CN106799237A - 一种吸音汽车三元催化器催化剂 - Google Patents
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Abstract
本发明公开了一种吸音汽车三元催化器催化剂，其特征在于：使用泡沫镍作为载体，在泡沫镍载体上涂覆有Pd：Rh：Pd质量比为1:2‑4：1‑2的涂层，涂覆量为400‑700g/L。本发明的三元催化器催化剂使用泡沫镍作为载体，提高了吸音降噪性能；再负载纳米二氧化钛和纳米铈锆固溶体，表面积提高，提高了光催化性能，提高了废气处理效果。使用硝酸钯、硝酸铑对活性炭处理，能够保证催化还原氮氧化合物的高活性和贵金属活性组分的抗高温老化能力。
Description
技术领域
本发明涉及汽车三元催化器技术领域，尤其是一种吸音汽车三元催化器催化剂。
背景技术
汽车尾气的主要污染物是一氧化碳（CO）、碳氢化合物（HC）和氮氧化合物（NOx），利用安装在排气系统的催化剂可以将一氧化碳、碳氢化合物氧化成二氧化碳（CO2）、水（H2O），并同时使氮氧化合物还原为氮气（N2），实现尾气的净化，这种催化剂通常称为三元催化剂。三元催化剂由两部分组成：蜂窝状的陶瓷或金属载体，以及附着在载体上的催化剂涂层。催化剂涂层通常由具有较大比表面积的氧化物材料（如氧化铝）、储氧材料和分散在氧化物或储氧材料表面的贵金属活性组分（常为Pt（铂）、Pd（钯）、Rh（铑）中的一种或几种）组成。其中的储氧材料一般为含铈锆的复合氧化物，它通过吸附储存尾气中的氧或释放出氧来调节尾气中氧化性组分和还原性组分的比例，使一氧化碳和碳氢化合物被氧化的同时氮氧化合物被还原。为了提高汽车冷启动时污染物的转化效率，三元催化剂常被安装在靠近发动机排气歧管出口的位置，在汽车高速行驶时，三元催化剂的床层温度可达到900℃-1100℃的高温。
主要为了抑制高温条件下Rh 与Pd（或Pt）的合金化作用而使催化剂活性下降，目前的三元催化剂通常都采用双涂层结构，即附着在蜂窝载体上的下涂层担载Pd（或Pt），而附着在下涂层上的上涂层担载Rh，为了使催化剂有足够的储氧能力，通常在Rh 涂层有大量的储氧材料和一定量的氧化铝或氧化锆。虽然Rh 负载在储氧材料上可以使储氧能力大幅提高，也抑制了高温条件下Rh 与氧化铝的不利的相互作用，但是，储氧材料的储放氧功能使其负载的Rh 更容易处在氧化态，而氧化态的Rh 催化氮氧化合物还原的活性很低，即使是在发动机尾气由稀变浓的瞬态工况。为此，近年来有一些研究人员提出将Rh 负载在不含CeO2 或含极少量CeO2 的ZrO2 的复合氧化物上，显著提高了高温老化后Rh 催化还原氮氧化合物的活性，但是由于储氧能力的不足，瞬态工况的污染物排放很高，尤其是对尾气空燃比变化非常敏感的氮氧化合物排放。虽然可通过在下层Pd（或Pt）涂层增加储氧材料提高储氧能力，但是由于气体扩散距离对储氧能力的影响很大，储氧能力的提高是很有限的。此外，Pd（或Pt）涂层储氧材料过多也会导致高温富氧条件下更多的Rh 向下层迁移并与Pd（或Pt）发生相互作用而使催化剂活性下降。
单独使用铈锆固溶体作为载体，韧性不够，降噪性能不好，没有光电催化性能，对有害物质的降解作用有限，需要改进。
发明内容
本发明为了克服现有技术的不足，提供了以下技术方案：
一种吸音汽车三元催化器催化剂，使用泡沫镍作为载体，在泡沫镍载体上涂覆有Pd：Rh：Pd质量比为1:2-4：1-2的涂层，涂覆量为400-700g/L。
所述泡沫镍载体上负载了纳米二氧化钛和纳米铈锆固溶体。
泡沫镍载体负载纳米二氧化钛和纳米铈锆固溶体的制备方法为：按体积比钛酸丁酯：无水乙醇：浓硝酸：去离子水=40-42:120-130：1:3-3.5称料，在室温下将钛酸丁酯：无水乙醇按体积比40：80混合均匀成A液，将浓硝酸：无水乙醇：去离子水按体积比1:40:3混成B液，在搅拌条件下把B液滴到A液中，滴速为5-6s1滴，滴加完毕后搅拌1-1.5小时，再往混合溶液中加入活性炭，活性炭：钛的物质的量比为2：6-6.5，搅拌0.5-0.7小时，再加入纳米铈锆固溶体，纳米铈锆固溶体：钛的物质的量比为1：1-1.5，搅拌均匀，得到的胶体，将泡沫镍加工成型，在胶体中浸渍提拉，置于烘箱中在60-62℃烘烤10-12分钟，反复提拉至所需的厚度，在450-470℃下煅烧1-1.5小时，即得。
所述纳米铈锆固溶体的组份为：20-30wt% 的ZrO2、20-25wt% 的Al2O3、22-25wt%的CeO2、5-8wt%的TiO2和3-4wt%的NiO。
所述纳米铈锆固溶体还含有1-2wt%的纳米氧化铟锡。
在泡沫镍载体负载纳米二氧化钛和纳米铈锆固溶体的制备方法中，将活性炭在硝酸钯：硝酸铑重量比为14:1的溶液中浸泡，进行干燥处理。
本发明的优点是：本发明的三元催化器催化剂使用泡沫镍作为载体，提高了吸音降噪性能；再负载纳米二氧化钛和纳米铈锆固溶体，表面积提高，提高了光催化性能，提高了废气处理效果。使用硝酸钯、硝酸铑对活性炭处理，能够保证催化还原氮氧化合物的高活性和贵金属活性组分的抗高温老化能力。使用纳米氧化铟锡，提高了催化剂的隔热性，提高了抗高温老化性能。
具体实施方式
为更进一步阐述本发明所采取的技术手段及其效果，以下结合本发明的优选实例进行详细描述。
实施例1 ：一种吸音汽车三元催化器催化剂，使用泡沫镍作为载体，，泡沫镍的孔隙率≥95%，在泡沫镍载体上涂覆有Pd：Rh：Pd质量比为1:3：1的涂层，涂覆量为500g/L。
所述泡沫镍载体上负载了纳米二氧化钛和纳米铈锆固溶体。
泡沫镍载体负载纳米二氧化钛和纳米铈锆固溶体的制备方法为：按体积比钛酸丁酯：无水乙醇：浓硝酸：去离子水=40:120：1:3称料，在室温下将钛酸丁酯：无水乙醇按体积比40：80混合均匀成A液，将浓硝酸：无水乙醇：去离子水按体积比1:40:3混成B液，在搅拌条件下把B液滴到A液中，滴速为5s1滴，滴加完毕后搅拌1小时，再往混合溶液中加入活性炭，活性炭：钛的物质的量比为2：6，搅拌0.5小时，再加入纳米铈锆固溶体，纳米铈锆固溶体：钛的物质的量比为1：1，搅拌均匀，得到的胶体，将泡沫镍加工成型，在胶体中浸渍提拉，置于烘箱中在60℃烘烤10分钟，反复提拉至所需的厚度，在450℃下煅烧1小时，即得。
所述纳米铈锆固溶体的组份为：20wt% 的ZrO2、20wt% 的Al2O3、22wt% 的CeO2、5wt%的TiO2和3wt%的NiO。
所述纳米铈锆固溶体还含有1wt%的纳米氧化铟锡。
在泡沫镍载体负载纳米二氧化钛和纳米铈锆固溶体的制备方法中，将活性炭在硝酸钯：硝酸铑重量比为14:1的溶液中浸泡，进行干燥处理。
Claims (6)
1.一种吸音汽车三元催化器催化剂，其特征在于：使用泡沫镍作为载体，在泡沫镍载体上涂覆有Pd：Rh：Pd质量比为1:2-4：1-2的涂层，涂覆量为400-700g/L。
2. 根据权利要求1 所述的吸音汽车三元催化器催化剂，其特征在于：所述泡沫镍载体上负载了纳米二氧化钛和纳米铈锆固溶体。
3.根据权利要求2所述的吸音汽车三元催化器催化剂，其特征在于：泡沫镍载体负载纳米二氧化钛和纳米铈锆固溶体的制备方法为：按体积比钛酸丁酯：无水乙醇：浓硝酸：去离子水=40-42:120-130：1:3-3.5称料，在室温下将钛酸丁酯：无水乙醇按体积比40：80混合均匀成A液，将浓硝酸：无水乙醇：去离子水按体积比1:40:3混成B液，在搅拌条件下把B液滴到A液中，滴速为5-6s1滴，滴加完毕后搅拌1-1.5小时，再往混合溶液中加入活性炭，活性炭：钛的物质的量比为2：6-6.5，搅拌0.5-0.7小时，再加入纳米铈锆固溶体，纳米铈锆固溶体：钛的物质的量比为1：1-1.5，搅拌均匀，得到的胶体，将泡沫镍加工成型，在胶体中浸渍提拉，置于烘箱中在60-62℃烘烤10-12分钟，反复提拉至所需的厚度，在450-470℃下煅烧1-1.5小时，即得。
4. 根据权利要求2-3所述的吸音汽车三元催化器催化剂，其特征在于：所述纳米铈锆固溶体的组份为：20-30wt% 的ZrO2、20-25wt% 的Al2O3、22-25wt% 的CeO2、5-8wt%的TiO2和3-4wt%的NiO。
5.根据权利要求4所述的吸音汽车三元催化器催化剂，其特征在于：所述纳米铈锆固溶体还含有1-2wt%的纳米氧化铟锡。
6.根据权利要求2所述的吸音汽车三元催化器催化剂，其特征在于：在泡沫镍载体负载纳米二氧化钛和纳米铈锆固溶体的制备方法中，将活性炭在硝酸钯：硝酸铑重量比为14:1的溶液中浸泡，进行干燥处理。
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