JP2020515766A - 統合された排出制御システム - Google Patents
統合された排出制御システム Download PDFInfo
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- JP2020515766A JP2020515766A JP2019554836A JP2019554836A JP2020515766A JP 2020515766 A JP2020515766 A JP 2020515766A JP 2019554836 A JP2019554836 A JP 2019554836A JP 2019554836 A JP2019554836 A JP 2019554836A JP 2020515766 A JP2020515766 A JP 2020515766A
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Classifications
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Abstract
Description
4NO+4NH3+O2→4N2+6H2O(標準のSCR反応)
2NO2+4NH3→3N2+6H2O(遅いSCR反応)
NO+NO2+NH3→2N2+3H2O(速いSCR反応)
第二のSCR触媒組成物を含む第二のSCRコーティング層を含む、先行する実施形態のいずれかのフロースルーモノリス触媒物品。
冠詞「1つの(a)」及び「1つの(an)」は、本明細書では、文法的対象語のうちの1つ又は2つ以上(すなわち、少なくとも1つ)を指す。本明細書に記載されるいずれの範囲も、包括的である。全体を通して使用される用語「約」とは、小規模な変動を記載及び説明するために使用される。例えば、「約」とは、±5%、±4%、±3%、±2%、±1%、±0.5%、±0.4%、±0.3%、±0.2%、±0.1%又は±0.05%だけ修飾し得る数値を意味し得る。あらゆる数値が用語「約」によって、明示的に示されているか否かに関わらず、修飾される。用語「約」によって修飾されている数値は、特定の指示された値を含む。例えば、「約5.0」は5.0を含む。
1つ以上の実施形態において、本明細書に開示する触媒組成物は、基材上に配置されて触媒物品を形成する。触媒物品のための本発明の基材は、円柱に類似した長さ、直径、及び体積を有する三次元である。形状は、必ずしも円柱に一致する必要はない。長さは、入口端及び出口端で規定される軸方向の長さである。直径は、最大の断面長さであり、例えば、形状が円柱に正確には一致していない場合、最大の断面である。
一態様では、軸方向長さL、直径D、及び体積を有する基材を含み、その基材は、前部、上流端及び後部、軸方向長さを規定する下流端、及び約1から約20のL/Dで規定されるアスペクト比を含む、モノリシックウォールフローフィルター触媒物品が提供される。図1Aは、例示的なウォールフローフィルター基材の斜視図である。
一部の実施形態では、フロースルーモノリス触媒物品は、ウォールフローフィルター触媒物品の下流にあり且つそれと流体連通している。
モノリシックウォールフローフィルター触媒物品は、その上に配置される機能性コーティング組成物を有する(上記のような)ウォールフローフィルター基材を一般に含み、機能性コーティング組成物は、第一の吸着剤組成物、酸化触媒組成物、及び任意に第二の吸着剤組成物を含む。このような各成分を、以下に説明する。
第一の吸着剤組成物は、排気ガスのNOx及び/又はCO及び/又はHC成分を吸着及び/又は吸収するのに適し得る。適した吸着剤には、アルカリ土類金属酸化物、アルカリ土類金属炭酸塩、希土類酸化物及び分子ふるいなどの材料が含まれるが、これらに限定されない。Mg、Ca、Sr又はBaの酸化物又は炭酸塩、及び/又はCe、La、Pr又はNdの酸化物が含まれる。吸着剤分子ふるいには、ゼオライトが含まれる。
酸化触媒組成物は、例えば、排気ガスのNO及び/又はCO及び/又はHC成分を、例えば<150℃の比較的低い温度で酸化するのに適している。適した酸化触媒組成物は、有利には、耐火性金属酸化物担体上に分散された白金族金属(PGM)を含む。
任意の第二の吸着剤組成物は、有利には、所定の条件下でアンモニア及び/又はNOxを吸着及び/又は吸収し、貯蔵されたアンモニア及び/又はNOxを放出するのに効果がある。放出されたアンモニアは、下流のSCR反応で用いられ得る。例えば、貯蔵されたアンモニアは、エンジンの加速中に放出され得る。
フロースルーモノリス触媒物品は、一般に、その上に配置されるSCRコーティング組成物を有するフロースルー基材を含む。SCRコーティング組成物は一般に、NOx汚染物質を窒素と水に変換する。本発明のSCRコーティング組成物は、例えば、2つの異なる温度範囲、特に<250℃の低温及び約250℃から約550℃の高温で運転するのに効果がある。本発明のSCRコーティング組成物は、第一のSCR触媒組成物及び第二のSCR触媒組成物を含み、第二のSCR触媒組成物は、卑金属を含む分子ふるいを含む。
有利には、第一のSCR組成物は、高表面積の耐火性金属酸化物担体、例えば高表面積アルミナ担体上に配置された1つ以上の白金族金属を含む。適した担体は、酸化触媒組成物に関して本明細書で上述されている。
第二のSCR触媒組成物は、約250℃から約550℃のより高い温度で効果がある、卑金属含有分子ふるい触媒組成物を含む。この触媒組成物は一般に、アンモニア前駆体として注入アンモニア又は注入尿素を用いるが、ここでアンモニアは活性還元剤である。運転中、水素、アンモニア及び尿素のうちの1つ以上が、フロースルーモノリス物品の上流の位置から排気流に定期的に計量供給される。注入器は、フロースルーモノリス物品と流体連通し、その上流にある。一般に、注入器は還元剤(又は還元剤前駆体)貯蔵器及びポンプにも関連する。貯蔵器、ポンプ等は機能性物品とはみなされない。
本明細書に記載するモノリシックウォールフローフィルター触媒物品基材及びフロースルーモノリス触媒物品基材は、その上にそれぞれ配置される機能性又はSCR触媒コーティングを有する。
本開示は、本明細書に開示するモノリシックウォールフローフィルター触媒物品を含む排気ガス処理システムをさらに提供し、ここでモノリシックウォールフローフィルター触媒物品は、内燃機関の下流に位置し且つそれと流体連通し、排気ガス処理システムは、水素注入物品をさらに含み、水素注入物品は、モノリシックウォールフローフィルター触媒物品の上流に水素を導入するように構成される。
Pd(0.5wt.%)、Ba(0.8wt.%)及びPt(0.3wt.%)を含浸させた粉砕アルミナ粉末を含有する底部コート触媒組成物スラリーを調製し、硝酸でpH4.5から5.0に調整した。底部コートスラリーの固形分は38wt.%であった。底部コートスラリーを、ウォッシュコート技術により、1”×3” のコア全長に、200cpsi(セル/平方インチ)及び壁厚12milの互い違いのチャネル開口部を備えたハニカム基材フィルターに施与した。底部コートスラリーは、出口チャネルのみに施与した。コーティングされた基材を120℃で風乾し、500℃で1時間焼成して、1.6g/in3のコーティング装填量を得た。
粉砕したCuCHA(3.7wt.%のCu)及び5wt.%のジルコニウムアセテート結合剤を含有するSCR触媒組成物スラリーを調製し、ウォッシュコート技術により70.8cm3の体積を有する400cpsi、1”×5.5” のハニカム基材に施与した。コーティングしたコアを130℃で乾燥し、550℃で1時間焼成して、2.75g/in3のコーティング装填量を得た。
コーティングされたモノリシックウォールフローフィルター触媒物品(実施例1)を、800℃の管状炉で16時間、10%のH2O、10%のO2、残りN2の供給ガス組成で、水熱熟成した。フロースルーモノリス触媒物品(実施例2)は新しいものであった。コーティングしたモノリシックウォールフローフィルター触媒物品の直前に、H2パルスの源として機能するH2/N2の個別の供給ラインを備えたシミュレートされたNEDC(新欧州運転サイクル)を実施するため装備された実験室反応器内で、試料を評価した(実施例1)。シミュレートされた排気ガス流条件、及びNEDCサイクルのエンジンから出る排気ガスの供給組成を図4に示し、図5に車両トレースとシミュレーター間のエンジンから出るCO排出量のグラフ比較を示す。
Claims (28)
- 軸方向長さL、直径D、及び体積を有し、前部、上流端及び後部、軸方向長さを規定する下流端、約1から約20のL/Dで規定されるアスペクト比を含む基材、及び
前記基材上に配置され、第一の吸着剤組成物、酸化触媒組成物、及び任意に第二の吸着剤組成物を含む機能性コーティング組成物
を含む、モノリシックウォールフローフィルター触媒物品。 - 前記第一の吸着剤組成物が、アルカリ土類金属酸化物、アルカリ土類金属炭酸塩、希土類酸化物、又は分子ふるいのうちの1つ以上を含む、請求項1に記載のモノリシックウォールフローフィルター触媒物品。
- 前記第一の吸着剤組成物が、フォージャサイト、チャバザイト、クリノプチロライト、モルデナイト、シリカライト、ゼオライトX、ゼオライトY、超安定ゼオライトY、ZSM−5ゼオライト、オフレタイト及びベータゼオライトからなる群から選択されるゼオライトを含む、請求項1又は2に記載のモノリシックウォールフローフィルター触媒物品。
- 前記酸化触媒組成物が、排気ガス流中のNO、CO、及びHCのうちの1つ以上を、約150℃未満の温度で効果的に酸化する、請求項1から3のいずれか一項に記載のモノリシックウォールフローフィルター触媒物品。
- 前記酸化触媒組成物が、耐火性金属酸化物担体上に分散された白金族金属(PGM)成分を含む、請求項1から4のいずれか一項に記載のモノリシックウォールフローフィルター触媒物品。
- 前記第二の吸着剤組成物が、小細孔又は中間細孔分子ふるい、及び、任意にPGM成分を含む、請求項1から5のいずれか一項に記載のモノリシックウォールフローフィルター触媒物品。
- 前記第一の吸着剤組成物、前記酸化触媒組成物、及び任意に前記第二の吸着剤組成物が、区分けされた構成で2つ又は3つの層に配置される、請求項1から6のいずれか一項に記載のモノリシックウォールフローフィルター触媒物品。
- 前記モノリシックウォールフローフィルター触媒物品が、前記機能性コーティング組成物がその上に配置されない同じ基材及び寸法のモノリシックウォールフローフィルター物品と比較して、空気流の関数として測定して≦25%の背圧の増加又は圧力降下を示す、請求項1から7のいずれか一項に記載のモノリシックウォールフローフィルター触媒物品。
- 請求項1から8のいずれか一項に記載のモノリシックウォールフローフィルター触媒物品を含む、車両。
- 内燃機関の下流に位置し且つそれと流体連通している、請求項1から8のいずれか一項に記載のモノリシックウォールフローフィルター触媒物品、及び
前記モノリシックウォールフローフィルター触媒物品の上流に水素を導入するように構成される第一の水素注入物品
を含む、排気ガス処理システム。 - 水素貯蔵物品をさらに含み、前記水素注入物品が、前記水素貯蔵物品に貯蔵された水素を断続的に導入するように構成される、請求項10に記載の排気ガス処理システム。
- 前記モノリシックウォールフローフィルター触媒物品の下流にあり且つそれと流体連通しているフロースルーモノリス触媒物品をさらに含み、前記フロースルーモノリス触媒物品は、選択的触媒還元(SCR)コーティング組成物がその上に配置された基材を含み、前記SCRコーティング組成物は、
耐火性金属酸化物担体上に分散したPGM成分を含む第一のSCR触媒組成物、及び
卑金属を含む分子ふるいを含む第二のSCR触媒組成物を含む、請求項10又は11に記載の排気ガス処理システム。 - 前記第一のSCR触媒組成物が、<250℃の温度で窒素酸化物(NOx)を還元するのに効果がある、請求項12に記載の排気ガス処理システム。
- 前記第二のSCR触媒組成物が、約250℃から約550℃の温度でNOxを還元するのに効果がある、請求項12又は13に記載の排気ガス処理システム。
- 前記分子ふるいが、CHA結晶構造及び約1から約1000のシリカ対アルミナ比を有するアルミノシリケートゼオライトである、請求項12から14のいずれか一項に記載の排気ガス処理システム。
- 前記SCRコーティング組成物が、
前記第一のSCR触媒組成物を含む第一のSCRコーティング層、及び
前記第二のSCR触媒組成物を含む第二のSCRコーティング層
を含む、請求項12から15のいずれか一項に記載の排気ガス処理システム。 - 前記第一のSCRコーティング層及び前記第二のSCRコーティング層が区分けされた構成にある、請求項16に記載の排気ガス処理システム。
- 前記フロースルーモノリス物品の上流に水素を導入するように構成される第二の水素注入物品をさらに含む、請求項12から17のいずれか一項に記載の排気ガス処理システム。
- 水素貯蔵物品をさらに含み、前記第二の水素注入物品が前記水素貯蔵物品に貯蔵された水素を断続的に導入するように構成される、請求項12から17のいずれか一項に記載の排気ガス処理システム。
- 軸方向長さL、直径D、及び体積を有し、前部、上流端及び後部、軸方向長さを規定する下流端、約1から約20のL/Dで規定されるアスペクト比を含む基材を含む、モノリシックウォールフローフィルター触媒物品、
前記基材上に配置され、第一の吸着剤組成物、酸化触媒組成物、及び任意に第二の吸着剤組成物を含む機能性コーティング組成物を有する、前記基材、及び
前記モノリシックウォールフローフィルター触媒物品の下流にあり且つそれと流体連通しているフロースルーモノリス触媒物品であって、選択的触媒還元(SCR)コーティング組成物がその上に配置された基材を含み、前記SCRコーティング組成物は第一のSCR触媒組成物及び第二のSCR触媒組成物を含み、前記第二のSCR触媒組成物は卑金属を含む分子ふるいを含む、フロースルーモノリス触媒物品
を含む、排気ガス処理システム。 - 前記フロースルーモノリス物品の上流にあり且つそれと流体連通している尿素注入器をさらに含む、請求項12から20のいずれか一項に記載の排気ガス処理システム。
- 前記モノリシックウォールフローフィルター触媒物品と流体連通し且つその上流にアンモニアを導入するように構成されるアンモニア注入器をさらに含む、請求項12から21のいずれか一項に記載の排気ガス処理システム。
- 前記フロースルーモノリス物品の上流に水素を導入するように構成される水素注入物品をさらに含む、請求項20に記載の排気ガス処理システム。
- 水素貯蔵物品をさらに含み、前記水素注入物品が前記水素貯蔵物品に貯蔵された水素を断続的に導入するように構成される、請求項23に記載の排気ガス処理システム。
- 前記機能性コーティング組成物がその上に配置されない同じ構造及び構成を有する排気ガス処理システムと比較して、空気流の関数として測定して≦25%の背圧の増加又は圧力降下を示す、請求項12から24のいずれか一項に記載の排気ガス処理システム。
- 請求項10から25に記載の排気ガス処理システムを含む、車両。
- NOx及び/又はCO及び/又はHC及び/又は煤を含有する排気流を処理する方法であって、前記排気流を請求項1から9のいずれか一項に記載のモノリシックウォールフローフィルター触媒物品中に受け入れることを含む、方法。
- NOx及び/又はCO及び/又はHC及び/又は煤を含有する排気流を処理する方法であって、前記排気流を請求項10から25のいずれか一項に記載の排気ガス処理システム内に受け入れることを含む、方法。
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- 2018-04-03 BR BR112019020841A patent/BR112019020841A2/pt not_active Application Discontinuation
- 2018-04-03 KR KR1020197031960A patent/KR102471292B1/ko active IP Right Grant
- 2018-04-03 CN CN201880036837.8A patent/CN110730858A/zh active Pending
- 2018-04-03 EP EP18781364.7A patent/EP3607177A4/en active Pending
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EP3607177A1 (en) | 2020-02-12 |
US20200032686A1 (en) | 2020-01-30 |
CN110730858A (zh) | 2020-01-24 |
KR20190127954A (ko) | 2019-11-13 |
US11199117B2 (en) | 2021-12-14 |
KR102471292B1 (ko) | 2022-11-29 |
EP3607177A4 (en) | 2020-09-02 |
WO2018185666A1 (en) | 2018-10-11 |
BR112019020841A2 (pt) | 2020-04-28 |
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