Fundamental Investigations of Thermal Aging Phenomena of Model NOx Storage Systems

Investigations of the aging behavior induced by high temperatures coupled with oxidizing atmosphere of model NO _x storage systems Ba/Al₂O₃ and Ba/CeO₂ are reported in this paper. The samples were prepared, calcined and exposed to temperatures between 500 and 1000 °C in air for 12 h for thermal aging. Samples were characterized with XRD, HRSEM, DSC-TGA-MS and BET analyses. In XRD investigations of all model systems calcined at 500 °C for 2 h, the NO _x storage component was present in form of BaCO₃. The release of CO₂ as a result of the decarbonization of the NO _x storage component at increased temperatures was verified by thermogravimetric investigations. In the case of Ba/Al₂O₃, already during calcination a partial reaction of the NO _x storage component with Al₂O₃ resulting in the formation of barium aluminate was observed. In the model system Ba/CeO₂ the decomposition of the barium carbonate started above 780 °C and the formation of a barium cerium mixed oxide was observed. The presence of the barium containing NO _x storage component has a strong influence on the specific surface area of the model NO _x storage systems. The morphology and crystallite size of CeO₂ modified with the barium containing NO _x storage component exhibited distinct changes compared to the unmodified oxide. The NO _x storage efficiency determined by model gas tests of freshly prepared and engine aged model NO _x storage catalysts correlates well with the above described observations.     

NOx Abatement by Catalytic Traps: On the Mechanism of NOx Trapping Under Automotive Conditions

NO _x adsorption was measured with a barium based NO_x storage catalyst at an engine bench equipped with a lean burn gasoline direct injection engine (GDI). In order to study the influence of gas phase NO₂ on the NO_x storage efficiency two different pre-catalysts were used: One with excellent NO oxidation activity to produce a high NO₂ concentration and another pre-catalyst without NO oxidation activity and therefore high NO concentration at the NO _x storage catalyst inlet. Both pre-catalyst had excellent HC and CO conversion efficiency and therefore the CO and HC concentration at the NO _x storage catalyst inlet was practically zero. No lean NO _x reduction was observed. Under that conditions, experiments with NO _x storage catalysts of different length show that a high NO₂ inlet concentration did not enhance the NO _x storage efficiency. Moreover, we observed reduction of NO₂ to NO over the NO_x storage catalyst. However, in presence of a high NO inlet concentration NO₂ formation was observed which may proceed parallel to NO _x storage.     

Reduction of NOx Stored at Low Temperatures on a NOx Adsorbing Catalyst

Isothermal storage and reduction of NO₂ with CO, C₃H₆ and H₂ as reducing agents on a lean NO _x adsorber was investigated by temperature programmed desorption (TPD) and temperature programmed reduction (TPR) studies. The reduction of NO _x was clearly favoured with H₂ as reducing agent. Carbon monoxide and C₃H₆ showed fairly low reduction of NO _x . The NO _x reduction at low temperatures with H₂ as reducing agent was found to be effective, clearly much more effective than for CO.     

Role of Support in Lean DeNOx Catalysis

FTIR and pulse thermal analysis were applied to investigate catalysts containing Pt (1 wt%)/Ba (17 wt%) supported on -Al₂O₃, SiO₂ and ZrO₂. The aim was to learn how the support material affects the thermal stability of barium carbonate and its activity in the reaction to bulk Ba(NO₃)₂. The lower thermal stability of BaCO₃ in alumina supported samples was found to influence the formation of barium nitrate during the NO _x storage process. Quantification of Ba(NO₃)₂ formed during NO _x storage indicated that for alumina supported catalysts only ca. 30% of barium present in the sample is involved in the storage process. The low thermal stability found for alumina supported barium nitrite excludes its role in the formation of barium nitrate during interaction of NO _x with the catalyst at 300 °C. The studies indicate that -Al₂O₃ plays a major role in influencing the thermal stability of BaCO₃ and Ba(NO₃)₂. This finding seems to be relevant for the higher activity of -Al₂O₃-supported catalysts in NO _x storage reduction reactions.     

A New Simulation Model for NOx Storage Catalyst Dynamics

The NO _x storage concept has been studied experimentally and by two differently detailed numerical simulation models. The first detailed model simulates the concentration fronts of the solid components in the barium particles. It shows the slow, diffusion-hindered formation of dense nitrate layers around barium nanoparticles during NO _x storage and their rapid break-up during regeneration. Based upon this knowledge a new simplified model was developed which is able to describe well the storage and regeneration and to explain the main chemical and physical processes in the NO _x storage catalyst.     

Influence of the Storage Material on the Storage of NOx at Low Temperatures

The NO _x storage performance at low temperature (100–200 °C) has been studied for model NO _x storage catalysts. The catalysts were prepared by sequentially depositing support, metal oxide and platinum on ceramic monoliths. The support material consisted of acidic aluminium silicate, alumina or basic aluminium magnesium oxide, and the added metal oxide was either ceria or barium oxide. The NO _x conversion was evaluated under net-oxidising conditions with transients between lean and rich gas composition and the NO _x storage performance was studied by isothermal adsorption of NO₂ followed by temperature programmed desorption of adsorbed species. The maximum in NO _x storage capacity was observed at 100 °C for all samples studied. The Pt/BaO/Al₂O₃ catalyst stored about twice the amount of NO _x compared with the Pt/Al₂O₃ and Pt/CeO₂/Al₂O₃ samples. The storage capacity increased with increasing basicity of the support material, i.e. Pt/Al₂O₃·SiO₂ < Pt/Al₂O₃ < Pt/Al₂O₃ · MgO. Water did not significantly affect the NO _x storage performance for Pt/Al₂O₃ or Pt/BaO/Al₂O₃.     

Dynamics and selectivity of NOx reduction in NOx storage catalytic monolith

Several nitrogen compounds can be produced during the regeneration phase in periodically operated NO_x storage and reduction catalyst (NSRC) for conversion of automobile exhaust gases. Besides the main product N₂, also NO, N₂O, and NH₃ can be formed, depending on the regeneration phase length, temperature, and gas composition. This contribution focuses on experimental evaluation of the NO_x reduction dynamics and selectivity towards the main products (NO, N₂ and NH₃) within the short rich phase, and consequent development of the corresponding global reaction-kinetic model. An industrial NSRC monolith sample of PtRh/Ba/CeO₂/ -Al₂O₃ type is employed in nearly isothermal laboratory micro-reactor. The oxygen and NO_x storage/reduction experiments are performed in the temperature range 100–500 °C in the presence of CO₂ and H₂O, using H₂, CO and C₃H₆ as the reducing agents.The spatially distributed NSRC model developed earlier is extended by the following reactions: NH₃ is formed by the reaction of H₂ with NO_x and it can further react with oxygen and NO_x deposited on the catalyst surface, producing N₂. Considering this scheme with ammonia as an active intermediate of the NO_x reduction, a good agreement with experiments is obtained in terms of the NO_x reduction dynamics and selectivity. A reduction front travelling in the flow direction along the reactor is predicted, with the NH₃ maximum on the moving boundary. When the front reaches the reactor outlet, the NH₃ peak is observed in the exhaust gas. It is assumed that the ammonia formation during the NO_x reduction by CO and HCs at higher temperatures proceed via the water gas shift and steam reforming reactions producing hydrogen. It is further demonstrated that oxygen storage effects influence the dynamics of the stored NO_x reduction. The temperature dependences of the outlet ammonia peak delay and the selectivity towards NH₃ are correlated with the effective oxygen and NO_x storage capacity.     

Platinum Oxidation and Sulphur Deactivation in NOx Storage Catalysts

Flow reactor experiments and X-ray photoelectron spectroscopy (XPS) measurements were used to investigate the importance of platinum oxide formation on Pt/BaO/Al₂O₃ NO _x storage catalysts during reactions conditions. The reaction studied was NO(g) + 1/2 O₂(g) NO₂(g). During NO₂ exposure of the catalyst the NO₂ dissociation rate decreased during the reaction. This activity decrease with time was also studied with XPS and it was found to be due to platinum oxide formation. The influence of sulphur exposure conditions on the performance of the NO _x storage catalysts was studied by exposing the samples to lean and/or rich gas mixtures, simulating the conditions in a mixed lean application, containing SO₂. The main results show that all samples are sensitive to sulphur and that the deactivation proceeds faster when SO₂ is present in the feed under rich conditions than under lean or continuous SO₂ exposure. Additionally, the influence of the noble metals present in the catalysts was investigated regarding sulphur sensitivity and it was found that a combination of platinum and rhodium seems to be preferable to retain high performance of the catalyst under SO₂ exposure and subsequent regeneration. Finally, the behaviour of micro-fabricated model NO _x storage catalysts was studied as a function of temperature and gas composition with area-resolved XPS. These model catalysts consisted of a thin film of Pt deposited on one-half of a BaCO₃ pellet. It was found that the combination of SO₂ and O₂ resulted in migration of Pt on the BaCO₃ support up to one mm away from the Pt/BaCO₃ interface.     

Exceptional Activity for NOx Reduction at Low Temperatures Using Combinations of Hydrogen and Higher Hydrocarbons on Ag/Al2O3 Catalysts

The effect of the addition of hydrogen on the SCR of NO _x with a hydrocarbon reaction was investigated. It was found that hydrogen had a remarkable effect on the temperature range over which NO _x could be reduced during the SCR reaction with octane. Reduction of NO _x was initiated at as low a temperature as 100 °C and >95% NO _x conversion was achieved over a temperature range of 200–450 °C. Hydrogen has the effect of activating octane at lower temperatures and also promotes the oxidation of NO to NO₂ in the absence of hydrocarbon. Transient kinetic and in situ DRIFTS measurements indicated that hydrogen has a direct role in the reaction mechanism by either promoting the formation and storage of an organic C = N species which can then readily reduce NO _x and/or removing a species which acts as a poison to the SCR reaction at low temperatures.     

Non-Isothermal NOx Storage/Release over Manganese Based Traps: Mechanistic Considerations

The NO storage properties of MnO _x /support materials (5–50 wt% MnO _x loading) was experimentally investigated in the presence of O₂ and H₂O between 50 and 700 °C applying a non-isothermal temperature-programmed method. In dependence on MnO _x loading and NO supply, the materials show an intermediate decrease of NO storage capacity between 200 and 300 °C. This effect is caused by decomposition of surface nitrites with release of NO into the gas phase as proved by in situ DRIFT measurement. The interpretation is corroborated by modelling of the underlying adsorption/desorption reaction steps, considering the different thermal stability of nitrite/nitrate surface species.     

NOx storage behavior and sulfur-resisting performance of the third-generation NSR catalysts Pt/K/TiO2–ZrO2

The NO_x storage and reduction (NSR) catalysts Pt/K/TiO₂–ZrO₂ were prepared by an impregnation method. The techniques of XRD, NH₃-TPD, CO₂-TPD, H₂-TPR and in situDRIFTS were employed to investigate their NO_x storage behavior and sulfur-resisting performance. It is revealed that the storage capacity and sulfur-resisting ability of these catalysts depend strongly on the calcination temperature of the support. The catalyst with theist support calcined at 500 °C, exhibits the largest specific surface area but the lowest storage capacity. With increasing calcination temperature, the NO_x storage capacity of the catalyst improves greatly, but the sulfur-resisting ability of the catalyst decreases. In situ DRIFTS results show that free nitrate species and bulk sulfates are the main storage and sulfation species, respectively, for all the catalysts studied. The CO₂-TPD results indicate that the decomposition performance of K₂CO₃ is largely determined by the surface property of the TiO₂–ZrO₂ support. The interaction between the surface hydroxyl of the support and K₂CO₃ promotes the decomposition of K₂CO₃ to form –OK groups bound to the support, leading to low NO_x storage capacity but high sulfur-resisting ability, while the interaction between the highly dispersed K₂CO₃ species and Lewis acid sites gives rise to high NO_x storage capacity but decreased sulfur-resisting ability. The optimal calcination temperature of TiO₂–ZrO₂ support is 650 °C.     

Excellent sulfur resistance of Pt/BaO/CeO2 lean NOx trap catalysts

In this work, we investigated the NO_x storage behavior of Pt/BaO/CeO₂ catalysts, especially in the presence of SO₂. High surface area CeO₂ (110 m²/g) with a rod like morphology was synthesized and used as a support. The Pt/BaO/CeO₂ sample demonstrated slightly higher NO_x uptake in the entire temperature range studied compared with Pt/BaO/γ-Al₂O₃. More importantly, this ceria-based catalyst showed higher sulfur tolerance than the alumina-based one. The time of complete NO_x uptake was maintained even after exposing the sample to 3 g/L of SO₂. The same sulfur exposure, on the other hand, eliminated the complete NO_x uptake time on the alumina-based NO_x storage catalysts. TEM images show no evidence of either Pt sintering or BaS phase formation during reductive de-sulfation up to 600 °C on the ceria-based catalyst, while the same process over the alumina-based catalyst resulted in both a significant increase in the average Pt cluster size and the agglomeration of a newly formed BaS phase into large crystallites. XPS results revealed the presence of about five times more residual sulfur after reductive de-sulfation at 600 °C on the alumina-based catalysts in comparison with the ceria-based ones. All of these results strongly support that, besides their superior intrinsic NO_x uptake properties, ceria-based catalysts have (a) much higher sulfur tolerance and (b) excellent resistance against Pt sintering when they are compared to the widely used alumina-based catalysts.     

Steam resistant CoLa-mordenite catalysts for the SCR of NOx with CH4

The stabilization of Co-mordenite catalysts through lanthanum exchange is reported here. The effect of exchange order and calcination conditions upon the reduction of NO_x to N₂ at 500 °C was tracked during 400 h on a stream containing NO_x, CH₄, O₂ and 10% H₂O. Both the fresh and used catalysts were characterized through TPR, Raman spectroscopy, FTIR spectroscopy using CO as probe molecule, and XPS. These techniques revealed that the CoLa-mordenite catalysts which were not affected by the severe hydrothermal treatment showed no sign of Co or La migration out of the exchange positions. Instead, those that rapidly deactivated showed the formation of cobalt oxides and, in some cases, the migration of the cations to other exchange positions. The presence of exchanged lanthanum seems to preserve the integrity of the zeolite structure preventing the migration of cobalt ions with the subsequent formation of cobalt oxides which favors the reaction of methane with O₂, thus decreasing N₂ production.     

Evaluation of a NOx Reduction System on an Engine Rig Under Stationary Operation

The NO _x storage and reduction approach was applied on a full-scale engine rig under stationary operation. NO _x reduction experiments were performed and a catalyst model developed and tested. The exhaust system was equipped with a bypass system. A NO _x reduction of 25–53% was achieved. At low temperature, higher values were reached when the exhaust gas bypass was longer than the injection period.     

Silver supported mesoporous SBA-15 as potential catalysts for SCR NOx by ethanol

Reduction of nitrogen oxides (NO_x) in a lean exhaust gases has become one of the most important environmental concerns. This study compared the performances of DeNO_x and the properties of silver/mesoporous aluminosilica synthesized by different methods. Silver nanoparticles were obtained after calcination of the materials prepared by incipient wetness or by the excess solvent impregnation of Al-SBA-15 support by silver nitrate. On the other hand, the silver nitrate was introduced on the synthesis gel of SBA-15. The solid product was used as support to deposit aluminium. The effect of synthesis method on silver incorporation and the porous structure of the resulting solids has been examined. Some techniques had been applied, such as: elemental analysis, X-ray diffraction (XRD), N₂ sorption measurements and Transmission Electron Microscopy (TEM). The nature of silver species in these catalysts was investigated by XPS measurements, high angle XRD, high resolution TEM and TPR/H₂ (temperature-programmed reduction). The resulting materials were tested in the selective catalytic reduction of NO_x by ethanol in the presence of oxygen. Finally, the effect of H₂ on the DeNO_x activity was also investigated.The impregnation method of Al-SBA-15 by silver nitrate influences the size, the location of the particles and the catalytic activity. To maintain a higher DeNO_x activity, the percentage of aluminium loading and the feed of H₂ gases should be increased.     

NOx storage/reduction catalysts based in cobalt/copper hydrotalcites

The use of materials based on hydrotalcites as NO_x storage/reduction (NSR) catalysts has been investigated, examining their activity at low temperature and their resistance to poisons such as H₂O and SO₂. The results obtained show that catalysts derived from Mg/Al hydrotalcites containing copper or cobalt is active at low temperatures, specially the samples containing 10 or 15% of Co. The addition of 1 wt% of transition metals with redox properties such as Pt, Pd, V and Ru to the hydrotalcite increases its activity because the combination of the redox properties of these metals and the acid-base properties of the hydrotalcite. The best results were obtained with the catalyst derived from a hydrotalcite with a molar ratio Co/Mg/Al = 15/60/25 and containing 1 wt% V. This material shows a higher activity, at low temperatures and in the presence of H₂O and SO₂, than a Pt–Ba/Al₂O₃ reference catalyst.     

Model Studies of NOx Storage and Sulphur Deactivation of NOx Storage Catalysts

The storage of NO _x under lean conditions in model NO _x storage catalysts as well as the deactivation by sulphur have been studied. We find that NO₂ plays an important role in the storage mechanism as an oxidising agent. Two different mechanisms for this are discussed: the formation of surface peroxides and the oxidation of nitrites to nitrates. FTIR studies show that NO _x is stored as surface nitrates. The sulphur deactivation is found to be more severe when SO₂ is added during the rich phase than when SO₂ is added during the lean period. FTIR shows the formation of bulk sulphates both under lean and rich conditions.     

Non-thermal plasma-assisted catalytic NOx storage over Pt/Ba/Al2O3 at low temperatures

NO_x storage performances have been investigated on a Pt/Ba/Al₂O₃ catalyst by comparison using two types of non-thermal plasma (NTP) reactor: the “PDC system” reactor and the “PFC system” reactor. In the PDC system, the catalyst was placed in the discharge space and was activated by the plasma directly, whereas in the PFC system, the plasma reactor was followed by the catalyst. The results showed that the NO_x storage capacity (NSC) of the Pt/Ba/Al₂O₃ catalyst was significantly enhanced by the non-thermal plasma in the PDC and PFC system, and the PDC system exhibited better promotional effect than the PFC system in the temperature range of 100–300 °C. The NSC of the catalyst was increased with the increase of the input energy density both in the PDC and PFC system due to the higher NO oxidation at higher input energy density. It was also found that the ionic wind induced by plasma in the PDC system enhanced the quantity of the NO adsorbed onto the catalyst surface and therefore could react with the O-radical to form more NO₂, and thus promote the formation of nitrate on the catalyst.     

Influence of Catalyst Support Geometry and Wall Thickness on NOx Trap Desulfation: Rich/Lean Wobbling Strategies and Hexagonal Cell Supports for High SO2 Selectivity During Desulfation

This Synthetic Gas Bench (SGB) study focuses on the effect of cell geometry and wall thickness on the gasoline NO _x trap functionality. The data show that besides a NO _x trap efficiency improvement, hexagonal cells increase the sulfur resistance of the NO _x trap. This feature is explained by the different wash-coat distributions in the hexagonal channels compared to square ones. The effect of lean/rich fast switching (wobbling) during desulfation was investigated and the SO₂/H₂S selectivity was studied: the combination of hexagonal cells and a wobbling desulfation strategy improves the H₂S/SO₂ selectivity by reducing the amount of H₂S formed.