IP Library Granted Patent US 11,732,625
Granted Patent B2
US 11,732,625 · App. 16/386,873 · Granted Aug 22, 2023

Low temperature NOx reduction using H

Inventor: Yuejin Li (Edison, NJ)
Assignee: BASF Corporation
F01N3/035B01D53/90B01D53/94B01D53/9418B01D53/9422B01D53/9427B01D53/9477F01N3/021F01N3/0814F01N3/0842F01N3/106F01N3/206F01N3/2066F01N13/009B01D53/9436B01D2251/202B01D2255/102B01D2255/1021B01D2255/1023B01D2255/20738B01D2255/20761B01D2255/50B01D2255/9205B01D2255/9207B01D2258/012F01N2370/00F01N2510/06F01N2610/04Y02A50/20Y02T10/12
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Quick Facts
Patent No.
US 11,732,625
App. No.
16/386,873
Granted
Aug 22, 2023
Kind
B2
Abstract

Disclosed herein are emission treatment systems, articles, and methods for selectively reducing NOx compounds. The systems include a hydrogen generator, a hydrogen selective catalytic reduction (H 2 -SCR) article, and one or more of a diesel oxidation catalyst (DOC) and/or a lean NOx trap (LNT) and/or a low temperature NOx adsorber (LTNA). Certain articles may comprise a zone coated substrate and/or a layered coated substrate and/or an intermingled coated substrate of one or more of the H 2 -SCR and/or DOC and/or LNT and/or LTNA catalytic compositions.

Claims (33)

1. An emission treatment system for selectively reducing NOx compounds, the system comprising:

a hydrogen generator; and

an H 2 -SCR catalytic article comprising a substrate and an H 2 -SCR catalyst composition, the hydrogen generator being in fluid communication with, and upstream of, the H 2 -SCR catalytic article;

wherein the H 2 -SCR catalyst composition comprises a platinum group metal component with a metal loading ranging from 0.1% to 1% by weight of the H 2 -SCR catalyst composition supported on a support consisting of (i) a hydrogen form of zeolite, (ii) a metal oxide selected from the group consisting of zirconia, titania, magnesia, and combinations thereof, or (iii) combinations of (i) and (ii); and

at least one of (a) a diesel oxidation catalyst (DOC) catalyst composition; and (b) a lean NOx trap (LNT) composition,

wherein when the LNT composition is present, the system comprises a lean NOx trap (LNT) catalytic article comprising a substrate and the LNT catalyst composition, the LNT catalytic article in fluid communication with, and downstream of, the H 2 -SCR catalytic article, and

wherein when the DOC catalyst composition is present, the DOC catalyst composition is

present in a zoned catalyst coating on the H 2 -SCR catalytic article with an upstream zone comprising the H 2 -SCR catalyst composition and a downstream zone comprising the DOC catalyst composition.

2. The emission treatment system according to claim 1 , further comprising a low temperature NOx adsorbent (LTNA) catalyst composition present in the zoned catalyst coating.

3. The emission treatment system according to claim 2 , wherein, in the zoned catalyst coating, the LTNA catalyst composition is incorporated into the upstream zone comprising the H 2 -SCR catalyst composition, incorporated into the downstream zone comprising the DOC composition, or positioned in a middle zone between the upstream zone comprising the H 2 -SCR catalyst composition and the downstream zone comprising the DOC composition.

4. The emission treatment system according to claim 1 , further comprising a low temperature NOx adsorbent (LTNA) catalytic article comprising a substrate and a LTNA catalyst composition, the LTNA catalytic article in fluid communication with the H 2 -SCR catalytic article and the hydrogen generator.

5. The emission treatment system according to claim 4 , wherein the LTNA catalytic article is positioned downstream from the H 2 -SCR catalytic article or positioned upstream from the H 2 SCR catalytic article and the hydrogen generator.

6. The emission treatment system according to claim 1 , wherein the LNT catalyst composition comprises a NOx sorbent and a platinum group metal component dispersed on a refractory metal oxide support.

7. The emission treatment system according to claim 1 , wherein the H 2 -SCR catalytic article is close coupled.

8. The emission treatment system according to claim 1 , wherein the platinum group metal component is platinum, palladium, or a combination thereof.

9. A method for treating an exhaust stream containing NOx, comprising passing the exhaust stream through the emission treatment system of claim 1 .

10. The method according to claim 9 , wherein the exhaust stream has a temperature that is about 200° C. or lower, about 175° C. or lower, about 150° C. or lower, about 125° C. or lower, or about 100° C. or lower.

11. The emission treatment system according to claim 1 , further comprising a catalytic soot filter (CSF), a selective catalytic reduction (SCR) catalyst, an ammonia oxidation catalyst (AMOX), or combinations thereof.

12. The emission treatment system according to claim 11 , wherein the SCR catalyst comprises a base metal-containing 8-ring small pore molecular sieve.

13. The emission treatment system according to claim 12 , wherein the SCR catalyst comprises an iron and/or copper-containing 8-ring small pore molecular sieve.

14. The emission treatment system according to claim 13 , wherein the molecular sieve is a zeolite having a structure selected from the group consisting of AEI, AFT, AFX, CHA, EAB, EM, KFI, LEV, SAS, SAT, and SAV.

15. The emission treatment system according to claim 14 , wherein the molecular sieve has a CHA crystal structure.

16. A method for treating an exhaust stream containing NOx, comprising:

introducing hydrogen gas into the exhaust stream to form a hydrogen-treated exhaust stream;

passing the hydrogen-treated exhaust stream through an emission treatment system comprising

an H 2 SCR catalytic article comprising a substrate and an H 2 SCR catalyst composition,

wherein the H 2 SCR catalyst composition comprises a platinum group metal component with a metal loading ranging from 0.1% to 1% by weight of the H 2 -SCR catalyst composition supported on a support consisting of (i) a hydrogen form of zeolite, (ii) a metal oxide selected from the group consisting of zirconia, titania, magnesia, and combinations thereof, or (iii) combinations of (i) and (ii); and

at least one of (a) a diesel oxidation catalyst (DOC) catalyst composition; and (b) a lean NOx trap (LNT) composition,

wherein when the LNT composition is present, the system comprises a lean NOx trap (LNT) catalytic article comprising a substrate and the LNT catalyst composition, the LNT catalytic article in fluid communication with, and downstream of, the H 2 -SCR catalytic article, and

wherein when the DOC catalyst composition is present, the DOC catalyst composition is

present in a zoned catalyst coating on the H 2 -SCR catalytic article with an upstream zone comprising the H 2 -SCR catalyst composition and a downstream zone comprising the DOC catalyst composition.

17. The method according to claim 16 , wherein the platinum group metal component is platinum, palladium, or a combination thereof.

18. The emission treatment system according to claim 1 , wherein the hydrogen generator is selected from the group consisting of on board hydrogen, hydrogen produced from alcohol reforming, hydrogen produced from ammonia decomposition, and combinations thereof.

Assignments (2)
NUNC PRO TUNC ASSIGNMENT Recorded Aug 8, 2024
From: BASF CORPORATION
To: BASF MOBILE EMISSIONS CATALYSTS LLC
Reel/Frame 068518/0394 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Apr 17, 2019
From: LI, YUEJIN
To: BASF CORPORATION
Reel/Frame 048913/0413 →
Continuity (3)
Continuation PCTIB2017056452 · Oct 17, 2017
Provisional Application 62409413 · Oct 18, 2016
Related Publication 20190242282A1 · Aug 8, 2019