JP2017527437A - 活性プラグを有する排気フィルタ - Google Patents
活性プラグを有する排気フィルタ Download PDFInfo
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- JP2017527437A JP2017527437A JP2017512802A JP2017512802A JP2017527437A JP 2017527437 A JP2017527437 A JP 2017527437A JP 2017512802 A JP2017512802 A JP 2017512802A JP 2017512802 A JP2017512802 A JP 2017512802A JP 2017527437 A JP2017527437 A JP 2017527437A
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Images
Classifications
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- B01D53/34—Chemical or biological purification of waste gases
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- B01D53/34—Chemical or biological purification of waste gases
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- 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
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- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
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- 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
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- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
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- B01D—SEPARATION
- B01D2255/00—Catalysts
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Abstract
Description
浸透性の膜によって分離された入口チャネルと出口チャネルを表す一対のチャネルを通る排ガスの流れをモデリングした。ゼオライトプラグを、モデルにおける交互のチャネルの入口面及び出口面に施した。モデリングにより、異なる温度において、及び異なるウォッシュコート方法について、どこに、どの程度のNO変換が生じていたかの判断がもたらされた。
第1の端面から第2の端面へと軸方向に延びるチャネルを形成する交差壁と、
前記第1の端面における前記チャネルの第1の部分及び前記第2の端面における前記チャネルの第2の部分のうち少なくとも一方を封止するための活性プラグと、
を備え、各活性プラグが、
第1の活性成分を含み、該第1の活性成分が、前記プラグ構造の触媒活性成分及び化学活性成分のうち少なくとも1つを含み、前記交差壁が、前記第1の活性成分を含まない
ことを特徴とする、多孔質セラミックハニカム体。
前記交差壁が、触媒活性成分及び化学活性成分のうち少なくとも1つを含む第2の活性成分を含み、
前記第2の活性成分が、壁面上に配置されている、前記壁の細孔内に配置されている、及び前記壁の前記構造の全体に配置されている、のうちの少なくとも1つである
ことを特徴とする、実施形態1に記載の多孔質セラミックハニカム体。
各プラグが、前記交差壁と接触して配置された第1の層と、前記交差壁から各チャネルの軸心の方向に内側に前記第1の層上に配置された第2の層とを備え、前記第1の層及び前記第2の層のうち少なくとも一方が前記第1の活性成分を含むことを特徴とする、実施形態1又は2に記載の多孔質セラミックハニカム体。
各プラグを形成するバッチセメント組成物が前記第1の活性成分を含むことを特徴とする、実施形態1〜3のいずれかに記載の多孔質セラミックハニカム体。
前記第1の端面がフィルタ入口を有し、かつ前記第2の端面がフィルタ出口を有し、
前記第1の活性成分が複数の活性成分を含み、該複数の活性成分が、
第1の温度範囲において活性な、前記入口端における第1の温度活性成分と、第2の温度範囲において活性な、前記出口端における第2の温度活性成分とを含む
ことを特徴とする、実施形態1〜4のいずれかに記載の多孔質セラミックハニカム体。
前記第1の温度範囲が前記第2の温度範囲の下限より低い下限を有し、前記第2の温度範囲が前記第1の温度範囲の上限より高い上限を有することを特徴とする、実施形態1〜5のいずれかに記載の多孔質セラミックハニカム体。
前記第1の端面及び前記第2の端面のうちの少なくとも一方においてチャネルを封止するように配置された非活性プラグをさらに含む、実施形態1〜6のいずれかに記載の多孔質セラミックハニカム体。
前記第1の端面がフィルタ入口を有し、かつ前記第2の端面がフィルタ出口を有し、
前記第1の活性成分が複数の活性成分を含み、該複数の活性成分が、
第1の温度範囲において活性な、前記入口端におけるチャネルの第1の群内の第1の温度活性成分と、第2の温度範囲において活性な、前記入口端におけるチャネルの第2の群内の第2の温度活性成分とを含む
ことを特徴とする、実施形態1〜7のいずれかに記載の多孔質セラミックハニカム体。
前記第1の温度範囲が前記第2の温度範囲の下限より低い下限を有し、前記第2の温度範囲が前記第1の温度範囲の上限より高い上限を有することを特徴とする、実施形態1〜8のいずれかに記載の多孔質セラミックハニカム体。
前記第1の端面がフィルタ入口を有し、かつ前記第2の端面がフィルタ出口を有し、
前記第1の活性成分が複数の活性成分を含み、前記複数の活性成分が、
排ガス中のNOxの少なくとも40%を変換するのに有効な、前記入口端における触媒活性成分と、前記排ガス中のHCを変換するのに有効な、前記出口端における化学活性成分とを含む
ことを特徴とする、実施形態1〜9のいずれかに記載の多孔質セラミックハニカム体。
前記チャネルの前記第1の部分及び前記チャネルの前記第2の部分のうち少なくとも一方における前記活性プラグが、前記それぞれの端面から軸方向に間隔をあけていることを特徴とする、実施形態1〜10のいずれかに記載の多孔質セラミックハニカム体。
前記活性プラグが、前記第1の活性成分を10質量%〜80質量%含むことを特徴とする、実施形態1〜11のいずれかに記載の多孔質セラミックハニカム体。
前記第1の活性成分が、銅−ゼオライト、HCトラップ、高表面積材料に貴金属を加えたもの、高表面積材料、オンボード診断酸素貯蔵材料、セリア:ジルコニア固溶体材料、セリア:ジルコニア多相材料、三元触媒(TWC)、白金族金属(PGM)、ロジウム−チタニア、炭酸カルシウム、ゼオライト、Cu−交換ゼオライト、Fe−交換ゼオライト、アルミナ上に配置されたPGM;小細孔ゼオライト、Cu−チャバサイトゼオライト、及びアルカリ土類金属酸化物のうちの少なくとも1つを含むことを特徴とする、実施形態1〜12のいずれかに記載の多孔質セラミックハニカム体。
第1の端面から第2の端面へと軸方向に延びるチャネルを形成する交差壁を備えた多孔質セラミックハニカム体を施栓する方法であって、
前記ハニカム体に組成物を施して活性プラグを形成する工程を含み、前記組成物が、
活性成分;
粒径分布を有する耐火性フィラー;
有機結合剤;
無機結合剤;及び
液体ビヒクル;
を含み、
前記活性成分が触媒活性成分及び化学活性成分のうち少なくとも1つを含み、
前記交差壁が前記活性成分を含まない
ことを特徴とする、方法。
前記組成物を施した前記セラミックハニカム体を乾燥及び焼成し、フィルタ又はパーシャルフィルタを形成する工程をさらに含む、実施形態14に記載の方法。
前記組成物を施す工程が、
第2の層パテの上に第1の層パテを配置する工程と、
担体の上に前記第2の層パテを配置する工程と、
前記担体及び前記多孔質セラミックハニカム体を共に軸方向に所定の距離だけ押圧して、前記第1の端面における前記チャネルの前記第1の部分及び前記第2の端面における前記チャネルの前記第2の部分のうち少なくとも一方に前記第1の層及び前記第2の層を注入してプラグを形成することにより、前記第1の端面における前記チャネルの前記第1の部分及び前記第2の端面における前記チャネルの前記第2の部分のうち少なくとも一方を封止する工程であって、前記プラグが、それぞれのチャネルの前記壁上に配置された第1の層と、該第1の層の上に各チャネルの軸心の方向に内側に配置された第2の層とを含む、工程と、
を含み、
前記第1の層及び前記第2の層のうち少なくとも一方が前記活性成分を含む
ことを特徴とする、実施形態14又は15に記載の方法。
前記活性プラグが、10質量%〜80質量%の活性成分を含むことを特徴とする、実施形態14〜16のいずれかに記載の方法。
前記活性成分が、銅−ゼオライト、HCトラップ、高表面積材料に貴金属を加えたもの、高表面積材料、オンボード診断酸素貯蔵材料、セリア:ジルコニア固溶体材料、セリア:ジルコニア多相材料、三元触媒(TWC)、白金族金属(PGM)、ロジウム−チタニア、炭酸カルシウム、ゼオライト、Cu−交換ゼオライト、Fe−交換ゼオライト、アルミナ上に配置されたPGM;小細孔ゼオライト、Cu−チャバサイトゼオライト、及びアルカリ土類金属酸化物のうち少なくとも1つを含むことを特徴とする、実施形態14〜17のいずれかに記載の方法。
有機塩、酢酸マグネシウム、及び酢酸銅のうち少なくとも1つを含むゲル化剤をさらに含み、
前記無機結合剤がコロイド状シリカを含み、前記有機結合剤がメチルセルロースを含み、前記活性成分がCu−チャバサイトを含む
ことを特徴とする、実施形態14〜18のいずれかに記載の方法。
前記組成物を施す工程が、前記チャネル内に前記組成物を配置して、最も近い端面から軸方向に間隔をあけた活性プラグを形成する工程を含む、実施形態14〜19のいずれかに記載の方法。
前記ハニカム体に非活性組成物を施して非活性プラグを形成する工程をさらに含み、前記非活性組成物が、
粒径分布を有する耐火性フィラー;
有機結合剤;
無機結合剤;及び
液体ビヒクル
を含むことを特徴とする、実施形態14〜20のいずれかに記載の方法。
101 本体
102 第1の端面/入口端面/入口端
104 第2の端面/出口端面/出口端
106 多孔質セラミック壁/ハニカム体の壁/チャネルの壁
108 入口チャネル
110 出口チャネル
112 プラグ
114 複合構造/第1の層/複合層状構造
116 複合構造/第2の層/複合層状構造
Claims (5)
- 第1の端面から第2の端面へと軸方向に延びるチャネルを形成する交差壁、及び
前記第1の端面における前記チャネルの第1の部分及び前記第2の端面における前記チャネルの第2の部分のうち少なくとも一方を封止するための活性プラグと、
を備え、各活性プラグが、
第1の活性成分を含み、該第1の活性成分が前記プラグ構造の触媒活性成分及び化学活性成分のうち少なくとも1つを含み、前記交差壁が前記第1の活性成分を含まない
ことを特徴とする、多孔質セラミックハニカム体。 - 前記交差壁が、触媒活性成分及び化学活性成分のうち少なくとも1つを含む第2の活性成分を含み、
前記第2の活性成分が、壁面上に配置されている、前記壁の細孔内に配置されている、及び前記壁の構造全体に配置されている、のうち少なくとも1つである
ことを特徴とする、請求項1に記載の多孔質セラミックハニカム体。 - 各プラグが、前記交差壁と接触して配置された第1の層と、前記交差壁から各チャネルの軸心の方向に内側に前記第1の層上に配置された第2の層とを含み、前記第1の層及び前記第2の層のうち少なくとも一方が前記第1の活性成分を含むことを特徴とする、請求項1又は2に記載の多孔質セラミックハニカム体。
- 前記第1の端面がフィルタ入口を有し、前記第2の端面がフィルタ出口を有し、
前記第1の活性成分が複数の活性成分を含み、該複数の活性成分が、
第1の温度範囲において活性な、前記入口端における第1の温度活性成分と、第2の温度範囲において活性な、前記出口端における第2の温度活性成分;及び/又は
第1の温度範囲において活性な、前記入口端におけるチャネルの第1の群内の第1の温度活性成分と、第2の温度範囲において活性な、前記入口端におけるチャネルの第2の群内の第2の温度活性成分
を含み、
前記第1の温度範囲が前記第2の温度範囲の下限より低い下限を有し、かつ、前記第2の温度範囲が前記第1の温度範囲の上限より高い上限を有する、又は
前記第2の温度範囲が前記第1の温度範囲の下限より低い下限を有し、かつ、前記第1の温度範囲が前記第2の温度範囲の上限より高い上限を有する
ことを特徴とする、請求項1〜3のいずれか一項に記載の多孔質セラミックハニカム体。 - 第1の端面から第2の端面へと軸方向に延びるチャネルを形成する交差壁を備えた多孔質セラミックハニカム体を施栓する方法であって、
前記ハニカム体に組成物を施して活性プラグを形成する工程を備え、前記組成物が、
活性成分;
粒径分布を有する耐火性フィラー;
有機結合剤;
無機結合剤;及び
液体ビヒクル;
を含み、
前記活性成分が触媒活性成分及び化学活性成分のうち少なくとも1つを含み、
前記交差壁が前記活性成分を含まない
ことを特徴とする、方法。
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PCT/US2015/048010 WO2016036780A1 (en) | 2014-09-03 | 2015-09-02 | Exhaust filter with active plugs |
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US20170282124A1 (en) | 2017-10-05 |
JP6789927B2 (ja) | 2020-11-25 |
US10898856B2 (en) | 2021-01-26 |
ZA201701580B (en) | 2022-05-25 |
MX2017002813A (es) | 2018-01-12 |
CN107073377A (zh) | 2017-08-18 |
EP3189020A1 (en) | 2017-07-12 |
CN107073377B (zh) | 2021-02-26 |
EP3189020B1 (en) | 2020-12-23 |
WO2016036780A1 (en) | 2016-03-10 |
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