Reduction-catalyst-coated diesel particle filter having improved characteristics
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B01D-053/94
F01N-003/20
F01N-003/022
F01N-003/035
출원번호
US-0583516
(2011-03-30)
등록번호
US-9347354
(2016-05-24)
우선권정보
EP-10003923 (2010-04-14)
국제출원번호
PCT/EP2011/001578
(2011-03-30)
§371/§102 date
20120907
(20120907)
국제공개번호
WO2011/128026
(2011-10-20)
발명자
/ 주소
Pfeifer, Marcus
Basso, Stephan
Dornhaus, Franz
출원인 / 주소
UMICORE AG & CO. KG
대리인 / 주소
Smith, Gambrell & Russell, LLP
인용정보
피인용 횟수 :
0인용 특허 :
10
초록▼
An SCR-catalytically active diesel particle filter having a ceramic wall flow filter substrate with inflow channels, outflow channels, walls separating the inflow and outflow channels, and two coatings. The first coating is applied in inflow channels, is composed of high-melting point materials, and
An SCR-catalytically active diesel particle filter having a ceramic wall flow filter substrate with inflow channels, outflow channels, walls separating the inflow and outflow channels, and two coatings. The first coating is applied in inflow channels, is composed of high-melting point materials, and closes the inflow sides of pores in walls connecting the inflow channels and outflow channels to soot particles without preventing passage of gaseous exhaust gas constituents. The second coating is within the walls between inflow channels and outflow channels, and effectively catalyzes the selective reduction of nitrogen oxides when in the presence of a reducing agent. The particle filter displays excellent banking-up pressure properties combined with high filtration efficiency and good regeneration properties; and displays good aging stability of NOx conversion activity.
대표청구항▼
1. A diesel particle filter, comprising: a ceramic wall flow filter substrate comprising inflow channels open at a first end of the wall flow filter substrate, outflow channels open at a second end of the wall flow filter substrate, and channel walls extending between the inflow channels and the out
1. A diesel particle filter, comprising: a ceramic wall flow filter substrate comprising inflow channels open at a first end of the wall flow filter substrate, outflow channels open at a second end of the wall flow filter substrate, and channel walls extending between the inflow channels and the outflow channels, the channel walls comprising pores that extend from openings at an inflow side to openings at an outflow side;a first coating in the inflow channels, the first coating forming closures at pore openings at the inflow sides of the channel walls that inhibit soot particles from entering the pores at the inflow sides without preventing passage of gaseous exhaust gas constituents through the pores; anda second coating inside the channel walls, the second coating being one that effectively catalyzes selective reduction of nitrogen oxides when in the presence of a reducing agent. 2. The diesel particle filter as claimed in claim 1, wherein the materials used in the first coating do not have any oxidation-catalytic activity with ammonia. 3. The diesel particle filter as claimed in claim 2, wherein the second coating contains one or more SCR-catalytically active components selected from the group consisting of: (a) iron- and/or copper-exchanged zeolite compounds selected from among MOR, USY, ZSM-5, ZSM-20, beta-zeolite, CHA, FER, and mixtures thereof; or(b) iron- and/or copper-exchanged zeolite-like compounds selected from among SAPO-34, ALPO-34, and mixtures thereof; or(c) vanadium oxide, titanium oxide, tungsten oxide, molybdenum oxide, cerium oxide, zirconium oxide, niobium oxide, iron oxide, manganese oxide, mixtures thereof, and mixed oxides thereof; or(d) mixtures of at least two of (a), (b), and (c). 4. The diesel particle filter as claimed in claim 2, wherein the first coating comprises, as a majority, one or more oxides,the d50 of the particle size distribution of the oxides in the first coating is equal to or greater than the d5 of the pore size distribution of the pores in the channel walls of the wall flow filter substrate,the d90 of the particle size distribution of the oxides in the first coating is equal to or greater than the d95 of the pore size distribution of the pores in the channel walls of the wall flow filter substrate,the d50 or the d90 of the particle size distribution of the oxides is the particle size at which 50% or 90%, respectively, of the total volume of the oxides contains only particles having diameters smaller than or equal to the value indicated as d50 or d90, respectively, andthe d5 or the d95 of the pore size distribution of the wall flow filter substrate is the pore size at which 5% or 95%, respectively, of the total pore volume that can be determined by mercury porosimetry is formed of pores having diameters smaller than or equal to the value indicated as d5 or d95, respectively. 5. The diesel particle filter as claimed in claim 2, wherein the first coating comprises: as a majority, one or more oxides; andpalladium, as an oxidation-catalytically active component. 6. The diesel particle filter as claimed in claim 1, wherein the second coating contains one or more SCR-catalytically active components selected from the group consisting of: (a) iron- and/or copper-exchanged zeolite compounds selected from among MOR, USY, ZSM-5, ZSM-20, beta-zeolite, CHA, FER, and mixtures thereof; or(b) iron- and/or copper-exchanged zeolite-like compounds selected from among SAPO-34, ALPO-34, and mixtures thereof; or(c) vanadium oxide, titanium oxide, tungsten oxide, molybdenum oxide, cerium oxide, zirconium oxide, niobium oxide, iron oxide, manganese oxide, mixtures thereof, and mixed oxides thereof; or(d) mixtures of at least two of (a), (b), and (c). 7. The diesel particle filter as claimed in claim 6, wherein the first coating comprises, as a majority, one or more oxidesthe d50 of the particle size distribution of the oxides in the first coating is equal to or greater than the d5 of the pore size distribution of the pores in the channel walls of the wall flow filter substrate,the d90 of the particle size distribution of the oxides in the first coating is equal to or greater than the d95 of the pore size distribution of the pores in the channel walls of the wall flow filter substrate,the d50 or the d90 of the particle size distribution of the oxides is the particle size at which 50% or 90%, respectively, of the total volume of the oxides contains only particles having diameters smaller than or equal to the value indicated as d50 or d90, respectively, andthe d5 or the d95 of the pore size distribution of the wall flow filter substrate is the pore size at which 5% or 95%, respectively, of the total pore volume that can be determined by mercury porosimetry is formed of pores having diameters smaller than or equal to the value indicated as d5 or d95, respectively. 8. The diesel particle filter as claimed in claim 6, wherein the wall flow filter substrate comprises silicon carbide, cordierite, or aluminum titanate, andthe pores present in the channel walls between inflow and outflow channels have an average diameter in the range from 5 to 50 μm. 9. The diesel particle filter as claimed in claim 6, wherein the first coating comprises, as a majority, a fiber material comprising fibers with an average length in the range from 50 to 250 μm, and an average mass-based diameter equal to or smaller than the d50 of the pore size distribution of the pores in the channel walls of the wall flow filter substrate,the d50 of the pore size distribution of the pores in the channel walls of the wall flow filter substrate is the pore size at which 50% of the total pore volume that can be determined by mercury porosimetry is formed of pores having diameters smaller than or equal to the value indicated as d50. 10. The diesel particle filter as claimed in claim 1, wherein the first coating comprises, as a majority, one or more oxides,the d50 of the particle size distribution of the oxides in the first coating is equal to or greater than the d5 of the pore size distribution of the pores in the channel walls of the wall flow filter substrate,the d90 of the particle size distribution of the oxides in the first coating is equal to or greater than the d95 of the pore size distribution of the pores in the channel walls of the wall flow filter substrate,the d50 or the d90 of the particle size distribution of the oxides is the particle size at which 50% or 90%, respectively, of the total volume of the oxides contains only particles having diameters smaller than or equal to the value indicated as d50 or d90, respectively, andthe d5 or the d95 of the pore size distribution of the wall flow filter substrate is the pore size at which 5% or 95%, respectively, of the total pore volume that can be determined by mercury porosimetry is formed of pores having diameters smaller than or equal to the value indicated as d5 or d95, respectively. 11. The diesel particle filter as claimed in claim 10, wherein the oxides in the first coating have a particle size distribution having a d50 greater than or equal to 5 μm and a d90 greater than or equal to 20 μm. 12. The diesel particle filter as claimed in claim 11, wherein the oxides in the first coating are selected from the group consisting of aluminum oxide, rare earth metal-stabilized aluminum oxide, rare earth metal sesquioxide, and mixtures thereof. 13. The diesel particle filter as claimed in claim 12, wherein the first coating has a layer thickness of from 10 to 150 μm. 14. The diesel particle filter as claimed in claim 1, wherein the first coating comprises, as a majority, a fiber material comprising fibers with an average length in the range from 50 to 250 μm and an average mass-based diameter equal to or smaller than the d50 of the pore size distribution of the pores in the channel walls of the wall flow filter substrate,the d50 of the pore size distribution of the pores in the channel walls of the wall flow filter substrate is the pore size at which 50% of the total pore volume that can be determined by mercury porosimetry is formed of pores having diameters smaller than or equal to the value indicated as d50. 15. The diesel particle filter as claimed in claim 14, wherein the fiber material is selected from the group consisting of rock wool, natural stone fibers, and mineral wool, andfibers in the fiber material have fiber diameters greater than 5 μm. 16. The diesel particle filter as claimed in claim 15, wherein the first coating has a layer thickness of from 1 to 50 μm. 17. The diesel particle filter as claimed in claim 1, wherein the wall flow filter substrate comprises silicon carbide, cordierite, or aluminum titanate, andthe pores present in the channel walls have an average diameter in the range from 5 to 50 μm. 18. The diesel particle filter as claimed in claim 1, wherein the first coating comprises: as a majority, one or more oxides, andpalladium, as an oxidation-catalytically active component. 19. A method for purifying the exhaust gases of a diesel engine, comprising: utilizing a diesel particle filter according to claim 18 in a diesel engine exhaust stream. 20. A method of decreasing the amount of nitrogen oxides and particles in an exhaust gas from a diesel engine, comprising: utilizing a diesel particle filter according to claim 1 in a diesel engine exhaust stream.
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