JP5369035B2 - ゼオライトハニカム成形体及びゼオライトハニカム焼成体 - Google Patents
ゼオライトハニカム成形体及びゼオライトハニカム焼成体 Download PDFInfo
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- JP5369035B2 JP5369035B2 JP2010070106A JP2010070106A JP5369035B2 JP 5369035 B2 JP5369035 B2 JP 5369035B2 JP 2010070106 A JP2010070106 A JP 2010070106A JP 2010070106 A JP2010070106 A JP 2010070106A JP 5369035 B2 JP5369035 B2 JP 5369035B2
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- Prior art keywords
- zeolite
- particles
- honeycomb
- plate
- molded body
- Prior art date
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- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 title claims abstract description 425
- 239000010457 zeolite Substances 0.000 title claims abstract description 317
- 229910021536 Zeolite Inorganic materials 0.000 title claims abstract description 314
- 239000002245 particle Substances 0.000 claims abstract description 236
- 238000005192 partition Methods 0.000 claims abstract description 150
- 238000001035 drying Methods 0.000 claims abstract description 137
- 239000002994 raw material Substances 0.000 claims abstract description 54
- 239000000945 filler Substances 0.000 claims abstract description 53
- 239000000463 material Substances 0.000 claims abstract description 13
- 239000012530 fluid Substances 0.000 claims abstract description 7
- 239000011230 binding agent Substances 0.000 claims description 76
- 238000010304 firing Methods 0.000 claims description 64
- 239000007787 solid Substances 0.000 claims description 16
- 229910021645 metal ion Inorganic materials 0.000 claims description 15
- 238000004519 manufacturing process Methods 0.000 claims description 13
- 229910001593 boehmite Inorganic materials 0.000 claims description 12
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 claims description 12
- 239000011521 glass Substances 0.000 claims description 11
- 239000010445 mica Substances 0.000 claims description 11
- 229910052618 mica group Inorganic materials 0.000 claims description 11
- 239000000203 mixture Substances 0.000 claims description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 8
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 6
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 claims description 6
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 6
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 6
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 6
- VSCWAEJMTAWNJL-UHFFFAOYSA-K aluminium trichloride Chemical compound Cl[Al](Cl)Cl VSCWAEJMTAWNJL-UHFFFAOYSA-K 0.000 claims description 6
- GUJOJGAPFQRJSV-UHFFFAOYSA-N dialuminum;dioxosilane;oxygen(2-);hydrate Chemical compound O.[O-2].[O-2].[O-2].[Al+3].[Al+3].O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O GUJOJGAPFQRJSV-UHFFFAOYSA-N 0.000 claims description 5
- 229910052742 iron Inorganic materials 0.000 claims description 5
- 229910052901 montmorillonite Inorganic materials 0.000 claims description 5
- 229910052709 silver Inorganic materials 0.000 claims description 5
- 239000004332 silver Substances 0.000 claims description 5
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 4
- 229910052710 silicon Inorganic materials 0.000 claims description 4
- 239000010703 silicon Substances 0.000 claims description 4
- 239000000454 talc Substances 0.000 claims description 4
- 229910052623 talc Inorganic materials 0.000 claims description 4
- 229910052582 BN Inorganic materials 0.000 claims description 3
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 3
- 229910052684 Cerium Inorganic materials 0.000 claims description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 3
- GYHNNYVSQQEPJS-UHFFFAOYSA-N Gallium Chemical compound [Ga] GYHNNYVSQQEPJS-UHFFFAOYSA-N 0.000 claims description 3
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims description 3
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 3
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 3
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 claims description 3
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 claims description 3
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 claims description 3
- 229910017052 cobalt Inorganic materials 0.000 claims description 3
- 239000010941 cobalt Substances 0.000 claims description 3
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 3
- 229910052802 copper Inorganic materials 0.000 claims description 3
- 239000010949 copper Substances 0.000 claims description 3
- GDVKFRBCXAPAQJ-UHFFFAOYSA-A dialuminum;hexamagnesium;carbonate;hexadecahydroxide Chemical compound [OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Mg+2].[Al+3].[Al+3].[O-]C([O-])=O GDVKFRBCXAPAQJ-UHFFFAOYSA-A 0.000 claims description 3
- 229910001657 ferrierite group Inorganic materials 0.000 claims description 3
- 229910052733 gallium Inorganic materials 0.000 claims description 3
- 229910002804 graphite Inorganic materials 0.000 claims description 3
- 239000010439 graphite Substances 0.000 claims description 3
- 229910001701 hydrotalcite Inorganic materials 0.000 claims description 3
- 229960001545 hydrotalcite Drugs 0.000 claims description 3
- 229910052738 indium Inorganic materials 0.000 claims description 3
- APFVFJFRJDLVQX-UHFFFAOYSA-N indium atom Chemical compound [In] APFVFJFRJDLVQX-UHFFFAOYSA-N 0.000 claims description 3
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 claims description 3
- 229910052759 nickel Inorganic materials 0.000 claims description 3
- 229910052763 palladium Inorganic materials 0.000 claims description 3
- 235000019353 potassium silicate Nutrition 0.000 claims description 3
- 239000011347 resin Substances 0.000 claims description 3
- 229920005989 resin Polymers 0.000 claims description 3
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 claims description 3
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 3
- 239000010936 titanium Substances 0.000 claims description 3
- 229910052719 titanium Inorganic materials 0.000 claims description 3
- 229910052720 vanadium Inorganic materials 0.000 claims description 3
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 claims description 3
- 229910052725 zinc Inorganic materials 0.000 claims description 3
- 239000011701 zinc Substances 0.000 claims description 3
- 238000005342 ion exchange Methods 0.000 description 23
- 238000000034 method Methods 0.000 description 23
- 238000001125 extrusion Methods 0.000 description 21
- 239000007789 gas Substances 0.000 description 21
- 239000011148 porous material Substances 0.000 description 17
- 230000000052 comparative effect Effects 0.000 description 16
- 230000002093 peripheral effect Effects 0.000 description 14
- 239000003054 catalyst Substances 0.000 description 12
- 239000013078 crystal Substances 0.000 description 9
- 229930195733 hydrocarbon Natural products 0.000 description 8
- 150000002430 hydrocarbons Chemical class 0.000 description 8
- 150000002500 ions Chemical class 0.000 description 8
- 238000000746 purification Methods 0.000 description 8
- 238000000926 separation method Methods 0.000 description 7
- 239000000243 solution Substances 0.000 description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- JPVYNHNXODAKFH-UHFFFAOYSA-N Cu2+ Chemical compound [Cu+2] JPVYNHNXODAKFH-UHFFFAOYSA-N 0.000 description 6
- 229910001431 copper ion Inorganic materials 0.000 description 6
- 238000006073 displacement reaction Methods 0.000 description 6
- 238000009826 distribution Methods 0.000 description 6
- 239000012528 membrane Substances 0.000 description 6
- 238000000465 moulding Methods 0.000 description 6
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 6
- 238000001179 sorption measurement Methods 0.000 description 6
- 239000003463 adsorbent Substances 0.000 description 5
- 238000001354 calcination Methods 0.000 description 5
- 229910052878 cordierite Inorganic materials 0.000 description 5
- 230000007423 decrease Effects 0.000 description 5
- 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 5
- 230000000694 effects Effects 0.000 description 5
- 238000010438 heat treatment Methods 0.000 description 5
- -1 iron ions Chemical class 0.000 description 5
- 239000007864 aqueous solution Substances 0.000 description 4
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 4
- 239000000919 ceramic Substances 0.000 description 4
- 238000002485 combustion reaction Methods 0.000 description 4
- 238000007906 compression Methods 0.000 description 4
- 230000006835 compression Effects 0.000 description 4
- 238000010276 construction Methods 0.000 description 4
- 239000002270 dispersing agent Substances 0.000 description 4
- 238000005259 measurement Methods 0.000 description 4
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 4
- 230000000704 physical effect Effects 0.000 description 4
- 239000000843 powder Substances 0.000 description 4
- 239000004215 Carbon black (E152) Substances 0.000 description 3
- 239000001866 hydroxypropyl methyl cellulose Substances 0.000 description 3
- 229920003088 hydroxypropyl methyl cellulose Polymers 0.000 description 3
- 235000010979 hydroxypropyl methyl cellulose Nutrition 0.000 description 3
- UFVKGYZPFZQRLF-UHFFFAOYSA-N hydroxypropyl methyl cellulose Chemical compound OC1C(O)C(OC)OC(CO)C1OC1C(O)C(O)C(OC2C(C(O)C(OC3C(C(O)C(O)C(CO)O3)O)C(CO)O2)O)C(CO)O1 UFVKGYZPFZQRLF-UHFFFAOYSA-N 0.000 description 3
- 238000004898 kneading Methods 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 239000001301 oxygen Substances 0.000 description 3
- 229910052760 oxygen Inorganic materials 0.000 description 3
- 238000000790 scattering method Methods 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 230000000007 visual effect Effects 0.000 description 3
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- 230000003197 catalytic effect Effects 0.000 description 2
- 238000012669 compression test Methods 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 230000006378 damage Effects 0.000 description 2
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 2
- 229910052753 mercury Inorganic materials 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- SQGYOTSLMSWVJD-UHFFFAOYSA-N silver(1+) nitrate Chemical compound [Ag+].[O-]N(=O)=O SQGYOTSLMSWVJD-UHFFFAOYSA-N 0.000 description 2
- 230000001629 suppression Effects 0.000 description 2
- JNYAEWCLZODPBN-JGWLITMVSA-N (2r,3r,4s)-2-[(1r)-1,2-dihydroxyethyl]oxolane-3,4-diol Chemical compound OC[C@@H](O)[C@H]1OC[C@H](O)[C@H]1O JNYAEWCLZODPBN-JGWLITMVSA-N 0.000 description 1
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 1
- 239000004375 Dextrin Substances 0.000 description 1
- 229920001353 Dextrin Polymers 0.000 description 1
- 229920000663 Hydroxyethyl cellulose Polymers 0.000 description 1
- 239000004354 Hydroxyethyl cellulose Substances 0.000 description 1
- 229920001479 Hydroxyethyl methyl cellulose Polymers 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- 229910001423 beryllium ion Inorganic materials 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 239000001768 carboxy methyl cellulose Substances 0.000 description 1
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 1
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 229910000365 copper sulfate Inorganic materials 0.000 description 1
- XTVVROIMIGLXTD-UHFFFAOYSA-N copper(II) nitrate Chemical compound [Cu+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O XTVVROIMIGLXTD-UHFFFAOYSA-N 0.000 description 1
- ARUVKPQLZAKDPS-UHFFFAOYSA-L copper(II) sulfate Chemical compound [Cu+2].[O-][S+2]([O-])([O-])[O-] ARUVKPQLZAKDPS-UHFFFAOYSA-L 0.000 description 1
- OPQARKPSCNTWTJ-UHFFFAOYSA-L copper(ii) acetate Chemical compound [Cu+2].CC([O-])=O.CC([O-])=O OPQARKPSCNTWTJ-UHFFFAOYSA-L 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000005238 degreasing Methods 0.000 description 1
- 235000019425 dextrin Nutrition 0.000 description 1
- 238000007604 dielectric heating drying Methods 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 239000002612 dispersion medium Substances 0.000 description 1
- 238000007580 dry-mixing Methods 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 238000007602 hot air drying Methods 0.000 description 1
- 235000019447 hydroxyethyl cellulose Nutrition 0.000 description 1
- 238000003384 imaging method Methods 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 238000009616 inductively coupled plasma Methods 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 229910000358 iron sulfate Inorganic materials 0.000 description 1
- BAUYGSIQEAFULO-UHFFFAOYSA-L iron(2+) sulfate (anhydrous) Chemical compound [Fe+2].[O-]S([O-])(=O)=O BAUYGSIQEAFULO-UHFFFAOYSA-L 0.000 description 1
- PVFSDGKDKFSOTB-UHFFFAOYSA-K iron(3+);triacetate Chemical compound [Fe+3].CC([O-])=O.CC([O-])=O.CC([O-])=O PVFSDGKDKFSOTB-UHFFFAOYSA-K 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229920000609 methyl cellulose Polymers 0.000 description 1
- 239000001923 methylcellulose Substances 0.000 description 1
- 235000010981 methylcellulose Nutrition 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 239000012778 molding material Substances 0.000 description 1
- 239000003345 natural gas Substances 0.000 description 1
- 239000005416 organic matter Substances 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 238000001878 scanning electron micrograph Methods 0.000 description 1
- CQLFBEKRDQMJLZ-UHFFFAOYSA-M silver acetate Chemical compound [Ag+].CC([O-])=O CQLFBEKRDQMJLZ-UHFFFAOYSA-M 0.000 description 1
- 229940071536 silver acetate Drugs 0.000 description 1
- 229910001961 silver nitrate Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011973 solid acid Substances 0.000 description 1
- 238000000638 solvent extraction Methods 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
Images
Classifications
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- B01J35/56—
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- 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
- B01D53/9404—Removing only nitrogen compounds
- B01D53/9409—Nitrogen oxides
- B01D53/9413—Processes characterised by a specific catalyst
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J29/00—Catalysts comprising molecular sieves
- B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
- B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
- C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/62605—Treating the starting powders individually or as mixtures
- C04B35/62625—Wet mixtures
- C04B35/62635—Mixing details
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/6303—Inorganic additives
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
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- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
- C04B2235/606—Drying
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
- C04B2235/61—Mechanical properties, e.g. fracture toughness, hardness, Young's modulus or strength
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24149—Honeycomb-like
Description
本発明のゼオライトハニカム成形体の一の実施形態は、図1に示すように、複数のゼオライト粒子と、ゼオライト粒子同士を結合させる無機結合材と、その長径の長さに対して厚さ方向の長さが短い薄片状の板状粒子からなる充填材と、を含有するゼオライト原料が、流体の流路となる一方の端面11から他方の端面12まで延びる複数のセル2を区画形成する隔壁1を備えるハニカム形状に押出形成された成形体(ゼオライトハニカム成形体100)からなるものである。
乾燥収縮率={(成形体寸法A−乾燥体寸法B)/成形体寸法A}×100 ・・・ (1)
ゼオライト粒子は、本実施形態のゼオライトハニカム成形体を焼成した際に骨材となるものである。
無機結合材は、これまでに説明したゼオライト粒子及び薄片状の板状粒子からなる充填材を結合させるための結合材である。
V:ゼオライトハニカム焼成体の体積(真体積)
VZ:ゼオライト粒子の体積
VPZ:(焼成後の)充填材の体積(板状粒子の体積)
VB2:(焼成後の)無機結合材の体積
VZ:ゼオライト粒子の体積
MZ:ゼオライト粒子の質量
DZ:ゼオライトの密度(1.85g/cm3)
VPZ:焼成後の充填材の体積(焼成後の板状粒子の体積)
MPZ:焼成後の充填材の質量(焼成後の板状粒子の質量)
DPZ:焼成後の充填材の密度(焼成後の板状粒子の密度)
MP2:焼成後の充填材の質量(焼成後の板状粒子の質量)
MP1:焼成前の充填材の質量(焼成前の板状粒子の質量)
mP:充填材の焼成前後での質量変化率
VB2:焼成後の無機結合材の体積
MB2:焼成後の無機結合材の質量
DB2:焼成後の無機結合材の密度
MB2:焼成後の無機結合材の質量
MB1:焼成前の無機結合材の質量
mB:無機結合材の焼成前後での質量変化率
板状粒子は、ゼオライト原料に含有される充填材であり、その長径の長さに対して厚さ方向の長さが短い薄片状のものである。このような薄片状の板状粒子からなる充填材を含有させることにより、特定の方向における乾燥収縮を良好に抑制し、乾燥クラックの発生を防止することができる。
ゼオライト原料(ゼオライト材料ともいう)は、本実施形態のゼオライトハニカム成形体を形成するための成形用の原料であり、これまでに説明した、ゼオライト原料と、無機結合材と、充填材としての板状粒子と、を含有するものである。
本実施形態のゼオライトハニカム成形体は、これまでに説明したゼオライト粒子と無機結合材と充填材としての板状粒子とを少なくとも含有するゼオライト原料を、流体の流路となる一方の端面から他方の端面まで延びる複数のセルを区画形成する隔壁を備えるハニカム形状に押出成形して形成された成形体である。
次に、本発明のゼオライトハニカム成形体の製造方法について説明する。
まず、ゼオライト粒子と、その長径の長さに対して厚さ方向の長さが短い薄片状の板状粒子からなる充填材と、ゼオライト粒子及び板状粒子からなる充填材を結合させる無機結合材と、を混合して、ゼオライト原料を調製する。この際、板状粒子として、その厚さ方向の長さに対する、長径の長さの比の値(長径/厚さ)が、10以上であるとともに、平均粒子径が20〜200μmである板状粒子を用いることが好ましい。このような板状粒子としては、本実施形態のゼオライトハニカム成形体において、板状粒子の好適例として挙げた、好ましいアスペクト比、及び好ましい平均粒子径の板状粒子を好適に用いることができる。このような板状粒子を用いることによって、乾燥収縮の異方性制御を良好に行うことができる。
次に、得られたゼオライト原料をハニカム形状に押出成形して、ゼオライトハニカム成形体を形成する。押出成形に際しては、所望の全体形状、セル形状、隔壁厚さ、セル密度等を有する口金を用いることが好ましい。口金の材質としては、摩耗し難い金属が好ましい。また、ゼオライトハニカム成形体をハニカム形状に成形する場合には、例えば、まず、ゼオライト原料を混練して円柱状の成形体を形成し、円柱状の成形体を押出成形して、ハニカム形状のゼオライト成形体を形成することが好ましい。成形原料を混練して円柱状の成形体を形成する方法としては特に制限はなく、例えば、ニーダー、真空土練機等を用いる方法を挙げることができる。
次に、本発明のゼオライトハニカム焼成体の一の実施形態について具体的に説明する。本発明のゼオライトハニカム焼成体の一の実施形態は、図3に示すように、これまでに説明した本実施形態のゼオライトハニカム成形体を焼成することによって得られたゼオライトハニカム焼成体200であり、流体の流路となる一方の端面31から他方の端面32まで延びる複数のセル22を区画形成する隔壁21を備えたものである。ここで、図3は、本発明のゼオライトハニカム焼成体の一の実施形態を模式的に示す斜視図である。
気孔率=気孔容量/(気孔容量+1/ゼオライトハニカム焼成体の真密度)×100 ・・・ (8)
次に、本発明のゼオライトハニカム焼成体の製造方法について説明する。
ゼオライト粒子として、β型ゼオライトからなり、銅イオンで3質量%イオン交換された、平均粒子径が0.7μmのゼオライト粒子(以下、このゼオライト粒子を「ゼオライト粒子(1)」という)の粉末を用意した。
得られたゼオライトハニカム成形体と、このゼオライトハニカム成形体を乾燥したゼオライトハニカム乾燥体とのそれぞれについて、セルを区画形成する隔壁の厚さを光学顕微鏡にて測定した。また、ゼオライトハニカム成形体とゼオライトハニカム乾燥体の外径及びセルの延びる方向の長さを、ノギスにて測定した。測定した長さより、各方向における乾燥収縮率(%)を、上述した式(1)に従い算出した。測定結果を表4に示す。
得られたゼオライトハニカム焼成体を、外径25mm、高さ25mmの円柱状に加工し、加工したゼオライトハニカム焼成体を、セルの延びる方向に圧縮し、破壊が生じる際の圧力(MPa)を、圧縮強度(MPa)として測定した。なお、「破壊が生じる」とは、上記のように加工したゼオライトハニカム焼成体を圧縮する圧縮試験を行った場合に、圧縮による変位に対して、急激に荷重が減少したときのことを意味する。即ち、上記圧縮試験において、横軸を圧縮による変位、縦軸を荷重とするグラフ(荷重−変位曲線)を作成した場合に、破壊が生じる前は、圧縮による変位の増加とともに、荷重が増加する。一方、破壊が生じた場合には、変位の増加に反して、荷重が減少する現状が確認される。このグラフの変曲点をもってして破壊が生じたと判断する。なお、その荷重(変曲点における荷重)から圧縮強度(MPa)を算出する際には、下記(9)によって行う。
圧縮強度=破壊荷重/5.07×0.098 ・・・ (9)
ゼオライトハニカム成形体を乾燥したゼオライトハニカム乾燥体について、目視による外観観察から、乾燥によるクラックの有無を判定した。クラックが確認された場合を「有」とし、クラックが確認されなかった場合を「無」とした。
表2及び表3に示すように、充填材の板状粒子として、アスペクト比が16で、平均粒子径が162μmのガラスフレーク(以下、このガラスフレークを「ガラスフレーク(1)」という)を250g用いた以外は、実施例1と同様にしてゼオライトハニカム成形体を作製し、乾燥及び焼成してゼオライトハニカム焼成体を製造した。実施例1と同様の方法で、焼成体の圧縮強度、成形体の厚さ方向の乾燥収縮率と径方向の乾燥収縮率の比の値、及び乾燥クラックの有無の測定を行った。結果を表4に示す。
表2及び表3に示すように、充填材の板状粒子として、アスペクト比が70で、平均粒子径が22μmのマイカ(以下、このマイカを「マイカ(3)」という)を250g用いた以外は、実施例1と同様にしてゼオライトハニカム成形体を作製し、乾燥及び焼成してゼオライトハニカム焼成体を製造した。実施例1と同様の方法で、焼成体の圧縮強度、成形体の厚さ方向の乾燥収縮率と径方向の乾燥収縮率の比の値、及び乾燥クラックの有無の測定を行った。結果を表4に示す。
表1及び表3に示すように、ゼオライト粒子として、ZSM−5型ゼオライトからなり、銅イオンで3質量%イオン交換された、平均粒子径が14μmのゼオライト粒子(以下、このゼオライト粒子を「ゼオライト粒子(2)」という)の粉末を3500g用いた以外は、実施例1と同様にしてゼオライトハニカム成形体を作製し、乾燥及び焼成してゼオライトハニカム焼成体を製造した。実施例1と同様の方法で、焼成体の圧縮強度、成形体の厚さ方向の乾燥収縮率と径方向の乾燥収縮率の比の値、及び乾燥クラックの有無の測定を行った。結果を表4に示す。また、「ゼオライト粒子の平均粒子径に対する板状粒子の平均粒子径の比」、「ゼオライト粒子と無機結合材と板状粒子との固形分換算の合計100体積%に対する板状粒子の体積比率(表4においては、「板状粒子の体積比率(体積%)」と記す)」、及び「ゼオライトハニカム焼成体100体積%に対する無機結合材の体積比率(体積%)」を表4に示す。
表3に示すように、充填材の板状粒子として、マイカ(1)を180g用いた以外は、実施例1と同様にしてゼオライトハニカム成形体を作製し、乾燥及び焼成してゼオライトハニカム焼成体を製造した。実施例1と同様の方法で、焼成体の圧縮強度、成形体の厚さ方向の乾燥収縮率と径方向の乾燥収縮率の比の値、及び乾燥クラックの有無の測定を行った。結果を表4に示す。
表5に示すように、充填材の板状粒子を用いなかったこと以外は、実施例1と同様にしてゼオライトハニカム成形体を作製し、乾燥及び焼成してゼオライトハニカム焼成体を製造した。実施例1と同様の方法で、焼成体の圧縮強度、成形体の厚さ方向の乾燥収縮率と径方向の乾燥収縮率の比の値、及び乾燥クラックの有無の測定を行った。結果を表6に示す。
表2及び表5に示すように、充填材として、アスペクト比が3で、平均粒子径が25μmのガラスフレーク(以下、このガラスフレークを「ガラスフレーク(2)」という)を250g用いた以外は、実施例1と同様にしてゼオライトハニカム成形体を作製し、乾燥及び焼成してゼオライトハニカム焼成体を製造した。実施例1と同様の方法で、焼成体の圧縮強度、成形体の厚さ方向の乾燥収縮率と径方向の乾燥収縮率の比の値、及び乾燥クラックの有無の測定を行った。結果を表6に示す。
表2及び表5に示すように、充填材として、アスペクト比が45で、平均粒子径が5μmの微粒板状ベーマイトを250g用いた以外は、実施例1と同様にしてゼオライトハニカム成形体を作製し、乾燥及び焼成してゼオライトハニカム焼成体を製造した。実施例1と同様の方法で、焼成体の圧縮強度、成形体の厚さ方向の乾燥収縮率と径方向の乾燥収縮率の比の値、及び乾燥クラックの有無の測定を行った。結果を表6に示す。
表1及び表5に示すように、ゼオライト粒子として、ゼオライト粒子(2)を3500g用いて、表2及び表5に示すように、充填材の板状粒子として、マイカ(2)を250g用いた以外は、実施例1と同様にしてゼオライトハニカム成形体を作製し、乾燥及び焼成してゼオライトハニカム焼成体を製造した。実施例1と同様の方法で、焼成体の圧縮強度、成形体の厚さ方向の乾燥収縮率と径方向の乾燥収縮率の比の値、及び乾燥クラックの有無の測定を行った。結果を表6に示す。
表1及び表5に示すように、ゼオライト粒子として、ZSM−5型ゼオライトからなり、銅イオンで3質量%イオン交換された、平均粒子径が43μmのゼオライト粒子(以下、このゼオライト粒子を「ゼオライト粒子(3)」という)の粉末を3500g用いた以外は、実施例1と同様にしてゼオライトハニカム成形体を作製し、乾燥及び焼成してゼオライトハニカム焼成体を製造した。実施例1と同様の方法で、焼成体の圧縮強度、成形体の厚さ方向の乾燥収縮率と径方向の乾燥収縮率の比の値、及び乾燥クラックの有無の測定を行った。結果を表6に示す。
表5に示すように、充填材の板状粒子として、マイカ(1)を70g用いた以外は、実施例1と同様にしてゼオライトハニカム成形体を作製し、乾燥及び焼成してゼオライトハニカム焼成体を製造した。実施例1と同様の方法で、焼成体の圧縮強度、成形体の厚さ方向の乾燥収縮率と径方向の乾燥収縮率の比の値、及び乾燥クラックの有無の測定を行った。結果を表6に示す。
表5に示すように、無機結合材として、ベーマイトを600g用いた以外は、実施例1と同様にしてゼオライトハニカム成形体を作製し、乾燥及び焼成してゼオライトハニカム焼成体を製造した。実施例1と同様の方法で、焼成体の圧縮強度、成形体の厚さ方向の乾燥収縮率と径方向の乾燥収縮率の比の値、及び乾燥クラックの有無の測定を行った。結果を表6に示す。
Claims (9)
- ゼオライト粒子と、前記ゼオライト粒子同士を結合させる無機結合材と、その長径の長さに対して厚さ方向の長さが短い薄片状の板状粒子からなる充填材と、を含有するゼオライト原料が、流体の流路となる一方の端面から他方の端面まで延びる複数のセルを区画形成する隔壁を備えるハニカム形状に押出成形された成形体からなり、前記隔壁は、前記隔壁の厚さ方向の乾燥収縮率が、前記隔壁のセルの延びる方向の乾燥収縮率及び前記隔壁のハニカム形状におけるセルの延びる方向に垂直な断面の径方向の乾燥収縮率よりも大きくなるように構成されたものであり、且つ、前記隔壁の厚さ方向の乾燥収縮率が、前記隔壁のハニカム形状におけるセルの延びる方向に垂直な断面の径方向の乾燥収縮率の1.2倍以上であるゼオライトハニカム成形体。
- 前記充填材を構成する前記板状粒子が、その厚さ方向の長さに対する、長径の長さの比の値(長径/厚さ)が、10以上のものであるとともに、前記板状粒子の平均粒子径が20μm以上であり、且つ前記ゼオライト粒子の平均粒子径の2倍以上であり、
前記板状粒子が、前記ゼオライト粒子と前記無機結合材と前記板状粒子との固形分換算の合計100体積%に対して、2.5〜15体積%含有されるとともに、前記無機結合材が、前記ゼオライトハニカム成形体を焼成した焼成体100体積%に対して、10〜50体積%に相当する量含有されてなる請求項1に記載のゼオライトハニカム成形体。 - 前記板状粒子が、タルク、マイカ、窒化ホウ素、ベーマイト、グラファイト、及びガラスフレークからなる群より選択される少なくとも一種の材料からなる粒子である請求項1又は2に記載のゼオライトハニカム成形体。
- 前記ゼオライト粒子の平均粒子径が、0.1〜40μmである請求項1〜3のいずれか一項に記載のゼオライトハニカム成形体。
- 前記ゼオライト粒子のうちの少なくとも一部のゼオライト粒子が、ZSM−5型ゼオライト、β型ゼオライト、Y型ゼオライト、モルデナイト型ゼオライト、及びフェリエライト型ゼオライトからなる群から選択される少なくとも一種のゼオライトからなる粒子である請求項1〜4のいずれか一項に記載のゼオライトハニカム成形体。
- 前記ゼオライト粒子のうちの少なくとも一部のゼオライト粒子が、銅、鉄、ニッケル、亜鉛、マンガン、コバルト、銀、パラジウム、インジウム、セリウム、ガリウム、チタン、及びバナジウムからなる群より選択される少なくとも一種の金属のイオンによりイオン交換されたゼオライトからなる粒子である請求項1〜5のいずれか一項に記載のゼオライトハニカム成形体。
- 前記無機結合材が、アルミナゾル、シリカゾル、チタニアゾル、ジルコニアゾル、セリアゾル、ベーマイト、モンモリロナイト、ハイドロタルサイト、塩基性塩化アルミニウム、水硬性アルミナ、シリコン樹脂、及び水ガラスからなる群より選択される少なくとも一種を含むものである請求項1〜6のいずれか一項に記載のゼオライトハニカム成形体。
- 請求項1〜7のいずれか一項に記載のゼオライトハニカム成形体を焼成することによって得られたゼオライトハニカム焼成体。
- ゼオライト粒子と、前記ゼオライト粒子同士を結合させる無機結合材と、その長径の長さに対して厚さ方向の長さが短い薄片状の板状粒子からなる充填材と、有機バインダと、を混合して、ゼオライト原料を調製する工程と、得られた前記ゼオライト原料をハニカム形状に押出成形してゼオライト成形体を形成する工程と、を備え、
前記充填材を構成する前記板状粒子として、その厚さ方向の長さに対する、長径の長さの比の値(長径/厚さ)が、10以上のものであるとともに、前記板状粒子の平均粒子径が20μm以上であり、且つ前記ゼオライト粒子の平均粒子径の2倍以上であるものを用い、
前記ゼオライト原料中に、前記板状粒子が、前記ゼオライト粒子と前記無機結合材と前記板状粒子との固形分換算の合計100体積%に対して、2.5〜15体積%含有され、前記無機結合材が、前記ゼオライトハニカム成形体を焼成した焼成体100体積%に対して、10〜50体積%に相当する量含有されてなるゼオライトハニカム成形体の製造方法。
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