desorption behaviors. Strongly acidic centers form stronger bonds to the adsorbed NH 3 molecules than weakly acidic centers.
- the desorption temperature is significantly higher for a zeolite with predominantly strongly acidic centers than for weakly acidic centers.
- the NH 3 storage function ie the amount of adsorbing NH 3 or of the NH 3 to be desorbed, can be adjusted in a targeted manner by suitably selecting the type of zeolite. Since the number of acidic centers can be influenced by the molar ratio of SiO 2 to Al 2 O 3 (the so-called "module"), the NH 3 storage capacity of an SCR catalyst can thus be precisely adjusted by varying this ratio.
- the preferred SiO 2 / Al 2 O 3 modulus (molar ratio) is in the range from 5: 1 to 150: 1, more preferably in the range from 5: 1 to 50: 1 and most preferably in the range from 10: 1 to 30: 1st
- the NH 3 storage zeolite is preferably present in an amount of from 2 to 30% by weight, more preferably in an amount of from 5 to 15% by weight, in the catalytically active composition.
- the type of zeolite used is important since not all zeolites have an optimum NH 3 storage capacity. sen.
- the zeolite is therefore preferably selected from the group comprising FAU (faujasite), MOR (mordenite), BEA (beta zeolite), MFI (Mobil Five, ZSM-5, Zeolite Secondary Mobile No. 5) and MEL, combinations of which above-mentioned zeolite can be used.
- FAU farnesulite
- MOR mordenite
- BEA beta zeolite
- MFI Mobil Five, ZSM-5, Zeolite Secondary Mobile No. 5
- MEL MEL
- the NH 3 storage zeolite is a metal-exchanged zeolite, for example an iron, copper or cobalt-exchanged zeolite.
- the metal-exchanged zeolite is also selected from the group comprising FAU (faujasite), MOR (mordenite), BEA (beta zeolite), MFI (Mobil Five, ZSM-5, Zeolite Secondary Mobile No. 5) and MEL, including combinations said zeolites can be used.
- the metal-exchanged zeolite is not an iron-exchanged zeolite in combination with a transition-metal-exchanged zeolite and / or in combination with a metal oxide-exchanged zeolite, wherein the transition metal oxide is selected from the group consisting of vanadium pentoxide, tungsten trioxide or titanium dioxide.
- the metal content or the degree of exchange of a zeolite is decisively determined by the metal species present in the zeolite.
- the zeolite can be doped with only a single metal or with different metals.
- the preferred metals for exchange and doping are catalytically active metals such as Fe, Ce, Co, Ni, Ag, V, Rh, Pd, Pt, Ir. He- According to the invention, very particular preference is given to zeolites which contain iron, copper or cobalt species.
- the production processes for metal-exchanged zeolites, for example via solid or liquid phase exchange, are known to the person skilled in the art.
- the SCR catalyst also requires an SCR active component.
- This may be, for example, a conventional vanadium / titanium / tungsten based component.
- the vanadium / titanium / tungsten based component is an oxide coating that essentially contains TiO 2 in the anatase modification.
- TiO 2 is stabilized by WO 3 in order to achieve an improvement in its thermal stability.
- the proportion of WO 3 is typically about 10 wt .-%.
- the actually active component forms the V 2 O 5 , which is typically present as a monolayer on the TiO 2 particles. It is also possible to add another NH 3 storage component, as will be suggested below.
- An advantage of, for example, a vanadium based component as the SCR active component is the excellent low temperature activity of such a system.
- the inventive combination of vanadium-based catalysts with zeolites can thus make use of the low-temperature activity of these catalysts and, at the same time, the NH 3 storage capacity of the zeolites, thus providing an SCR catalyst with excellent cold-start properties.
- an SCR-active zeolite for example a metal-doped or exchanged zeolite, such as a Cu zeolite or Fe zeolite.
- this provides many possible combinations for an SCR catalyst, which can be specifically adapted to the respective area of use.
- an SCR-active zeolite which is active at low temperatures can be combined with an SCR-active zeolite which is active at higher temperatures and an NH 3 storage zeolite.
- low temperatures are temperatures in the range below 280 ° C., preferably below 250 ° C.
- high temperatures are understood to mean temperatures in the range of more than 350 ° C., preferably more than 400 ° C.
- a corresponding example of such a combination is, for example, a mixture of a copper-exchanged zeolite such as Cu-ZSM-5 with a modulus of 150, which has a low-temperature, an iron-exchanged zeolite, such.
- Catalyst in the form of an at least partially coating on a preferably monolithic carrier is present.
- monolithic carriers are metallic or ceramic carriers, for example in honeycomb or foam form.
- the NH 3 storage component is applied only on the inlet side and the SCR-active component only on the outlet side of such a coated monolithic carrier. It would also be possible for all of the components, such as the NH 3 storage component and the SCR active component (s), to be applied as a homogeneous coating to the entire surface of the monolith, thus greatly simplifying the preparation of such catalysts.
- the application of the SCR catalyst is carried out according to methods known in the art, for example by applying a washcoat, by coating in an immersion bath or by spray coating.
- the SCR catalyst according to the invention is outstandingly suitable for reducing nitrogen oxide emission from mobile or stationary combustion devices.
- Mobile combustion devices in the context of this invention are, for example, internal combustion engines of motor vehicles, in particular diesel engines, power generators based on internal combustion engines, or other units based on internal combustion engines.
- the stationary combustion facilities are usually power plants, combustion plants, waste incineration plants and also heating systems of private households.
- the subject matter of the invention is also a method for reducing nitrogen oxide emissions in mobile or stationary incinerators, the method being characterized in that an exhaust gas stream is passed over an SCR catalyst according to the invention.
- Fig. l the NH 3 storage capacity of zeolites as a function of the Si0 2 / Al 2 O 3 modulus
- FIG. 1 shows the NH 3 storage capacity of zeolites as a function of the SiO 2 / Al 2 O 3 module.
- the optimum modulus is in the range of 5 to 50, most preferably in the range of 10 to 30.
- the selection of the module is also determined by the analysis of the later field of application and the conditions.
- the range of application of the catalyst is determined by several factors Right. For example, the temperature range in operation varies considerably from car to truck. Typical work areas of internal combustion engines in trucks are between 180 and 430 0 C, and in the case of passenger cars temperatures of up to 600 0 C are often reached. Basically, the smaller the engines are (in terms of their cubic capacity), the more intensively a full-load operation occurs and thus the temperatures rise. Plays a role, whether installed in the exhaust system of the SCR catalyst before or after the diesel particulate filter (DPF), there can form high temperature peaks during the regeneration of the diesel particulate filter by burning off the collected PM in the filter above about 600 0 C.
- DPF diesel particulate filter
- the module not all areas of the module are accessible with any type of zeolite which can be used according to the invention.
- a BEA zeolite only SiO 2 : Al 2 O 3 ratios of above 19 can be achieved. In order to achieve a certain storage capacity of NH3, therefore, in the case of using such zeolites, the amount must be increased.
- the lower and upper limits for the SiO 2 : Al 2 O 3 ratios are as follows: FAU: 3 - 10, MOR: 10 - 400, BEA: 19 - 1000, MFI: 19-1000, MEL: 19-1000.
- FIG. 2 shows the result of temperature-programmed desorption (TPD) of NH 3 in an iron-exchanged zeolite with the topology MFI and a SiO 2 / Al 2 O 3 modulus of 25.
- TPD temperature-programmed desorption
- the zeolite with the module according to the invention was saturated with NH 3 . That is, the maximum possible NH 3 concentration was adsorbed on the surface and then desorbed by increasing the temperature. The amount of NH 3 was detected by a mass spectrometer and simultaneously correlated with the discharge temperature. Thus, both the quantity and the temperature at which the desorption occurred could be determined what evidence was obtained to the strength of the bond between NH 3 and the zeolite.
- test conditions were as follows:
- the carrier structure used was a ceramic carrier from NGK with a honeycomb density of 400 cpsi.
- Vanadyl oxalate solution and 80 g of distilled water mixed together.
- the ZSM-5 zeolite had a modulus of 25.
- the washcoat thus prepared was vibrated on the ceramic monolith with the volume of the washcoat equal to 50-120% of the carrier volume.
- the monolith was emptied.
- the washcoat residues on the outlet side of the monolith were sucked off.
- the SCR catalyst thus obtained was then dried at 80 ° C. and calcined at about 500 ° C. for 5 hours.
- Preparation of the catalyst 2 As the support structure, the same structure as in Example 1 was used. To prepare the washcoat, 90 g of TiO 2 powder, 10 g of WO 3 , 10 g of ZSM-5, 10 g of BEA, 20 g of SiO 2 sol, 15 g of TiO 2 sol, 20 ml of 10% aqueous vanadyl oxalate solution and 80 g of distilled water mixed together.
- the ZSM-5 zeolite had a modulus of 25, the BEA zeolite a modulus of 150.
- the washcoat thus prepared was applied to the monolith as in Example 1 and then calcined.
- Example 1 As the support structure, the same structure as in Example 1 was used.
- washcoat 110 g of TiO 2 powder, 10 g of WO 3 , 20 g of SiO 2 sol, 15 g of TiO 2 sol, 20 ml of 10% aqueous vanadyl oxalate solution and 80 g of distilled water were mixed together.
- the washcoat so prepared was applied to the monolith as in Example 1 and calcined.
- the cold start was simulated by a temperature increase from room temperature to 400 0 C with a heating rate of 50 K / min. Rapid change of throughput and temperature simulates a load change from full load to idle and vice versa.
- the space velocity of 100,000 h "1 and the temperature of 400 0 C (full load) were changed to a space velocity of 30,000 h " 1 and a temperature of 180 0 C (idle).
- the exhaust gas composition corresponded to a typical diesel car and a load change between full load and idle was simulated.
- Both catalysts according to the invention showed a significant improvement with respect to the NO x conversion and a reduced NH 3 slip at the catalyst outlet.
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Abstract
Description
SCR-Katalysator mit Ammoniak-Speicherfunktion SCR catalytic converter with ammonia storage function
Die vorliegende Erfindung betrifft einen SCR-Katalysator, welcher einer SCR-aktive Komponente und eine NH3-Speicherkompo- nente umfasst, wobei die NH3-Speicherkomponente bevorzugt ein Zeolith ist. Die Erfindung betrifft ferner die Verwendung des SCR-Katalysators zur Verringerung von Stickoxiden mobiler oder stationärer Verbrennungseinrichtungen .The present invention relates to an SCR catalyst which comprises an SCR-active component and an NH 3 storage component, wherein the NH 3 storage component is preferably a zeolite. The invention further relates to the use of the SCR catalyst for reducing nitrogen oxides of mobile or stationary incinerators.
Mit SCR (selective catalytic reduction) wird die selektive ka- talytische Reduktion von Stickoxiden aus Abgasen von Verbrennungsmotoren und auch Kraftwerken bezeichnet. Mit einem SCR- Katalysator werden nur die Stickoxide NO und NO2 (allgemein als NOx bezeichnet) selektiv reduziert, wobei für die Reaktion gewöhnlich NH3 (Ammoniak) zugemischt wird. Als Reaktionsprodukt entstehen daher nur die unbedenklichen Stoffe Wasser und Stickstoff. Für den Einsatz von Kraftfahrzeugen ist das Mitführen von Ammoniak in Druckgasflaschen ein Sicherheitsrisiko. Deshalb werden gewöhnlich Vorläuferverbindungen des Ammoniaks eingesetzt, die im Abgasstrang der Fahrzeuge unter Ammoniak- bildung zersetzt werden. Bekannt in diesem Zusammenhang ist beispielsweise die Verwendung von AdBlue®, welches eine etwa 32,5 % eutektische Lösung von Harnstoff in Wasser ist. Andere Ammoniakquellen sind beispielsweise Ammoniumcarbamat , Ammo- niumformiat oder Harnstoffpellets .SCR (Selective Catalytic Reduction) refers to the selective catalytic reduction of nitrogen oxides from exhaust gases of combustion engines and also power plants. With an SCR catalyst, only the nitrogen oxides NO and NO 2 (commonly referred to as NO x ) are selectively reduced, with NH 3 (ammonia) usually added to the reaction. Therefore, only the harmless substances water and nitrogen are formed as reaction products. For the use of motor vehicles carrying ammonia in compressed gas cylinders is a security risk. Therefore, precursor compounds of ammonia are usually used, which are decomposed in the exhaust line of the vehicles with ammonia formation. Known in this context is, for example, the use of AdBlue® , which is an approximately 32.5% eutectic solution of urea in water. Other ammonia sources are, for example, ammonium carbamate, ammonium formate or urea pellets.
Vor der eigentlichen SCR-Reaktion muss aus Harnstoff zunächst Ammoniak gebildet werden. Dies geschieht in zwei Reaktionsschritten, die zusammengefasst als Hydrolysereaktion bezeich- net werden. Zunächst werden in einer Thermolysereaktion NH3 und Isocyansaure gebildet. Anschließend wird in der eigentlichen Hydrolysereaktion Isocyansaure mit Wasser zu Ammoniak und Kohlendioxid umgesetzt.Before the actual SCR reaction, ammonia must first be formed from urea. This is done in two reaction steps, collectively referred to as a hydrolysis reaction. net. First, NH 3 and isocyanic acid are formed in a thermolysis reaction. Isocyanic acid is then reacted with water to form ammonia and carbon dioxide in the actual hydrolysis reaction.
Zur Vermeidung von festen Ausscheidungen ist es erforderlich, dass die zweite Reaktion durch die Wahl geeigneter Katalysatoren und genügend hoher Temperaturen (ab 250 0C) ausreichend schnell erfolgt. Moderne SCR-Reaktoren übernehmen gleichzeitig die Funktion des Hydrolysekatalysators.To avoid solid precipitates, it is necessary that the second reaction by the choice of suitable catalysts and sufficiently high temperatures (from 250 0 C) is sufficiently fast. Modern SCR reactors simultaneously take over the function of the hydrolysis catalyst.
Das durch die Thermohydrolyse entstandene Ammoniak reagiert am SCR-Katalysator nach den folgenden Gleichungen:The ammonia produced by the thermohydrolysis reacts on the SCR catalyst according to the following equations:
4NO + 4NH3 + O2 → 4N2 + 6H2O (1)4NO + 4NH 3 + O 2 → 4N 2 + 6H 2 O (1)
NO + NO2 + 2NH3 → 2N2 + 3H2O (2) 6NO2 + 8NH3 → 7N2 + 12H2O (3)NO + NO 2 + 2NH 3 → 2N 2 + 3H 2 O (2) 6NO 2 + 8NH 3 → 7N 2 + 12H 2 O (3)
Bei niedrigen Temperaturen (<300 0C) lauft der Umsatz uberwie- gend über Reaktion (2) ab. Für einen guten Niedertemperaturumsatz ist es deshalb erforderlich, ein NO2 :NO-Verhaltnis von etwa 1:1 einzustellen. Unter diesen Umstanden kann die Reaktion (2) bereits bei Temperaturen ab 170-200 0C erfolgen.At low temperatures (<300 0 C), sales uberwie- quietly through reaction (2) runs off. For a good low-temperature conversion, it is therefore necessary to set a NO 2 : NO ratio of about 1: 1. Under these circumstances, the reaction (2) already at temperatures from 170-200 0 C take place.
Die Oxidation von NO zu NOx erfolgt in einem vorgelagerten Oxi- dationskatalysator der für einen optimalen Wirkungsgrad erforderlich ist.The oxidation of NO to NO x takes place in an upstream oxidation catalyst which is required for optimum efficiency.
Wird mehr Reduktionsmittel dosiert, als bei der Reduktion mit NOx umgesetzt wird, so kann es zu einem unerwünschten NH3- Schlupf kommen. Die Entfernung des NH3 kann durch einen zusatzlichen Oxidationskatalysator hinter dem SCR-Katalysator erzielt werden. Dieser Sperrkatalysator oxidiert das ggf. auf- tretende Ammoniak zu N2 und H2O. Darüber hinaus ist eine sorgfältige Applikation der Harnstoffdosierung unerlässlich .If more reducing agent is metered than is reacted during the reduction with NO x , undesirable NH 3 slip may occur. The removal of the NH 3 can be achieved by an additional oxidation catalyst downstream of the SCR catalyst. This barrier catalyst oxidizes the possibly ammonia to N 2 and H 2 O. In addition, careful application of urea dosing is essential.
Eine für die SCR-Katalyse wichtige Kenngröße ist das so ge- nannte Feedverhältnis α, definiert als das molare Verhältnis von zudosiertem NH3 zu dem im Abgas vorhandenen NOx. Bei idealen Betriebsbedingungen (kein NH3-Schlupf, keine Nebenreaktionen, keine NH3-Oxidation) ist α direkt proportional zur NOx- Reduktionsrate :An important parameter for SCR catalysis is the so-called feed ratio α, defined as the molar ratio of metered NH 3 to the NO x present in the exhaust gas. Under ideal operating conditions (no NH 3 slip, no side reactions, no NH 3 oxidation), α is directly proportional to the NO x reduction rate:
Bei ot = 1 wird theoretisch eine einprozentige NOx-Reduktion erreicht. Im praktischen Einsatz kann bei einem NH3-Schlupf von < 20 ppm eine NOx-Reduktion von 90 % im stationären und instationären Betrieb erzielt werden.At ot = 1 theoretically a one percent NO x reduction is achieved. In practical use, with NH 3 slip of <20 ppm, a NO x reduction of 90% in stationary and transient operation can be achieved.
Durch die vorgelagerte Hydrolysereaktion wird bei den heutigen SCR-Katalysatoren ein NOx-Umsatz > 50% erst bei Temperaturen oberhalb von ca. 250 0C erreicht, optimale Umsatzraten werden im Temperaturfenster von 250 - 450 °C erzielt.Through the upstream hydrolysis a NOx conversion is achieved> 50% only at temperatures above about 250 0 C with today's SCR catalysts, optimum conversion rates are within the temperature window of 250 - achieved 450 ° C.
Die Dosierstrategie ist bei Katalysatoren mit hohem NH3- Speichervermögen von großer Wichtigkeit, da die NH3- Speicherfähigkeit von SCR-Katalysatoren des Standes der Technik typischerweise mit steigender Temperatur abnimmt.The dosing strategy is of great importance in high NH 3 storage capacity catalysts because the NH 3 storage capability of prior art SCR catalysts typically decreases with increasing temperature.
Derzeit werden sowohl im Kraftwerksbereich als auch im Automobilbereich überwiegend Katalysatoren auf Basis von Titandioxid, Vanadiumpentoxid und Wolframoxid eingesetzt. Auch ist die Verwendung von SCR-Katalysatoren auf Basis von Zeolithen im Stand der Technik bekannt.At present, catalysts based on titanium dioxide, vanadium pentoxide and tungsten oxide are predominantly used both in the power plant sector and in the automotive sector. Also, the use of SCR catalysts based on zeolites is known in the art.
Nachteilig bei den im Stand der Technik verwendeten SCR- Katalysatoren, auch bei den auf Zeolithen basierenden SCR- Katalysatoren, ist die verhältnismäßig schlechte Umsetzung der Abgase im Kaltstartbetrieb. Das heißt, die beim Start des Motors auftretenden Abgase fließen über einen noch kalten Katalysator und werden daher nicht umgesetzt. Auch die Harnstoff- dosierung erfolgt aus Gründen einer möglichen Kondensation in der Regel erst oberhalb von 250 0C. Das bedeutet, dass in der Kaltstartphase nahezu keine Stickoxidemissionen reduziert werden.A disadvantage of the SCR catalysts used in the prior art, even in the zeolite-based SCR catalysts. Catalysts, is the relatively poor conversion of the exhaust gases in cold start operation. That is, the exhaust gases occurring at the start of the engine flow over a still cold catalyst and are therefore not implemented. Also, the urea dosage is due to a possible condensation usually only above 250 0 C. This means that in the cold start phase almost no nitrogen oxide emissions are reduced.
Weitere Probleme ergeben sich bei schnellen Lastwechseln. Mit einem Lastwechsel ist eine sprunghafte Änderung der Abgaskonzentration verbunden und die Harnstoffdosierung kann wegen der Trägheit des Dosiersystems erst zeitlich versetzt angepasst werden. Insbesondere weisen die Katalysatoren des Standes der Technik Probleme beim Auftreten von NH3-Schlupf auf. Dies führt zu einem unnötigen Ausstoß von NOx.Further problems arise with fast load changes. With a load change, a sudden change in the exhaust gas concentration is connected and the urea dosing can be adjusted only offset in time due to the inertia of the dosing system. In particular, the prior art catalysts have problems in the occurrence of NH 3 slip. This leads to unnecessary emission of NO x .
Die Aufgabe der vorliegenden Erfindung bestand somit darin, einen SCR-Katalysator mit gegenüber den aus dem Stand der Technik bekannten SCR-Katalysatoren verbesserten Eigenschaften bereit zu stellen, der sich auch für den Einsatz in Abgasanlagen von Verbrennungsmotoren eignet.The object of the present invention was thus to provide an improved SCR catalyst with respect to the SCR catalysts known from the prior art, which is also suitable for use in exhaust systems of internal combustion engines.
Es wurde nun überraschend gefunden, dass SCR-Katalysatoren, die eine bestimmte NH3-Speicherkomponente umfassen, die Probleme der aus dem Stand der Technik bekannten Katalysatoren nicht zeigen .It has now surprisingly been found that SCR catalysts comprising a certain NH 3 storage component do not show the problems of the catalysts known from the prior art.
Überraschenderweise wurde im Rahmen der vorliegenden Erfindung gefunden, dass durch das Vorliegen der NH3-Speicherkomponente keine Imprägnierung mit einem Edelmetall wie beispielsweise Palladium, Platin, etc. auf dem SCR-Katalysator vonnöten ist. Ebenso hat sich gezeigt, dass durch das Vorliegen der Ammo- niak-Speicherkomponente im SCR-Katalysator ein weiterer Oxydationskatalysator hinter dem SCR-Katalysator in einem Abgassystem unnötig ist. Dieser im Stand der Technik bisher benutzte Sperrkatalysator zur Entfernung des NH3 oxidiert das ggf. auf- tretende Ammoniak zu N2 und H2O. Aufgrund der Speicherung des überschüssigen NH3 kann somit überraschenderweise auf den Sperrkatalysator verzichtet werden.Surprisingly, it has been found within the scope of the present invention that the presence of the NH 3 storage component does not require impregnation with a noble metal such as palladium, platinum, etc. on the SCR catalyst. It has also been shown that the existence of the Ammo niak storage component in the SCR catalyst, a further oxidation catalyst behind the SCR catalyst in an exhaust system is unnecessary. This barrier catalyst hitherto used in the prior art for removing the NH 3 oxidizes the possibly occurring ammonia to N 2 and H 2 O. Due to the storage of the excess NH 3 , the barrier catalyst can thus surprisingly be dispensed with.
Ferner wurde überraschend gefunden, dass SCR-Katalysatoren, die eine NH3-Speicherkomponente mit einem Zeolithen umfassen, der SiO2 und Al2O3 in einem speziell bestimmten Mengenverhältnis enthält und der in einem bestimmten Prozentsatz bezogen auf die Menge der katalytisch aktiven Zusammensetzung in dem SCR-Katalysator vorhanden ist, besonders vorteilhafte Eigen- schaften aufweisen. Es wurde insbesondere gefunden, dass ein Zeolith, der ein ganz bestimmtes Siθ2/Al203-Molverhältnis um- fasst und in einem bestimmten Prozentsatz bezogen auf die katalytisch aktive Zusammensetzung in einem SCR-Katalysator eingesetzt wird, eine optimierte Absorptions- und Desorptionscha- rakteristik zeigt. Dies führt dazu, dass ein so gestalteter SCR-Katalysator bei einem Kaltstart bereits ausreichend NH3 freisetzt, sodass der SCR-aktive Bestandteil auch im Kaltstartverhalten optimale NOx-Umsetzungsraten aufweist. Ein zusätzlicher Effekt hierbei ist, dass bei schnellen Lastwech- sein, wie sie beispielsweise im Automobilbereich üblich sind, ein vorhandenes träges Harnstoffdosiersystem entlastet wird, da durch optimierte Absorptions- und Desorptionseigenschaften die damit verbundenen Konzentrationsspitzen kompensiert werden können.Furthermore, it has surprisingly been found that SCR catalysts comprising a NH 3 storage component with a zeolite containing SiO 2 and Al 2 O 3 in a specific specific ratio and which in a certain percentage based on the amount of the catalytically active composition in the SCR catalyst is present, have particularly advantageous properties. It has been found, in particular, that a zeolite comprising a very specific SiO 2 / Al 2 O 3 molar ratio and used in a certain percentage of the catalytically active composition in an SCR catalyst has an optimized absorption and desorption character - shows characteristic. As a result, a SCR catalyst designed in this way already releases enough NH 3 during a cold start, so that the SCR-active constituent also has optimum NO x conversion rates in cold start behavior. An additional effect here is that at fast Lastwech-, as they are common, for example in the automotive industry, an existing inert urea dosing is relieved, as can be compensated by optimized absorption and desorption the associated concentration peaks.
Die vorliegende Erfindung betrifft daher in einem ersten Aspekt einen SCR-Katalysator umfassend eine katalytisch aktive Zusammensetzung, enthaltend eine SCR-aktive Komponente und ei- ne NH3-Speicherkomponente, wobei die SCR-aktive Komponente und die NH3-Speicherkomponente voneinander verschieden sind, und wobei die NH3-Speicherkomponente einen Zeolithen mit einem Si02/Al2θ3-Molverhältnis von 5:1 bis 150:1 umfasst und der Zeo- lith in einer Menge von 2 bis 30 Gew.-% in der katalytisch aktiven Zusammensetzung enthalten ist.The present invention therefore relates, in a first aspect, to an SCR catalyst comprising a catalytically active composition comprising an SCR-active component and an a NH 3 storage component, wherein the SCR active component and the NH 3 storage component are different from each other, and wherein the NH 3 storage component comprises a zeolite having a Si0 2 / Al 2 θ 3 molar ratio of 5: 1 to 150: 1 and the zeolite is contained in an amount of 2 to 30 wt .-% in the catalytically active composition.
Weiter umfasst der Gegenstand der vorliegenden Erfindung auch ein Abgasreinigungssystem für die Reinigung von Dieselmotorab- gasen enthaltend eine Gruppe von hintereinander angeordneten Katalysatoreinrichtungen, bestehend aus einem Oxidationskata- lysator und einem erfindungsgemäßen SCR-Katalysator .Furthermore, the subject matter of the present invention also includes an exhaust gas purification system for the purification of diesel engine exhaust gases comprising a group of catalyst devices arranged one behind the other, consisting of an oxidation catalyst and an SCR catalyst according to the invention.
Schließlich betrifft die vorliegende Erfindung auch die Ver- wendung des erfindungsgemäßen SCR-Katalysators zur Verringerung der Stickoxidemission mobiler oder stationärer Verbrennungseinrichtungen .Finally, the present invention also relates to the use of the SCR catalyst according to the invention for reducing the nitrogen oxide emission of mobile or stationary combustion devices.
Der Begriff „SCR-aktive Komponente" bezeichnet ein Material, das die vorstehend erwähnte SCR-Reaktion katalysiert.The term "SCR active component" refers to a material that catalyzes the aforementioned SCR reaction.
Unter dem Begriff „NH3-Speicherkomponente" wird ein Material verstanden, das NH3 reversibel zu adsorbieren vermag. Vorzugsweise handelt es sich dabei um ein poröses bzw. besonders be- vorzugt um ein mikrosoporöses Material.The term "NH 3 storage component" is understood as meaning a material which is capable of reversibly adsorbing NH 3. It is preferably a porous or particularly preferably a microsoporous material.
Im Rahmen der vorliegenden Erfindung ist die Speicherkomponente ein Zeolith mit einem Siθ2/Al2θ3-Molverhältnis von 5:1 bis 150:1.In the context of the present invention, the storage component is a zeolite having a SiO 2 / Al 2 O 3 molar ratio of 5: 1 to 150: 1.
Unter dem Begriff "Zeolith" wird allgemein gemäß der Definition der International Mineralogical Association (D.S. Coombs et al., Can. Mineralogist, 35, 1997, 1571) eine kristalline Subs- tanz aus der Gruppe der Aluminiumsilikate mit Raumnetzstruktur der allgemeinen FormelThe term "zeolite" generally used in the definition of the International Mineralogical Association (DS Coombs et al., Can. Mineralogist, 35, 1997, 1571) is a crystalline substance. dance from the group of aluminum silicates with spatial network structure of the general formula
Mn+[ (AlO2)X(SiO2)Y]XH2OM n + [(AlO 2 ) X (SiO 2 ) Y] XH 2 O
verstanden, die aus Siθ4/Alθ4 Tetraedern bestehen, die durch gemeinsame Sauerstoffatome zu einem regelmäßigen dreidimensionalen Netzwerk verknüpft sind. Das Verhältnis von Si/Al=y/x beträgt immer > 1 gemäß der so genannten "Löwenstein-Regel", die das benachbarte Auftreten zweier benachbarter negativ geladener AlO4-Tetraeder verbietet. Dabei stehen bei einem geringen Si/Al-Verhältnis zwar mehr Austauschplätze für Metalle zur Verfügung, der Zeolith wird jedoch zunehmend thermisch instabiler .understood that consist of Siθ 4 / Alθ 4 tetrahedra, which are linked by common oxygen atoms to a regular three-dimensional network. The ratio of Si / Al = y / x is always> 1 according to the so-called "Löwenstein rule", which prohibits the adjacent occurrence of two adjacent negatively charged AlO 4 tetrahedra. Although there are more exchange sites for metals available at a low Si / Al ratio, the zeolite is becoming increasingly thermally unstable.
Die Zeolithstruktur enthält Hohlräume und Kanäle, die für jeden Zeolithen charakteristisch sind. Die Zeolithe werden gemäß ihrer Topologie in verschiedene Strukturen (siehe oben) eingeteilt. Das Zeolithgerüst enthält offene Hohlräume in Form von Kanälen und Käfigen, die normalerweise von Wassermolekülen und extra Gerüstkationen, die ausgetauscht werden können, besetzt sind. Auf ein Aluminiumatom kommt eine überschüssige negative Ladung, die durch diese Kationen kompensiert wird. Das Innere des Porensystems stellt die katalytisch aktive Oberfläche dar. Je mehr Aluminium und je weniger Silizium ein Zeolith enthält, desto dichter ist die negative Ladung in seinem Gitter und desto polarer seine innere Oberfläche. Die Porengröße und Struktur wird neben den Parametern bei der Herstellung (Verwendung bzw. Art von Templaten, pH, Druck, Temperatur, Anwe- senheit von Impfkristallen) durch das Si/Al-Verhältnis bestimmt, das den größten Teil des katalytischen Charakters eines Zeolithen bestimmen. Durch die Anwesenheit von z. B. 3-wertigen Atomen (z. B. Al oder Ga) erhält der Zeolith eine negative Gitterladung in Form von so genannten Anionstellen, in deren Nachbarschaft sich die entsprechenden Kationenpositionen befinden. Die negative La- düng wird durch den Einbau von Kationen in die Poren des Zeo- lithmaterials kompensiert. Die Zeolithe unterscheidet man hauptsächlich nach der Geometrie der Hohlräume, die durch das starre Netzwerk der SiO4/AlO4-Tetraeder gebildet werden. Die Eingänge zu den Hohlräumen werden von 8, 10 oder 12 "Ringen" gebildet (eng-, mittel- und weitporige Zeolithe) . Bestimmte Zeolithe zeigen einen gleichförmigen Strukturaufbau (z. B. ZSM-5 mit MFI-Topologie) mit linearen oder zickzackförmig verlaufenden Kanälen, bei anderen schließen sich hinter den Porenöffnungen größere Hohlräume an, z. B. bei den Y- und A- Zeolithen, mit den Topologien FAU und LTA.The zeolite structure contains voids and channels characteristic of each zeolite. The zeolites are classified according to their topology into different structures (see above). The zeolite framework contains open cavities in the form of channels and cages that are normally occupied by water molecules and extra framework cations that can be exchanged. An aluminum atom has an excess negative charge which is compensated by these cations. The interior of the pore system represents the catalytically active surface. The more aluminum and the less silicon a zeolite contains, the denser the negative charge in its lattice and the more polar its internal surface. The pore size and structure are determined by the Si / Al ratio, which determines most of the catalytic character of a zeolite, in addition to the parameters in the preparation (use or type of template, pH, pressure, temperature, presence of seed crystals) , Due to the presence of z. B. 3-valent atoms (eg., Al or Ga), the zeolite receives a negative lattice charge in the form of so-called Anionstellen, in the vicinity of which are the corresponding cation positions. The negative charge is compensated by the incorporation of cations into the pores of the zeolite material. The zeolites are distinguished mainly by the geometry of the cavities formed by the rigid network of SiO4 / AlO4 tetrahedra. The entrances to the cavities are formed by 8, 10 or 12 "rings" (narrow, medium and large pore zeolites). Certain zeolites show a uniform structure structure (eg ZSM-5 with MFI topology) with linear or zigzag running channels, in others close behind the pore openings larger cavities, eg. As in the Y and A zeolites, with the topologies FAU and LTA.
Grundsätzlich kann im Rahmen der vorliegenden Erfindung jeder Zeolith, insbesondere jeder 10 und 12 „Ring"-Zeolith, verwendet werden, der ein Siθ2/Al2θ3-Molverhältnis von 5:1 bis 150:1 aufweist. Erfindungsgemäß bevorzugt sind Zeolithe mit den Topologien AEL, BEA, CHA, EUO, FAO, FAU, FER, KFI, LTA, LTL, MAZ, MOR, MEL, MTW, LEV, OFF, TON und MFI. Ganz besonders bevorzugt Zeolithe der topologischen Strukturen FAU, MOR, BEA, MFI und MEL.In principle, any zeolite, in particular any 10 and 12 "ring" zeolite, which has a SiO 2 / Al 2 O 3 molar ratio of from 5: 1 to 150: 1, can be used in the context of the present invention the topologies AEL, BEA, CHA, EUO, FAO, FAU, FER, KFI, LTA, LTL, MAZ, MOR, MEL, MTW, LEV, OFF, TON and MFI Very particular preference is given to zeolites of the topological structures FAU, MOR, BEA , MFI and MEL.
Es gibt in Zeolithen üblicherweise drei verschiedene Zentren, die als so genannte α-, ß- und γ-Positionen bezeichnet werden, die die Position der Austauschplätze (auch als "austauschbare Positionen bzw. Stellen" bezeichnet) definieren. Alle diese drei Positionen sind für Reaktanten während der NH3-SCR- Reaktion zugänglich, insbesondere beim Einsatz von MFI, BEA, FAU, MOR, MTW und MEL Zeolithen. Überraschenderweise wurde festgestellt, dass die Verbesserung der Kaltstartemissionen von der NH3-Speicherfähigkeit des SCR- Katalysators abhängig ist. Die NH3-Speicherfähigkeit hängt jedoch von den (Br0nstedt) sauren Oberflächenzentren des erfin- dungsgemäß bevorzugt eingesetzten Zeoliths ab. Verschiedene Zeolithtypen weisen unterschiedlich starke, saure Zentren und damit ein unterschiedliches Adsorption- und Desorptionsverhal- ten auf. Stark saure Zentren bilden stärkere Bindungen zu den adsorbierten NH3-Molekülen aus, als schwach saure Zentren.There are usually three different centers in zeolites, referred to as α, β and γ positions, which define the position of the exchange sites (also referred to as "interchangeable locations"). All of these three positions are accessible to reactants during the NH 3 -SCR reaction, especially when using MFI, BEA, FAU, MOR, MTW, and MEL zeolites. Surprisingly, it has been found that the improvement in cold start emissions is dependent on the NH 3 storage capability of the SCR catalyst. However, the NH 3 storage capacity depends on the (BrOnstedt) acidic surface centers of the zeolite preferably used according to the invention. Different zeolite types have different acid sites and thus different adsorption and desorption behaviors. Strongly acidic centers form stronger bonds to the adsorbed NH 3 molecules than weakly acidic centers.
Es wurde gefunden, dass die Desorptionstemperatur bei einem Zeolithen mit überwiegend stark sauren Zentren wesentlich höher als bei schwach sauren Zentren ist. Somit kann erfindungsgemäß durch die geeignete Auswahl des Zeolithtypen die NH3- Speicherfunktion, d. h. die Menge des adsorbierenden NH3 bzw. des zu desorbierenden NH3 gezielt eingestellt werden. Da die Anzahl der sauren Zentren durch das Molverhältnis von SiO2 zu Al2O3 (das sogenannte „Modul") beeinflusst werden kann, ist somit durch Variation dieses Verhältnisses die NH3- Speicherkapazität eines SCR-Katalysators genau einstellbar.It has been found that the desorption temperature is significantly higher for a zeolite with predominantly strongly acidic centers than for weakly acidic centers. Thus, according to the invention, the NH 3 storage function, ie the amount of adsorbing NH 3 or of the NH 3 to be desorbed, can be adjusted in a targeted manner by suitably selecting the type of zeolite. Since the number of acidic centers can be influenced by the molar ratio of SiO 2 to Al 2 O 3 (the so-called "module"), the NH 3 storage capacity of an SCR catalyst can thus be precisely adjusted by varying this ratio.
Das erfindungsgemäß bevorzugte Siθ2/Al203-Modul (Molverhältnis) liegt im Bereich von 5:1 bis 150:1, besonders bevorzugt im Bereich von 5:1 bis 50:1 und ganz besonders bevorzugt im Bereich von 10:1 bis 30:1.The preferred SiO 2 / Al 2 O 3 modulus (molar ratio) is in the range from 5: 1 to 150: 1, more preferably in the range from 5: 1 to 50: 1 and most preferably in the range from 10: 1 to 30: 1st
Bevorzugt ist der NH3-Speicherzeolith in einer Menge von 2 bis 30 Gew.-%, besonders bevorzugt in einer Menge von 5 bis 15 Gew.-% in der katalytisch aktiven Zusammensetzung enthalten.The NH 3 storage zeolite is preferably present in an amount of from 2 to 30% by weight, more preferably in an amount of from 5 to 15% by weight, in the catalytically active composition.
Neben der Menge des Zeolithen kommt es wie vorstehend schon erläutert auch auf die Art des verwendeten Zeolithen an, da nicht alle Zeolithe eine optimale NH3-Speicherkapazität aufwei- sen. Bevorzugt ist der Zeolith deshalb ausgewählt aus der Gruppe umfassend FAU (Faujasit), MOR (Mordenit) , BEA (Beta- Zeolith) , MFI (Mobil Five, ZSM-5, Zeolite Secondary Mobile No. 5) und MEL, wobei auch Kombinationen der vorgenannten Zeo- lithe eingesetzt werden können. Vorzugsweise werden alle genannten Zeolithe in der H-Form eingesetzt. Die genannten Katalysatoren sowie Verfahren zu deren Herstellung sind dem Fachmann bekannt.In addition to the amount of zeolite, as already explained above, the type of zeolite used is important since not all zeolites have an optimum NH 3 storage capacity. sen. The zeolite is therefore preferably selected from the group comprising FAU (faujasite), MOR (mordenite), BEA (beta zeolite), MFI (Mobil Five, ZSM-5, Zeolite Secondary Mobile No. 5) and MEL, combinations of which above-mentioned zeolite can be used. Preferably, all said zeolites are used in the H form. The cited catalysts and processes for their preparation are known in the art.
In bevorzugten Weiterbildungen der Erfindung ist der NH3- Speicherzeolith ein metallausgetauschter Zeolith, beispielsweise ein Eisen, Kupfer oder Kobalt-ausgetauschter Zeolith. Bevorzugt ist der metallausgetauschte Zeolith ebenfalls ausgewählt aus der Gruppe umfassend FAU (Faujasit), MOR (Mordenit), BEA (Beta-Zeolith) , MFI (Mobil Five, ZSM-5, Zeolite Secondary Mobile No. 5) und MEL, wobei auch Kombinationen der genannten Zeolithe eingesetzt werden können.In preferred developments of the invention, the NH 3 storage zeolite is a metal-exchanged zeolite, for example an iron, copper or cobalt-exchanged zeolite. Preferably, the metal-exchanged zeolite is also selected from the group comprising FAU (faujasite), MOR (mordenite), BEA (beta zeolite), MFI (Mobil Five, ZSM-5, Zeolite Secondary Mobile No. 5) and MEL, including combinations said zeolites can be used.
Besonders bevorzugt ist es jedoch, wenn es sich bei dem me- tallausgetauschten Zeolithen nicht um ein Eisen-ausgetauschten Zeolithen in Kombination mit einem Übergangsmetall- ausgetauschten Zeolithen und/oder in Kombination mit einem Me- talloxid-ausgetauschten Zeolithen handelt, wobei das Übergangsmetalloxid ausgewählt ist aus der Gruppe bestehend aus Vanadiumpentoxid, Wolframtrioxid oder Titandioxid.However, it is particularly preferred if the metal-exchanged zeolite is not an iron-exchanged zeolite in combination with a transition-metal-exchanged zeolite and / or in combination with a metal oxide-exchanged zeolite, wherein the transition metal oxide is selected from the group consisting of vanadium pentoxide, tungsten trioxide or titanium dioxide.
Bei metallausgetauschten bzw. dotierten Zeolithen wird der Metallgehalt bzw. der Austauschgrad eines Zeolithen maßgeblich durch die im Zeolithen vorliegende Metallspezies bestimmt. Da- durch kann der Zeolith sowohl nur mit einem einzigen Metall oder mit verschiedenen Metallen dotiert sein. Die bevorzugten Metalle für den Austausch und die Dotierung sind katalytisch aktive Metalle wie Fe, Ce, Co, Ni, Ag, V, Rh, Pd, Pt, Ir. Er- findungsgemäß sind Zeolithe ganz besonders bevorzugt, die Eisen-, Kupfer oder Kobaltspezies enthalten. Die Herstellungsverfahren für metallausgetauschte Zeolithe, beispielsweise über Fest- oder Flüssigphasenaustausch, sind dem Fachmann be- kannt .In the case of metal-exchanged or doped zeolites, the metal content or the degree of exchange of a zeolite is decisively determined by the metal species present in the zeolite. As a result, the zeolite can be doped with only a single metal or with different metals. The preferred metals for exchange and doping are catalytically active metals such as Fe, Ce, Co, Ni, Ag, V, Rh, Pd, Pt, Ir. He- According to the invention, very particular preference is given to zeolites which contain iron, copper or cobalt species. The production processes for metal-exchanged zeolites, for example via solid or liquid phase exchange, are known to the person skilled in the art.
Zusätzlich zu der NH3-Speicherkomponente benötigt der SCR- Katalysator auch noch eine SCR-aktive Komponente. Dies kann beispielsweise eine herkömmliche auf Vanadium/Titan/Wolfram basierende Komponente sein. Typischerweise ist die auf Vanadium/Titan/Wolfram basierende Komponente eine oxidische Be- schichtung, die im Wesentlichen TiÜ2 in der Anatas-Modifikation enthält. TiO2 wird dabei in der Regel durch WO3 stabilisiert, um eine Verbesserung seiner thermischen Haltbarkeit zu errei- chen. Der Anteil an WO3 liegt dabei typischerweise bei ca. 10 Gew.-%. Die eigentlich aktive Komponente bildet das V2O5, das typischerweise als Monolage auf den TiO2 Partikeln vorliegt. Möglich ist ebenfalls die Zugabe noch einer weiteren NH3- Speicherkomponente wie es weiter unten vorgeschlagen wird.In addition to the NH 3 storage component, the SCR catalyst also requires an SCR active component. This may be, for example, a conventional vanadium / titanium / tungsten based component. Typically, the vanadium / titanium / tungsten based component is an oxide coating that essentially contains TiO 2 in the anatase modification. As a rule, TiO 2 is stabilized by WO 3 in order to achieve an improvement in its thermal stability. The proportion of WO 3 is typically about 10 wt .-%. The actually active component forms the V 2 O 5 , which is typically present as a monolayer on the TiO 2 particles. It is also possible to add another NH 3 storage component, as will be suggested below.
Ein Vorteil einer z.B. auf Vanadium basierenden Komponente als SCR-aktive Komponente ist die hervorragende Tieftemperaturak- tivität eines solchen Systems. Durch die erfindungsgemäße Kombination von auf Vanadium basierenden Katalysatoren mit Zeoli- then kann man sich somit die Tieftemperaturaktivität dieser Katalysatoren und zugleich die NH3-Speicherfähigkeit der Zeolithe zunutze machen und damit einen SCR-Katalysator mit hervorragenden Kaltstarteigenschaften bereitzustellen.An advantage of, for example, a vanadium based component as the SCR active component is the excellent low temperature activity of such a system. The inventive combination of vanadium-based catalysts with zeolites can thus make use of the low-temperature activity of these catalysts and, at the same time, the NH 3 storage capacity of the zeolites, thus providing an SCR catalyst with excellent cold-start properties.
Alternativ zu der auf Vanadium basierenden SCR-aktiven Komponente kann erfindungsgemäß auch ein SCR-aktiver Zeolith (z.B. ein metalldotierter bzw. -ausgetauschter Zeolith wie ein Cu- Zeolith oder Fe-Zeolith eingesetzt werden. In weiteren vorteilhaften Ausgestaltungen der Erfindung werden damit viele Kombinationsmöglichkeiten für einen SCR- Katalysator bereitgestellt, der an den jeweiligen Einsatzbe- reich gezielt angepasst werden kann. Beispielsweise kann erfindungsgemäß ein SCR-aktiver Zeolith, der bei tiefen Temperaturen aktiv ist, mit einem SCR-aktiven Zeolith, der bei höheren Temperaturen aktiv ist und einem NH3-Speicherzeolithen kombiniert werden.As an alternative to the vanadium-based SCR-active component, it is also possible according to the invention to use an SCR-active zeolite (for example a metal-doped or exchanged zeolite, such as a Cu zeolite or Fe zeolite. In further advantageous embodiments of the invention, this provides many possible combinations for an SCR catalyst, which can be specifically adapted to the respective area of use. For example, according to the invention, an SCR-active zeolite which is active at low temperatures can be combined with an SCR-active zeolite which is active at higher temperatures and an NH 3 storage zeolite.
Unter „tiefen Temperaturen" werden vorliegend Temperaturen im Bereich von unter 280 0C, bevorzugt unter 250 0C, unter „hohen Temperaturen" werden vorliegend Temperaturen im Bereich von mehr als 350 0C, bevorzugt mehr als 400 0C, verstanden. Ein entsprechendes Beispiel für eine derartige Kombination bildet beispielsweise eine Mischung aus einem kupferausgetauschten Zeolithen wie Cu-ZSM-5 mit einem Modul von 150, der eine Tie- fentemperaturaktivität aufweist, einem eisenausgetauschten Zeolithen, wie z. B. Fe-BEA mit einem Modul von 35, der eine Hochtemperaturaktivität aufweist, sowie einem nichtmetallausgetauschten Zeolithen wie H-BEA mit einem Modul von 20, der als NH3-Speicherzeolith dient.In the present context, "low temperatures" are temperatures in the range below 280 ° C., preferably below 250 ° C. "high temperatures" are understood to mean temperatures in the range of more than 350 ° C., preferably more than 400 ° C. A corresponding example of such a combination is, for example, a mixture of a copper-exchanged zeolite such as Cu-ZSM-5 with a modulus of 150, which has a low-temperature, an iron-exchanged zeolite, such. B. Fe-BEA with a modulus of 35 exhibiting high temperature activity and a non-metal exchanged zeolite such as H-BEA with a modulus of 20 serving as the NH 3 storage zeolite.
Damit ist eine gute katalytische Umsetzung von tiefen bis ho- hen Temperaturen an einen Katalysator, der die erfindungsgemäße Kombination als katalytische Zusammensetzung erhält, gegeben.Thus, a good catalytic reaction of low to high temperatures is given to a catalyst which receives the combination according to the invention as a catalytic composition.
Erfindungsgemäß hat es sich auch als Vorteil herausgestellt, wenn die katalytisch aktive Zusammensetzung des SCR-According to the invention, it has also turned out to be an advantage if the catalytically active composition of the SCR
Katalysators in Form einer zumindest bereichsweisen Beschich- tung auf einem bevorzugt monolithischen Träger vorliegt. Als monolithische Träger kommen beispielsweise metallische oder keramische Träger z.B. in Waben- oder Schaumform zum Einsatz.Catalyst in the form of an at least partially coating on a preferably monolithic carrier is present. When For example, monolithic carriers are metallic or ceramic carriers, for example in honeycomb or foam form.
Besonders vorteilhaft hat es sich erwiesen, wenn die NH3- Speicherkomponente nur an der Eintrittsseite und die SCR- aktive Komponente nur an der Austrittsseite eines solchen beschichteten monolithischen Trägers aufgebracht sind. Ebenso wäre es möglich, dass sämtliche Komponenten wie beispielsweise die NH3-Speicherkomponente und die SCR-aktive Komponente (n) als homogene Beschichtung auf die gesamte Oberfläche des Monolithen aufgebracht werden, was insgesamt die Herstellung derartiger Katalysatoren bedeutend vereinfacht.It has proven to be particularly advantageous if the NH 3 storage component is applied only on the inlet side and the SCR-active component only on the outlet side of such a coated monolithic carrier. It would also be possible for all of the components, such as the NH 3 storage component and the SCR active component (s), to be applied as a homogeneous coating to the entire surface of the monolith, thus greatly simplifying the preparation of such catalysts.
Die Aufbringung des SCR-Katalysators erfolgt dabei nach im Stand der Technik bekannten Methoden, beispielsweise durch Aufbringen eines Washcoats, durch Beschichtung im Tauchbad oder durch Sprühbeschichtung vorgenommen werden.The application of the SCR catalyst is carried out according to methods known in the art, for example by applying a washcoat, by coating in an immersion bath or by spray coating.
Der erfindungsgemäße SCR-Katalysator eignet sich demgemäß her- vorragend zur Verringerung von Stickoxidemission von mobilen oder stationären Verbrennungseinrichtungen.Accordingly, the SCR catalyst according to the invention is outstandingly suitable for reducing nitrogen oxide emission from mobile or stationary combustion devices.
Mobile Verbrennungseinrichtungen im Sinne dieser Erfindung sind beispielsweise Verbrennungsmotoren von Kraftfahrzeugen, insbesondere Dieselmotoren, Stromerzeugungsaggregate auf Basis von Verbrennungsmotoren, oder sonstige Aggregate auf Basis von Verbrennungsmotoren .Mobile combustion devices in the context of this invention are, for example, internal combustion engines of motor vehicles, in particular diesel engines, power generators based on internal combustion engines, or other units based on internal combustion engines.
Bei den stationären Verbrennungseinrichtungen handelt es sich gewöhnlich um Kraftwerksanlagen, Feuerungsanlagen, Müllverbrennungsanlagen und auch um Heizungssysteme von Privathaushalten. Somit ist auch Gegenstand der Erfindung ein Verfahren zur Verringerung von Stickoxidemissionen in mobilen oder stationären Verbrennungseinrichtungen, wobei das Verfahren dadurch gekennzeichnet ist, dass ein Abgasstrom über einen erfindungsgemäßen SCR-Katalysator geleitet wird.The stationary combustion facilities are usually power plants, combustion plants, waste incineration plants and also heating systems of private households. Thus, the subject matter of the invention is also a method for reducing nitrogen oxide emissions in mobile or stationary incinerators, the method being characterized in that an exhaust gas stream is passed over an SCR catalyst according to the invention.
Die Erfindung wird nun anhand der nachfolgenden Beispiele und Figuren, die jedoch nicht als beschränkend zu verstehen sind, näher erläutert.The invention will now be explained in more detail with reference to the following examples and figures, which, however, are not intended to be limiting.
Es zeigenShow it
Fig . l die NH3-Speicherf ähigkeit von Zeolithen in Abhängigkeit vom Si02/Al2θ3-Modul ,Fig. l the NH 3 storage capacity of zeolites as a function of the Si0 2 / Al 2 O 3 modulus,
Fig.2 ein TPD Diagramm der NH3 Desorption bei einem Fe dotierten Zeolithen vom TYP MFI mit einem Modul von 25.2 shows a TPD diagram of the NH 3 desorption in a Fe-doped zeolite of type MFI with a modulus of 25.
Figur 1 zeigt die NH3~Speicherfähigkeit von Zeolithen in Abhän- gigkeit vom Siθ2/Al2θ3-Modul .FIG. 1 shows the NH 3 storage capacity of zeolites as a function of the SiO 2 / Al 2 O 3 module.
Wie aus Figur 1 ersichtlich ist, liegt das optimale Modul im Bereich von 5 bis 50, ganz besonders bevorzugt im Bereich von 10 bis 30.As can be seen from Figure 1, the optimum modulus is in the range of 5 to 50, most preferably in the range of 10 to 30.
Dies trifft insbesondere auf die im automobilen Bereich bevorzugt in Frage kommenden Zeolithtypen mit der Topologie FAU, MOR, BEA, MFI, MEL zu. Diese werden einzeln oder als Mischungen eingesetzt.This applies in particular to the types of zeolites which may be preferred in the automotive sector with the topology FAU, MOR, BEA, MFI, MEL. These are used individually or as mixtures.
Jedoch wird die Auswahl des Moduls auch durch die Analyse des späteren Einsatzbereichs und der Bedingungen bestimmt. Der Einsatzbereich des Katalysators wird von mehreren Faktoren be- stimmt. Beispielsweise unterscheidet sich der Temperaturbereich im Betrieb von Pkw zu Lkw erheblich. Typische Arbeitsbereiche von Verbrennungsmotoren im Lkw liegen dabei zwischen 180 bis 430 0C, bei Pkw werden oft Temperaturen bis 600 0C er- reicht. Grundsätzlich gilt, dass, je kleiner die Motoren sind (in Bezug auf ihren Hubraum) desto verstärkt tritt ein Volllastbetrieb auf und damit steigen die Temperaturen an. Weiter spielt eine Rolle, ob im Abgassystem der SCR-Katalysator vor oder nach dem Dieselpartikelfilter (DPF) eingebaut wird, da sich während der Regenerierung des Dieselpartikelfilters durch Abbrennen des gesammelten Rußes im Filter oberhalb von ca. 600 0C hohe Temperaturspitzen bilden können. Daraus ergibt sich, dass insbesondere bei längeren thermischen Belastungen des SCR-Katalysators hochtemperaturstabile Zeolithe mit mög- liehst hohem Modul verwendet werden, wofür als nicht einschränkende Beispiele Fe-BEA mit einem Modul von 50 oder Fe- ZSM-5 mit einem Modul von 150 genannt werden.However, the selection of the module is also determined by the analysis of the later field of application and the conditions. The range of application of the catalyst is determined by several factors Right. For example, the temperature range in operation varies considerably from car to truck. Typical work areas of internal combustion engines in trucks are between 180 and 430 0 C, and in the case of passenger cars temperatures of up to 600 0 C are often reached. Basically, the smaller the engines are (in terms of their cubic capacity), the more intensively a full-load operation occurs and thus the temperatures rise. Plays a role, whether installed in the exhaust system of the SCR catalyst before or after the diesel particulate filter (DPF), there can form high temperature peaks during the regeneration of the diesel particulate filter by burning off the collected PM in the filter above about 600 0 C. It follows that high-temperature-stable zeolites with the highest possible modulus are used, in particular for longer thermal loads on the SCR catalyst, for which Fe-BEA with a modulus of 50 or Fe-ZSM-5 with a modulus of 150 is mentioned as non-limiting examples become.
Mit steigendem Modul steigt auch die hydrothermale Stabilität und damit die Hochtemperaturstabilität. Die NH3- Aufnahmefähigkeit verläuft wie der Figur 1 zu entnehmen ist genau gegenläufig. Daraus ergibt sich der oben angegebene erfindungsgemäß bevorzugte Bereich.As the modulus increases, so does the hydrothermal stability and thus the high temperature stability. The NH 3 absorption capacity runs as shown in FIG. 1 and is exactly opposite. This results in the above-mentioned preferred range according to the invention.
Allerdings sind nicht alle Bereiche des Moduls mit jedem erfindungsgemäß einsetzbaren Zeolithtyp zugänglich. Beispielsweise können mit einem BEA-Zeolithen nur SiO2: Al2O3- Verhältnisse von oberhalb 19 erreicht werden. Zur Erreichung einer bestimmten Speicherkapazität von NH3 muss daher im Falle einer Verwendung derartiger Zeolithe die Menge erhöht werden. Bei den erfindungsgemäß bevorzugten Zeolithen liegen die Unter- und Obergrenzen für die SiO2 : Al2θ3~Verhältnisse (Module) wie folgt: FAU: 3 - 10, MOR : 10 - 400, BEA : 19 - 1000, MFI : 19-1000, MEL : 19-1000.However, not all areas of the module are accessible with any type of zeolite which can be used according to the invention. For example, with a BEA zeolite, only SiO 2 : Al 2 O 3 ratios of above 19 can be achieved. In order to achieve a certain storage capacity of NH3, therefore, in the case of using such zeolites, the amount must be increased. In the case of the zeolites preferred according to the invention, the lower and upper limits for the SiO 2 : Al 2 O 3 ratios (modules) are as follows: FAU: 3 - 10, MOR: 10 - 400, BEA: 19 - 1000, MFI: 19-1000, MEL: 19-1000.
Figur 2 zeigt das Ergebnis der temperaturprogrammierten De- sorption (TPD) von NH3 bei einem eisenausgetauschten Zeolithen mit der Topologie MFI und einem Si02/Al203-Modul von 25.FIG. 2 shows the result of temperature-programmed desorption (TPD) of NH 3 in an iron-exchanged zeolite with the topology MFI and a SiO 2 / Al 2 O 3 modulus of 25.
Aus Figur 2 ist ersichtlich, dass die höchste Desorption im Bereich von 200 - 290 °C gefolgt von einem weiteren Maximum zwischen 310 - 400 0C stattfindet.From Figure 2 it can be seen that the highest desorption in the range of 200 - 290 ° C followed by another maximum between 310 - 400 0 C takes place.
Dabei wurde wie folgt vorgegangen:The procedure was as follows:
Der Zeolith mit dem erfindungsgemäßen Modul wurde mit NH3 gesättigt. Das heißt, die maximal mögliche NH3-Konzentration wurde auf der Oberfläche adsorbiert und anschließend durch Temperaturerhöhung wieder desorbiert. Die Menge an NH3 wurde über ein Massenspektrometer detektiert und gleichzeitig mit der Ab- gabetemperatur korreliert. Damit konnte sowohl die Menge als auch die Temperatur bei der die Desorption erfolgte bestimmt werden, worauf Hinweise zur Stärke der Bindung zwischen NH3 und dem Zeolithen erhalten wurden.The zeolite with the module according to the invention was saturated with NH 3 . That is, the maximum possible NH 3 concentration was adsorbed on the surface and then desorbed by increasing the temperature. The amount of NH 3 was detected by a mass spectrometer and simultaneously correlated with the discharge temperature. Thus, both the quantity and the temperature at which the desorption occurred could be determined what evidence was obtained to the strength of the bond between NH 3 and the zeolite.
Die Testbedingungen waren wie folgt :The test conditions were as follows:
NH3-Beladung: Gas : 0,473 % NH3 in HeNH 3 loading: gas: 0.473% NH 3 in He
Beladungstemperatur [0C] : 110Loading temperature [ 0 C]: 110
NH3-Desorption: Gas: HeliumNH 3 desorption: gas: helium
Heizrate [°C/min] : 5Heating rate [° C / min]: 5
Endtemperatur [0C] : 750Final temperature [ 0 C]: 750
Haltedauer [h] : 1 NH3-Detektion mit Massenspektrometer, Massezahl 16: Peakflächen-Kalibrierung (FE/μmol NH3] : l,16E-08 Peakfläche-Desorption [FE] : l,13E-06Holding time [h]: 1 NH3 detection with mass spectrometer, mass number 16: Peak area calibration (FE / μmol NH 3 ): l, 16E-08 peak area desorption [FE]: l, 13E-06
Ausführungsbeispieleembodiments
Beispiel 1:Example 1:
Herstellung des Katalysators 1Preparation of the catalyst 1
Als Trägerstruktur wurde ein keramischer Träger der Firma NGK mit einer Wabendichte von 400 cpsi verwendet. Zur Herstellung des Washcouts mit der katalytisch aktiven Zusammensetzung für den SCR-Katalysator wurden 90 g TiO2-Pulver, 10 g WO3, 20 gThe carrier structure used was a ceramic carrier from NGK with a honeycomb density of 400 cpsi. To prepare the washcoat with the catalytically active composition for the SCR catalyst, 90 g of TiO 2 powder, 10 g of WO 3 , 20 g
ZSM-5, 20 g SiO2-SoI, 15 g TiO2-SoI, 20 ml 10%ige wässrigeZSM-5, 20 g SiO 2 sol, 15 g TiO 2 sol, 20 ml 10% aqueous
Vanadyloxalat-Lösung und 80 g destilliertes Wasser miteinander vermischt. Der ZSM-5-Zeolith wies ein Modul von 25 auf.Vanadyl oxalate solution and 80 g of distilled water mixed together. The ZSM-5 zeolite had a modulus of 25.
Der so hergestellte Washcoat wurde auf den keramischen Monolithen unter Vibration aufgebracht, wobei das Volumen des Wash- coats 50 - 120 % des Trägervolumens entsprach. Mittels an sich bekannter Verfahren wurde der Monolith entleert. Die Washcoat- Reste an der Auslaufseite des Monolithen wurden abgesaugt. Der so erhaltene SCR-Katalysator wurde dann bei 80 0C getrocknet und bei ca. 500 0C für 5 Stunden kalziniert.The washcoat thus prepared was vibrated on the ceramic monolith with the volume of the washcoat equal to 50-120% of the carrier volume. By means of known methods, the monolith was emptied. The washcoat residues on the outlet side of the monolith were sucked off. The SCR catalyst thus obtained was then dried at 80 ° C. and calcined at about 500 ° C. for 5 hours.
Analoges gilt bei der Verwendung von beispielsweise metallischen Monolithen, die anstelle des in Beispiel 1 verwendeten keramischen Monolithen ebenso verwendet werden können.The same applies to the use of, for example, metallic monoliths which can be used in place of the ceramic monoliths used in Example 1 as well.
Beispiel 2:Example 2:
Herstellung des Katalysators 2 Als Tragerstruktur wurde die gleiche Struktur wie in Beispiel 1 verwendet. Zur Herstellung des Washcoats wurden 90 g TiO2- Pulver, 10 g WO3, 10 g ZSM-5, 10 g BEA, 20 g SiO2-SoI, 15 g TiO2-SoI, 20 ml 10%ige wassrige Vanadyloxalat-Losung und 80 g destilliertes Wasser miteinander vermischt. Der ZSM-5-Zeolith wies dabei ein Modul von 25 auf, der BEA-Zeolith ein Modul von 150.Preparation of the catalyst 2 As the support structure, the same structure as in Example 1 was used. To prepare the washcoat, 90 g of TiO 2 powder, 10 g of WO 3 , 10 g of ZSM-5, 10 g of BEA, 20 g of SiO 2 sol, 15 g of TiO 2 sol, 20 ml of 10% aqueous vanadyl oxalate solution and 80 g of distilled water mixed together. The ZSM-5 zeolite had a modulus of 25, the BEA zeolite a modulus of 150.
Der so hergestellte Washcoat wurde wie in Beispiel 1 auf den Monolithen aufgebracht und anschließend kalziniert.The washcoat thus prepared was applied to the monolith as in Example 1 and then calcined.
Beispiel 3 :Example 3:
Herstellung des Vergleichskatalysators , Katalysator 3Preparation of the Comparative Catalyst, Catalyst 3
Als Tragerstruktur wurde die gleiche Struktur wie in Beispiel 1 verwendet .As the support structure, the same structure as in Example 1 was used.
Zur Herstellung des Washcoats wurden 110 g Tiθ2~Pulver, 10 g WO3, 20 g SiO2-SoI, 15 g TiO2-SoI, 20 ml 10%ige wassrige Vanadyloxalat-Losung und 80 g destilliertes Wasser miteinander vermischt . Der so hergestellte Washcoat wurde wie in Beispiel 1 auf den Monolithen aufgebracht und kalziniert.To prepare the washcoat, 110 g of TiO 2 powder, 10 g of WO 3 , 20 g of SiO 2 sol, 15 g of TiO 2 sol, 20 ml of 10% aqueous vanadyl oxalate solution and 80 g of distilled water were mixed together. The washcoat so prepared was applied to the monolith as in Example 1 and calcined.
Mit den so erhaltenen Katalysatoren der Beispiele 1 bis 3 wurden LaborprufStandsuntersuchungen mit simuliertem Kaltstart und simulierten Lastwechseln an einem dynamischen Prufstand für schnelle Wechsel von Temperatur, Abgas und Durchsatz durchgeführt . Die Auswertung wurde als Korrelation der erfindungsgemäßen Katalysatoren 1 und 2 in Bezug auf den Vergleichskatalysator aus Beispiel 3 durchgeführt. Kriterien waren insbesondere das Kaltstartverhalten und das Verhalten bei Lastwechsel.With the catalysts of Examples 1 to 3 thus obtained, laboratory test investigations with simulated cold start and simulated load changes were carried out on a dynamic test stand for rapid changes of temperature, exhaust gas and throughput. The evaluation was carried out as a correlation of the inventive catalysts 1 and 2 with respect to the comparative catalyst from Example 3. The criteria were in particular the cold start behavior and the behavior during load changes.
Der Kaltstart wurde durch eine Temperaturerhöhung von Raumtemperatur auf 400 0C mit einer Aufheizrate von 50 K/min simuliert. Durch eine schnelle Änderung des Durchsatzes und der Temperatur wird ein Lastwechsel von Volllast zu Leerlauf und umgekehrt simuliert. Dabei wurden die Raumgeschwindigkeit von 100.000 h"1 und die Temperatur von 400 0C (Volllast) auf eine Raumgeschwindigkeit von 30.000 h"1 und eine Temperatur von 180 0C (Leerlauf) geändert.The cold start was simulated by a temperature increase from room temperature to 400 0 C with a heating rate of 50 K / min. Rapid change of throughput and temperature simulates a load change from full load to idle and vice versa. The space velocity of 100,000 h "1 and the temperature of 400 0 C (full load) were changed to a space velocity of 30,000 h " 1 and a temperature of 180 0 C (idle).
Es zeigte sich, dass durch die Adsorption von NH3 durch eine erfindungsgemäße NH3~Speicherkomponente in der katalytischen Zusammensetzung schon in der Kaltstartphase nennenswerte Um- satzerhöhungen erreicht wurden (s. Tabelle 1) . Der (vorkonditionierte) Katalysator verfügte über bereits adsorbiertes NH3 und zeigte daher diesen Effekt. Gleiches wurde bei plötzlicher Erhöhung der NOx-Konzentration erhalten (Wechsel Leerlauf nach Volllast) , wobei auch hier auf das NH3-Reservoir zugegriffen werden konnte. Bei einer plötzlichen NOx-Verminderung (Wechsel Volllast nach Leerlauf) wird überdosiertes NH3 in der Speicher- komponente eingespeichert und damit verringert sich der NH3- Schlupf (s. Tabelle 1) .It was found that by the adsorption of NH 3 by an inventive NH 3 - storage component in the catalytic composition in the cold start phase significant increases in sales were achieved (see Table 1). The (preconditioned) catalyst had already adsorbed NH 3 and therefore exhibited this effect. The same was obtained with a sudden increase in the NO x concentration (change idle to full load), which also here on the NH 3 reservoir could be accessed. In the event of a sudden reduction in NO x (change from full load to idling), overdosed NH 3 is stored in the storage component and thus the NH 3 slip is reduced (see Table 1).
Die Abgaszusammensetzung entsprach einem typischen Diesel-PKW und es wurde ein Lastwechsel zwischen Volllast und Leerlauf simuliert.The exhaust gas composition corresponded to a typical diesel car and a load change between full load and idle was simulated.
Die Ergebnisse sind in der Tabelle 1 dargestellt. Tabelle 1: Ergebnisse der erfindungsgemäßen Katalysatoren in Bezug auf den Vergleichskatalysator 3The results are shown in Table 1. Table 1: Results of the catalysts according to the invention in relation to the comparative catalyst 3
Beide erfindungsgemäßen Katalysatoren zeigten eine signifikante Verbesserung in Bezug auf den NOx-Umsatz und einen verminderten NH3-Schlupf am Katalysatoraustritt. Both catalysts according to the invention showed a significant improvement with respect to the NO x conversion and a reduced NH 3 slip at the catalyst outlet.
Claims
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE102008010330A DE102008010330A1 (en) | 2008-02-21 | 2008-02-21 | SCR catalytic converter with ammonia storage function |
| DE102008010330.6 | 2008-02-21 |
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| WO2009103549A1 true WO2009103549A1 (en) | 2009-08-27 |
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Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP2130605A3 (en) * | 2008-05-20 | 2010-03-10 | Ibiden Co., Ltd. | Exhaust gas treating apparatus |
| EP2130604A3 (en) * | 2008-05-20 | 2010-03-10 | Ibiden Co., Ltd. | Honeycomb structure |
| CN101791549A (en) * | 2010-03-30 | 2010-08-04 | 东南大学 | Method for preparing formed selective catalytic reduction denitration catalyst by using ultrasonic mixing sedimentation method |
| EP2324915A1 (en) * | 2009-11-19 | 2011-05-25 | Ibiden Co., Ltd. | Honeycomb structure and exhaust gas converter |
| WO2014128270A1 (en) * | 2013-02-25 | 2014-08-28 | Umicore Ag & Co. Kg | Scr catalytic converter having improved nox conversion |
| US9512760B2 (en) | 2014-12-15 | 2016-12-06 | Caterpillar Inc. | Aftertreatment system implementing low-temperature SCR |
| WO2018115045A1 (en) | 2016-12-20 | 2018-06-28 | Umicore Ag & Co. Kg | Scr catalyst device containing vanadium oxide and molecular sieve containing iron |
| WO2018115044A1 (en) | 2016-12-20 | 2018-06-28 | Umicore Ag & Co. Kg | Scr catalyst device containing vanadium oxide and molecular sieve containing iron |
| CN110668463A (en) * | 2019-11-06 | 2020-01-10 | 中国天辰工程有限公司 | A kind of preparation method of titanium-containing high-silicon-aluminum ratio mordenite |
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| WO2014173813A2 (en) | 2013-04-23 | 2014-10-30 | Bayer Technology Services Gmbh | Catalyst and method for the direct aromatisation of methane |
| WO2014173824A1 (en) | 2013-04-23 | 2014-10-30 | Bayer Technology Services Gmbh | Process for the preparation of benzene from methane and carbon dioxide |
| WO2014173791A1 (en) | 2013-04-23 | 2014-10-30 | Bayer Technology Services Gmbh | Process for the preparation of benzene from methane and carbon dioxide with a fluid-tight dividing wall in the reactor |
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| DE102004058210A1 (en) * | 2004-12-02 | 2006-06-14 | Hte Ag The High Throughput Experimentation Company | Integrated catalyst system to remove e.g. nitric oxides from exhaust gases comprises nitric oxide storing component, ammonia-generating component, ammonia-storing component and selective catalytic reduction component on common substrate |
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| GB9808876D0 (en) * | 1998-04-28 | 1998-06-24 | Johnson Matthey Plc | Combatting air pollution |
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| DE102006031724B3 (en) * | 2006-07-08 | 2008-04-30 | Umicore Ag & Co. Kg | Structured selective catalytic reduction-catalyst, useful for removing nitrogen oxide in exhaust gas, comprises catalytically active material zones of iron-exchanged zeolite and transition metal-exchanged zeolite |
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- 2008-02-21 DE DE102008010330A patent/DE102008010330A1/en not_active Withdrawn
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| EP0773057A1 (en) * | 1995-11-09 | 1997-05-14 | Toyota Jidosha Kabushiki Kaisha | Exhaust gas purifying catalyst |
| EP1222952A1 (en) * | 2001-01-11 | 2002-07-17 | Delphi Technologies, Inc. | NOx catalyst comprising alkaline earth-alumina and alkaline earth-zeolite |
| DE102004058210A1 (en) * | 2004-12-02 | 2006-06-14 | Hte Ag The High Throughput Experimentation Company | Integrated catalyst system to remove e.g. nitric oxides from exhaust gases comprises nitric oxide storing component, ammonia-generating component, ammonia-storing component and selective catalytic reduction component on common substrate |
| US20080286184A1 (en) * | 2007-05-09 | 2008-11-20 | N.E Chemcat Corporation | Selective catalytic reduction type catalyst, and exhaust gas purification equipment and purifying process of exhaust gas using the same |
Cited By (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP2130605A3 (en) * | 2008-05-20 | 2010-03-10 | Ibiden Co., Ltd. | Exhaust gas treating apparatus |
| EP2130604A3 (en) * | 2008-05-20 | 2010-03-10 | Ibiden Co., Ltd. | Honeycomb structure |
| US8105544B2 (en) | 2008-05-20 | 2012-01-31 | Ibiden Co., Ltd. | Exhaust gas treating apparatus |
| EP2324915A1 (en) * | 2009-11-19 | 2011-05-25 | Ibiden Co., Ltd. | Honeycomb structure and exhaust gas converter |
| CN101791549A (en) * | 2010-03-30 | 2010-08-04 | 东南大学 | Method for preparing formed selective catalytic reduction denitration catalyst by using ultrasonic mixing sedimentation method |
| CN101791549B (en) * | 2010-03-30 | 2012-09-05 | 东南大学 | Method for preparing formed selective catalytic reduction denitration catalyst by using ultrasonic mixing sedimentation method |
| WO2014128270A1 (en) * | 2013-02-25 | 2014-08-28 | Umicore Ag & Co. Kg | Scr catalytic converter having improved nox conversion |
| US9694320B2 (en) | 2013-02-25 | 2017-07-04 | Umicore Ag & Co. Kg | SCR catalytic converter having improved NOx conversion |
| US9512760B2 (en) | 2014-12-15 | 2016-12-06 | Caterpillar Inc. | Aftertreatment system implementing low-temperature SCR |
| WO2018115045A1 (en) | 2016-12-20 | 2018-06-28 | Umicore Ag & Co. Kg | Scr catalyst device containing vanadium oxide and molecular sieve containing iron |
| WO2018115044A1 (en) | 2016-12-20 | 2018-06-28 | Umicore Ag & Co. Kg | Scr catalyst device containing vanadium oxide and molecular sieve containing iron |
| US11229901B2 (en) | 2016-12-20 | 2022-01-25 | Umicore Ag & Co. Kg | SCR catalyst device containing vanadium oxide and molecular sieve containing iron |
| US11300029B2 (en) | 2016-12-20 | 2022-04-12 | Umicore Ag & Co, Kg | SCR catalyst device containing vanadium oxide and molecular sieve containing iron |
| CN110668463A (en) * | 2019-11-06 | 2020-01-10 | 中国天辰工程有限公司 | A kind of preparation method of titanium-containing high-silicon-aluminum ratio mordenite |
| CN110668463B (en) * | 2019-11-06 | 2021-04-02 | 中国天辰工程有限公司 | A kind of preparation method of titanium-containing high-silicon-aluminum ratio mordenite |
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| DE102008010330A1 (en) | 2009-09-03 |
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