CN1084102A - 催化剂载体 - Google Patents
催化剂载体 Download PDFInfo
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- CN1084102A CN1084102A CN93116707A CN93116707A CN1084102A CN 1084102 A CN1084102 A CN 1084102A CN 93116707 A CN93116707 A CN 93116707A CN 93116707 A CN93116707 A CN 93116707A CN 1084102 A CN1084102 A CN 1084102A
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- carrier
- catalyst
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- alumina
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- 239000003054 catalyst Substances 0.000 title claims abstract description 83
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 37
- 239000007789 gas Substances 0.000 claims description 52
- 239000000463 material Substances 0.000 claims description 22
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 11
- 239000001301 oxygen Substances 0.000 claims description 11
- 229910052760 oxygen Inorganic materials 0.000 claims description 11
- 239000011148 porous material Substances 0.000 claims description 11
- 229910052751 metal Inorganic materials 0.000 claims description 10
- 239000002184 metal Substances 0.000 claims description 10
- 238000012797 qualification Methods 0.000 claims description 9
- 239000003426 co-catalyst Substances 0.000 claims description 7
- 239000012535 impurity Substances 0.000 claims description 5
- 229910052684 Cerium Inorganic materials 0.000 claims description 3
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 claims description 3
- 229910000323 aluminium silicate Inorganic materials 0.000 claims description 3
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 claims description 3
- 229910052746 lanthanum Inorganic materials 0.000 claims description 3
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 claims description 3
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- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 claims description 2
- 229910052750 molybdenum Inorganic materials 0.000 claims description 2
- 239000011733 molybdenum Substances 0.000 claims description 2
- 229910052758 niobium Inorganic materials 0.000 claims description 2
- 239000010955 niobium Substances 0.000 claims description 2
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 claims description 2
- 230000000737 periodic effect Effects 0.000 claims description 2
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- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims 1
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- 229910052804 chromium Inorganic materials 0.000 claims 1
- 239000011651 chromium Substances 0.000 claims 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 claims 1
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- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 4
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 4
- 229910002091 carbon monoxide Inorganic materials 0.000 description 4
- 238000001125 extrusion Methods 0.000 description 4
- 238000009472 formulation Methods 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
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- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 2
- 238000003915 air pollution Methods 0.000 description 2
- 229910000287 alkaline earth metal oxide Inorganic materials 0.000 description 2
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- ZMIGMASIKSOYAM-UHFFFAOYSA-N cerium Chemical compound [Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce] ZMIGMASIKSOYAM-UHFFFAOYSA-N 0.000 description 2
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- 229920000098 polyolefin Polymers 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- RSWGJHLUYNHPMX-UHFFFAOYSA-N Abietic-Saeure Natural products C12CCC(C(C)C)=CC2=CCC2C1(C)CCCC2(C)C(O)=O RSWGJHLUYNHPMX-UHFFFAOYSA-N 0.000 description 1
- 235000009025 Carya illinoensis Nutrition 0.000 description 1
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- KHPCPRHQVVSZAH-HUOMCSJISA-N Rosin Natural products O(C/C=C/c1ccccc1)[C@H]1[C@H](O)[C@@H](O)[C@@H](O)[C@@H](CO)O1 KHPCPRHQVVSZAH-HUOMCSJISA-N 0.000 description 1
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- 230000009471 action Effects 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 239000000728 ammonium alginate Substances 0.000 description 1
- 235000010407 ammonium alginate Nutrition 0.000 description 1
- KPGABFJTMYCRHJ-YZOKENDUSA-N ammonium alginate Chemical compound [NH4+].[NH4+].O1[C@@H](C([O-])=O)[C@@H](OC)[C@H](O)[C@H](O)[C@@H]1O[C@@H]1[C@@H](C([O-])=O)O[C@@H](O)[C@@H](O)[C@H]1O KPGABFJTMYCRHJ-YZOKENDUSA-N 0.000 description 1
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- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 description 1
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- 229920003087 methylethyl cellulose Polymers 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 235000014571 nuts Nutrition 0.000 description 1
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical class CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 1
- 150000002894 organic compounds Chemical group 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- 239000005416 organic matter Substances 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 235000011837 pasties Nutrition 0.000 description 1
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- 229910052703 rhodium Inorganic materials 0.000 description 1
- 239000010948 rhodium Substances 0.000 description 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 1
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- KHPCPRHQVVSZAH-UHFFFAOYSA-N trans-cinnamyl beta-D-glucopyranoside Natural products OC1C(O)C(O)C(CO)OC1OCC=CC1=CC=CC=C1 KHPCPRHQVVSZAH-UHFFFAOYSA-N 0.000 description 1
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- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 1
- 235000020234 walnut Nutrition 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation 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
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/9445—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
- B01D53/945—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific catalyst
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
- B01J21/02—Boron or aluminium; Oxides or hydroxides thereof
- B01J21/04—Alumina
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/30—Catalysts, in general, characterised by their form or physical properties characterised by their physical properties
- B01J35/31—Density
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
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- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
- B01J35/61—Surface area
- B01J35/612—Surface area less than 10 m2/g
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
- B01J35/64—Pore diameter
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
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- B01J35/657—Pore diameter larger than 1000 nm
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
- B01J35/66—Pore distribution
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- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A50/00—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE in human health protection, e.g. against extreme weather
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- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
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- General Chemical & Material Sciences (AREA)
- Oil, Petroleum & Natural Gas (AREA)
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- Exhaust Gas Treatment By Means Of Catalyst (AREA)
Abstract
一种多孔的载体材料，它含有至少90％(重量)
的至少95％纯的α-氧化铝。它用作处理发动机排
气的催化剂的载体是十分有效的，并且能显著地比常
规载体更好地经受极端条件。
Description
本发明涉及能用于载持催化剂的催化剂载体，它能满足各种不同的用途，如处理来自烃类燃料燃烧或不完全燃烧产生的含有一氧化碳、烃类和氮的氧化物（NOx）的废气产物。
来自燃料燃烧的废气产物产生了严重的卫生和环境问题。从烃类燃料燃烧源，如电站发动机，工业锅炉，工业加工中释放的气体，导致了明显的空气污染，并且业已发现汽车内燃发动机所排出的气体是主要的空气污染源。近年来，由于我们道路上尤其是市区行驶的大量车辆，对于控制汽车排气产物的数量已不断引起关注。
含有排气催化剂的汽车催化转化器（converter）多少都能使汽车符合由政府部门制定的现行标准，将大量的烃类和一氧化碳转化成水和二氧化碳，将NOx气体转化成氮气及氧气和/或水。大量不同的金属和金属氧化物，或是单独或是组合，被载持于不同的基材上，已得到应用。近年来，大多数的排气催化剂已使用了稀有金属的组合，特别是铂，铑和/或钯，作为催化剂的活性物质。
典型地，排气催化剂含有一种相对低孔隙率的陶瓷载体，载持有一层具高表面积的过渡氧化铝涂层。下层的陶瓷载体的制备通常是通过高温烧结一模粘土或其它陶瓷材料以使其具有密度和强度。然而，这通常导致载体具有很低的表面积。因而，该陶瓷载体必须涂有其它具有大得多的表面积的材料以包容催化组分。在低表面积陶瓷载体上涂覆具有高表面积“洗气涂层”（washcoat）的步骤，正如通常所知的这些涂层，被揭示于例如美国专利2，742，437和3，824，196中。所提供的陶瓷载体可以是任何形态，但典型地它们是丸状或通常是整块的蜂窝型外形。
在这些排气催化剂中γ-氧化铝通常被用作洗气涂层。虽然γ-氧化铝洗气涂层使排气催化剂具有了相对高的表面积，它导致了一些不理想的后果。通常在强热压下该洗气涂层不能很好地粘附于下层的陶瓷载体上，或者与陶瓷载体具有一定程度不一致的热膨胀。另外，γ-氧化铝或过渡氧化铝洗气涂层是热力学上不稳定的氧化铝相。最终该不稳定的γ-氧化铝相转化成热力学上稳定的α-氧化铝相;然而，在转化的过程中，该氧化铝损失了表面积并将催化金属夹在其中而甚至可能改变它们的氧化态，使其减效或失效。
传统的涂有洗气涂层的排气催化剂也需要一个耗时，冗长，昂贵，多步骤的制备过程。该过程包括载体的制备，洗气涂层的制备，将洗气涂层施涂在载体上，以及分别地或集合地在载持着的洗气涂层上浸渍所有催化及助催化的组分。
虽然涂有洗气涂层的排气催化剂具有可以接受的初始点火（light-off）温度，但随着时间它们的点火温度通常上升，有时会很快。点火温度（“T50”）是指一种排气催化剂开始将50%排气废物转化成二氧化碳，水，氮气和氧气时的温度。因此，当汽车起动直到催化剂达到其点火温度的一段时间内，大多数排气未能得到催化处理而仅简单地排入大气。
稳定的催化活性正开始成为汽车排气催化剂的重要需求。传统的排气催化剂相对快地失去其约一半活性。即，在最初12，000英里使用期间。通常涂有洗气涂层的排气催化剂其实有形耗损。对含有排气催化剂的催化转化器所制定的新的政府标准具有严格得多的耐久要求，其中催化转化器必须在长得多的时间内，即50，000-100，000里的使用中有效地工作。
本发明的催化剂载体不需要洗气涂层。而且，一种多孔的，基本上为纯α-氧化铝载体得到使用，在其中催化组分能直接被浸渍。这些催化剂载体通常能使用比常规载体更少的催化剂，却能达到比已知催化剂更好的总的催化活性。本发明的载体也以一种简便而节俭的方式便于催化剂的再生，使其几乎所有可以回收并进一步再循环使用。
重要地，虽然该催化剂载体显示了与传统的涂有洗气涂层催化剂相似的初始点火温度，但在整个使用期间这些催化剂比涂有洗气涂层催化剂更稳定，并具有极好的高温强度及理想的高热冲击强度（无需考虑α-氧化铝相对于传统洗气涂层催化剂中用作载体的陶瓷而具有的更高的热膨胀性质）。因此，当将排气催化剂放于离排气源更近的地方。能得到改进的点火作用而无需耗损排气催化剂的长期作用。
本发明的载体是高纯度的α-氧化铝，即优选含有少于约5%（重量）杂质的α-氧化铝。载体中杂质的极低浓度导致了高温时稳定的催化活性，例如当在常规情况，尤其在瞬变工况下操作汽车催化转化器。
催化剂载体可用于氮氧化物气体的还原以及含有一氧化碳和烃类的氧化，例如，从内燃发动机或电站工业排放源中放出的气体。一种典型的排气催化剂包括多孔的，基本纯净的α-氧化铝载体，以及浸渍入载体中的催化有效量的稀有金属。
载体可以具不同外形;然而，优选整体材料，尤其是作为汽车催化转化器使用时。作为汽车催化转化器的整体载体可以是圆柱形，球形，正方形，卵形，跑道形或椭球形，按所需的最终用途而定。对于用于处理电站工业排放源的排气催化剂，可以使用丸形载体并将其装入一合适的催化室。挑选载体外形的一个基本考虑是在指定的催化室中所被使用的能力。
对于具有限定的气体通道的载体，例如，一种载体结构，其中排放气体直接穿过限定的通道而非围绕载体，通常优选使用大量的限定气体通道，同时使压降减至最小并且可供扩散进和出载体孔的可得到的表面积达到最大。因此，在大多数时候这种载体的至少约25%，优选40%，更优选60-70%的开放正面区域（即当载体使用时朝向气流的表面）含有限定气体通道。
通常，催化剂载体的开放的气室（cell）密度约为100-400气室/吋2（“cpi”），优选约200-400cpi。载体的开放正面面积越大，压降越低。然而，载体中的高几何表面积对增大废气产物与催化剂接触是理想的。因此，更高的开放气室密度结合有相对薄的壁是理想的。通常保持每个限定气体通道的最小横截直径大于约1.0毫米是理想的。通常，这些限定气体通道间的壁厚低于约5毫米，并且使用壁厚低于约3毫米，如0.2，0.4，1或2毫米，能得到有利的效果。
限定气体通道的横截面的外形可以是任何方便的形状。通常，可以使用方形，圆形，三角形，或六角形。一般优选限定气体通道是均一间隔的，从而增加流动，热产生和形状稳定性。限定气体通道的路径可以是直的，弯曲的，或如海棉结构中的扭曲状。对用于处理不含颗粒物质的排放气体的排气催化剂来说，笔直的限定气体通道是优选的。对于处理含有颗粒物质的排放气体，如来自柴油发动机，弯曲或扭曲的气体通道是优选的，以捕住颗粒物质而不显著地减少气相转化或增加压降。
载体的大小通常决定于其所设定起作用的催化器外壳大小。必须防止过量的排放气体绕过限定气体通道。因此，对于汽车排气催化剂，其载体是，例如，具有直径相当于一个典型汽车催化转化器外壳内径的圆柱体，例如约10-20厘米。该载体的长度能各不相同，对于汽车排气催化剂优选小于典型的市场有售的汽车催化转化器外壳的长度，即，约10-30厘米。
通常，本发明载体侧面（average side）及二端（end-on）平均挤压强度至少约10磅，优选20磅。更优选地，该载体的平均侧面和二端挤压强度在50-100磅范围内或更多。
丸形载体的磨损优选小于约每小时25%，更优选地，少于约每小时15%。
多孔的，基本上纯净的α-氧化铝载体优选具有下列特征。载体的孔隙率，（或总体孔体积），优选约0.2-0.6cm3/g载体;表面积约为0.2-10m2/g α-氧化铝载体，优选约0.3-4m2/g;载体中孔的平均孔径约0.1-100微米，大部分孔的大小在约0.1-10微米之间，优选的平均孔径为约0.2-5微米。
有时具有双峰孔分布是有利的，即，有一些细孔和一些粗孔，每种均有其很窄的大小范围。
多孔的α-氧化铝载体具有很高的纯度，即至少含约95%（重量）α-氧化铝，优选至少约98%（重量）α-氧化铝。杂质，特别是碱或碱土金属氧化物的硅酸盐和铝硅酸盐对排气催化剂是极有害的。这些杂质优选含有不超过约4%如不超过2%，最优选不超过载体的1%。
载体经常有利地含有氧助催化剂，其量高达约10%（重量）。这些化合物是本专业内已知的。它们有能力在富含氧的环境中进行氧化反应时可释放地存贮氧气，并在缺氧反应条件下将其放回。其作用在于消除在使用排气组合物时可能发生的任何组分的差异。典型的氧助催化剂化合物是周期表中ⅢA至ⅦA族金属和稀土金属的氧化物，如钛，钒，锰，锆，铌，钼，镧和铈。优选的氧助催化剂是镧和铈的氧化物。
本发明载体的制造是通过将粉末状的具有粒子大小约0.2-20优选约0.5-10微米的α-氧化铝，与氧助催化剂（如果存在），烧尽材料（burn-out）以及粘合剂一起混合直至煅烧结束。如果载体是以挤出方法生成，粘合剂是特别必需的。
烧尽材料的作用是在制成的催化剂中提供孔隙，在煅烧过程中被彻底除去。它因此倾向于是一种有机材料而能在低于载体形成时的灼烧温度下充分地烧光。适宜的材料包括焦炭，碳粉，石墨，粉末状的塑料如聚烯烃，聚苯乙烯，聚碳酸酯，以及天然物质如松香，锯屑，磨碎的果壳如胡桃，漆树坚果，美洲山核桃和欧洲榛。所提供烧尽剂的数量和颗粒大小依制成的载体的所需孔径而定。
粘合剂的作用是在燃烧前以及尤其在挤出过程中将组合物的材料聚在一起。它也增加了润滑性而有助于挤出。适宜的粘合剂包括氧化铝凝胶，如勃姆石，尤其当通过加酸而使其胶溶，它能经燃烧转化为α-氧化铝。其它粘合剂是有机化合物如纤维素类，如甲基-，乙基-，及羧乙基-纤维素类，有机硬脂酸酯类，蜡类，聚烯烃氧化物等。这些有机粘合剂通常也能如生成孔的烧尽材料同样起作用。
优选载体的整体成形，例如，是通过挤压模塑法，或用湿的载体原料饱和的瓦楞纸折合成一束的方法来制得的。将挤出的或湿成形的载体小心干燥以保持整体外形及结构并使整体材料与周围大气间的水气成分减至最小。将干燥后的整体材料在高达约1200-1600℃的温度下灼烧，优选约1300-1500℃，以除去可燃的有机物和结合氧化铝。灼烧的时间可以是约0.5-10小时。当然更常用的优选燃烧时间是5小时。
按理不需要洗涤，可以相信高纯度α-氧化铝载体的结构，即，孔径，孔隙率和表面积的特定结合，便于回收催化剂中所含的几乎所有的催化金属。因此，再生催化剂过程中高达95%的催化剂金属被回收。
下列实施例的提供，其目的仅在于说明本发明的具体实施方法，具体地说，是其在转化来自汽车内燃机的废气产物过程中的应用。不能认为这些实施例是对本发明范围的限制。
在此所用的各参数测定方法如下。“表面积”的测定是通过传统的B.E.T方法，由S.Brunauer等在J.Am.Chem，Soc.，60∶309-16（1938）中所述。
“孔体积”或“孔隙率”的测定是通过或者传统的水银孔隙率或水吸收技术，除了其他的说明，在此所用的是水吸收技术。“孔径和分布”的测定是通过C.Orr，Jr.在“Application of Mercury Penetration to Materials Analysis”，Powder Technoloqy，3：117-123（1970）一文中所述的方法而得到。
实施例1
按本发明制备一种催化剂载体。该载体用99.6%纯α-氧化铝制备并按实施例2所述的方法制成一整体结构。该载体的表面积为0.93m2/g，载体的孔体积为0.35cc/g，平均孔径为1.2微米。
将催化剂组合物沉积于载体中，在控制的温度下干燥此载持有催化剂的载体。即，在30-32℃置于高速流动的湿空气中（即含水）。开始干燥时，空气湿度约96%。随着干燥的进行，空气的相对湿度在8小时中缓慢地降至35%。然后，另外，将湿度保持在约35%6小时。控制湿度干燥后，将载体/催化剂组合在500℃空气中灼烧1小时。
将本发明的载持于载体上的催化剂用高温稳定的氧化铝纤维毡片包裹起来后放入一合适容器中，以提供一个汽车排气催化回气管。然后将其装在V-8，5.7升Chevrolet发动机上。
在催化剂插入及一些测试评估后，在500℃，测量该系统的起始工作状况。约80，000GHSV（气体时空速度）及+/-0.5A/F（空气对燃料比率），扫频14.2-15.4A/F。
然后将排气催化剂放在V-8，7.5升Ford发动机的排气装置中，以测试高温稳定性。通过在富油档（rich side）运转发动机并注入另外的空气，将催化剂的温度设定在1100℃，保持40分钟。然后从发动机中移去火花塞，使过量未燃烧的燃料和空气靠近催化剂以模拟汽缸内的点火不良，造成发动机温度达到约1200℃。将排气催化剂温度在约1100℃保持1分钟后测定催化剂载体。观察没有裂纹，结构破坏或熔毕区域。再次测量在相同V-8 Chevrolet发动机上催化剂/载体的转化率。
为了比较，在相同的条件下及在相同的发动机上测试由Honda Accord生产的市场有售的催化转化器。该载体具有在陶瓷基体上用γ-氧化铝洗气涂层表面的传统配方。催化剂/载体结构的总体积是81吋3，开放气室密度是300cpi。然而催化剂配方显著地含有比本发明载体上所沉积的催化组分中更多的稀有金属。
虽然市场有售的Honda催化剂具有比本发明载体上的催化剂稍好一些的最初转化性能，（烃，一氧化碳和NOx），但是高温测试后，在本发明载体上的催化剂的性能仅对烃类转化轻微受损，而对CO和NOx转化实际均有改进。与此形成对比的是Honda产品在对所有组分的转化率上均显著下降，而且由于熔化而显示出整体结构熔失的区域。
因此，本发明的α-氧化铝载体用作汽车的催化剂配方的载体是有效的，并显示了比本专业传统载体明显优异的高温稳定性。
实施例2
本实施例详述本发明的一种典型载体的制造。
将含有100份（重量）99.6%纯的平均粒径为3.5微米的α-氧化铝，5份（重量）胡桃壳粉末，2份（重量）Superloid，从Merck&Co.的Kelco分公司购得的一种海藻酸铵粘合剂，0.1份（重量）表面活性剂，及4.5份（重量）凡士林作为润滑剂，的一种配方物彻底混合以生成可挤出的糊状。（所有按重量的份数均以100份氧化铝为基准）。混合技术是将所有的组分除了凡士林外干混合，然后加入水，在加入凡士林前混合3分钟，再混合2-5分钟。加入足量的水使混合物可在至少1000KPa的挤出压力下从1/4吋模（die）中挤出。
在传统挤出机的挤出腔内装入上述糊状物，封闭挤出机并将腔内抽成真空。挤出开始的速度为约12吋/分钟，压力约1000psi，通过模制备具有多大量限定通道的整料。将该整料挤出在一载体上并在控制温度下干燥，开始时为96%R.H.，8小时后减至40%R.H.。相对湿度在40%保持6小时。对每克载体（终重量）脱水的速度为约0.1克/小时。
可使用的微波干燥程序是高频5分钟，接着冷却1分钟，再高频10分钟接着冷却1分钟，最后高频15分钟处理。
然后将干燥后的整料放在烧箱上的支持床上。升温速率为28℃/小时，高达1343℃后保持该温度水平5小时。
制成的产物具有表观孔隙率56.2%，吸水率32.5%，表观比重3.95，粒子密度1.73g/cc，表面积0.93m2/g，孔隙率0.35cc/g，平均孔径1.2微米。
Claims (16)
1、一种催化剂载体，其特征在于：它包括至少90%(重量)的至少95%纯的α-氧化铝，和约10%(重量)氧助催化剂，载体的孔隙率为约0.2-0.6厘米3/克载体，表面积为约0.2-10米2/克，平均孔径为约0.1-100微米。
2、如权利要求1所述的催化剂载体，其特征在于：其中，所存在的硅酸盐和铝硅酸盐的量低于2%（重量）。
3、如权利要求1所述的催化剂载体，其特征在于：其中，所存在的氧助催化剂的量为约1-5%（重量）。
4、如权利要求1所述的催化剂载体，其特征在于：其中，氧助催化剂是选自铈，钼，钒，锰，铬，钛，镧，铌，锆和稀土金属的一种金属。
5、如权利要求1所述的催化剂载体，其特征在于：它是具有限定气体通道的整料。
6、如权利要求5所述的催化剂载体，其特征在于：其中，该结构的开放气室密度是约100-400气室/平方英寸。
7、如权利要求5所述的催化剂载体，其特征在于：其中，整料包含一个具有限定气体通道开放正面区域，这些气体通道含有至少约25%的开放正面区域。
8、如权利要求5所述的催化剂载体，其特征在于：其中，限定气体通道的最小横截面直径大于约1毫米。
9、如权利要求5所述的催化剂载体，其特征在于，其中，相邻二个限定气体通道的壁厚少于5毫米。
10、如权利要求5所述的催化剂载体，其特征在于，其中，整料具有侧面及二端平均挤压强度为至少20磅。
11、如权利要求1所述的催化剂载体，其特征在于：其中，载体以丸形颗粒形式存在。
12、如权利要求11所述的催化剂载体，其特征在于：其中，该载体具有的抗磨耗性低于每小时25%。
13、一种整料的催化剂载体，其特征在于：其中，它具有限定气体通道，并含有至少95%（重量）α-氧化铝，1-5%（重量）氧助催化剂，它是选自稀土金属和元素周期表ⅣA、ⅤA、ⅥA和ⅦA族的金属的氧化物的一种氧化物，以及低于2%的硅酸盐和/或铝硅酸盐杂质;所述的整料具有孔隙率约0.3-0.5厘米3/克载体，表面积约0.3-4米2/克，平均孔径约0.2-5微米。
14、如权利要求13所述的催化剂载体，其特征在于：其中，它含有一个开放正面区域，其中至少约40%开放正面区域由限定气体通道提供。
15、如权利要求13所述的催化剂载体，其特征在于：其中开放气室密度为约200-400气室/平方英寸，相邻二个限定气体通道的壁厚低于3mm。
16、如权利要求13所述的催化剂载体，其特征在于：其中氧化铝组分是至少98%纯的α-氧化铝。
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US07/937,257 | 1992-08-31 | ||
| US07/937,257 US5266548A (en) | 1992-08-31 | 1992-08-31 | Catalyst carrier |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1084102A true CN1084102A (zh) | 1994-03-23 |
| CN1050530C CN1050530C (zh) | 2000-03-22 |
Family
ID=25469693
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN93116707A Expired - Fee Related CN1050530C (zh) | 1992-08-31 | 1993-08-31 | 催化剂载体 |
Country Status (10)
| Country | Link |
|---|---|
| US (1) | US5266548A (zh) |
| EP (1) | EP0585879B1 (zh) |
| JP (1) | JPH06154599A (zh) |
| KR (1) | KR100254868B1 (zh) |
| CN (1) | CN1050530C (zh) |
| AU (1) | AU655114B2 (zh) |
| CA (1) | CA2101955C (zh) |
| DE (1) | DE69324201T2 (zh) |
| ES (1) | ES2129056T3 (zh) |
| RU (1) | RU2111789C1 (zh) |
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| CN104324935A (zh) * | 2014-10-09 | 2015-02-04 | 四川农业大学 | 一种利用生物质材料分别淋洗去除污染土壤中镧和铈的方法 |
| CN104981430A (zh) * | 2013-02-07 | 2015-10-14 | 科学设计公司 | 用于基于银的环氧乙烷催化剂的改性载体 |
| CN108291484A (zh) * | 2015-11-20 | 2018-07-17 | 麦克鄂斯控股有限公司 | 分层充气燃烧发动机 |
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- 1992-08-31 US US07/937,257 patent/US5266548A/en not_active Expired - Lifetime
-
1993
- 1993-08-04 AU AU44424/93A patent/AU655114B2/en not_active Ceased
- 1993-08-05 CA CA002101955A patent/CA2101955C/en not_active Expired - Fee Related
- 1993-08-27 RU RU93044908A patent/RU2111789C1/ru not_active IP Right Cessation
- 1993-08-30 KR KR1019930016965A patent/KR100254868B1/ko not_active IP Right Cessation
- 1993-08-30 JP JP5214405A patent/JPH06154599A/ja active Pending
- 1993-08-31 ES ES93113912T patent/ES2129056T3/es not_active Expired - Lifetime
- 1993-08-31 EP EP93113912A patent/EP0585879B1/en not_active Expired - Lifetime
- 1993-08-31 DE DE69324201T patent/DE69324201T2/de not_active Expired - Fee Related
- 1993-08-31 CN CN93116707A patent/CN1050530C/zh not_active Expired - Fee Related
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101193699B (zh) * | 2005-06-07 | 2012-11-28 | 圣戈本陶瓷及塑料股份有限公司 | 催化剂载体以及用来制备该催化剂载体的方法 |
| CN104981430A (zh) * | 2013-02-07 | 2015-10-14 | 科学设计公司 | 用于基于银的环氧乙烷催化剂的改性载体 |
| CN104981430B (zh) * | 2013-02-07 | 2018-02-06 | 科学设计公司 | 用于基于银的环氧乙烷催化剂的改性载体 |
| CN104324935A (zh) * | 2014-10-09 | 2015-02-04 | 四川农业大学 | 一种利用生物质材料分别淋洗去除污染土壤中镧和铈的方法 |
| CN108291484A (zh) * | 2015-11-20 | 2018-07-17 | 麦克鄂斯控股有限公司 | 分层充气燃烧发动机 |
Also Published As
| Publication number | Publication date |
|---|---|
| CA2101955C (en) | 1998-02-24 |
| US5266548A (en) | 1993-11-30 |
| AU4442493A (en) | 1994-03-10 |
| DE69324201T2 (de) | 1999-11-25 |
| AU655114B2 (en) | 1994-12-01 |
| KR940003612A (ko) | 1994-03-12 |
| DE69324201D1 (de) | 1999-05-06 |
| JPH06154599A (ja) | 1994-06-03 |
| EP0585879A1 (en) | 1994-03-09 |
| CN1050530C (zh) | 2000-03-22 |
| EP0585879B1 (en) | 1999-03-31 |
| CA2101955A1 (en) | 1994-03-01 |
| RU2111789C1 (ru) | 1998-05-27 |
| ES2129056T3 (es) | 1999-06-01 |
| KR100254868B1 (ko) | 2000-05-01 |
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