JP2022539875A - 放射状にゾーニングされたコーティングを含む触媒基材 - Google Patents
放射状にゾーニングされたコーティングを含む触媒基材 Download PDFInfo
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- JP2022539875A JP2022539875A JP2022500938A JP2022500938A JP2022539875A JP 2022539875 A JP2022539875 A JP 2022539875A JP 2022500938 A JP2022500938 A JP 2022500938A JP 2022500938 A JP2022500938 A JP 2022500938A JP 2022539875 A JP2022539875 A JP 2022539875A
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- B01D53/9463—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts with catalysts positioned on one brick
- B01D53/9472—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts with catalysts positioned on one brick in different zones
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- F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
- F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
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Abstract
Description
本出願は、2019年7月12日に出願された米国仮出願第62/873,600号の全体に対する優先権の利益を主張する。
基材
1つ以上の実施形態では、本触媒組成物は、触媒物品を形成するために基材上に配設される。基材を含む触媒物品は、排気ガス処理システムの一部である(例えば、触媒物品としては、本明細書で開示されるDOC組成物を含む物品が挙げられるが、これらに限定されない)。有用な基材は、三次元であり、円柱に似た長さ、直径および体積を有する。形状は、必ずしも円柱に一致する必要はない。長さは、入口端および出口端によって画定される軸方向長さである。
いくつかの実施形態では、基材は、フロースルー基材(例えば、フロースルーハニカムモノリス基材を含むモノリス基材)である。フロースルー基材は、通路が流体の流れに対して開放されているように、基材の入口端から出口端まで延在する微細で平行なガス流路を有する。流体入口から流体出口まで本質的に直線的な経路である通路は、通路を通って流れるガスが触媒材料と接触するように触媒コーティングが配設されている壁によって画定されている。フロースルー基材の流路は、薄い壁のチャネルであり、台形、長方形、正方形、正弦波、六角形、楕円形、円形などのあらゆる好適な断面形状およびサイズであり得る。フロースルー基材は、上記のようにセラミックまたは金属であり得る。
いくつかの実施形態では、基材はウォールフローフィルタであり、これは一般に、基材の長手方向軸線に沿って延在する複数の微細で実質的に平行なガス流路を有する。典型的には、各通路は、基材本体の一端でブロックされ、代替の通路は、反対の端面で遮断される。このようなモノリシックウォールフローフィルタ基材は、断面の平方インチあたり最大約900以上の流路(または「セル」)を含有してもよいが、はるかに少ない数が用いられてもよい。例えば、基材は、平方インチあたり約7~600、より一般的には約100~400のセル(「cpsi」)を有し得る。セルは、長方形、正方形、円形、楕円形、三角形、六角形、または他の多角形の断面を有し得る。
触媒物品(catalytic composition)を製造するために、本明細書に開示されている基材を触媒組成物でコーティングする。コーティングは、「触媒コーティング組成物」または「触媒コーティング」である。「触媒組成物」および「触媒コーティング組成物」という用語は同義である。
本明細書で使用されるとき、「放射状にゾーニングされた酸化領域」という語句は、基材をガス入口側から見ると、触媒物品の基材の少なくとも2つの異なる領域に異なる触媒組成物を適用することを指しており、その結果として、2つ以上の酸化領域の各々が、異なるレベルの酸化活性を提供する。上記のように、基材は、入口側および出口側、ならびに入口側から出口側へと延在している複数の通路を含むことができる。第1の領域は、当該複数の通路の第1のサブセットを含む。第2の領域は、当該複数の通路の第2のサブセットを含む。この場合も、本開示の実施形態は2つの領域に限定されないことに留意されたい。例えば、本開示による基材は、3、4、またはそれ以上の領域を含むことができ、各領域は、基材の複数の通路のサブセットを含む。しかしながら、考察し易くするために、以下の図および説明では、2つの領域のみについて言及する。
本明細書に記載の触媒および/または吸着剤組成物は、機能的に活性な種をさらに含む高融点無機固体酸化物多孔質粉末などの1つまたは複数の担体または「キャリア」を含んでもよい。
PGMまたは卑金属成分を有する多孔質担体の調製は、典型的には、多孔質担体(例えば、粒子状アルミナなどの粒子状形態の耐火性酸化物担体材料)にPGMまたは卑金属溶液を含浸させることを含む。複数の金属成分(例えば、白金およびパラジウム)は、同時または別々に含浸させることができ、また初期湿潤技術を使用して、同じ担体粒子または別々の担体粒子に含浸させることができる。担体粒子は、典型的には、溶液の実質的にすべてを吸収して、湿潤固体を形成するのに十分に乾燥している。水溶性化合物の水溶液または金属成分の複合体の水溶液、例えば、硝酸パラジウムまたは硝酸白金、硝酸テトラアンミンパラジウムまたは硝酸白金、酢酸テトラアンミンパラジウムまたは酢酸白金、硝酸銅(II)、硝酸マンガン(II)、および硝酸セリウムアンモニウムが、典型的には、利用される。ある特定の実施形態では、コロイダル白金を、本明細書に記載の触媒組成物の実施形態で使用することができる。金属溶液で担体粒子を処理した後、粒子を、例えば、高温(例えば、100~150℃)で一定時間(例えば、1~3時間)熱処理し、次いで、焼成することによって乾燥させ、金属成分をより触媒的に活性な形態に変換する。例示的な焼成プロセスは、約400~550℃の温度で1~3時間にわたって空気中で熱処理することを含む。上記のプロセスは、所望のレベルの金属含浸に達するために、必要に応じて繰り返してもよい。得られた材料は、乾燥粉末として、またはスラリー形態で貯蔵することができる。
本開示はまた、本明細書に記載の触媒物品を組み込む排出物処理システムを提供する。典型的には、一体型の排出物処理システムは、排気ガス排出物、例えばディーゼルエンジンからの排気ガス排出物を処理するための1種以上の触媒物品/構成要素を備える。例えば、排出物処理システムは、本明細書に記載されているディーゼル酸化(DOC)触媒物品に加えて、触媒化煤フィルタ(CSF)、選択的触媒還元(SCR)触媒、および選択的触媒還元/アンモニア酸化(SCR/AMOx)触媒のうちの1つ以上を含み得る。いくつかの排出物処理システムは、リーンNOxトラップ(LNT)、CSF触媒、SCR触媒、および/またはSCR/AMOx触媒を含む。CO/HC変換もしくはNO酸化用のPGM含有触媒、またはSCR反応(SCRoF)用のSCR触媒のいずれかを充填されているCSFは、典型的にはDOCまたはLNT触媒の下流に位置するが、排出物処理システムの様々な構成要素の相対的な位置は変動させることができる。
本開示の態様は、以下の実施例によってより完全に示され、これらは、本開示のある特定の態様を示すために記載され、態様を限定するものとして解釈されるべきではない。
放射状にゾーニングされた構成で2つの酸化触媒組成物を有する、本開示による触媒物品を調製した。
実施例1に従って調製された触媒物品を出る排気ガスのNO2/NOx比は、異なる排気ガス入口温度で測定した。実施例1に従って調製した触媒物品を出る排気ガスのNO2/NOx比を、従来のDOC触媒物品(すなわち、放射状コーティングなし)を出る排気ガスのNO2/NOx比と比較した。従来のDOCは、1:2のPt:Pd比を有し、30g/ft3のPGM充填量で、アルミナ担体上にPGMを備えた入口ゾーンからなっていた。従来のDOCの出口ゾーンは、5:1のPt:Pd比を有し、10g/ft3のPGM充填量で、アルミナ担体上にPGMがコーティングされていた。
放射状にコーティングされたDOCは、部品の中央部分に5:1のPt:Pd比でPGMをコーティングして製造した。Pdのみのコーティングを、部品の環状領域に適用した。参照部品は、部品の軸線(axial axis)に沿ってゾーニングして製造した。入口ゾーンのPt:Pd比は1:2であり、出口ゾーンのPt:Pd比は5:1であった。
Claims (23)
- 触媒物品であって、
入口側と、出口側と、前記入口側から前記出口側へ延在している複数の通路と、を含む基材であって、排気ガスが、前記基材の前記入口側に入ることができ、前記基材の前記出口側から出ることができるようになっており、前記触媒物品が、前記複数の通路の第1のサブセットを含む第1の酸化領域と、前記複数の通路の第2のサブセットを含む第2の酸化領域とを含む、基材と、
前記第1の酸化領域の各通路の少なくとも一部をコーティングしている第1の触媒組成物であって、前記第1の触媒組成物が、少なくとも1つの白金族金属(PGM)成分と、前記少なくとも1つのPGM成分が担持されている第1の担体材料とを含む、第1の触媒組成物と、
前記第2の酸化領域の各通路の少なくとも一部をコーティングしている第2の触媒組成物であって、前記第2の触媒組成物が、少なくとも1つの白金族金属(PGM)成分と、前記少なくとも1つのPGM成分が担持されている担体材料とを含む、第2の触媒組成物と、を含み、
前記第1の酸化領域の通路の数と、前記第2の酸化領域の通路の数との比が、約10:90~約90:10の範囲であり、
前記第1の触媒組成物が、白金を含み、前記第1の触媒組成物におけるPt:Pdの重量比が、前記第2の触媒組成物におけるPt:Pdの重量比よりも大きい、触媒物品。 - 前記第1の触媒組成物におけるPt:Pdの重量比が、約1:0~約1:1である、請求項1に記載の触媒物品。
- 前記第1の触媒組成物が、約0.5~約200g/ft3の総PGM充填量を含む、請求項1に記載の触媒物品。
- 前記第2の触媒組成物におけるPt:Pdの重量比が、約0:1~約1:1である、請求項1に記載の触媒物品。
- 前記第2の触媒組成物が、約0.5~約200g/ft3の総PGM充填量を含む、請求項1に記載の触媒物品。
- 前記第1の触媒組成物および前記第2の触媒組成物のうちの一方または両方の前記担体材料が、耐火性金属酸化物を含む、請求項1に記載の触媒物品。
- 前記耐火性金属酸化物が、アルミナ、チタニア、ジルコニア、アルミナとチタニア、ジルコニアおよびセリアのうちの1つ以上との混合物、アルミナ上にコーティングされたセリア、アルミナ上にコーティングされたチタニア、シリカ-アルミナ、アルミノシリケート、アルミナ-ジルコニア、およびアルミナ-セリアからなる群から選択される、請求項6に記載の触媒物品。
- 前記第1の触媒組成物および前記第2の触媒組成物のうちの一方または両方が、ゼオライトを含む、請求項1に記載の触媒物品。
- 前記ゼオライトが、フォージャサイト、チャバサイト、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、ZSM-5ゼオライト、オフレタイト、およびベータゼオライトからなる群から選択される、請求項8に記載の触媒物品。
- 前記基材が、コーディエライト、ムライト、コーディエライト-αアルミナ、炭化ケイ素、窒化ケイ素、ジルコンムライト、スポジュメン、アルミナ-シリカマグネシア、ジルコンシリケート、シリマナイト、ケイ酸マグネシウム、ジルコン、ペタライト、αアルミナ、アルミノシリケート、またはこれらの任意の組み合わせからなる群から選択されるセラミック材料を含む、請求項1に記載の触媒物品。
- 前記基材が、金属材料を含む、請求項1に記載の触媒物品。
- 前記基材を前記入口端から見ると、前記第1の酸化領域および前記第2の酸化領域のうちの一方が、中央に位置する領域であり、前記第1の酸化領域および前記第2の酸化領域のうちの他方が、環状領域である、請求項1に記載の触媒物品。
- 前記基材を前記入口端から見ると、前記第1の酸化領域および前記第2の酸化領域のうちの一方が、パイくさび形領域であり、前記第1の酸化領域および前記第2の酸化領域のうちの他方が、前記基材の残りの領域である、請求項1に記載の触媒物品。
- 前記第1の触媒組成物および前記第2の触媒組成物が、前記第1の酸化領域および前記第2の酸化領域のうちの一方または両方において層構成になっている、請求項1に記載の触媒物品。
- 前記第1の触媒組成物が、前記第1の酸化領域において前記第2の触媒組成物上に層状になっている、請求項14に記載の触媒物品。
- 前記第2の触媒組成物が、前記第2の酸化領域において前記第1の触媒組成物上に層状になっている、請求項14に記載の触媒物品。
- 前記第2の触媒組成物が、前記第1の酸化領域および前記第2の酸化領域の両方において前記基材上にコーティングされ、前記第1の触媒組成物が、第1の酸化領域においてのみ前記基材上にコーティングされている、請求項14に記載の触媒物品。
- 前記第1の触媒組成物および前記第2の触媒組成物のうちの少なくとも1つが、第3の触媒組成物で横方向にゾーンコーティングされている、請求項1に記載の触媒物品。
- 前記基材が、流体の流れに対して開放された複数の平行な通路を有するモノリシックフロースルー基材である、請求項1~18のいずれか一項に記載の触媒物品。
- 前記基材が、複数の通路が多孔質壁部分を含むようなウォールフロー基材である、請求項1~18のいずれか一項に記載の触媒物品。
- 請求項1~18のいずれか一項に記載の触媒物品を含む、内燃機関のための排気ガス処理システムであって、前記触媒物品が、前記内燃機関の下流にあり、かつ前記内燃機関と流体連通している排気ガス処理システム。
- 選択的触媒還元(SCR)触媒、煤フィルタ、アンモニア酸化(AMOx)触媒、およびリーンNOxトラップ(LNT)からなる群から選択される1つ以上の触媒物品をさらに含む、請求項21に記載の排気ガス処理システム。
- 炭化水素、一酸化炭素、およびNOxを含む排気ガス流を処理するための方法であって、前記排気ガス流を請求項1~18のいずれか一項に記載の触媒物品に通すことを含む、方法。
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- 2020-07-09 JP JP2022500938A patent/JP2022539875A/ja active Pending
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US11872542B2 (en) | 2024-01-16 |
CN114270020B (zh) | 2024-05-24 |
CN114270020A (zh) | 2022-04-01 |
US20220258137A1 (en) | 2022-08-18 |
EP3997315A1 (en) | 2022-05-18 |
KR20220034779A (ko) | 2022-03-18 |
EP3997315A4 (en) | 2023-07-19 |
WO2021011272A1 (en) | 2021-01-21 |
BR112021026658A2 (pt) | 2022-02-15 |
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