CN109922883A - 催化剂基质 - Google Patents

催化剂基质 Download PDF

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Publication number
CN109922883A
CN109922883A CN201680089489.1A CN201680089489A CN109922883A CN 109922883 A CN109922883 A CN 109922883A CN 201680089489 A CN201680089489 A CN 201680089489A CN 109922883 A CN109922883 A CN 109922883A
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matrix
tilt angle
layer
metal foil
foil
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何建军
邓水平
褚庚生
M·加利根
刘也
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BASF SE
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BASF SE
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2807—Metal other than sintered metal
    • F01N3/281—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates
    • F01N3/2821—Metallic honeycomb monoliths made of stacked or rolled sheets, foils or plates the support being provided with means to enhance the mixing process inside the converter, e.g. sheets, plates or foils with protrusions or projections to create turbulence
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    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
    • B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B01J23/46—Ruthenium, rhodium, osmium or iridium
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    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
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    • F01N2330/00—Structure of catalyst support or particle filter
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    • F01N2330/00—Structure of catalyst support or particle filter
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Abstract

提供了由具有倾斜角度的波纹金属箔形成的金属箔基体。该金属箔基体能够提供通过其中的湍流气流。基体可含有催化涂层。基体可以用在催化转化器中，用于处理内燃机的废气排放。

Description

催化剂基质
本发明涉及含有偏斜通道的某些金属基体及其制备方法。本发明还涉及包含该金属基体的基质。本文所述的基质和基体可用于催化转化器中，与车辆发动机一起使用以控制废气排放。
背景
通常，催化转化器应用中使用的基质具有直通通道，这导致层流而不是湍流。当用作催化剂基质时，这些普通基质引起以下三个主要问题：a)由于层流而催化转化率较低；b)高箔消耗导致制造成本增加；和/或c)在发动机排放控制应用中的热摇试验(the HotShake Test)、热循环试验(the Hot Cycling Test)和这些试验的组合、冷振动试验(coldvibration testing)，水骤冷试验(water quench testing)和冲击试验中测试时的机械强度弱。
热摇试验涉及在高温(800至1050℃；分别为1472至1922°F)下以垂直、径向或成角度的姿态振荡(50至200赫兹和28至80G惯性载荷)装置，同时来自燃气燃烧器或运行中的内燃机的废气传送通过该装置。如果装置直至预定时间如5至200小时时嵌进，或显示箔叶片的前缘或上游边缘的分离或折叠，或者显示其它机械变形或破裂，则称该装置未通过测试。
热循环试验在800至1050℃(1472至1922°F)下随着排气流动进行，循环至120至200℃，每13至20分钟一次，持续300小时。薄金属箔条的前缘的嵌进或分离或机械变形、裂纹或破裂被认为是失败的。
有时将热摇试验和热循环试验结合起来，即两个试验同时进行或一个叠加另一个。
本领域仍然需要用于催化转化器应用的催化剂基质以
1)减少构建基质所需材料的消耗；
2)在制造基质时节省成本；
3)在不增加催化转化器尺寸的情况下改进催化转化器的转化率；
4)降低铂族金属(PGM)载荷；和
5)提供具有增加的强度并且可以抵抗发动机排放控制应用中的热摇试验、热循环试验以及这些试验的组合，冷振动试验，水骤冷试验和冲击试验的基质。
摘要
因此，公开了一种金属箔基体，其包括多个金属箔层，每个金属箔层具有倾斜角度波纹。
还公开了一种催化剂基质，其包括套管和在其内部的本发明金属箔基体。
还公开了制备本发明催化剂基质的方法，该方法包括：
a)提供具有倾斜角度波纹的金属箔条；
b)缠绕、卷绕或折叠该金属箔条以形成包括多个金属箔层的基体；
c)将基体插入套管中；和
d)将基体的周边结合到套管内部。
附图的简要说明
图1A显示了具有隔离箔的参比基质设计。
图1B显示了具有隔离箔的参比设计的变化。
图1C显示了另一种没有形成通道的参比设计。
图1D显示了能够提供湍流的本发明通道基体。
图2A、2B、2C和2D显示了本发明通道基体的倾斜角度波纹的可能形状/角度。
图3A、3B和3C显示了本发明通道基体的倾斜角度波纹的可能形状/角度。
图4显示了偏斜通道基质具有比参比(普通)更小的背压(流动阻力)。
图5显示偏斜通道基质催化剂具有比参比(普通)更高的转化率(更少的排放)。
图6显示偏斜通道基质催化剂具有比参比(普通)更高的转化率(更少的排放)。
图7A、7B、7C、7D、7E和7F显示了本发明偏斜通道基质比普通的更加机械耐用。
图8显示了如何缠绕偏斜通道基质。
图9显示了罩或套管中的偏斜通道基体。
详细说明
金属箔基体是指包括具有倾斜角度波纹的金属箔条的基体。“倾斜”意味着“不直”。因此，倾斜角度是锐角或钝角，其不是直角或直角的倍数。
将金属箔基体适当地插入套管中以形成催化剂基质或“偏斜催化剂基质”。基质的周边可以与套管内部结合以获得偏斜通道基质。套管可包括金属或金属合金。
“孔道”是指通过波纹金属箔片的缠绕、卷绕或折叠而在偏斜通道基体中形成的空间，其中这些空间在偏斜通道基体的相对端之间延伸。
具有倾斜角度波纹的本发明波纹金属箔的缠绕、卷绕或折叠导致在每层之间波纹“未对齐”或“不对齐”的层。例如，每个层可以具有与前一层和/或下一层相反的倾斜角度波纹。参见例如图1D。具有未对齐波纹的层导致偏斜(非直)通道。
如本文所用，“普通”或普通基质是指先前已知和使用的现有技术基质。
有利地，本发明基质不含有隔离箔。隔离箔是例如平箔、具有蚀刻孔的平箔或微波纹箔。隔离箔可以定义为波纹箔之间的任何附加箔。
倾斜角度波纹在由金属箔条的熔合层产生的孔道中提供湍流。
“多个”意味着两个或更多个。例如，3个或更多个，4个或更多个，5个或更多个，6个或更多个，7个或更多个，8个或更多个，9个或更多个，10个或更多个。
金属箔条可以是金属或金属合金。金属或金属合金可以是例如“铁素体”不锈钢，例如美国专利No.4,414,023中所述的。合适的铁素体不锈钢合金的实例包含约20％的铬，约5％的铝和约0.002％至约0.05％的至少一种选自铈、镧、钕、钇和镨的稀土金属或者两种或更多种这种稀土金属混合物，余量铁和微量炼钢杂质，按重量计。铁素体不锈钢可以商品名ALFA IV从Allegheny Ludlum Steel Co.商购获得。
另一种可用的市售不锈钢金属合金被鉴定为Haynes 214合金。该合金和其它有用的含镍合金描述于例如美国专利No.4,671,931中。这些合金的特征在于高抗氧化性和耐高温性。具体实例包含约75％镍，约16％铬，约4.5％铝，约3％铁，任选痕量的一种或多种除钇之外的稀土金属，约0.05％碳和炼钢杂质，按重量计。也可用于本文的Haynes 230合金具有含约22％铬，约14％钨，约2％钼，约0.10％碳，痕量镧，余量镍(按重量计)的组成。
铁素体不锈钢和Haynes合金214和230，都被认为是不锈钢，是耐高温、抗氧化(或耐腐蚀)金属合金的实例，可用于制造偏斜通道基体和本发明基质。
用于本发明的合适的金属合金应该能够经受长时间的“高”温，例如约900℃至约1200℃(约1652°F至约2012°F)。
其他耐高温、抗氧化的金属合金是已知的并且可能是合适的。对于大多数应用，特别是汽车应用，这些合金用作“薄”金属或箔，即厚度为约0.001“至约0.005”，例如约0.0015“至约0.0037”。
金属箔条在波纹状之后可以预先涂覆，但是在组装成偏斜通道基体或基质之前。金属箔条也可以在组装成蜂窝体之后涂覆，例如通过浸涂。涂层可包括催化剂载体材料，例如难熔金属氧化物，例如氧化铝，氧化铝/二氧化铈，二氧化钛，二氧化钛/氧化铝，二氧化硅，氧化锆等，如果需要，催化剂可以负载在难熔金属氧化物涂层上。对于在催化转化器中使用，催化剂可包含铂族金属(PGM)，例如铂，钯，铑，钌，铟，或者两种或更多种这种金属的混合物，例如铂/铑。难熔金属氧化物涂层的施用量通常为约5毫克/平方英寸至约200毫克/平方英寸。催化剂也可以直接涂覆在金属箔条上。含有催化剂的涂层是催化涂层。
金属箔条可以具有穿孔。在一些实施方案中，具有约2至约30cpsi的穿孔/孔道的金属箔条可用于产生偏斜通道基质。或者，金属箔条可以没有穿孔。
倾斜角度波纹可以是直的或曲线的。两层或更多层可以通过钎焊熔合在一起。偏斜通道基质还可包括催化剂，例如催化涂层。
图1A(参比)显示了具有隔离箔的普通基质设计。图1B(参比)显示了普通设计的一种变化，也具有隔离箔。图1C(参比)显示了另一种普通设计，其未形成没有任何隔离箔的通道。图1D显示了本发明偏斜通道基体，其没有任何隔离箔并且具有可以提供湍流的通道。
在一些实施方案中，倾斜角度(即，非直通道)波纹的形状/角度可以是但不限于图2A、2B、2C、2D及其组合中所示的形状。
在其他实施方案中，倾斜角度(即，非直通道)波纹的形状/角度可以是但不限于图3A、3B和3C中所示的形状。在本发明中，具有倾斜角度波纹的波纹箔卷绕(未折叠)，而周边箔大部分保持其形状。具有螺旋缠绕结构的各层通过例如钎焊结合在一起。
根据本发明的基质和基体，基质和基体的孔道中的湍流可以提供比层流更高的催化转化率。此外，本发明的基质和基体提供了分支道路通道，与直通道相比，其可以产生增加的湍流。另外，本发明的基质和基体包括偏斜通道，其可以产生高密度的分支道路通道，其允许改进的排放流量。
本发明的基质和基体可以通过本发明方法制备，箔消耗量减少高达40％，同时表现出改进的耐久性和优异的催化活性。
实施例
在下面的实施例中，比较了两种基质的性能。偏斜基质如下制备。
波纹箔用齿轮制备，具有如图2C所示的波形截面。齿轮小齿轮齿条相对于轴是倾斜的(不是直的)，使得它们形成具有倾斜角(非直)通道波纹的箔，如图3A所示。不需要隔离箔(例如平箔、具有蚀刻孔的平箔或微波纹箔)。将波纹箔卷绕成圆柱基体，使得每个层具有与直接相邻的层相反的倾斜角，从而形成具有交错和交流通道的基体。在此过程中，钎料沉积在适当的点。缠绕后(见图8)，将偏斜基质插入套管中(见图9)，并放入真空钎焊炉内进行钎焊。
标记为“普通”的另一基质是市售的直通道基质。在这种情况下，普通基质意味着蜂窝状通道由波纹箔和隔离箔形成(参见图1A和图1B)。普通基质可以从供应商处购买，包括但不限于Emitec Gesellschaft für Emissionstechnologie mbH、Nippon Steel&Sumitomo Metal Corporation或BASF Corporation。在本发明实施例中，普通基质样品由BASF Catalysts(Guilin)Co.，Ltd.制造。
实施例1
根据欧III试验程序/HJ150试验摩托车，测试基质的一氧化碳(CO)、烃(HC)和氮氧化物(NOx)转化率。基质的直径为40mm，长度为90mm，300cpsi(孔道每平方英寸)，DIN1.4767合金的箔厚度为0.05mm。基质具有Pt/Pd/Rh 2/9/1的催化涂层，其总PGM载荷为45g/ft3。本发明的偏斜通道基质使用比普通基质少47重量％的箔。然而，本发明基质比普通基质表现更好。
实施例2
图4显示了偏斜通道基质具有比普通基质更小的背压。空气传送通过基质(普通的和偏斜的)并且由通道壁和孔道截面积引起的流体阻力导致空气流速变化和空气压力增加。空气流动压力的变化称为“背压”，该参数用于测量普通和偏斜基质的性能。
实施例3
图5显示在涂覆具有相同PGM载荷和比率的催化涂层之后，相同尺寸的偏斜通道基质催化剂具有比普通的更高的转化率或更少的排放，这可能是由于其湍流效应。
图5中的普通基质和偏斜基质具有相同的尺寸，52mm×85mm，300cpsi，相同的催化剂PGM Pt/Pd/Rh(1/15/3)，相同载荷30g/cft。将具有催化涂层的基质组装到试验摩托车中的消声器中，并根据世界摩托车试验循环，WMTC2-1on Lib125cc with EFI system进行测试。“原始的”没有基质或催化剂。
实施例4
图6显示，偏斜通道基质催化剂具有比普通的更高的转化率或更少的排放，这可能是由于其湍流效应。图6中普通的和偏斜的具有相同的尺寸，42mm×100mm，300cpsi，相同的催化剂Pt/Pd/Rh(2/9/1)，相同的载荷75g/cft。根据试验循环Euro-III，将具有催化涂层的基质组装到具有HJ124-3A化油器的试验摩托车中的消声器中。“原始的”没有基质或催化剂。
实施例5
本发明基质和普通基质以5000-6000K/min的速率经受200至900℃的温度，循环时间210秒/循环和2000-3000K/min的冷却速率。图7A-7F显示在热循环试验之后，在本发明的偏斜通道基质中没有发现变形或破裂，然而在普通基质中发现一些破裂的箔和基体变形。附图显示本发明的偏斜通道基质比普通基质更加机械耐用。
尽管为了说明的目的，这里已经基于目前被认为是最实用和优选的实施方案详细地描述了本发明，但是应该理解，这样的细节仅用于说明的目的，本发明不限于所公开的实施方案，而是相反，旨在覆盖落在所附权利要求的精神和范围内的修改和等同布置。例如，应该理解，本发明设想，在可能的范围内，任何实施方案的一个或多个特征可以与任何其他实施方案的一个或多个特征组合。
这里的冠词“一”和“一个”指的是一个或多于一个(例如至少一个)语法对象。本文引用的任何范围包括在内。贯穿全文使用的术语“约”用于描述和解释小的波动。例如，“约”可能意味着数值可能会变化±5％，±4％，±3％，±2％，±1％，±0.5％，±0.4％，±0.3％，±0.2％，±0.1％或±0.05％。无论是否明确指出，所有数值均由术语“约”修饰。由术语“约”修饰的数值包括具体的确定值。例如，“约5.0”包括5.0。
除非另有说明，否则所有份数和百分数均以重量计。如果没有另外说明，重量百分数(重量％)基于不含任何挥发物的整个组合物，即基于干燥固体含量。
本文提及的所有美国专利申请、公开的专利申请和专利均通过引用并入本文中。

Claims (14)

1.一种金属箔基体，包括多个金属箔层，每层具有倾斜角度波纹。
2.根据权利要求1所述的基体，其中每层具有不与前一层和/或下一层对齐的倾斜角度波纹。
3.根据权利要求1所述的基体，其中所述层熔合在一起。
4.根据权利要求1所述的基体，其不含有隔离箔。
5.根据权利要求1至4中任一项所述的基体，其中倾斜角度波纹能够提供湍流气流。
6.根据权利要求1至4中任一项所述的基体，其中金属箔层具有穿孔。
7.根据权利要求1至4中任一项所述的基体，其中金属箔层没有穿孔。
8.根据权利要求1至4中任一项所述的基体，其中倾斜角度波纹是直的。
9.根据权利要求1至4中任一项所述的基体，其中倾斜角度波纹是曲线的。
10.根据权利要求1-4中任一项所述的基体，还包含在其上的催化涂层。
11.一种催化剂基质，其包含套管和在其内部的根据权利要求10的基体。
12.制备根据权利要求11的催化剂基质的方法，该方法包括：
a)提供具有倾斜角度波纹的金属箔条；
b)缠绕、卷绕或折叠所述金属箔条以形成包括多个金属箔层的基体；
c)将基体插入套管中；和
d)将基体的周边结合到套管内部。
13.根据权利要求12所述的方法，还包括在步骤b)之后将各层熔合在一起。
14.根据权利要求13所述的方法，其中所述结合和/或熔合包括钎焊。
CN201680089489.1A 2016-09-23 2016-09-23 催化剂基质 Pending CN109922883A (zh)

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