CN108778504A - 基于非织造纤维材料的蜂窝催化剂的制备方法 - Google Patents

基于非织造纤维材料的蜂窝催化剂的制备方法 Download PDF

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CN108778504A
CN108778504A CN201780015713.7A CN201780015713A CN108778504A CN 108778504 A CN108778504 A CN 108778504A CN 201780015713 A CN201780015713 A CN 201780015713A CN 108778504 A CN108778504 A CN 108778504A
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substrate
washcoat
precoating
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C·S·约恩森
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Abstract

本发明公开了用于制备蜂窝催化剂的方法，所述方法包括以下步骤：预涂覆非织造纤维片材，使所述纤维片形成波纹并卷起或堆叠所述形成波纹的片材以形成蜂窝主体。随后将所述蜂窝主体进行修补基面涂覆，包括添加至少一种催化活性化合物。

Description

基于非织造纤维材料的蜂窝催化剂的制备方法
本发明涉及制备由波纹状基底形成的蜂窝形催化剂的方法，所述波纹状基底由非织造纤维材料组成。
具体地讲，本发明提供了由非织造纤维材料的波纹状片材制备的改善的蜂窝形催化剂，其优选地具有平坦内衬。
已发现，当在纤维材料形成波纹或成形为波纹状片材之前，利用预涂覆层涂覆所述材料时，可由非织造纤维材料(例如E玻璃纤维)作为原料制成稳定的蜂窝形催化剂。成形方法可包括预涂覆的纤维材料的加热和/或加湿。预涂覆层以陶瓷材料的水性悬浮液形式施加。
还已经发现当以一定量在基底上施加预涂层，从而导致介于60-120g/m2之间的基底和涂层的总重量时，导致纸材的改善的稳定性和硬度，使得在起皱工艺中形成的波在最终蜂窝催化剂产品的后续成形阶段和蜂窝催化剂产品的操作中基本上保持其形状。
根据上述发现，本发明提供了一种制备蜂窝催化剂的方法，所述方法包括以下步骤：
(a)提供呈非织造纤维材料的一个或多个片材形式的基底；
(b)用包含陶瓷材料和一种或多种粘合剂的水性预涂覆悬浮液以一定量预涂覆所述基底，从而导致介于60和120g/m2之间的所述基底和第一涂层的总重量；
(c)使预涂覆的基底形成波纹；
(d)将预涂覆的和形成波纹的基底卷起或堆叠成螺旋卷绕的圆柱形主体或铆接的矩形主体；
(e)利用催化剂载体修补基面涂料将步骤(d)的圆柱形或矩形主体进行修补基面涂覆，所述催化剂载体修补基面涂料包含一种或多种催化活性组分或其前体；并且
(f)干燥并任选地煅烧步骤(e)的经修补基面涂覆的主体；或另选地
(g)用催化剂载体修补基面涂料将步骤(d)的圆柱形或矩形主体进行修补基面涂覆，并用一种或多种催化活性组分或其前体的溶液浸渍所述经修补基面涂覆的主体；并且
(h)干燥并煅烧步骤(g)的经修补基面涂覆的主体。
优选地，在步骤(d)之前，步骤(c)的预涂覆和形成波纹的基底具有平坦内衬。
在本发明的此类实施方案中，在设置于所述形成波纹和预涂覆的基底上之前，所述平坦内衬以一定量预涂覆有所述水性预涂覆悬浮液，从而导致介于60和120g/m2之间的所述内衬和预涂层的总重量。
目前，优选包括玻璃纤维在内的非织造纤维材料。
在水性预涂层悬浮液中使用的优选陶瓷材料
包含高岭土、粘土材料、硅酸镁铝、球形粘土或膨润土中的至少一种。
用于预涂层材料中的粘合剂和增塑剂包括一种或多种聚合物化合物，诸如聚乙酸乙烯酯、聚乙烯醇、聚丙烯酸酯、纤维素醚、多糖、聚乙二醇、天然树胶如黄原胶和阿拉伯树胶。
用于预涂层中的粘合剂改善了起皱工艺中基底的可塑性、成形能力和形状稳定性，并且同时使预涂覆和形成波纹的基底对用于后续涂覆催化剂载体修补基面涂料的有机溶剂具有抗性。
优选的预涂覆悬浮液包含悬浮于水中的高岭土和乙酸乙烯酯，其中总固体含量为15-60重量％。
所述预涂层可施用于片材的一侧上或一个或多个片材的两侧上和任选的内衬上。
在这两种涂覆方法中，预涂层浆液渗透一个或多个片材。
蜂窝主体通过将多个预涂覆和形成波纹的片材堆叠，或通过将单个预涂覆和形成波纹的片材(优选衬有平坦内衬)卷起成矩形或圆柱形蜂窝主体来形成。
在每种情况下，形成的蜂窝主体具有多个由波纹状片材的波形成的平行流通式通道和施用于波纹状片材上的任选内衬。
随后用包含催化剂载体材料的修补基面涂料对由此形成的蜂窝主体进行修补基面涂覆。
所述催化剂载体材料选自氧化铝、二氧化钛、二氧化硅、以及它们的混合物中的至少一种。优选地，所述载体修补基面涂料包含二氧化钛。
所述催化剂载体修补基面涂料优选包含一种或多种有机溶剂，优选地包含丁醇、异丁醇、乙醇、丙醇、异丙醇和芳族溶剂。
蜂窝主体的修补基面涂覆通常通过将修补基面涂料浆液倒入蜂窝主体的通道中，或通过将主体在一侧处浸入修补基面涂料浆液中并且任选地在相对侧处施加真空，在预涂覆有第一涂层的蜂窝主体中浆液拾取来进行。
存在两种合适的催化蜂窝主体的方法。
在一种方法中，所述修补基面涂料包含催化活性材料。
在另一种方法中，最终利用包含期望的催化活性材料的一种或多种前体的水溶液浸渍预涂覆和修补基面涂覆的蜂窝主体，之后进行干燥和煅烧。
蜂窝催化剂通常用于清洁发动机废气。出于该目的，将蜂窝催化剂成形为圆柱形主体，并且罐装在金属外壳中，在所述蜂窝催化剂主体和所述金属外壳之间具有垫。在罐装过程中，圆柱形蜂窝主体被径向压缩，以便在垫和主体之间以及垫和金属外壳之间提供足够的摩擦。径向压缩通常导致经涂覆和煅烧的主体中的裂纹。因此，在基底上提供的预涂层的另一个优点在于罐装过程导致蜂窝主体的裂纹大大减少。
如上文所述，罐装蜂窝催化剂通常用于催化移除废气中的有毒化合物，包括氮氧化物、未燃烧的发动机燃料和一氧化碳。
因此，优选的是，蜂窝催化剂的催化活性化合物在移除发动机废气中的有毒化合物时具有活性。
催化剂化合物在发动机废气清洁中具有活性本身是本领域已知的。仅举几个例子，通常使用的催化剂为单独使用或作为其混合物使用的氧化钒、氧化钨、钯和铂、以及沸石材料。
当在移除废气或尾气中包含的氮氧化物中操作蜂窝形催化剂时，在SCR催化剂的存在下，通过选择性催化还原，利用还原剂(通常为氨)将氮氧化物转化为游离氮：
4NO+4NH3+O2→4N2+6H2O
NO+NO2+2NH3→2N2+3H2O
已知的SCR催化剂组合物中的任一种均将适用于本发明。
附图的图1为根据本发明的蜂窝催化剂的截面图。
如图1所示，根据本发明的蜂窝催化剂的基底1由非织造纤维材料基底的波纹状片材2组成，其任选地具有内衬(未示出)。基底1可卷起成圆柱形主体。
将由陶瓷材料制成的预涂覆涂层3涂覆在片材2上。预涂覆材料还可扩散通过片材2的纤维材料并在片材2的两侧上和在纤维材料内形成预涂层，如图1所示。将修补基面涂层4涂覆在预涂层3上。修补基面涂层4包含催化剂颗粒5。催化剂颗粒5另外可存在于预涂层3中(图中未示出)。

Claims (13)

1.用于制备蜂窝催化剂的方法，包括以下步骤：
(a)提供呈非织造纤维材料的一个或多个片材形式的基底；
(b)用包含陶瓷材料和一种或多种粘合剂的水性预涂覆悬浮液以一定量预涂覆所述基底，从而导致介于60g/m2和120g/m2之间的所述基底和预涂层的总重量；
(c)使预涂覆的基底形成波纹；
(d)将预涂覆和形成波纹的基底卷起或堆叠成螺旋卷绕的圆柱形主体或铆接的矩形主体；
(e)利用催化剂载体修补基面涂料将步骤(d)的圆柱形或矩形主体进行修补基面涂覆，所述催化剂载体修补基面涂料包含一种或多种催化活性组分或其前体；以及
(f)干燥并任选地煅烧步骤(e)的经修补基面涂覆的主体；或另选地
(g)用催化剂载体修补基面涂料将步骤(d)的圆柱形或矩形主体进行修补基面涂覆，并且用一种或多种催化活性组分或其前体的溶液浸渍所述经修补基面涂覆的主体；以及
(h)干燥并煅烧步骤(g)的经修补基面涂覆的主体。
2.根据权利要求1所述的方法，其中所述非织造纤维材料包括玻璃纤维。
3.根据权利要求1或2所述的方法，其中所述水性预涂覆悬浮液中的陶瓷材料包含高岭土、粘土材料、硅酸镁铝、球形粘土或膨润土中的至少一种。
4.根据权利要求1至3中任一项所述的方法，其中所述水性预涂覆悬浮液中的一种或多种粘合剂还包含一种或多种聚合物化合物、聚乙酸乙烯酯、聚乙烯醇、聚丙烯酸酯、纤维素醚、多糖、聚乙二醇、天然树胶、黄原胶和阿拉伯树胶。
5.根据权利要求1或2所述的方法，其中所述水性预涂覆悬浮液包含悬浮于水中的高岭土和乙酸乙烯酯，其中总固体含量为15重量％-60重量％。
6.根据权利要求1至5中任一项所述的方法，其中所述催化剂载体包含氧化铝、二氧化钛、二氧化硅、以及它们的混合物中的至少一种。
7.根据权利要求6所述的方法，其中所述催化剂载体包含二氧化钛。
8.根据权利要求1至6中任一项所述的方法，其中所述催化剂载体修补基面涂料包含一种或多种有机溶剂。
9.根据权利要求8所述的方法，其中所述一种或多种有机溶剂包含丁醇、异丁醇、乙醇、丙醇、异丙醇、芳族溶剂中的至少一种。
10.根据权利要求1至9中任一项所述的方法，其中所述一种或多种催化活性化合物在移除发动机废气中的有毒化合物时具有活性。
11.根据权利要求10所述的方法，其中所述一种或多种催化活性化合物包括氧化钒、氧化钨、氧化钼、沸石材料、铂和钯中的至少一种。
12.根据权利要求1至11中任一项所述的方法，其中在步骤(d)之前，步骤(c)的所述预涂覆和形成波纹的基底具有平坦内衬。
13.根据权利要求12所述的方法，其中在设置于所述形成波纹和预涂覆的基底上之前，所述平坦内衬以一定量预涂覆有所述水性预涂覆悬浮液，从而导致介于60g/m2和120g/m2之间的所述内衬和预涂层的总重量。
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