JP2017523040A - 触媒を製造するための方法及び触媒物品 - Google Patents
触媒を製造するための方法及び触媒物品 Download PDFInfo
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- JP2017523040A JP2017523040A JP2017505129A JP2017505129A JP2017523040A JP 2017523040 A JP2017523040 A JP 2017523040A JP 2017505129 A JP2017505129 A JP 2017505129A JP 2017505129 A JP2017505129 A JP 2017505129A JP 2017523040 A JP2017523040 A JP 2017523040A
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Images
Classifications
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- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/02—Impregnation, coating or precipitation
- B01J37/024—Multiple impregnation or coating
- B01J37/0246—Coatings comprising a zeolite
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- 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
- B01D53/92—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
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- 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
- B01D53/9404—Removing only nitrogen compounds
- B01D53/9409—Nitrogen oxides
- B01D53/9413—Processes characterised by a specific catalyst
- B01D53/9418—Processes characterised by a specific catalyst for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas
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- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
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- B01J29/00—Catalysts comprising molecular sieves
- B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
- B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
- B01J29/70—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65
- B01J29/72—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65 containing iron group metals, noble metals or copper
- B01J29/76—Iron group metals or copper
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J29/00—Catalysts comprising molecular sieves
- B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
- B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
- B01J29/70—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65
- B01J29/72—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65 containing iron group metals, noble metals or copper
- B01J29/76—Iron group metals or copper
- B01J29/763—CHA-type, e.g. Chabazite, LZ-218
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/30—Catalysts, in general, characterised by their form or physical properties characterised by their physical properties
- B01J35/396—Distribution of the active metal ingredient
- B01J35/397—Egg shell like
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Abstract
Description
−機能粒子中で細孔成形剤により形成され、
−更に無機粒子を含むマトリクス中に埋め込まれ、
−細孔構造を形成し、かつ
−機能粒子の触媒的に活性な材料の層を含む活性な界面層により少なくとも部分的に囲まれる
多孔性の触媒的に不活性なセル、
を少なくとも含むセラミック体を形成するように、触媒組成物は、最終的に触媒を形成するような熱的処理に供される。
−触媒からなる押出成形触媒物品、
−触媒からなるハニカム、
−触媒からなるプレート触媒コンバーター、
−触媒からなるペレット、
−触媒からなるウォッシュコートでコーティングされたモノリス支持体、
−ハニカムを含むウォールフローフィルターであって、ハニカムが触媒からなりかつ/又はハニカムが触媒から構成されるウォッシュコートでコーティングされたウォールフローフィルター、
の何れかである成形体である。
4 細孔成形剤
5 層
6 粉末粒子
8 機能粒子
10 バインダー成分
12 触媒組成物
14 成形体
17 触媒物品
18 細孔構造
20 セル
22 活性界面層
24 マトリクス
Claims (39)
- 特に排気ガス処理のための、セラミック触媒(2)を製造するための方法であって、
a)触媒的に活性な材料の層(5)により囲まれている支持体として触媒的に不活性な細孔成形剤を有する機能粒子(8)を提供し、
b)機能材料(8)を、更なる無機粒子(10)で処理して触媒組成物(12)を与え、
c)触媒組成物(12)を、熱的に処理してセラミック触媒(2)を形成することにおいて、触媒(2)が、
− 機能粒子(8)中の細孔成形剤(4)により形成され、
− 更なる無機粒子(10)を含むマトリクス(24)中に埋め込まれ、
− 多孔性構造(18)を形成し、かつ
− 機能粒子(8)の触媒的に活性な材料の層(5)を含む活性な界面層(22)により少なくとも部分的に囲まれている、
少なくとも多孔性の触媒的に不活性なセル(20)を含む、セラミック触媒(2)を形成する、方法。 - 細孔成形剤(4)は、特に熱可塑物又はエラストマーを含むか又はそれらからなる有機材料であって、セルが細孔(20)として形成されるように、触媒組成物(12)の熱処理の過程で漏れる有機材料からなる、請求項1に記載の方法。
- 細孔成形剤(4)が、少なくともメソ多孔性、好ましくはマクロ多孔性を特に有する無機多孔性材料からなる、請求項1に記載の方法。
- 無機材料が、クレイ鉱物、特にピラードクレイ鉱物、珪藻土、シリカゲル及び多孔性ガラスから選択される、請求項3に記載の方法。
- 触媒的に活性な材料の粉末粒子(6)が、細孔成形剤(4)に塗布される、請求項1から4の何れか一項に記載の方法。
- 粉末粒子(6)は、粘着により塗布され、かつこの目的のために、特に、任意選択的に有機材料からなる細孔成形剤(4)が、それらが柔らかくなりかつ粉末粒子(6)が細孔成形剤の表面に付着したままであるように、加熱されるか、又は細孔成形剤(4)に接着剤を塗布することにより塗布される、請求項5に記載の方法。
- 層(5)が、触媒的に活性な層(5)への触媒的に不活性な細孔成形剤(4)の外部層の変換により形成される、請求項1から4の何れか一項に記載の方法。
- 細孔成形剤(4)が、10μmから200μmの範囲内、特に、30−150μmの範囲内の粒径を有する、請求項1から7の何れか一項に記載の方法。
- 更なる無機粒子が、工程c)での処理後にセラミックマトリクス(24)を形成するバインダー成分(10)を有する、請求項1から8の何れか一項に記載の方法。
- 成形体(14)が押出成形により触媒組成物から形成され、かつその後、成形体(14)が熱的に処理される、請求項1から9の何れか一項に記載の方法。
- 触媒(2)が、熱処理の後に、触媒的に活性な材料を含むウォッシュコートでコーティングされる、請求項10に記載の方法。
- 触媒組成物(12)がウォッシュコートとしてモノリス支持体に塗布され、かつその後、このコーティングされた支持体が熱的に処理される、請求項1から10の何れか一項に記載の方法。
- 機能粒子(8)の形成のための細孔成形剤(4)への層(5)の塗布、及び触媒組成物(12)の処理が、単一の方法工程で行われる、請求項1から12の何れか一項に記載の方法。
- 細孔成形剤(4)が、乾燥触媒組成物(12)ベースで40体積%から80体積%の範囲内、特に50−60%の範囲内の割合を占める、請求項1から13の何れか一項に記載の方法。
- 使用される触媒的に活性な材料が、
− 結晶性モレキュラーシーブ、特に(イオン−交換)ゼオライト
− 卑金属ベースの触媒システム、特にチタン−ベースのシステム
− タングステン/セリウム−ベースの触媒システム
− 金属酸化物若しくは混合酸化物
− 卑金属ベースの触媒システム
− PGM−ベースのシステム
のいずれか又は組み合わせである、請求項1から14の何れか一項に記載の方法。 - 結晶性モレキュラーシーブが個々の結晶子として存在する、請求項15に記載の方法。
- 結晶性モレキュラーシーブが、それらの固有のミクロ多孔性に加えて、IUPAC規格により規定される少なくともメソ多孔性を有する、請求項15又は16に記載の方法。
- 工程b)で触媒組成物中に導入される更なる粒子が、更なる触媒的に活性な材料である、請求項1から17の何れか一項に記載の方法。
- 異なる粒径分布の種々の細孔成形剤(4)が使用される、請求項1から18の何れか一項に記載の方法。
- 触媒組成物(12)が、層(5)に使用されている触媒的に活性な材料の面で異なる2以上の異なる機能粒子(8)を含み、
− 2以上の異なる触媒的に活性な材料の混合物、特に異なる粉末粒子(6)の混合物が、層(5)に使用され、かつ/又は
− 異なる触媒的に活性な材料が、混合され触媒組成物(12)を形成する第一及び第二の機能粒子(8)を得るように、特に、第一の細孔成形剤(4)に第一の粉末粒子(6a)を塗布すること及び第二の細孔成形剤(4)に第二の粉末粒子(6b)を塗布することにより、個々の細孔成形剤(4)のそれぞれに塗布される、
請求項1から19の何れか一項に記載の方法。 - 無機マトリクス(24)中に埋め込まれている多孔性構造(18)を有する複合構造を有する触媒(2)を含み、多孔性構造(18)が、触媒的に活性な材料を含む活性な界面層(22)により少なくとも部分的に囲まれる触媒的に不活性な少なくとも多孔性のセル(20)から形成されている、触媒物品(17)であって、
− 触媒(2)からなる押出成形触媒物品、
− 触媒(2)からなるハニカム、
− 触媒(2)からなるプレート触媒コンバーター、
− 触媒(2)からなるペレット、
− 触媒(2)からなるウォッシュコートでコーティングされているモノリス支持体、
− 触媒(2)からなるハニカム及び/又は触媒(2)から構成されるウォッシュコートでコーティングされているハニカムを含むウォールフローフィルター
の何れかである触媒物品。 - 押出成形触媒物品が、押出成形触媒物品と同様な触媒(2)又はそれらと異なる触媒含むウォッシュコートでコーティングされている、請求項21に記載の触媒物品(17)。
- 界面層(22)が、バインダー成分(20)を少なくとも実質的に含まない、請求項22に記載の触媒物品(17)。
- 触媒的に活性な材料が、セラミック的に結合されている、請求項22又は23に記載の触媒物品(17)。
- 個々のセル(20)の活性な界面層(22)が、セラミックセル状構造の形成のために互いに結合されている、請求項24に記載の触媒物品(17)。
- セラミックマトリクス(24)は、触媒的に活性な材料を少なくとも実質的に含まない、請求項19から22の何れか一項に記載の触媒物品(17)。
- 異なるサイズクラスのセル(20)を有する、請求項19から23の何れか一項に記載の触媒物品(17)。
- 2以上の異なる触媒的に活性な材料を有する触媒物品であって、
−第一のセル(20)を画定する活性な界面層(22)中の触媒的に活性な材料が、第二のセル(20)を画定する触媒的に活性な界面層(22)中の触媒的に活性な材料と異なり、かつ/又は
−特定のセル(20)を画定する活性な界面層(22)が、2以上の異なる触媒的に活性な材料を含有する、
請求項19から24の何れか一項に記載の触媒物品(17)。 - セル(20)が、10μmから200μmの範囲内の、特に、100μm未満のセルサイズを有する、請求項19から25の何れか一項に記載の触媒物品(17)。
- セル(20)により形成されているセル体積及び残りのソリッド体体積を有し、セル体積が、触媒の総体積ベースで45体積%から75体積%の範囲内である、請求項19から26の何れか一項に記載の触媒物品(17)。
- 触媒的に活性な界面層(22)が、ソリッド体体積の約20体積%から80体積%を占める、請求項27に記載の触媒物品(17)。
- 触媒的に活性な材料の活性な界面層(22)の層厚さが、活性な材料の粒径の範囲内、特に0.01−20μmの範囲内、特別には1μm−10μmの範囲内である、請求項19から28の何れか一項に記載の触媒物品(17)。
- SCR触媒の形態をとる、請求項19から29の何れか一項に記載の触媒物品(17)。
- ウォッシュコートでコーティングされているモノリス支持体がフィルター体である、請求項30又は31に記載の触媒物品(17)。
- 触媒的に活性な材料が、
− 結晶性モレキュラーシーブ、特に(イオン−交換)ゼオライト
− 卑金属ベース、特にチタンベースの触媒システム
− タングステン/セリウムベースの触媒システム
− 金属酸化物又は混合酸化物
− 卑金属ベースの触媒システム
− PGMベースのシステム
から選択される、請求項19から32の何れか一項に記載の触媒物品(17)。 - 結晶性モレキュラーシーブが個々の結晶子として存在する、請求項35に記載の触媒物品。
- 結晶性モレキュラーシーブが、それらの固有のミクロ多孔性に加えて、IUPAC規格により規定される少なくともメソ多孔性を有する、請求項35又は36に記載の触媒物品。
- 請求項1から20の何れか一項に記載の方法により得られ得る、請求項21から37の何れか一項に記載の触媒物品。
- 請求項1から20に記載の方法における使用のためか、又は請求項21から37の何れか一項に記載の触媒物品(17)における使用のための機能粒子(8)であって、触媒的に活性な材料の層(5)により囲まれている支持体の形態をとる細孔成形剤(4)を含む、機能粒子(8)。
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KR20200114460A (ko) | 2019-03-28 | 2020-10-07 | 한국생산기술연구원 | 계층형 구조의 다공성 TiO2 촉매지지체를 포함하는 질소산화물 제거용 저온형 탈질촉매 및 그 제조방법 |
JP7401376B2 (ja) | 2020-03-27 | 2023-12-19 | トヨタ自動車株式会社 | 排ガス浄化装置 |
WO2023063174A1 (ja) * | 2021-10-14 | 2023-04-20 | 三井金属鉱業株式会社 | 排ガス浄化触媒及びその製造方法 |
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GB2531859A (en) | 2016-05-04 |
DE102014215112A1 (de) | 2016-02-04 |
EP3174635B1 (en) | 2021-04-21 |
DK3174635T3 (da) | 2021-06-28 |
GB2531859B (en) | 2018-05-23 |
RU2017106177A (ru) | 2018-08-28 |
RU2751774C2 (ru) | 2021-07-16 |
US10441918B2 (en) | 2019-10-15 |
KR102397755B1 (ko) | 2022-05-13 |
US20170239619A1 (en) | 2017-08-24 |
GB201513133D0 (en) | 2015-09-09 |
EP3174635A1 (en) | 2017-06-07 |
EP3721997A1 (en) | 2020-10-14 |
KR20170037643A (ko) | 2017-04-04 |
BR112017001795B1 (pt) | 2020-09-15 |
JP2020078794A (ja) | 2020-05-28 |
RU2017106177A3 (ja) | 2019-01-24 |
JP6808007B2 (ja) | 2021-01-06 |
EP3721997B1 (en) | 2022-03-02 |
KR20220012994A (ko) | 2022-02-04 |
DK3721997T3 (da) | 2022-03-28 |
BR112017001795A2 (pt) | 2018-02-14 |
JP2021000631A (ja) | 2021-01-07 |
KR102479285B1 (ko) | 2022-12-21 |
CN106659974B (zh) | 2020-10-20 |
CN106659974A (zh) | 2017-05-10 |
WO2016016622A1 (en) | 2016-02-04 |
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