JP2006524630A - 改良された多孔質ムライト体及びそれらの形成方法 - Google Patents
改良された多孔質ムライト体及びそれらの形成方法 Download PDFInfo
- Publication number
- JP2006524630A JP2006524630A JP2006513305A JP2006513305A JP2006524630A JP 2006524630 A JP2006524630 A JP 2006524630A JP 2006513305 A JP2006513305 A JP 2006513305A JP 2006513305 A JP2006513305 A JP 2006513305A JP 2006524630 A JP2006524630 A JP 2006524630A
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- Prior art keywords
- mullite
- composition
- mullite composition
- porous
- temperature
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
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- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 title claims abstract description 129
- 229910052863 mullite Inorganic materials 0.000 title claims abstract description 128
- 238000000034 method Methods 0.000 title claims description 33
- 230000015572 biosynthetic process Effects 0.000 title description 5
- 239000000203 mixture Substances 0.000 claims abstract description 115
- 150000001875 compounds Chemical class 0.000 claims abstract description 46
- 239000008187 granular material Substances 0.000 claims abstract description 39
- 239000002243 precursor Substances 0.000 claims abstract description 21
- 229910052779 Neodymium Inorganic materials 0.000 claims abstract description 17
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 16
- 230000002708 enhancing effect Effects 0.000 claims abstract description 16
- 229910052749 magnesium Inorganic materials 0.000 claims abstract description 16
- 229910052727 yttrium Inorganic materials 0.000 claims abstract description 15
- 229910052684 Cerium Inorganic materials 0.000 claims abstract description 13
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 claims abstract description 11
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 11
- 229910052731 fluorine Inorganic materials 0.000 claims abstract description 11
- 239000011737 fluorine Substances 0.000 claims abstract description 11
- 229910052691 Erbium Inorganic materials 0.000 claims abstract description 10
- 229910052693 Europium Inorganic materials 0.000 claims abstract description 10
- 229910052688 Gadolinium Inorganic materials 0.000 claims abstract description 10
- 229910052689 Holmium Inorganic materials 0.000 claims abstract description 10
- 229910052777 Praseodymium Inorganic materials 0.000 claims abstract description 10
- 229910052772 Samarium Inorganic materials 0.000 claims abstract description 10
- 229910052771 Terbium Inorganic materials 0.000 claims abstract description 10
- 229910052775 Thulium Inorganic materials 0.000 claims abstract description 10
- 229910052769 Ytterbium Inorganic materials 0.000 claims abstract description 10
- 229910052746 lanthanum Inorganic materials 0.000 claims abstract description 10
- 229910052706 scandium Inorganic materials 0.000 claims abstract description 10
- 229910052692 Dysprosium Inorganic materials 0.000 claims abstract description 9
- 229910052791 calcium Inorganic materials 0.000 claims abstract description 9
- 229910052742 iron Inorganic materials 0.000 claims abstract description 8
- 239000004927 clay Substances 0.000 claims abstract description 7
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 7
- 229910052708 sodium Inorganic materials 0.000 claims abstract description 5
- 229910052700 potassium Inorganic materials 0.000 claims abstract description 4
- 229910052570 clay Inorganic materials 0.000 claims abstract description 3
- 239000003054 catalyst Substances 0.000 claims description 17
- 238000010438 heat treatment Methods 0.000 claims description 17
- 230000035939 shock Effects 0.000 claims description 12
- 229910016569 AlF 3 Inorganic materials 0.000 claims description 5
- 229910052796 boron Inorganic materials 0.000 claims description 5
- 230000003197 catalytic effect Effects 0.000 claims description 4
- 239000011248 coating agent Substances 0.000 claims description 4
- 238000000576 coating method Methods 0.000 claims description 4
- 239000000454 talc Substances 0.000 claims description 4
- 229910052623 talc Inorganic materials 0.000 claims description 4
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 claims description 3
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 claims description 3
- 229910002651 NO3 Inorganic materials 0.000 claims description 3
- NHNBFGGVMKEFGY-UHFFFAOYSA-N Nitrate Chemical compound [O-][N+]([O-])=O NHNBFGGVMKEFGY-UHFFFAOYSA-N 0.000 claims description 3
- 229910021536 Zeolite 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
- 238000007493 shaping process Methods 0.000 claims description 3
- 239000010457 zeolite Substances 0.000 claims description 3
- 229910052765 Lutetium Inorganic materials 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 claims description 2
- -1 fluorotopaz Chemical compound 0.000 claims 2
- 239000011777 magnesium Substances 0.000 description 13
- 239000003570 air Substances 0.000 description 10
- 239000002245 particle Substances 0.000 description 9
- 239000007789 gas Substances 0.000 description 8
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- 239000000654 additive Substances 0.000 description 6
- 239000011521 glass Substances 0.000 description 6
- 239000004071 soot Substances 0.000 description 6
- 230000005540 biological transmission Effects 0.000 description 5
- 230000000996 additive effect Effects 0.000 description 4
- 229910052782 aluminium Inorganic materials 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 229910052757 nitrogen Inorganic materials 0.000 description 4
- 230000035699 permeability Effects 0.000 description 4
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 4
- 238000004458 analytical method Methods 0.000 description 3
- 239000011230 binding agent Substances 0.000 description 3
- 238000004814 ceramic processing Methods 0.000 description 3
- VGBWDOLBWVJTRZ-UHFFFAOYSA-K cerium(3+);triacetate Chemical compound [Ce+3].CC([O-])=O.CC([O-])=O.CC([O-])=O VGBWDOLBWVJTRZ-UHFFFAOYSA-K 0.000 description 3
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 229910052878 cordierite Inorganic materials 0.000 description 3
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 3
- 239000011261 inert gas Substances 0.000 description 3
- 238000001878 scanning electron micrograph Methods 0.000 description 3
- 229910052710 silicon Inorganic materials 0.000 description 3
- 229910010271 silicon carbide Inorganic materials 0.000 description 3
- XTEGARKTQYYJKE-UHFFFAOYSA-M Chlorate Chemical compound [O-]Cl(=O)=O XTEGARKTQYYJKE-UHFFFAOYSA-M 0.000 description 2
- 229920003091 Methocel™ Polymers 0.000 description 2
- 235000014676 Phragmites communis Nutrition 0.000 description 2
- 229910004298 SiO 2 Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 230000033228 biological regulation Effects 0.000 description 2
- 229910002114 biscuit porcelain Inorganic materials 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 238000013329 compounding Methods 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 229920000609 methyl cellulose Polymers 0.000 description 2
- 239000001923 methylcellulose Substances 0.000 description 2
- 150000002894 organic compounds Chemical class 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 238000013001 point bending Methods 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 239000002244 precipitate Substances 0.000 description 2
- 230000008929 regeneration Effects 0.000 description 2
- 238000011069 regeneration method Methods 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 239000010409 thin film Substances 0.000 description 2
- 238000002834 transmittance Methods 0.000 description 2
- 238000004876 x-ray fluorescence Methods 0.000 description 2
- 101150010783 Aard gene Proteins 0.000 description 1
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- KLZUFWVZNOTSEM-UHFFFAOYSA-K Aluminium flouride Chemical compound F[Al](F)F KLZUFWVZNOTSEM-UHFFFAOYSA-K 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- KRHYYFGTRYWZRS-UHFFFAOYSA-M Fluoride anion Chemical compound [F-] KRHYYFGTRYWZRS-UHFFFAOYSA-M 0.000 description 1
- 229910017855 NH 4 F Inorganic materials 0.000 description 1
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 239000012080 ambient air Substances 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 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 1
- 229910000420 cerium oxide Inorganic materials 0.000 description 1
- 238000009614 chemical analysis method Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000007931 coated granule Substances 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 239000002270 dispersing agent Substances 0.000 description 1
- 238000001493 electron microscopy Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 239000010408 film Substances 0.000 description 1
- 229910001679 gibbsite Inorganic materials 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000000462 isostatic pressing Methods 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 229910052743 krypton Inorganic materials 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- HCWCAKKEBCNQJP-UHFFFAOYSA-N magnesium orthosilicate Chemical compound [Mg+2].[Mg+2].[O-][Si]([O-])([O-])[O-] HCWCAKKEBCNQJP-UHFFFAOYSA-N 0.000 description 1
- 239000000391 magnesium silicate Substances 0.000 description 1
- 229910052919 magnesium silicate Inorganic materials 0.000 description 1
- 235000019792 magnesium silicate Nutrition 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 229910052754 neon Inorganic materials 0.000 description 1
- QJGQUHMNIGDVPM-UHFFFAOYSA-N nitrogen group Chemical group [N] QJGQUHMNIGDVPM-UHFFFAOYSA-N 0.000 description 1
- 229910052756 noble gas Inorganic materials 0.000 description 1
- 150000002835 noble gases Chemical class 0.000 description 1
- 229910000510 noble metal Inorganic materials 0.000 description 1
- 239000000615 nonconductor Substances 0.000 description 1
- 150000002902 organometallic compounds Chemical class 0.000 description 1
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 description 1
- 239000011236 particulate material Substances 0.000 description 1
- 239000013618 particulate matter Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 229910052704 radon Inorganic materials 0.000 description 1
- 239000011819 refractory material Substances 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 238000007569 slipcasting Methods 0.000 description 1
- 238000010345 tape casting Methods 0.000 description 1
- 238000005382 thermal cycling Methods 0.000 description 1
- 229910052724 xenon Inorganic materials 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
- B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
- B01D53/86—Catalytic processes
- B01D53/88—Handling or mounting catalysts
- B01D53/885—Devices in general for catalytic purification of waste gases
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- 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
- B01D53/944—Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
- B01D71/02—Inorganic material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
- B01J21/12—Silica and alumina
-
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- B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
- B01J21/16—Clays or other mineral silicates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
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- B01J23/002—Mixed oxides other than spinels, e.g. perovskite
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- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/02—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the alkali- or alkaline earth metals or beryllium
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- B01J23/10—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of rare earths
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- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
- B01J23/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
- B01J23/78—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36 with alkali- or alkaline earth metals
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- B01J35/30—
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- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/22—Halogenating
- B01J37/26—Fluorinating
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
- C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
- C04B35/185—Mullite 3Al2O3-2SiO2
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/64—Burning or sintering processes
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
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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
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
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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
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/033—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices
- F01N3/035—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
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- B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract
Description
a)ムライト中に存在する複数の元素を有する1種又はそれ以上の先駆体化合物と、Mg、Ca、Fe、Na、K、Ce、Pr、Nd、Sm、Eu、Gd、Tb、Dy、Ho、Er、Tm、Yb、Lu、B、Y、Sc、La及びこれらの組合せよりなる群から選ばれる元素を含む特性を増進させる化合物(即ち、特性増進性化合物)(property enhancing compound)との混合物を形成せしめ、
b)前記混合物を多孔質の生の造形物(green shape)に賦形し、
c)工程b)の多孔質の生の造形物を、フッ素含有ガスを有する雰囲気下で、本質的に化学的に結合した、針状ムライト粒状物から実質的になるムライト組成物を形成せしめるのに十分な温度に加熱する、
ことを含んでなる。
ムライト組成物は、本質的に化学的に結合した針状ムライト粒状物で構成される。そのムライト粒状物は、少なくともムライト組成物の約90%を構成することが望ましい。好ましくは、そのムライト粒状物は、その組成物の少なくとも約95体積%、より好ましくは少なくとも約98体積%、さらに好ましくは少なくとも約99体積%のムライト組成物を構成するのがよい。ムライト組成物は、ムライト粒状物に加えて、シリカ及び酸化物の形態の金属不純物で構成されるガラス相を含有するが、この金属不純物はガラス中に結晶沈殿物として存在しうる。ガラス相は、通常、粒状物の表面及び粒状物の界面(intersecting grain surfaces)に位置している。
ムライト組成物の作製において、Al、Si及び酸素を含む先駆体化合物を特性増進性化合物と混合して、ムライトを形成性混合物が生成される。使用しうる先駆体化合物は、米国特許第5,194,154号;第5,198,007号;第5,173,349号;第4,911,902号;第5,252,272号;第4,948,766号及び第4,910,172号の各明細書に記載されており、それぞれ引用により本明細書に組み込まれる。この混合物もまた、混合物の賦形を促進するため、有機化合物(例えば、J.Reedの“Introduction to the Principles of Ceramic Processing”、Wiley Interscience,1988年刊行に記載のものなどのバインダー及び分散剤)を含むことができる。
Al/Si化学量論約2.95を有するムライト先駆体物質から、棒状体を加圧成型した。この先駆体物質は、酢酸セリウム(“α−Aesar”,Aard Hill,MA)を、先駆体物質の合計量の11.6重量%と等しい量となるように、5重量%メチルセルロース水溶液(“METHOCEL A15LV”,The Dow Chemical Co.,Midland,MI)中に溶解することにより作製した。酢酸セリウムの量は、表IIに示すように、ムライト組成物中の酸化セリウム3.6体積%に相当するものであった。これに、“Pioneer Kaolin”(DBK Company,Dry Branch,GA)約57.2重量部(pbw)、及びκ−アルミナ約42.8pbwを添加した。“Pioneer Kaolin”の組成は表Iに示す。κ−アルミナは、水酸化アルミニウム(“P3 Gibbsite”,Alcoa,Pittsbourgh,PA)を、1000℃で1時間加熱することにより調製した。この混合物を約1時間攪拌し、次いで45℃で乾燥した。得られた乾燥混合物を粉砕して、100メッシュの篩にかけた。乾燥粉砕混合物は、次いで、一軸プレスを用い、圧力約5,000〜約10,000psiで棒状体に加圧成型した。この棒状物は、有機バインダー(すなわち“METHOCEL”)を除去するために、前記クレーを脱水(すなわちビスク焼き)するために、1100℃で10時間加熱し、1100℃で1時間保持し、次いで5時間冷却した。
表II及びIIIに示すように、酢酸セリウムとは異なる添加剤を用いたことを除き実施例1と同様にして、実施例2〜12を実施した。もし添加剤が水に溶解しなければ、少量の水でよく分散してメチルセルロース水溶液に混合した。棒状体に対する圧縮圧は、表II及びIIIに示す最終的な多孔度を達成するため、約5000〜約10,000psiに変動させた。
添加剤を用いず、且つ表II及びIIIに示す多孔度を達成するため圧縮圧を変動させたことを除き実施例1と同様にして、比較例1及び2を実施した。比較例1及び2の透過率を測定したところ、透過率は約2×10-13m2及び約3×10-13m2であった。
Claims (31)
- a)ムライト中に存在する複数の元素を有する1種又はそれ以上の先駆体化合物と、Mg、Ca、Fe、Na、K、Ce、Pr、Nd、Sm、Eu、Gd、Tb、Dy、Ho、Er、Tm、Yb、Lu、B、Y、Sc、La及びこれらの組合せよりなる群から選ばれる元素を含む特性増進性化合物との混合物を形成せしめ、
b)前記混合物を多孔質の生の造形物に賦形し、
c)工程b)の多孔質の生の造形物を、フッ素含有ガスを有する雰囲気下に、本質的に化学的に結合した、針状のムライト粒状物から実質的になるムライト組成物を形成せしめるのに十分な温度に加熱する
ことを含んでなる針状ムライト組成物の製造方法。 - 先駆体化合物がクレー並びにアルミナ、シリカ、フルオロトパーズ、ゼオライト、AlF3及びこれらの混合物よりなる群から選ばれる別の化合物である請求項1に記載の方法。
- 他の先駆体化合物がアルミナ、シリカ、フルオロトパーズ、ゼオライト及びこれらの混合物よりなる群から選ばれる別の化合物である請求項2に記載の方法。
- 先駆体化合物がアルミナ、シリカ及びクレーである請求項1に記載の方法。
- フッ素含有ガスが別に供給されるSiF4である請求項1に記載の方法。
- 特性増進性化合物が酸化物、酢酸塩、炭酸塩又は硝酸塩である請求項1に記載の方法。
- 特性増進性化合物がタルクである請求項1に記載の方法。
- 特性増進性化合物がCe、B、Fe及びNdよりなる群から選ばれる元素を有する第一の特性増進性化合物並びにMg、Ca、Pr、Sm、Eu、Gd、Tb、Dy、Ho、Er、Tm、Yb、Lu、Y、Sc、La及びこれらの組合せよりなる群から選ばれる元素を有する第二の特性増進性化合物から構成される請求項1に記載の方法。
- 第二の特性増進性化合物の元素がMg、Ca、Y又はこれらの組合せである請求項8に記載の方法。
- 前記元素がB、Y、Ce、Nd及びこれらの組合せよりなる群から選ばれる請求項1に記載の方法。
- 前記元素がNd及びMgで、ムライト組成物中のNd/Mgの比が重量で約0.1〜約10である請求項1に記載の方法。
- 工程(c)の加熱が、第一の温度にまでなされ、次いで第二のより高い温度までなされ、フルオロトパーズが第一の温度で形成され、そしてムライトが第二のより高い温度で形成される請求項1に記載の方法。
- 第一の温度で形成されるフルオロトパーズが、別に供給されるSiF4で構成される雰囲気中で形成される請求項12に記載の方法。
- 第一の温度が約500℃〜約950℃である請求項13に記載の方法。
- 第一の温度が少なくとも650℃から約750℃までである請求項14に記載の方法。
- 第二の温度が少なくとも約960℃から高くても約1300℃である請求項13に記載の方法。
- 少なくともムライト粒状物の一部の上に、Ce、Pr、Nd、Sm、Eu、Gd、Tb、Dy、Ho、Er、Tm、Yb、Lu、B、Y、Sc、La及びこれらの組合せよりなる群から選ばれる元素で構成される相を有する、本質的に化学的に結合した針状のムライト粒状物で実質的に構成される多孔質ムライト組成物。
- 前記元素がCe、Nd、B、Y又はこれらの組合せよりなる群から選ばれる請求項17に記載の多孔質ムライト組成物。
- 前記組成物がその中にNd及びMgを有し、且つNd/Mgの比が重量で約0.1〜約10である請求項17に記載の多孔質ムライト組成物。
- 前記比が約0.2〜約5である請求項19に記載の多孔質ムライト組成物。
- 前記多孔質ムライト組成物が約50%〜約70%の多孔度を有する請求項17に記載の多孔質ムライト組成物。
- 前記多孔質ムライト組成物が少なくとも約300℃の耐熱衝撃係数を有する請求項17に記載の多孔質ムライト組成物。
- 前記ムライト組成物が少なくとも約400℃の耐熱衝撃係数を有する請求項22に記載の多孔質ムライト組成物。
- 請求項17に記載のムライト組成物で構成されるディーゼル粒子フィルター。
- 前記ムライト組成物がムライト組成物のムライト粒状物の少なくとも一部の上に触媒被膜を有する請求項24に記載のディーゼル粒子フィルター。
- 請求項23に記載のムライト組成物で構成されるディーゼル粒子フィルター。
- 前記ムライト組成物がムライト組成物のムライト粒状物の少なくとも一部の上に触媒被膜を有する請求項26に記載のディーゼル粒子フィルター。
- ムライト組成物の粒状物の少なくとも一部に触媒被膜を有する請求項17に記載のムライト組成物で構成される触媒。
- 前記触媒が排気処理又は触媒燃焼器用の自動車触媒である請求項28に記載の触媒。
- 本質的に化学的に結合した針状のムライト粒状物から実質的に構成され、ほうき柄型ムライト粒状物を実質的に含まない多孔質ムライト組成物。
- 前記元素がFe及びMgで、Fe/Mgの比が約0.5〜1.5である請求項1に記載の方法。
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- 2004-04-23 KR KR1020057020044A patent/KR101116955B1/ko active IP Right Grant
- 2004-04-23 EP EP04750626A patent/EP1618078B1/en not_active Expired - Lifetime
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2007
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JP2010513025A (ja) * | 2006-12-21 | 2010-04-30 | ダウ グローバル テクノロジーズ インコーポレイティド | 改善されたすすフィルター |
JP2015178104A (ja) * | 2006-12-21 | 2015-10-08 | ダウ グローバル テクノロジーズ エルエルシー | 改善されたすすフィルター |
JP2014166635A (ja) * | 2009-09-04 | 2014-09-11 | Hitachi Metals Ltd | セラミックハニカム構造体の製造方法 |
JP5630437B2 (ja) * | 2009-09-04 | 2014-11-26 | 日立金属株式会社 | セラミックハニカム構造体 |
US9074504B2 (en) | 2009-09-04 | 2015-07-07 | Hitachi Metals, Ltd. | Ceramic honeycomb structure and its production method |
US9724633B2 (en) | 2009-09-04 | 2017-08-08 | Hitachi Metals, Ltd. | Ceramic honeycomb structure and its production method |
JP2014518193A (ja) * | 2011-07-06 | 2014-07-28 | ダウ グローバル テクノロジーズ エルエルシー | 多孔質針状ムライト体の製造方法 |
JP2016507684A (ja) * | 2012-11-30 | 2016-03-10 | ダウ グローバル テクノロジーズ エルエルシー | ハニカムフィルタによるガソリン直噴射エンジン排ガスの濾過 |
JP2016505491A (ja) * | 2012-12-05 | 2016-02-25 | ダウ グローバル テクノロジーズ エルエルシー | 改良された熱安定性を有する多孔質ムライト体 |
JP2016508105A (ja) * | 2012-12-05 | 2016-03-17 | ダウ グローバル テクノロジーズ エルエルシー | 改良された熱安定性を有する多孔性ムライト体 |
Also Published As
Publication number | Publication date |
---|---|
US20070203315A1 (en) | 2007-08-30 |
ATE409172T1 (de) | 2008-10-15 |
CN101164965B (zh) | 2012-09-26 |
WO2004096729A2 (en) | 2004-11-11 |
CN100368339C (zh) | 2008-02-13 |
WO2004096729A3 (en) | 2005-01-27 |
PL1618078T3 (pl) | 2009-04-30 |
PL1754692T3 (pl) | 2013-05-31 |
BRPI0410493A (pt) | 2006-06-13 |
ZA200508293B (en) | 2007-10-31 |
US20060197265A1 (en) | 2006-09-07 |
EP1754692A1 (en) | 2007-02-21 |
KR20060008912A (ko) | 2006-01-27 |
EP1754692B1 (en) | 2012-10-31 |
CN101164965A (zh) | 2008-04-23 |
EP1618078A2 (en) | 2006-01-25 |
CA2522916A1 (en) | 2004-11-11 |
JP2012046418A (ja) | 2012-03-08 |
KR101116955B1 (ko) | 2012-03-14 |
CA2522916C (en) | 2011-11-22 |
US7528087B2 (en) | 2009-05-05 |
ES2311160T3 (es) | 2009-02-01 |
CN1777566A (zh) | 2006-05-24 |
DE602004016742D1 (de) | 2008-11-06 |
EP1618078B1 (en) | 2008-09-24 |
JP5184781B2 (ja) | 2013-04-17 |
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