EP3946692A1 - Filtre à particules à activité catalytique - Google Patents

Filtre à particules à activité catalytique

Info

Publication number
EP3946692A1
EP3946692A1 EP19716102.9A EP19716102A EP3946692A1 EP 3946692 A1 EP3946692 A1 EP 3946692A1 EP 19716102 A EP19716102 A EP 19716102A EP 3946692 A1 EP3946692 A1 EP 3946692A1
Authority
EP
European Patent Office
Prior art keywords
oxide
filter
coating
oxygen storage
channels
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP19716102.9A
Other languages
German (de)
English (en)
Inventor
Jan Schoenhaber
Naina DEIBEL
Martin Roesch
Joerg-Michael Richter
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Umicore AG and Co KG
Original Assignee
Umicore AG and Co KG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Umicore AG and Co KG filed Critical Umicore AG and Co KG
Publication of EP3946692A1 publication Critical patent/EP3946692A1/fr
Pending legal-status Critical Current

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Classifications

    • 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
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/19—Catalysts containing parts with different compositions
    • 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
    • F01N3/101—Three-way catalysts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9445—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
    • B01D53/945—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific catalyst
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9459—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts
    • B01D53/9463—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts with catalysts positioned on one brick
    • B01D53/9468—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts with catalysts positioned on one brick in different layers
    • 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
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/002—Mixed oxides other than spinels, e.g. perovskite
    • 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
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/10—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of rare earths
    • 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
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B01J23/46—Ruthenium, rhodium, osmium or iridium
    • B01J23/464—Rhodium
    • 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
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/54—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
    • B01J23/56—Platinum group metals
    • B01J23/63—Platinum group metals with rare earths or actinides
    • 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
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J35/61—Surface area
    • B01J35/613—10-100 m2/g
    • 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
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J35/61—Surface area
    • B01J35/615—100-500 m2/g
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/033—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices
    • F01N3/035—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/10—Noble metals or compounds thereof
    • B01D2255/102—Platinum group metals
    • B01D2255/1023—Palladium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/10—Noble metals or compounds thereof
    • B01D2255/102—Platinum group metals
    • B01D2255/1025—Rhodium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/206—Rare earth metals
    • B01D2255/2061—Yttrium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/206—Rare earth metals
    • B01D2255/2063—Lanthanum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/209—Other metals
    • B01D2255/2092—Aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/40—Mixed oxides
    • B01D2255/407—Zr-Ce mixed oxides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/902—Multilayered catalyst
    • B01D2255/9022—Two layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/908—O2-storage component incorporated in the catalyst
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/915—Catalyst supported on particulate filters
    • B01D2255/9155—Wall flow filters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/92—Dimensions
    • B01D2255/9207—Specific surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2258/00—Sources of waste gases
    • B01D2258/01—Engine exhaust gases
    • B01D2258/014—Stoichiometric gasoline engines
    • 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
    • F01N2510/00—Surface coverings
    • F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction
    • F01N2510/068—Surface coverings for exhaust purification, e.g. catalytic reaction characterised by the distribution of the catalytic coatings
    • F01N2510/0682—Surface coverings for exhaust purification, e.g. catalytic reaction characterised by the distribution of the catalytic coatings having a discontinuous, uneven or partially overlapping coating of catalytic material, e.g. higher amount of material upstream than downstream or vice versa
    • 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
    • F01N2570/00—Exhaust treating apparatus eliminating, absorbing or adsorbing specific elements or compounds
    • F01N2570/16—Oxygen

Definitions

  • the present invention relates to a catalytically active particle filter which is particularly suitable for the removal of particles, carbon monoxide, hydrocarbons and nitrogen oxides from the exhaust gas of internal combustion engines operated with a stoichiometric air / fuel mixture.
  • Exhaust gases from internal combustion engines operated with a stoichiometric air / fuel mixture ie gasoline engines, are cleaned in conventional processes with the aid of three-way catalytic converters. These are able to convert the three essential gaseous pollutants of the engine, namely hydrocarbons, carbon monoxide and nitrogen oxides, into harmless components at the same time.
  • the exhaust gas from gasoline engines also contains extremely fine particles (PM), which result from the incomplete combustion of the fuel and which essentially consist of soot.
  • PM extremely fine particles
  • the particles in the exhaust gas of stoichiometrically operated internal combustion engines are very small and have an average particle size of less than 1 ⁇ m. Typical particle sizes are in the range from 10 to 200 nm.
  • the amount of particles emitted is very small and ranges from 2 to 4 mg / km.
  • the European emissions standard EU-6c is linked to a change in the limit value for such particles from the particulate mass limit value to a more critical particle number limit value of 6 x 10 11 / km (in the Worldwide Harmonized Light Vehicles Test Cycle - WLTP). This creates a need for exhaust gas cleaning concepts for stoichiometrically operated internal combustion engines that include effectively working devices for removing particles.
  • Wall-flow filters made of ceramic materials such as silicon carbide, aluminum titanate and cordierite have proven themselves in the area of cleaning exhaust gas from lean-burn engines, in particular diesel engines. These are made up of a large number of parallel channels that are formed by porous walls. The channels are mutually closed at one of the two ends of the filter, so that channels A are formed which are open on the first side of the filter and closed on the second side of the filter, and channels B which are closed on the first side of the filter and are open on the second side of the filter.
  • Exhaust gas flowing into channels A can only leave the filter via channels B, and for this purpose must flow through the porous walls between channels A and B. When the exhaust gas passes through the wall, the particles are retained and the exhaust gas is cleaned.
  • the wall flow filter is provided with catalytically active coatings that lower the ignition temperature of soot.
  • EP 1 657 410 A2 also already describes a combination of both types of coating, i.e. part of the catalytically active material is present in the porous walls and another part on the porous walls.
  • a wall flow filter carries two layers arranged one above the other, one in the porous wall and the other on the porous wall can be arranged.
  • porous filter walls contain a catalyst material of a three-way catalyst, while a catalyst material of a three-way catalyst is additionally applied to partial areas of the filter walls.
  • the present invention relates to a particle filter which comprises a wall flow filter of length L and two coatings Y and Z, which can preferably be completely identical, wherein the wall flow filter comprises channels E and A, which extend parallel between a first and a second end of the wall flow filter extend and which are separated by porous walls, the surfaces OE and OA form and wherein the channels E are closed at the second end and the channels A at the first end, and wherein the coatings Y and Z include the same oxygen storage components and the same carrier materials for precious metals , and the coating Y is located in the channels E on the surfaces OE and extends from the first end of the wall flow filter over 55 to 90% of the length L, and the coating Z is and is in the channels A on the surfaces OA extending from the second end of the wall flow filter over 55 to 90% of the length L, and
  • the coatings Y and Z are three-way catalytically active, especially at operating temperatures of 250 to 1,100 ° C. They usually contain one or more precious metals that are fixed on one or more carrier materials, as well as one or more oxygen storage components.
  • the coatings Y and Z comprise the same oxygen storage components and the same carrier materials for noble metals in different, but preferably in the same, amounts.
  • the coatings Y and Z also contain the same or different precious metals in the same or different amounts. Coatings Y and Z are particularly preferably completely identical.
  • noble metals are platinum, palladium and rhodium, palladium, rhodium or palladium and rhodium being preferred and palladium and rhodium being particularly preferred.
  • the proportion of rhodium in the total precious metal content is in particular greater than or equal to 10% by weight.
  • the porous walls of the particle filter according to the invention are preferably free of noble metals.
  • the noble metals are usually used in amounts of 0.15 to 5 g / l, based on the volume of the wall flow filter.
  • Suitable carrier materials for the noble metals are all materials familiar to the person skilled in the art for this purpose. Such materials are in particular metal oxides with a BET surface area of 30 to 250 m 2 / g, preferably 100 to 200 m 2 / g (determined according to DIN 66132).
  • Particularly suitable support materials for the noble metals are selected from the series consisting of aluminum oxide, doped aluminum oxide, silicon oxide, titanium dioxide and mixed oxides of one or more thereof.
  • Doped aluminum oxides are, for example, lanthanum oxide, zirconium oxide and / or titanium oxide-doped aluminum oxides.
  • Lanthanum-stabilized aluminum oxide is advantageously used, lanthanum being advantageously used in amounts of 1 to 10% by weight, preferably 3 to 6% by weight, calculated in each case as La 2 O 3 and based on the weight of the stabilized aluminum oxide .
  • Another suitable carrier material is lanthanum-stabilized aluminum oxide, the surface of which is coated with lanthanum oxide, barium oxide or strontium oxide.
  • Cerium / zirconium / rare earth metal mixed oxides are particularly suitable as oxygen storage components.
  • the term “cerium / zirconium / rare earth metal mixed oxide” in the context of the present invention excludes physical mixtures of cerium oxide, zirconium oxide and rare earth oxide. Rather, “cerium / zirconium / rare earth metal mixed oxides” are characterized by a largely homogeneous, three-dimensional crystal structure that is ideally free of phases of pure cerium oxide, zirconium oxide or rare earth oxide. Depending on the manufacturing process, however, products that are not completely homogeneous can also arise, which can usually be used without any disadvantage. Furthermore, the term rare earth metal or rare earth metal oxide in the context of the present invention does not include cerium or cerium oxide.
  • rare earth metal oxides in the cerium / zirconium / rare earth metal mixed oxides for example, lanthanum oxide, yttrium oxide, praseodymium oxide, neodymium oxide and / or Sa marium oxide come into consideration.
  • Lanthanum oxide, yttrium oxide and / or praseody oxide are preferred.
  • Lanthanum oxide and / or yttrium oxide are particularly preferred and lanthanum oxide and yttrium oxide, yttrium oxide and praseodymium oxide, such as lanthanum oxide and praseodymium oxide, are very particularly preferred.
  • the oxygen storage components are particularly preferably free from neodymium oxide.
  • the mass ratio of cerium oxide to zirconium oxide in the cerium / zirconium / rare earth metal mixed oxides can vary within wide limits. It is, for example, 0.1 to 1.5, preferably 0.2 to 1 or 0.3 to 0.5.
  • cerium / zirconium / rare earth metal mixed oxides contain yttrium oxide as the rare earth metal, its proportion in the mixed oxide is in particular 2 to 15% by weight, preferably 3 to 10% by weight.
  • cerium / zirconium / rare earth metal mixed oxides contain praseodic oxide as rare earth metal, its proportion is in particular 2 to 15% by weight, preferably 3 to 10% by weight.
  • cerium / zirconium / rare earth metal mixed oxides contain lanthanum oxide and yttrium oxide as rare earth metal, its mass ratio is in particular between 0.1 and 1, preferably 0.3 to 1.
  • cerium / zirconium / rare earth metal mixed oxides contain lanthanum oxide and praseodymium oxide as rare earth metal, its mass ratio is in particular 0.1 to 1, preferably 0.3 to 1.
  • the coatings Y and Z usually contain oxygen storage components in amounts of 15 to 120 g / l, based on the volume of the wall-flow filter.
  • the mass ratio of carrier materials and oxygen storage components in coatings Y and Z is usually 0.3 to 1.5, for example 0.4 to 1.3.
  • one or both of coatings Y and Z contain an alkaline earth compound such as e.g. Strontium oxide, barium oxide or barium sulfate.
  • the amount of barium sulfate per coating is in particular 2 to 20 g / l volume of the wall-flow filter.
  • one or both of the coatings Y and Z contain additives such as rare earth compounds such as lanthanum oxide and / or binders such as aluminum compounds. These additives are used in amounts which can vary within wide limits and which the person skilled in the art can determine with simple means in the specific case. These may help to improve the rheology of the coating.
  • coatings Y and Z comprise lanthanum-stabilized aluminum oxide, rhodium, palladium or palladium and rhodium and an oxygen storage component comprising zirconium oxide, cerium oxide, yttrium oxide and lanthanum oxide.
  • the coatings Y and Z comprise lanthanum-stabilized aluminum oxide, rhodium, palladium or palladium and rhodium and an oxygen storage component comprising zirconium oxide, cerium oxide, praseodymium oxide and lanthanum oxide.
  • the coatings Y and Z comprise lanthanum-stabilized aluminum oxide, rhodium, palladium or palladium and rhodium, a first oxygen storage component comprising zirconium oxide, ceria, yttrium oxide and lanthanum oxide, and a second zirconium oxide, cerium oxide, yttrium oxide and praseodymium oxide comprehensive oxygen storage component.
  • the coatings Y and Z each comprise lanthanum-stabilized aluminum oxide in amounts of 20 to 70% by weight, particularly preferably 30 to 60% by weight, and the oxygen storage component in amounts of 30 to 80% by weight , particularly preferably 40 to 70% by weight, based in each case on the total weight of the coating Y or Z.
  • the coating Y preferably extends from the first end of the wall flow filter over 55 to 90%, particularly preferably over 57 to 80%, but very particularly preferably over 57 to 65% of the length L of the wall flow filter.
  • the loading of the wall-flow filter with coating Y is preferably 33 to 125 g / l, based on the volume of the wall-flow filter.
  • the coating Z preferably extends from the second end of the wall flow filter over 55 to 90%, in particular over 57 to 80%, but very particularly preferably over 67 to 65% of the length L of the wall flow filter.
  • the loading of the wall flow filter with coating Z is preferably 33 to 125 g / l, based on the volume of the wall flow filter.
  • a preferred embodiment relates to a wall flow filter with a coating Y with a length L of 57 to 80% starting from the first end of the wall flow filter and a coating Z with a length L of 57 to 80% starting from the second end of the wall flow filter.
  • the sum of the lengths of coating Y and coating Z is 1 10 to 160% of the length L, preferably 1 15 to 140% of the length L.
  • coatings Y and Z contain no zeolite and no molecular sieve.
  • the total loading of the particle filter according to the invention with the coatings Y and Z is in particular 40 to 150 g / l, based on the volume of the wall flow filter.
  • this relates to a particle filter comprising a wall flow filter of length L and two coatings Y and Z, the wall flow filter comprising channels E and A which extend in parallel between a first and a second end of the wall flow filter and which are separated by porous walls, which form the surfaces O E and OA, respectively, and wherein the channels E are closed at the second end and the channels A at the first end, and the coatings Y and Z include identical oxygen storage components and identical carrier materials for precious metals, characterized in that
  • Coating Y is located in the channels E on the surfaces O E and extends from the first end of the wall flow filter over 57 to 80% of the length L
  • coating Z is located in the channels A on the surfaces OA and starts from the second End of the wall flow filter over 57 to 80% of the length L it stretches
  • the coatings Y and Z aluminum oxide in an amount of 20 to 70 wt .-%, based on the total weight of the coating Y or Z, rhodium, palladium or palladium and rhodium and an oxygen storage component in an amount of 30 to 80 wt .-%, based on the total weight of the coating Y or Z
  • the oxygen storage component zirconium oxide, cerium oxide, lanthanum oxide and yttrium oxide or zirconium oxide, cerium oxide, lanthanum oxide and Praseody oxide or comprises a mixture of two oxygen storage components, one oxygen storage component being zirconium oxide, cerium oxide, lanthanum oxide and yttri
  • Wall flow filters that can be used in accordance with the present invention are known and are available on the market. They consist, for example, of silicon carbide, aluminum titanate or cordierite, have a cellularity of 200 to 400 cells per inch and usually a wall thickness between 6 and 12 mils, or 0.1524 and 0.305 millimeters. In the uncoated state, for example, they have porosities of 50 to 80, in particular 55 to 75%. Their average pore size in the uncoated state be, for example, 10 to 25 micrometers. As a rule, the pores of the wall flow filter are so-called open pores, i.e. they are connected to the channels. Furthermore, the pores are usually connected to one another. This enables on the one hand the light coating of the inner pore surfaces and on the other hand an easy passage of the exhaust gas through the porous walls of the wall flow filter.
  • the particle filter according to the invention can be produced by methods familiar to those skilled in the art, for example by applying a coating suspension, usually called a washcoat, to the wall-flow filter using one of the usual dip-coating processes or pump and suction coating processes. Thermal aftertreatment or calcination usually follow. Coatings Y and Z are obtained in separate and consecutive coating steps.
  • a coating suspension usually called a washcoat
  • the average pore size of the wall flow filter and the average particle size of the catalytically active materials must be coordinated with one another in order to achieve an on-wall coating or an in-wall coating.
  • the mean particle size of the catalytically active materials must be small enough to penetrate into the pores of the wall flow filter.
  • the mean particle size of the catalytically active materials must be large enough not to penetrate into the pores of the wall flow filter.
  • the particle filter according to the invention is ideal for removing particles, carbon monoxide, hydrocarbons and nitrogen oxides from the exhaust gas of internal combustion engines operated with a stoichiometric air / fuel mixture.
  • the present invention thus also relates to a method for removing particles, carbon monoxide, hydrocarbons and nitrogen oxides from the exhaust gas of internal combustion engines operated with a stoichiometric air / fuel mixture, which is characterized in that the exhaust gas is passed through a particle filter according to the invention.
  • the exhaust gas can be passed through a particle filter according to the invention in such a way that it enters the particle filter through channels E and leaves it again through channels A. But it is also possible that the exhaust gas enters the particulate filter through channels A and leaves it again through channels E.
  • the decisive factor for a low exhaust back pressure is not the degree of coverage of the filter walls, as originally assumed, but rather the layer thickness of the catalytic coating applied.
  • the coating By distributing the coating over a large area over at least 55% of the filter length per zone, the exhaust gas back pressure can be reduced and at the same time a high catalytic activity can be achieved. This was not to be expected based on the known state of the art.
  • Figure 1 shows a particle filter according to the invention, which comprises a wall flow filter of length L (1) with channels E (2) and channels A (3), which run parallel between a first end (4) and a second end (5) of the wall flow filter extend and which are separated by porous walls (6), the surfaces OE (7) and OA (8) and where the channels E (2) at the second end (5) and the channels A (3) at the first end ( 4) are closed.
  • Coating Y (9) is located in channels E (2) on the Surfaces O E (7) and coating Z (10) in channels A (3) on the surfaces
  • Aluminum oxide stabilized with lanthanum oxide was used together with a first oxygen storage component, which comprised 40% by weight of cerium oxide, zirconium oxide, lanthanum oxide and praseodymium oxide, and a second oxygen storage component, which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide, in Suspended in water. Both oxygen storage components were used in equal parts. The weight ratio of the alumina and the oxygen storage component was 30:70. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring.
  • the resulting coating suspension was used directly for coating a commercially available wall-flow filter substrate, the coating being introduced into the porous filter wall over 100% of the substrate length.
  • the total loading of this filter was 75 g / l, the total noble metal loading was 1.27 g / l with a ratio of palladium to rhodium of 5: 1.
  • the coated filter thus obtained was dried and then calcined. It is hereinafter referred to as VGPF1.
  • Aluminum oxide stabilized with lanthanum oxide was suspended in water together with an oxygen storage component which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide.
  • the weight ratio of the alumina and the oxygen storage component was 56:44.
  • a palladium nitrate solution and a rhodium nitrate solution were then added to the suspension thus obtained, with constant stirring.
  • the resulting coating suspension was used directly for coating a commercially available wall-flow filter substrate.
  • the coating suspension was coated onto the filter walls of the substrate, first in the inlet channels over a length of 60% of the filter length.
  • the loading of the inlet channel was 62.5 g / l, the noble metal loading 1.06 g / l with a ratio of palladium to rhodium of 5: 1.
  • the coated filter obtained in this way was dried and then calcined.
  • the outlet channels of the filter were then coated with the same coating suspension over a length of 60% of the filter length.
  • the coated filter thus obtained was dried again and then calcined.
  • the total loading of this filter was thus 75 g / l, the total precious metal loading 1.27 g / l with a ratio of palladium to rhodium of 5: 1. It is referred to below as GPF1.
  • Aluminum oxide stabilized with lanthanum oxide was used together with a first oxygen storage component, which comprised 40% by weight of cerium oxide, zirconium oxide, lanthanum oxide and praseodymium oxide, and a second oxygen storage component, which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide, suspended in water. Both oxygen storage components were used in equal parts. The weight ratio of the alumina and the oxygen storage component was 30:70. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring. The resulting coating suspension was used directly to coat a commercially available wall-flow filter substrate.
  • a first oxygen storage component which comprised 40% by weight of cerium oxide, zirconium oxide, lanthanum oxide and praseodymium oxide
  • a second oxygen storage component which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yt
  • the coating suspension was coated onto the filter walls of the substrate, initially in the inlet channels over a length of 60% of the filter length.
  • the loading of the inlet channel was 62.5 g / l, the noble metal loading 1.06 g / l with a ratio of palladium to rhodium of 5: 1.
  • the coated filter thus obtained was dried and then calcined.
  • the outlet channels of the filter were then coated with the same coating suspension over a length of 60% of the filter length.
  • the coated filter thus obtained was dried again and then calcined.
  • the total loading of this filter was thus 75 g / l, the total precious metal loading was 1.27 g / l with a ratio of palladium to rhodium of 5: 1. It is referred to below as GPF2.
  • Table 1 shows the temperatures T o 5, in each of which 50% of the subject components are reacted.
  • the amplitude of l was ⁇ 3.4%.
  • Table 2 contains the conversion at the intersection of the CO and NOx conversion curves, as well as the associated HC conversion of the aged particle filters.
  • the particle filters GPF1 and GPF2 according to the invention show, compared to VGPF1 in the aged state, a significant improvement in the light-off behavior and in the dynamic CO / NOx conversion. Comparative example 2:
  • Aluminum oxide stabilized with lanthanum oxide was used together with a first oxygen storage component, which comprised 40% by weight of ceria, zirconium oxide, lanthanum oxide and praseodymium oxide, and a second oxygen storage component, which comprised 24% by weight of ceria, zirconium oxide, lanthanum oxide and yttrium oxide , suspended in water. Both oxygen storage components were used in equal parts. The weight ratio of the alumina and the oxygen storage component was 30:70. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring.
  • the resulting coating suspension was used directly for coating a commercially available wall-flow filter substrate, the coating being introduced into the porous filter wall over 100% of the substrate length.
  • the total loading of this filter was 100 g / l, the noble metal loading 2.60 g / l with a ratio of palladium to rhodium of 60: 13.75.
  • the coated filter thus obtained was dried and then calcined.
  • Aluminum oxide stabilized with lanthanum oxide was suspended in water together with an oxygen storage component which comprised 40% by weight of cerium oxide, zirconium oxide, lanthanum oxide and praesodymium oxide. The weight ratio of aluminum oxide and oxygen storage component was 50:50.
  • the suspension obtained in this way was then mixed with a palladium nitrate solution and a rhodium nitrate solution with constant stirring.
  • the resulting coating suspension was used directly for coating the wall flow filter substrate obtained under a), the filter walls of the substrate being coated, specifically in the inlet channels over a length of 25% of the filter length.
  • the loading of the inlet channel was 58 g / l, the noble metal loading 2.30 g / l with a ratio of palladium to rhodium of 10: 3.
  • the coated filter thus obtained was dried and then calcined. c) Coating of the exit channels
  • Aluminum oxide stabilized with lanthanum oxide was suspended in water together with an oxygen storage component which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide.
  • the weight ratio of alumina and oxygen storage component was 56:44.
  • a palladium nitrate solution and a rhodium nitrate solution were then added to the suspension thus obtained, with constant stirring.
  • the resulting coating suspension was used directly for coating the wall flow filter substrate obtained under b), the filter walls of the substrate being coated over a length of 25% of the filter length in the outlet channels.
  • the loading of the outlet channel was 59 g / l, the noble metal loading 1.06 g / l with a ratio of palladium to rhodium of 1: 2.
  • the coated filter thus obtained was dried and then calcined.
  • the total loading of this filter was thus 130 g / l, the total noble metal loading 3.44 g / l with a ratio of palladium to rhodium of 10: 3. It is referred to below as VGPF2.
  • Aluminum oxide stabilized with lanthanum oxide was used together with a first oxygen storage component, which comprised 40% by weight of cerium oxide, zirconium oxide, lanthanum oxide and praseodymium oxide, and a second oxygen storage component, which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide, suspended in water. Both oxygen storage components were used in equal parts. The weight ratio of the alumina and the oxygen storage component was 30:70. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring.
  • the resulting coating suspension was used directly to coat a commercially available wall-flow filter substrate, the coating being introduced into the porous filter wall over 100% of the substrate length.
  • the loading of this filter was 100 g / l, the noble metal loading 2.07 g / l with a ratio of palladium to rhodium of 45: 13.5.
  • the coated filter obtained in this way was dried and then calcined. b) Coating of the input channels
  • Aluminum oxide stabilized with lanthanum oxide was suspended in water together with an oxygen storage component which comprised 40% by weight of cerium oxide, zirconium oxide, lanthanum oxide and praseous oxide. The weight ratio of aluminum oxide and oxygen storage component was 50:50.
  • the suspension obtained in this way was then stirred with a palladium nitrate solution and a rhodium nitrate solution is added.
  • the resulting coating suspension was used directly for coating the wall flow filter substrate obtained under a), the filter walls of the substrate being coated, specifically in the inlet channels over a length of 60% of the filter length.
  • the loading of the inlet channel was 90 g / l, the noble metal loading 2.30 g / l with a ratio of palladium to rhodium of 10: 3.
  • the coated filter thus obtained was dried and then calcined.
  • the total loading of this filter was thus 154 g / l, the total noble metal loading 3.44 g / l with a ratio of palladium to rhodium of 10: 3. It is referred to below as VGPF3.
  • the loading of the inlet channel was 83.33 g / l, the noble metal loading 2.87 g / l with a ratio of palladium to rhodium of 10: 3.
  • the coated filter thus obtained was dried and then calcined.
  • the outlet channels of the filter were then coated with the same coating suspension over a length of 60% of the filter length.
  • the coated filter thus obtained was dried again and then calcined.
  • the total loading of this filter was thus 100 g / l, the total precious metal loading 3.44 g / l with a ratio of palladium to rhodium of 10: 3. It is referred to below as GPF3.
  • Table 3 contains the temperatures T o 5, in each of which 50% of the subject components are reacted.
  • the amplitude of l was ⁇ 3.4%.
  • Table 4 contains the conversion at the intersection of the CO and NOx conversion curves, as well as the associated HC conversion of the aged particle filters.
  • the particle filter GPF3 according to the invention shows, compared to VGPF2 and VGPF3 in the aged state, a significant improvement in the light-off behavior and in the dynamic CO / NOx conversion. Comparative example 4:
  • Alumina stabilized with lanthanum oxide was suspended in water together with an oxygen storage component which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide. The weight ratio of alumina and oxygen storage component was 56/44.
  • a palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring.
  • the resulting coating suspension was used directly to coat a commercially available wall-flow filter substrate. Since the coating suspension was coated on the filter walls of the substrate in the inlet channels over a length of 50% of the filter length.
  • the loading of the inlet channel was 100 g / l, the noble metal loading 1.42 g / l with a ratio of palladium to rhodium of 5:
  • the resulting coating suspension was used directly for coating the wall-flow filter substrate obtained under a), the filter walls of the substrate being coated over a length of 50% of the filter length in the outlet channels.
  • the loading of the exhaust duct was 100 g / l, the noble metal loading 1.42 g / l with a ratio of palladium to rhodium of 5: 1.
  • the coated filter thus obtained was dried and then calcined.
  • the total loading of this filter was thus 100 g / l, the total noble metal loading 1.42 g / l with a ratio of palladium to rhodium of 5: 1. It is referred to below as VGPF4.
  • Alumina stabilized with lanthanum oxide was suspended in water together with an oxygen storage component which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide.
  • the weight ratio of alumina and oxygen storage component was 56/44.
  • a palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring.
  • the resulting coating suspension was used directly to coat a commercially available wall-flow filter substrate. Since the coating suspension was coated on the filter walls of the substrate in the inlet channels over a length of 55% of the filter length.
  • the loading of the inlet channel was 91 g / l, the noble metal loading 1.16 g / l with a ratio of palladium to rhodium of 5: 1.
  • the coated filter thus obtained was dried and then calcined. Coating of the exit channels
  • Alumina stabilized with lanthanum oxide was combined with a first oxygen storage component, which comprised 40% by weight of ceria, zirconium oxide, lanthanum oxide and praseodymium oxide, and a second oxygen storage component, which comprised 24% by weight of ceria, zirconium oxide, lanthanum oxide and yttrium oxide, in Suspended in water. Both oxygen storage components were used in equal parts. The weight ratio of the alumina and the oxygen storage component was 30:70. The suspension obtained in this way was then with constant stirring a palladium nitrate solution and a rhodium nitrate solution are added.
  • the resulting coating suspension was used directly for coating the wall-flow filter substrate obtained under a), the filter walls of the substrate being coated over a length of 55% of the filter length in the outlet channels.
  • the loading of the outlet channel was 91 g / l, the noble metal loading 1.16 g / l with a ratio of palladium to rhodium of 5: 1.
  • the coated filter thus obtained was dried and then calcined.
  • the total loading of this filter was thus 100 g / l, the total noble metal loading 1.42 g / l with a ratio of palladium to rhodium of 5: 1. It is referred to below as GPF3.
  • Alumina stabilized with lanthanum oxide was suspended in water together with an oxygen storage component which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide.
  • the weight ratio of alumina and oxygen storage component was 56/44.
  • a palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring.
  • the resulting coating suspension was used directly to coat a commercially available wall-flow filter substrate. Since the coating suspension was coated on the filter walls of the substrate, namely in the inlet channels over a length of 60% of the filter length.
  • the loading of the inlet channel was 83.33 g / l, the noble metal loading 1.06 g / l with a ratio of palladium to rhodium of 5: 1.
  • the coated filter obtained in this way was dried and then calcined. Coating of the exit channels
  • Aluminum oxide stabilized with lanthanum oxide was combined with a first oxygen storage component, which comprised 40% by weight of ceria, zirconium oxide, lanthanum oxide and praseodymium oxide, and a second oxygen storage component, which comprised 24% by weight of ceria, zirconium oxide, lanthanum oxide and yttrium oxide, suspended in water. Both oxygen storage components were used in equal parts. The weight ratio of the alumina and the oxygen storage component was 30:70. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring.
  • the resulting coating suspension was used directly to coat the wall-flow filter substrate obtained under a), the filter walls of the substrate being coated on a length of 60% of the filter length in the outlet channels.
  • the loading of the outlet channel was 83.33 g / l, the noble metal loading 1.06 g / l with a ratio of palladium to rhodium of 5: 1.
  • the coated filter thus obtained was dried and then calcined.
  • the total loading of this filter was thus 100 g / l, the total noble metal loading 1.42 g / l with a ratio of palladium to rhodium of 5: 1. It is referred to below as GPF4.
  • Alumina stabilized with lanthanum oxide was suspended in water together with an oxygen storage component which comprised 24% by weight of cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide. The weight ratio of alumina and oxygen storage component was 56/44.
  • a palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring.
  • the resulting coating suspension was used directly to coat a commercially available wall-flow filter substrate. Since the coating suspension was coated on the filter walls of the substrate in the input channels over a length of 80% Filter length.
  • the loading of the inlet channel was 62.5 g / l, the noble metal loading 0.79 g / l with a ratio of palladium to rhodium of 5:
  • Aluminum oxide stabilized with lanthanum oxide was combined with a first oxygen storage component, which comprised 40% by weight of ceria, zirconium oxide, lanthanum oxide and praseodymium oxide, and a second oxygen storage component, which comprised 24% by weight of ceria, zirconium oxide, lanthanum oxide and yttrium oxide, suspended in water. Both oxygen storage components were used in equal parts. The weight ratio of aluminum oxide and oxygen storage component was 30:70. A palladium nitrate solution and a rhodium nitrate solution were then added to the suspension obtained in this way, with constant stirring.
  • the resulting coating suspension was used directly for coating the wall-flow filter substrate obtained under a), the filter walls of the substrate being coated over a length of 80% of the filter length in the outlet channels.
  • the loading of the outlet channel was 62.5 g / l, the noble metal loading 0.79 g / l with a ratio of palladium to rhodium of 5: 1.
  • the coated filter obtained in this way was dried and then calcined.
  • the total loading of this filter was thus 100 g / l, the total noble metal loading 1.42 g / l with a ratio of palladium to rhodium of 5: 1. It is referred to below as GPF5.
  • the particulate filters VGPF4, GPF4, GPF5 and GPF6 were compared on a cold blow test bench with regard to the exhaust back pressure.
  • the following table 5 contains pressure loss data which were determined at an air temperature of 21 ° C and a volume flow of 600 m3 / h. The values have been standardized to VGPF4 for a better overview.
  • the filters GPF4, GPF5 and GPF6 according to the invention all surprisingly have a lower pressure loss than the comparative example VGPF4, although they cover a larger surface area of the filter walls. This is quite surprising, since one could actually assume that longer coatings cause a higher exhaust gas back pressure, since here more exhaust gas has to flow through the catalytic coatings, since as a result less exhaust gas can flow through the uncoated filter wall.

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Abstract

La présente invention concerne un filtre à particules qui comporte un filtre à effet wall-flow de longueur L et deux revêtements à activité catalytique Y et Z, le filtre à effet wall-flow comportant des conduits E et A qui s'étendent parallèlement entre une première et une seconde extrémité du filtre à effet wall-flow et qui sont séparés par des parois poreuses qui forment respectivement les surfaces OE et OA, les conduits E étant fermés à la seconde extrémité et les conduits A étant fermés à la première extrémité, les revêtements Y et Z comportent les mêmes composants accumulateurs d'oxygène et les mêmes supports pour métaux précieux. Ce filtre à particules est caractérisé en ce que le revêtement Y se trouve dans les conduits E sur les surfaces OE et le revêtement Z se trouve dans les conduits A sur les surfaces OA.
EP19716102.9A 2019-03-29 2019-03-29 Filtre à particules à activité catalytique Pending EP3946692A1 (fr)

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DE102007046158B4 (de) 2007-09-27 2014-02-13 Umicore Ag & Co. Kg Verwendung eines katalytisch aktiven Partikelfilters zur Entfernung von Partikeln aus dem Abgas von mit überwiegend stöchiometrischem Luft/Kraftstoff-Gemisch betriebenen Verbrennungsmotoren
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WO2016056573A1 (fr) * 2014-10-09 2016-04-14 株式会社キャタラー Dispositif de purification de gaz d'échappement
JP6353918B2 (ja) 2014-10-16 2018-07-04 株式会社キャタラー 排ガス浄化用触媒
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CN107073447B (zh) 2014-10-16 2021-01-19 株式会社科特拉 废气净化用催化剂
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