EP2621611A2

EP2621611A2 - Method for treating a gas containing nitrogen oxides (nox), in which a composition comprising cerium oxide and niobium oxide is used as a catalyst

Info

Publication number: EP2621611A2
Application number: EP11761629.2A
Authority: EP
Inventors: Julien Hernandez; Emmanuel Rohart; Rui Jorge Coelho Marques; Deborah Jayne Harris; Clare Jones
Original assignee: Rhodia Operations SAS; Magnesium Elektron Ltd
Current assignee: Rhodia Operations SAS; Magnesium Elektron Ltd
Priority date: 2010-09-29
Filing date: 2011-09-28
Publication date: 2013-08-07
Also published as: US20130195743A1; CA2807665A1; US8734742B2; FR2965189A1; RU2541070C2; CA2807665C; CN103153438B; JP5771276B2; KR20130062349A; JP2013544628A; CN103153438A; KR101990156B1; WO2012041921A3; RU2013119605A; WO2012041921A2

Abstract

The invention relates to a method for treating a gas containing nitrogen oxides (NOX), comprising a reduction reaction of the nitrogen oxides by a nitrogen-containing reducing agent. The invention is characterised in that the catalyst used for the reduction reaction is a catalytic system containing a composition based on cerium oxide and comprising niobium oxide in a proportion by mass of between 2 and 20 %.

Description

PROCESS FOR TREATING A GAS CONTAINING NITROGEN OXIDES (NOX) USING AS A CATALYST A COMPOSITION

BASIS OF CERIUM OXIDE AND NIOBIUM OXIDE

The present invention relates to a process for treating a gas containing nitrogen oxides (NOx) using as catalyst a composition based on cerium oxide and niobium oxide.

Motor vehicle engines are known to emit gases containing nitrogen oxides (NOx) that are harmful to the environment. It is therefore necessary to treat these oxides in order to transform them into nitrogen.

One known method for this treatment is the SCR process in which NOx reduction is performed by ammonia or a precursor of ammonia such as urea.

The SCR process allows an efficient treatment of the gases but nevertheless its effectiveness at low temperature remains to be improved. Thus, the catalytic systems currently used for the implementation of this process are often effective only for temperatures above 250 ° C. It would therefore be advantageous to have catalysts that can have significant activity at temperatures of 250 ° C or lower.

Finally, we also seek catalysts whose aging resistance is improved.

The object of the invention is therefore to provide more efficient catalysts for SCR catalysis.

For this purpose, the process of the invention is a process for treating a gas containing nitrogen oxides (NOx) in which a reduction reaction of NOx is carried out with a nitrogen reducing agent and is characterized in that The catalyst used in this reduction reaction is a catalytic system containing a cerium oxide-based composition which comprises niobium oxide with the following proportions by weight: - niobium oxide of 2 to 20%;

the complement in cerium oxide.

Other features, details and advantages of the invention will appear even more fully on reading the description which follows, as well as various concrete but non-limiting examples intended to illustrate it. For the purposes of this description rare earth is understood to mean the elements of the group consisting of yttrium and the elements of the Periodic Table with an atomic number inclusive of between 57 and 71.

By specific surface is meant the specific surface B.E.T. determined by nitrogen adsorption in accordance with ASTM D 3663-78 established from the BRUNAUER-EMMETT-TELLER method described in "The Journal of the American Society, 60, 309 (1938)".

The specific surface values that are given for a given temperature and time, unless otherwise indicated, correspond to single stage air calcinations at that temperature and over the specified time.

The calcinations mentioned in the description are calcinations under air unless otherwise indicated. The duration of calcination which is indicated for a temperature corresponds to the duration of the plateau at this temperature.

The contents or proportions are given in mass and oxide

(in particular CeO ₂ , Ln ₂ O 3, Ln denoting a trivalent rare earth, Pr ₆ In the particular case of praseodymium, Nb ₂ Os in the case of niobium) unless otherwise indicated.

It is also specified for the remainder of the description that, unless otherwise indicated, in the ranges of values that are given, the values at the terminals are included.

The composition of the catalytic system of the invention is characterized first of all by the nature and the proportions of its constituents. Thus, and according to a first embodiment, it is based on cerium and niobium, these elements being present in the composition generally in the form of oxides. These elements are also present in the specific proportions given above.

The cerium oxide of the composition can be stabilized, by "stabilized" here means stabilization of the specific surface, by at least one rare earth other than cerium, in oxide form. This rare earth may be more particularly yttrium, neodymium, lanthanum or praseodymium. The stabilizing rare earth oxide content is generally at most 20%, preferably when the rare earth is lanthanum, more preferably at most 15% and preferably at most 10% by weight. The minimum stabilizing rare earth oxide content is that from which the stabilizing effect is felt and is generally at least 1%, more preferably at least 2%. This content is expressed as rare earth oxide relative to the mass of the stabilized rare earth cerium oxide-oxide complex. The cerium oxide can also be stabilized, always stabilizing in the sense of the specific surface, by an oxide chosen from silica, alumina and titanium oxide. The content of this stabilizing oxide can be at most 10% and more particularly at most 5%. The minimum content may be at least 1%. This content is expressed as stabilizing oxide relative to the weight of the stabilizing cerium oxide-oxide complex.

According to a second embodiment of the invention, the composition of the catalytic system of the invention comprises three constituent elements, again in the form of oxides, which are cerium, niobium and zirconium.

The respective proportions of these elements are then as follows:

- cerium oxide: at least 50%;

niobium oxide: from 2 to 20%;

- zirconium oxide: up to 48%.

The minimum proportion of zirconium oxide in the case of this second embodiment of the invention is preferably at least 10%, more preferably at least 15%. The maximum content of zirconium oxide may more particularly be at most 40% and even more particularly at most 30%.

According to a third embodiment of the invention, the composition of the catalytic system of the invention also contains at least one oxide of an element M chosen from the group comprising tungsten, molybdenum, iron, copper and silicon. , aluminum, manganese, titanium, vanadium and rare earths other than cerium, with the following proportions by mass:

- cerium oxide: at least 50%;

niobium oxide: from 2 to 20%;

oxide of the element M: up to 20%;

the zirconium oxide supplement.

This element M can in particular act as a stabilizer of the surface of the mixed oxide of cerium and zirconium or improve the reducibility of the composition. For the remainder of the description, it should be understood that, if, for the sake of simplicity, only one element M is mentioned, it is understood that the invention applies to the case where the compositions comprise several elements M.

The maximum proportion of oxide of element M in the case of rare earths and tungsten may more particularly be at most 15% and even more particularly at most 10% by weight of oxide of element M ( rare earth and / or tungsten). The minimum content is at least 1%, plus especially at least 2%, the contents given above being expressed relative to the whole oxide of cerium oxide of zirconium oxide of the element M.

In the case where M is neither a rare earth nor tungsten, the oxide content of the element M may more particularly be at most 10% and even more particularly at most 5%. The minimum content may be at least 1%. This content is expressed as the oxide of the element M with respect to the whole cerium oxide-zirconium oxide and oxide of the element M.

In the case of rare earths, the element M may be more particularly ryttrium, lanthanum, praseodymium and neodymium.

For the various embodiments described above, the proportion of niobium oxide may be more particularly between 3% and 15% and even more particularly between 5% and 10%.

In the case of the compositions according to the second or third mode and according to an advantageous variant, the cerium content may be at least 65%, more particularly at least 70% and even more particularly at least 75% and that of niobium between 2 and 12% and more particularly between 2 and 10%. The compositions according to this variant have high acidity and reducibility.

In the case of compositions according to the second or third embodiment and according to another advantageous variant, the cerium oxide content may be at least 60%, more particularly at least 65%, and that in zirconium oxide in a proportion by mass of at most 25%, more particularly between 15% and 25%.

For these different embodiments, the proportion of niobium may even more particularly be less than 10% and for example between a minimum value which may be 2%, 4% or even 5% and a maximum value strictly less than 10%. 10% for example of at most 9% and more particularly at most 8% and even more particularly at most 7%. This niobium content is expressed in weight of niobium oxide relative to the mass of the entire composition. The values for the niobium proportions which have just been given, in particular that strictly less than 10%, apply to the advantageous variants according to the second or the third mode which have been described previously.

According to a variant of the invention, the compositions of the invention according to the first mode, that is to say the compositions based on cerium oxide and niobium oxide and those according to the second embodiment may comprise in addition to oxides of at least one metal M 'selected from the group comprising vanadium, copper, manganese, tungsten and iron in a proportion which may be between 1 and 10%, more particularly between 1% and 5%. %, more preferably between 1 and 3%, proportion expressed by weight of oxide of the metal relative to the entire composition. These compositions according to this variant can exhibit improved catalytic activity.

The compositions of the catalytic system of the invention finally have a sufficiently stable specific surface area, that is to say sufficiently high at high temperature, so that they are used in the field of catalysis.

Thus, generally, the compositions according to the first embodiment have a specific surface after calcination for 4 hours at 800 ° C. which is at least 15 m ² / g. For the compositions according to the second and the third embodiment, this surface, under the same conditions, is generally at least 20 m ² / g. For the three modes, the compositions of the catalytic system of the invention may have an area of up to about 55 m ² / g still under the same calcination conditions.

The compositions of the catalytic system of the invention, in the case where they contain a quantity of niobium of at least 10%, and according to an advantageous embodiment, may have a specific surface after calcination for 4 hours at 800 ° C. which is at least 35 m ² / g, more particularly at least 40 m ² / g.

Still for the three modes, the compositions of the catalytic system of the invention may have a surface after calcination at 900 ° C. for 4 hours which is at least 10 m ² / g. Under the same calcination conditions they can have surface areas of up to about 30 m ² / g.

The compositions of the catalyst system of the invention have high acidity which can be measured by a method of TPD analysis, which will be described later, and which is at least 5.10 ^"2, more preferably at least ^{6.10" 2} and even more particularly at least 7.10 ^-2 , this acidity being expressed in ml of ammonia (TPN: normal temperature and pressure) per m ² (BET measurement) of product The surface taken into account here is the value expressed in m ² of the specific surface of the product after calcination at 800 ° C. for 4 hours Acidities of at least about 9.5 × 10 ^-2 can be obtained.

The compositions of the catalytic system of the invention also have significant reducibility properties. These properties can be measured by the programmed temperature reduction measurement method (TPR) which will be described later. The compositions of the system Catalyst of the invention have a reducibility of at least 15, this reducibility being expressed in ml of hydrogen (TPN) per g of product.

The compositions may be in the form of a solid solution of the niobium oxides, the stabilizing element in the case of the first embodiment, zirconium and the element M or M 'in the cerium oxide for the other modes. We then observe in this case the presence of a single phase X-ray diffraction corresponding to the cubic phase of cerium oxide. In general the stability of this solid solution is such that its presence can be observed on compositions which may have been calcined up to 900 ° C., 4 hours.

The invention also relates to the case where the compositions consist essentially of oxides of the abovementioned elements, cerium, niobium and, where appropriate, zirconium and element M or M '. By "consists essentially", it is meant that the composition in question contains only the oxides of the abovementioned elements and that it contains no oxide of another functional element, that is to say capable of having a positive influence on the reducibility and / or the acidity and / or the stability of the composition. On the other hand, the composition may contain elements such as impurities which may notably come from its preparation process, for example raw materials or starting reagents used.

The compositions of the catalyst system of the invention may be prepared by the known impregnation process. Thus, a cerium oxide or a mixed oxide of cerium and zirconium prepared beforehand by a solution comprising a niobium compound, for example an oxalate or an oxalate of niobium and ammonium, is impregnated. In the case of the preparation of a composition which further comprises an oxide of the element M or M ', a solution is used for the impregnation which contains a compound of this element M or M' in addition to the niobium compound. The element M or M 'may also be present in the starting cerium oxide which is impregnated.

It is more particularly used dry impregnation. The dry impregnation consists in adding to the product to be impregnated a volume of an aqueous solution of the impregnant element which is equal to the pore volume of the solid to be impregnated.

Cerium oxide or mixed oxide of cerium and zirconium must have specific surface properties which make it suitable for use in catalysis. Thus this surface must be stable, ie it must have a value sufficient for such use even at high temperature. Such oxides are well known. For the cerium oxides, use may be made in particular of those described in patent applications EP 0153227, EP 0388567 and EP 0300852. For cerium oxides stabilized by an element such as rare earths, silicon, aluminum and iron, it is possible to use use the products described in EP 2160357, EP 547924, EP 588691 and EP 207857. For mixed oxides of cerium and zirconium with optionally an element M, especially in the case where M is a rare earth, may be mentioned as suitable products for the present invention those described in patent applications EP 605274, EP 1991354, EP 1660406, EP 1603657, EP 0906244 and EP 0735984. For the implementation of the present invention, it will therefore be possible, if necessary, to refer to the present invention. set of the description of the patent applications mentioned above.

The compositions of the catalyst system of the invention may also be prepared by a second method which will be described below.

This process comprises the following steps:

(a1) mixing a suspension of a niobium hydroxide with a solution comprising cerium salts and, if appropriate zirconium and element M;

(b1) the mixture thus formed is brought into contact with a basic compound whereby a precipitate is obtained;

(c1) the precipitate is separated from the reaction medium and calcined.

The first step of this process involves a suspension of a niobium hydroxide. This suspension can be obtained by reacting a niobium salt, such as a chloride, with a base, such as ammonia, to obtain a niobium hydroxide precipitate. This suspension can also be obtained by reacting a niobium salt such as potassium or sodium niobate with an acid such as nitric acid to obtain a niobium hydroxide precipitate.

This reaction can be done in a mixture of water and alcohol such as ethanol. The hydroxide thus obtained is washed by any known means and is then resuspended in water in the presence of a peptizing agent such as nitric acid.

The second step (b1) of the process comprises mixing the suspension of niobium hydroxide with a solution of a cerium salt. This solution may also contain a zirconium salt and also the element M or M 'in the case of the preparation of a composition which further comprises a zirconium oxide or the oxide of this element M or M . These salts can be selected from nitrates, sulphates, acetates, chlorides, cerium-ammoniacal nitrate.

By way of example of zirconium salts, mention may be made of zirconium sulphate, zirconyl nitrate or zirconyl chloride. Zirconyl nitrate is most commonly used.

When a cerium salt in form III is used, it is preferable to introduce into the solution of salts an oxidizing agent, for example hydrogen peroxide.

The different salts of the solution are present in the stoichiometric proportions necessary to obtain the desired final composition.

The mixture formed from the niobium hydroxide suspension and the solution of the salts of the other elements is brought into contact with a basic compound.

Hydroxide products can be used as base or basic compound. Mention may be made of alkali or alkaline earth hydroxides. It is also possible to use secondary, tertiary or quaternary amines. However, amines and ammonia may be preferred in that they reduce the risk of pollution by alkaline or alkaline earth cations. We can also mention urea. The basic compound may more particularly be used in the form of a solution.

The reaction between the above mixture and the basic compound is preferably continuous in a reactor. This reaction is done by continuously introducing the mixture and the basic compound and continuously withdrawing also the product of the reaction.

The precipitate which is obtained is separated from the reaction medium by any conventional solid-liquid separation technique such as, for example, filtration, decantation, spinning or centrifugation. This precipitate can be washed and then calcined at a temperature sufficient to form the oxides, for example at least 500 ° C.

The compositions of the catalytic system of the invention may be further prepared by a third method which comprises the following steps:

- (a2) in a first step a liquid mixture containing a cerium compound and, where appropriate, a zirconium compound and the M or M 'element is prepared for the preparation of the compositions containing the oxide zirconium and / or an oxide of the element M or M ';

(b2) said mixture is brought into contact with a basic compound, whereby a suspension containing a precipitate is obtained; (c2) this suspension is mixed with a solution of a niobium salt;

- (d2) the solid is separated from the liquid medium;

- (e2) calcining said solid.

The cerium compound may be a cerium III or cerium compound

IV. The compounds are preferably soluble compounds such as salts. What has been said above for the salts of cerium, zirconium and the element M or M 'also applies here. It is the same for the nature of the basic compound. The different compounds of the starting mixture of the first step are present in the stoichiometric proportions necessary to obtain the desired final composition.

The liquid medium of the first stage is usually water.

The starting mixture of the first step can be indifferently obtained either from compounds initially in the solid state which will be introduced later in a water tank for example, or even directly from solutions of these compounds and then mixing, in any order, said solutions.

The order of introduction of the reagents into the second step (b2) may be arbitrary, the basic compound may be introduced into the mixture or vice versa or the reagents may be introduced simultaneously into the reactor.

The addition can be carried out all at once, gradually or continuously, and it is preferably carried out with stirring. This operation can be conducted at a temperature between room temperature (18-25 ° C) and the reflux temperature of the reaction medium, the latter can reach 120 ° C for example. It is preferably conducted at room temperature.

As in the case of the first process, it can be noted that it is possible, particularly in the case of the use of a cerium III compound, to add either to the starting mixture or during the introduction of the compound. basic oxidizing agent such as hydrogen peroxide.

At the end of the second step (b2) of addition of the basic compound, one can optionally further maintain the reaction medium with stirring for a time, and this in order to complete the precipitation.

It is also possible at this stage of the process to ripen.

This can be carried out directly on the reaction medium obtained after contacting with the basic compound or on a suspension obtained after returning the precipitate to water. The ripening is done by heating the middle. The temperature at which the medium is heated is at least 40 ° C, more preferably at least 60 ° C and even more preferably at least 100 ° C. The medium is thus maintained at a constant temperature for a period of time which is usually at least 30 minutes and more particularly at least 1 hour. The ripening can be carried out at atmospheric pressure or optionally at a higher pressure and at a temperature above 100 ° C. and in particular between 100 ° C. and 150 ° C.

The next step (c2) of the process consists in mixing the suspension obtained at the end of the preceding step with a solution of a niobium salt. Niobium salt that may be mentioned niobium chloride, niobate potassium or sodium and especially here niobium oxalate and niobium oxalate and ammonium.

This mixture is preferably at room temperature.

The following steps of the process (d2) and (e2) consist in separating the solid from the suspension obtained in the preceding step, optionally washing this solid and then calcining it. These steps proceed in a manner identical to that described above for the second method.

In the case of the preparation of compositions which contain the oxide of the element M or M ', the third method may have a variant in which the compound of this element M or M' is not present in the stage ( a2). The compound of the element M or M 'is then added to step (c2) either before or after mixing with the niobium solution or at the same time.

Finally, the compositions of the catalyst system of the invention which are based on the oxides of cerium, niobium and zirconium and optionally an oxide of the element M may also be prepared by a fourth process which will be described below. below.

This process comprises the following steps:

- (a3) a mixture in liquid medium containing a zirconium compound and a cerium compound and, where appropriate, the element M;

- (b3) heating said mixture to a temperature above 100 ° C;

(c3) the reaction medium obtained at the end of the heating is brought to a basic pH;

- (c'3) is optionally carried out a ripening of the reaction medium;

(d3) this medium is mixed with a solution of a niobium salt;

- (e3) the solid is separated from the liquid medium;

- (f3) calcine said solid. The first step of the process consists in preparing a mixture in a liquid medium of a zirconium compound and a cerium compound and, where appropriate, of the element M. The various compounds of the mixture are present in the necessary stoichiometric proportions to obtain the desired final composition.

The liquid medium is usually water.

The compounds are preferably soluble compounds. This can be in particular salts of zirconium, cerium and element M as described above.

The mixture can be indifferently obtained either from compounds initially in the solid state which will subsequently be introduced into a water tank for example, or even directly from solutions of these compounds and then mixed in any order of said solutions.

The initial mixture is thus obtained, then, in accordance with the second step (b3) of this fourth method, it is heated.

The temperature at which this heat treatment, also called thermohydrolysis, is carried out is greater than 100 ° C. It can thus be between 100 ° C. and the critical temperature of the reaction medium, in particular between 100 and 350 ° C., preferably between 100 and 200 ° C.

The heating operation can be carried out by introducing the liquid medium into a closed chamber (autoclave-type closed reactor), the necessary pressure then resulting only from the sole heating of the reaction medium (autogenous pressure). Under the conditions of the temperatures given above, and in aqueous media, it is thus possible to specify, by way of illustration, that the pressure in the closed reactor can vary between a value greater than 1 bar (10 ⁵ Pa) and 165 bar (1 bar). , 65. 10 ⁷ Pa), preferably between 5 Bar (5 × 10 ⁵ Pa) and 165 Bar (1, 65. 10 ⁷ Pa). It is of course also possible to exert an external pressure which is added to that subsequent to heating.

It is also possible to carry out heating in an open reactor for temperatures close to 100 ° C.

The heating may be conducted either in air or in an atmosphere of inert gas, preferably nitrogen.

The duration of the treatment is not critical, and can thus vary within wide limits, for example between 1 and 48 hours, preferably between 2 and 24 hours. Similarly, the rise in temperature is carried out at a speed which is not critical, and it is thus possible to reach the reaction temperature set by heating the medium for example between 30 minutes and 4 hours, these values being given for all purposes. indicative fact. At the end of this second step, the reaction medium thus obtained is brought to a basic pH. This operation is performed by adding to the medium a base such as for example an ammonia solution.

By basic pH is meant a pH value greater than 7 and preferably greater than 8.

Although this variant is not preferred, it is possible to introduce to the reaction mixture obtained at the end of the heating, in particular at the time of addition of the base, the element M in particular in the form which has been described more high.

At the end of the heating step, a solid precipitate is recovered which can be separated from its medium as described above.

The product as recovered can then be subjected to washes, which are then operated with water or optionally with a basic solution, for example an ammonia solution. The washing can be carried out by resuspension in water of the precipitate and maintenance of the suspension thus obtained at a temperature which can go up to 100 ° C. To eliminate the residual water, the washed product can optionally be dried, for example in an oven or by atomization, and this at a temperature which can vary between 80 and

300 ° C, preferably between 100 and 200 ° C.

According to a particular variant of the invention, the process comprises a ripening (step c'3).

The ripening is done under the same conditions as those described above for the third method.

The ripening can also be carried out on a suspension obtained after putting the precipitate back into water. The pH of this suspension can be adjusted to a value greater than 7 and preferably greater than 8.

It is possible to do several matures. Thus, it is possible to resuspend in water the precipitate obtained after the ripening step and possibly to wash and then to perform another ripening of the medium thus obtained. This other ripening is done under the same conditions as those described for the first. Of course, this operation can be repeated several times.

The following steps of this fourth process (d3) to (f3), that is to say the mixing with the niobium salt solution, the solid / liquid separation and the calcination, are done in the same way as for the steps corresponding of the second and third processes. What has been described above for these steps therefore applies here. The catalyst system used in the process of the invention contains a composition as described above, this composition being generally mixed with a material usually employed in the field of the catalyst system, that is to say a material chosen from among inert materials. thermally. This material may thus be chosen from alumina, titanium oxide, cerium oxide, zirconium oxide, silica, spinels, zeolites, silicates, crystalline silicoaluminium phosphates, calcium phosphates and crystalline aluminum.

The proportions between the composition and the inert material are those usually used in the technical field concerned herein and are well known to those skilled in the art. By way of example, these proportions can be between 2% and 20% and more particularly between 2% and 10%, expressed as mass of inert material relative to the inert material and composition.

Generally the catalyst system used in the process of the invention may consist of the aforementioned mixture deposited on a substrate. More specifically, the mixture of the composition and the thermally inert material constitutes a coating (wash coat) with catalytic properties and this coating is deposited on a substrate of the type for example metal monolith, for example FerCralloy, or ceramic, for example in cordierite , of silicon carbide, of alumina titanate or of mullite.

This coating is obtained by mixing the composition with the thermally inert material so as to form a suspension which can then be deposited on the substrate.

According to another embodiment, the catalyst system used in the process of the invention may be based on the composition as described above, this being used in an extruded form. It can thus be in the form of a monolith having a honeycomb structure or in the form of a monolith of particle filter type (partially closed channels). In both cases the composition of the invention can be mixed with additives of known type to facilitate the extrusion and ensure the mechanical strength of the extruded. Such additives may be chosen in particular from silica, alumina, clays, silicates, titanium sulphate and ceramic fibers, especially in generally used proportions, ie up to about 30% by weight. compared to the entire composition.

The invention also relates to a catalyst system which contains a zeolite in addition to the composition based on cerium and niobium oxides. The zeolite may be natural or synthetic and may be of aluminosilicate, aluminophosphate or silicoaluminophosphate type.

A treated zeolite is preferably used to improve its hydrothermal stability. As an example of treatment of this type may be mentioned (i) the dealumination by steam treatment and acid extraction using an acid or a complexing agent (for example EDTA - ethylenediaminetetraacetic acid); by treatment with an acid and / or a complexing agent; by treatment with a gas stream of SiCl ₄ ; (ii) cation exchange using polyvalent cations such as La; and (iii) the use of phosphorus-containing compounds.

According to another particular embodiment of the invention and in the case of an aluminosilicate zeolite, this zeolite may have an Si / Al atomic ratio of at least 10, more particularly at least 20.

According to a more particular embodiment of the invention, the zeolite comprises at least one other element chosen from the group comprising iron, copper or cerium.

By zeolite comprising at least one other element is meant a zeolite in the structure of which have been added by ion exchange, impregnation or isomorphous substitution one or more metals of the aforementioned type.

In this embodiment, the metal content may be between about 1% and about 5%, content expressed as the weight of metal element relative to the zeolite.

The aluminosilicate zeolites which may form part of the composition of the catalytic system of the invention are particularly suitable for those selected from the group comprising zeolites beta, gamma, ZSM 5 and ZSM 34. For aluminophosphate zeolites, those of the type SAPO-17, SAPO-18, SAPO-34, SAPO-35, SAPO-39, SAPO-43 and SAPO-56.

In the catalytic system of the invention the mass percentage of zeolite relative to the total mass of the composition may vary from 10 to 70%, more preferably from 20 to 60% and even more preferably from 30 to 50%.

For the implementation of this zeolite variant of the catalytic system, it is possible to perform a simple physical mixture of the composition based on the cerium and niobium oxides and the zeolite.

The gas treatment method of the invention is a SCR type process whose implementation is well known to those skilled in the art. It may be recalled that this process uses as reducing agent NOx a nitrogen reducing agent which may be ammonia, hydrazine or any suitable precursor of ammonia, such as ammonium carbonate, urea, ammonium carbamate, ammonium hydrogencarbonate, ammonium formate or organometallic compounds containing ammonia. Ammonia or urea may be more particularly chosen.

Several chemical reactions can be implemented in the SCR process for the reduction of NOx to elemental nitrogen. As an example, only some of the reactions that may occur are given below, with ammonia being the reducing agent.

A first reaction can be represented by equation (1)

4NO + 4NH ₃ + O ₂ → 4N ₂ + 6H ₂ O (1)

In addition, the NO ₂ reaction present in NOx with NH ₃ can be mentioned according to equation (2).

3NO ₂ + 4NH ₃ → (7/2) N ₂ + 6H ₂ O (2)

In addition, the reaction between NH ₃ and NO and NO ₂ can be represented by equation (3)

NO + NO ₂ + 2NH ₃ → 2N ₂ + 3H ₂ O (3)

The method can be implemented for the treatment of a gas coming from an internal combustion engine (mobile or stationary), in particular from an engine of a motor vehicle, or gas coming from a gas turbine, from power stations operating on coal or fuel oil or any other industrial installation.

According to a particular embodiment, the method is used for treating the exhaust gas of a lean-burn internal combustion engine or a diesel engine.

The process can also be carried out using, in addition to the composition of the invention, another catalyst which is a catalyst for oxidation of the nitric oxide of the gas to nitrogen dioxide. In such a case, the process is used in a system in which this oxidation catalyst is disposed upstream of the injection point of the nitrogen reductant in the exhaust gas.

This oxidation catalyst may comprise at least one platinum group metal, such as platinum, palladium or rhodium, on a support of the alumina, ceria, zirconia or titanium oxide type, for example, the catalyst / support assembly. being included in a coating (washcoat) on a substrate of the monolithic type in particular. According to an advantageous variant of the invention and in the case of an exhaust system equipped with a particulate filter intended to stop the carbonaceous particles or soot generated by the combustion of the various fuels, it is possible to implement the gas treatment method of the invention by arranging the catalytic system which has been described above on this filter, for example in the form of a wash-coat deposited on the walls of the filter. It is observed that the use of the compositions of the invention according to this variant also makes it possible to reduce the temperature from which the combustion of the particles starts.

Examples will now be given.

Examples 1 to 14 which follow relate to the synthesis of compositions which are used in the process of the invention. EXAMPLE 1

This example relates to the preparation of a composition comprising cerium oxide, zirconium oxide and niobium oxide in the following respective proportions by weight: 64% -26% -10%.

A suspension of niobium hydroxide is first prepared by the following method.

In a 5 liter reactor equipped with a stirrer and a condenser, 1200 g of anhydrous ethanol are introduced. While stirring, 295 g of niobium chloride powder (V) are added over 20 minutes. 625 g of anhydrous ethanol are then added. The medium is left standing for 12 hours.

50 g of deionized water are introduced into the reactor and the medium is refluxed at 70 ° C for 1 hour. Let cool. This solution is named A.

In a 6 liter reactor equipped with a stirrer, 870 g of ammonia solution (29.8% of NH 3) are introduced. With stirring, all solution A and 2250 ml of deionized water are introduced in the course of 15 minutes. The suspension is recovered and washed several times by centrifugation. The centrifugate is named B.

In a 6 liter reactor equipped with a stirrer, 2.4 liters of a 1 mol / l nitric acid solution are introduced. Under stirring, the centrifugate B is introduced into the reactor. Stirring is maintained for 12 hours. The pH is 0.7. The concentration is 4.08% in Nb ₂ Os. This suspension is named C. A solution of ammonia D is then prepared by introducing 1040 g of a solution (D1) of concentrated ammonia (29.8% of NH ₃ ) in 6690 g of deionized water (D2).

A solution E is prepared by mixing 4250 g of deionized water (E1), 1640 g of a solution (E2) of cerium (III) nitrate (30.32% CeO ₂ ), 1065 g of a solution ( E3) of zirconium oxynitrate (20.04% ZrO2), 195 g of a solution (E4) of hydrogen peroxide (50.30% of H2O2), 1935 g of suspension C (4.08% by weight), Nb ₂ Os). This solution E is stirred.

In a stirred reactor of 4 liters equipped with an overflow, solution D and solution E are added simultaneously at a flow rate of 3.2 liters / hour. After putting the system into operation, the precipitate is recovered in a drum. The pH is stable and close to 9.

The suspension is filtered, the solid product obtained is washed and calcined at 800 ° C. for 4 hours.

EXAMPLES 2 to 6

The compositions of these examples are prepared in the same manner as in Example 1. Solutions D and E are prepared with the same compounds but with different proportions.

Table 1 below gives the precise conditions of preparation.

Table 1

Meaning of abbreviations of the table:

- in the "Example" column for each example the numbers given below the example number correspond to the proportions their respective mass of cerium, zirconium and niobium oxides for the composition of the example in question;

D1: quantity of concentrated ammonia solution (29.8% of NH ₃ ) used in the preparation of the ammonia solution D;

D 2: amount of deionized water used in the preparation of the ammonia solution D;

- E1: quantity of deionized water used in the preparation of the solution

E;

E2: quantity of solution of cerium (III) nitrate (30.32% CeO ₂ ) used in the preparation of solution E;

E3: quantity of zirconium oxynitrate solution (20.04% ZrO ₂ ) used in the preparation of solution E;

E4: qunatity of oxygenated water solution (50.30% in H ₂ O ₂ ) used in the preparation of solution E;

C: amount of suspension C (4.08% in Nb ₂ Os) used in the preparation of solution E.

EXAMPLE 7

This example relates to the preparation of a composition comprising cerium oxide, zirconium oxide and niobium oxide in the following respective proportions by weight: 72% -18% -10%.

A solution of niobium oxalate (V) and ammonium is prepared by hot dissolving 192 g of niobium (V) oxalate and ammonium in 300 g of deionized water. This solution is maintained at 50 ° C. The concentration of this solution is 14.2% in Nb ₂ Os. This solution is then introduced onto a powder of a mixed oxide of cerium and zirconium (mass composition CeO ₂ / ZrO ₂ 80/20, specific surface after calcination at 800 ° C. 4 hours of 59 m ² / g) up to saturation of the pore volume.

The impregnated powder is then calcined at 800 ° C. (4 hour stage).

EXAMPLES 8 to 10

Table 2 below gives the precise conditions of preparation. Table 2

Abbreviations have the same meaning as in Table 1.

EXAMPLE 1 1

This example relates to the preparation of a composition comprising cerium oxide, zirconium oxide and niobium oxide in the following respective proportions by weight: 63% -27% -10%.

A solution of nitrates of zirconium and cerium IV is prepared by mixing 264 g of deionized water, 238 g of cerium (IV) nitrate solution (252 g / L in CeO ₂ ) and 97 grams of sodium hydroxide solution. zirconium oxynitrate (261 g / l ZrO ₂ ). The concentration of this solution is 120 g / l of oxide.

1.53 g of deionized water and 11 g of ammonia solution (32% of NH ₃ ) are introduced into a stirred reactor of 1.5 liters. The nitrate solution is introduced in one hour. The final pH is around 9.5.

The suspension thus prepared is cured at 95 ° C. for 2 hours. The medium is then allowed to cool.

A solution of niobium oxalate (V) is prepared by hot dissolving 44.8 g of niobium oxalate (V) in 130 g of deionized water. This solution is maintained at 50 ° C. The concentration of this solution is 3.82% in Nb ₂ O ₅ .

The solution of niobium oxalate (V) is introduced in 20 minutes on the cooled suspension.

The suspension is filtered and washed. The cake is then introduced into an oven and calcined at 800 ° C. (4 hour stage).

EXAMPLE 12

This example concerns the preparation of a composition identical to that of Example 11.

A solution of nitrates of zirconium and cerium IV is prepared by mixing 451 g of deionized water, 206 g of cerium nitrate solution (IV) (252 g / l CeO 2) and 75 g of zirconium oxynitrate solution (288 g / l in Ζ1 2). The concentration of this solution is 80 g / l of oxide.

This solution of nitrates is introduced into an autoclave. The temperature is raised to 100 ° C. The medium is stirred at 100 ° C. for 1 hour. Let cool.

The suspension is transferred to a stirred reactor of 1.5 liters. A solution of 6 mol / l of ammonia is introduced under stirring until a pH in the region of 9.5 is obtained.

The suspension is cured at 95 ° C for 2 hours. The medium is then allowed to cool.

A solution of niobium oxalate (V) is prepared by hot dissolving 39 g of niobium oxalate (V) in 13 g of deionized water. This solution is maintained at 50 ° C. The concentration of this solution is 3.84% The solution of niobium oxalate (V) is introduced in 20 minutes on the cooled suspension. The pH is then raised to pH 9 by adding an ammonia solution (32% NH ₃ ).

EXAMPLE 13

This example relates to the preparation of a composition comprising cerium oxide, zirconium oxide and niobium oxide in the following respective proportions by weight: 64% -27% -9%.

The procedure is as in Example 12. However, the solution of niobium oxalate (V) is prepared by hot dissolving 35.1 g of niobium oxalate (V) in 13 g of water. deionized. The concentration of this solution is 3.45% in Nb ₂ Os. COMPARATIVE EXAMPLE 14 A

This example relates to the preparation of a composition comprising cerium oxide, zirconium oxide and niobium oxide in the following respective proportions by weight: 19% -78% -3%.

A solution of ammonia D is prepared as in Example 1 and with the same compounds but in the following proportions:

- concentrated ammonia solution: 940 g

- deionized water: 6730 g A solution E is also prepared as in Example 1 and with the same compounds but in the following proportions:

- deionized water: 5710 g

- solution of cerium (III) nitrate: 2540 g

- hydrogen peroxide solution: 298 g

- suspension C: 625 g

The procedure is then as in Example 1.

The following table 3 gives for each of the compositions examples above:

the BET specific surface area after calcination for 4 hours at 800 ° C. and 900 ° C .;

- the acidity properties;

- the properties of reducibility. Acidity

The acidity properties are measured by the TPD method which is described below.

The probe molecule used to characterize acid sites in TPD is ammonia.

- Preparation of the sample:

The sample (100 mg) is heated to 500 ° C. under a stream of helium (30 ml / min) according to a rise in temperature of 20 ° C./min and is maintained at this temperature for 30 minutes in order to remove the vapor. water and avoid clogging the pores. Finally the sample is cooled to 100 ° C under a stream of helium at 10 ° C / min.

- Adsorption:

The sample is then subjected to a flux (30 ml / min) of ammonia (5% vol of NH ₃ in helium at 100 ° C. at atmospheric pressure for 30 minutes (until saturation). subjected for a minimum of 1 hour to a stream of helium (30 ml / min).

- Desorption:

TPD is conducted by raising the temperature by 10 ° C / min to 700 ° C.

During the rise in temperature, the concentration of the desorbed species, that is to say ammonia, is recorded. The ammonia concentration during the desorption phase is deduced by calibrating the variation of the thermal conductivity of the gas flow measured at the outlet of the cell using a thermal conductivity detector (TCD). In Table 3 the amounts of ammonia are expressed in ml (normal conditions of temperature and pressure) / m ² (area at 800 ° C) of composition. The higher the amount of ammonia, the higher the surface acidity of the product.

reductibility

The reducibility properties are measured by performing a programmed temperature reduction (TPR) on a Micromeritics Autochem 2. This meter measures the hydrogen consumption of a composition as a function of temperature.

More precisely, hydrogen is used as a reducing gas at 10% by volume in argon with a flow rate of 30 ml / min. The experimental protocol consists in weighing 200 mg of the sample in a previously tared container. The sample is then introduced into a quartz cell containing in the bottom of the quartz wool. The sample is finally covered with quartz wool and positioned in the oven of the measuring device. The temperature program is as follows:

- rise in temperature from room temperature to 900 ° C with a ramp up to 20 ° C / min under H ₂ to 10% vol in Ar.

In this program, the temperature of the sample is measured using a thermocouple placed in the quartz cell above the sample. Hydrogen consumption during the reduction phase is deduced by calibrating the variation of the thermal conductivity of the gas stream measured at the outlet of the cell using a thermal conductivity detector (TCD).

The hydrogen consumption is measured between 30 ° C and 900 ° C. It is reported in Table 1 in ml (normal conditions of temperature and pressure) of H ₂ per g of product. The higher this hydrogen consumption, the better the properties of reducibility of the product (redox properties). Table 3

EXAMPLE 15

This example describes the catalytic properties of the compositions of the preceding examples in SCR catalysis. These properties are evaluated under the following conditions.

In a first series of measurements, the compositions used are those directly derived from the syntheses described in the examples previous, that is to say compositions that have been calcined at 800 ° C 4 hours.

In a second series of measurements, the compositions used are those of the preceding examples but after hydrothermal aging. This hydrothermal aging consists of continuously circulating a synthetic gas mixture of air containing 10% by volume of H ₂ O in a reactor containing the composition. During the circulation of the gas, the temperature of the reactor is brought to 750 ° C. for 16 hours to overcome it.

The compositions are then evaluated in catalytic test. In this test, the composition (90 mg) is passed over a synthetic gaseous mixture (30 L / h) representative of the catalysis process (Table 4).

Table 4

Composition of a representative mixture

The NOx conversion is monitored as a function of the temperature of the gas mixture.

The results are given in% of NOx conversion (here NO and NO ₂ ) in Table 5 which follows.

Table 5

Example No. 14B is a comparative example with a composition based on vanadium oxide on a support based on titanium oxide and tungsten. The proportions are in mass.

Example No. 14C is a comparative example with an aluminosilicate zeolite comprising iron. The proportions are in mass.

Example No. 14D is a comparative example with an aluminosilicate zeolite comprising copper. The proportions are in mass. It appears from Table 5 that the products according to the invention are more efficient than the comparative products, especially after aging. EXAMPLE 16

This example illustrates the catalytic properties of the compositions according to the invention when they are used in a coating on a particle filter or else used in extruded form as described above.

The compositions used are compositions having undergone the hydrothermal treatment described above.

The compositions according to Examples 1, 14C and 14D are mixed in a mortar with a model soot (Carbon Black Cabot Eltex) in a mass proportion of 20% soot with 80% composition.

Thermogravimetric analysis (TGA) is performed by circulating a flow of air (1 l / h) with a rise in ambient temperature at 900 ° C over 20 mg of the mixture prepared above. The mass loss of the sample is measured between 250 ° C and 900 ° C. It is considered that the loss of mass in this temperature range corresponds to the oxidation of the soot.

The results of the analysis are given in Table 6 below, indicating the start-up temperature of the soot combustion and the "light-off" temperature (T50%) for which 50% of the soot is oxidized.

Table 6

The product of the invention (example No. 1) makes it possible to reduce the ignition temperature by 90 ° C. and the light-off temperature by 70 ° C. relative to a combustion of soot without catalyst.

The products of the comparative examples have no catalytic effect on the oxidation of soot.

Claims

1 - Process for the treatment of a gas containing nitrogen oxides (NOx) in which a reduction reaction of NOx is carried out by a nitrogen reducing agent, characterized in that a reduction system is used as a catalyst for this reduction reaction. catalytic composition containing a composition based on cerium oxide and which comprises niobium oxide with the following proportions by mass:

niobium oxide of 2 to 20%;

the complement in cerium oxide.

2. Process according to claim 1, characterized in that the cerium oxide-based composition of the above-mentioned catalytic system further comprises zirconium oxide with the following proportions by mass:

- cerium oxide at least 50%;

niobium oxide of 2 to 20%;

zirconium oxide up to 48%.

3. Process according to claim 2, characterized in that the composition based on cerium oxide of the aforementioned catalytic system further comprises at least one oxide of an element M selected from the group comprising tungsten, molybdenum, iron , copper, silicon, aluminum, manganese, titanium, vanadium and rare earths other than cerium, with the following proportions by mass:

- cerium oxide: at least 50%;

niobium oxide: from 2 to 20%;

oxide of the element M: up to 20%;

the zirconium oxide supplement. 4. Process according to one of the preceding claims, characterized in that the cerium oxide-based composition of the above-mentioned catalytic system comprises niobium oxide in a mass proportion of between 3% and 15%, more particularly between 5% and 10%. 5. Method according to one of claims 2 to 4, characterized in that the cerium oxide-based composition of the aforementioned catalyst system comprises cerium oxide in a mass proportion of at least 65% and niobium oxide in a proportion by mass of between 2 and 12% and more particularly between 2 and 10%.

6. Process according to claim 5, characterized in that the composition based on cerium oxide of the above-mentioned catalytic system comprises cerium oxide in a proportion by weight of at least 70% and more particularly of at least 70% by weight. 75%.

7- Method according to one of the preceding claims, characterized in that the cerium oxide-based composition of the aforementioned catalytic system comprises niobium oxide in a mass proportion of less than 10% and more particularly between 2 % and 10%, this value being excluded. 8- Method according to one of claims 2 to 7, characterized in that the cerium oxide-based composition of the aforementioned catalyst system comprises cerium oxide in a proportion by mass of at least 60%, plus particularly at least 65%, and zirconium oxide in a proportion by mass of at most 25%, more particularly between 15% and 25%.

9- Method according to one of claims 1 or 2, characterized in that the cerium oxide-based composition of the aforementioned catalyst system comprises an oxide of at least one metal M 'chosen from the group comprising vanadium, copper, manganese, tungsten and iron in a proportion of between 1 and 10%, more preferably between 1 and 3%.

10- Method according to one of the preceding claims, characterized in that the aforementioned catalyst system further contains a zeolite.

1 1 - Method according to one of the preceding claims, characterized in that ammonia or urea is used as nitrogen reducing agent.

12- Method according to one of the preceding claims, characterized in that an exhaust gas from an engine of a motor vehicle is treated. 13- Method according to claim 12, characterized in that the aforementioned catalytic system is disposed on a particulate filter or in that it is based on the aforementioned composition, the latter being in an extruded form.