EP2694204A1

EP2694204A1 - Composition based on oxides of zirconium, of cerium, of at least one rare earth other than cerium and of silicon, preparation processes and use in catalysis

Info

Publication number: EP2694204A1
Application number: EP12713951.7A
Authority: EP
Inventors: Simon Ifrah
Original assignee: Rhodia Operations SAS
Current assignee: Rhodia Operations SAS
Priority date: 2011-04-08
Filing date: 2012-04-04
Publication date: 2014-02-12
Also published as: JP2014515698A; CN103492067A; ZA201307341B; CA2831173A1; WO2012136705A1; FR2973793A1; KR20140023965A; US20140044628A1; RU2013149805A

Abstract

The composition according to the invention is based on zirconium oxide, cerium oxide and at least one oxide of a rare earth other than cerium, in a proportion, by weight, of zirconium oxide of at least 5% and of cerium oxide of at most 90%, and it is characterized in that it additionally comprises silicon oxide in an amount, by weight, of between 0.1% and 2%. This composition may be used in catalysis, in particular in systems for treating the exhaust gases of internal combustion engines.

Description

COMPOSITION BASED ON ZIRCONIUM OXIDES, CERIUM, AT LEAST ONE RARE EARTH OTHER THAN CERIUM AND SILICON, PROCESSES FOR PREPARATION AND USE IN CATALYSIS

The present invention relates to a composition based on zirconium oxide, cerium oxide, at least one oxide of a rare earth other than cerium and silicon oxide, its methods of preparation and its use in catalysis.

At the present time, so-called multifunctional catalysts are used for the treatment of the exhaust gases of internal combustion engines (automotive post-combustion catalysis). Multifunctional means catalysts capable of operating not only the oxidation in particular of carbon monoxide and hydrocarbons present in the exhaust gas but also the reduction in particular nitrogen oxides also present in these gases (catalysts "three ways"). Zirconium oxide and ceria appear today as two particularly important and interesting components for this type of catalyst. A quality required for these materials is their reducibility. Reducibility means, here and for the remainder of the description, the cerium IV content in these materials may be converted into cerium III under the effect of a reducing atmosphere and at a given temperature. This reducibility can be measured for example by a consumption of hydrogen in a given temperature range. It is due to cerium, which has the property of being reduced or oxidized. This reducibility must, of course, be as high as possible.

In addition, it is important that this reducibility retains a sufficiently high value that the products remain effective even after exposure thereof at high temperatures.

The object of the invention is to provide a product which has satisfactory reducibility properties in a temperature range which remains rather high.

For this purpose, the composition according to the invention is based on zirconium oxide, cerium oxide and at least one oxide of a rare earth other than cerium, in a proportion by mass of zirconium oxide. at least 5% and cerium oxide of at most 90%, and it is characterized in that it further comprises silicon oxide in a mass amount of between 0.1% and 2%. 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 remainder of the description, the term "specific surface" means the specific surface B.E.T. determined by nitrogen adsorption according to ASTM D 3663-78 established from the BRUNAUER-EMMETT-TELLER method described in the journal "The Journal of the American Chemical Society, 60, 309 (1938)".

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.

In addition, the calcinations for a given temperature and duration correspond, unless otherwise indicated, to calcinations under air at a temperature level over the time indicated.

The contents are given in oxide mass unless otherwise indicated.

The cerium oxide is in the form of ceric oxide, the oxides of the other rare earths in Ln ₂ 03 form, Ln denoting the rare earth, with the exception of praseodymium expressed as Pr ₆ On.

It is 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 compositions according to the invention are characterized first of all by the nature of their constituents.

The compositions of the invention are based on zirconium oxide and cerium oxide and they also comprise at least one oxide of at least one other rare earth which is different from cerium and silicon oxide. (S1O2).

According to an advantageous embodiment of the invention the compositions comprise at least two rare earth oxides other than cerium.

The rare earth (s) other than cerium may be more particularly chosen from yttrium, lanthanum, neodymium, praseodymium or gadolinium. There may be mentioned more particularly the compositions based on oxides of zirconium, cerium, praseodymium and lanthanum or based on oxides of zirconium, cerium, yttrium, neodymium and lanthanum.

As indicated above, the amount of silicon oxide in the compositions of the invention is between 0.1% and 2%. Below 0.1%, the presence of silicon no longer plays a role in the properties of the compositions and beyond 2% the specific surface of the compositions may not be sufficiently stable at elevated temperature for uses in the field of catalysis.

This amount of silicon oxide may be more particularly between 0.1% and 1% and even more particularly between 0.1% and 0.6%.

According to a preferred embodiment this amount may be between 0.2% and 0.5%.

The cerium oxide content is at most 90% and more particularly at most 60%. The minimum amount of cerium is not critical. Preferably, however, it is at least 0.1% and more preferably at least 1% and even more preferably at least 5%.

Depending on the embodiments, this content may be between 5% and 20% or between 30% and 60%. In the case of compositions with a high cerium content, the amount of cerium may be at least 70%.

The oxide content of the rare earth (s) other than cerium is generally at most 30%, more particularly at most 25% and at least 4%, preferably at least 5%, and especially at least 10%. It can be in particular between 5% and 25% and even more particularly between 5% and 20%.

According to the embodiments, the zirconium oxide content may be more particularly between 15% and 65% or between 60% and 90%.

According to a particular embodiment, the compositions of the invention consist essentially of zirconium oxide, cerium oxide, silicon oxide and one or more oxides of a rare earth other than cerium in the proportions given above. By "consists essentially" is meant that apart from the usual impurities that can come from its process of preparation, for example raw materials or starting reagents used, the composition does not contain other elements that may have an influence on its specific surface characteristics or reducibility.

The compositions of the invention have important specific surfaces even after calcination at elevated temperature.

Thus, they may have a specific surface after calcination for 4 hours at 1000 ° C. of at least 30 m ² / g, preferably at least 35 m ² / g and even more preferably at least 40 m ² / g. . Surface values up to about 45 m ² / g or even 50 m ² / g can be achieved. The compositions of the invention may also have a specific surface area after calcination for 4 hours at 1100 ° C. of at least 10 m ² / g, this area possibly being even at least 15 m ² / g. Surface values up to about 21 m ² / g or 24 m ² / g can be achieved under these same calcination conditions.

The compositions of the invention may be in the form of pure solid solutions of the elements zirconium, cerium, rare earth (s) other than cerium and silicon in the cerium oxide or zirconium in function respective contents of these two elements.

In this case, the X-ray diffraction patterns of these compositions reveal the existence of a single phase corresponding to that of a zirconium oxide (for compositions with a higher zirconium content) or cerium (for compositions with higher cerium content), crystallized in the cubic or quadratic system, thus reflecting the incorporation of elements zirconium, cerium, rare earths other than cerium, and silicon in the crystal lattice of cerium or zirconium oxide, and therefore obtaining a true solid solution. This embodiment, solid solution, applies to compositions which have been calcined at a temperature as high as 1100 ° C and for 4 hours. This means that after calcination under these conditions no demixing is observed, that is to say the appearance of other phases.

Another characteristic of the compositions of the invention is their oxygen storage capacity (OSC).

For the whole of the description, the OSC values that are given correspond to capacitances measured between 400 ° C. and 500 ° C.

The compositions of the invention have indeed a high OSC at high temperatures, that is to say up to 1000 ° C which makes these compositions usable in applications in catalysis at least up to this temperature.

This capacity depends on the amount of cerium in the compositions.

For cerium oxide contents which are between 5% and 15% or at least 70% and for compositions which have also undergone calcination at 1000 ° C. for 4 hours, this OSC is at least 0, 20 ml of O ₂ / g. It may be more particularly at least 0.25 ml of O2 g. Values up to about 0.4 ml of O 2 g can be obtained.

For cerium oxide contents which are between 30% and 60% and still for compositions which have been calcined at 1000 ° C. for 4 hours, this OSC is at least 0.6 ml O 2 g, more particularly 'at minus 0.7 ml 02 g. Values up to about 0.95 ml of 02 g can be obtained.

On the other hand, the compositions of the invention exhibit a significant decrease in their OSC and, more generally, their reducibility property at higher temperature, that is to say from 1200 ° C. Thus, after calcination for 10 hours at 1200 ° C. they have a decrease in their OSC (expressed by the ratio in% (OSC after calcination for 4 hours at 1000 ° C. - OSC after calcination at 1200 ° C.) / OSC after calcination for 4 hours at 1000 ° C) of at least 80%, more particularly at least 90%.

For cerium oxide contents which are between 5% and

15% or at least 70% and for compositions which have been calcined for 10 hours at 1200 ° C. this OSC is at most 0.1 ml of O ₂ / g, more particularly at most 0, 05 of 02 g and even more particularly this value can be null.

For cerium oxide contents which are between 30% and

60% and for compositions which have undergone calcination under the same conditions this OSC is at most 0, 15 ml of O 2 g, more particularly at most 0, 10 O ₂ / g.

This significant drop in OSC allows the use of the compositions of the invention in on-board diagnostic systems (OBD) which will be described later.

Another characteristic of the compositions of the invention is their reducibility. This reducibility is determined by measuring their ability to capture hydrogen as a function of temperature. This measurement also determines a maximum reducibility temperature (Tmax) which corresponds to the temperature at which hydrogen uptake is maximal and in which, in other words, the reduction of cerium IV to cerium III is also maximal.

The compositions of the invention have the characteristic of having a large variation in their Tmax between 1000 ° C. and 1200 ° C. More precisely, these compositions may, after calcination for 4 hours at 1000 ° C. and then calcination for 10 hours at 1200 ° C., a displacement or an increase in their maximum reducibility temperature with an amplitude of at least 150 ° C., more particularly at least 170 ° C and even more preferably at least 200 ° C.

Generally the Tmax of the compositions of the invention is between 550 ° C and 580 ° C after calcination at 4 hours 1000 ° C and is between 750 ° C and 850 ° C after calcination at 10 hours 1200 ° C. The methods for preparing the compositions of the invention will now be described.

According to a first embodiment, the invention relates to a method which comprises the following steps:

(a1) forming a mixture comprising compounds of zirconium, cerium, at least one rare earth other than cerium and silicon;

(b1) said mixture is brought into contact with a basic compound, whereby a precipitate is obtained;

(c1) said precipitate is heated in a liquid medium;

(d1) adding to the precipitate obtained in the preceding step an additive chosen from anionic surfactants, nonionic surfactants, polyethylene glycols, carboxylic acids and their salts and surfactants of the ethoxylates type of carboxymethylated fatty alcohols;

- (e1) the product thus obtained is calcined.

The first step (a1) of the process therefore consists in preparing a mixture of the compounds of the constituent elements of the composition that is to be prepared. The mixture is generally in a liquid medium which is water preferably.

The compounds are preferably soluble compounds. It can be in particular salts of zirconium, cerium and rare earth. These compounds can be chosen from nitrates, sulphates, acetates, chlorides, ceric nitrate or cerium-ammoniacal nitrate.

By way of examples, mention may be made of zirconium sulphate, zirconyl nitrate or zirconyl chloride.

The zirconyl sulphate can come from the solution of crystallized zirconyl sulphate. It may also have been obtained by dissolving basic zirconium sulphate with sulfuric acid, or else by dissolving zirconium hydroxide with sulfuric acid. In the same way, the zirconyl nitrate can come from the solution solution of crystallized zirconyl nitrate or it may have been obtained by dissolution of basic zirconium carbonate or by dissolution of zirconium hydroxide with nitric acid .

It is advantageous to use salts of purity of at least 99.5% and more particularly at least 99.9%.

It may be advantageous to use a zirconium compound in the form of a combination or a mixture of the aforementioned salts. For example, the combination of zirconium nitrate with zirconium sulphate or the combination of zirconium sulphate with sodium chloride may be mentioned. zirconyl. The respective proportions of the various salts can vary to a large extent, from 90/10 up to 10/90, for example, these proportions designating the contribution of each of the salts in grams of total zirconium oxide.

Note that when the starting mixture contains cerium form III, it is preferable to involve in the course of the process an oxidizing agent, for example hydrogen peroxide. This oxidizing agent can be used by being added to the reaction medium during step (a1), during step (b1) or at the beginning of step (c1).

Finally, it is also possible to use a sol as starting compound of zirconium or cerium. By sol is meant any system consisting of fine solid particles of colloidal dimensions, ie dimensions of between about 1 nm and about 200 nm, based on a compound of zirconium or cerium, this compound being generally an oxide and or a hydrated oxide of zirconium or cerium, in suspension in an aqueous liquid phase.

The soils or colloidal dispersions used can be stabilized by the addition of stabilizing ions.

These colloidal dispersions can be obtained by any means known to those skilled in the art. In particular, mention may be made of the partial dissolution of zirconium precursor. Partially means that the amount of acid used in the attack reaction of the precursor is less than the amount required for the total dissolution of the precursor.

The colloidal dispersions can also be obtained by hydrothermal treatment of solutions of zirconium or cerium precursors.

As the silicon compound, it is possible to use siliconates or else alkali or quaternary ammonium silicates. Among the siliconates, mention may be made more particularly of alkylsiliconates of alkalis, such as, for example, potassium methylsiliconate and for alkali silicates and sodium silicate.

The quaternary ammonium ion of the silicates which can be used according to the invention has hydrocarbon radicals preferably having 1 to 3 carbon atoms. Thus, at least one silicate chosen from: tetramethylammonium silicate, tetraethylammonium silicate, tetrapropylammonium silicate and tetrahydroxyethylammonium silicate (or tetraethanolammonium silicate) is preferably used. In particular, tetramethylammonium silicate is described in YUI Smolin "Structure The tetraethanolammonium silicate is especially described in Helmut H. Weldes, K. Robert Lange "Properties of soluble silicates" in "Industrial and Engineering Chemistry", vol. N4, April 1969, and in US Patent 3,239,521 The references cited above also describe other water soluble quaternary ammonium silicates which can be used according to the invention.

The mixture of step (a1) may be indifferently obtained either from compounds initially in the solid state that will be introduced later in a water tank for example, or even directly from solutions. or suspensions of these compounds and then mixing, in any order, said solutions or suspensions. The compounds of zirconium, cerium, rare earths other than cerium and silicon are present in the necessary stoichiometric quantities.

In the second step (b1) of the process, said mixture is brought into contact with a basic compound to react. 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. Finally, it can be used with a stoichiometric excess to ensure optimal precipitation.

This placing in presence is generally under agitation. It can be carried out in any manner, for example by the addition of a previously formed mixture of the compounds of the aforementioned elements in the basic compound in the form of a solution. At the end of this step (b1), a precipitate is obtained.

The next step (c1) of the process is the step of heating this precipitate in a liquid medium. It may be noted that at the beginning of this step the pH of this medium is basic and that it is generally at least 8.

This heating can be carried out directly on the reaction medium obtained at the end of step (b1) or on a suspension obtained after separation of the precipitate from the reaction medium, optional washing and return to water of the precipitate. The temperature at which the medium is heated is at least 100 ° C and even more preferably at least 110 ° C. She may be for example between 100 ° C and 160 ° C. The heating operation can be conducted by introducing the liquid medium into a closed chamber (autoclave type closed reactor). Under the conditions of the temperatures given above, and in aqueous medium, 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 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 heating can vary within wide limits, for example between 30 minutes 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.

It is possible to do several heats. Thus, the precipitate obtained after the heating step can be resuspended in water and possibly a washing and then another heating of the medium thus obtained. This other heating is done under the same conditions as those described for the first.

The next step (d1) of the process consists in adding to the precipitate from the preceding step an additive which is chosen from anionic surfactants, nonionic surfactants, polyethylene glycols and carboxylic acids and their salts and surfactants. ethoxylates of carboxymethylated fatty alcohols.

As regards this additive, reference may be made to the teaching of the application WO-98/45212 and use the surfactants described in this document.

Mention may be made, as surfactants of the anionic type, of ethoxycarboxylates, ethoxylated fatty acids, sarcosinates, phosphate esters, sulphates such as alcohol sulphates, ether alcohol sulphates and sulphated alkanolamide ethoxylates, sulphonates such as sulphosuccinates. , alkyl benzene or alkyl naphthalene sulfonates.

As nonionic surfactants there may be mentioned acetylenic surfactants, alcohol ethoxylates, alkanolamides, amine oxides, ethoxylated alkanolamides, long chain ethoxylated amines, ethylene oxide / propylene oxide copolymers, derivatives thereof. of sorbiatan, ethylene glycol, propylene glycol, glycerol, polyglyceryl esters and their ethoxylated derivatives, alkylamines, alkylimidazolines, ethoxylated oils and alkylphenol ethoxylates. These include in particular the products sold under the trademark IGEPAL ^®, DOWANOL ^®, DAM RHO OX ^® and Alkamide ^®

As regards the carboxylic acids, it is possible to use, in particular, aliphatic mono- or dicarboxylic acids and, among these, more particularly saturated acids. It is also possible to use fatty acids and more particularly saturated fatty acids. These include formic, acetic, propionic, butyric, isobutyric, valeric, caproic, caprylic, capric, lauric, myristic and palmitic acids. As dicarboxylic acids, there may be mentioned oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid and sebacic acid.

The salts of the carboxylic acids can also be used, especially the ammoniacal salts.

By way of example, there may be mentioned more particularly lauric acid and ammonium laurate.

Finally, it is possible to use a surfactant which is chosen from those of the type ethoxylates of carboxymethylated fatty alcohols.

By carboxymethyl alcohol fatty alcohol ethoxylates product is meant products consisting of ethoxylated or propoxylated fatty alcohols having at the end of the chain a CH ₂ -COOH group.

These products can meet the formula:

R 1 -O- (CR ₂ R 3 -RC ₄ R ₅ -O) n -CH ₂ -COOH

wherein R 1 denotes a carbon chain, saturated or unsaturated, the length of which is generally at most 22 carbon atoms, preferably at least 12 carbon atoms; R ₂ , R 3, R ₄ and R ₅ may be identical and represent hydrogen or R ₂ may represent a CH ₃ group and R ₃ , R ₄ and R ₅ represent hydrogen; n is a non-zero integer of up to 50 and more particularly between 5 and 15, these values being included. It will be noted that a surfactant may consist of a mixture of products of the above formula for which R 1 may be saturated and unsaturated respectively or products comprising both -CH ₂ -CH ₂ -O groups. and -C (CH ₃ ) -CH ₂ -O-.

The addition of the surfactant can be done in two ways. It can be added directly to the precipitate suspension resulting from the previous heating step (c1). It may also be added to the solid precipitate after separation thereof by any known means from the medium in which the heating took place. The amount of surfactant used, expressed as a percentage by mass of additive relative to the weight of the composition calculated as oxide, is generally between 5% and 100%, more particularly between 15% and 60%.

According to another advantageous variant of the invention, before carrying out the last stage of the process (calcination step), the precipitate is washed after having separated it from the medium in which it was in suspension. This washing can be done with water, preferably with water at basic pH, for example ammonia water.

In a last step (e1) of the process according to the invention, the precipitate recovered is then calcined. This calcination makes it possible to develop the crystallinity of the product formed and it can also be adjusted and / or chosen as a function of the temperature of subsequent use reserved for the composition according to the invention, and this taking into account the fact that the specific surface of the product is even lower than the calcination temperature used is higher. Such calcination is generally carried out under air, but a calcination carried out for example under inert gas or under a controlled atmosphere (oxidizing or reducing) is obviously not excluded.

In practice, the calcination temperature is generally limited to a range of values between 500 and 900 ° C., more particularly between 700 ° C. and 800 ° C.

The method for preparing the compositions of the invention may be implemented according to a second embodiment.

In this case, the process comprises the following first three steps: (a2) a mixture is formed comprising compounds of zirconium, cerium and rare earths other than cerium;

- (b2) said mixture is brought into contact with a basic compound, whereby a precipitate is obtained;

- (c2) said precipitate is heated in a liquid medium;

The steps (a2), (b2) and (c2) of this second mode are respectively identical to the steps (a1), (b1) and (c1) described for the first mode. The only difference is that the starting mixture of step (a1) does not comprise a silicon compound, this compound being added later. Apart from this difference, what has been described above for steps (a1), (b1) and (c1) likewise applies to steps (a2), (b2) and (c2).

The method according to the second mode then comprises a step (d2) in which a compound obtained in the preceding step (c2) is added to the precipitate silicon, in the necessary stoichiometric quantities. This silicon compound is of the same type as that described above.

The method finally comprises two other steps, a step (e2) in which is added to the product obtained in the preceding step an additive of the same type as that used in step (d1) of the method according to the first embodiment and a step ( f2) in which the product thus obtained is calcined.

The conditions for implementing steps (e2) and (f2) are the same as those given for steps (d1) and (e1) of the first method.

It can be noted here that it is possible to simultaneously perform the two steps (d2) and (e2), that is to say to simultaneously add the silicon compound and the additive to the precipitate from the step (c2).

According to a third embodiment, the compositions of the invention may be prepared by a process which comprises the following steps:

(a3) forming a mixture comprising compounds of zirconium, cerium, at least one rare earth other than cerium and optionally a silicon compound;

- (b3) said precipitate is heated in a liquid medium;

- (c3) is added to the precipitate obtained in the preceding step a silicon compound if it was not present in step (a3);

- (d3) is added to the product obtained in the preceding step an additive selected from anionic surfactants, nonionic surfactants, polyethylene glycols, carboxylic acids and their salts and ethoxylates type surfactants of carboxymethylated fatty alcohols;

(e3) the product thus obtained is calcined.

Step (a3) of this third mode is similar to step (a1) described above. It should be noted, however, that the silicon compound may or may not be present in this step.

Unlike the previous embodiments, the method according to the third mode does not implement basic compound. It comprises a step (b3) of heating the mixture prepared in the preceding step, this heating being done in a liquid medium, this medium being acidic starting from step (b3) for example at a pH below 4.

The temperature at which this heat treatment, also called thermohydrolysis, is conducted is at least 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 (closed reactor of the autoclave type), the pressure necessary, resulting only from the mere 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 July

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 duration of the treatment is not critical, and can thus vary within wide limits, for example between 30 minutes and 48 hours, preferably between 1 and 5 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 the heating, a precipitate is obtained which is separated from the liquid medium by any suitable means.

The next step (c3) consists in adding to the precipitate thus obtained the silicon compound in the case where it was not introduced during the step

(A3).

Steps (d3) and (e3) are identical to steps (d1) and (c1) described above.

It can be noted that, here again, it is possible to carry out simultaneously the two steps (c3) and (d3), that is to say to simultaneously add the silicon compound and the additive to the precipitate from step (b3).

A fourth embodiment for the process for preparing the compositions of the invention will be described also below.

The method according to the latter mode comprises the following steps:

(a4) forming a mixture comprising compounds of zirconium, cerium and silicon only these compounds with one or more rare earth compounds other than cerium in an amount of this or these latter compounds which is less than amount necessary to obtain the desired composition;

- (b4) is brought, with stirring, said mixture with a basic compound; (c4) the medium obtained in the preceding step is brought into contact, with stirring, with either the rare earth compound (s) other than cerium if this or these compounds were not present in step (a4) the remaining amount required of said one or more compounds, the stirring energy used in step (c4) being less than that used in step (b4), whereby a precipitate is obtained;

- (d4) said precipitate is heated in aqueous medium;

(e4) adding to the precipitate obtained in the preceding step an additive chosen from anionic surfactants, nonionic surfactants, polyethylene glycols, carboxylic acids and their salts and surfactants of the ethoxylate type of carboxymethylated fatty alcohols;

(f4) the precipitate thus obtained is calcined.

Steps (a4) and (b4) of this method are quite similar to steps (a1) and (b1) of the first mode, and what has been described about them therefore applies likewise here. The difference lies in the fact that the mixture formed in step (a4) does not comprise, as regards the constituent elements of the composition, that is to say zirconium, cerium, silicon and other (s) earth ( s) rare, that the compounds of zirconium, cerium and silicon in a first variant.

According to a second variant, the mixture formed in step (a4) comprises, in addition to the compounds of zirconium, cerium and silicon, the compound (s) of the other rare earths other than cerium but in an amount which is less than the total amount stoichiometric required of this or these compounds of other rare earths to obtain the desired composition. This quantity may be more particularly at most equal to half of the total amount.

It will be noted that this second variant must be understood as covering the case, for the compositions based on oxides of zirconium, cerium, silicon and at least two other rare earths, where in step (a4) the The total required amount of the compound of at least one of the rare earths is present at this stage and it is only for at least one of the remaining rare earths that the amount of the compound of this other rare earth is less than the amount required. It is also possible that the compound of this other rare earth is absent at this stage (a4).

The next step (c4) of the process consists in bringing the medium resulting from the preceding step (b4) into contact with the rare earth compounds other than cerium. In the case of the first variant mentioned above in which the starting mixture formed in step (a4) does not comprise, as As components of the composition, such as zirconium, cerium and silicon compounds, these compounds are therefore introduced for the first time in the process and in the total required stoichiometric amount of these other rare earths. In the case of the second variant in which the mixture formed in step (a4) already comprises compounds of the other rare earths other than cerium, it is therefore the necessary remaining quantity of these compounds or, possibly, the quantity required compound of a rare earth compound if this compound was not present in step (a4).

This bringing into association may be carried out in any manner, for example by the addition of a previously formed mixture of rare earth compounds other than cerium in the mixture obtained at the end of step (b4). It is also agitated but under conditions such that the stirring energy used during this step (c4) is less than that used in step (b4). More precisely, the energy used during step (c4) is at least 20% less than that of step (b4) and may more particularly be less than 40% and even more particularly less than 50%. of it.

At the end of step (c4), a precipitate is obtained in suspension in the reaction medium.

The following steps (d4), (e4) and (f4) are then identical to the steps

(c1), (d1) and (e1) respectively of the method according to the first mode.

The method according to the fourth embodiment makes it possible to obtain products whose stability of the specific surface is improved.

The compositions of the invention as described above or as obtained by the preparation methods described above are in the form of powders but they may optionally be shaped to be in the form of granules, beads, cylinders or nests bee of varying sizes.

These compositions may be used with any material usually employed in the field of the catalyst system, ie in particular thermally inert materials. This material may be chosen from alumina, titanium oxide, cerium oxide, zirconium oxide, silica, spinels, zeolites, silicates, crystalline silicoaluminium phosphates, phosphates of crystalline aluminum.

The compositions may also be used in catalytic systems comprising a coating (wash coat) with catalytic properties and based on these compositions with a material of the type mentioned above, the coating being deposited on a substrate of the type for example metal monolith, for example FerCralloy, or ceramic, for example cordierite, silicon carbide, alumina titanate or mullite.

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

These catalytic systems and more particularly the compositions of the invention can find very many applications.

They are thus particularly well adapted to, and therefore usable in the catalysis of various reactions such as, for example, dehydration, hydrosulfuration, hydrodenitrification, desulphurization, hydrodesulphurization, dehydrohalogenation, reforming, reforming. steam, cracking, hydrocracking, hydrogenation, dehydrogenation, isomerization, disproportionation, oxychlorination, dehydrocyclization of hydrocarbons or other organic compounds, oxidation and / or reduction reactions, Claus reaction, exhaust gas treatment of internal combustion engines, demetallation, methanation, shift conversion, catalytic oxidation of soot emitted by internal combustion engines such as diesel or gasoline engines operating in a lean regime .

The catalytic systems and compositions of the invention can finally be used as NOx traps or to promote the reduction of NOx even in an oxidizing medium.

In the case of these uses in catalysis, the compositions of the invention are used in combination with precious metals, they thus play the role of support for these metals. The nature of these metals and the techniques for incorporating them into the support compositions are well known to those skilled in the art. For example, the metals may be platinum, rhodium, palladium or iridium, they may in particular be incorporated into the compositions by impregnation.

Among the uses mentioned, the treatment of the exhaust gases of internal combustion engines (automotive post-combustion catalysis) is a particularly advantageous application insofar as the compositions of the invention exhibit a high CSO at temperatures of at least up to at 1000 ° C.

Accordingly, the invention also relates to a method for treating the exhaust gases of internal combustion engines, which is characterized in that a catalytic system as described above or a composition according to the invention is used as catalyst. invention and as previously described. A more particular use of the composition of the invention will be described below.

Because it has a high OSC at high temperature, that is, between 1000 ° C and 1100 ° C, but also a CSO which decreases markedly after calcination at a temperature of at least 1100 ° C. more particularly at least 1200 ° C over a period of 10 hours, the composition of the invention can act as a control. One can indeed measure regularly his OSC. If the measured OSC decreases abruptly, this means that the system has been subjected to a high temperature, at least 1150 ° C, for a long time, at least a few hours.

In catalytic systems which contain compositions whose OSC is likely to vary significantly less when exposed to temperatures of the order of 1200 ° C, the OSC measurement thereof does not allow to know what the system may have suffered as a thermal stress during its use. The presence of a composition according to the invention in these systems makes it possible to demonstrate the fact that the system has been subjected to high temperatures, which may have led to a degradation of its properties.

Therefore, the invention also relates to an on-board diagnostic system which contains only a composition according to the invention or which is based on such a composition. This system further comprises means, known per se, for measuring the OSC of the composition.

The invention also relates to an on-board diagnostic system as described above but which contains, as a first composition, a composition according to the invention and, in addition, a second composition which exhibits a variation of its measured OSC on the one hand after calcination for 4 hours at 1000 ° C. and, on the other hand, 10 hours at 1150 ° C., more particularly at 1200 ° C., significantly less than the OSC variation of a composition according to the invention after calcination in the same conditions.

More particularly, this second composition may have, after calcination for 10 hours at 1150 ° C., more particularly at 1200 ° C., an OSC at least twice greater than that of the composition according to the invention after calcination under the same conditions.

Such compositions are known, and may be mentioned in particular those described in patent applications EP 2288426, EP 2024084, EP 1991354, EP 1660406 or EP 0906244.

Examples will now be given. For these examples, the methods for measuring the oxygen storage capacity and the maximum reducibility temperature are given below.

Measurement of oxygen storage capacity

This measurement is carried out by performing a temperature reduction programmed on an AUTOCHEM II 2920. This apparatus makes it possible to measure the hydrogen consumption of a composition according to the invention as a function of the temperature and to deduce the reduction rate therefrom. cerium or the amount of oxygen labile or stored oxygen because this amount corresponds to half the hydrogen consumption.

This measurement is made on samples which have been calcined beforehand for 4 hours at 1000 ° C. or 10 hours at 1200 ° C. as the case may be.

The measurement is made using hydrogen diluted to 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. A rise in temperature is carried out up to 900 ° C. with a ramp up to 10 ° C./min under H ₂ at 10% vol in Ar.

The consumption of hydrogen is calculated from the missing surface of the hydrogen signal between 400 ° C and 500 ° C.

Maximum reducibility temperature

The measurement is made with the same device and under the same conditions as those given above.

Hydrogen capture is calculated from the missing surface of the baseline hydrogen signal at room temperature at baseline at 900 ° C. The maximum temperature of reducibility (temperature at which the capture of hydrogen is maximum and where, in other words, the reduction of cerium IV cerium III is also maximum and which corresponds to maximum lability O2 of the composition) is measured using a thermocouple placed in the center of the sample.

EXAMPLE1

This example relates to a composition with 44.875% of zirconium,

44.875% of cerium, 4.875% of lanthanum, 4.875% of praseodymium and 0.5% of silica, these proportions being expressed as a percentage by weight of the oxides ZrO ₂ , CeO ₂ , La ₂ O ₃ , Pr ₆ On and SiO ₂ . In a stirred beaker, the necessary quantity of solutions of zirconium nitrate (267 g / l in ZrO ₂ ), cerium nitrate (249 g / l), lanthanum nitrate (469 g / l in La ₂ O 3) is introduced. ) and praseodymium nitrate (500 g / l in Pr ₆ On) and 1, 1 ml of potassium methylsiliconate at 453 g / l in SiO _{2 are introduced} . Then complete with distilled water so as to obtain 1 liter of a solution of nitrates.

In a stirred reactor, a solution of ammonia (12 mol / l) is introduced and then it is made up with distilled water so as to obtain a total volume of 1 liter and a stoichiometric excess of ammonia of 40% with respect to nitrates to precipitate.

The nitrate solution is introduced into the reactor with constant stirring.

The solution obtained is placed in a stainless steel autoclave equipped with a stirrer. The temperature of the medium is brought to 1 15 ° C for 35 minutes with stirring.

32 grams of lauric acid are added to the suspension thus obtained. The suspension is stirred for 1 hour.

The suspension is then filtered on Buchner, and then the filtered precipitate is washed with ammonia water.

The product obtained is then heated to 700 ° C. for 4 hours in stages.

EXAMPLE 2

This example relates to a composition containing 44.10% of zirconium, 44.10% of cerium, 4.9% of lanthanum, 4.9% of praseodymium and 2% of silica, these proportions being expressed as a percentage by weight of the ZrO ₂ oxides. , CeO ₂ , La ₂ O ₃ , Pr ₆ On and SiO ₂ .

In a stirred beaker is introduced the necessary amount of solutions of zirconium nitrate, cerium nitrate, lanthanum nitrate and praseodymium nitrate used for Example 1 and 4.4 ml of potassium methylsiliconate at 453 g / l in SiO ₂ . Then complete with distilled water so as to obtain 1 liter of a solution of nitrates.

The nitrate solution is introduced into the reactor with constant stirring.

The procedure is then as in Example 1. EXAMPLE 3

This example relates to a composition containing 44.875% of zirconium, 44.875% of cerium, 4.875% of lanthanum, 4.875% of praseodymium and 0.5% of silica, these proportions being expressed as a percentage by weight of the oxides Zr0 ₂ , CeO ₂ , La ₂ O ₃ , Pr ₆ On and Si0 ₂ .

In a stirred beaker, the necessary amount of the solutions of zirconium nitrate, cerium nitrate, lanthanum nitrate and praseodymium nitrate used for Example 1 and 3 ml of sodium silicate at 200 g / l were introduced. Si0 ₂ . Then complete with distilled water so as to obtain 1 liter of a solution of nitrates.

The nitrate solution is introduced into the reactor with constant stirring.

The procedure is then as in Example 1. EXAMPLE 4

This example concerns a composition containing 74.9% of zirconium, 9.9% of cerium, 1.9% of lanthanum, 7.9% of yttrium, 4.9% of neodymium and 0.5% of silica. proportions being expressed as a percentage by weight of ZrO ₂ , CeO ₂ , La ₂ O ₃ , Y ₂ O ₃ , Nd ₂ O ₃ and SiO ₂ oxides

In a stirred beaker, the necessary quantity of solutions of zirconium nitrate (267 g / l in ZrO ₂ ), cerium nitrate at 249 g / l, lanthanum nitrate (469 g / l in La ₂ O _{3) is introduced.} ), of neodymium nitrate (484 g / l in Nd ₂ O ₃ ) and of yttrium nitrate (261 g / l in Y ₂ O ₃ ) and 1, 1 ml of potassium methylsiliconate at 453 g / l are introduced in SiO ₂ . Then complete with distilled water so as to obtain 1 liter of a solution of nitrates.

The nitrate solution is introduced into the reactor with constant stirring.

The procedure is then as in Example 1. EXAMPLE 5

This example illustrates the preparation of a composition according to the invention by a method according to the fourth embodiment.

It concerns a composition containing 74.9% of zirconium, 9.9% of cerium, 1.9% of lanthanum, 7.9% of yttrium, 4.9% of neodymium and 0.5% of silica, these proportions being expressed as a weight percentage of ZrO ₂ , CeO ₂ , La ₂ O ₃ , Y ₂ O ₃ , Nd ₂ O ₃ and SiO ₂ oxides.

Two nitrate solutions are prepared beforehand, one consisting of cerium and zirconium nitrates and the other consisting of nitrates of lanthanum, yttrium and neodymium. In a first beaker are introduced 0.39 l of water with 0.25 l of zirconium nitrate ([ZrO ₂ ] = 288 g / l and d = 1.433) as well as 0.04 l of cerium nitrate ( [CeO ₂ ] = 246 g / l and d = 1.43). In a second beaker are introduced 76.6 ml of water, 4.1 ml of lanthanum nitrate ([La ₂ O ₃ ] = 471 g / l and d = 1.69), 29.4 ml of nitrate of yttrium ([Y ₂ O ₃ ] = 261 g / l and d = 1.488) and 9.9 ml of neodymium nitrate ([Nd ₂ O ₃ ] = 484 g / l and d = 1.74 and then 1, 1 ml of potassium methylsiliconate at 453 g / l in SiO _{2, and} the mixture is then added with distilled water so as to obtain 1 liter of nitrate solution.

The two solutions previously prepared are stirred constantly. The first solution of nitrates of cerium and zirconium is introduced into the stirred reactor at a speed of 500 rpm, the second nitrate solution is then introduced and stirring is set at 250 rpm.

The solution obtained is placed in a stainless steel autoclave equipped with a stirrer.

The procedure is then as in Example 1. EXAMPLE 6

This example concerns a composition with a high cerium content. The properties are as follows: 9.95% of zirconium, 79.6% of cerium, 2.985% of lanthanum, 6.965% of praseodymium and 0.5% of silica, these proportions being expressed as a percentage by weight of the ZrO ₂ , CeO oxides. ₂ , La ₂ O ₃ , Pr ₆ On and SiO ₂ .

In a stirred beaker, the necessary amount of zirconium nitrate (267 g / l in ZrO ₂ ), cerium nitrate at 249 g / l, lanthanum nitrate (469 g / l in La ₂ O ₃ ) and of praseodymium nitrate (500 g / l in Pr ₆ On) then 1 ml of potassium methylsiliconate at 453 g / l in S102. Then complete with distilled water so as to obtain 1 liter of a solution of nitrates.

The nitrate solution is introduced into the reactor with constant stirring.

The procedure is then as in Example 1.

COMPARATIVE EXAMPLE 7

This example relates to a composition containing 45% of zirconium, 45% of cerium, 5% of lanthanum and 5% of praseodymium, these proportions being expressed as a percentage by weight of the oxides ZrO 2, CeO ₂ , La ₂ O ₃ and Pr ₆ On.

In a stirred beaker, the required amount of the solutions of zirconium nitrate, cerium nitrate, lanthanum nitrate and praseodymium nitrate used for Example 1 are introduced. Then complete with distilled water so as to obtain 1 liter of a solution of nitrates.

The nitrate solution is introduced into the reactor with constant stirring.

The procedure is then as in Example 1. COMPARATIVE EXAMPLE 8

This example relates to a composition containing 75% zirconium, 10% cerium, 2% lanthanum 8% yttrium, 5% neodymium, these proportions being expressed as a percentage by weight of the oxides ZrO ₂ , CeO ₂ , La ₂ O 3, Y ₂ O 3 and Nd ₂ O ₃ .

In a stirred beaker, the necessary amount of the solutions of zirconium nitrate, cerium nitrate, lanthanum nitrate, neodymium nitrate and yttrium nitrate used for Example 4 are introduced. distilled water so as to obtain 1 liter of a solution of nitrates.

In a stirred reactor, a solution of ammonia (12 mol / l) is introduced and then complete with distilled water so as to obtain a volume of total of 1 liter and a stoichiometric excess of ammonia of 40% with respect to the nitrates to be precipitated.

The nitrate solution is introduced into the reactor with constant stirring.

The procedure is then as in Example 1.

EXAMPLE 9 COMPARATIVE

This example relates to a composition containing 10% zirconium, 80% cerium, 3% lanthanum and 7% praseodymium, these proportions being expressed in percentages by weight of the oxides ΖΓΟ ₂ , CeO ₂ , La ₂ O ₃ and Pr ₆ On.

In a stirred beaker, the required amount of zirconium nitrate (267 g / l ZrO ₂ ), cerium nitrate 249 g / l, lanthanum nitrate (469 g / l La ₂ O 3) and Praseodymium nitrate (500 g / l in Pr ₆ On). Then complete with distilled water so as to obtain 1 liter of a solution of nitrates.

The nitrate solution is introduced into the reactor with constant stirring.

The procedure is then as in Example 1.

Table 1 below gives the specific surfaces of the products of the examples.

Table 1

Surface (m ² / ç)) after

Example calcination 4 hours at

1000 ° C 1100 ° C

1 41 20

2 45 21

3 43 21

4 38 12

5 45 19

6 33 19

7 compare 49 27 8 comparative 51 23

9 comparative 30 19

Table 2 below gives the characteristics of reducibility of the products of the examples.

Table 2

The temperatures in columns Tmax and OSC are the temperatures at which the Tmax and OSC values were measured for 4 hours (1000 ° C) or 10 hours (1200 ° C).

The variation of OSC is the decrease of OSC measured on products calcined at 1000 ° C or at 1200 ° C.

It is observed that the products of the invention have Tmax and comparable OSC values after calcination at 1000 ° C to those of comparative products of similar compositions.

On the other hand, the comparative products see their Tmax vary in an amplitude of about 100 ° C between those calcined at 1000 ° C. and those calcined at 1200 ° C. whereas for the products of the invention this amplitude is at least about 170 ° C and may be greater than 200 ° C. The variation of the OSC is about 60% for the comparative products while it is at least 80% for the products of the invention.

Claims

1 - Composition based on zirconium oxide, cerium oxide and at least one oxide of a rare earth other than cerium, in a mass proportion of zirconium oxide of at least 5% and in cerium oxide of at most 90%, characterized in that it further comprises silicon oxide in an amount by mass of between 0, 1% and 2%. 2- Composition according to claim 1, characterized in that it comprises silicon oxide in an amount by mass of between 0, 1% and 1%.

3. Composition according to claim 1, characterized in that it comprises silicon oxide in a mass amount of between 0.1% and 0.6%.

4- Composition according to one of the preceding claims, characterized in that it has a cerium oxide content of between 30% and 60%. 5. Composition according to one of claims 1 to 3, characterized in that it has a cerium oxide content of between 5% and 20%.

6. Composition according to one of the preceding claims, characterized in that it has a content of rare earth oxides other than cerium between 5% and 25%.

7- Composition according to one of the preceding claims, characterized in that it has after calcination for 4 hours at 1000 ° C and then calcination for 10 hours at 1200 ° C a decrease in oxygen storage capacity (OSC) of at least 80%, more particularly at least 90%.

8- Composition according to one of the preceding claims, characterized in that for a cerium oxide content of between 30% and 60% it after calcination 4 hours at 1000 ° C a CSO of at least 0.6 ml 02 and for a cerium oxide content of between 5% and 15% or at least 70%, an OSC of at least 0.2 ml O 2 g. 9- Composition according to one of the preceding claims, characterized in that it after calcination for 4 hours at 1000 ° C and calcining for 10 hours at 1200 ° C an increase in its maximum reducibility temperature of at least 150 ° C.

10- Process for preparing a composition according to one of claims 1 to 9, characterized in that it comprises the following steps:

(c1) said precipitate is heated in a liquid medium;

- (e1) the product thus obtained is calcined.

1 1 - Process for the preparation of a composition according to one of claims 1 to 9, characterized in that it comprises the following steps:

(a2) forming a mixture comprising compounds of zirconium, cerium and at least one rare earth other than cerium;

- (c2) said precipitate is heated in a liquid medium;

- (d2) is added to the precipitate obtained in the preceding step a silicon compound;

(e2) adding to the product obtained in the preceding step an additive chosen from anionic surfactants, nonionic surfactants, polyethylene glycols, carboxylic acids and their salts and surfactants of the ethoxylate type of carboxymethylated fatty alcohols, the steps (d2) and (e2) possibly being performed at the same time;

(f2) the product thus obtained is calcined. 12- Process for preparing a composition according to one of claims 1 to 9, characterized in that it comprises the following steps: (a3) forming a mixture comprising compounds of zirconium, cerium, at least one rare earth other than cerium and optionally a silicon compound;

- (b3) said precipitate is heated in a liquid medium;

- (d3) is added to the product obtained in the preceding step an additive selected from anionic surfactants, nonionic surfactants, polyethylene glycols, carboxylic acids and their salts and surfactants of the ethoxylates type of carboxymethylated fatty alcohols. steps (d3) and (c3) possibly being performed at the same time;

(e3) the product thus obtained is calcined.

13- Process for preparing a composition according to one of claims 1 to 9, characterized in that it comprises the following steps:

- (b4) is brought, with stirring, said mixture with a basic compound;

(c4) the medium obtained in the preceding step is brought into contact, with stirring, with either the rare earth compound (s) other than cerium if this or these compounds were not present in step (a4) the remaining amount required of said one or more compounds, the stirring energy used in step (c4) being less than that used in step (b4), whereby a precipitate is obtained;

- (d4) said precipitate is heated in aqueous medium;

(f4) the precipitate thus obtained is calcined.

14- Method according to one of claims 10 to 13, characterized in that as compounds of zirconium, cerium and other rare earths a compound selected from nitrates, sulphates, acetates, chlorides, cerium-ammoniacal nitrate.

15- Method according to one of claims 10 to 14, characterized in that silicon compounds, an alkali silicate or a quaternary ammonium silicate are used as silicon compounds.

16- Method according to one of claims 10 to 15, characterized in that the heating of the precipitate of step (c1), (c2), (b3) or (d4) is carried out at a temperature of at least 100 ° C.

17- catalytic system, characterized in that it comprises a composition according to one of claims 1 to 9. 18- embedded diagnostic system characterized in that it comprises a composition according to one of claims 1 to 9.

19- The system of claim 18, characterized in that it further comprises a second composition which has after calcination 10 hours at 1150 ° C a OSC at least twice greater than that of the composition according to one of claims 1 at 9 after calcination under the same conditions.

20- Process for treating the exhaust gas of internal combustion engines, characterized in that a catalytic system according to Claim 17 or a composition according to one of Claims 1 to 9 is used as catalyst.