Selective catalytic reduction articles and systems

Abstract

The present disclosure relates to copper-containing molecular sieve catalysts that are highly suitable for the treatment of exhaust containing NOx pollutants. The copper-containing molecular sieve catalysts contain ion-exchanged copper as Cu+2 and Cu(OH)+1, and DRIFT spectroscopy of the catalyst exhibits perturbed T-O-T vibrational peaks corresponding to the Cu+2 and Cu(OH)+1. In spectra taken of the catalytic materials, a ratio of the Cu+2 to the Cu(OH)+1 peak integration areas preferably can be ≥1. The copper-containing molecular sieve catalysts are aging stable such that the peak integration area percentage of the Cu+2 peak (area Cu+2/(area Cu+2+area Cu(OH)+1)) increases by ≤20% upon aging at 800° C. for 16 hours in the presence of 10% H2O/air, compared to the fresh state.

1 . A selective catalytic reduction article comprising a substrate having a catalytic coating on at least a portion of a surface thereof, the catalytic coating including a copper-containing molecular sieve containing ion-exchanged copper as Cu +2  cations and as Cu(OH) +1  cations, wherein the copper-containing molecular sieve exhibits a perturbed T-O-T asymmetric stretching vibrational peak corresponding to the Cu +2  cations and a perturbed T-O-T asymmetric stretching vibrational peak corresponding to the Cu(OH) +1  cations, and wherein the integrated peak areas of the perturbed T-O-T asymmetric stretching vibrational peak corresponding to the Cu +2  cations and a perturbed T-O-T asymmetric stretching vibrational peak corresponding to the Cu(OH) +1  cations have a ratio of ≥1 as measured using Diffuse Reflectance Infrared Fourier Transform (DRIFT) spectroscopy. 
     
     
         2 . The selective catalytic reduction article of  claim 1 , wherein the copper-containing molecular sieve exhibits the perturbed T-O-T asymmetric stretching vibrational peaks corresponding to the Cu +2  cations and the Cu(OH) +1  cations at about 900 cm −1  and about 950 cm −1 , respectively, in the infrared spectrum, or wherein the copper-containing molecular sieve exhibits perturbed T-O-T asymmetric stretching vibrational peaks corresponding to the Cu +2  cations and the Cu(OH) +1  cations at about 900 cm −1  and about 970 cm −1 , respectively, in the infrared spectrum. 
     
     
         3 . The selective catalytic reduction article of  claim 1 , wherein a percentage of the total integrated peak area that is attributable to the perturbed T-O-T asymmetric stretching vibrational peak corresponding to the Cu +2  cations is calculated by dividing the integrated peak area for the perturbed T-O-T asymmetric stretching vibrational peak corresponding to the Cu +2  cations by the integrated peak areas for the perturbed T-O-T asymmetric stretching vibrational peaks corresponding to the Cu +2  cations and Cu(OH) +1  cations combined, and wherein the percentage of the total integrated peak area that is attributable to the perturbed T-O-T asymmetric stretching vibrational peak for Cu +2  cations is ≥50%. 
     
     
         4 . The selective catalytic reduction article of  claim 3 , wherein the contribution by the perturbed T-O-T asymmetric stretching vibrational peak corresponding to the Cu +2  cations to the combined integrated peak areas for the perturbed T-O-T asymmetric stretching vibrational peaks of the Cu +2  cations and Cu(OH) +1  cations for the copper-containing molecular sieve in an aged state is increased by ≤20% relative to the contribution for the copper-containing molecular sieve in the fresh state, wherein the aged state is defined by having aged the selective catalytic reduction article at a temperature of about 800° C. for a time of about 16 hours in the presence of air with an H 2 O content of about 10 mol. %. 
     
     
         5 . The selective catalytic reduction article of  claim 1 , wherein the total amount of copper in the copper-containing molecular sieve, calculated as copper oxide, is about 1.0 wt. % to about 10 wt. %, based on the total weight of the copper-containing molecular sieve. 
     
     
         6 . The selective catalytic reduction article of  claim 1 , wherein the copper-containing molecular sieve comprises crystals or agglomerates having a mean size ≤2.0 microns. 
     
     
         7 . The selective catalytic reduction article of  claim 1 , wherein the copper-containing molecular sieve comprises a small pore molecular sieve selected from the group consisting of framework types AEI, AFT, AFV, AFX, AVL, CHA, DDR, EAB, EEI, ERI, IFY, IRN, KFI, LEV, LTA, LTN, MER, MWF, NPT, PAU, RHO, RTE, RTH, SAS, SAT, SAV, SFW, TSC, UFI, mixtures thereof, and intergrowths thereof. 
     
     
         8 . The selective catalytic reduction article of  claim 1 , wherein the molecular sieve comprises a medium pore molecular sieve selected from the group consisting of framework types AEL, AFO, AHT, BOF, BOZ, CGF, CGS, CHI, DAC, EUO, FER, HEU, IMF, ITH, ITR, JRY, JSR, JST, LAU, LOV, MEL, MFI, MFS, MRE, MTT, MVY, MWW, NAB, NAT, NES, OBW, PAR, PCR, PON, PUN, RRO, RSN, SFF, SFG, STF, STI, STT, STW, SVR, SZR, TER, TON, TUN, UOS, VSV, WEI, WEN, mixtures thereof, and intergrowths thereof. 
     
     
         9 . The selective catalytic reduction article of  claim 1 , wherein the molecular sieve comprises a large pore molecular sieve selected from the group consisting of framework types AFI, AFR, AFS, AFY, ASV, ATO, ATS, BEA, BEC, BOG, BPH, BSV, CAN, CON, CZP, DFO, EMT, EON, EZT, FAU, GME, GON, IFR, ISV, ITG, IWR, IWS, IWV, IWW, JSR, LTF, LTL, MAZ, MEI, MOR, MOZ, MSE, MTW, NPO, OFF, OKO, OSI, RON, RWY, SAF, SAO, SBE, SBS, SBT, SEW, SFE, SFO, SFS, SFV, SOF, SOS, STO, SSF, SSY, USI, UWY, VET, mixtures thereof, and intergrowths thereof. 
     
     
         10 . The selective catalytic reduction article of  claim 1 , wherein the molecular sieve is selected from the group consisting of aluminosilicate zeolites, borosilicates, gallosilicates, SAPOs, AlPOs, MeAPSOs, MeAPOs, and combinations thereof. 
     
     
         11 . The selective catalytic reduction article of  claim 1 , wherein the molecular sieve has CHA cages and double-six ring building units and is selected from the group consisting of Cu-CHA, Cu-SAPO-34, AEI, Cu-SAPO-18, and combinations thereof. 
     
     
         12 . The selective catalytic reduction article of  claim 1 , wherein the selective catalytic reduction article further comprises one or more catalytically active metals selected from the group consisting of manganese, iron, cobalt, nickel, cerium, platinum, palladium and rhodium; or containing one or more base metals selected from the group consisting of sodium, potassium, magnesium, calcium, strontium, barium, and combinations thereof. 
     
     
         13 . The selective catalytic reduction article of  claim 1 , wherein the catalytic coating comprises:
 a first catalytic coating comprising the copper-containing molecular sieve; and   a second catalytic coating that is different from the first catalytic coating.   
     
     
         14 . The selective catalytic reduction article of  claim 13 , wherein the second catalytic coating comprises a copper-containing molecular sieve that is different from the copper-containing molecular sieve in the first coating. 
     
     
         15 . The selective catalytic reduction article of  claim 13 , wherein the second catalytic coating comprises a platinum group metal on a refractory metal oxide support. 
     
     
         16 . The selective catalytic reduction article of  claim 15 , wherein the platinum group metal is present in an amount of about 0.5 g/ft 3  to about 30 g/ft 3 , based on the total volume of the substrate. 
     
     
         17 . The selective catalytic reduction article of  claim 13 , wherein the catalytic coating including the copper-containing molecular sieve is present in an amount of about 0.1 g/in 3  to about 4.5 g/in 3 , based on the total volume of the substrate. 
     
     
         18 . The selective catalytic reduction article of  claim 13 , wherein the first catalytic coating and the second catalytic coating are in a layered or zoned configuration. 
     
     
         19 . The selective catalytic reduction article of  claim 1 , wherein the substrate is a porous wall-flow filter or a flow-through monolith. 
     
     
         20 . An exhaust gas treatment system comprising:
 a selective catalytic reduction article according to  claim 1 ; and   a reductant injector in fluid communication with and upstream of the selective catalytic reduction article.   
     
     
         21 . The exhaust gas treatment system of  claim 20 , further comprising one or more of a diesel oxidation catalyst, a soot filter, a lean NOx trap (LNT), and an ammonia oxidation catalyst. 
     
     
         22 . A method for treating an exhaust stream containing NOx, comprising passing the exhaust stream through a selective catalytic reduction article or an exhaust gas treatment system of  claim 1 . 
     
     
         23 . A method for identifying a catalytic material that is stable toward aging, the method comprising:
 providing a plurality of samples that each comprise particles of a copper-containing molecular sieve containing ion-exchanged copper as Cu +2  cations and as Cu(OH) +1  cations;   subjecting the particles of the copper-containing molecular sieve to Diffuse Reflectance Infrared Fourier Transform (DRIFT) spectroscopy so as to evaluate perturbed T-O-T asymmetric stretching vibrational peaks corresponding to the Cu +2  cations in the copper-containing molecular sieve and perturbed T-O-T asymmetric stretching vibrational peaks corresponding to the Cu(OH) +1  cations in the copper-containing molecular sieve; and   selecting one or more of the samples wherein the copper-containing molecular sieve exhibits a ratio for an integrated peak area of the perturbed T-O-T asymmetric stretching vibrational peak corresponding to the Cu +2  cations to an integrated peak area of the perturbed T-O-T asymmetric stretching vibrational peak corresponding to the Cu(OH) +1  cations that is ≥1.   
     
     
         24 . The method of  claim 23 , wherein a percentage of the total integrated peak area that is attributable to the perturbed T-O-T asymmetric stretching vibrational peak corresponding to the Cu +2  cations is calculated by dividing the integrated peak area for the perturbed T-O-T asymmetric stretching vibrational peak corresponding to the Cu +2  cations by a peak integration area for the perturbed T-O-T asymmetric stretching vibrational peak corresponding to the Cu +2  cations and the perturbed T-O-T asymmetric stretching vibrational peak corresponding to the Cu(OH) +1  cations combined, and wherein the method comprises selecting one or more samples wherein the percentage of the total peak integration area that is attributable to the perturbed T-O-T asymmetric stretching vibrational peak for Cu +2  cations is ≥50%. 
     
     
         25 . The method of  claim 24 , wherein the plurality of samples is subjected to the DRIFT spectroscopy in a fresh state, and wherein the method further comprises:
 aging the plurality of samples at a temperature of about 800° C. for a time of about 16 hours in the presence of air with an H 2 O content of about 10 mol % to form aged samples;   subjecting the aged samples to the DRIFT spectroscopy; and   selecting one or more of the samples wherein the contribution to the total integrated peak area by the perturbed T-O-T asymmetric stretching vibrational peak corresponding to the Cu +2  cations for the one or more samples in an aged state is increased by ≤20% relative to the contribution to the total integrated peak area by the perturbed T-O-T asymmetric stretching vibrational peak corresponding to the Cu +2  cations for the one or more samples in the fresh state.   
     
     
         26 . A method of manufacturing a catalytic article, the method comprising
 developing a process for preparing a first composition comprising copper-containing molecular sieves;   analyzing at least a sample of the first composition using DRIFT spectroscopy to determine the relative amount of Cu +2  and Cu(OH) +1  in the first composition based on a comparison of intensities of perturbed T-O-T asymmetric stretching peaks corresponding to the Cu +2  and Cu(OH) +1      selecting the process for commercial manufacturing of the first composition if the contribution by the perturbed T-O-T asymmetric stretching peak corresponding to Cu +2  to the total integrated peak areas of the perturbed T-O-T asymmetric stretching peaks is ≥50%;   applying the commercially manufactured first composition made by the process to a substrate to produce the catalytic article.