Purification of exhaust gases

BACKGROUND OF THE INVENTION
This invention relates to a method of purifying exhaust gases from internal combustion engines, especially exhaust gases from motor vehicles, the purification being effected catalytically and serving to simultaneously remove hydrocarbons, carbon monoxide and nitrogen oxides from the gases when a nearly stoichiometric fuel-air ratio is being maintained. Such catalytic converters are well known in the art.
It is known that the gases which are exhausted from an internal combustion engine when the fuel-air ratio is nearly stoichiometric (.lambda. = 0.99 - 1.01) contain only a little carbon monoxide, hydrogen and unburned hydrocarbons, whereas their content of nitroen oxide is higher in comparison to a richer adjustment. On the other hand, an exhaust gas from the combustion of a nearly stoichiometric mixture also contains a quantity of oxygen which is roughly equivalent to the quantity of the components that have not been burned. Since it is technically possible to adjust fuel-air mixtures to stoichiometric proportions and to maintain these proportions during operation, an exhaust gas which is nearly free from carbon monoxide, hydrocarbons and nitrogen oxides will be obtained if the nitrogen oxides can be successfully catalytically reacted with some of the hydrogen or carbon monoxide present in the exhaust gas to form nitrogen, and the hydrocarbons and the remainder of the carbon monoxide present in the exhaust can likewise be reacted with the oxygen.
In principle the following reactions would be involved
CO + 0.5 O.sub.2 .fwdarw.CO.sub.2 ( 2) ##EQU1##
H.sub.2 + 0.5 O.sub.2 .fwdarw. H.sub.2 O (3)
CO + NO .fwdarw. CO.sub.2 + 0.5 N.sub.2 ( 4)
h.sub.2 + no .fwdarw. h.sub.2 o + 0.5 n.sub.2 ( 5)
if the stoichiometric proportion of the oxidizing to the reducing reactants in the exhaust gas is equated with unity, the following relationship will hold ##EQU2## In this equation (O.sub.2), (NO), (CO), (H.sub.2) and (C.sub.n H.sub.2n+2) are the molar concentrations of oxygen, nitric oxides, carbon monoxide, hydrogen and hydrocarbons, respectively, and n is an integer If the ratio L < 1, the reducing components of the system are preponderant, whereas if the ratio L > 1 there is an excess of oxidizing components. This ratio is hereinafter referred to as the L-value of the exhaust gas.
If the fuel-air ratio supplied to the vehicle engine is kept constant between about 0.99 and 1.01 by a control system of fuel injection, the exhaust gas will contain on the order of about 1% carbon monoxide, 0.4% hydrogen, 0.02% propane, and 0.1% nitric oxide, whereas the oxygen content will be from about 0.5 to 0.9%. If these limits for the oxygen concentration are introduced into equation (6), all other quantities remaining unchanged, then the values of L will be
L = 0.69, when O.sub.2 = 0.5% and
L = 1.19, when O.sub.2 = 0.9%
and the stoichiometric ratio L = 1 will be attained when the oxygen content is 0.75%.
The effect of a catalyst for different L-values in the neighborhood of L= 1 (stoichiometric composition of the exhaust gas) is determined as follows:
The conversion percentages of nitrogen oxides (NO.sub.x), carbon monoxide and the hydrocarbons are plotted on a graph as functions of L. The variability range of L within which the conversion percentages of the three above-mentioned exhaust gas constituents exceed 90% (.DELTA.L) can be used as a criterion for the effectiveness of the catalyst and should be as wide as possible.
Catalysts which satisfy this criterion have already been described in German Offenlegungsschrift No. 2,304,831, and consist of a combination of platinum, ruthenium, rhodium and rhenium on a carrier which has been calcined at a temperature of not less than 800.degree. C.. These catalysts contain a relatively large proportion of noble metals and they are therefore expensive.
German Offenlegungsschrift No. 2,306,395 describes supported catalysts which comprise an intermetallic system consisting of at least three metals as the catalytically active component, the system including a platinum group metal and one base metal selected from aluminum, titanium, chromium, manganese, cobalt and nickel. Such catalysts also have a relatively high noble metal content.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an improved process for the purification of exhaust gas, particularly exhaust gas from an internal combustion engine.
Another object of the invention resides in the provision of an improved exhaust gas purification process employing an improved catalyst.
It is also an object of the invention to provide an improved process and catalyst wherein smaller amounts of noble metal are used in the catalyst.
A further object of the invention is to provide an improved process and catalyst for simultaneously removing hydrocarbons, carbon monoxide and nitrogen oxides from an automatic exhaust gas.
In accomplishing the foregoing objects, there has been provided in accordance with the present invention a process for purifying exhaust gases from an internal combustion engine being operated with a substantially stoichiometric fuel-to-air mixture, the exhaust gases containing hydrocarbons (C.sub.n H.sub.2n+2), carbon monoxide and nitric oxide and having an L-value of between about 0.8 and 1.2 where ##EQU3## and n is an integer, comprising the step of contacting the exhaust gases at an elevated temperature with a catalyst comprised of catalytically effective amounts of molybdenum and rhodium supported on a carrier, which has been calcined at a temperature of at least about 800.degree. C., whereby the hydrocarbons, carbon monoxide and nitric oxide are simultaneously removed from said exhaust gases. Preferably the molybdenum and rhodium are present in the catalyst in an atomic ratio of from about 1:1 to 4:1, most preferably about 2:1. Typically, the catalyst contains from about 0.01 to 0.1% by weight each of molybdenum and rhodium, and more preferably from about 0.02 to 0.08% by weight of molybdenum and from about 0.2 to 0.04% by weight of rhodium. In a preferred embodiment of the invention, the catalyst further comprises platinum, preferably from about 0.01, to 0.1% by weight and more preferably from about 0.04 and 0.08% by weight thereof.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Unexpectedly it has now been found that if molybdenum is used as an active catalytic component the required quantity of platinum metals can be very considerably reduced. A catalyst having a low content of noble metals has now been developed, which oxidizes the hydrocarbons and carbon monoxide while at the same time reducing the nitrogen oxides within a wide range of L-values.
Accordingly, the present invention provides a method of purifying exhaust gases from an internal combustion engine operated with a substantially stoichiometric fuel-to-air mixture, the gases having an L-value (as hereinabove defined) of from about 0.8 to 1.2, wherein the exhaust gases having a temperature between 300.degree. and 1000.degree. C are brought into contact with a catalyst comprising molybdenum, rhodium and, optionally, platinum supported on a carrier which has been calcined at a temperature of not less than about 800.degree. C.
The molybdenum, rhodium, and optional platinum content of the catalyst may be from about 0.01 to 0.1% by weight of each metal, and the catalyst preferably contains, by weight, about 0.02 to 0.08% molybdenum, about 0.02 to 0.04% rhodium, and about 0.04 to 0.08% platinum, the atomic ratio of molybdenum: rhodium being preferably from about 1 : 1 to 4 : 1.
Although catalysts which contain exclusively molybdenum and rhodium as their active components are very effective, their activity and thermal stability can be further improved by an addition of platinum.
Suitable carriers for the present catalyst, are carriers consisting of alumina and aluminosilicates molded into highly refractory and abrasion-resistant pellets such as extrudates, spheres and other shapes. Preferably the content of sodium oxide in such carriers is kept under about 0.1% and the content of anions derived from inorganic acids, such as Cl' or SO.sub.4 ", is kept under about 0.2%.
Before being provided with the catalytically active components, the carrier material is calcined at a temperature of not less than about 800.degree. C. e.g., for about 10 to 120 minutes at a temperature of from 800.degree. to 1500.degree. C., preferably from 800.degree. to 1100.degree. C. Cellular or corrugated ceramic bodies made of refractories such as cordierite, .beta.-spodumene, mullite, alpha-alumina, or combinations of these substances, and coated with aluminum oxide are also suitable as carriers.
The application of the active components to the carrier is effected by impregnation with water-soluble compounds of the catalytically active components.
If the catalysts are to contain platinum, it is preferable to apply the platinum after impregnation of the carrier with molybdenum and rhodium compounds has been completed, and to use a solution containing platinum in the form of platinum tetrammine hydroxide.
When preparing catalysts of which the carrier is a cellular ceramic, either all the active components may be incorporated in the suspension used for applying the aluminum oxide coating or, in the case of catalysts containing platinum, only molybdenum and rhodium will be incorporated in the suspension, the platinum being introduced by impregnation with a solution of platinum tetrammine hydroxide.
The application of the active components to cellular ceramic bodies may also proceed by impregnating the carrier after it has been coated with aluminum oxide.
The invention will now be more particularly described with reference to the following illustrative Examples.

EXAMPLE 1
Catalysts numbered 1 to 3 are prepared as follows:
A commercial spheroidal carrier material of active alumina is calcined for 1 hour at 1000.degree. C. and then impregnated at boiling temperature with an aqueous solution containing 0.20 g. of rhodium in the form of rhodium nitrate and, additionally in the case of catalyst No. 1, 0.187 g. of molybdenum, in the case of catalyst No. 2, 0.374 g. of molybdenum, and in the case of catalyst No. 3, 0.561 g. of molybdenum in the form of ammonium molybdate, per liter of carrier employed bulk density of the carrier 0.75 kg/l). The removal of surplus solvent is effected at 120.degree. C. in a rotary dryer and the catalysts are then calcined at 800.degree. C. The finished catalysts Nos. 1 to 3 then have the following compositions:
______________________________________Catalyst No. Mo Rh______________________________________ (% by weight)1 0.025 0.0272 0.050 0.0273 0.075 0.027______________________________________
EXAMPLE 2
Catalysts Nos. 1 to 3 produced as described in Example 1 are treated with an aqueous solution at its boiling point containing 0.4 g. platinum in the form of platinum tetrammine hydroxide per liter of catalyst. The removal of surplus solvent is effected at 120.degree. C. in a rotary dryer. The finished catalysts Nos. 4-6 have the following compositions after calcination at 800.degree. C.:
______________________________________Catalyst No. Pt Rh Mo______________________________________ (% by weight)4 0.053 0.027 0.0255 0.053 0.027 0.0506 0.053 0.027 0.075______________________________________
EXAMPLE 3
The carrier used in Example 1 is impregnated with an aqueous solution at its boiling point containing 0.2 g. rhodium in the form of rhodium nitrate, 0.4 g. platinum in the form of hexachloroplatinic acid and 0.374 g. of molybdenum in the form of ammonium molybdate, per liter of carrier used. The removal of surplus solvent is effected at 120.degree. C. in a rotary dryer. After having been calcined at 800.degree. C., the prepared catalyst No. 7 has a metal content comprising 0.053% by weight of platinum, 0.027% by weight of rhodium and 0.05% by weight of molybdenum.
EXAMPLE 4
A cellular ceramic body made of cordierite (bulk density 0.72 kg./l.) ) is immersed in a suspension of 20% by weight of finely-divided pseudo-beohmite (aluminum oxide content 73.5% by weight, grain size <3.mu.), and 1.65% by weight of finely divided cerium oxide (grain size <3.mu.). After having been dried at 200.degree. C. and calcined at 900.degree. C. the body is treated at the boiling point with an aqueous solution of 0.4 g. molybdenum in the form of ammonium molybdate, 0.2 g. rhodium in the form of rhodium nitrate and 0.4 g. platinum in the form of hexachloroplatinic acid, per liter of carrier treated. The removal of the surplus solvent is effected at 120.degree. C. in a rotary dryer. After having been calcined at 800.degree. C., the finished catalyst No. 8 contains 0.055% by weight of molybdenum, 0.028% by weight of rhodium and 0.055% by weight of platinum.
EXAMPLE 5
A cellular ceramic body made of cordierite (bulk density 0.72 kg./l. ) is immersed in a suspension consisting of 20% by weight of finely divided pseudo-boehmite (aluminum oxide content 73.5% by weight, grain size <3.mu.), 1.65% by weight of finely-divided cerium oxide (grain size <3.mu.), 0.265% by weight of molybdenum in the form of ammonium molybdate, 0.142% by weight of rhodium in the form of rhodium nitrate and water. After having been dried at 120.degree. C. and calcined at 800.degree. C. the finished catalyst No. 9 contains 0.055% by weight of molybdenum and 0.029% by weight of rhodium.
EXAMPLE 6
A catalyst produced as described in Example 5 is treated with a solution at boiling point containing 0.4 g. of platinum per liter of catalyst in the form of platinum tetrammine hydroxide. The removal of surplus solvent is effected at 120.degree. C, in a rotary dryer. After having been calcined at 800.degree. C. the finished catalyst No. 10 contains 0.55% by weight of platinum, 0.029% by weight of rhodium and 0.055% by weight of molybdenum.
EXAMPLE 7
For the purpose of testing their activities, catalysts Nos. 1 to 10 are contacted with a gas mixture with a composition approximating that of an automative exhaust gas when the air-fuel mixture in the engine is kept approximately stoichiometric. Since the .DELTA. L-value depends on the conversion of the oxides of nitrogen and of the carbon monoxide and since, as a matter of experience, the percentage conversion of the hydrocarbons in this range is above 90%, the admixture of hydrocarbons was dispensed within the preparation of the test gas.
The gas mixture used had the following composition:
______________________________________0.1% by vol. NO1 " CO0.4 " H.sub.210 " CO.sub.214 " steam0.3-0.8 " O.sub.2balance N.sub.2.______________________________________
The oxygen content was varied from 0.3 to 0.8% by volume. The space velocity was 50,000 (v./vh.) and the gas entry temperature was 500.degree. C. If the stoichiometric ratio of the oxidizing to the reducing reactants is equated with unity, then the following equation will hold: ##EQU4##
The range of L within which the percentage conversions of carbon monoxide and nitric oxide exceed 90% (.DELTA.L) is the criterion for assessing the effectiveness of the catalyst.
After having been tested when fresh under the stated conditions, the catalysts were each aged in air for 24 hours at 870.degree. and 980.degree. C. respectively. After each aging step, a fresh activity test was performed. The results are collated in Tables 1 (catalysts 1 - 3), 2 (catalysts 4 - 7) and 3 (catalysts 8 - 10).
It will be apparent from the listed results that the catalysts containing molybdenum and rhodium as active components reduce the nitric oxide and carbon monoxide contents of the tested gas by at least 90% within a wide .DELTA.L range (catalysts Nos. 1 - 3 and No. 9). Catalysts in which the ratio of Mo : Rh is 2 : 1 are the most effective.
An addition of platinum improves the activity and themal stability (catalysts Nos. 4 to 8 and No. 10).
TABLE 1__________________________________________________________________________ CATALYST 1 CATALYST 2 CATALYST__________________________________________________________________________ 3 NO- NH.sub.3 CO NO- NH.sub.3 CO NO- NH.sub.3 COO.sub.2 L Conv. form. Conv. Conv. form. Conv. Conv. form. Conv.Vol. % Aging % ppm % .DELTA.L % ppm % .DELTA.L % ppm % .DELTA.L__________________________________________________________________________0.30 0.50 Fresh 100 150 72 0.20 100 380 82 0.38 100 320 77 0.330.40 0.64 100 50 80 100 270 88 100 170 820.50 0.79 100 30 87 100 120 92 100 60 910.55 0.86 100 10 92 100 70 97 100 30 950.60 0.93 100 0 97 100 20 98 100 20 960.65 1.00 100 0 99 100 0 99 100 10 990.70 1.07 68 0 100 100 0 100 100 0 990.75 1.14 75 0 100 77 0 1000.80 1.220.30 0.50 24h 870.degree. C. 100 100 70 0.19 100 380 48 0.17 100 230 55 0.120.40 0.64 100 60 75 100 150 62 100 110 680.50 0.79 100 20 88 100 40 72 100 40 800.55 0.86 100 10 91 100 20 80 100 25 850.60 0.93 100 0 97 100 10 97 100 10 910.65 1.00 100 0 98 100 0 96 100 0 980.70 1.07 77 0 99 100 0 99 82 0 990.75 1.14 87 0 1000.80 1.220.30 0.50 24h 980.degree. C. 100 300 45 0.11 100 300 47 0.13 98 350 46 0.080.40 0.64 100 160 55 100 120 57 98 140 580.50 0.79 100 50 68 100 60 68 99 50 700.55 0.86 100 20 76 100 30 78 99 25 800.60 0.93 100 10 84 100 15 85 99 15 880.65 1.00 100 0 92 100 0 93 99 0 950.70 1.07 95 0 98 100 0 97 73 0 990.75 1.14 78 0 99 76 0 990.80 1.22__________________________________________________________________________
TABLE 2__________________________________________________________________________ CATALYST 4 CATALYST 5 NO- NH.sub.3 CO NO- NH.sub.3 COO.sub.2 L Conv. form. Conv. Conv. form. Conv.Vol. % Aging % ppm % .DELTA.L % ppm % .DELTA.L__________________________________________________________________________0.30 0.50 Fresh 100 400 65 0.30 100 400 76 0.420.40 0.64 100 200 78 100 250 890.50 0.79 100 100 86 100 150 960.55 0.86 100 40 90 100 80 970.60 0.93 100 20 92 100 40 980.65 1.00 100 10 97 100 10 990.70 1.07 100 0 99 92 0 1000.75 1.14 94 0 100 75 0 1000.80 1.22 80 0 1000.30 0.50 24h 100 300 67 0.22 100 360 73 0.240.40 0.64 870.degree. C 100 140 78 100 200 790.50 0.79 100 40 81 100 100 880.55 0.86 100 25 86 100 50 970.60 0.93 100 15 92 100 25 990.65 1.00 100 0 97 100 0 990.70 1.07 100 0 99 85 0 990.75 1.14 100 0 1000.80 1.22 67 0 1000.30 0.50 24h 100 300 43 0.15 100 300 62 0.180.40 0.64 980.degree. C 100 140 61 100 200 640.50 0.79 100 70 76 100 100 750.55 0.86 100 50 81 100 80 800.60 0.93 100 25 88 100 50 900.65 1.00 100 0 92 100 0 960.70 1.07 100 0 96 96 0 990.75 1.14 87 0 98 86 0 990.80 1.22 CATALYST 6 CATALYST 7 NO- NH.sub.3 CO N0- NH.sub.3 COO.sub.2 L Conv. form. Conv. Conv. form. Conv.Vol. % Aging % ppm % .DELTA.L % ppm % .DELTA.L__________________________________________________________________________0.30 0.50 Fresh 100 400 74 0.36 100 400 63 0.320.40 0.64 100 200 86 100 250 770.50 0.79 100 100 94 100 80 850.55 0.86 100 50 97 100 60 920.60 0.93 100 25 98 100 25 970.65 1.00 95 10 99 100 10 990.70 1.07 90 0 99 100 0 990.75 1.14 76 0 100 96 0 1000.80 1.22 75 0 1000.30 0.50 24h 100 200 58 0.18 100 380 12 0.170.40 0.64 870.degree. C 100 120 72 100 200 330.50 0.79 100 50 88 100 50 570.55 0.86 100 25 90 100 25 700.60 0.93 100 10 96 100 10 820.65 1.00 100 0 99 100 0 970.70 1.07 82 0 99 96 0 980.75 1.14 90 0 990.80 1.22 78 0 1000.30 0.50 24h 100 360 48 0.16 100 400 45 0.150.40 0.64 980.degree. C 100 200 62 100 200 650.50 0.79 100 120 72 100 50 700.55 0.86 100 60 78 100 25 770.60 0.93 100 30 84 100 15 870.65 1.00 100 20 88 100 5 940.70 1.07 100 0 93 100 0 990.75 1.14 100 0 98 82 0 1000.80 1.22 86 0 99__________________________________________________________________________
TABLE 3__________________________________________________________________________ CATALYST 8 CATALYST 9 CATALYST 10 NO- NH.sub.3 CO NO- NH.sub.3 CO NO- NH.sub.3 COO.sub.2 L Conv. form. Conv. Conv. form. Conv. Conv. form. Conv.Vol. % Aging % ppm % .DELTA. L % ppm % .DELTA. L % ppm % .DELTA.__________________________________________________________________________ L0.30 0.50 Fresh 100 400 60 0.30 100 400 60 0.19 100 400 72 0.360.40 0.64 100 250 70 100 250 70 100 200 800.50 0.79 100 120 79 100 100 89 100 90 870.55 0.86 100 70 87 100 50 87 100 40 910.60 0.93 100 25 94 100 15 92 100 20 940.65 1.00 100 10 97 100 10 97 100 10 960.70 1.07 100 0 99 98 0 99 100 0 990.75 1.14 98 0 99 73 0 99 100 0 990.80 1.22 87 0 100 87 0 1000.30 0.50 24h 870.degree. C 100 400 57 0.18 100 450 60 0.15 100 600 68 0.230.40 0.64 100 200 59 100 350 70 100 500 730.50 0.79 100 100 65 100 200 78 100 300 800.55 0.86 100 50 78 100 100 82 100 200 830.60 0.93 100 30 82 100 25 88 100 100 880.65 1.00 100 10 89 100 10 93 100 40 920.70 1.07 100 0 95 100 0 97 100 25 950.75 1.14 100 0 0 82 0 98 100 0 980.80 1.22 86 0 0 86 0 990.30 0.50 24h 980.degree. C 100 350 20 0.18 100 450 65 0.10 100 600 40 0.180.40 0.64 100 200 40 100 200 70 100 440 580.50 0.79 100 100 60 100 80 80 100 360 750.55 0.86 100 50 68 100 40 85 100 220 850.60 0.93 100 20 85 100 20 90 100 100 910.65 1.00 100 10 82 100 5 97 100 50 990.70 1.07 100 0 95 89 0 99 100 20 990.75 1.14 95 0 98 77 0 99 76 0 1000.80 1.22 89 0 99__________________________________________________________________________

Number	Name	Date
3619127	Hass	Nov 1971
3839225	Acres	Oct 1974
3840471	Acres	Oct 1974
3895093	Weidenbach et al.	Jul 1975

Purification of exhaust gases

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