CA2563802A1 - Nonwoven composites and related products and methods - Google Patents

Nonwoven composites and related products and methods Download PDF

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Publication number
CA2563802A1
CA2563802A1 CA002563802A CA2563802A CA2563802A1 CA 2563802 A1 CA2563802 A1 CA 2563802A1 CA 002563802 A CA002563802 A CA 002563802A CA 2563802 A CA2563802 A CA 2563802A CA 2563802 A1 CA2563802 A1 CA 2563802A1
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CA
Canada
Prior art keywords
substrate
catalytic
catalytic substrate
fibers
alumina
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002563802A
Other languages
French (fr)
Other versions
CA2563802C (en
Inventor
Gordon S. Alward
Robert A. Dichiara, Jr.
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
GEO2 Technologies Inc
Original Assignee
Geo2 Technologies, Inc.
Gordon S. Alward
Robert A. Dichiara, Jr.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Geo2 Technologies, Inc., Gordon S. Alward, Robert A. Dichiara, Jr. filed Critical Geo2 Technologies, Inc.
Publication of CA2563802A1 publication Critical patent/CA2563802A1/en
Application granted granted Critical
Publication of CA2563802C publication Critical patent/CA2563802C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/12Silica and alumina
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D39/00Filtering material for liquid or gaseous fluids
    • B01D39/14Other self-supporting filtering material ; Other filtering material
    • B01D39/20Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2068Other inorganic materials, e.g. ceramics
    • B01D39/2082Other inorganic materials, e.g. ceramics the material being filamentary or fibrous
    • B01D39/2089Other inorganic materials, e.g. ceramics the material being filamentary or fibrous otherwise bonded, e.g. by resins
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D53/00Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/92Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/944Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B01J35/58
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02Impregnation, coating or precipitation
    • B01J37/0215Coating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2258/00Sources of waste gases
    • B01D2258/01Engine exhaust gases
    • B01D2258/012Diesel engines and lean burn gasoline engines
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00Structure of catalyst support or particle filter
    • F01N2330/06Ceramic, e.g. monoliths
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00Structure of catalyst support or particle filter
    • F01N2330/10Fibrous material, e.g. mineral or metallic wool
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00Structure of catalyst support or particle filter
    • F01N2330/10Fibrous material, e.g. mineral or metallic wool
    • F01N2330/101Fibrous material, e.g. mineral or metallic wool using binders, e.g. to form a permeable mat, paper or the like
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00Structure of catalyst support or particle filter
    • F01N2330/14Sintered material
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/10Internal combustion engine [ICE] based vehicles
    • Y02T10/12Improving ICE efficiencies

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Biomedical Technology (AREA)
  • Environmental & Geological Engineering (AREA)
  • Analytical Chemistry (AREA)
  • Combustion & Propulsion (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Health & Medical Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Geology (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Catalysts (AREA)
  • Porous Artificial Stone Or Porous Ceramic Products (AREA)
  • Filtering Materials (AREA)

Abstract

The present invention in certain embodiments is directed to a catalytic substrate suitable for use in a number of applications, including as a substrate in a catalytic converter. Another aspect of the present invention is a filtering substrate suitable for use in a number of applications, including as a substrate in a particulate filter, such as a diesel particulate filter (DPF), or diesel particulate trap (DPT). The invention also provides an improved substrate for removing and/or eliminating pollutants from the exhaust of combustion engines. The catalytic substrate and filtering substrate provide, in certain embodiments, improvements in removing pollutants from an exhaust gas. The improvements include one or more of the following: faster light-off period, depth filtration of PM, less backpressure, lower probability of clogging, ability to be placed in multiple locations in the exhaust system including the manifold or the head itself, high probability of catalytic reaction, high conversion ratios of NOx, HC, and CO, a faster burnoff of PM, minimization of catalyst material use, and the like.

Claims (47)

1. A catalytic or filtering substrate comprising a non-woven sintered refractory fibrous ceramic composite and a catalyst, optionally further comprising a washcoat, and optionally further comprising a plurality of channels.
2. The catalytic substrate of claim 1, wherein said composite comprises alumina-boria-silica fibers.
3. The catalytic substrate of claim 1, wherein said composite comprises alumina-zirconia fibers.
4. The catalytic substrate of claim 1, wherein said composite comprises alumina-boria-silica fibers and alumina fibers.
5. The catalytic substrate of claim 1, wherein said composite comprises alumina-oxide fibers.
6. The catalytic substrate of claim 1, wherein said composite comprises silica-oxide fibers.
7. The catalytic substrate of claim 1, wherein said composite comprises aluminaboriasilica fibers, silica fibers, and alumina fibers.
8. The catalytic substrate of claim 1, wherein said composite comprises from about 50 to about 90% silica, from about 5 to about 50%
alumina, and from about 10 to about 25% aluminoborosilicate.
9. The catalytic substrate of claim 1, wherein said composite is a alumina enhanced thermal barrier (AETB) composite.
10. The catalytic substrate of claim 9, where said AETB is selected from the group consisting of AETB-8, AETB-12, and AETB-14, and
11. The catalytic substrate of claim 1, wherein said composite comprises an Orbital Ceramics Thermal Barrier (OCTB) composite.
12. The catalytic substrate of any of claims 1-11, wherein said composite comprises a boron binder.
13. The catalytic substrate of any of claims 1-12, wherein said catalyst comprises a metal catalyst.
14. The catalytic substrate of any of claims 1-13, wherein said catalyst is selected from the group consisting of palladium, platinum, rhodium, mixtures thereof, and derivatives thereof.
15. The catalytic substrate of any of claims 1-14, further wherein said catalyst is present in an amount of about 1 to about 50 g/ft3.
16. The catalytic substrate of any of claims 1-15, wherein said washcoat comprises alumina oxide.
17. The catalytic substrate of any of claims 1-16, comprising a plurality of channels extending longitudinally through the substrate, and wherein said substrate comprises a wall flow configuration, a flow through configuration, or a combination thereof.
18. The catalytic substrate of any of claims 1-17, having about 100 to about 100,000 channels per square inch.
19. The catalytic substrate of any of claims 1-18, having about 600 channels per square inch.
20. The catalytic substrate of any of claims 1-19 wherein said channels comprise a square, triangular, hexagonal shape, and further have a longitudinal cross-sectional area shape of substantially rectangular, trapezoidal, or triangular.
21. The catalytic substrate of any of claims 1-20 having frontal surface area of about 1 square inch to about 50 square inches.
22. The catalytic substrate of any of claims 1-21 suitable for use in a commercially available catalytic converter or diesel oxidation catalyst (DOC).
23. The catalytic substrate of any of claims 1-21 suitable for use with a stationary engine.
24. The catalytic substrate of any of claims 1-21 suitable for use in a head-cat, mani-cat, or pre-cat.
25. The catalytic substrate of any of claims 1-21 having a density of about 6 to about 16 lb/ft3.
26. The catalytic substrate of any of claims 1-25 wherein said substrate has an emissivity of about 0.8 to about 0.95.
27. The catalytic substrate of any of claims 1-26 wherein said substrate has a porosity of about 90% to about 99%.
28. The catalytic substrate of any of claims 1-27 further comprising an oxygen storing oxide.
29. The catalytic substrate of any of claims 1-28, wherein said substrate produces a pressure drop less than a pressure drop produced by cordierite.
30. A catalytic converter comprising a catalytic substrate of any of claims 1-29.
31. The catalytic converter of claim 30, wherein said converter is suitable for use on a commercial automobile.
32. The catalytic converter of claim 31, wherein said converter is selected from the group consisting of a main cat, a pre-cat, a back-cat, or a mani-cat.
33. A particulate filter comprising a catalytic substrate or filtering substrate of any of claims 1-29.
34. The particulate filter of claim 33 wherein said filter is a diesel particulate filter.
35. A method of catalyzing a reaction, comprising exposing flow of one or more fluids to a catalytic substrate or catalytic converter of any one of claims 1-32.
36. The method according to claim 35 wherein said fluid is an exhaust gas from an internal combustion engine.
37. The method according to claim 36, wherein said exhaust gas comprises one or more the six criteria pollutants.
38. A method of filtering a gas, comprising exposing a flow of one or more fluids to a filtering substrate, catalytic substrate, particulate filter, or catalytic converter of any of claims 1-34.
39. The method according to claim 38 wherein said fluid is an exhaust gas from an internal combustion engine.
40. The method according to claim 39, wherein said exhaust gas comprises one or more the six criteria pollutants.
41. A process of preparing a catalytic or filtering substrate according to any one of claims 1-29, comprising heating a plurality of refractory silica fibers, refractory alumina fibers, and refractory aluminoborosilicate fibers; mixing said fibers; washing said fibers;optionally chopping said fibers to one or more lengths; blending or mixing the chopped fibers into a slurry; adjusting the viscosity of said slurry, preferably by adding thickening agent; adding a dispersant; adding the slurry to a mold; removing water the slurry to form a green billet; removing the green billet from the mold; drying the green billet in oven, preferably drying at a temperature of about 250 °F to about 500 °F; heating, preferably prewarming and incrementally heating, the green billet in an oven at approximately 2000-2500°
F; optionally machining said billet; optionally forming a plurality of channels in said billet; optionally adding a catalyst; and optionally adding a washcoat to form said substrate
42. A process of preparing a filtering substrate according to any of claims 1-29, comprising machining a plurality of channels in a non-woven sintered refractory fibrous ceramic composite, wherein said machining comprises using a combing method to form or shape said channels.
43. A filtering substrate prepared according to the process of claim 42 or 43.
44. A composition comprising refractory grade alumina fibers, refractory grade silica fibers, refractory grade aluminaboriasilica fibers, water, and a catalyst.
45. A composition of claim 44 wherein said fibers had an average length of about 10 microns.
46. A composition of claim 44 wherein said alumina will comprise approximately 50 90 percent of the inorganic fiber mix; the alumina fiber will comprise approximately 5-50 percent of the inorganic fiber mix; and the aluminaboriasilica will comprise approximately 10-25 percent.
47. An improved engine exhaust system, the improvement comprising a catalytic substrate, a filtering substrate, a catalytic converter, or a particulate filter of any of claims 1-34.
CA2563802A 2004-04-28 2004-04-28 Nonwoven composites and related products and methods Expired - Fee Related CA2563802C (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2004/012963 WO2005113126A1 (en) 2004-04-28 2004-04-28 Nonwoven composites and related products and methods

Publications (2)

Publication Number Publication Date
CA2563802A1 true CA2563802A1 (en) 2005-12-01
CA2563802C CA2563802C (en) 2011-01-04

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ID=35428280

Family Applications (1)

Application Number Title Priority Date Filing Date
CA2563802A Expired - Fee Related CA2563802C (en) 2004-04-28 2004-04-28 Nonwoven composites and related products and methods

Country Status (9)

Country Link
EP (1) EP1740300A4 (en)
JP (1) JP5028257B2 (en)
KR (1) KR101152320B1 (en)
CN (1) CN1976749B (en)
AU (1) AU2004319871B2 (en)
BR (1) BRPI0418706A (en)
CA (1) CA2563802C (en)
MX (1) MXPA06012525A (en)
WO (1) WO2005113126A1 (en)

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Also Published As

Publication number Publication date
CA2563802C (en) 2011-01-04
MXPA06012525A (en) 2006-12-15
KR101152320B1 (en) 2012-06-13
KR20070021204A (en) 2007-02-22
EP1740300A4 (en) 2012-04-18
WO2005113126A1 (en) 2005-12-01
JP5028257B2 (en) 2012-09-19
AU2004319871B2 (en) 2010-04-22
BRPI0418706A (en) 2007-09-11
CN1976749A (en) 2007-06-06
CN1976749B (en) 2012-05-30
EP1740300A1 (en) 2007-01-10
AU2004319871A1 (en) 2005-12-01
JP2007534483A (en) 2007-11-29

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