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In this work, an alternative method is proposed and validated for quantifying the axial performance of a state-of-the-art Cu zeolite SCR catalyst. Catalyst cores of a standard length, with varying lengths of wash-coated regions were used to axially resolve the functional performance of the SCR catalyst. This proposed method was validated by quantifying the catalyst entrance and exit effects, as well as the effect of non-uniform wash-coat loading densities. This method is less susceptible to some of the complications highlighted in the previous studies, such as flow uniformity between channels, as well as radiative heating effects, since the product gases are sampled across the entire monolith cross-section rather than through a single catalyst channel. The specific catalyst functions quantified include: NO and NH₃ oxidation, NH₃ storage capacity, as well as NOx conversion efficiency.

Selective catalytic reduction (SCR) of NOx by NH3 is under intensive development as a technology to enable diesel engines to meet stringent NOx emission regulations. Cu/zeolite SCR catalysts are leading candidates because of their ability to catalyze NOx reduction at the low temperatures encountered on many diesel vehicles. However, both engine evaluation and laboratory studies indicated that commonly available Cu/zeolite SCR catalysts did not have sufficient thermal stability to maintain performance during the full useful life of a vehicle (with steady-state NOx conversion decreasing ~ 10% over 64 hours of hydrothermal aging at 670 °C). Characterization of aged Cu/zeolite catalysts revealed that the loss of zeolite acidity was the main deactivation mechanism; while the zeolite support maintained its framework structure and surface area after aging. Improvement of the hydrothermal stability of the acid sites resulted in a new generation of SCR catalysts.

The effects of propylene (C₃H₆) and dodecane (n-C₁₂H₂₆) exposure on the NH₃-based selective catalytic reduction (SCR) performance of two Cu-exchanged zeolite catalysts were investigated. The first sample was a model Cu/beta zeolite sample and the second a state-of-the-art Cu/zeolite sample, with the zeolite material characterized by relatively small pores. Overall, the state-of-the-art sample performed better than the model sample, in terms of hydrocarbon inhibition (which was reduced) and N₂O formation (less formed). The state-of-the-art sample was completely unaffected by dodecane at temperatures lower than 300°C, and only slightly inhibited (less than 5% conversion loss), for standard SCR, by C₃H₆. There was no evidence of coke formation on this catalyst with C₃H₆ exposure. The model sample was more significantly affected by hydrocarbon exposure. With C₃H₆, inhibition is associated with its partial oxidation intermediates adsorbed on the catalyst surface.

NOx adsorber catalyst technology has been successfully applied on diesel vehicles to enable them to satisfy stringent NOx emission regulations. One limitation of this technology is the requirement to regularly desulfate the adsorber to maintain high NOx conversion efficiency. In addition to adding significant engine and calibration complexity, these high temperature desulfation events accelerate the thermal degradation of the exhaust system components. Minimization of the severity and the frequency of the desulfation events is highly desirable. Laboratory studies to understand desulfation processes and to identify improved NOx Adsorber washcoat compositions are described. These studies led to a new generation of NOx adsorber catalysts with reduced desulfation temperatures, faster desulfation rates and enhanced low-temperature activity. The new generation of catalysts also enabled the potential for PGM thrifting, especially for applications with low engine- out NOx emissions.

Mitigation of ammonia slip from SCR system is critical to meeting the evolving NH₃ emission standards, while achieving maximum NOx conversion efficiency. Ammonia slip catalysts (ASC) are expected to balance high activity, required to oxidize ammonia across a broad range of operating conditions, with high selectivity of converting NH₃ to N₂, thus avoiding such undesirable byproducts as NOx or N₂O. In this work, new insights into the behavior of an advanced ammonia slip catalyst have been developed by using accelerated progressive catalyst aging as a tool for catalyst property interrogation. The overall behavior was deconstructed to several underlying functions, and referenced to an active but non-selective NH₃ oxidation function of a diesel oxidation catalyst (DOC) and to the highly selective but minimally active NH₃ oxidation function of an SCR catalyst.