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Current NOx emission reduction systems, selective catalytic reduction (SCR) and NOx storage and reduction (NSR), function well after achieving their operation temperature (typically ca. 250 °C) but have unsatisfactory NOx conversion at lower exhaust temperatures encountered during cold start and low load operation. The reduced exhaust temperature of advanced diesel engines with higher fuel efficiency challenges the low-T NOx reduction. We report here a new concept of high low-T deNOx efficiency of up to 80% at a feed temperature of ca. 200 °C at relevant space velocities (70k h−1). It utilizes high-frequency hydrocarbon pulsing on a dual-layer LNT-SCR monolithic catalyst under lean conditions. This system has the potential to expand the operating temperature window of the conventional deNOx devices.

Monolithic catalysts consisting of a layer of SCR catalyst deposited on top of a LNT catalyst were optimized to provide high NOx conversion at both low and high temperatures with minimal precious group metal (PGM) loading for effective diesel NOx emission control. In this study we demonstrate the application of LNT & SCR zoning in dual-layer catalyst to improve NOx reduction efficiency and show the potential to reduce the expensive PGM loading by up to 40% from that of LNT only catalyst without degrading its deNOx performance under simulated diesel exhaust conditions. We investigated the NOx reduction pathway in the SCR layer of the dual-layer catalyst using simulated rich exhaust of C3H6/CO/H2 as reductants. The non-NH3 reduction pathway by N-containing organic intermediates via the synergy of LNT and SCR catalysts can play a major role in the incremental NOx conversion over SCR layer at low temperatures (<= 225 °C).