JP5106261B2 - メタルハニカム基材、その製造方法、及びメタルハニカム触媒コンバータ - Google Patents
メタルハニカム基材、その製造方法、及びメタルハニカム触媒コンバータ Download PDFInfo
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- JP5106261B2 JP5106261B2 JP2008158254A JP2008158254A JP5106261B2 JP 5106261 B2 JP5106261 B2 JP 5106261B2 JP 2008158254 A JP2008158254 A JP 2008158254A JP 2008158254 A JP2008158254 A JP 2008158254A JP 5106261 B2 JP5106261 B2 JP 5106261B2
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- 229910052751 metal Inorganic materials 0.000 title claims description 135
- 239000002184 metal Substances 0.000 title claims description 135
- 239000000758 substrate Substances 0.000 title claims description 84
- 230000003197 catalytic effect Effects 0.000 title claims description 37
- 238000004519 manufacturing process Methods 0.000 title claims description 14
- 239000003054 catalyst Substances 0.000 claims description 152
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 136
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 116
- 239000010410 layer Substances 0.000 claims description 95
- 239000011247 coating layer Substances 0.000 claims description 70
- MWUXSHHQAYIFBG-UHFFFAOYSA-N Nitric oxide Chemical compound O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 claims description 60
- 239000000725 suspension Substances 0.000 claims description 57
- 239000011248 coating agent Substances 0.000 claims description 50
- 238000000576 coating method Methods 0.000 claims description 50
- 239000007789 gas Substances 0.000 claims description 48
- 239000000377 silicon dioxide Substances 0.000 claims description 47
- 239000008119 colloidal silica Substances 0.000 claims description 41
- 239000007864 aqueous solution Substances 0.000 claims description 21
- 238000000746 purification Methods 0.000 claims description 21
- 239000000463 material Substances 0.000 claims description 11
- 229910017135 Fe—O Inorganic materials 0.000 claims description 10
- 239000011230 binding agent Substances 0.000 claims description 8
- 229910000510 noble metal Inorganic materials 0.000 claims description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 8
- 238000001035 drying Methods 0.000 claims description 7
- 239000011347 resin Substances 0.000 claims description 7
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- 241000264877 Hippospongia communis Species 0.000 description 125
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- 238000000034 method Methods 0.000 description 26
- 230000000694 effects Effects 0.000 description 23
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- 238000011156 evaluation Methods 0.000 description 16
- 239000000919 ceramic Substances 0.000 description 15
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- 238000007254 oxidation reaction Methods 0.000 description 10
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- 239000000843 powder Substances 0.000 description 9
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- 238000012360 testing method Methods 0.000 description 8
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- 238000005259 measurement Methods 0.000 description 7
- 238000003980 solgel method Methods 0.000 description 7
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 6
- 238000004458 analytical method Methods 0.000 description 6
- 239000012298 atmosphere Substances 0.000 description 6
- 229910002091 carbon monoxide Inorganic materials 0.000 description 6
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 6
- 238000006722 reduction reaction Methods 0.000 description 6
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 5
- 229910004298 SiO 2 Inorganic materials 0.000 description 5
- 239000006185 dispersion Substances 0.000 description 5
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 4
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 description 4
- 239000002518 antifoaming agent Substances 0.000 description 4
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- 239000004215 Carbon black (E152) Substances 0.000 description 3
- 229910010413 TiO 2 Inorganic materials 0.000 description 3
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 3
- MCMNRKCIXSYSNV-UHFFFAOYSA-N ZrO2 Inorganic materials O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 3
- 150000004703 alkoxides Chemical class 0.000 description 3
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 3
- 230000005540 biological transmission Effects 0.000 description 3
- 238000002485 combustion reaction Methods 0.000 description 3
- 229910052878 cordierite Inorganic materials 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
- 238000000354 decomposition reaction Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 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 3
- 239000007788 liquid Substances 0.000 description 3
- -1 nitrogen-aluminum compound Chemical class 0.000 description 3
- 230000001590 oxidative effect Effects 0.000 description 3
- 239000001301 oxygen Substances 0.000 description 3
- 229910052760 oxygen Inorganic materials 0.000 description 3
- 229910052763 palladium Inorganic materials 0.000 description 3
- 229910052697 platinum Inorganic materials 0.000 description 3
- 229910052703 rhodium Inorganic materials 0.000 description 3
- 239000010948 rhodium Substances 0.000 description 3
- 229910052710 silicon Inorganic materials 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 229910052719 titanium Inorganic materials 0.000 description 3
- 239000010936 titanium Substances 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- 229920002472 Starch Polymers 0.000 description 2
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 2
- 239000012790 adhesive layer Substances 0.000 description 2
- 239000004202 carbamide Substances 0.000 description 2
- 239000003638 chemical reducing agent Substances 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
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- 238000010276 construction Methods 0.000 description 2
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- 238000009616 inductively coupled plasma Methods 0.000 description 2
- 238000007561 laser diffraction method Methods 0.000 description 2
- 238000000691 measurement method Methods 0.000 description 2
- 239000002736 nonionic surfactant Substances 0.000 description 2
- 150000002902 organometallic compounds Chemical class 0.000 description 2
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 2
- 239000013618 particulate matter Substances 0.000 description 2
- 239000010703 silicon Substances 0.000 description 2
- 239000008107 starch Substances 0.000 description 2
- 235000019698 starch Nutrition 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 230000003746 surface roughness Effects 0.000 description 2
- 239000004094 surface-active agent Substances 0.000 description 2
- BNGXYYYYKUGPPF-UHFFFAOYSA-M (3-methylphenyl)methyl-triphenylphosphanium;chloride Chemical compound [Cl-].CC1=CC=CC(C[P+](C=2C=CC=CC=2)(C=2C=CC=CC=2)C=2C=CC=CC=2)=C1 BNGXYYYYKUGPPF-UHFFFAOYSA-M 0.000 description 1
- 229910000505 Al2TiO5 Inorganic materials 0.000 description 1
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 1
- 238000004438 BET method Methods 0.000 description 1
- 229910052582 BN Inorganic materials 0.000 description 1
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 1
- 150000000703 Cerium Chemical class 0.000 description 1
- 229910052684 Cerium Inorganic materials 0.000 description 1
- 239000001856 Ethyl cellulose Substances 0.000 description 1
- ZZSNKZQZMQGXPY-UHFFFAOYSA-N Ethyl cellulose Chemical compound CCOCC1OC(OC)C(OCC)C(OCC)C1OC1C(O)C(O)C(OC)C(CO)O1 ZZSNKZQZMQGXPY-UHFFFAOYSA-N 0.000 description 1
- 108010010803 Gelatin Proteins 0.000 description 1
- 229910000502 Li-aluminosilicate Inorganic materials 0.000 description 1
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical group OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 1
- 229910019018 Mg 2 Si Inorganic materials 0.000 description 1
- 229910002651 NO3 Inorganic materials 0.000 description 1
- NHNBFGGVMKEFGY-UHFFFAOYSA-N Nitrate Chemical compound [O-][N+]([O-])=O NHNBFGGVMKEFGY-UHFFFAOYSA-N 0.000 description 1
- ODUCDPQEXGNKDN-UHFFFAOYSA-N Nitrogen oxide(NO) Natural products O=N ODUCDPQEXGNKDN-UHFFFAOYSA-N 0.000 description 1
- MXRIRQGCELJRSN-UHFFFAOYSA-N O.O.O.[Al] Chemical compound O.O.O.[Al] MXRIRQGCELJRSN-UHFFFAOYSA-N 0.000 description 1
- 230000010718 Oxidation Activity Effects 0.000 description 1
- 229920003171 Poly (ethylene oxide) Polymers 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- BUGBHKTXTAQXES-UHFFFAOYSA-N Selenium Chemical compound [Se] BUGBHKTXTAQXES-UHFFFAOYSA-N 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- 239000003945 anionic surfactant Substances 0.000 description 1
- 239000007900 aqueous suspension Substances 0.000 description 1
- 229910001593 boehmite Inorganic materials 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 238000006555 catalytic reaction Methods 0.000 description 1
- 238000010531 catalytic reduction reaction Methods 0.000 description 1
- 239000003093 cationic surfactant Substances 0.000 description 1
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 description 1
- 229910000175 cerite Inorganic materials 0.000 description 1
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 description 1
- 229910000420 cerium oxide Inorganic materials 0.000 description 1
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
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- 150000001875 compounds Chemical class 0.000 description 1
- 230000001186 cumulative effect Effects 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 230000032798 delamination Effects 0.000 description 1
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- 238000013461 design Methods 0.000 description 1
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- 229910001873 dinitrogen Inorganic materials 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000000921 elemental analysis Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 229920001249 ethyl cellulose Polymers 0.000 description 1
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- 238000001704 evaporation Methods 0.000 description 1
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- 239000008273 gelatin Substances 0.000 description 1
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- 235000011852 gelatine desserts Nutrition 0.000 description 1
- 230000007062 hydrolysis Effects 0.000 description 1
- 238000006460 hydrolysis reaction Methods 0.000 description 1
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 description 1
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- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
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- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 description 1
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- AABBHSMFGKYLKE-SNAWJCMRSA-N propan-2-yl (e)-but-2-enoate Chemical compound C\C=C\C(=O)OC(C)C AABBHSMFGKYLKE-SNAWJCMRSA-N 0.000 description 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 1
- 239000012266 salt solution Substances 0.000 description 1
- 238000004062 sedimentation Methods 0.000 description 1
- 229910052711 selenium Inorganic materials 0.000 description 1
- 239000011669 selenium Substances 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 238000001179 sorption measurement Methods 0.000 description 1
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- 238000004876 x-ray fluorescence Methods 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
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Description
Claims (7)
- メタルハニカム基材に3質量%〜10質量%のシリカを含有する活性アルミナが被覆され、前記被覆層の表面の算術平均粗さRaが、0.3μm〜3.0μmであり、前記被覆層の表面の凹凸平均間隔RSmが、0.3μm〜26.0μmであることを特徴とするメタルハニカム基材。
- 前記被覆層が、メタルハニカム基材の容積当りの質量として、100g/L〜300g/Lであることを特徴とする請求項1記載のメタルハニカム基材。
- 水溶性有機樹脂バインダーを、後記塗布用懸濁液中の含有量が1.3質量%〜3.1質量%になる量で、水に溶解して水溶液を調製する工程と、
前記水溶液に活性アルミナを分散して懸濁液を調製する工程と、
前記懸濁液にコロイダルシリカ分散水溶液を添加して、シリカ/(アルミナ+シリカ)の質量%で3質量%〜10質量%の塗布用懸濁液を調製する工程と、
前記塗布用懸濁液をメタルハニカム基材に塗布して乾燥する工程と、
前記乾燥体を500℃〜700℃の温度で熱処理する工程と、
を含むことを特徴とするメタルハニカム基材の製造方法。 - 前記塗布用懸濁液中の活性アルミナとコロイダルシリカの含有量が28質量%〜38質量%であることを特徴とする請求項3記載のメタルハニカム基材の製造方法。
- 請求項1又は2に記載のメタルハニカム基材に、排気ガス浄化触媒の触媒層を有することを特徴とするメタルハニカム触媒コンバータ。
- 前記排気ガス浄化触媒が、三元触媒又は窒素酸化物除去触媒であることを特徴とする請求項5記載のメタルハニカム触媒コンバータ。
- 前記三元触媒が、貴金属触媒を担持したSr−Fe−O系酸化物触媒であることを特徴とする請求項6記載のメタルハニカム触媒コンバータ。
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RU2650142C2 (ru) * | 2013-02-04 | 2018-04-09 | Джонсон Мэтти Паблик Лимитед Компани | Выхлопная система с катализатором реформинга |
JP6984246B2 (ja) * | 2017-02-21 | 2021-12-17 | 日本製鉄株式会社 | 触媒構造体の製造方法、及び、水素の製造方法 |
JP7047273B2 (ja) | 2017-07-25 | 2022-04-05 | 株式会社Ihi | 親水化材料、親水化部材及びそれを用いた気液接触装置 |
CN111263661B (zh) * | 2017-10-27 | 2023-05-30 | 株式会社科特拉 | 使用了金属基材的排气净化装置及其制造方法 |
JP6840283B1 (ja) * | 2020-10-19 | 2021-03-10 | 株式会社三井E&Sマシナリー | ハニカム触媒構造体及びscr装置 |
CN113385221A (zh) * | 2021-07-14 | 2021-09-14 | 安徽元琛环保科技股份有限公司 | 一种基于金属蜂窝载体的超高温催化剂及其制备方法 |
JP7378531B1 (ja) | 2022-04-26 | 2023-11-13 | 株式会社キャタラー | 排ガス浄化触媒装置の製造方法 |
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JPS5511079A (en) * | 1978-07-12 | 1980-01-25 | Hitachi Zosen Corp | Plate form denitration catalyst |
JPS61230746A (ja) * | 1985-04-05 | 1986-10-15 | Matsushita Electric Ind Co Ltd | 排ガス浄化用触媒担体 |
JPH0811188B2 (ja) * | 1991-05-16 | 1996-02-07 | 松下電器産業株式会社 | 脱臭用触媒体 |
DE69210127T2 (de) * | 1991-07-25 | 1996-11-14 | Corning Inc | Katalysator mit imprägnierten Poren |
JPH0538454A (ja) * | 1991-08-06 | 1993-02-19 | Nippon Yakin Kogyo Co Ltd | 触媒担体用金属箔 |
JP4495576B2 (ja) * | 2004-05-07 | 2010-07-07 | 朝日化学工業株式会社 | 触媒体担持基材 |
JP2006007169A (ja) * | 2004-06-29 | 2006-01-12 | Mitsubishi Heavy Ind Ltd | 金属基材担持粉末用スラリー及びこれを用いた金属基材担持触媒担体 |
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