CN1845780B - 改进的柴油机排气滤清器 - Google Patents

改进的柴油机排气滤清器 Download PDF

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Publication number
CN1845780B
CN1845780B CN2004800248622A CN200480024862A CN1845780B CN 1845780 B CN1845780 B CN 1845780B CN 2004800248622 A CN2004800248622 A CN 2004800248622A CN 200480024862 A CN200480024862 A CN 200480024862A CN 1845780 B CN1845780 B CN 1845780B
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porous wall
diesel
diesel exhaust
exhaust filter
rigidity
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CN1845780A (zh
Inventor
C·G·李
R·P·齐巴思
M·C·康奈尔
S·B·斯沃茨米勒
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Dow Global Technologies LLC
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Dow Global Technologies LLC
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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
    • B01J23/42—Platinum
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Abstract

一种改进的柴油机排气滤清器元件，具有由针状陶瓷(例如针状莫来石)形成的刚性多孔壁部分，该多孔壁部分具有第一侧和第二侧，该多孔壁部分涂覆贵金属催化剂和NOX吸收剂，使得当柴油机排放的废气从第一侧到第二侧流过刚性多孔壁时，排放的废气含有过量的氧气，NOX和烟尘，排放废气中的烟尘被收集在刚性多孔壁中，并被催化氧化成二氧化碳，NO被催化氧化成NO2，然后这些NO2被NOX吸收剂吸收；并且使得当排放的废气含有过量碳氢化合物和一氧化碳时，则NOX吸收剂再生，而剩余碳氢化合物和一氧化碳被催化转化成氮气和二氧化碳。此外，一种在诸如刚性多孔壁的表面上沉积沉淀金属离子的方法。

Description

改进的柴油机排气滤清器
优先权
本申请要求2003年8月29日提交的美国临时申请60/499130的优先权。
技术领域
本发明涉及排气滤清器领域，更具体地，本发明涉及柴油排气滤清器领域。
背景技术
公知地，催化转化器用于控制装有汽油发动机的汽车和卡车的氮氧化合物、碳氢化合物和一氧化碳排放。废气流过球形或蜂窝形的固体材料，该固体材料上涂覆有催化剂。有害气体在催化剂间传播，并被催化转化成无害或有害程度较低的气体，例如水蒸气、氮气，和二氧化碳。这种催化转化器在控制装有柴油机的汽车和卡车的排放时无效，因为柴油机废气比汽油机废气含有更多的烟尘和过量的氧。
已经为柴油机开发了排气滤清器。例如，美国专利US 5,098,455，这里全部结合作为参考，公开了一种包括针状莫来石过滤介质的可再生排气滤清器。使废气流过针状莫来石过滤介质以过滤烟尘颗粒。定期地，将过滤的烟尘颗粒燃烧掉，以再生滤清器。
据Corning报道，已经在烟尘过滤器单元下游采用一个氮氧化合物吸收器单元和柴油氧化单元，以控制柴油机的烟尘、氮氧化合物和碳氢化合物排放(Johnson，T.，Developing Trends-Diesel EmissionControl Update，August 7，2001)。Heck和Farrauto在题为CATALYTIC AIR POLLUTION CONTROL-COMMERCIAL TECHNOLOGY，2002年出版，出版号为ISBN0-471-43624-0的教科书中，特别是在该书第8和9章中给出了柴油机排气滤清器的常用处理。
美国专利申请公开US 2001/0032459A1公开了一种具有刚性多孔壁过滤元件的柴油机废气净化系统，该过滤元件涂覆有贵金属催化剂和氮氧化合物吸收剂的混合物，使得当柴油机排放的废气在正常操作条件下流过刚性多孔壁时，废气中的烟尘被收集在刚性多孔壁中，并被催化氧化成二氧化碳，同时氮氧化合物被催化氧化成NO2，然后这些NO2被氮氧化合物吸收剂吸收。通过使排放的废气含有过量的碳氢化合物和一氧化碳，以便吸收剂通过释放NOX而再生，这些NOX和剩余的碳氢化合物及一氧化碳被催化转化成氮气和二氧化碳，从而专利公开US 2001/0032459A1中的系统得以再生。
专利公开US 2001/0032459A1中的系统是现有技术中一个重要的改进，但所采用的多孔壁材料(堇青石)的多孔性小于期望值(需要较大的单元以控制背压)，且根据专利公开US 2001/0032459A1所制造装置的总成本效率也小于期望值。
发明内容
本发明提供一种具有改进综合性能和成本特性的单一单元，用于控制柴油机排放的烟尘，氮氧化合物，一氧化碳和碳氢化合物。更具体地，本发明是一种改进的柴油机排气滤清器元件，具有一个刚性多孔壁部分，该多孔壁部分具有第一侧和第二侧，该多孔壁部分涂覆贵金属催化剂和NOX吸收剂，使得当柴油机排放的废气从第一侧到第二侧流过刚性多孔壁，排放的废气含有过量的氧气，NOX和烟尘，然后排放废气中的烟尘被收集在刚性多孔壁中，并被催化氧化成二氧化碳，NO被催化氧化成NO2，然后这些NO2被NOX吸收剂吸收；并且使得当排放的废气含有过量碳氢化合物和一氧化碳时，则NOX吸收剂再生，而剩余碳氢化合物和一氧化碳被催化转化成氮气和二氧化碳。改进包括在刚性多孔壁中采用针状陶瓷(例如针状莫来石)。
在一个相关实施例中，本发明是一种改进的柴油机排气滤清器元件，具有一个刚性多孔壁部分，该多孔壁部分具有第一侧和第二侧，使得当柴油机排放的废气从第一侧到第二侧流过刚性多孔壁，排放废气中的烟尘被收集在刚性多孔壁中。改进包括：刚性多孔壁包括三层，第一层靠近刚性多孔壁的第一侧，第一层包括柴油氧化催化剂，第三层靠近刚性多孔壁的第二侧，第三层包括三元催化剂，第二层位于第一层和第三层中间，第二层包括氮氧化和物吸收剂，第二层包括针状陶瓷，例如针状莫来石。
在另一个相关实施例中，本发明是一种改进的柴油机排气滤清器元件，具有一个刚性多孔壁部分，该多孔壁部分具有第一侧和第二侧，使得当柴油机排放的废气从第一侧到第二侧流过刚性多孔壁，排放废气中的烟尘被收集在刚性多孔壁中。改进包括：刚性多孔壁包括两层，第一层靠近刚性多孔壁的第一侧，第一层包括柴油氧化催化剂，第二层位于第一层和刚性多孔壁的第二侧之间，第二层包括氮氧化和物吸收剂和三元催化剂，第二层包括针状陶瓷，例如针状莫来石。
本发明还涉及一种方法，用于在诸如针状陶瓷的刚性多孔壁表面上沉积沉淀金属离子。该方法包括四个步骤。第一步是形成在溶剂中包含金属离子，胶凝剂和沉淀剂的液体溶液，胶凝剂的浓度足以在高温下使液体溶液胶凝，沉淀剂在高温下不稳定，从而沉淀剂分解，以生成至少沉淀了一部分金属离子的产品，从而形成沉淀金属离子。第二步是用液体溶液填充刚性多孔壁的至少一部分孔腔，以形成填充结构。第三步是升高填充结构的温度，以使液体溶液胶凝，并沉淀金属离子。第四步是进一步升高填充结构的温度，以从填充结构中蒸发溶液和胶凝剂，留下沉淀金属离子在刚性多孔壁至少一部分表面上沉积。
附图说明
图1表示根据本发明的柴油机滤清器/催化转化器一端的部分剖面图；
图2表示图1中柴油机滤清器/催化转化器的侧视图，去除了通道的端部，其可选择地可以是堵塞或不堵塞的；
图3更清楚地表示了柴油机排放废气的流动通道和方向；
图4表示了一个由针状莫来石组成的刚性多孔壁结构，其上涂覆了由铂、铑、钯和氧化钡构成的混合物；
图5表示了一个由针状莫来石组成的刚性多孔壁结构，其上涂覆有氧化铝、铂和氧化钡，具有浸渍有铂的上部氧化铝颗粒层，及浸渍有铂和铑的下部氧化铝颗粒层；
图6表示了一个由针状莫来石组成的刚性多孔壁结构，其上涂覆了由氧化钡、铂和铑构成的混合物，并具有浸渍有铂的上部氧化铝颗粒层；而
图7表示了一个由针状莫来石组成的刚性多孔壁结构，其上涂覆有一层氧化铝和氧化钡中间层，一层涂覆有铂的上层，和一层涂覆有铂、铑和钯的下层。
具体实施方式
现在参考图1，表示了一个根据本发明构造的柴油机排气滤清器10。刚性多孔道壁12包括分隔进气道14和排气道16的针状陶瓷。进气道通过用塞子18堵塞其下游端而形成，而排气道通过用塞子20堵塞其上游端而形成。
现在参考图2，表示柴油机滤清器上游端的侧视图。可以看到进气道的上游端22被腔道壁12包围。排气道上游端的塞子20同样也被腔道壁12包围。可以从图2中看出，相邻进气和排气道沿着行和列交替布置。
现在参考图3，具体表示腔道，可以看到气体进入进气道14的上游端22，流过壁12，然后从排气道16的下游端24排出。在本发明的该实施例中，密封腔道端部的塞子决定哪些腔道作为进气道，哪些腔道作为排气道。通过使滤请器上游端的腔道端部保持敞开，同时密封滤请器下游端的腔道端部，从而形成进气道。这样，气体进入腔道的上游端，从而被迫流过腔道周围的壁。同样，通过堵塞滤请器上游端的腔道端部，同时使相同腔道在滤请器下游端保持敞开，从而形成排气道。这样，通过周围壁流入排气道的气体可以自由地流出腔道下游端，同时可以阻止气体从上游端流出。
滤请器10的壁12必须能够收集并保存柴油机排放气体的烟尘颗粒，与此同时允许气体本身没有过大阻力地流过腔道壁。当然，滤清器10对流过的排放气体具有一定的阻力。该阻力，较小程度地是因为排放气体必须通过的狭窄通道的限制作用，但更大程度上是由于气体被迫流过的通道壁12有限的渗透性。排放气体流过滤清器10的这种阻力的结果是从滤清器10的上游端至下游端形成压降。在柴油机的应用场合中，不希望产生这种压降，因为其会造成发动机承受增大的背压，这降低了发动机的效率，并最终会导致发动机停机。在本发明中通过使壁12具有足够大的表面积，及对于排放气体的流动具有充足的渗透性，使这种背压维持在可接受的较低水平。
壁12包括针状陶瓷，例如针状莫来石。多孔介质中孔的平均尺寸以及孔尺寸的分布很重要。如果孔的尺寸过大，则过多的烟尘颗粒会穿过壁12，从而没有收集在壁12中。另一方面，如果多孔介质的孔尺寸过小，则为了获得可接受的背压，壁12所需的面积(从而滤清器10的体积和重量)将相对较大。优选地，多孔介质的多孔性(即，多孔介质中开孔的体积百分比)相对较高，例如，大于50％，从而壁的特定面积使用得更有效率。孔的平均尺寸优选地处于10-20微米之间。
壁12的厚度也是一个需要考虑的因素，壁12(对于壁12的特定区域)越厚，排放气体暴露在催化剂中的时间越长。但是，相对较厚的壁12也会导致相对较高的背压。优选地，壁12的厚度大致处于1/4-10毫米范围内。
壁12多孔介质优选的材料是如美国专利US 5,098,455中公开的熔化伸长莫来石晶体交替网络。这种莫来石可以称为“针状莫来石”。针状莫来石在本发明中特别优选地用作多孔介质，因为针状莫来石可以具有优异的强度，优异的耐热性能，和优异的渗透性能。
应该可以理解，本发明中滤清器的特定几何形状不是绝对的。例如，本发明中的滤清器可以是壳形和管形的装置，其中的管由多孔介质形成。可选择地，(且没有限制地)本发明中的多孔介质可以是垂直密封在一个容器内的螺旋缠绕片。从而，只要排放气体流过滤清器的刚性多孔壁部分，任何几何形状都可以用在本发明中。
现在参考图4，图中表示了本发明的一个实施例40，其中柴油氧化、NOX吸收和三元催化功能通过在针状莫来石41上涂覆一层单一的覆层42实现。覆层42可以是美国专利公开2001/0032459A1中说明的任何材料。换句话说，覆层42含有贵金属催化剂(且优选地为贵金属的混合物)，用作柴油氧化催化剂(优选地，铂含量范围为5-150克/28.3升)，NOX吸收剂(优选地，氧化钡含量处于相对高的水平，如，占体积的10％)和三元催化剂(优选地，铂含量范围为0.1-10克/升，铑含量范围为0.02-2克/升，而钯含量范围为0.1-10克/升，以及其它成分，例如氧化铝、活性氧化铝、氧化铈和氧化锆，例如参见美国专利4,965,243和4,714,694)。硫氧化物(SOX)吸收剂也可以用于本发明。例如，图4中表示的系统可以在其内侧涂覆一层含有SOX吸收剂的覆层。
现在参考图5，图中表示了本发明的一个优选实施例50，其中柴油氧化、NOX吸收和三元催化功能通过各自的覆层实现。中间层由涂覆有氧化铝，铂和氧化钡混合物52的针状莫来石51组成，其中氧化钡用作NOX吸收剂。上层由浸渍并涂覆有铂54(或其它合适的贵金属催化剂)的多孔氧化铝颗粒53组成，铂54用作柴油氧化催化剂(优选地，铂含量范围为5-150克/28.3升过滤元件)。下层由浸渍并涂覆有贵金属催化剂混合物56(优选地，混合物中铂含量范围为0.1-10克/升，铑含量范围为0.02-2克/升，而钯含量范围为0.1-10克/升，以及其它成分，例如氧化铝、活性氧化铝、氧化铈和氧化锆，例如参见美国专利4,965,243)的多孔氧化铝颗粒组成。图5中表示的实施例在操作性能和贵金属使用的经济性上都具有较高的效率。
现在参考图6，图中表示了本发明的一个实施例60，其中NO2吸收和三元催化功能通过在针状莫来石61表面上涂覆一层混合覆层62实现，而柴油氧化功能通过在多孔氧化铝颗粒63上浸渍并涂覆一层贵金属催化剂覆层64实现。覆层62包括NOX吸收剂(优选地为氧化铝和氧化钡含量相对较高的混合物，例如占体积的10％)和三元催化剂(优选地，混合物中铂含量范围为0.1-10克/升，铑含量范围为0.02-2克/升，而钯含量范围为0.1-10克/升，以及其它成分，例如活性氧化铝、氧化铈和氧化锆，例如参见美国专利4,965,243)的多孔氧化铝颗粒)。覆层64由贵金属催化剂(优选地，铂含量范围为5-150克/28.3升过滤元件)组成。图6中表示的实施例在操作性能和贵金属使用的经济性上也具有较高的效率。
现在参考图7，图中表示了本发明的另一个优选实施例70，其中柴油氧化、NOX吸收和三元催化功能通过各自的覆层实现。中间层由涂覆有氧化铝、铂和氧化钡混合物73的针状莫来石71组成，其中氧化钡用作NOX吸收剂。上层由针状莫来石71涂覆铂72(或其它合适的贵金属催化剂)而形成，铂72用作柴油氧化催化剂(优选地，铂含量范围为5-150克/28.3升过滤元件)。下层由针状莫来石71涂覆贵金属催化剂混合物74(优选地，混合物中铂含量范围为0.1-10克/升，铑含量范围为0.02-2克/升，而钯含量范围为0.1-10克/升，以及其它成分，例如活性氧化铝、氧化铈和氧化锆，例如参见美国专利4,965,243)而形成。图7中表示的实施例在操作性能和贵金属使用的经济性上都具有较高的效率。
实施例1
一种具有刚性多孔壁部分的柴油机排气滤清器，其中刚性多孔壁部分包括根据美国专利US 5,098,455的公开内容准备的尺寸为2.5厘米×2.5厘米×7.6厘米的针状莫来石。准备液体溶液，其由3.0克8wt％的Methocel A15LV溶液(The DowChemical，Midland，MI，USA)和30.0克26.7wt％的胶体氧化铝悬浮液(Dispal 18N4-80，Sasol North America，Inc.，Housion，TX，USA)组成。13.2克该溶液用在滤清器中，使得柴油机排气滤清器的多孔壁充满该液体。溶液均匀地分布在柴油机排气滤清器中后，将滤清器置于加热炉中在115℃下烘干。然后将柴油机排气滤清器置于加热炉中在500℃下煅烧一个小时。煅烧后，通过将煅烧过的滤清器浸入硝酸铂溶液(Heraeus Metal Processing，Inc.，Santa Fe Springs，CA，USA)中，使0.091克Pt涂覆到煅烧过的滤清器上。在115℃下烘干后，将滤清器浸入80℃的由10.0克水和1.56克硝酸钡形成的溶液中(Aldrich Chemical Co，Milwaukee，WI，USA)，然后在115℃下烘干。将烘干的滤清器在600℃下煅烧一个小时以形成吸收氮氧化物的柴油机排气滤清器。柴油机排气滤清器的进气道通过将滤清器一端的90％浸入由湿式浸渍产生的20.0克1wt％的基于γ-氧化铝的铂(platinum on gamma-alumina)(Catalox Sba-150，Sasol NorthAmerica，Inc.，Houston，TX，USA)，2.0克Di spal 18N4-80(SasolNorth America，Inc.，Houston，TX，USA)，2.0克8wt％的MethocelA15LV(The Dow Chemical，Midland，MI，USA)和77克水组成的覆层悬浮液中而涂覆，使得只有柴油机排气滤清器多孔壁的进气端涂覆有颗粒，以形成柴油氧化催化层。滤清器在加热炉中115℃下干燥。相似地，柴油机排气滤清器的排气道通过将滤清器相反端的90％浸入由13.33克1.2％的基于γ-氧化铝的铂(Catalox Sba-150，Sasol NorthAmerica，Inc.，Houston，TX，USA)，6.67克0.24wt％的基于共同沉淀CeO2∶ZrO2为2∶1的铑，2.0克Dispal 18N-4(Sasol NorthAmerica，Inc.，Houston，TX，USA)，2.0克8wt％的Methocel A15LV(Dow Chemical，Midland，MI，USA)和77克水组成的覆层悬浮液中而涂覆，使得只有柴油机排气滤清器多孔壁的排气端涂覆有颗粒，以形成三元(three way)催化层。将滤清气烘干后，将柴油机排气滤清器置于加热炉中在600℃下加热一个小时，以形成根据本发明的具有如图5所示多孔壁部分的柴油机排气滤清器实施例。
实施例2
一种具有刚性多孔壁部分的柴油机排气滤清器，其中刚性多孔壁部分包括根据美国专利US 5,098,455的公开内容准备的尺寸为2.5厘米×2.5厘米×7.6厘米的针状莫来石。准备液体溶液，其由3.0克8wt％的Methocel A15LV溶液(The DowChemical，Midland，MI，USA)和30.0克26.7wt％的胶体氧化铝悬浮液(Dispal 18N4-80，Sasol North America，Inc.，Housion，TX，USA)组成。13.2克该溶液用在滤清器中，使得柴油机排气滤清器的多孔壁充满该液体。溶液均匀地分布在柴油机排气滤清器中后，将滤清器置于加热炉中在115℃下烘干。然后将柴油机排气滤清器置于加热炉中在500℃下煅烧一个小时。煅烧后，通过将煅烧过的滤清器浸入硝酸铂溶液(Heraeus Metal Processing，Inc.，Santa Fe Springs，CA，USA)中，使0.091克Pt涂覆到煅烧过的滤清器上。在115℃下烘干后，将滤清器浸入80℃的由10.0克水和1.56克硝酸钡形成的溶液中(Aldrich Chemical Co，Milwaukee，WI，USA)，然后在115℃下烘干。将烘干的滤清器在600℃下煅烧一个小时以形成吸收氮氧化物的柴油机排气滤清器。柴油机排气滤清器的进气道通过将滤清器一端的80％浸入由湿式浸渍产生的20.0克1wt％的基于γ-氧化铝的铂(Catalox Sba-150，Sasol North America，Inc.，Houston，TX，USA)，2.0克Dispal 18N4-80(Sasol North America，Inc.，Houston，TX，USA)，2.0克8wt％的Methocel A15LV(The Dow Chemical，Midland，MI，USA)和77克水组成的覆层悬浮液中而涂覆，使得只有柴油机排气滤清器多孔壁的进气端涂覆有颗粒，以形成柴油氧化催化层。将滤清器在加热炉中115℃下烘干后，将柴油机排气滤清器置于600℃下煅烧一个小时，以形成根据本发明的具有如图6所示多孔壁部分的柴油机排气滤清器实施例。
实施例3
一种具有刚性多孔壁部分的2.5升柴油机排气滤清器，其中刚性多孔壁部分包括根据美国专利US 5,098,455的公开内容准备的针状莫来石。准备液体溶液，其由10克Methocel A15LV(The DowChemical，Midland，MI，USA)，160克胶体氧化铝颗粒(Dispal18N4-80，Sasol North America，Inc.，Housion，TX，USA)，和10克硝酸铂(Heraeus Metal Processing，Inc.，Santa Fe Springs，CA，USA)，1克硝酸铑(Heraeus Metal Processing，Inc.，Santa FeSprings，CA，USA)，50克尿素溶于650克水组成。将柴油排气滤清器浸在液体溶液中，使得柴油机排气滤清器的多孔壁充满该液体。然后将柴油排气滤清器密封在塑料袋中，并在95℃下水浴加热一天，使甲基纤维素胶凝，且使尿素分解成氨和二氧化碳，从而使氧化铝和铑及铂离子沉积在针状莫来石上。然后将柴油机排气滤清器移出塑料袋，并在105℃下加热一天，以去除水。然后将柴油机排气滤清器置于烤箱中在500℃下加热一个小时，以煅烧零件。然后将煅烧过的滤清器浸在100克醋酸钡溶于500克水形成的溶液中，在115℃下烘干，然后在600℃下煅烧一个小时以形成氮氧化物吸收剂和三元催化剂组合覆层。然后将柴油机排气滤清器的进气道用基于平均直径为40微米的氧化铝颗粒的铂覆层悬浮液(50克铂/28.3升滤清器)冲洗，使得柴油机滤清器多孔壁的近气侧涂覆氧化铝颗粒，以形成如图6所示的系统。

Claims (3)

1.一种改进的柴油机排气滤清器，具有一个刚性多孔壁部分，该多孔壁部分具有第一侧和第二侧，使得当柴油机排放的废气从第一侧到第二侧流过刚性多孔壁时，排放废气中的烟尘被收集在刚性多孔壁中，其中改进包括：刚性多孔壁包括两层，第一层靠近刚性多孔壁的第一侧，第一层包括柴油氧化催化剂，第二层位于第一层和刚性多孔壁的第二侧之间，第二层包括NOx吸收剂和三元催化剂，第二层包括针状陶瓷。
2.根据权利要求1所述改进的柴油机排气滤清器，其中NOx吸收剂包括钡盐或氧化钡。
3.根据权利要求1所述改进的柴油机排气滤清器，其中针状陶瓷由针状莫来石组成。
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