Catalysts for Cleaning Exhaust Gases

The present invention relates to a catalyst for cleaning exhaust gases containing nitrogen oxides (hereinafter abbreviated as NOx), carbon monoxide (CO) and hydrocarbons (HC).

In the automobile exhaust gas disposal, NOx is generally cleaned within a very limited region around the logical air/fuel ratio by a catalyst while utilizing CO and HC contained in the exhaust gas. However, in cases of exhaust gas disposal of lean burn gasoline engines and diesel engines, denitration is prevented completely when using a conventional catalyst because of an excessively large amount of oxygen in the exhaust gas. Recently, crystalline silicate catalysts containing cobalt or copper have been proposed as catalysts capable of cleaning NOx even in an excessive oxygen atmosphere.

However, these catalysts suffer problems of deterioration due to heat, water vapor and sulfur dioxide in the exhaust gas, although they exhibit satisfactory performance at the initial stage of the reaction.

We have already found after making much effort to obtain a catalyst capable of overcoming the problems mentioned above that a catalyst on which iridium is supported is a highly active and durable catalyst (Japanese Patent Application Numbers H5-26369, H5-100698, H5-228382 and H5-287986). Nevertheless, the catalyst supporting iridium provides a denitration rate which is not sufficient when applied to a practical car driving because of the limited cleaning ability against CO and HC at a low exhaust gas temperature of 300.degree. C. or lower.

An objective of the present invention is to provide a catalyst for cleaning exhaust gases which exhibits denitration performance not only at a high temperature but also at a temperature as low as 300.degree. C. or lower.

An aspect of the present invention is a catalyst for cleaning exhaust gases comprising a first catalyst layer having as an active metal on an elemental support at least one noble metal selected from the group consisting of platinum, rhodium and palladium on which a second catalyst layer having iridium as an active metal is provided as a overlayer.

The catalyst for cleaning exhaust gases according to the present invention is a highly durable and stable catalyst, which can be utilized as an exhaust gas cleaning catalyst for a lean burn gasoline engine as well as a diesel engine.

A carrier for carrying iridium as an active metal in the second layer catalyst according to the present invention is a crystalline silicate which has a X-ray diffraction pattern shown in Table A in the specification and which is represented by the formula in the molar ratio as dehydrated: (1.+-.0.8)R.sub.2 O. ›aM.sub.2 O.sub.3.bM'O.cAl.sub.2 O.sub.3 !.ySiO.sub.2 wherein R denotes an alkaline metal ion and/or hydrogen ion, M denotes at least one elemental ion selected from the group consisting of VIII group elements, rare earth element, titanium, vanadium, chromium, niobium, antimony or gallium, M' denotes an alkaline earth metal ion of magnesium, calcium, strontium or barium, a>0, 20>b.gtoreq.0, a+c=1 and 3000>y>11.

A preferable example of the carrier for carrying iridium as an active metal in the second catalyst layer according to the present invention other than the silicate mentioned above is one or more substances selected from the group consisting of simple oxides such as .gamma.-alumina, .theta.-alumina, silica, zirconia and titania, complex oxides such as alumina.zirconia, zirconia.titania and alumina.titania, a solid strong acid sulfate-containing zirconia (obtained by immersing zirconium hydroxide in 1N sulfuric acid for about 1 hour at room temperature followed by filtration, drying and sintering) as well as a series of zeolites such as zeolite type Y, silicalite (a zeolite having a pentasil structure cosisting only of Si and O), zeolite type A and mordenite.

A carrier for carrying as the first layer catalyst of an active metal, which is at least one noble metal selected from the group consisting of platinum, rhodium and palladium, according to the present invention may be any of those which can be used as a carrier for a standard catalyst, and .gamma.-alumina is generally preferred.

The thickness of the coating of the first catalyst layer on the elemental support is within the range from 1 to 300 .mu.m, preferably 5 to 100 .mu.m, and that of the second catalyst layer is within the range from 1 to 300 .mu.m, preferably 3 to 200 .mu.m. At least one noble metal selected as the first layer catalyst from the group consisting of platinum, rhodium, and palladium and iridium as the second layer catalyst are supported on respective carriers preferably by means of an ion exchange method or an impregnation method. The noble metal of the first catalyst layer is coated in an amount of 0.05 to 5 g, and the iridium of the second catalyst layer is coated in an amount of 0.03 to 10 g, both per 1 L of the elemental support (generally a coagulate support but any heat-resistant ceramic is acceptable).

In the catalyst according to the present invention, for the purpose of achieving the denitrating activity covering a wider range of low temperature, the catalyst layer carrying at least one noble metal selected from the group consisting of platinum, rhodium and palladium is provided beneath the layer carrying iridium.

Thus, the first catalyst layer having as an active metal at least one noble metal selected from the group consisting of platinum, rhodium and pallatium is provided on the elemental support, and then the second catalyst layer having iridium as an active metal is provided as a overlayer to form a multilayer catalyst.

When applied to an exhaust gas at a temperature of about 250.degree. C. or higher, no denitration can be effected only by the second layer iridium-carrying catalyst because there is no burning of CO or HC. However, in the case where the catalyst carrying at least one noble metal selected from the group consisting of platinum, rhodium and palladium is provided as the first layer catalyst, sufficient burning of CO and HC at 250.degree. C. is effected, resulting in the increase in the temperature of the second layer iridium-carrying catalyst up to the active temperature range, whereby exhibiting the denitration performance.

In addition, the denitration performance can be obtained continuously from the exhaust gas temperature ranging from 200.degree. C. to a higher temperature since platinum, rhodium and palladium can exhibit denitration activity in association with the burning of CO and HC at a temperature as low as 200.degree. to 300.degree. C. (Japanese Patent Application Number H4-230700). On the other hand, at a high exhaust gas temperature of 400.degree. C. or higher, the performance of the second iridium-carrying catalyst layer becomes predominant, and the first catalyst layer scarcely affects the reaction, thereby maintaining the high performance.

The exhaust gas containing NOx, CO and HC is cleaned by a catalyst which carries iridium as the second layer catalyst in the reactions represented by the formulae shown below. ##STR1##

In the reactions shown above, formula (1) shows the activation of HC, formula (2) shows the burning of HC, formula (3) shows the denitration, and formula (4) shows the burning of CO.

5616 g of water glass #1 (SiO.sub.2 : 30%) was dissolved in 5429 g of water to yield solution A. Separately, 718.9 g of aluminum sulfate, 110 g of ferric chloride, 47.2 g of calcium acetate, 262 g of sodium chloride and 2020 g of concentrated hydrochloric acid were dissolved together in 4175 g of water to yield solution B. Solution A and solution B were mixed and stirred thoroughly to yield a slurry at pH8. These two solutions were fed keeping the pH as constant as possble at 8. Namely, solution A was fed at 11045/30=368 g/min., whereas Solution B was fed at 7333/30=244 g/min. so that the pH was kept at 8. The slurry thus obtained was charged in a 20 L autoclave, to which 500 g of tetrapropyl ammonium bromide was added and the mixture was subjected to hydrothermal synthesis at 160.degree. C. for 72 hours. After synthesis, washing with water, drying and sintering for 3 hours at 500.degree. C., crystalline silicate 1 was obtained. Crystalline silicate 1 thus obtained is represented in a molar ratio (excluding crystal water) by the formula shown below and has the crystal structure characterized by the X-ray diffraction pattern shown in Table A.

Crystalline silicate 1 obtained above was subjected to NH.sub.4 ion exchange by stirring with 4N aqueous solution of NH.sub.4 Cl at 40.degree. C. for 3 hours. After the ion exchange, the silicate was washed and dried at 100.degree. C. for 24 hours and sintered at 400.degree. C. for 3 hours to obtain crystalline silicate 1 of type H.

100 g of .gamma.-alumina was immersed in an aqueous solution of chloro platinic acid (H.sub.2 PtCl.sub.6.6H.sub.2 O: 2.66 g/100 cc) and kept at 120.degree. C. to evaporate to dryness, and then purged with nitrogen for 3 hours at 500.degree. C. to yield powder catalyst 1.

On the other hand, 100 g of crystalline silicate 1 was immersed in an aquelous solution of chloroiridic acid (H.sub.2 IrCl.sub.6 : 2.1 g/100 cc) and kept at 120.degree. C. to evaporate to dryness, and then purged with nitrogen for 3 hours at 500.degree. C. to yield powder catalyst 1'.

Then, to mixtures of 100 parts each of powder catalysts 1 and 1', 3 parts of alumina sol and 55 parts of silica sol (20% SiO.sub.2) as binders and 200 parts of water were added, and the mixtures were stirred thoroughly to yield slurries of catalysts 1 and 1' for wash coats. Then a monolith support for coagulate (400-cell lattice/inch.sup.2) was immersed in the slurry of powder catalyst 1, and taken out. After blowing excessive slurry off, the support was dried at 200.degree. C. By this procedure 100 g/L of powder catalyst 1 (first layer catalyst) was coated on the substratate.

Then the support coating with powder catalyst 1 was immersed in the slurry of powder catalyst 1', and taken out. After blowing excessive slurry off, the support was dried at 200.degree. C. By this procedure 100 g/L of powder catalyst 1' (second layer catalyst) was coated.

The catalyst thus obtained was designated as honeycomb catalyst 1.

Except for adding cobalt chloride, ruthenium chloride, rhodium chloride, lanthanum chloride, cerium chloride, titanium chloride, vanadium chloride, chromium chloride, antimony chloride, gallium chloride and niobium chloride in molar amounts as oxides similar to that of Fe.sub.2 O.sub.3 instead ferric chloride used in the synthesis of crystalline silicate 1 in Example 1, the procedure similar to that employed for crystalline silicate 1 was conducted to obtain crystalline silicates 2 to 12. The crystal structures of these crystalline silicates as X-ray diffraction patterns are characterized as shown above in Table A, with the compositions being represented by the following formula in molar ratios of the oxides (dehydrated forms): 0.5Na.sub.2 O.0.5H.sub.2 O.(0.2M.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25CaO).25SiO.sub.2, wherein M denotes Co, Ru, Rh, La, Ce, Ti, V, Cr, Sb, Ga or Nb.

Except for adding magnesium acetate, strontium acetate and barium acetate each in the molar amount as an oxide similar to that of CaO instead of calcium acetate used in the synthesis of crystalline silicate 1 in Example 1, the procedure similar to that employed for crystalline silicate 1 was conducted to obtain crystalline silicates 13 to 15. The crystal structures of these crystalline silicates as X-ray diffraction patterns were shown above in Table A, with the compositions being represented by the following formula in molar ratios of the oxides (dehydrated forms): 0.5Na.sub.2 O.0.5H.sub.2 O.(0.2Fe.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25MeO).25SiO.sub.2, wherein Me denotes Mg, Sr or Ba.

Using crystalline silicates 2 to 15 and the procedure similar to that employed in Example 1, silicates of type H were obtained and then immersed in the aqueous solution of chloroiridic acid to obtain powder catalysts 2' to 15'.

Each of powder catalysts 2' to 15' was processed similarly as in Example 1 to form slurries, which were used as the second layer catalyst and coated instead of the slurry of powder catalyst 1' at the rate of 100 g/L onto the surface of the support which had already been coated with powder catalyst 1. The catalysts thus obtained were designated as honeycomb catalysts 2 to 15.

.gamma.-Al.sub.2 O.sub.3, .theta.-Al.sub.2 O.sub.3, SiO.sub.2, ZrO.sub.2, TiO.sub.2, Al.sub.2 O.sub.3.ZrO.sub.2 (1:1 by weight), ZrO.sub.2.TiO.sub.2 (1:1 by weight), Al.sub.2 O.sub.3. TiO.sub.2 (1:1 by weight), SO.sub.4 /ZrO.sub.2, zeolite of type Y, silicalite, zeolite of type A, and mordenite instead of crystalline silicate 1 used in Example 1 were immersed in and impregnated with the aqueous solution of chloroiridic acid solution similarly as in Example 1 to obtain powder catalysts 16' to 28'.

Then, each of powder catalysts 16' to 28' was processed similarly as in Example 1 to form slurries, which were used as the second layer catalyst and coated instead of the slurry of powder catalyst 1' at the rate of 100 g/L onto the surface of the support which had already been coated with powder catalyst 1. The catalysts thus obtained were designated as honeycomb catalysts 16 to 28.

Instead of the aqueous solution of chloroplatinic acid used in the preparation of powder catalyst 1 in Example 1, 100 g of .gamma.-alumina was immersed in each of aqueous solutions of rhodium chloride (RhCl.sub.3.3H.sub.2 O: 1.45 g/100 cc) or palladium chloride (PdCl.sub.2.2H.sub.2 O: 1.10 g/100 cc), mixed aqueous solutions of chloroplatinic acid rhodium chloride (H.sub.2 PtCl.sub.6.6H.sub.2 O: 1.33 g+RhCl.sub.3.3H.sub.2 O: 0.73 g/100 cc), mixed aqueous solutions of chloroplatinic acid.palladium chloride (H.sub.2 PtCl.sub.6.6H.sub.2 O: 1.33 g+PdCl.sub.2.2H.sub.2 O: 0.55 g/100 cc) and mixed aqueous solutions of chloroplatinic acid.rhodium chloride.palladium chloride (H.sub.2 PtCl.sub.6.6H.sub.2 O: 0.89 g+RhCl.sub.3.3H.sub.2 O: 0.48 g+PdCl.sub.2.2H.sub.2 O: 0.37 g/100 cc), kept at 120.degree. C., evaporated to dryness, and then purged with nitrogen for 3 hours at 500.degree. C. to obtain powder catalysts 2 to 6

Then, each of powder catalysts 2 to 6 was processed similarly as in Example 1 to form slurries, which were used as the first layer catalyst and coated instead of powder catalyst 1 at the rate of 100 g/L onto the surface of the support in a manner similar to that employed in Example 1, and then powder catalyst 1' was coated as an overlayer similarly as in Example 1. The catalysts thus obtained were designated as honeycomb catalysts 29 to 33.

Crystalline silicate 1 of type H in Example 1 was employed instead of .gamma.-alumina for powder catalyst 1 in Example 1 and immersed in the aqueous solution of chloroplatinic acid similarly as in Example 1 to obtain powder catalyst 7. Powder catalyst 7 as the first layer catalyst and powder catalyst 1' as the second layer catalyst were processed similarly as in Example 1 to obtain honeycomb catalyst 34.

Only powder catalyst 1 was coated onto a honeycomb elemental support at the rate of 200 g/L similarly as in Example 1 to obtain honeycomb catalyst 35.

Compositions of the inventive and comparative catalysts described above are shown in Table B.

Honeycomb catalysts 1 to 35 obtained in Examples 1, 2, 3, 4 and 5 and Comparative 1 were examined for the activity. The results are shown below.

NO: 500 ppm, CO: 1000 ppm, C.sub.2 H.sub.4 : 1500 ppm, O.sub.2 : 8%, CO.sub.2 : 10%, H.sub.2 O: 10%, Balance: N.sub.2, GHSV: 30000 h.sup.-1, Catalyst dimension: 15 mm.times.15 mm.times.60 mm (144 cells)

The denitration rates of the catalysts in the initial state at the inlet gas temperatures of 250.degree. C. and 350.degree. C. are shown in Table C.

Honeycomb catalysts 1 to 34 according to the present invention shown in Table C had a sufficient denitration activity even at a low gas temperature of approximately 250.degree. C., indicating that they can keep a high denitration activity over a wide range of temperatures. In contrast, a comparative catalyst 35 did not show an effective denitration activity at a low temperature of approximately 250.degree. C.

Honeycomb catalysts 1 to 34 according to the present invention had stable activity in a reducing atmosphere also at a high temperature of approximately 700.degree. C., thus ensuring high durability.