JP5094717B2 - 燃焼生成物中のNOxを還元する触媒の組み合わせ方法及び装置 - Google Patents
燃焼生成物中のNOxを還元する触媒の組み合わせ方法及び装置 Download PDFInfo
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- JP5094717B2 JP5094717B2 JP2008518128A JP2008518128A JP5094717B2 JP 5094717 B2 JP5094717 B2 JP 5094717B2 JP 2008518128 A JP2008518128 A JP 2008518128A JP 2008518128 A JP2008518128 A JP 2008518128A JP 5094717 B2 JP5094717 B2 JP 5094717B2
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- Prior art keywords
- catalyst
- nox
- gas stream
- gas flow
- alumina
- Prior art date
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- XTVVROIMIGLXTD-UHFFFAOYSA-N copper(II) nitrate Chemical compound [Cu+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O XTVVROIMIGLXTD-UHFFFAOYSA-N 0.000 description 2
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- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 1
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Classifications
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- B01D53/34—Chemical or biological purification of waste gases
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- B01J29/42—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively containing iron group metals, noble metals or copper
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- F01N13/0097—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series the purifying devices are arranged in a single housing
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- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—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
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Description
特に、本発明の触媒処理装置は、例えば、排気ガス中に比較的高い割合で酸素分が含まれているディーゼルエンジンなどのリーンバーンエンジンからの排気ガスを、効率よく処理する。本発明では、相乗効果を生むため、比較的高温でNOx転化活性を示す第1の触媒と、これより低温で少なくとも同様の活性を示す第2の触媒と、の組み合わせを用いている。本発明は、運転時の幅広い温度領域に対応しているという特徴があり、これにより排気ガス流の処理能力が高められている。より詳しくは、本発明は、第1の触媒にて適切な中間の窒素化合物を生成し、第2の触媒にてその化合物を還元する場合に、これら触媒を単純にまとめた場合に比べて、より高い相乗効果が得られるような触媒の組み合わせを用いている。
銅を含有するZSM-5ゼオライト触媒の試料は、68グラムの硝酸銅(II)水和物と、1000mlの脱イオン水とを含む溶液を作成することにより、生成した。この溶液を作成した後、溶液を撹拌しつつ、200グラムのZSM-5ゼオライト結晶を加えた。この混合物を約1.5時間撹拌した後、35.7グラムのNH4OHを加えて、pHが7.25になるように調節した。この混合物の撹拌を、約1時間にわたり続けた。ゼオライト混合物をろ過し、1000mlの脱イオン水により洗浄した。このろ液を約85℃で一晩中乾燥した。この後、交換ゼオライトを、550℃までは2℃/分の温度勾配で温度を上げ、約2時間維持することにより空気か焼した後、室温まで冷却した。銅分析では、銅充填量が約11.5重量%であることを示した。
γ−アルミナ担体は、錯化剤に補助されるゾル−ゲル法により作成した。500gのアルミニウムイソプロポキシド(AIP)(98%+、アルドリッチケミカル社製)を、ビーカー内の600mlの2−メチル−2,4−ペンタンジオール(MPD)(99%、アルドリッチケミカル社製)に溶解した。この混合物をメカニカルポリエチレンスターラーで激しく撹拌した。混合物が均一になったら、ビーカーを約120℃の恒温槽に入れ、連続して約1時間撹拌した。AIPの全てがMPDに溶解すると、鮮明な黄緑色の溶液が得られた。AIPがMPDと反応し、120℃の反応条件にて蒸気状の2−プロパノールを生成し、溶液がゲル化を開始した。4時間後、ゲル化が完了すると、400mlの水を加えてゲル化を止めて、白色沈殿物(水酸化アルミニウム)を得た。この白色固体生成物を水に再分散させ、90℃の温度で撹拌を続けながら一晩エージング(aging)させた。
銀を含有するγ-アルミナ触媒の試料のうちのいくつかは、初期湿潤含浸の技術により作成した。水溶性の硝酸銀溶液または硫酸銀水溶液を、実施例2のγーアルミナ生成物に液滴し、混合した。硝酸溶液の容積は、γ−アルミナ生成物の細孔容積と大幅に適合するように計算される。この計算では、γ−アルミナの単位グラムあたりで約1.4mlであった。したがって、0.322グラムの硝酸銀を14mlの水に溶解し、10.0グラムのアルミナと混合した。この後、この試料をへらにより手動で混合し、90〜110℃で一晩中乾燥した。そして、600℃で約5時間、空気中でか焼する。他の作成方法では、0.2966グラムの硫酸銀は、溶解度が低いため、42mlの水に溶解した。この場合、14mlごとに分けて3段階で加え、各段階の間で乾燥及びか焼を行った。触媒の銀充填量は、触媒の総重量に対して2重量%であった。
2つの触媒は、実施例2に記載されているゾル−ゲル手順を用いて、500gのアルミニウムイソプロポキシド(AIP)を、600mlの2−メチル−2,4−ペンタンジオール(MPD)に溶解することにより、作成した。しかしながら、本実施例では、作成の一部において、4.025gのAg(NO3)または3.7075gのAg2(SO4)を600mlのプロパノールに溶解し、実施例2のプロパノール洗浄の段階にて、スラリーを加えた。スラリーを約1時間混合し、得られた生成物を真空ろ過して触媒を生成した。
触媒評価実験を、電気炉にて加熱される石英反応管(quartz reactor)で行った。混合ガスが、石英反応管内に支持された触媒を通過するようにした。混合ガスは、1000ppmのNO(一酸化窒素)、還元剤としての1000ppmのプロピレン、及び9%の酸素、残部ヘリウムを含んでいた。ガスの総流量は約1500ml/分であり、触媒容積は、ガス空間速度(GHSV)30,000に対応する約3.0mlであった。触媒温度は150℃から550℃まで上昇させ、その後、150℃まで下降させて戻した。温度が下降すると、データを記録した。第1の評価では、1.5mlのAg/アルミナ触媒を、1.5mlのCu/ZSM-5触媒の上流側に配置した。第2及び第3の評価では、触媒を各別に評価した。銅充填量は、銅を含有する触媒の総重量に対して約11.5重量%であった。アルミナ触媒は、2重量%の銀を含んでいた。
触媒床を通過する混合ガスが7%の水分を含んでいる点以外は、実施例5にて示した手順に一致させて、触媒評価実験を、電気炉にて加熱される石英反応管で行った。また、更なる評価実験として、銅を含有する触媒の総重量に対して銅充填量が約3重量%(wt%)と約11.5重量%(wt%)とにそれぞれなっている場合の影響の比較を行った。
Ag/アルミナ触媒とCu/ZSM-5触媒とを、直径1”(インチ)(約2.5cm)で長さ3”(約7.6cm)のモノリス上にウォッシュコートし、還元剤としてドデカン(ディーゼル・レンジの分子)を用いて評価した。この評価実験を、電気炉にて加熱される石英反応管で行った。混合ガスが、石英反応管内に支持された触媒床を通過するようにした。混合ガスは、500ppmのNO(一酸化窒素)、還元剤としての3000ppmのドデカン、50ppmのプロペン、500ppmのCO、8%の二酸化炭素、7%の水分及び9%の酸素、残部ヘリウムを含んでいた。ガス空間速度(GHSV)を約35,000に調節した。触媒温度は150℃から550℃まで上昇させ、その後、150℃まで下降させて戻した。温度が下降すると、データを記録した。第1の評価では、Ag/アルミナ触媒を、Cu/ZSM-5触媒の上流側に配置した。第2及び第3の評価では、触媒を各別に評価した。
エンジン排気によるエージングをシミュレーションするために、様々な結晶サイズ及びシリカ/アルミナ比のZSM-5粉末のセットを、水蒸気10%濃度の蒸気に、約16時間、600℃でさらした。この後、粉末をペレット状にして、試験をし、またはNOx転化の評価をした。また、触媒の別のセットを、上述と同じ粉末により作成した。ここで、別のセットの触媒は、蒸気にさらす前に予め鉄を含有している。鉄を含有する触媒の別のセットを、撹拌しながら40グラムの脱イオン水に5.4グラムの硝酸鉄(III)九水和物を加えることにより、作成した。この溶液を30グラムのZSM-5に液滴し、混合した。この後、この粉末を約85℃で一晩中乾燥した。鉄を含有するZSM-5触媒を、約400℃で約3時間、空気か焼した。この触媒は、2.5重量%の鉄を含んでいた。
Ag/アルミナと、これより下流側に配置されたCu/ZSM-5とからなる触媒の組み合わせと、Cu/ZSM-5を混ぜたAg/アルミナからなる触媒との評価試験を行った。触媒は、電気炉にて加熱される石英反応管を用いて評価した。1000ppmのNO(一酸化窒素)、1000ppmのプロピレン、2000ppmの水素、9%の酸素及び残部ヘリウムを含む混合ガスが、石英反応管内に支持された触媒床を通過するようにした。ガスの総流量は約1500ml/分であり、触媒容積は、ガス空間速度(GHSV)30,000に対応する約3.0mlであった。触媒温度は150℃から550℃まで上昇させ、その後、150℃まで下降させて戻した。温度が下降すると、データを記録した。この結果を、図7に示す。
触媒床を通過する混合ガスが7%の水分を含んでいる点以外は実施例5で示した手順と同様に、触媒評価実験を、電気炉にて加熱される石英反応管で行った。Ag/アルミナと、銅充填量が3重量%の下流側Cu/ZSM-5との触媒組み合わせ、及び、Ag/アルミナと、白金充填量が1重量%の下流側Pt/アルミナとの触媒組み合わせを用いて、NOx除去活性を、475℃で測定した。この評価結果を図8に示す。Ag/アルミナと、下流側Cu/ZSM-5との触媒組み合わせは、符号56で示したように、NOxからN2への転化率が80%を示した。一方、Ag/アルミナと、下流側Pt/アルミナとの触媒組み合わせは、符号58で示したように、NOxからN2への転化率が4%を示した。
Claims (15)
- 通過するガス流中のNOxを還元するためのガス流の触媒処理装置であって、
ガス流における相対的に上流の部分に配置された第1の触媒と、
ガス流における前記第1の触媒より相対的に下流の部分に配置された第2の触媒と、
を含んで構成され、
前記第1の触媒は、銀を含有するγ-アルミナを含んで構成されてガス流の触媒処理に用いられ、
前記第1の触媒は、最高のNOx還元触媒活性を生じる第1の温度を有し、
前記第1の触媒は、NOxの一部をN 2 に直接転化することとNOxの別の一部を窒素含有の中間生成物に転化することとの両方に適して、NOxの更に別の一部を残部とし、
前記第2の触媒は、銅を含有するZSM-5を含んで構成され、このZSM-5は結晶サイズが約0.5μm〜約2.0μmの範囲内であり、かつ、アルミナに対するシリコンの比率が約50であり、
前記第2の触媒は、その銅含有量が前記第2の触媒の総重量に対して約3重量パーセントであり、前記第1の触媒より下流のガス流の触媒処理に用いられ、
前記第2の触媒は、最高のNOx還元触媒活性を生じる第2の温度を有し、
前記第2の触媒は、NOxの前記残部及び前記中間生成物の反応を促進してN 2 に更に還元することに適し、
前記第2の温度が前記第1の温度に比べて低温であることを特徴とするガス流の触媒処理装置。 - 前記第1の触媒と、前記第2の触媒とは、互いに当接して配置されることを特徴とする請求項1記載のガス流の触媒処理装置。
- 前記第1の触媒と、前記第2の触媒とは、互いに間隔を開けて配置されることを特徴とする請求項1記載のガス流の触媒処理装置。
- 前記第1の触媒と、前記第2の触媒とは、これらの体積比が約1:2から約2:1までの範囲に含まれることを特徴とする請求項1記載のガス流の触媒処理装置。
- 前記第1の触媒と、前記第2の触媒とは、これらの体積比が約1:1であることを特徴とする請求項1記載のガス流の触媒処理装置。
- 前記第1の触媒より上流に配置されてガス流に還元剤を導入するインジェクタを更に含んで構成されることを特徴とする請求項1記載のガス流の触媒処理装置。
- 前記還元剤は、炭化水素化合物であること特徴とする請求項6記載のガス流の触媒処理装置。
- 前記γ-アルミナは、ゾル−ゲル合成法により作成されることを特徴とする請求項1記載のガス流の触媒処理装置。
- 前記銀は、前記第1の触媒の総重量に対して、約1重量パーセントから約15重量パーセントまでの範囲に含まれることを特徴とする請求項1記載のガス流の触媒処理装置。
- 前記銀は、前記第1の触媒の総重量に対して、約2重量パーセントから約5重量パーセントまでの範囲に含まれることを特徴とする請求項1記載のガス流の触媒処理装置。
- 前記第1及び第2の触媒は、粉末型、ペレット型、モノリス型、流動床型及びこれらの組み合わせから選択されたものであることを特徴とする請求項1記載のガス流の触媒処理装置。
- ガス流に含まれるNOxを還元するガス流の触媒処理方法であって、
ガス流における相対的に上流の部分に第1の触媒を配置するステップと、
ガス流における前記第1の触媒より相対的に下流の部分に第2の触媒を配置するステップと、
前記第1の触媒へガス流を送るステップと、
前記第1の触媒から前記第2の触媒へガス流を送るステップと、
を有し、
前記第1の触媒は、銀を含有するγ-アルミナを含んで構成されてガス流の触媒処理に用いられ、
前記第1の触媒は、NOxの一部をN 2 に直接転化することとNOxの別の一部を窒素含有の中間生成物に転化することとの両方に適して、NOxの更に別の一部を残部とし、
前記第1の触媒は、最高のNOx還元触媒活性を生じる第1の温度を有し、
前記第2の触媒は、銅を含有するZSM-5を含んで構成され、このZSM-5は結晶サイズが約0.5μm〜約2.0μmの範囲内であり、かつ、アルミナに対するシリコンの比率が約50であり、
前記第2の触媒は、その銅含有量が前記第2の触媒の総重量に対して約3重量パーセントであり、ガス流の触媒処理に用いられ、
前記第2の触媒は、最高のNOx還元触媒活性を生じる第2の温度を有し、
前記第2の触媒は、NOxの前記残部及び前記中間生成物の反応を促進してN 2 に更に還元することに適し、
前記第2の温度が前記第1の温度に比べて低温であることを特徴とするガス流の触媒処理方法。 - 前記第1の触媒へガス流を送る前に、更に、ガス流中のNOxの還元を促進するのに効果的な量の還元剤をガス流中に噴射するステップを有することを特徴とする請求項12記載のガス流の触媒処理方法。
- 更に、前記第1の触媒と、前記第2の触媒と、の間隔を開けるステップを有することを特徴とする請求項12記載のガス流の触媒処理方法。
- 更に、前記第1の触媒と、前記第2の触媒と、の間隔を開けるステップを有することを特徴とする請求項13記載のガス流の触媒処理方法。
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/157,729 US7803338B2 (en) | 2005-06-21 | 2005-06-21 | Method and apparatus for combination catalyst for reduction of NOx in combustion products |
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PCT/US2006/005464 WO2007001500A1 (en) | 2005-06-21 | 2006-02-16 | Method and apparatus for reducing nox with first and second catalysis |
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JP (1) | JP5094717B2 (ja) |
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CN (1) | CN101203295B (ja) |
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DE602006013972D1 (de) | 2010-06-10 |
CN101203295B (zh) | 2011-06-29 |
EP1893321A1 (en) | 2008-03-05 |
WO2007001500A9 (en) | 2008-02-21 |
CN101203295A (zh) | 2008-06-18 |
KR100992156B1 (ko) | 2010-11-04 |
WO2007001500A1 (en) | 2007-01-04 |
EP1893321B1 (en) | 2010-04-28 |
KR20080021123A (ko) | 2008-03-06 |
US7803338B2 (en) | 2010-09-28 |
JP2008543559A (ja) | 2008-12-04 |
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