JP2018202405A - Catalyst structure for volatile organic substance and method for producing the same and device for removing volatile organic substance - Google Patents

Abstract

To provide a catalyst structure for a volatile organic substance which can suppress the deterioration of catalytic activity, prevent the deactivation of catalytic functions by facilitating the removal of catalyst poison and prevent leakage of a catalyst from a catalyst structure and a method for producing the same and to provide a device for removing volatile organic substances.SOLUTION: There is provided a catalyst structure for a volatile organic substance which comprises a carrier with a porous structure composed of a zeolite-type compound and at least one catalyst for oxidation of volatile organic substances which is inherent in the carrier and composed of a metal, wherein the carrier has mutually communicating passages and the catalyst for oxidation of volatile organic substances is at least present in the passages of the carrier.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a catalyst structure for a volatile organic substance comprising a porous structure carrier and a catalyst for a volatile organic substance, a method for producing the same, and a volatile organic substance removing apparatus.

  With the recent increase in environmental awareness, the demand for air purification is increasing, and the removal of volatile organic substances (hereinafter sometimes referred to as “VOC”) is required. Examples of VOCs include toluene, benzene, chlorofluorocarbons, and dichloromethane. These are widely used because they are important substances as solvents and fuels. However, when VOC is released into the environment, it causes health damage such as pollution.

  Therefore, removal of VOC by a catalyst has been studied. For example, removal of VOC by an oxidation reaction has been studied. As the catalyst, a Pt-based catalyst is used from the viewpoint of high catalytic activity and stability. On the other hand, since a Pt-based catalyst is expensive, use of a non-noble metal-based catalyst instead of a Pt-based catalyst has been studied. However, the cost of the non-noble metal-based catalyst can be reduced, but the reaction temperature becomes higher than that of the Pt-based catalyst.

  Non-Patent Document 1 reports many catalyst systems that support Pt on a carrier and exhibit excellent activity.

Industrial Materials January 2017 Vol. 65 No. 1 p. 71-74

  However, in the conventional catalyst structure as described above, since the catalyst particles are supported on or near the surface of the carrier, the catalyst particles are supported on the carrier due to the influence of the force and heat received from the fluid including VOC. The catalyst particles tend to agglomerate (sinter) between the catalyst particles. When aggregation of the catalyst particles occurs, the effective surface area as a catalyst decreases, and the catalyst activity decreases, so the life becomes shorter than usual. Furthermore, the aggregation of the catalyst particles makes it difficult to remove the catalyst poison, which is a compound containing N, S, and the like derived from VOC, and the catalyst function tends to be deactivated.

  It is an object of the present invention for a volatile organic substance that can suppress a decrease in catalyst activity, can prevent catalyst poisoning by facilitating removal of catalyst poisons, and can prevent the catalyst from leaking from the catalyst structure. It is an object of the present invention to provide a catalyst structure, a manufacturing method thereof, and a volatile organic substance removing device.

  As a result of intensive studies to achieve the above object, the present inventors have obtained a porous structure carrier composed of a zeolite-type compound and oxidation of a volatile organic substance composed of at least one metal present in the carrier. A catalyst, and the carrier has a passage communicating with each other, and the volatile organic substance oxidation catalyst is present in at least the passage of the carrier. It has been found that a catalyst structure for a volatile organic substance capable of suppressing the decrease and realizing a long life can be obtained, and the present invention has been completed based on such knowledge.

That is, the gist configuration of the present invention is as follows.
[1] a porous support composed of a zeolite-type compound;
At least one volatile organic substance oxidation catalyst comprising a metal inherent in the carrier;
With
The carrier has passages communicating with each other;
A catalyst structure for a volatile organic substance, wherein the volatile organic substance oxidation catalyst is present in at least the passage of the carrier.
[2] The passage includes any one of a one-dimensional hole, a two-dimensional hole, and a three-dimensional hole defined by a skeleton structure of the zeolite-type compound, and the one-dimensional hole, the two-dimensional hole, and the three-dimensional hole. The volatile organic substance according to [1], wherein the volatile organic substance oxidation catalyst is present at least in the enlarged diameter part. Catalyst structure.
[3] The volatile property according to [2], wherein the enlarged diameter portion communicates a plurality of holes constituting any one of the one-dimensional hole, the two-dimensional hole, and the three-dimensional hole. Catalyst structure for organic substances.
[4] The catalyst structure for volatile organic substances according to [2] or [3] above, wherein the volatile organic substance oxidation catalyst is fine metal particles.
[5] The catalyst for volatile organic substances according to the above [4], wherein an average particle diameter of the metal fine particles is larger than an average inner diameter of the passage and not more than an inner diameter of the expanded portion. Structure.
[6] The metal element (M) of the metal fine particles is contained in an amount of 0.5 to 2.5% by mass with respect to the catalyst structure for volatile organic substances, [5] The catalyst structure for volatile organic substances described in 1.
[7] The catalyst structure for volatile organic substances according to any one of [4] to [6] above, wherein an average particle diameter of the metal fine particles is 0.08 nm to 30 nm.
[8] The catalyst structure for volatile organic substances according to [7] above, wherein an average particle diameter of the metal fine particles is 0.4 nm to 11.0 nm.
[9] The volatilization according to any one of [4] to [8] above, wherein a ratio of an average particle diameter of the metal fine particles to an average inner diameter of the passage is 0.05 to 300. Catalyst structure for organic substances.
[10] The catalyst structure for volatile organic substances according to [9] above, wherein a ratio of an average particle diameter of the metal fine particles to an average inner diameter of the passage is 0.1 to 30.
[11] The catalyst structure for volatile organic substances according to [10] above, wherein a ratio of an average particle diameter of the metal fine particles to an average inner diameter of the passage is 1.4 to 3.6. .
[12] The average inner diameter of the passage is 0.1 nm to 1.5 nm,
The catalyst structure for volatile organic substances according to any one of [2] to [11] above, wherein an inner diameter of the expanded portion is 0.5 nm to 50 nm.
[13] The volatile property as described in any one of [1] to [12] above, further comprising at least one other volatile organic substance oxidation catalyst held on the outer surface of the carrier. Catalyst structure for organic substances.
[14] The content of the at least one volatile organic substance oxidation catalyst inherent in the carrier is greater than the content of the at least one other volatile organic substance oxidation catalyst held on the outer surface of the carrier. The catalyst structure for volatile organic substances according to [13] above, wherein
[15] The catalyst structure for volatile organic substances according to any one of [1] to [14], wherein the zeolite-type compound is a silicate compound.
[16] A volatile organic substance removing device having the volatile organic substance catalyst structure according to any one of [1] to [15].
[17] A firing step of firing a precursor material (B) obtained by impregnating a precursor material (A) with a metal-containing solution into a porous structure carrier composed of a zeolite-type compound;
A hydrothermal treatment step of hydrothermally treating the precursor material (C) obtained by firing the precursor material (B);
Performing a reduction treatment on the hydrothermally treated precursor material (C);
A process for producing a catalyst structure for volatile organic substances, comprising:
[18] The volatile material as described in [17] above, wherein a nonionic surfactant is added in an amount of 50 to 500 mass% with respect to the precursor material (A) before the firing step. A method for producing a catalyst structure for organic substances.
[19] Before the firing step, the precursor material (A) is impregnated with the metal-containing solution by adding the metal-containing solution to the precursor material (A) in a plurality of times. The method for producing a catalyst structure for volatile organic substances according to [17] or [18] above,
[20] When the precursor material (A) is impregnated with the metal-containing solution before the firing step, the amount of the metal-containing solution added to the precursor material (A) is changed to the precursor material. In terms of the ratio of silicon (Si) constituting the precursor material (A) to the metal element (M) contained in the metal-containing solution added to (A) (atomic ratio Si / M), It adjusts so that it may become 10-1000, The manufacturing method of the catalyst structure for volatile organic substances as described in any one of said [17]-[19] characterized by the above-mentioned.
[21] The method for producing a catalyst structure for a volatile organic substance according to the above [17], wherein the precursor material (C) and a structure directing agent are mixed in the hydrothermal treatment step.
[22] The method for producing a catalyst structure for a volatile organic substance according to [17], wherein the hydrothermal treatment step is performed in a basic atmosphere.

  According to the present invention, it is possible to suppress a decrease in catalyst activity, to prevent the catalyst function from being deactivated by facilitating the removal of the catalyst poison, and to prevent the catalyst from leaking from the catalyst structure. A catalyst structure, a manufacturing method thereof, and a volatile organic substance removing device can be provided.

FIG. 1 schematically shows the internal structure of a catalyst structure for a volatile organic substance according to an embodiment of the present invention. FIG. 1 (a) is a perspective view (partially cross-sectional view). 1 (b) is a partially enlarged sectional view. 2 is a partially enlarged sectional view for explaining an example of the function of the catalyst structure for a volatile organic substance in FIG. 1, FIG. 2 (a) is a sieving function, and FIG. It is a figure to do. FIG. 3 is a flowchart showing an example of a method for producing the volatile organic substance catalyst structure of FIG. FIG. 4 is a schematic view showing a modification of the catalyst structure for volatile organic substances in FIG.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

[Configuration of catalyst structure for volatile organic substances]
FIG. 1 is a diagram schematically showing a configuration of a catalyst structure for a volatile organic substance according to an embodiment of the present invention, in which (a) is a perspective view (a part is shown in cross section), (b). FIG. Note that the volatile organic substance catalyst structure in FIG. 1 shows an example thereof, and the shape, size, and the like of each component according to the present invention are not limited to those in FIG.

  As shown in FIG. 1 (a), a catalyst structure 1 for a volatile organic substance has a porous structure carrier 10 composed of a zeolite-type compound, and at least one volatile component present in the carrier 10. And metal fine particles 20 that are organic material oxidation catalyst materials. The volatile organic substance oxidation catalyst substance functions as a volatile organic substance removal catalyst by oxidizing the volatile organic substance.

  In the catalyst structure 1 for volatile organic substances, the plurality of metal fine particles 20, 20,... Exist inside the porous structure of the carrier 10. Details of the metal fine particles will be described later.

  The carrier 10 has a porous structure and, as shown in FIG. 1 (b), preferably has a plurality of holes 11a, 11a,. Here, the metal fine particles 20 are present in at least the passage 11 of the carrier 10, and are preferably held in at least the passage 11 of the carrier 10.

  With such a configuration, the movement of the metal fine particles 20 in the carrier 10 is restricted, and aggregation of the metal fine particles 20 and 20 is effectively prevented. As a result, a reduction in the effective surface area of the metal fine particles 20 that are volatile organic substance oxidation catalyst substances can be effectively suppressed, and the catalytic activity of the metal fine particles 20 lasts for a long time. That is, according to the catalyst structure 1 for volatile organic substances, it is possible to suppress a decrease in catalytic activity due to aggregation of the metal fine particles 20 that are volatile organic substance oxidation catalyst substances. Life can be extended. In addition, by extending the life of the volatile organic substance catalyst structure 1, the replacement frequency of the volatile organic substance catalyst structure 1 can be reduced, and the amount of used volatile organic substance catalyst structure 1 is greatly reduced. Can be reduced to save resources.

  Usually, when the catalyst structure 1 for volatile organic substances is used in a fluid containing VOC, there is a possibility of receiving an external force from the fluid. In this case, if the metal fine particles 20 are only held in the attached state on the outer surface of the carrier 10, there is a problem that the metal fine particles 20 are easily detached from the outer surface of the carrier 10 due to the influence of the external force from the fluid. On the other hand, in the catalyst structure 1 for volatile organic substances, the metal fine particles 20 are present in at least the passage 11 of the carrier 10, so that even if the metal fine particles 20 are affected by an external force due to fluid, Difficult to leave. That is, when the volatile organic substance catalyst structure 1 is in the fluid, the fluid flows into the passage 11 from the hole 11a of the carrier 10, so that the speed of the fluid flowing in the passage 11 depends on the flow resistance ( The frictional force) is considered to be slower than the speed of the fluid flowing on the outer surface of the carrier 10. Due to the influence of the flow path resistance, the pressure that the metal fine particles 20 existing in the passage 11 receive from the fluid is lower than the pressure that the metal fine particles 20 receive from the fluid outside the carrier 10. Therefore, it is possible to effectively suppress the separation of the metal fine particles 20 existing in the carrier 11, and it is possible to stably maintain the catalytic activity of the metal fine particles 20 for a long period of time. The flow path resistance as described above is considered to increase as the passage 11 of the carrier 10 has a plurality of bends and branches and the inside of the carrier 10 has a more complicated and three-dimensional structure. .

  Further, the passage 11 includes any one of a one-dimensional hole, a two-dimensional hole, and a three-dimensional hole defined by a skeleton structure of the zeolite type compound, and the one-dimensional hole, the two-dimensional hole, and the three-dimensional hole. Preferably, the metal fine particles 20 are present at least in the diameter-expanded portion 12, and are at least included in the diameter-expanded portion 12. It is more preferable. As used herein, a one-dimensional hole means a tunnel-type or cage-type hole forming a one-dimensional channel, or a plurality of tunnel-type or cage-type holes forming a plurality of one-dimensional channels (a plurality of one-dimensional holes). Channel). A two-dimensional hole refers to a two-dimensional channel in which a plurality of one-dimensional channels are two-dimensionally connected. A three-dimensional hole refers to a three-dimensional channel in which a plurality of one-dimensional channels are three-dimensionally connected. Point to. Thereby, the movement of the metal fine particles 20 in the carrier 10 is further restricted, and the separation of the metal fine particles 20 and the aggregation of the metal fine particles 20, 20 can be more effectively prevented. Inclusion refers to a state in which the metal fine particles 20 are encapsulated in the carrier 10. At this time, the metal fine particles 20 and the carrier 10 are not necessarily in direct contact with each other, and another substance (for example, a surfactant or the like) is interposed between the metal fine particles 20 and the carrier 10. Thus, the metal fine particles 20 may be present indirectly on the carrier 10.

Although FIG. 1B shows a case where the metal fine particles 20 are present in the enlarged diameter portion 12, the present invention is not limited to this configuration, and a part of the metal fine particles 20 is outside the enlarged diameter portion 12. You may exist in the channel | path 11 in the state which protruded. Further, the metal fine particles 20 may be partially embedded in a portion of the passage 11 other than the enlarged diameter portion 12 (for example, an inner wall portion of the passage 11), or may be present by fixing or the like.
Moreover, it is preferable that the enlarged diameter part 12 is connecting the some hole 11a and 11a which comprise either of the said one-dimensional hole, the said two-dimensional hole, and the said three-dimensional hole. Thereby, since the separate channel | path different from a one-dimensional hole, a two-dimensional hole, or a three-dimensional hole is provided in the inside of the support | carrier 10, the function of the metal microparticle 20 can be exhibited more.

  The passage 11 is formed in a three-dimensional manner inside the carrier 10 including a branch portion or a merge portion, and the enlarged diameter portion 12 is preferably provided in the branch portion or the merge portion of the passage 11. .

The average inner diameter _DF of the passage 11 formed in the carrier 10 is calculated from the average value of the short diameter and the long diameter of the hole 11a constituting any one of the one-dimensional hole, the two-dimensional hole, and the three-dimensional hole. The thickness is 0.1 nm to 1.5 nm, preferably 0.5 nm to 0.8 nm. Further, the inner diameter _DE of the enlarged diameter portion 12 is, for example, 0.5 nm to 50 nm, preferably 1.1 nm to 40 nm, and more preferably 1.1 nm to 3.3 nm. The inner diameter D _E of the enlarged diameter portion 12 is, for example pore size of which will be described later precursor material (A), and on the average particle diameter D _C of the fine metal particles 20 present. The inner diameter _DE of the enlarged diameter portion 12 is a size that allows the metal fine particles 20 to exist.

  The carrier 10 is composed of a zeolite type compound. Zeolite type compounds include, for example, zeolites (aluminosilicates), cation exchange zeolites, silicate compounds such as silicalite, zeolite related compounds such as aluminoborate, aluminoarsenate, germanate, molybdenum phosphate, etc. And phosphate-based zeolite-like substances. Among these, the zeolite type compound is preferably a silicate compound.

  The framework structure of zeolite type compounds is FAU type (Y type or X type), MTW type, MFI type (ZSM-5), FER type (ferrierite), LTA type (A type), MWW type (MCM-22) , MOR type (mordenite), LTL type (L type), BEA type (beta type), etc., preferably MFI type, more preferably ZSM-5. In the zeolite type compound, a plurality of pores having a pore size corresponding to each skeleton structure are formed. For example, the maximum pore size of the MFI type is 0.636 nm (6.36 mm), and the average pore size is 0.560 nm (5.60 mm). is there.

  Hereinafter, the metal fine particles 20 which are volatile organic substance oxidation catalyst substances will be described in detail.

And when the fine metal particles 20 are primary particles, but there is the case the primary particle is a secondary particle formed by aggregation, the average particle diameter D _C of the fine metal particles 20 have an average internal diameter D _F of the preferred path 11 Larger than the inner diameter D _E of the enlarged diameter portion 12 (D _F <D _C ≦ D _E ). Such metal fine particles 20 are present in the diameter-expanded portion 12 in the passage 11 and are preferably enclosed, and the movement of the metal fine particles 20 in the carrier 10 is restricted. Therefore, even when the metal fine particle 20 receives an external force from the fluid, the movement of the metal fine particle 20 in the carrier 10 is suppressed, and the diameter-enlarged portions 12, 12,. It is possible to effectively prevent the metal fine particles 20, 20,.

The average particle diameter _{D C} of the fine metal particles 20, in either case of the primary particles and secondary particles, preferably 0.08Nm～30nm, more preferably less than than 0.08 nm 25 nm, more preferably It is 0.4 nm-11.0 nm, Most preferably, it is 0.8 nm-2.7 nm. The ratio of the average particle diameter _{D C} of the fine metal particles 20 to the average inner diameter _{D F} of the passage 11 _(D C / D _F) is preferably from 0.05 to 300, more preferably 0.1 to 30 More preferably, it is 1.1-30, Most preferably, it is 1.4-3.6.
Moreover, when the volatile organic substance oxidation catalyst substance 20 is a metal fine particle, the metal element (M) of the metal fine particle is contained at 0.5 to 2.5 mass% with respect to the catalyst structure 1 for a volatile organic substance. It is preferable that it is contained in an amount of 0.5 to 1.5% by mass with respect to the catalyst structure 1 for volatile organic substances. For example, when the metal element (M) is Co, the content (mass%) of the Co element is [(mass of Co element) / (mass of all elements of the volatile organic substance catalyst structure 1)] × 100.

  The metal fine particles 20 may be composed of a metal that is not oxidized, and may be composed of, for example, a single metal or a mixture of two or more metals. In this specification, “metal” (as a material) constituting the metal fine particles includes a single metal containing one kind of metal element (M), a metal alloy containing two or more kinds of metal elements (M), and Is a generic term for metals containing one or more metal elements.

  Examples of such a metal include platinum (Pt), palladium (Pd), ruthenium (Ru), rhodium (Rh), silver (Ag), and the like, and any one or more of the above as a main component. Is preferred.

  Further, the ratio of the silicon (Si) constituting the carrier 10 to the metal element (M) constituting the metal fine particle 20 (atomic number ratio Si / M) is preferably 10 to 1000, and preferably 50 to 200. Is more preferable. If the ratio is greater than 1000, the activity is low, and there is a possibility that the action as a volatile organic substance oxidation catalyst substance cannot be sufficiently obtained. On the other hand, if the ratio is less than 10, the ratio of the metal fine particles 20 becomes too large, and the strength of the carrier 10 tends to decrease. The metal fine particles 20 referred to here are fine particles that exist inside the carrier 10 and are preferably held or supported, and do not include the metal fine particles attached to the outer surface of the carrier 10.

[Function of catalyst structure for volatile organic substances]
As described above, the volatile organic substance catalyst structure 1 includes a porous support 10 and at least one metal fine particle 20 present in the support. The catalyst structure 1 for a volatile organic substance exhibits catalytic ability corresponding to the catalytic activity of the metal fine particles 20 when the metal fine particles 20 existing in the carrier come into contact with the fluid. Specifically, the fluid that has contacted the outer surface 10a of the volatile organic substance catalyst structure 1 flows into the inside of the carrier 10 from the holes 11a formed in the outer surface 10a, and is guided into the passage 11 so that the inside of the passage 11 It moves through and goes out of the catalyst structure 1 for volatile organic substances through the other hole 11a. In the path in which the fluid moves through the passage 11, a catalytic reaction corresponding to the catalytic ability of the metal fine particles 20 occurs by contacting the metal fine particles 20 existing in the passage 11. Moreover, the catalyst structure 1 for volatile organic substances has molecular sieving ability because the carrier has a porous structure.

  First, the molecular sieving ability of the catalyst structure 1 for a volatile organic substance will be described with reference to FIG. 2A, taking as an example the case where the fluid is a gas containing a volatile organic substance (VOC) such as benzene or toluene. . As shown in FIG. 2A, VOC (for example, benzene, toluene, etc.) composed of molecules having a size smaller than the diameter of the hole 11a, in other words, smaller than the inner diameter of the passage 11, flows into the carrier 10. can do. On the other hand, the non-VOC component 15 having a size exceeding the hole diameter of the hole 11 a cannot flow into the carrier 10. Thus, when the fluid contains a plurality of types of compounds, the reaction of the compound that cannot flow into the carrier 10 is restricted, and the compound that can flow into the carrier 10 can be reacted.

  Of the compounds produced in the carrier 10 by the reaction, only compounds composed of molecules having a size equal to or smaller than the pore diameter of the pores 11a can go out of the carrier 10 through the pores 11a and are obtained as reaction products. On the other hand, a compound that cannot go out of the carrier 10 through the holes 11a can be put out of the carrier 10 if converted into a compound composed of molecules of a size that can go out of the carrier 10. . Thus, a specific reaction product can be selectively obtained by using the catalyst structure 1 for volatile organic substances.

In the catalyst structure 1 for volatile organic substances, the metal fine particles 20 are present in the enlarged diameter portion 12 of the passage 11 as shown in FIG. When the average particle diameter D _C of the metal fine particles 20 is larger than the average inner diameter D _F of the passage 11 and smaller than the inner diameter D _E of the enlarged diameter portion 12 (D _F <D _C <D _E ), the metal fine particles 20 A small passage 13 is formed between the small diameter portion 12 and the enlarged diameter portion 12. Therefore, as shown by the arrow in FIG. 2B, the fluid containing VOC flowing into the small passage 13 comes into contact with the metal fine particles 20. Since each metal fine particle 20 exists in the enlarged diameter part 12, the movement in the support | carrier 10 is restrict | limited. Thereby, aggregation of the metal fine particles 20 and 20 in the carrier 10 is prevented. As a result, a large contact area between the metal fine particles 20 and the fluid can be stably maintained.

  When the VOC flowing into the passage 11 comes into contact with the metal fine particles 20, the VOC is oxidized by an oxidative decomposition reaction by the metal fine particles 20. For example, when ruthenium contained in the metal fine particles 20 is used as a catalyst, VOC is decomposed into carbon dioxide and water to make them harmless. By performing the oxidative decomposition treatment with the metal fine particles 20 in this way, VOC can be rendered harmless. Moreover, the volatile organic substance removal apparatus may be formed using the catalyst structure 1 for volatile organic substances. By using the volatile organic substance catalyst structure 1 according to the above embodiment, a volatile organic substance removing apparatus that exhibits the same effect as described above can be obtained.

[Method for producing catalyst structure for volatile organic substances]
FIG. 3 is a flowchart showing a method of manufacturing the volatile organic substance catalyst structure 1 of FIG. Hereinafter, an example of a method for producing a catalyst structure for a volatile organic substance in which the volatile organic substance oxidation catalyst substance present in the carrier is metal fine particles will be described.

(Step S1: Preparation process)
As shown in FIG. 3, first, a precursor material (A) for obtaining a porous support composed of a zeolite-type compound is prepared. The precursor material (A) is preferably a regular mesoporous material, and can be appropriately selected according to the type (composition) of the zeolite-type compound constituting the carrier of the catalyst structure for volatile organic substances.

  Here, when the zeolite-type compound constituting the carrier of the catalyst structure for volatile organic substances is a silicate compound, the regular mesoporous material has a one-dimensional pore having a pore diameter of 1 to 50 nm, A compound composed of a Si—O skeleton that is uniform in size in two or three dimensions and regularly developed is preferable. Such regular mesoporous materials can be obtained as various composites depending on the synthesis conditions. Specific examples of the composites include, for example, SBA-1, SBA-15, SBA-16, KIT-6, FSM- 16, MCM-41, etc., among which MCM-41 is preferable. The pore diameter of SBA-1 is 10 to 30 nm, the pore diameter of SBA-15 is 6 to 10 nm, the pore diameter of SBA-16 is 6 nm, the pore diameter of KIT-6 is 9 nm, and the pore diameter of FSM-16 is 3 -5 nm, MCM-41 has a pore diameter of 1-10 nm. Examples of such regular mesoporous materials include mesoporous silica, mesoporous aluminosilicate, and mesoporous metallosilicate.

  The precursor material (A) may be a commercially available product or a synthetic product. When the precursor material (A) is synthesized, it can be performed by a known method for synthesizing regular mesoporous materials. For example, a mixed solution containing a raw material containing the constituent elements of the precursor material (A) and a templating agent for defining the structure of the precursor material (A) is prepared, and the pH is adjusted as necessary. Hydrothermal treatment (hydrothermal synthesis) is performed. Thereafter, the precipitate (product) obtained by hydrothermal treatment is recovered (for example, filtered), washed and dried as necessary, and further calcined to form a regular mesoporous material in powder form. A precursor material (A) is obtained. Here, as a solvent of the mixed solution, for example, water, an organic solvent such as alcohol, or a mixed solvent thereof can be used. Moreover, although a raw material is selected according to the kind of support | carrier, for example, silica agents, such as tetraethoxysilane (TEOS), fumed silica, quartz sand, etc. are mentioned. Further, as the templating agent, various surfactants, block copolymers and the like can be used, and it is preferable to select according to the type of the synthesized compound of regular mesoporous materials. For example, when preparing MCM-41 A surfactant such as hexadecyltrimethylammonium bromide is preferred. The hydrothermal treatment can be performed, for example, in a sealed container at 80 to 800 ° C., 5 hours to 240 hours, and treatment conditions of 0 to 2000 kPa. The baking treatment can be performed, for example, in air at 350 to 850 ° C. for 2 to 30 hours.

(Step S2: impregnation step)
Next, the prepared precursor material (A) is impregnated with the metal-containing solution to obtain the precursor material (B).

  The metal-containing solution may be a solution containing a metal component (for example, metal ion) corresponding to the metal element (M) constituting the metal fine particles of the catalyst structure for a volatile organic substance. It can be prepared by dissolving a metal salt containing the element (M). Examples of such metal salts include metal salts such as chlorides, hydroxides, oxides, sulfates, nitrates, etc. Among them, nitrates are preferable. As the solvent, for example, water, an organic solvent such as alcohol, or a mixed solvent thereof can be used.

  The method for impregnating the precursor material (A) with the metal-containing solution is not particularly limited. For example, a plurality of metal-containing solutions are mixed while stirring the powdery precursor material (A) before the firing step described later. It is preferable to add in small portions in portions. Further, from the viewpoint of facilitating the penetration of the metal-containing solution into the pores of the precursor material (A), a surfactant as an additive is added in advance to the precursor material (A) before adding the metal-containing solution. It is preferable to add it. Such an additive has a function of coating the outer surface of the precursor material (A), suppresses the metal-containing solution added thereafter from adhering to the outer surface of the precursor material (A), and the metal It is considered that the contained solution is more likely to enter the pores of the precursor material (A).

  Examples of such additives include nonionic surfactants such as polyoxyethylene oleyl ether, polyoxyethylene alkyl ether, and polyoxyethylene alkylphenyl ether. Since these surfactants have a large molecular size and cannot penetrate into the pores of the precursor material (A), they do not adhere to the inside of the pores, and the metal-containing solution penetrates into the pores. It is thought not to interfere. As a method for adding the nonionic surfactant, for example, it is preferable to add 50 to 500% by mass of the nonionic surfactant with respect to the precursor material (A) before the firing step described later. When the addition amount of the nonionic surfactant to the precursor material (A) is less than 50% by mass, the above-described inhibitory action is hardly exhibited, and the nonionic surfactant is added to the precursor material (A) at 500. Addition of more than% by mass is not preferable because the viscosity increases excessively. Therefore, the addition amount of the nonionic surfactant with respect to the precursor material (A) is set to a value within the above range.

  The amount of the metal-containing solution added to the precursor material (A) is the amount of the metal element (M) contained in the metal-containing solution impregnated in the precursor material (A) (that is, the precursor material (B It is preferable to adjust appropriately in consideration of the amount of the metal element (M) contained in (). For example, before the firing step described later, the addition amount of the metal-containing solution added to the precursor material (A) is the metal element (M) contained in the metal-containing solution added to the precursor material (A), In terms of the ratio of silicon (Si) constituting the precursor material (A) (atomic number ratio Si / M), it is preferably adjusted to be 10 to 1000, and adjusted to be 50 to 200. It is more preferable. For example, when a surfactant is added as an additive to the precursor material (A) before the metal-containing solution is added to the precursor material (A), the addition of the metal-containing solution to be added to the precursor material (A) By converting the amount to 50 to 200 in terms of the atomic ratio Si / M, the metal element (M) of the metal fine particles is 0.5 to 2.5 with respect to the catalyst structure 1 for volatile organic substances. It can be contained by mass%. In the state of the precursor material (B), the amount of the metal element (M) present in the pores is the same as the metal concentration of the metal-containing solution, the presence or absence of the additive, and other conditions such as temperature and pressure. If so, it is roughly proportional to the amount of the metal-containing solution added to the precursor material (A). The amount of the metal element (M) contained in the precursor material (B) is proportional to the amount of the metal element constituting the metal fine particles contained in the carrier of the catalyst structure for volatile organic substances. Therefore, by controlling the amount of the metal-containing solution added to the precursor material (A) within the above range, the metal-containing solution can be sufficiently impregnated inside the pores of the precursor material (A), and thus The amount of fine metal particles contained in the carrier of the catalyst structure for volatile organic substances can be adjusted.

  After impregnating the precursor material (A) with the metal-containing solution, a cleaning treatment may be performed as necessary. As the cleaning solution, water, an organic solvent such as alcohol, or a mixed solution thereof can be used. In addition, it is preferable to impregnate the precursor material (A) with a metal-containing solution and perform a cleaning treatment as necessary, followed by a drying treatment. Examples of the drying treatment include natural drying overnight or high temperature drying at 150 ° C. or lower. In addition, the regular mesopores of the precursor material (A) are obtained by performing the baking treatment described later in a state where a large amount of moisture contained in the metal-containing solution and the moisture of the cleaning solution remain in the precursor material (A). Since the skeletal structure as a substance may be broken, it is preferable to dry it sufficiently.

(Step S3: Firing step)
Next, the precursor material (B) obtained by impregnating the precursor material (A) for impregnating the porous material structure composed of the zeolite type compound with the metal-containing solution is calcined to obtain the precursor material (C). Get.

  The firing treatment is preferably performed, for example, in the air at 350 to 850 ° C. for 2 to 30 hours. By such a baking treatment, the metal component impregnated in the pores of the regular mesoporous material grows and crystal particles are formed in the pores.

(Step S4: Hydrothermal treatment process)
Next, a mixed solution in which the precursor material (C) and the structure directing agent are mixed is prepared, and the precursor material (C) obtained by firing the precursor material (B) is hydrothermally treated to be volatile. A catalyst structure for organic substances is obtained.

  The structure directing agent is a templating agent for defining the skeletal structure of the support of the catalyst structure for volatile organic substances, and for example, a surfactant can be used. The structure-directing agent is preferably selected according to the skeletal structure of the support of the catalyst structure for volatile organic substances. For example, tetramethylammonium bromide (TMABr), tetraethylammonium bromide (TEABr), tetrapropylammonium bromide (TPABr) And the like are preferable.

  Mixing of the precursor material (C) and the structure directing agent may be performed during the main hydrothermal treatment step, or may be performed before the hydrothermal treatment step. Moreover, the preparation method of the said mixed solution is not specifically limited, A precursor material (C), a structure directing agent, and a solvent may be mixed simultaneously, or precursor material (C) and structure prescription | regulation are carried out to a solvent. After each agent is dispersed in each solution, each dispersion solution may be mixed. As the solvent, for example, water, an organic solvent such as alcohol, or a mixed solvent thereof can be used. In addition, the pH of the mixed solution is preferably adjusted using an acid or a base before hydrothermal treatment.

Hydrothermal treatment can be performed by a well-known method, for example, it is preferable to perform in 80-800 degreeC, 5 hours-240 hours, and processing conditions of 0-2000 kPa in an airtight container. The hydrothermal treatment is preferably performed in a basic atmosphere. Although the reaction mechanism here is not necessarily clear, by performing hydrothermal treatment using the precursor material (C) as a raw material, the skeleton structure of the precursor material (C) as a regular mesoporous material gradually collapses. While maintaining the position of the metal fine particles inside the pores of the precursor material (C), a new skeletal structure (porous structure) as a support for the catalyst structure for volatile organic substances by the action of the structure-directing agent. ) Is formed. The catalyst structure for volatile organic substances thus obtained comprises a porous structure carrier and metal fine particles present in the carrier, and the carrier has a passage in which a plurality of holes communicate with each other due to the porous structure. And at least a part of the metal fine particles are present in the passage of the carrier.
In this embodiment, in the hydrothermal treatment step, a mixed solution in which the precursor material (C) and the structure directing agent are mixed is prepared, and the precursor material (C) is hydrothermally treated. Not limited to this, the precursor material (C) may be hydrothermally treated without mixing the precursor material (C) and the structure directing agent.

  The precipitate (catalyst structure for a volatile organic substance) obtained after the hydrothermal treatment is preferably washed, dried and calcined as necessary after collection (for example, filtration). As the cleaning solution, water, an organic solvent such as alcohol, or a mixed solution thereof can be used. Examples of the drying treatment include natural drying overnight or high temperature drying at 150 ° C. or lower. In addition, if the calcination treatment is performed in a state where a large amount of moisture remains in the precipitate, the skeleton structure as a support of the catalyst structure for a volatile organic substance may be broken. Therefore, it is preferable to sufficiently dry the precipitate. Moreover, a baking process can be performed on the process conditions of 350-850 degreeC and 2 to 30 hours, for example in the air. By such a calcination treatment, the structure directing agent adhering to the catalyst structure for volatile organic substances is burned out. Moreover, the catalyst structure for volatile organic substances can also be used as it is, without baking the collect | recovered deposit according to the intended purpose. For example, if the environment in which the catalyst structure for volatile organic substances is used is a high-temperature environment in an oxidizing atmosphere, the structure directing agent will be burned out by exposure to the environment for a certain period of time, and it will be the same as when it is fired. Thus, it is possible to use the catalyst structure for a volatile organic substance as it is.

  The production method described above is an example in the case where the metal element (M) contained in the metal-containing solution impregnated in the precursor material (A) is a metal species that is difficult to be oxidized (for example, a noble metal).

  When the metal element (M) contained in the metal-containing solution impregnated in the precursor material (A) is a metal species that is easily oxidized (eg, Fe, Co, Cu, etc.), after the hydrothermal treatment step, It is preferable to perform a reduction treatment on the hydrothermally treated precursor material (C). When the metal element (M) contained in the metal-containing solution is an easily oxidized metal species, the metal component is oxidized by the heat treatment in the steps (steps S3 to S4) after the impregnation treatment (step S2). . Therefore, the metal oxide fine particles are inherent in the support formed in the hydrothermal treatment step (step S4). Therefore, in order to obtain a catalyst structure for volatile organic substances in which fine metal particles are present in the carrier, the recovered precipitate is calcined after the hydrothermal treatment, and further reduced under a reducing gas atmosphere such as hydrogen gas. It is desirable (step S5: reduction process). By performing the reduction treatment, the metal oxide fine particles present in the carrier are reduced, and metal fine particles corresponding to the metal element (M) constituting the metal oxide fine particles are formed. As a result, a catalyst structure for a volatile organic substance in which metal fine particles are inherently present in the carrier is obtained. In addition, such a reduction treatment may be performed as necessary. For example, when the environment in which the catalyst structure for volatile organic substances is used is a reducing atmosphere, by exposing it to the use environment for a certain period of time, Since the metal oxide fine particles are reduced, the same volatile organic substance catalyst structure as that obtained by the reduction treatment can be obtained, so that the oxide fine particles can be used as they are in the carrier.

[Modification of Catalyst Structure 1 for Volatile Organic Substances]
FIG. 4 is a schematic view showing a modification of the volatile organic substance catalyst structure 1 of FIG.
The volatile organic substance catalyst structure 1 of FIG. 1 shows a case where the support 10 and the metal fine particles 20 existing in the support 10 are provided. However, the present invention is not limited to this configuration. For example, FIG. As shown, the catalyst structure 2 for volatile organic substances may further include other metal fine particles 30 that are volatile organic substance oxidation catalyst substances held on the outer surface 10 a of the carrier 10.

  The other metal fine particles 30 are substances that exhibit one or more catalytic ability. The catalytic ability of the other metal fine particles 30 may be the same as or different from the catalytic ability of the metal fine particles 20. In addition, when both of the metal fine particles 20 and 30 are substances having the same catalytic ability, the material of the other metal fine particles 30 may be the same as or different from the material of the metal fine particles 20. According to this configuration, it is possible to increase the content of the volatile organic material oxidation catalyst material held in the volatile organic material catalyst structure 2, and further promote the catalytic activity of the volatile organic material oxidation catalyst material. be able to.

  In this case, the content of the metal fine particles 20 inherent in the carrier 10 is preferably larger than the content of the other metal fine particles 30 held on the outer surface 10 a of the carrier 10. As a result, the catalytic ability of the metal fine particles 20 held inside the carrier 10 becomes dominant, and the catalytic ability of the volatile organic substance oxidation catalyst substance is stably exhibited.

  As mentioned above, although the catalyst structure for volatile organic substances according to the embodiment of the present invention has been described, the present invention is not limited to the above embodiment, and various modifications and changes can be made based on the technical idea of the present invention. Is possible.

(Examples 1 to 384)
[Synthesis of Precursor Material (A)]
A mixed aqueous solution in which a silica agent (tetraethoxysilane (TEOS), manufactured by Wako Pure Chemical Industries, Ltd.) and a surfactant as a templating agent was mixed was prepared, pH was adjusted as appropriate, and 80 to 80 in a sealed container. Hydrothermal treatment was performed at 350 ° C. for 100 hours. Thereafter, the produced precipitate is filtered off, washed with water and ethanol, and further calcined in air at 600 ° C. for 24 hours to obtain precursor materials (A) of the types and pore sizes shown in Tables 1-8. Obtained. The following surfactants were used according to the type of the precursor material (A) (“type of precursor material (A): surfactant”).
MCM-41: hexadecyltrimethylammonium bromide (CTAB) (manufactured by Wako Pure Chemical Industries, Ltd.)
・ SBA-1: Pluronic P123 (manufactured by BASF)

[Preparation of precursor materials (B) and (C)]
Next, a metal salt containing the metal element (M) is dissolved in water according to the metal element (M) constituting the type of metal fine particles shown in Tables 1 to 8 to prepare a metal-containing aqueous solution. did. The following metal salts were used according to the type of metal fine particles (“metal fine particles: metal salt”).
Pt: Chloroplatinic acid hexahydrate (manufactured by Wako Pure Chemical Industries, Ltd.)
Pd: palladium nitrate (II) hydrate (manufactured by Wako Pure Chemical Industries, Ltd.)
Ru: Ruthenium (III) chloride n hydrate (Wako Pure Chemical Industries, Ltd.)
Rh: rhodium nitrate (III) (n hydrate) (manufactured by Wako Pure Chemical Industries, Ltd.)

  Next, the metal-containing aqueous solution is added to the powdery precursor material (A) in small portions in small portions, and dried at room temperature (20 ° C. ± 10 ° C.) for 12 hours or more to obtain the precursor material (B). Got.

  In addition, when the condition of the presence or absence of the additive shown in Tables 1 to 8 is “Yes”, polyoxyethylene (15) as an additive with respect to the precursor material (A) before adding the metal-containing aqueous solution A pretreatment of adding an aqueous solution of oleyl ether (NIKKOL BO-15V, manufactured by Nikko Chemicals Co., Ltd.) was performed, and then the metal-containing aqueous solution was added as described above. In the case of “None” in the presence or absence of the additive, the pretreatment with the additive as described above is not performed.

  Moreover, the addition amount of the metal-containing aqueous solution added to the precursor material (A) is the ratio of silicon (Si) constituting the precursor material (A) to the metal element (M) contained in the metal-containing aqueous solution ( The numerical values when converted to the atomic ratio (Si / M) were adjusted to the values shown in Tables 1-8.

  Next, the precursor material (B) impregnated with the metal-containing aqueous solution obtained as described above was baked in air at 600 ° C. for 24 hours to obtain a precursor material (C).

  The precursor material (C) obtained as described above and the structure directing agent shown in Tables 1 to 8 are mixed to prepare a mixed aqueous solution, and 80 to 350 ° C. and Tables 1 to 8 in a sealed container. Hydrothermal treatment was performed under the conditions of pH and time shown in FIG. Thereafter, the produced precipitate was filtered off, washed with water, dried at 100 ° C. for 12 hours or more, and further calcined in air at 600 ° C. for 24 hours. Thereafter, the fired product was recovered and subjected to reduction treatment at 400 ° C. for 350 minutes under inflow of hydrogen gas to obtain a catalyst structure having a carrier and metal fine particles as a catalyst material shown in Tables 1 to 8 ( Examples 1-384).

(Comparative Example 1)
In Comparative Example 1, cobalt oxide powder (II, III) (manufactured by Sigma Aldrich Japan G.K.) having an average particle size of 50 nm or less was mixed with MFI type silicalite and subjected to hydrogen reduction treatment in the same manner as in Example, As a result, a catalyst structure in which cobalt fine particles were adhered as a catalyst material to the outer surface of silicalite was obtained. MFI type silicalite was synthesized in the same manner as in Examples 52 to 57 except for the step of adding metal.

(Comparative Example 2)
In Comparative Example 2, MFI type silicalite was synthesized by the same method as Comparative Example 1 except that the step of attaching cobalt fine particles was omitted.

[Evaluation]
Various characteristics evaluation was performed on the catalyst structures of the above-mentioned examples including a support and a catalyst substance and silicalites of the comparative examples under the following conditions.

[A] Cross-sectional observation About the catalyst structure of the said Example provided with a support | carrier and a catalyst substance, and the silicalite of the comparative example 1, an observation sample was produced with the grinding | pulverization method, and a transmission electron microscope (TEM) (TITA G2, FEI company) Were used for cross-sectional observation.
As a result, in the catalyst structures of the above examples, it was confirmed that the catalyst substance was present and retained inside the support made of silicalite or zeolite. On the other hand, in the silicalite of Comparative Example 1, the catalyst substance was only attached to the outer surface of the carrier and was not present inside the carrier.
Moreover, about the catalyst structure whose metal is iron fine particles (Fe) among the said Example, a cross section is cut out by FIB (focused ion beam) processing, SEM (SU8020, Hitachi High-Technologies company make), EDX (X-Max, Cross-sectional elemental analysis was performed using HORIBA, Ltd. As a result, Fe element was detected from inside the support.
From the results of cross-sectional observation using the TEM and SEM / EDX, it was confirmed that iron fine particles were present inside the carrier.

[B] Average inner diameter of carrier passage and average particle diameter of catalyst substance In the TEM image taken by cross-sectional observation performed in the above evaluation [A], arbitrarily select 500 passages of the carrier, The short diameter was measured, the inner diameter was calculated from the average value (N = 500), and the average inner diameter was further calculated as the average inner diameter _DF of the carrier passage. Similarly, for the catalyst material, 500 catalyst materials are arbitrarily selected from the TEM image, each particle size is measured (N = 500), an average value thereof is obtained, and the average of the catalyst materials is determined. I was having a particle diameter _{D C.} The results are shown in Tables 1-8.
Moreover, in order to confirm the average particle diameter and dispersion state of a catalyst substance, it analyzed using SAXS (small angle X-ray scattering). The SAXS measurement was performed using Spring-8 beam line BL19B2. The obtained SAXS data was fitted with a spherical model by the Guinier approximation method, and the particle size was calculated. The particle size was measured for a catalyst structure in which the metal is iron fine particles. In addition, as a comparison object, commercially available iron fine particles (manufactured by Wako) were observed and measured with an SEM.
As a result, in the commercial product, iron oxide fine particles of various sizes are randomly present in the particle size range of about 50 nm to 400 nm, whereas the average particle size obtained from the TEM image is 1.2 nm to 2.0 nm. In the catalyst structure of each Example, a scattering peak having a particle size of 10 nm or less was detected in the SAXS measurement results. From the SAXS measurement result and the cross-sectional measurement result by SEM / EDX, it was found that a catalyst substance having a particle size of 10 nm or less was present in the carrier in a very dispersed state with a uniform particle size.

[C] Relationship between the addition amount of the metal-containing solution and the amount of metal included in the support The addition amount of the atomic ratio Si / M = 50, 100, 200, 1000 (M = Co, Ni, Fe, Cu) Then, a catalyst structure in which metal fine particles were included in the inside of the support was prepared, and then the amount of metal (mass%) included in the support of the catalyst structure prepared in the above addition amount was measured. In this measurement, the catalyst structure with atomic number ratio Si / M = 100, 200, 1000 is the same as the catalyst structure with atomic number ratio Si / M = 100, 200, 1000 in Examples 1 to 384, respectively. The catalyst structure having an atomic ratio Si / M = 50 was prepared by adjusting the amount of addition of the metal-containing solution by the method described above, except that the amount of addition of the metal-containing solution was changed. = 100, 200, 1000 It was produced by the same method as the catalyst structure.
The amount of metal was determined by using ICP (high frequency inductively coupled plasma) alone or a combination of ICP and XRF (fluorescence X-ray analysis). XRF (energy dispersive X-ray fluorescence spectrometer “SEA1200VX”, manufactured by SSI Nanotechnology Inc.) was performed under the conditions of a vacuum atmosphere, an acceleration voltage of 15 kV (using a Cr filter), or an acceleration voltage of 50 kV (using a Pb filter).
XRF is a method of calculating the abundance of a metal by fluorescence intensity, and a quantitative value (mass% conversion) cannot be calculated with XRF alone. Therefore, the amount of metal in the catalyst structure added with metal at Si / M = 100 was quantified by ICP analysis, and the amount of metal in the catalyst structure added with metal at Si / M = 50 and less than 100 was determined by XRF measurement results. And calculated based on the ICP measurement results.
As a result, it was confirmed that the amount of metal included in the catalyst structure increased as the amount of the metal-containing solution added increased at least in the atomic ratio Si / M in the range of 50 to 1000. It was.

[D] Performance Evaluation The catalytic ability of the catalyst material was evaluated for the catalyst structures of the above examples and the silicalite of the comparative example provided with a support and a catalyst material. The results are shown in Tables 1-8.

(1) Catalytic activity The catalytic activity was evaluated under the following conditions.
First, 0.2 g of the catalyst structure is charged into an atmospheric pressure flow reactor, nitrogen gas (N ₂ ) is used as a carrier gas (5 ml / min), and a toluene (model material of VOC) gas at 400 ° C. for 2 hours. The decomposition reaction of was carried out.
After completion of the reaction, the collected product gas and product liquid were subjected to component analysis by gas chromatography mass spectrometry (GC / MS). Note that TRACE 13 10GC (manufactured by Thermo Fisher Scientific Co., Ltd., detector: thermal conductivity detector) was used as a product gas analyzer.
Furthermore, based on the results of the component analysis, the yield (mol%) of a compound having a smaller molecular weight than toluene (specifically, CO ₂ , CO, HCOH, etc.) was determined. The yield of the above compound was calculated as a percentage (mol%) of the total amount (mol) of the compound amount having a molecular weight smaller than that of toluene contained in the product gas with respect to the amount (mol) of toluene before starting the reaction. .
In this example, when the yield of the compound having a molecular weight smaller than that of toluene contained in the product gas is 80 mol% or more, it is determined that the catalytic activity (resolution) is excellent, “◎”, 50 mol% or more. When it is less than 80 mol%, it is determined that the catalyst activity is good, and “◯”, and when it is 20 mol% or more and less than 50 mol%, it is determined that the catalyst activity is not good but the pass level is acceptable. The case where “Δ” was less than 20 mol% was judged to be inferior in catalyst activity (impossible), and “x” was assigned.

(2) Durability (life)
The durability was evaluated under the following conditions.
First, the catalyst structure used in the evaluation (1) was collected and heated at 650 ° C. for 12 hours to produce a heated catalyst structure. Next, by using the obtained catalyst structure after heating, a decomposition reaction of toluene (model material of VOC) gas is performed by the same method as in the above evaluation (1), and the same as in the above evaluation (1). The component analysis of the product gas was performed by this method.
Based on the obtained analysis results, the yield (mol%) of a compound having a molecular weight smaller than that of toluene was determined in the same manner as in the evaluation (1). Furthermore, compared to the yield of the compound by the catalyst structure before heating (the yield obtained in the evaluation (1) above), how much the yield of the compound by the catalyst structure after heating is maintained. Compared. Specifically, the yield of the compound by the catalyst structure after the heating (the present evaluation (2)) relative to the yield of the compound by the catalyst structure before the heating (the yield obtained in the evaluation (1)). The percentage (%) of the yield obtained in step 1) was calculated.
In this example, the yield of the above compound by the catalyst structure after heating (the yield determined in this evaluation (2)) is the yield of the above compound by the catalyst structure before heating (in the above evaluation (1)). It is judged that the durability (heat resistance) is excellent when it is maintained at 80% or more compared to the yield (determined yield), and the durability when it is maintained at 50% or more and less than 80%. Judgment is good (heat resistance), “○”, and when 20% or more and less than 50% are maintained, the durability (heat resistance) is not good, but it is judged as acceptable level (possible) A case where “△” and a decrease to less than 20% was judged that the durability (heat resistance) was inferior (impossible), and “X” was assigned.

  About Comparative Examples 1-2, the same performance evaluation as said evaluation (1) and (2) was performed. In addition, the comparative example 2 is a support | carrier itself, and does not have a catalyst substance. Therefore, in the performance evaluation, only the support of Comparative Example 2 was filled instead of the catalyst structure. The results are shown in Table 8.

  As is clear from Tables 1 to 8, the catalyst structures (Examples 1 to 384) in which the catalyst substance was confirmed to be present inside the support by cross-sectional observation were simply put on the outer surface of the support. Compared with the catalyst structure (Comparative Example 1) that is only adhered or the carrier itself without any catalytic substance (Comparative Example 2), it exhibits excellent catalytic activity in the decomposition reaction of toluene, It was found to be excellent in durability.

  On the other hand, the support itself of Comparative Example 2, which does not have any catalyst substance, shows almost no catalytic activity in the decomposition reaction of toluene. Compared with the catalyst structures of Examples 1 to 384, the carrier activity and durability of the support itself. Both were inferior.

  In addition, the catalytic structure of Comparative Example 1 in which the catalytic material is attached only to the outer surface of the carrier has a catalytic activity in the decomposition reaction of toluene as compared with the carrier of Comparative Example 2 that does not have any catalytic material. Although improved, the durability as a catalyst was inferior to the catalyst structures of Examples 1 to 384.

1 volatile organic material for the catalytic structure 10 support 10a outer surface 11 passages 11a hole 12 enlarged diameter portion 20 the metal particles 30 metal fine particles D _C average particle diameter D _F average inner diameter D _E inner diameter

Claims (22)

A porous structure carrier composed of a zeolite-type compound;
At least one volatile organic substance oxidation catalyst comprising a metal inherent in the carrier;
With
The carrier has passages communicating with each other;
A catalyst structure for a volatile organic substance, wherein the volatile organic substance oxidation catalyst is present in at least the passage of the carrier. The passage is any one of a one-dimensional hole, a two-dimensional hole, and a three-dimensional hole defined by a skeleton structure of the zeolite-type compound, and any one of the one-dimensional hole, the two-dimensional hole, and the three-dimensional hole. 2. The catalyst structure for volatile organic substances according to claim 1, wherein the volatile organic substance oxidation catalyst is present at least in the enlarged diameter part.   The volatile organic substance catalyst according to claim 2, wherein the enlarged-diameter portion communicates a plurality of holes constituting any one of the one-dimensional hole, the two-dimensional hole, and the three-dimensional hole. Structure.   The catalyst structure for volatile organic substances according to claim 2 or 3, wherein the volatile organic substance oxidation catalyst is metal fine particles.   5. The catalyst structure for volatile organic substances according to claim 4, wherein an average particle diameter of the metal fine particles is larger than an average inner diameter of the passage and is equal to or smaller than an inner diameter of the enlarged diameter portion.   The volatilization according to claim 5, wherein the metal element (M) of the metal fine particles is contained in an amount of 0.5 to 2.5% by mass with respect to the catalyst structure for a volatile organic substance. Catalyst structure for organic substances.   7. The catalyst structure for a volatile organic substance according to claim 4, wherein an average particle diameter of the metal fine particles is 0.08 nm to 30 nm.   8. The catalyst structure for volatile organic substances according to claim 7, wherein an average particle diameter of the metal fine particles is 0.4 nm to 11.0 nm.   The catalyst structure for volatile organic substances according to any one of claims 4 to 8, wherein a ratio of an average particle diameter of the metal fine particles to an average inner diameter of the passage is 0.05 to 300. body.   10. The catalyst structure for volatile organic substances according to claim 9, wherein a ratio of an average particle diameter of the metal fine particles to an average inner diameter of the passage is 0.1 to 30. 11.   11. The catalyst structure for a volatile organic material according to claim 10, wherein a ratio of an average particle diameter of the metal fine particles to an average inner diameter of the passage is 1.4 to 3.6. An average inner diameter of the passage is 0.1 nm to 1.5 nm,
12. The catalyst structure for a volatile organic material according to claim 2, wherein an inner diameter of the expanded portion is 0.5 nm to 50 nm.   The catalyst structure for volatile organic substances according to any one of claims 1 to 12, further comprising at least one other volatile organic substance oxidation catalyst held on the outer surface of the carrier. .   The content of the at least one volatile organic substance oxidation catalyst inherent in the carrier is greater than the content of the at least one other volatile organic substance oxidation catalyst held on the outer surface of the carrier. The catalyst structure for volatile organic substances according to claim 13.   The catalyst structure for volatile organic substances according to any one of claims 1 to 14, wherein the zeolite type compound is a silicate compound.   The volatile organic substance removal apparatus which has the catalyst structure for volatile organic substances of any one of Claims 1-15. A firing step of firing the precursor material (B) obtained by impregnating the precursor material (A) with a metal-containing solution to obtain a porous structure carrier composed of a zeolite-type compound;
A hydrothermal treatment step of hydrothermally treating the precursor material (C) obtained by firing the precursor material (B);
Performing a reduction treatment on the hydrothermally treated precursor material (C);
A process for producing a catalyst structure for volatile organic substances, comprising:   The catalyst for volatile organic substances according to claim 17, wherein a nonionic surfactant is added in an amount of 50 to 500 mass% with respect to the precursor material (A) before the firing step. Manufacturing method of structure.   Before the firing step, the precursor material (A) is impregnated with the metal-containing solution by adding the metal-containing solution to the precursor material (A) in a plurality of times. The manufacturing method of the catalyst structure for volatile organic substances of Claim 17 or 18.   When the precursor material (A) is impregnated with the metal-containing solution before the firing step, the amount of the metal-containing solution added to the precursor material (A) is changed to the precursor material (A). 10 to 1000 in terms of the ratio of silicon (Si) constituting the precursor material (A) to the metal element (M) contained in the metal-containing solution added to (atom ratio Si / M) It adjusts so that it may become, The manufacturing method of the catalyst structure for volatile organic substances of any one of Claims 17-19 characterized by the above-mentioned.   The method for producing a catalyst structure for a volatile organic substance according to claim 17, wherein in the hydrothermal treatment step, the precursor material (C) and a structure directing agent are mixed.   The method of manufacturing a catalyst structure for a volatile organic material according to claim 17, wherein the hydrothermal treatment step is performed in a basic atmosphere.

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