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Phosphorus resistant three-way catalyst

A catalytic material, zirconia technology, applied in the direction of catalyst carrier, catalyst activation/preparation, physical/chemical process catalyst, etc., can solve problems such as difficulty in saturation of protective devices or filters

Active Publication Date: 2020-06-12
BASF CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

However, when the guard or filter becomes PO x Difficulty when saturated

Method used

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  • Phosphorus resistant three-way catalyst

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0146] Example 1 : Screening powder catalyst

[0147] A high-throughput experimental system was used to screen powdered catalysts for phosphorus (P) tolerance. TWC powder catalysts were prepared by impregnating palladium nitrate or rhodium nitrate on different supports and calcining at 550 °C for 2 h. Prepare the following TWC powder catalyst: Pd / CeO 2 -ZrO 2 , Pd / La 2 o 3 -Al 2 o 3 , Pd / La 2 o 3 -Al 2 o 3 +BaO (physical mix), Pd / BaO-Al 2 o 3 , Rh / Al 2 o 3 , Rh / La 2 o 3 -Al 2 o 3 , Rh / ZrO 2 -La 2 o 3 -Al 2 o 3 and Rh / La 2 o 3 -ZrO 2 . Will (NH 4 ) 2 HPO 4 (s) used as P source and mixed well with the above Pd and Rh-containing powder catalyst (5 wt% P target), calcined at 550°C for 5h, and then steamed at 950 / 1050°C under rich-lean conditions with 10% aged. The tests included TWC light-off performance, lambda-sweep and OSC functional measurements.

[0148] as by Figure 6 The shown HC light-off results show that Pd / CeO 2 -ZrO 2 Most suscepti...

Embodiment 2

[0150] Example 2: Characterization of powdered catalysts aged with and without phosphorus (P)

[0151] To better understand the effect of P on different Pd and Rh catalysts, several selected catalysts were aged with and without P. Select Pd / La 2 o 3 -Al 2 o 3 , Pd / CeO 2 -ZrO 2 and Rh / La 2 o 3 -ZrO 2 and using CO chemisorption and H 2 - TPR method characterization. For CO chemisorption, the samples were pretreated in He from room temperature to 150 °C, and then in 4% H 2 / N 2 from 150°C to 400°C. Subsequently, the samples were cooled to room temperature and pulsed with 10% CO / He to observe CO chemisorption. for H 2 -TPR, place the sample in 4% O 2 / He at 500°C for 30 minutes, then cooled to 50°C. Subsequently, the samples were placed in 1% H 2 / N 2 Medium reduction, in which the temperature was programmed to 900 °C to observe the H 2 consumption curve. As shown in Table 1, Pd / La 2 o 3 -Al 2 o 3 The P aging of Pd mildly reduced the dispersion of Pd by 30%, ...

Embodiment 3

[0156] Example 3 : Design of Washcoat-Coated Catalysts

[0157] Based on the test results of the powder catalysts, three washcoat-coated catalytic articles with layered structures were designed. For example, all three catalytic article designs include the same PGM-containing catalyst composition (Pd / CeO 2 -ZrO 2 , Pd / La 2 o 3 -Al 2 o 3 ) and BaO and different rhodium-containing catalyst compositions in the second layer (see Figure 9 ). For example, the entire rhodium component of the rhodium-containing catalyst composition in Catalytic Article 1 (Cat. #1) is supported on La 2 o 3 -Al 2 o 3 and the rhodium-containing component of Cat.#1 also contains La 2 o 3 -Al 2 o 3 as a diluent. In Catalyst Article 2 (Cat.#2), the entire rhodium component is supported on La 2 o 3 -Al 2 o 3 and the rhodium-containing catalyst composition further comprises BaO-Al 2 o 3 as a phosphorus collector material. In catalytic article 3 (Cat.#3), a part of the rhodium component...

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Abstract

Described are three-way conversion (TWC) catalytic articles effective to abate hydrocarbons (HCs), carbon monoxide (CO), and nitrogen oxides (NOx) from an engine exhaust gas containing phosphorous impurities. The disclosed catalytic article has a layered catalytic material, wherein the first layer of the catalytic material is disposed directly on the substrate and a second layer is disposed on topof the first layer. The second layer includes phosphorus resistant materials that prevent catalytic poisoning of the catalytic article by the phosphorous impurities. In particular, the second layer includes a phosphorus trap material having an alkaline earth metal component and a rhodium component impregnated on a phosphorus-resistant support material.

Description

[0001] field of invention [0002] The present invention relates to catalyst compositions, catalytic articles for purification of exhaust emissions, and methods of making and using the same. More particularly, the present invention relates to three-way conversion catalytic articles having enhanced phosphorus tolerance for efficient conversion of hydrocarbons, carbon monoxide and nitrogen oxides. [0003] Background of the invention [0004] Catalysts in catalytic converters within exhaust gas treatment systems have been used to reduce pollution caused by exhaust gases from internal combustion engines. For example, three-way conversion (TWC) catalysts can reduce pollutants such as carbon monoxide (CO), unburned hydrocarbons (HCs) and nitrogen oxides (NO x ). TWC catalysts typically contain platinum group metals (PGMs) such as platinum (Pt), palladium (Pd) and rhodium (Rh). Pt and Pd are commonly used for HC and CO conversion, while Rh is for the reduction of NO x More effect...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): B01J23/46B01J23/02B01J35/00F01N3/10F01N3/20B01J21/06B01J23/10B01D53/94
CPCB01D53/945B01D2255/1025B01D2255/2042B01D2255/2063B01D2255/20715B01D2255/2092B01D2255/9155F01N3/0828F01N3/101F01N3/021F01N3/035F01N2510/0682F01N2510/0684F01N2570/08F01N2510/068B01J37/0244B01J37/0248B01J23/63Y02A50/20Y02T10/12B01J35/56B01J23/464B01J23/02F01N3/20B01J21/066B01J23/10B01D2255/9022B01D2258/012B01J35/19B01J21/04F01N3/0857F01N2330/30
Inventor 刘福东M·迪巴
Owner BASF CORP
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