JP4849035B2 - 触媒付パティキュレートフィルタ - Google Patents
触媒付パティキュレートフィルタ Download PDFInfo
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- JP4849035B2 JP4849035B2 JP2007206365A JP2007206365A JP4849035B2 JP 4849035 B2 JP4849035 B2 JP 4849035B2 JP 2007206365 A JP2007206365 A JP 2007206365A JP 2007206365 A JP2007206365 A JP 2007206365A JP 4849035 B2 JP4849035 B2 JP 4849035B2
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- 239000003054 catalyst Substances 0.000 title claims description 199
- 239000002131 composite material Substances 0.000 claims description 75
- 239000002245 particle Substances 0.000 claims description 69
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 30
- 150000002910 rare earth metals Chemical class 0.000 claims description 30
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 27
- 229910052779 Neodymium Inorganic materials 0.000 claims description 19
- 229910052777 Praseodymium Inorganic materials 0.000 claims description 15
- 229910052746 lanthanum Inorganic materials 0.000 claims description 15
- 229910052684 Cerium Inorganic materials 0.000 claims description 14
- 229910052727 yttrium Inorganic materials 0.000 claims description 13
- 229910052726 zirconium Inorganic materials 0.000 claims description 11
- 229910017493 Nd 2 O 3 Inorganic materials 0.000 claims description 9
- 239000007789 gas Substances 0.000 description 74
- 229910052760 oxygen Inorganic materials 0.000 description 44
- 239000001301 oxygen Substances 0.000 description 43
- 229910052799 carbon Inorganic materials 0.000 description 36
- 238000002485 combustion reaction Methods 0.000 description 36
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 35
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 35
- 239000000463 material Substances 0.000 description 32
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Substances [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 25
- 238000007254 oxidation reaction Methods 0.000 description 15
- 239000000843 powder Substances 0.000 description 14
- 238000000746 purification Methods 0.000 description 14
- 230000003647 oxidation Effects 0.000 description 12
- 229910052751 metal Inorganic materials 0.000 description 9
- 239000002184 metal Substances 0.000 description 9
- -1 oxygen ion Chemical class 0.000 description 8
- 238000011144 upstream manufacturing Methods 0.000 description 8
- 229910002091 carbon monoxide Inorganic materials 0.000 description 7
- 239000011148 porous material Substances 0.000 description 7
- 238000011156 evaluation Methods 0.000 description 6
- 238000005192 partition Methods 0.000 description 6
- 239000000523 sample Substances 0.000 description 6
- 230000001965 increasing effect Effects 0.000 description 5
- 239000013618 particulate matter Substances 0.000 description 5
- 230000003197 catalytic effect Effects 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 229910052688 Gadolinium Inorganic materials 0.000 description 3
- 229910052772 Samarium Inorganic materials 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000010304 firing Methods 0.000 description 3
- 239000000446 fuel Substances 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 239000007800 oxidant agent Substances 0.000 description 3
- 230000032683 aging Effects 0.000 description 2
- 210000004027 cell Anatomy 0.000 description 2
- 210000002421 cell wall Anatomy 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 230000002950 deficient Effects 0.000 description 2
- 150000002500 ions Chemical class 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000011232 storage material Substances 0.000 description 2
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- 229910052769 Ytterbium Inorganic materials 0.000 description 1
- QRSFFHRCBYCWBS-UHFFFAOYSA-N [O].[O] Chemical compound [O].[O] QRSFFHRCBYCWBS-UHFFFAOYSA-N 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 150000001721 carbon Chemical class 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 229910052878 cordierite Inorganic materials 0.000 description 1
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- UYXRCZUOJAYSQR-UHFFFAOYSA-N nitric acid;platinum Chemical compound [Pt].O[N+]([O-])=O UYXRCZUOJAYSQR-UHFFFAOYSA-N 0.000 description 1
- 229910000510 noble metal Inorganic materials 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 239000011164 primary particle Substances 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 229910052706 scandium Inorganic materials 0.000 description 1
- 239000011163 secondary particle Substances 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 238000003878 thermal aging Methods 0.000 description 1
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- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/944—Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts
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- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/9445—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
- B01D53/945—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific catalyst
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Description
上記触媒層の表面は、第1触媒部が露出した領域と第2触媒部が露出した領域とが入り混じった状態に形成され、且つ上記第2触媒部の方が第1触媒部よりも触媒層表面に広く露出しており、
上記第1触媒部は、Ptを担持した活性アルミナ粒子を含有し、
上記第2触媒部は、Zr、Nd、並びにCe及びNd以外の希土類金属Mを含有するZrNd系複合酸化物粒子を含有し、
上記第1触媒部及び第2触媒部の少なくとも一方に、Ce、Zr、及びCe以外の希土類金属Rを含有するCeZr系複合酸化物粒子がさらに含まれていることを特徴とする
。
上記触媒層の少なくとも一部では、第1触媒部と第2触媒部とが、前者が下層に、後者が上層になるように積層されて、第2触媒部が触媒層表面に露出しており、
下層を形成する第1触媒部は、Ptを担持した活性アルミナ粒子を含有し、
上層を形成する第2触媒部は、Zr、Nd、並びにCe及びNd以外の希土類金属Mを含有するZrNd系複合酸化物粒子を含有し、
上記第1触媒部及び第2触媒部の少なくとも一方に、Ce、Zr、及びCe以外の希土類金属Rを含有するCeZr系複合酸化物粒子がさらに含まれていることを特徴とする。
表1に示す各酸化物粉末を使用して表2に示す実1〜11及び比1〜5の各供試材(触媒付パティキュレートフィルタ)を準備した。
10g/L(フィルタ)相当量のカーボン(カーボンブラック)に10mLのイオン交換水を加え、スターラーを用いて5分間攪拌することにより、カーボンを水中に十分に分散させた。このカーボン分散液に供試材の一端面を浸すと同時に、他端面よりアスピレータによる吸引を行なった。この吸引によって除去できない水分を、上記一端面からのエアブローにより除去し、次いで供試材を乾燥器に入れ150℃の温度に2時間保持して乾燥させた。これにより、カーボンを供試材フィルタの排ガス通路壁面に堆積させた。
カーボン燃焼速度(g/h)={ガス流速(L/h)×[CO,CO2濃度(ppm)/1×106]}/22.4×12
供試材を固定床模擬ガス流通装置に取り付け、模擬排ガス(HC=200ppmC,CO=400ppm,NO=100ppm,O2=10%,CO2=4.5%,H2O=10%,残N2)を空間速度50000/hで供試材に流し、且つ供試材入口ガス温度を30℃/分の速度で上昇させていき、HC及びCO各々の浄化率が50%になったときの上記入口ガス温度(ライトオフ温度)を求めた。
試験結果は上記表2に各供試材の触媒構成と併せて示している。実1〜実3は比1よりも、カーボン燃焼速度が大きく且つHC及びCOのライトオフ温度も低くなっている。従って、実1〜実3のように、CeZr系複合酸化物粉末を第1触媒部及び第2触媒部の少なくとも一方に添加することがパティキュレートの燃焼性向上及び排ガスの低温浄化性向上に有効であることがわかる。比2よりも比3のカーボン燃焼性能及びライトオフ性能が良いことも、CeZr系複合酸化物粉末の触媒層への添加がパティキュレートの燃焼性向上及び排ガスの低温浄化性向上に有効であることを示している。また、実2,3に比べて実1のカーボン燃焼性能及びライトオフ性能が良いことから、CeZr系複合酸化物粉末は第2触媒部(上層)に配置することが好ましいことがわかる。
ZrNd系複合酸化物の好ましい組成を策定するために、希土類金属MとしてLa、Pr及びY各々を採用し、且つNd2O3モル%及びMOモル%が異なる各種の複合酸化物粉末を調製した。次いでそれら複合酸化物粉末にPtを担持させることにより、各種の触媒材を調製した。但し、これら触媒材には、活性アルミナ及びCeZr系複合酸化物は含まれていない。
CeZr系複合酸化物(CeZrRO)における希土類金属Rの種類及び比率を変えた種々の複合酸化物粉末を調製し、該複合酸化物粉末にPtを担持させることにより、各種の触媒材を調製した。但し、これら触媒材には、活性アルミナ及びZrNd系複合酸化物は含まれていない。
2 排ガス流入路(排ガス通路)
3 排ガス流出路(排ガス通路)
4 栓
5 隔壁
6 細孔通路(排ガス通路)
7 触媒層
8 第1触媒部
9 第2触媒部
Claims (7)
- エンジンから排出されるパティキュレートを捕集するフィルタ本体の排ガス通路壁面に触媒層が形成されている触媒付パティキュレートフィルタであって、
上記触媒層の表面は、第1触媒部が露出した領域と第2触媒部が露出した領域とが入り混じった状態に形成され、且つ上記第2触媒部の方が第1触媒部よりも触媒層表面に広く露出しており、
上記第1触媒部は、Ptを担持した活性アルミナ粒子を含有し、
上記第2触媒部は、Zr、Nd、並びにCe及びNd以外の希土類金属Mを含有するZrNd系複合酸化物粒子を含有し、
上記第1触媒部及び第2触媒部の少なくとも一方に、Ce、Zr、及びCe以外の希土類金属Rを含有するCeZr系複合酸化物粒子がさらに含まれていることを特徴とする触媒付パティキュレートフィルタ。 - 請求項1において、
上記第2触媒部が露出した領域の少なくとも一部では、上記第1触媒部が下層になるように、該第1触媒部と第2触媒部とが積層されていることを特徴とする触媒付パティキュレートフィルタ。 - エンジンから排出されるパティキュレートを捕集するフィルタ本体の排ガス通路壁面に触媒層が形成されている触媒付パティキュレートフィルタであって、
上記触媒層の少なくとも一部では、第1触媒部と第2触媒部とが、前者が下層に、後者が上層になるように積層されて、第2触媒部が触媒層表面に露出しており、
下層を形成する第1触媒部は、Ptを担持した活性アルミナ粒子を含有し、
上層を形成する第2触媒部は、Zr、Nd、並びにCe及びNd以外の希土類金属Mを含有するZrNd系複合酸化物粒子を含有し、
上記第1触媒部及び第2触媒部の少なくとも一方に、Ce、Zr、及びCe以外の希土類金属Rを含有するCeZr系複合酸化物粒子がさらに含まれていることを特徴とする触媒付パティキュレートフィルタ。 - 請求項1乃至請求項3のいずれか一において、
上記ZrNd系複合酸化物粒子及び上記CeZr系複合酸化物粒子の少なくとも一方にPtが担持されていることを特徴とする触媒付パティキュレートフィルタ。 - 請求項1乃至請求項4のいずれか一において、
上記ZrNd系複合酸化物粒子が含有する希土類金属Mが、La、Pr及びYから選ばれる少なくとも一種であることを特徴とする触媒付パティキュレートフィルタ。 - 請求項1乃至請求項5のいずれか一において、
上記ZrNd系複合酸化物粒子は、上記希土類金属Mの酸化物をMOと表したとき、ZrO2、Nd2O3及びMOの合計量に占めるNd2O3及びMOの合計量の割合(Nd2O3+MO)/(ZrO2+Nd2O3+MO)が18モル%以上30モル%以下であることを特徴とする触媒付パティキュレートフィルタ。 - 請求項1乃至請求項6のいずれか一において、
上記CeZr系複合酸化物粒子が含有する希土類金属Rが、La、Nd、Pr及びYから選ばれる少なくとも一種であることを特徴とする触媒付パティキュレートフィルタ。
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