JP2020510601A - 多孔性セラミック粒子および多孔性セラミック粒子を生成する方法 - Google Patents
多孔性セラミック粒子および多孔性セラミック粒子を生成する方法 Download PDFInfo
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- JP2020510601A JP2020510601A JP2019550721A JP2019550721A JP2020510601A JP 2020510601 A JP2020510601 A JP 2020510601A JP 2019550721 A JP2019550721 A JP 2019550721A JP 2019550721 A JP2019550721 A JP 2019550721A JP 2020510601 A JP2020510601 A JP 2020510601A
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- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 102
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 83
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 71
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 68
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- 230000008569 process Effects 0.000 description 65
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- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 45
- 239000011575 calcium Substances 0.000 description 30
- 239000011777 magnesium Substances 0.000 description 30
- 239000010955 niobium Substances 0.000 description 30
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 15
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 15
- 229910052788 barium Inorganic materials 0.000 description 15
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 15
- 229910052797 bismuth Inorganic materials 0.000 description 15
- JCXGWMGPZLAOME-UHFFFAOYSA-N bismuth atom Chemical compound [Bi] JCXGWMGPZLAOME-UHFFFAOYSA-N 0.000 description 15
- 229910052791 calcium Inorganic materials 0.000 description 15
- 229910017052 cobalt Inorganic materials 0.000 description 15
- 239000010941 cobalt Substances 0.000 description 15
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 15
- 229910052746 lanthanum Inorganic materials 0.000 description 15
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 15
- 229910052749 magnesium Inorganic materials 0.000 description 15
- 229910052759 nickel Inorganic materials 0.000 description 15
- 229910052758 niobium Inorganic materials 0.000 description 15
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 15
- 229910052712 strontium Inorganic materials 0.000 description 15
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 description 15
- JBQYATWDVHIOAR-UHFFFAOYSA-N tellanylidenegermanium Chemical compound [Te]=[Ge] JBQYATWDVHIOAR-UHFFFAOYSA-N 0.000 description 15
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 15
- 229910052721 tungsten Inorganic materials 0.000 description 15
- 239000010937 tungsten Substances 0.000 description 15
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 description 10
- 238000012545 processing Methods 0.000 description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 10
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- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 6
- VXAUWWUXCIMFIM-UHFFFAOYSA-M aluminum;oxygen(2-);hydroxide Chemical compound [OH-].[O-2].[Al+3] VXAUWWUXCIMFIM-UHFFFAOYSA-M 0.000 description 6
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- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 5
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- JCCNYMKQOSZNPW-UHFFFAOYSA-N loratadine Chemical compound C1CN(C(=O)OCC)CCC1=C1C2=NC=CC=C2CCC2=CC(Cl)=CC=C21 JCCNYMKQOSZNPW-UHFFFAOYSA-N 0.000 description 4
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Abstract
Description
本出願は、2017年3月14日に出願された米国仮出願第62/470,929号の利益を主張する。
Claims (32)
- 多孔性セラミック粒子であって、粒径が少なくとも約200ミクロンであり、かつ約4000ミクロン以下であり、前記粒子の断面が、コア領域と、前記コアコア領域の上にある層状領域とを含み、
前記層状領域は、前記コア領域の周囲に第1の層状部分を含み、
前記コア領域は、コア領域組成物を含み、
前記第1の層状部分は、前記コア領域組成物とは異なる第1の層状部分組成物を含む、多孔性セラミック粒子。 - 前記コア領域がモノリス型である、請求項1に記載の多孔性セラミック粒子。
- 前記コア領域組成物が、アルミナ、ジルコニア、チタニア、シリカまたはこれらの組み合わせを含む、請求項1に記載の多孔性セラミック粒子。
- 前記第1の層状部分組成物が、アルミナ、ジルコニア、チタニア、シリカまたはこれらの組み合わせを含む、請求項1に記載の多孔性セラミック粒子。
- 前記第1の層状部分は、内表面と外表面とを有する、請求項1に記載の多孔性セラミック粒子。
- 前記第1の層状部分の前記第1の層状組成物は、前記第1の層状部分の内表面と前記第1の層状部分の外表面との間の前記第1の層状部分の厚さ全体にわたって均一な層状部分組成物を含む、請求項5に記載の多孔性セラミック粒子。
- 前記第1の層状部分の前記第1の層状組成物は、前記第1の層部分の内表面と前記第1の層部分の外表面との間の前記第1の層状部分の厚さ全体にわたって徐々に濃度が変化する勾配組成を含み、徐々に変化する濃度勾配は、前記第1の層状部分の内表面で測定される前記第1の層状部分組成物中の材料の第1の濃度から、前記第1の層状部分の外表面で測定される前記第1の層状部分組成物中の同じ材料の第2の濃度までの徐々に変わる変化として定義される、請求項5に記載の多孔性セラミック粒子。
- 前記第1の層状部分中の前記材料の第1の濃度は、前記第1の層状部分中の同じ材料の第2の濃度より低い、請求項7に記載の多孔性セラミック粒子。
- 前記第1の層状部分中の前記材料の第1の濃度は、前記第1の層状部分中の同じ材料の第2の濃度より高い、請求項7に記載の多孔性セラミック粒子。
- 前記層状領域は、前記第1の層状部分の周囲に第2の層状部分をさらに含み、前記第2の層部分は、前記第1の層状部分組成物とは異なる第2の層状部分組成物を含む、請求項1に記載の多孔性セラミック粒子。
- 前記第2の層状部分は、内表面と外表面とを有する、請求項10に記載の多孔性セラミック粒子。
- 前記第2の層状部分の前記第2の層状組成物は、前記第2の層状部分の内表面と前記第2の層状部分の外表面との間の前記第2の層状部分の厚さ全体にわたって均一な層状部分組成物を含む、請求項11に記載の多孔性セラミック粒子。
- 前記第2の層状部分の前記第2の層状組成物は、前記第2の層部分の内表面と前記第2の層部部分の外表面との間の前記第2の層状部分の厚さ全体にわたって徐々に濃度が変化する勾配組成を含み、徐々に変化する濃度勾配は、前記第2の層状部分の内表面で測定される前記第2の層状部分組成物中の材料の第1の濃度から、前記第2の層状部分の外表面で測定される前記第2の層状部分組成物中の同じ材料の第2の濃度までの徐々に変わる変化として定義される、請求項11に記載の多孔性セラミック粒子。
- 前記第2の層状部分中の前記材料の第1の濃度は、前記第2の層状部分中の同じ材料の第2の濃度より低い、請求項11に記載の多孔性セラミック粒子。
- 前記第2の層状部分中の前記材料の第1の濃度は、前記第2の層状部分中の同じ材料の第2の濃度より高い、請求項11に記載の多孔性セラミック粒子。
- 複数の多孔性セラミック粒子であって、
平均空隙率が、少なくとも約0.01cc/gであり、かつ約1.60cc/g以下であり、
平均粒径が、少なくとも約200ミクロンであり、かつ約4000ミクロン以下であり、
前記複数の多孔性セラミック粒子は、第1のバッチ噴霧流動化生成サイクルを含むバッチモードで操作する噴霧流動化生成プロセスによって作られ、
前記第1のバッチ噴霧流動化生成サイクルは、第1のコーティング液の微細に分散した液滴を、空気を含む多孔性セラミック粒子に繰り返し分注することを含み、
前記セラミック粒子は、コア領域組成物を含み、
前記第1のコーティング液は、第1のコーティング材料組成物を含み、
前記第1のコーティング材料組成物は、前記コア領域組成物とは異なっている、複数の多孔性セラミック粒子。 - 多孔性セラミック粒子のバッチを作成する方法であって、当該方法は、
初期粒度分布の広がりIPDSが、(Id90〜Id10)/Id50に等しい初期のバッチのセラミック粒子を調製することであって、ここで、Id90は、初期のバッチのセラミック粒子のd90粒度分布測定に等しく、Id10は、初期のバッチのセラミック粒子のd10粒度分布測定に等しく、Id50は、初期のバッチのセラミック粒子のd50粒度分布測定に等しい、調整することと、
第1のバッチ噴霧流動化生成サイクルを含む噴霧流動化生成プロセスを用い、初期のバッチから、処理されたバッチの多孔性セラミック粒子を作成することであって、処理されたバッチの多孔性セラミック粒子は、処理された粒度分布の広がりPPDSが、(Pd90〜Pd10)/Pd50に等しく、ここで、Pd90は、処理されたバッチの多孔性セラミック粒子のd90粒度分布測定に等しく、Pd10は、処理されたバッチの多孔性セラミック粒子のd10粒度分布測定に等しく、Pd50は、処理されたバッチの多孔性セラミック粒子のd50粒度分布測定に等しい、作成することとを含み、
初期のバッチから、処理されたバッチの多孔性セラミック粒子を作成するための比IPDS/PPDSが、少なくとも約0.90であり、
前記第1のバッチ噴霧流動化生成サイクルは、第1のコーティング液の微細に分散した液滴を、空気を含む多孔性セラミック粒子に繰り返し分注することを含み、
前記セラミック粒子は、コア領域組成物を含み、
前記第1のコーティング液は、第1のコーティング材料を含み、
前記第1のコーティング材料組成物は、前記コア領域組成物とは異なっている、方法。 - 触媒担体を作成する方法であって、当該方法は、
第1のバッチ噴霧流動化生成サイクルを含む噴霧流動化生成プロセスを用い、多孔性セラミック粒子を作成することと、前記多孔性セラミック粒子を少なくとも約350℃であり、かつ約1400℃以下の温度で焼結することとを含み、
前記多孔性セラミック粒子は、粒径が少なくとも約200ミクロンであり、かつ約4000ミクロン以下であり、
前記第1のバッチ噴霧流動化生成サイクルは、第1のコーティング液の微細に分散した液滴を、空気を含む多孔性セラミック粒子に繰り返し分注することを含み、
前記セラミック粒子は、コア領域組成物を含み、
前記第1のコーティング液は、第1のコーティング材料組成物を含み、
前記第1のコーティング材料組成物は、前記コア領域組成物とは異なっている、方法。 - 複数のであって、当該方法は、
バッチモードで行われ、少なくとも第1のバッチ噴霧流動化生成サイクルを含む噴霧流動化生成プロセスを用い、複数の多孔性セラミック粒子を作成することを含み、
前記複数の多孔性セラミック粒子は、粒径が少なくとも約200ミクロンであり、かつ約4000ミクロン以下であり、
前記第1のバッチ噴霧流動化生成サイクルは、第1のコーティング液の微細に分散した液滴を、空気を含む多孔性セラミック粒子に繰り返し分注することを含み、
前記セラミック粒子は、コア領域組成物を含み、
前記第1のコーティング液は、第1のコーティング材料組成物を含み、
前記第1のコーティング材料組成物は、前記コア領域組成物とは異なっている、方法。 - 前記コア領域組成物が、アルミナ、ジルコニア、チタニア、シリカまたはこれらの組み合わせを含む、請求項16、17、18および19のいずれか一項に記載の複数の多孔性セラミック粒子または方法。
- 前記第1のコーティング材料組成物が、アルミナ、ジルコニア、チタニア、シリカまたはこれらの組み合わせを含む、請求項16、17、18および19のいずれか一項に記載の複数の多孔性セラミック粒子または方法。
- 前記第1のコーティング材料組成物は、前記第1のバッチ噴霧流動化生成サイクル全体で一定のままである、請求項16、17、18および19のいずれか一項に記載の複数の多孔性セラミック粒子または方法。
- 前記第1のコーティング材料組成物中の材料の濃度を第1のバッチ噴霧流動化生成サイクルの開始時に材料の第1の濃度から、第1のバッチ噴霧流動化生成サイクルの終了時に材料の第2の濃度まで徐々に変えることによって、前記第1のコーティング材料組成物は、第1のバッチ噴霧流動化生成サイクルの持続時間の一部または全体で徐々に変化する、請求項16、17、18および19のいずれか一項に記載の複数の多孔性セラミック粒子または方法。
- 前記材料の第1の濃度は、前記材料の第2の濃度よりも低い、請求項23に記載の複数の多孔性セラミック粒子または方法。
- 前記材料の第1の濃度は、前記材料の第2の濃度よりも高い、請求項23に記載の多孔性セラミック粒子、複数の多孔性セラミック粒子または方法。
- 前記噴霧流動化生成プロセスが、第2のバッチ噴霧流動化生成サイクルをさらに含み、
前記第2のバッチ噴霧流動化生成サイクルは、第2のコーティング液の微細に分散した液滴を、前記第1のバッチ噴霧流動化生成サイクル中に作られた空気を含む多孔性セラミック粒子に繰り返し分注し、処理されたバッチの多孔性セラミック粒子を作成することを含み、
前記第2のコーティング液は、第2のコーティング材料組成物を含み、
前記第2のコーティング材料組成物は、前記第1のコーティング材料組成物とは異なる、請求項16、17、18および19のいずれか一項に記載の複数の多孔性セラミック粒子または方法。 - 前記第2のコーティング材料組成物が、アルミナ、ジルコニア、チタニア、シリカまたはこれらの組み合わせを含む、請求項26に記載の複数の多孔性セラミック粒子または方法。
- 前記第2のコーティング材料組成物は、前記第2のバッチ噴霧流動化生成サイクル全体で一定のままである、請求項27に記載の複数の多孔性セラミック粒子または方法。
- 前記第2のコーティング材料組成物中の材料の濃度を第2のバッチ噴霧流動化生成サイクルの開始時に材料の第1の濃度から、第2のバッチ噴霧流動化生成サイクルの終了時に材料の第2の濃度まで徐々に変えることによって、前記第2のコーティング材料組成物は、第2のバッチ噴霧流動化生成サイクルの持続時間の一部または全体で徐々に変化する、請求項27に記載の複数の多孔性セラミック粒子または方法。
- 前記材料の第1の濃度は、前記材料の第2の濃度よりも低い、請求項29に記載の複数の多孔性セラミック粒子または方法。
- 前記材料の第1の濃度は、前記材料の第2の濃度よりも高い、請求項29に記載の複数の多孔性セラミック粒子または方法。
- 多孔性セラミック粒子であって、粒径が少なくとも約200ミクロンであり、かつ約4000ミクロン以下であり、前記粒子の断面が、コア領域と、前記コアコア領域の上にある層状領域とを含み、
前記層状領域は、前記コア領域の周囲に第1の層状部分を含み、
前記第1の層状部分は、内表面と外表面とを有し、
前記コア領域は、コア領域組成物を含み、
前記第1の層状部分は、前記コア領域組成物とは異なる第1の層状部分組成物を含み、
前記第1の層状部分の第1の層状組成物は、前記第1の層部分の内表面と前記第1の層部分の外表面との間の前記第1の層状部分の厚さ全体にわたって徐々に濃度が変化する勾配組成を含む、多孔性セラミック粒子。
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US20210121865A1 (en) * | 2019-10-04 | 2021-04-29 | Saint-Gobain Ceramics & Plastics, Inc. | Porous catalyst carrier particles and methods of forming thereof |
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