Catalyzed soot filter with reduced ammonia oxidation
The present disclosure is directed to a system for treating an exhaust gas stream from an engine, which includes a diesel oxidation catalyst (DOC) located downstream of the engine and adapted for oxidation of hydrocarbons and carbon monoxide, an injector adapted for the addition of a reductant to the exhaust gas stream located downstream of the DOC, a catalyzed soot filter (CSF) located downstream of the injector, and a selective catalytic reduction component adapted for the oxidation of nitrogen oxides located downstream of the CSF. The CSF is adapted for oxidizing hydrocarbons and includes a selective oxidation catalyst composition on a filter with high selectivity ratio for hydrocarbon oxidation:ammonia oxidation (e.g., at least 0.6).
1. A system for treatment of an exhaust gas stream from an engine, the emission treatment system comprising: a diesel oxidation catalyst located downstream of the engine and adapted for oxidation of hydrocarbons (HCs), carbon monoxide (CO) and nitric oxide (NO); an injector adapted for the addition of a reductant to the exhaust gas stream located downstream of the diesel oxidation catalyst; a catalyzed soot filter (CSF) comprising a selective oxidation catalyst composition on a filter, located downstream of the injector and adapted for oxidizing HCs with a selectivity ratio for HC oxidation:ammonia oxidation of at least 0.6 at a temperature of about 450° C. to about 550° C.; a selective catalytic reduction (SCR) component comprising a first SCR material adapted for the reduction of nitrogen oxides (NO x ), located downstream of the CSF; wherein all components are in fluid communication with the exhaust gas stream, and wherein the selective oxidation catalyst composition comprises: a base metal oxide component; a rare earth metal oxide component; a platinum group metal (PGM) component; or combinations thereof.
2. The system of claim 1 , wherein the selective oxidation catalyst composition comprises a palladium component.
3. The system of claim 1 , wherein the selective oxidation catalyst composition is substantially free of platinum.
4. The system of claim 1 , wherein the selective oxidation catalyst composition comprises a PGM component and wherein the PGM component has a loading on the filter of about 0.1 g/ft 3 to about 10 g/ft 3 .
5. The system of claim 1 , wherein the selective oxidation catalyst composition comprises a base metal oxide component selected from oxides of Cu, Fe, Ni, Zn, Al, Sn, W, Mo, Ta, Co, Bi, Ti, Zr, Sb, Mn, Be, Ge, V, Gd, Hf, In, Nb, Re, Ce, La, Pr, Nd and combinations thereof.
6. The system of claim 5 , wherein the base metal oxide component comprises copper oxide.
7. The system of claim 1 , wherein the selective oxidation catalyst composition comprises a base metal oxide component or a rare earth metal oxide component, with a loading of the selective oxidation catalyst composition on the filter of about 0.05 g/in 3 to about 0.5 g/in 3 .
8. The system of claim 1 , wherein the selective oxidation catalyst composition is impregnated or ion-exchanged on a support material chosen from a refractory metal oxide, an oxygen storage component, a molecular sieve, and a combination thereof.
9. The system of claim 8 , wherein the selective oxidation catalyst composition comprises a PGM component impregnated or ion-exchanged on a zeolite.
10. The system of claim 8 , wherein the support material is an oxygen storage component comprising ceria, zirconia, yttria, lanthana, neodymia, praseodymia, or a combination thereof.
11. The system of claim 8 , wherein the support material is a ceria-zirconia composite.
12. The system of claim 11 , wherein the ceria-zirconia composite comprises at least 10 wt. % ceria.
13. The system of claim 8 , wherein the support material is a refractory metal oxide selected from alumina, silica, silica-alumina, titania, and combinations thereof.
14. The system of claim 1 , wherein the selective oxidation catalyst component comprises a palladium component impregnated on ceria.
15. The system of claim 1 , wherein the selective oxidation catalyst composition comprises a rare earth metal oxide component selected from ceria, gadolinia, lanthana, neodymia, praseodymia, samaria, scandia, ytterbia, yttria, and combinations thereof.
16. The system of claim 15 , wherein the rare earth metal oxide component comprises ceria.
17. The system of claim 1 , wherein the selective oxidation catalyst composition comprises a ceria-zirconia composite comprising ceria in an amount of at least about 10% by weight of the composite.
18. The system of claim 1 , wherein the selective oxidation catalyst composition comprises copper oxide and ceria.
19. The system of claim 1 , wherein the selective oxidation catalyst composition has a loading of about 0.05 g/in 3 to about 0.5 g/in 3 on the filter.
20. The system of claim 1 , wherein the CSF further comprises a second SCR material on the filter.
21. The system of claim 20 , wherein the selective oxidation catalyst composition and the second SCR material are mixed.
22. The system of claim 20 , wherein the selective oxidation catalyst composition and the second SCR material are disposed on the filter in an axially zoned configuration, wherein the selective oxidation catalyst composition is disposed upstream or downstream of the second SCR material.
23. The system of claim 20 , wherein the second SCR material has a loading of about 0.1 g/in 3 to about 1 g/in 3 on the filter.
24. The system of claim 1 , wherein the first SCR material comprises a mixed metal oxide or a metal-promoted molecular sieve.
25. The system of claim 24 , wherein the metal-promoted molecular sieve is promoted with a metal selected from Cu, Co, Ni, La, Mn, Fe, V, Ag, Ce, Nd, Mo, Hf, Y, W, and combinations thereof.
26. The system of claim 25 , wherein the metal is present in an amount of about 0.1% to about 10% by weight based on the weight of the metal-promoted molecular sieve, calculated as metal oxide.
27. The system of claim 24 , wherein the mixed metal oxide is selected from Fe 2 O 3 /TiO 2 , Fe 2 O 3 /Al 2 O 3 , MgO/TiO 2 , MgO/Al 2 O 3 , MnO x /TiO 2 , CuO/TiO 2 , CeO 2 /ZrO 2 , TiO 2 /ZrO 2 , V 2 O 5 /TiO 2 , V 2 O 5 /WO 3 /TiO 2 , V 2 O 5 /SiO 2 /TiO 2 , and mixtures thereof.
28. The system of claim 20 , wherein the first and second SCR material independently comprise a mixed metal oxide or a metal-promoted molecular sieve.
29. The system of claim 28 , wherein the metal-promoted molecular sieve is a zeolite with a structure type selected from AEI, AFT, AFV, AFX, AVL, CHA, DDR, EAB, EEI, ERI, IFY, IRN, KFI, LEV, LTA, LTN, MER, MWF, NPT, PAU, RHO, RTE, RTH, SAS, SAT, SAV, SFW, TSC, and UFI, and combinations thereof.
30. The system of claim 20 , wherein the second SCR material comprises a copper-promoted molecular sieve with structure type CHA.
31. The system of claim 1 , wherein the catalyzed soot filter is located immediately downstream of the injector.
32. The system of claim 1 , further comprising a selective catalytic reduction catalyst/ammonia oxidation catalyst (SCR/AMOx) component located downstream of the SCR component.
33. The system of claim 1 , wherein the engine is a diesel engine.
34. The system of claim 1 , wherein the reductant comprises ammonia or an ammonia precursor.
35. The system of claim 34 , wherein the reductant comprises urea.