JP2013516307A - モノリス基材を触媒成分でコーティングする方法 - Google Patents
モノリス基材を触媒成分でコーティングする方法 Download PDFInfo
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- JP2013516307A JP2013516307A JP2012546507A JP2012546507A JP2013516307A JP 2013516307 A JP2013516307 A JP 2013516307A JP 2012546507 A JP2012546507 A JP 2012546507A JP 2012546507 A JP2012546507 A JP 2012546507A JP 2013516307 A JP2013516307 A JP 2013516307A
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- B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B05D7/22—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to internal surfaces, e.g. of tubes
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/24—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials for applying particular liquids or other fluent materials
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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- 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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- 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
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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- 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
- F01N3/105—General auxiliary catalysts, e.g. upstream or downstream of the main catalyst
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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
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- F01N3/18—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 methods of operation; Control
- F01N3/20—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 methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
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- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
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- F01N3/18—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 methods of operation; Control
- F01N3/20—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 methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
- F01N3/2066—Selective catalytic reduction [SCR]
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Abstract
Description
(i)前記ピストンヘッドが注入された液体を密封可能に維持するための手段を含み、密封が真空適用およびスイッチオフに続いて維持(すなわち、静的真空が基材に残る)される実施形態において、基材は、前記ピストンヘッドと空圧的密封を形成することができる。前記真空手段上の前記(第2)保持手段は、前記基材が前記ピストンヘッドから引っ張られるようにする。
(ii)前記基材チャネルにおけるいかなる真空損失も防ぐ。
(iii)基材のエッジ(edge)損傷を防ぐか減少させることで、基材を保護する。
(iv)空気が前記ハウジングに接近できるようにし、液体が注入される前記基材の端部を介して前記基材に入るが、これは、ハウジングの壁に穴を形成することによってなされることも可能である。
実施例1において、商業的に利用可能な炭化ケイ素ウォールフローフィルタ(NGK Insulator Ltd.、製品コード:MSC−111)(円形断面(直径5.66インチ(14.4cm))と軸方向長さ6インチ(15.24cm)、セル密度300cpsi、チャネル壁厚さ0.305mm、空隙率52%、水銀空隙測定によって評価された平均空隙大きさ23μmおよび供給者(すなわち、NGK)によって微細に分離された耐火粒子を含むメンブランでプリコーティングされた入口チャネルを備える)が、本発明にかかる方法および従来のディップコーティング方法によってSCR触媒でコーティングされた出口チャネルを含むフィルタの物理化学的性質を比較するために使用された。
実施例1および比較実施例2によって製造された、コーティングされたウォールフローフィルタがx線密度分析を利用して分析され、供給者から提供されたMSC−111フィルタ(すなわち、メンブラン層でプリコーティングされた入口チャネルを備えるが、出口チャネルに塗布されたSCRコーティングは備えられていない)と比較された。結果が図8に示されているが、x線密度線がコーティングされたか、または「バージン(virgin:未処理)」部分のx線上に重なる。フィルタの長さに沿って所与の軸方向位置に対して左側に最も遠いX線密度データポイントは、例えば、ウォールフローフィルタのエンドプラグ(end−plug)に比べて相対的に高い密度を示す。反面、フィルタの長さ方向に沿って所与の軸方向位置に対する右側に最も遠いデータポイントは、相対的に低い密度を示す。
粒子性物質を含むディーゼル排気ガスを用いた実施例1と比較実施例2の各フィルタの煤含有量に対する背圧増加率が、ディーゼル粒子発生器(DPG)と欧州特許1850068A1に開示され、Cambustion Ltd.によって製造されたテストセルを用いてテストされた。すなわち、液体炭素含有燃料の燃焼で誘導された粒子性物質を発生させて捕集するための装置は、ノズルを備える燃料燃焼器を含み、前記ノズルは、コンテナ内に収容され、前記コンテナは、ガス入口とガス出口を含み、前記ガス出口は、ガスを大気に伝達するための配管に連結され、前記ガス入口を介して流れるガス速度を検出するための手段と、酸化ガスをガス入口からコンテナ、ガス出口および配管を経て大気に流れるようにする手段と、前記配管を介して流れるガスから粒子性物質を捕集するためのステーション(station)およびガス入口で検出されたガス流れ速度に対応してガス流れ手段を制御するための手段とを含み、前記ガス入口におけるガス流れ速度は、コンテナ内でサブ化学量論的(sub−stoichiometric)燃料の燃焼を提供する所望の速度で維持され、それによって粒子性物質の形成を促進させる。
実施例1と比較実施例2のフィルタは、それぞれベンチ実験台(bench−mounted)ユーロ4規格(2リットルの直接噴射、コモンレール(common rail)エンジン(例えば、乗用車用として適切)の下流側の1リットルの酸化触媒(350cpsiのコーディエライトモノリスフロースルー基材にコーティングされた、2:1の重量比を有する白金およびパラジウム95g/ft3)、フィルタは、プリコーティングされたメンブラン層を備えるチャネルがフィルタのガス入口側にあるように配置)の排気ガスシステムにそれぞれ順次に装着された。標準ディーゼルエンジン燃料は50ppmの硫黄分を含有する。尿素水溶液(AdBlue)を排気ガス内に噴射するための尿素インジェクタが酸化触媒とフィルタとの間に配置される。10ppm未満の硫黄のディーゼル燃料が使用された。初期ウォーミングアップ状態に続き、エンジンは、所望のフィルタ入口温度を得るために、一連のエンジン荷重で作動した。テスト条件は、表1に記載されたとおりである。「アルファ」は、NH3/NOx比として定義される。「0.7のアルファ」の場合、理論的な最大NOx転換率は、反応式4NO+4NH3+3O2→4N2+6H2OおよびNO+NO2+2NH3→2N2+3H2Oによって70%である。エンジン制御技術内でプログラムされた排気ガス循環バルブの位置は、EGRをオフにするために移り、工程3−5は、包括的に合理的な期間(時間の代わり)内に完了した。工程1〜工程5の全過程は、後に続いて直ちに1つで行われた。
Claims (24)
- 複数のチャネルを含むハニカムモノリス基材を、触媒成分を含有する液体でコーティングする方法であって、
(i)ハニカムモノリス基材を実質的に垂直に維持し、
(ii)前記液体の予め決定された量を前記基材の下端で前記チャネルの開放端部を介して前記基材内に注入し、
(iii)前記基材内の注入した液体を密封維持し、
(iv)前記維持した液体を含む基材を反転させ、及び
(v)前記基材の反転した下端で前記基材のチャネルの開放端部に真空を付与し、前記液体を前記基材のチャネルを介して吸収する、各工程を含んでなる、方法。 - 工程(i)と工程(ii)との間に、前記基材の外部表面を前記基材の下端で前記チャネルの開放端部と密封させる工程を含んでなる、請求項1に記載の方法。
- 前記工程(v)で前記液体を維持させる密封が、後の真空付与によってのみ解除される、請求項1又は2に記載の方法。
- 前記基材が、フィルタである、請求項1〜3の何れか一項に記載の方法。
- 複数のチャネルを含むハニカムモノリス基材を、触媒成分を含有する液体でコーティングする装置であって、
(a)前記ハニカムモノリス基材を実質的に垂直に維持するための手段と、
(b)前記基材内に前記液体の予め決定された量を前記基材の下端で前記チャネルの開放端部を介して注入するための手段と、
(c)前記基材内の前記注入された液体を密封維持するための手段と、
(d)前記維持された液体を含む前記基材を反転させるための手段と、及び
(e)前記基材の反転した下端で前記基材のチャネルの開放端部に真空を付与し、前記液体を前記基材のチャネルを介して吸収するための手段とを備えなる、装置。 - 前記保持手段が、前記基材の少なくとも下端を収容するためのハウジングを備えてなる、請求項5に記載の装置。
- 前記保持手段が、前記基材の外部表面と結合するために、前記ハウジングの内部表面に設けられてなる膨張可能なカラーを備えてなる、請求項6に記載の装置。
- 前記液体注入手段が、シリンダ内で往復運動するピストンを備えてなる、請求項5〜7の何れか一項に記載の装置。
- 前記ピストンが、第1位置と第2位置との間で往復運動してなり、
前記ピストンヘッドがシリンダヘッドに隣接してなるものであり、
前記シリンダの内壁、シリンダヘッドおよびピストンヘッドが少なくとも部分的に変位容積を定義する、請求項8に記載の装置。 - 前記ピストンヘッドの表面が、前記ピストンが前記第1位置に位置する時、前記基材の下端を支持するものである、請求項9に記載の装置。
- 前記シリンダのケーシングが、前記シリンダボアに前記液体を供給するためのバルブを含んでなる、請求項8〜10の何れか一項に記載の装置。
- 前記基材内の前記注入された液体を密封維持するための手段が、前記ピストンヘッドの表面を備えてなる、請求項8〜11の何れか一項に記載の装置。
- 前記ハウジング、ピストン、およびシリンダが、前記反転手段によって反転する、請求項12に記載の装置。
- 前記基材の外部表面を前記基材の下端で前記チャネルの開放端部から密封させるための手段を含む請求項5〜13の何れか一項に記載の装置。
- 請求項7において、
前記基材の外部表面を前記基材の下端で前記チャネルの開放端部から密封させるための手段が、前記膨張可能カラーを備えてなる、請求項14に記載の装置。 - 前記真空手段が、前記基材の反転した端部を収容する、端部が広い漏斗を備えてなる、請求項5〜15の何れか一項に記載の装置。
- 請求項1〜4の何れか一項に記載の方法工程を行う装置を制御するためのコンピュータ動作手段を備えてなる、請求項5〜16の何れか一項に記載の装置。
- 触媒化されたウォールフローフィルタ基材モノリスであって、
ウォールフローフィルタ基材の入口チャネルに予備コーティングし、微細に分離された耐火性固体物を含む表面メンブラン層を備えてなり、
出口チャネルが、軸方向に沿って実質的に均一な触媒ウォッシュコートのコーティングプロファイルを備えてなり、
請求項1〜4の何れか一項に記載の方法によって得られてなる、触媒化されたウォールフローフィルタ基材モノリス。 - 触媒化されたウォールフローフィルタ基材モノリスであって、
ウォールフローフィルタ基材の入口チャネルに予備コーティングし、微細に分離された耐火性固体物を含む表面メンブラン層を備えてなり、
出口チャネルが、軸方向に沿って実質的に均一な触媒ウォッシュコートのコーティングプロファイルを備えてなり、
前記触媒化されたウォールフローフィルタ基材モノリスの軸方向の上流側半分の前記ウォッシュコーティング含有量が、軸方向の下流側半分の含有量の10%以内である、触媒化されたウォールフローフィルタ基材モノリス。 - 前記ウォールフローフィルタ基材モノリスのコーティング前の空隙率が、40〜80%である、請求項18又は19に記載の触媒化されたウォールフローフィルタ基材モノリス。
- 前記ウォールフローフィルタ基材モノリスのコーティング前の平均空隙容積が、8〜45μmである、請求項18〜20の何れか一項に記載の触媒化されたウォールフローフィルタ基材モノリス。
- 前記触媒ウォッシュコートが、NOxトラップ、担持された白金族金属を含んでなる触媒化された煤フィルタウォッシュコート、又はNH3−SCR触媒である、請求項18〜21の何れか一項に記載の触媒化されたウォールフローフィルタ基材モノリス。
- 前記NH3−SCR触媒が、ゼオライトで置換された遷移金属を含んでなる、請求項22に記載の触媒化されたウォールフローフィルタ基材モノリス。
- 前記遷移金属が、銅、鉄、セリウムおよびこらの二種以上の混合物からなる群より選択されてなり、
前記ゼオライトが、フェリエライト、CHA、BEAおよびMFI(ZSM−5)からなる群より選択されてなる、請求項23に記載の触媒化されたウォールフローフィルタ基材モノリス。
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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GB1000019.8 | 2010-01-04 | ||
GBGB1000019.8A GB201000019D0 (en) | 2010-01-04 | 2010-01-04 | Coating a monolith substrate with catalyst component |
PCT/GB2011/050005 WO2011080525A1 (en) | 2010-01-04 | 2011-01-04 | Method of coating a monolith substrate with catalyst component |
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JP6244421B1 (ja) * | 2016-07-27 | 2017-12-06 | 株式会社キャタラー | 排ガス浄化用触媒の製造方法及び製造装置 |
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