JP2018528847A - 排気システム用の亜酸化窒素除去触媒 - Google Patents
排気システム用の亜酸化窒素除去触媒 Download PDFInfo
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- JP2018528847A JP2018528847A JP2017568161A JP2017568161A JP2018528847A JP 2018528847 A JP2018528847 A JP 2018528847A JP 2017568161 A JP2017568161 A JP 2017568161A JP 2017568161 A JP2017568161 A JP 2017568161A JP 2018528847 A JP2018528847 A JP 2018528847A
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- catalyst
- ceria
- removal
- carrier
- removal catalyst
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- 239000001272 nitrous oxide Substances 0.000 title claims abstract description 18
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 claims abstract description 72
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 claims abstract description 71
- 229910052751 metal Inorganic materials 0.000 claims abstract description 51
- 239000002184 metal Substances 0.000 claims abstract description 51
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical group [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims abstract description 50
- 239000000463 material Substances 0.000 claims abstract description 43
- 239000002131 composite material Substances 0.000 claims abstract description 38
- 238000000034 method Methods 0.000 claims abstract description 38
- 238000002485 combustion reaction Methods 0.000 claims abstract description 29
- 230000001052 transient effect Effects 0.000 claims abstract description 24
- 229910052760 oxygen Inorganic materials 0.000 claims abstract description 22
- 239000001301 oxygen Substances 0.000 claims abstract description 21
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims abstract description 20
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Abstract
Description
本発明は、化学量論的条件下か、またはリッチ側への周期的かつ過渡的な変動を伴うリーン条件下で運転する内燃機関の排気システム用の浄化触媒およびその使用方法を対象とする。より具体的には本発明は、セリア含有担体に担持された白金族金属(PGM)、例えばロジウム(Rh)成分、パラジウム(Pd)成分および/または白金(Pt)成分を含む触媒であって、内燃機関の排気流中に存在する亜酸化窒素(N2O)の除去に有効である触媒に関する。例えば該N2O除去触媒は、N2Oから窒素(N2)および酸素(O2)への分解に有効であり、かつ/または存在する還元剤に応じてN2Oから窒素および水および/もしくは二酸化炭素への還元に有効である。
亜酸化窒素(N2O)は、CO2の310倍の地球温暖化係数を有する温室効果ガスであり、大気中での寿命は114年である。考えられるN2O排出ガス発生源の1つが自動車排ガスであり、N2O排出ガスは、燃料自体の燃焼の副生成物としてだけではなく、触媒によるNOx還元の際に生じる副生成物としても発生する。その地球温暖化係数を認識して、米国環境保護庁(US EPA)はすでに、MY2012から開始されるFTPサイクルでの軽量車のN2O排出量制限を10mg/マイルに設定し、またMY2014から開始される重量FTPサイクルでの重量車のN2O排出量制限を0.1g/bhp−hに設定している。これまで、自動車用触媒システムは通常は、N2O水準を考慮せずにNOx(規制された汚染物質)の最大限の削減に向けて最適化が行われていた。今や、N2Oが10mg/マイルの制限を超えると、CAFEの燃費要件に対する処罰の対象となる。
N2Oは、これらに限定されるものではないが例えば、従来の/化学量論的であるガソリン車やガソリン直噴(GDI)ガソリン車に見られる三元転化(TWC)触媒や四元転化(FWC)触媒といったあらゆる種類の主要な排出ガス制御触媒での過渡的条件下で形成される。さらにN2Oは、ディーゼル車に見られるディーゼル酸化触媒(DOC)、キャタライズド・スート・フィルター(CSF)、リーンNOxトラップ(LNT)、選択的接触還元(SCR)触媒および選択的アンモニア酸化(AMOx)触媒での過渡的条件下でも形成される。さらにより厳しいN2O排出量規制では、排出ガス制御システムの設計を、NOx転化性能の向上だけでなくN2O排出量の削減に向けても最適化することが要求される。理論的にはN2O排出量の削減は、N2Oの形成を最小限に抑えることによっても対処可能であるし、N2OをN2およびO2へと直接転化しかつ/または(還元剤に応じて)N2OをN2およびH2Oおよび/またはCO2へと還元する触媒を用いることによっても対処可能である。有効なN2O触媒を、場合によってはスタンドアローン型の装置として提供してもよいし、既存の触媒システムに組み込んでもよい。
立方晶系の蛍石結晶構造の単相を有するセリア含有担体に担持された白金族金属(PGM)成分を含む亜酸化窒素(N2O)除去触媒が提供される。該触媒は、亜酸化窒素(N2O)から窒素(N2)および酸素(O2)への分解に有効であり、かつ/または多くの条件下で(還元剤に応じて)N2OからN2およびH2Oおよび/もしくはCO2への還元に有効であり、ここで、該条件としては特に、(1)空燃比が揺動的であり、わずかにリッチな条件とわずかにリーンな条件とが交互に生じることを特徴とする化学量論的条件か、または(2)リッチ側への周期的かつ過渡的な変動を伴うリーン条件が含まれる。該触媒は、400℃以下の温度で特に有効である。適切なセリア含有担体は、単相の立方晶系の蛍石結晶構造を有する。1つまたは複数の実施形態において、セリア含有担体は、少なくとも約0.20cm3/gの細孔容積を有する。1つまたは複数の実施形態は、リーンフィードとリッチフィードとを交互にして約950℃で約20時間エージング処理を行った後に、少なくとも約10m2/gのBET表面積を有する。特定の一実施形態は、0.517〜0.541の範囲のXRD立方格子定数a0を有する。
分解:2N2O→2N2+O2 (I)
還元:
N2O+H2→N2+H2O (IIa)
N2O+HC→N2+CO2+H2O (IIb)
N2O+CO→N2+CO2 (IIc)
3N2O+2NH3→4N2+3H2O (IId)
4NO+4NH3+O2→4N2+6H2O、および
NO+NO2+2NH3→2N2+3H2O
N2O触媒を、内燃機関の下流で種々の方法で組み込むことができる。図面を参照すると、図20は、N2O触媒を含む例示的なガソリンTWC排気システムの流れ図を示す。システムAは、三元転化(TWC)触媒と、それに続くN2O触媒とを示す。システムBは、TWC触媒と、それに続くガソリン・パティキュレート・フィルター(GPF)と、それに続くN2O触媒とを示す。システムCは、TWC触媒と、それに続くガソリン・パティキュレート・フィルター上のN2O触媒(GPF+N2O)とを示す。システムDは、同一のキャリア上のTWC触媒とN2O触媒とを示す。TWC触媒およびN2O触媒は、例えば層状であってもよいし区画されていてもよい。
単相の立方晶系の蛍石結晶構造を有するセリア含有担体に担持された白金族金属(PGM)成分を含むN2O触媒材料のウォッシュコートは、様々な技術によって作製可能である。一般的には、PGMの塩を、例えばインシピエントウェットネス技術(incipient wetness techniques)によってセリア含有粉末に含浸させる。この含浸された粉末を、次いで脱イオン水でスラリー化してウォッシュコートを形成させる。該ウォッシュコートをキャリアにコーティングする前に、追加の処理ステップを、含浸された粉末に対して適用することも、スラリーに対して適用することもできる。
触媒材料は典型的には、例えば排ガス用途向けのモノリシック型基材のようなキャリア上に配置される。
様々な実施形態を以下に列挙する。以下に列挙する実施形態を、本発明の範囲にしたがうすべての態様および他の実施形態と組合せてもよいことが理解されよう。
前記触媒複合体は、キャリア上にN2O除去触媒材料を含み、前記触媒材料は、単相の立方晶系の蛍石結晶構造を有するセリア含有担体に担持された白金族金属(PGM)成分を含み、前記N2O除去触媒材料は、前記排気流中でのN2Oから窒素(N2)および酸素(O2)への分解に有効であるか、またはN2OからN2および水(H2O)もしくは二酸化炭素(CO2)への還元に有効である、前記N2O除去触媒複合体。
試料1〜試料10のための触媒調製
試料1〜試料3は、湿式含浸法によって調製された1重量%Rhを有する担持Rh触媒であった。担体材料粉末に脱イオン水を加えることによって、固形分約30%の担体材料スラリーを作製した。その後、このスラリーのpHをHNO3でpH=4に調整した。ミル処理ステップの後、このスラリーに硝酸のRh塩の溶液を加え、次いでこのスラリーを撹拌下で乾燥させた。得られた粉末を、空気中で、500℃で2時間か焼し、この粉末に対してさらに、空気中で10%の水を含んだ状態で、750℃で20時間にわたって熱エージング処理を行った。CeO2担体およびAl2O3担体は市販の材料であり、ZrO2−SiO2材料は、米国特許第7,850,842号明細書に記載の手法により社内で作製したものであり、ここで、本明細書の一部を構成するものとして該米国特許明細書の内容を援用する。試料1〜試料3と同様の手法を用いて、硝酸のRh塩および第2の金属(CuまたはAg)の塩の溶液を同時にCeO2に含浸させることにより、試料4および試料5を作製した。か焼されたRh/CeO2(試料1)に第2の金属の前駆体溶液を含浸させることにより、試料6〜試料10を作製した。表1に、試料1〜試料10に関する触媒の情報をまとめる。
試料1〜試料10の試験
プロトコール:試料1〜試料10を、250μm〜500μmに成形された0.2gの試料を用いて、高処理型反応器システムで試験した。全ガス流量は50L/hであり、これは、2g/in3のウォッシュコート負荷量で30,000h−1のモノリス空間速度に相当した。400℃でリーンフィード/リッチフィードを交互に用いてN2O転化率を測定した。リーンフィードは、200ppmのN2O、5%のCO2、5%のH2Oおよび残部のN2からなり、一方でリッチフィードは、200ppmのN2O、0.75%のCO、0.25%のH2、5%のCO2、5%のH2Oおよび残部のN2を含む。リーン/リッチサイクルを、20分間のリーンおよび1分間のリッチで各触媒について3回運転した。
触媒調製
試料1〜試料3に用いたのと1つの例外を除いては同様の手法で表2に記載の担体を用いて、担持されたRh、PdおよびPt触媒を調製した。いずれの触媒も、リーン/リッチサイクリングフィードで、950℃で20時間エージング処理した。いずれの担体材料も、商業的供給元より入手した。担体B〜担体Gについて、元素の後の数字は、その元素の酸化物としての重量パーセントを表す。
試験
λ=1の摂動条件下での試験プロトコール:
担体A〜担体Hに担持されたRh、Pd、Ptを、200℃、250℃、300℃、350℃、400℃、450℃、500℃および550℃で、1秒間のリーン(λ=1.05)/1秒間のリッチ(λ=0.95)という揺動するフィードでN2O転化率について試験した。各温度で、この揺動するフィードを180秒間平衡化させたが、最後の30秒間のデータのみを収集した。リーンフィードは、200ppmのN2O、0.7%のCO、0.22%のH2、14%のCO2および10%のH2Oからなり、λ=1.05となるようにラムダセンサによってO2濃度を調整した。リッチフィードは、2.33%のCO、0.77%のH2、14%のCO2および10%のH2Oを含み、λ=0.95となるようにラムダセンサによってO2濃度を調整した。触媒を、250μm〜500μmに成形された0.2gの試料を用いて、高処理型反応器システムで試験した。全ガス流量は50L/hであり、これは、2g/in3のウォッシュコート負荷量で30,000h−1のモノリス空間速度に相当した。
図5は、1%Rh触媒のN2O転化率を示す。この実験において試験したすべての触媒のうち最も活性の高い触媒は、1%Rh/Aであり(200℃で転化率60%)、一方で最も活性の低い触媒は、1%Rh/Gである。他の触媒は、その間で可変の活性プロファイルを示す。
試験
Rh試料の特性解析、X線回折データ:
モノリス型N2O触媒の調製
従来のウォッシュコート法を用いて、30g/ft3のRh負荷量で、モノリス型セラミック基材(600セル/in2)上に試料1(Rh/CeO2粉末)を堆積させた。この触媒を、空気中で10%のH2Oを含んだ状態で、750℃で20時間にわたってエージング処理した。
試験
モノリシック型Rh/CeO2触媒の試験
実施例6のモノリス型Rh/CeO2触媒を、ガソリン車の排気をシミュレートする実験室反応器で試験した。図18に、シミュレートされたエンジンの運転および排気の条件の過渡的なトレースを示す。この試験では、三元転化(TWC)触媒を用いて、シミュレートされたエンジン試験中にN2Oを生成させ、この三元転化(TWC)触媒をN2O触媒の前に配置した。このN2O触媒の前後でのN2O排出量を測定し、これを用いて各サイクルの累積N2O排出量を算出した。図19に、累積N2O排出量を時間に対して示す。TWC触媒後の累積N2O排出量0.30g/L触媒は、過渡的な車両試験中にこのTWC触媒を通って形成されたN2Oを表し、一方でN2O触媒後の0.084g/Lは、モノリス型Rh/CeO2 N2O分解触媒によるN2O転化率が72%であることを表す。
Claims (25)
- 化学量論的条件下またはリッチ側への周期的かつ過渡的な変動を伴うリーン条件下で運転する内燃機関の排気流を処理するための亜酸化窒素(N2O)除去触媒複合体であって、
前記触媒複合体は、キャリア上にN2O除去触媒材料を含み、前記触媒材料は、単相の立方晶系の蛍石結晶構造を有するセリア含有担体に担持された白金族金属(PGM)成分を含み、前記N2O除去触媒材料は、前記排気流中でのN2Oから窒素(N2)および酸素(O2)への分解に有効であるか、またはN2OからN2および水(H2O)もしくは二酸化炭素(CO2)への還元に有効である、前記N2O除去触媒複合体。 - 前記セリア含有担体は、少なくとも0.20cm3/gの細孔容積を有する、請求項1記載のN2O除去触媒複合体。
- 前記セリア含有担体は、リーンフィードとリッチフィードとを交互にして950℃で20時間エージング処理を行った後に、少なくとも10m2/gのBET表面積を有する、請求項1記載のN2O除去触媒複合体。
- 前記セリア含有担体のBET表面積は、約10m2/g〜約100m2/gである、請求項3記載のN2O除去触媒複合体。
- 前記セリア含有担体は、0.517nm〜0.541nmの範囲のX線回折(XRD)格子定数a0を有する、請求項1記載のN2O除去触媒複合体。
- 前記セリア含有担体は、セリアと、ジルコニア、プラセオジミア、酸化ランタン、ネオジミア、イットリア、サマリアおよびガドリニアからなる群から選択される1つまたは複数の金属酸化物とを含む固溶体形態の混合金属酸化物を含む、請求項1記載のN2O除去触媒複合体。
- 前記混合金属酸化物は、
約5重量%〜約95重量%の量のセリアと、
約5重量%〜約95重量%の量のジルコニアと、
0重量%〜約20重量%の量のプラセオジミア、酸化ランタン、ネオジミア、イットリア、サマリアおよびガドリニアのうちの1つまたは複数と
を含む、請求項6記載のN2O除去触媒複合体。 - 前記セリア含有担体は、約90重量%〜約100重量%のセリアと、前記PGM成分とは異なる0重量%〜約10重量%の助触媒金属とを含む、請求項1記載のN2O除去触媒複合体。
- 前記PGM成分は、ロジウム成分、パラジウム成分、白金成分またはそれらの組合せ物を含み、前記PGM成分は、前記セリア含有担体上に、前記セリア含有担体の約0.01重量%〜約5重量%の量で存在する、請求項1記載のN2O除去触媒複合体。
- 前記セリア含有担体の約0.001重量%〜約10重量%の量の、前記PGM成分とは異なる助触媒金属であって、銅(Cu)、マンガン(Mn)、鉄(Fe)、コバルト(Co)、ニッケル(Ni)、バナジウム(V)、クロム(Cr)、亜鉛(Zn)およびスズ(Sn)からなる群から選択される1つまたは複数の卑金属を含む助触媒金属と、
銀(Ag)、イリジウム(Ir)、金(Au)およびルテニウム(Ru)からなる群から選択される1つまたは複数の追加の白金族金属成分と
をさらに含む、請求項9記載のN2O除去触媒複合体。 - 銀(Ag)、イリジウム(Ir)、金(Au)およびルテニウム(Ru)からなる群から選択される1つまたは複数の追加の白金族金属成分をさらに含む、請求項9記載のN2O除去触媒複合体。
- 前記キャリアは、フロースルー型基材またはウォールフロー型フィルターを含む、請求項1記載のN2O除去触媒複合体。
- 化学量論的条件下またはリッチ側への周期的かつ過渡的な変動を伴うリーン条件下で運転する内燃機関の排気流を処理するための排出ガス処理システムであって、
排気マニホルドを介して前記内燃機関に流体連通する排気ダクトと、
処理触媒と、
請求項1から12までのいずれか1項記載のN2O除去触媒複合体と
を含む、前記排出ガス処理システム。 - 前記処理触媒は、窒素酸化物処理触媒を含み、前記窒素酸化物処理触媒は、三元転化(TWC)触媒、リーンNOxトラップ(LNT)または選択的接触還元(SCR)触媒を含む、請求項13記載の排出ガス処理システム。
- 前記処理触媒は、ディーゼル酸化触媒(DOC)を含む、請求項13記載の排出ガス処理システム。
- 前記N2O除去触媒複合体と前記処理触媒とは、別個の層または別個のゾーンとして前記キャリア上に堆積されている、請求項13記載の排出ガス処理システム。
- 第2のキャリアをさらに含み、前記第2のキャリアの上に前記処理触媒が配置されている、請求項13記載の排出ガス処理システム。
- 摂動化された化学量論的条件下またはリッチ側への周期的かつ過渡的な変動を伴うリーン条件下で運転する内燃機関の排気流の排ガスを処理するための方法であって、炭化水素、一酸化炭素および窒素酸化物を含む排気流を、請求項1から12までのいずれか1項記載のN2O除去触媒複合体と接触させることを含む、前記方法。
- 前記内燃機関の運転条件は、第1の継続時間にわたる還元条件と、それに続く第2の継続時間にわたるリーン運転条件とを含み、前記第2の継続時間は、前記第1の継続時間の少なくとも2倍の長さであり、前記第2の継続時間中に、前記接触ステップによって、前記排ガス流中のN2Oの少なくとも90%が転化される、請求項18記載の方法。
- 前記N2O除去触媒複合体は、約200℃〜約500℃の温度にある、請求項18記載の方法。
- 前記N2O除去触媒複合体は、約200℃〜約500℃の温度にある、請求項19記載の方法。
- 前記接触ステップは、約400℃以下の温度にある、請求項20記載の方法。
- 前記第1の継続時間は、約0.25秒間〜約30秒間であり、前記第2の継続時間は、約1分間〜約30分間である、請求項19記載の方法。
- 前記N2O除去触媒複合体は、リーンNOxトラップ(LNT)または三元転化(TWC)触媒を含む排ガス処理システムに含まれ、前記排ガス処理システムは、窒素酸化物(NOx)制御のためにリッチ条件を周期的に必要とする、請求項18記載の方法。
- 前記N2O除去触媒複合体は、ディーゼル酸化触媒を必要に応じて選択的接触還元(SCR)触媒と組合せて含む排ガス処理システムに含まれ、前記内燃機関の運転条件は、N2O除去のためのリッチ運転の期間を含む、請求項18記載の方法。
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