Pt–Ba–Al2O3 for NOx storage and reduction: Characterization of the dispersed species

Pt–Ba–Al₂O₃ active and selective for NO_x storage and selective reduction to N₂ has been prepared and tested. Characterization of the parent Al₂O₃, Pt–Al₂O₃ and Ba–Al₂O₃ materials, as well as of Pt–Ba–Al₂O₃ catalyst in the oxidized, reduced and sulphated state has been performed by FT-IR spectroscopy of low-temperature adsorbed carbon monoxide and of adsorbed acetonitrile. XRD, TEM and XPS analyses have also been performed. Evidence for the predominance of Ba species, which are highly dispersed on the alumina support surface, and may be carbonated or sulphated, has been provided. Competitive interaction of Pt and Ba species with the surface sites of alumina has also been found.     

Influence of CO2 and H2O on NOx storage and reduction on a Pt–Ba/γ-Al2O3 catalyst

In this paper, the effect of CO₂ and H₂O on NO_x storage and reduction over a Pt–Ba/γ-Al₂O₃ (1 wt.% Pt and 30 wt.% Ba) catalyst is shown. The experimental results reveal that in the presence of CO₂ and H₂O, NO_x is stored on BaCO₃ sites only. Moreover, H₂O inhibits the NO oxidation capability of the catalyst and no NO₂ formation is observed. Only 16% of the total barium is utilized in NO storage. The rich phase shows 95% selectivity towards N₂ as well as complete regeneration of stored NO. In the presence of CO₂, NO is oxidized into NO₂ and more NO_x is stored as in the presence of H₂O, resulting in 30% barium utilization. Bulk barium sites are inactive in NO_x trapping in the presence of CO₂·NH₃ formation is seen in the rich phase and the selectivity towards N₂ is 83%. Ba(NO₃)₂ is always completely regenerated during the subsequent rich phase. In the absence of CO₂ and H₂O, both surface and bulk barium sites are active in NO_x storage. As lean/rich cycling proceeds, the selectivity towards N₂ in the rich phase decreases from 82% to 47% and the N balance for successive lean/rich cycles shows incomplete regeneration of the catalyst. This incomplete regeneration along with a 40% decrease in the Pt dispersion and BET surface area, explains the observed decrease in NO_x storage.     

Impact of copper on the performance and sulfur tolerance of barium-based NOx storage-reduction catalysts

The presence of sulfur in automotive exhaust is known to be detrimental to lean-NO_x traps as SO₂ is oxidized to SO₃ that competes with NO₂ for sites on the trap and is difficult to remove. In this study the effect of adding Cu to the prototypical Pt–BaO/γ-Al₂O₃ formulation on the system's tolerance for sulfur was investigated. It was found that in the absence of sulfur, Cu decreases the performance in terms of both NO_x storage capacity and reduction of NO_x to N₂ during regeneration. In the presence of SO₂, Cu provides a significant improvement in sulfur tolerance so that, after sulfur exposure, the storage capacity of the Cu-modified material can exceed that of the baseline material. The sulfur tolerance afforded by Cu is attributed to a moderation in the activity for SO₂ oxidation resulting from the formation of a Pt–Cu bimetallic phase. The propensity for NO oxidation is also modified, but to a lesser effect. Evidence for the bimetallic phase is provided by temperature-programmed reduction (TPR) and electron microscopy. The impact of SO₂ on the Cu-modified material is greater during the regenerative reduction cycle. In this case, the results suggest that sulfur blocks Pt and possibly Cu sites and that the sulfur is not removed by oxidation during the subsequent storage cycle. Hence, activity lost during the reduction cycle is not restored. In contrast, sulfur that blocks Pt sites on the baseline material during the reduction cycle is subsequently oxidized and desorbs from the Pt, restoring the activity. However, some of the resulting SO₃ reacts with the BaO to form BaSO₄, and there is a partial loss of storage capacity.     

On the dynamic behavior of “NOx-storage/reduction” Pt–Ba/Al2O3 catalyst

The NO_x storage and reduction functions of a Pt–Ba/Al₂O₃ “NO_x storage–reduction” catalyst has been investigated in the present work by applying the transient response and the temperature programmed reaction methods, by using propylene as the reducing agent. It is found that: (i) the storage of NO_x occurs first at BaO and then at BaCO₃, which are the most abundant sites following regeneration of catalyst with propylene; (ii) the overall storage process at BaCO₃ is slower than at BaO; (iii) CO₂ inhibits the NO_x storage at low temperatures; (iv) the amount of NO_x stored up to catalyst saturation at 350 °C corresponds to 17.6% of Ba; (v) the reduction of stored NO_x groups is fast and is limited by the concentration of propylene in the investigated T range (250–400 °C); (vi) selectivity to N₂ is almost complete at 400 °C but is significantly lower at 300 °C due to the formation of NO which can be tentatively ascribed to the presence of unselective Pt–O species.     

Mean field modelling of NOx storage on Pt/BaO/Al2O3

A mean field model, for storage and desorption of NO_x in a Pt/BaO/Al₂O₃ catalyst is developed using data from flow reactor experiments. This relatively complex system is divided into five smaller sub-systems and the model is divided into the following steps: (i) NO oxidation on Pt/Al₂O₃; (ii) NO oxidation on Pt/BaO/Al₂O₃; (iii) NO_x storage on BaO/Al₂O₃; (iv) NO_x storage on Pt/BaO/Al₂O₃ with thermal regeneration and (v) NO_x storage on Pt/BaO/Al₂O₃ with regeneration using C₃H₆. In this paper, we focus on the last sub-system. The kinetic model for NO_x storage on Pt/BaO/Al₂O₃ was constructed with kinetic parameters obtained from the NO oxidation model together with a NO_x storage model on BaO/Al₂O₃. This model was not sufficient to describe the NO_x storage experiments for the Pt/BaO/Al₂O₃, because the NO_x desorption in TPD experiments was larger for Pt/BaO/Al₂O₃, compared to BaO/Al₂O₃. The model was therefore modified by adding a reversible spill-over step. Further, the model was validated with additional experiments, which showed that NO significantly promoted desorption of NO_x from Pt/BaO/Al₂O₃. To this NO_x storage model, additional steps were added to describe the reduction by hydrocarbon in experiments with NO₂ and C₃H₆. The main reactions for continuous reduction of NO_x occurs on Pt by reactions between hydrocarbon species and NO in the model. The model is also able to describe the reduction phase, the storage and NO breakthrough peaks, observed in experiments.     

Kinetic modelling of sulfur deactivation of Pt/BaO/Al2O3 and BaO/Al2O3 NOx storage catalysts

In this work, a kinetic model is constructed to simulate sulfur deactivation of the NO_x storage performance of BaO/Al₂O₃ and Pt/BaO/Al₂O₃ catalysts. The model is based on a previous model for NO_x storage under sulfur-free conditions. In the present model the storage of NO_x is allowed on two storage sites, one for complete NO_x uptake and one for a slower NO_x sorption. The adsorption of SO_x is allowed on both of these NO_x storage sites and on one additional site which represent bulk storage. The present model is built-up of six sub-models: (i) NO_x storage under sulfur-free conditions; (ii) SO₂ storage on NO_x storage sites; (iii) SO₂ oxidation; (iv) SO₃ storage on bulk sites; (v) SO₂ interaction with platinum in the presence of H₂; (vi) oxidation of accumulated sulfur compounds on platinum by NO₂. Data from flow reactor experiments are used in the implementation of the model. The model is tested for simulation of experiments for NO_x storage before exposure to sulfur and after pre-treatments either with SO₂ + O₂ or SO₂ + H₂. The simulations show that the model is able to describe the main features observed experimentally.     

Pt-Ba/alumina NOx storage-reduction catalysts: Influence of Ba loading on NOx storage behavior

The NO_x storage behavior of a series of Pt-Ba/Al₂O₃ catalysts, prepared by wet impregnation of Pt/Al₂O₃ with Ba(Ac)₂, has been investigated. The catalysts with Ba loadings in the range 4.5–28 wt.% were calcined at 500 °C in air and subsequently exposed to NO pulses in 5 vol.% O₂/He atmosphere. Catalysts were characterized by means of thermogravimetry (TG) combined with mass spectroscopy (MS) and XRD before and after exposure to NO pulses. Characterization of the calcined catalysts corroborated the existence of three Ba-containing phases which are discernible based on their different thermal stability: BaO, LT-BaCO₃ and HT-BaCO₃. Characterization after NO_x exposure showed that the different Ba-containing phases present in the catalysts possess different reactivity for barium nitrate formation, depending on their interfacial contact. The different Ba(NO₃)₂ species produced upon NO_x exposure could be distinguished based on their thermal stability. The study revealed that during the NO_x storage process a new thermally instable BaCO₃ phase formed by reaction of evolved CO₂ with active BaO. The fraction of Ba-containing species that were active in NO_x storage depended on the Ba loading, showing a maximum at a Ba loading of about 17 wt.%. Lower and higher Ba loading resulted in a significant loss of the overall efficiency of the Ba-containing species in the storage process. The loss in efficiency observed at higher loading is attributed to the lower reactivity of the HT-BaCO₃, which becomes dominant at higher loading, and the increased mass transfer resistance.     

Investigations of sulphur deactivation of NOx storage catalysts: influence of sulphur carrier and exposure conditions

The influence of SO₂, H₂S and COS in low concentrations on the deactivation of Pt/Rh/BaO/Al₂O₃ NO_x storage catalysts was investigated. Different samples of the catalyst were exposed to synthetic gas mixtures mimicking lean/rich engine cycling in a mixed lean application at 400 °C. The lean gas mixture contained 8 vol.% O₂, 500 vol-ppm C₃H₆ and 400 vol-ppm NO balanced to 100 vol.% with Ar. The rich excursions were performed by switching off the oxygen supply. Sulphur, 25 vol-ppm of either SO₂, H₂S or COS, was added to the gas flow either during the lean, the rich or both periods. This procedure aimed at investigating the influence of the exposure conditions and therefore the lean and rich periods were kept equally long (5 min). In addition, thermodynamical calculations for the prevailing conditions were performed.

It was concluded that all sulphur compounds investigated, i.e. SO₂, H₂S and COS, had similar, negative impact on the NO_x storage ability of the catalyst and that they all showed increased deactivation rates during rich exposure compared to lean. During lean exposure, all sulphur carriers showed similar behaviour, while H₂S and COS caused severe loss of noble metal activity during rich exposure.     

Effect of hydrogen on reaction intermediates in the selective catalytic reduction of NOx by C3H6

Selective catalytic reduction of NO_x by C₃H₆ in the presence of H₂ over Ag/Al₂O₃ was investigated using in situ DRIFTS and GC–MS measurements. The addition of H₂ promoted the partial oxidation of C₃H₆ to enolic species, the formation of –NCO and the reactions of enolic species and –NCO with NO_x on Ag/Al₂O₃ surface at low temperatures. Based on the results, we proposed reaction mechanism to explain the promotional effect of H₂ on the SCR of NO_x by C₃H₆ over Ag/Al₂O₃ catalyst.     

Performances of SOx traps derived from Cu/Al hydrotalcite for the protection of NOx traps from the deactivation by sulphur

The behavior of Cu/Al mixed oxides (Cu/Al ratio in the 1:2–1:5 range) have been studied as novel, noble-metal free SO_x traps to protect NO_x traps from the deactivation by sulphur. The investigation was made both in a thermobalance apparatus and in a flow reactor, the latter simulating the reaction conditions and space-velocities of exhaust gases from lean-burn or diesel engines. The analysis of the SO₂ uptake curves as a function of the Cu/Al ratio and reaction temperature indicates that the reaction mechanism of SO₂ uptake depends on two reversible surface processes (the chemisorption of SO₂ and its oxidation by copper ions) and a nearly irreversible process (bulk diffusion of the sulphate species). The rate of these processes depends on (i) the Cu/Al ratio and nature of the surface copper species, (ii) the surface area of the catalyst, (iii) the reaction conditions, and (iv) the degree of sulphation. The SO_x traps showing the best performances in thermogravimetric tests were found also to show the best behavior in flow reactor tests, confirming the validity of thermogravimetric tests, notwithstanding the different composition of the feed used. The SO_x trap having a Cu/Al ratio of 1:2 shows better performances with respect to a reference “state-of-the-art” SO_x trap containing 2% Pt.     

Sulphur dioxide interaction with NOx storage catalysts

The effect of SO₂ on the NO_x storage capacity and oxidation and reduction activities of a model Pt/Rh/BaO/Al₂O₃ NO_x storage catalyst was investigated. Addition of 2.5, 7.5 or 25 vol. ppm SO₂ to a synthetic lean exhaust gas caused deactivation of the NO_x storage function, the oxidation activity and the reduction activity of the catalyst. The degree of deactivation of the NO_x storage capacity was found to be proportional to the total SO₂ dose that the catalyst had been exposed to. SO₂ was found to be accumulated in the catalyst as sulphate.     

Reactivity of Mg-Ba catalyst in NOx storage/reduction

A new catalyst for NO_x storage/reduction was prepared to improve the activity of Ba-Pt/γ-Al₂O₃ by replacing Ba with a mixture of Ba and Mg. The catalyst was prepared by impregnating 1 wt.% Pt and then the alkaline-earth metals (Mg, Ba) on commercial γ-Al₂O₃. The tests have been carried out in a wide temperature range (ca. 200–400 °C) in order to understand the role of the mixture of alkaline-earth metals as a function of temperature. The behaviour of the two catalysts was different and indicated a synergetic effect between Mg and Ba.     

Causes of deactivation and regeneration of an industrial Pt-NiO/Al2O3 nitrogen oxides reduction catalyst

The deactivation mechanism and regeneration of spent industrial Pt-NiO/Al₂O₃ catalysts used for NO_x reduction was studied by means of SEM-EDS, chemical analysis and kinetic measurements. It was found that the main cause of deactivation under industrial operating conditions is fouling due to carbonaceous and ZnO deposits. Various contaminant removal procedures (calcination, wet screening and acetic acid leaching) were tested and the influence of these procedures on contaminant removal and the catalyst activity were investigated. Regeneration of the spent industrial catalyst using inexpensive processes was shown to be feasible.     

NOx storage and reduction characteristics of Pd/MnOx–CeO2 at low temperature

The reaction between hydrogen and NO was studied over 1 wt.% Pd supported on NO_x-sorbing material, MnO_x–CeO₂, at low temperatures. The result of pulse mode reactions suggest that NO_x adsorbed as nitrate and/or nitrite on MnO_x–CeO₂ was reduced by hydrogen, which was spilt-over from Pd catalyst. The NO_x storage and reduction (NSR) cycles were carried out over Pd/MnO_x–CeO₂ in a conventional flow reactor at 150 °C. In a storage step, NO was removed by the oxidative adsorption from a stream of 0.04–0.08% NO, 5–10% O₂, and He balance. This was followed by a reducing step, where a stream of 1% H₂/He was supplied to ensure the conversion of nitrate/nitrite to N₂ and thus restore the adsorbability. It was revealed that the NSR cycle is much more suitable for the H₂–deNO_x process in excess O₂, compared to a conventional steady state reaction mode.     

Catalytic activation of ceramic filter elements for combined particle separation, NOx removal and VOC total oxidation

The development of a catalytically active filter element for combined particle separation and NO_x removal or VOC total oxidation, respectively, is presented. For NO_x removal by selective catalytic reduction (SCR) a catalytic coating based on a TiO₂–V₂O₅–WO₃ catalyst system was developed on a ceramic filter element. Different TiO₂ sols of tailor-made mean particle size between 40 and 190 nm were prepared by the sol–gel process and used for the impregnation of filter element cylinders by the incipient wetness technique. The obtained TiO₂-impregnated sintered filter element cylinders exhibit BET surface areas in the range between 0.5 and 1.3 m²/g. Selected TiO₂-impregnated filter element cylinders of high BET surface area were catalytically activated by impregnation with a V₂O₅ and WO₃ precursor solution. The obtained catalytic filter element cylinders show high SCR activity leading to 96% NO conversion at 300 °C, a filtration velocity of 2 cm/s and an NO inlet concentration of 500 vol.-ppm. The corresponding differential pressures fulfill the requirements for typical hot gas filtration applications. For VOC total oxidation, a TiO₂-impregnated filter element support was catalytically activated with a Pt/V₂O₅ system. Complete oxidation of propene with 100% selectivity to CO₂ was achieved at 300 °C, a filtration velocity of 2 cm/s and a propene inlet concentration of 300 vol.-ppm.     

Formation and stability of barium aluminate and cerate in NOx storage-reduction catalysts

The formation and stability of BaAl₂O₄ and BaCeO₃ in Pt-Ba/Al₂O₃ and Pt-Ba/CeO₂ based NO_x storage-reduction (NSR) catalysts has been investigated using kinetic measurements, X-ray diffraction, thermal analysis and X-ray absorption spectroscopy. In as-prepared state, the Ba-component in the NSR catalysts was made up of amorphous BaO and BaCO₃. The formation of BaAl₂O₄ started above 850 °C, whereas the formation of BaCeO₃ was already observed at 800 °C and was faster than that of BaAl₂O₄. The stability of BaAl₂O₄ and BaCeO₃ in various liquid and gaseous atmospheres was different. BaAl₂O₄ was rapidly hydrated at room temperature in the presence of water and transformed to Ba(NO₃)₂ and γ-alumina in the presence of HNO₃, whereas BaCeO₃ was decomposed to much lower extent under these conditions. Interestingly, BaCeO₃ was transformed to Ba(NO₃)₂/CeO₂ in the presence of NO₂/H₂O at 300–500 °C. Also, the presence of CO₂ led to decomposition of barium cerate, which has important consequences for the catalyst ageing under NO_x-storage conditions and can be exploited for regeneration of thermally aged NSR-catalysts.     

Influence of metal oxides on the catalytic behavior of Au/Al2O3 for the selective reduction of NOx by hydrocarbons

The reduction of NO by propene in the presence of excess oxygen over mechanical mixtures of Au/Al₂O₃ with a bulk oxide has been investigated. The oxides studied were: Co₃O₄, Mn₂O₃, Cr₂O₃, CuO, Fe₂O₃, NiO, CeO₂, SnO₂, ZnO and V₂O₅. Under lean C₃H₆-SCR conditions, these oxides (with the exception of SnO₂) convert selectively NO to NO₂. When mechanically mixed with Au/Al₂O₃, the Mn₂O₃ and Co₃O₄ oxides and, to a much greater extent, CeO₂ act synergistically with this catalyst greatly enhancing its SCR performance. It was found that their synergistic action is not straightforwardly related to their activity for NO oxidation to NO₂. The exhibited catalytic synergy may be due to the operation of either remote control or a bifunctional mechanism. In the later case, the key intermediate must be a short-lived compound and not the NO₂ molecule in gas-phase.     

New insight into the interaction of sulfur with diesel NOx storage catalysts

A commercial NO_x-storage catalyst (NSC) has been subjected to different aging procedures on the engine bench simulating 100,000 km mileage. The aging consisted of cyclical sulfur exposure, subsequent sulfur removal and testing of the catalytic activity. More aggressive desulfation procedures result in more efficient sulfur removal and consequently good high temperature NO_x-conversion. However, low temperature NO_x-performance is lower than for agings employing more moderate desulfation conditions.

Sulfur post mortem analyses reveal a slight decrease of residual sulfur concentration over the length of all catalysts after completion of the aging. BET and CO-chemisorption data are in line with the increase of temperature from catalyst inlet to outlet during the desulfation. The conversion of BaCO₃ to BaSO₄ during the sulfur poisoning was followed by IR, TPD and TPR. A quantitative analysis of the data shows that at the end of the agings all residual sulfur is mainly located at barium sites as opposed to other oxide components like e.g. alumina or ceria. TPR data suggest that prolonged rich purges of the sulfated catalyst lead to an efficient decomposition of sulfates however some sulfur is being trapped in the form of BaS which seems difficult to remove under constant rich conditions.

XPS data suggest that the bulk sulfur amounts in the catalyst may be decoupled from the actual concentration at the catalyst surface. In that sense, the residual sulfur concentration might be limited in some cases as a criterion to assess the performance of a NSC. More reducing desulfation conditions cause the residual sulfur to be present in the form of more reduced sulfur species (sulfites, sulfides) on the catalyst.     

Effect of Pt on the water resistance of Co-zeolites upon the SCR of NOx with CH4

The objective of this work was to study the promotional effect of Pt on Co-zeolite (viz. mordenite, ferrierite, ZSM-5 and Y-zeolite) and Co/Al₂O₃ on the selective catalytic reduction (SCR) of NO_x with CH₄ under dry and wet reaction stream. After being reduced in H₂ at 350°C, the PtCo bimetallic zeolites showed higher NO to N₂ conversion and selectivity than the monometallic samples, as well as a combination of the latter samples such as mechanical mixtures or two-stage catalysts. After the same pretreatment, under wet reaction stream, the bimetallic samples were also more active. Among the other catalysts studied with 5% of water in the feed, (NO = CH₄ = 1000 ppm, O₂ = 2%), the NO conversion dropped to zero over Co_2.0Mor at 500°C and GHSV = 30,000 h⁻¹, whereas it is 20% in Pt_0.5Co_2.0Mor. In Pt/Co/Al₂O₃ the NO_x conversion dropped below 5% with only 2% of water under the same reaction conditions. The specific activity given as molecules of NO converted per total metal atom per second were 16.5 × 10⁻⁴ s⁻¹ for Pt_0.5Co_2.0Fer, 13 × 10⁻⁴ s⁻¹ for Pt_0.5Co_2.0Mor, 4.33 × 10⁻⁴ s⁻¹ for Pt_0.5Co_2.0ZSM-5 and 0.5 × 10⁻⁴ s⁻¹ for Pt/Co/Al₂O₃. The Y-zeolite-based samples were inactive in both mono and bimetallic samples. The species initially present in the solid were Pt° and Co°, together with Co²⁺ and Pt²⁺ at exchange positions. Co° seems not to participate as an active site in the SCR of NO_x. Those species remained after the reaction but some reorganization occurred. A synergetic effect among the different species that enhances both the NO to NO₂ reaction, the activation of CH₄ and also the ability of the catalyst to adsorb NO, could be responsible for the high activity and selectivity of the bimetallic zeolites.     

Transient behaviour of catalytic monolith with NOx storage capacity

Transient behaviour of catalytic monolith converter with NO_x storage is studied under conditions typical for automobiles with lean-burn engines (i.e., diesel and advanced gasoline ones). Periodical alternation of inlet concentrations is applied—NO_x are adsorbed on the catalyst surface during a long reductant-lean phase (2–3 min) and then reduced to N₂ within a short reductant-rich phase (2–6 s). Samples of industrial NO_x storage and reduction catalyst of NM/Ba/CeO₂/γ-Al₂O₃ type (NM = noble metal), washcoated on 400 cpsi cordierite substrate, are used in the study. Effects of the rich-phase length and composition on the overall NO_x conversions are examined experimentally. Reduction of NO_x by CO, H₂ and unburned hydrocarbons (represented by C₃H₆) in the presence of CO₂ and H₂O is considered.

Effective, spatially 1D, heterogeneous mathematical model of catalytic monolith with NO_x and oxygen storage capacity is described. The minimum set of experiments needed for the evaluation of relevant reaction kinetic parameters is discussed: (i) CO, H₂ and HC oxidation light-off under both lean and rich conditions, including inhibition effects, (ii) NO/NO₂ transformation, (iii) NO_x storage, including temperature dependence of effective NO_x storage capacity, (iv) water gas shift and steam reforming under rich conditions, i.e., in situ production of hydrogen, (v) oxygen storage and reduction, including temperature dependence of effective oxygen storage capacity, and (vi) NO_x desorption and reduction under rich conditions. The experimental data are compared with the simulation results.