JP5847094B2 - 押出しソリッド体を含む三元触媒 - Google Patents
押出しソリッド体を含む三元触媒 Download PDFInfo
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- JP5847094B2 JP5847094B2 JP2012550519A JP2012550519A JP5847094B2 JP 5847094 B2 JP5847094 B2 JP 5847094B2 JP 2012550519 A JP2012550519 A JP 2012550519A JP 2012550519 A JP2012550519 A JP 2012550519A JP 5847094 B2 JP5847094 B2 JP 5847094B2
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- way catalyst
- zeolite molecular
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- 239000003054 catalyst Substances 0.000 title claims description 91
- 239000007787 solid Substances 0.000 title claims description 79
- 229910052751 metal Inorganic materials 0.000 claims description 90
- 239000002184 metal Substances 0.000 claims description 90
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 claims description 83
- 239000010457 zeolite Substances 0.000 claims description 82
- 229910021536 Zeolite Inorganic materials 0.000 claims description 81
- 239000000203 mixture Substances 0.000 claims description 79
- 239000002808 molecular sieve Substances 0.000 claims description 77
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 76
- URGAHOPLAPQHLN-UHFFFAOYSA-N sodium aluminosilicate Chemical compound [Na+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O URGAHOPLAPQHLN-UHFFFAOYSA-N 0.000 claims description 76
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 58
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 45
- 239000011148 porous material Substances 0.000 claims description 42
- 239000000377 silicon dioxide Substances 0.000 claims description 34
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 33
- 150000002739 metals Chemical class 0.000 claims description 27
- 238000000034 method Methods 0.000 claims description 26
- 229910000510 noble metal Inorganic materials 0.000 claims description 24
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 claims description 23
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 claims description 23
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- 229910052878 cordierite Inorganic materials 0.000 claims description 12
- 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 claims description 12
- 239000011159 matrix material Substances 0.000 claims description 12
- 229910052763 palladium Inorganic materials 0.000 claims description 12
- 229910052703 rhodium Inorganic materials 0.000 claims description 12
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- 229910052845 zircon Inorganic materials 0.000 claims description 11
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims description 11
- 238000000576 coating method Methods 0.000 claims description 10
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- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 4
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- 239000000843 powder Substances 0.000 claims description 4
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- 238000004898 kneading Methods 0.000 claims description 3
- 150000002736 metal compounds Chemical class 0.000 claims description 3
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- 239000002253 acid Substances 0.000 claims description 2
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 claims description 2
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- 241000264877 Hippospongia communis Species 0.000 description 19
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 19
- 239000007789 gas Substances 0.000 description 18
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 14
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- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 6
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 6
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 6
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 6
- 238000012360 testing method Methods 0.000 description 6
- 239000005995 Aluminium silicate Substances 0.000 description 5
- 229920003171 Poly (ethylene oxide) Polymers 0.000 description 5
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 5
- 235000012211 aluminium silicate Nutrition 0.000 description 5
- 239000003795 chemical substances by application Substances 0.000 description 5
- 239000004927 clay Substances 0.000 description 5
- 238000010304 firing Methods 0.000 description 5
- 229930195733 hydrocarbon Natural products 0.000 description 5
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 description 5
- 229910003480 inorganic solid Inorganic materials 0.000 description 5
- 239000010970 precious metal Substances 0.000 description 5
- 229910052710 silicon Inorganic materials 0.000 description 5
- 239000010703 silicon Substances 0.000 description 5
- 238000001179 sorption measurement Methods 0.000 description 5
- 238000011144 upstream manufacturing Methods 0.000 description 5
- ZZBAGJPKGRJIJH-UHFFFAOYSA-N 7h-purine-2-carbaldehyde Chemical compound O=CC1=NC=C2NC=NC2=N1 ZZBAGJPKGRJIJH-UHFFFAOYSA-N 0.000 description 4
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 4
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 description 4
- 229910052777 Praseodymium Inorganic materials 0.000 description 4
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- 239000000395 magnesium oxide Substances 0.000 description 4
- 229910052748 manganese Inorganic materials 0.000 description 4
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 4
- 239000004014 plasticizer Substances 0.000 description 4
- 239000010944 silver (metal) Substances 0.000 description 4
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- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
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- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical group CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 3
- 229910021193 La 2 O 3 Inorganic materials 0.000 description 3
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 3
- 239000000654 additive Substances 0.000 description 3
- ILRRQNADMUWWFW-UHFFFAOYSA-K aluminium phosphate Chemical compound O1[Al]2OP1(=O)O2 ILRRQNADMUWWFW-UHFFFAOYSA-K 0.000 description 3
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Description
ABW、AEL、AET、AFG、AFI、AFO、AFR、AFS、AFY、AHT、AST、ASV、ATN、ATO、ATS、ATV、AWO、AWW、BCT、BEA、BEC、BIK、BOF、BOG、BPH、BRE、BSV、CAN、CAS、CFI、CGF、CGS、-CHI、-CLO、CON、CZP、DAC、DFO、DOH、DON、EMT、EON、ESV、ETR、EUO、EZT、FAR、FAU、FER、FRA、GIU、GME、GON、HEU、IFR、IMF、ISV、ITH、ITR、IWR、IWS、IWV、IWW、JBW、JRY、LAU、LIO、-LIT、LOS、LOV、LTF、LTL、LTN、MAR、MAZ、MEI、MEL、MEP、MFI、MFS、MOR、MOZ、MRE、MSE、MOS、MTF、MTN、MTT、MTW、MWW、NAB、NAT、NES、NON、NPO、OBW、OFF、OSI、OSO、-PAR、PON、-RON、RRO、RSN、RTE、RUT、RWR、RWY、SAO、SAS、SBE、SBS、SBT、SFE、SFF、SFG、SFH、SFN、SFO、SFS、SGT、SOD、SOF、SOS、SSF、SSY、STF、STI、STO、STT、STW、-SVR、SZR、TER、TOL、TON、TUN、UOS、UOZ、USI、UTL、VET、VFI、VSV、WEI又は-WEN
及びこれらのうち2つ以上の混合物。
(i)触媒媒煙フィルタは、ウォールフローフィルタで基本的に以下のように構成された押出しソリッド体を含む:15-70重量%のコーディエライト、窒化物、炭化物、ホウ化物、合金、リチウムアルミノ珪酸塩、スピネル、場合によってドーピングされたアルミナ、チタニア、ジルコニア、チタニア−ジルコニア、ジルコン及びこれらのうち2つ以上の混合物、0-20重量%のシリカソース、それぞれが1つ以上の金属を含有する5-50重量%のゼオライトモレキュラシーブ、非ゼオライトモレキュラシーブ又はこれらのうち2つ以上の混合物、20-80重量%の場合によって安定化されたセリア、及び0-20重量%の無機繊維。押出しソリッド触媒体は、少なくとも1つの貴金属と2つ以上の貴金属の組み合わせを含む1つ以上の層でコーティングされる。
(ii)三元触媒は、フロースルー構造で基本的に以下のように構成された押出しソリッド体を含む:15-30重量%のコーディエライト、窒化物、炭化物、ホウ化物、合金、リチウムアルミノ珪酸塩、スピネル、場合によってドーピングされたアルミナ、チタニア、ジルコニア、チタニア−ジルコニア、ジルコン及びこれらのうち2つ以上の混合物、0-20重量%のシリカソース、それぞれが1つ以上の金属を含有する5-81重量%のゼオライトモレキュラシーブ、非ゼオライトモレキュラシーブ又はこれらのうち2つ以上の混合物、0-20重量%の無機繊維。押出しソリッド触媒体は、大部分のγ-アルミナとパラジウムのみを担持する安定化したセリアの混合物、大部分のパラジウムとロジウムの混合物、白金とロジウムの混合物又は白金、パラジウム及びロジウムの混合物を含む単一層でコーティングされる。
次の粉末の出発物質を混合する段階:ここで、前記粉末の出発物質は、少なくとも1つのバインダ/マトリックス成分又はこれの1つ以上の前駆体、少なくとも1つの金属に結合されるゼオライトモレキュラシーブ、非ゼオライトモレキュラシーブ又はこれらのうち2つ以上の混合物、場合によって安定化されたセリア、及び場合によって少なくとも1つの金属化合物であり;場合によって無機繊維と共に混合する段階;場合によって有機補助剤を添加する段階;
混合物を形成するように、少なくとも1つの金属の金属塩を場合によって含有する酸又はアルカリ水溶液で、混合された出発物質を混合及び/又は混練を通じて処理する段階、
前記混合物は触媒体に押し出し、前記触媒体を乾燥させ、ソリッド押出し体を形成するために焼成する段階、
前記ソリッド押出し体が10-100重量%の少なくとも1つのバインダ/マトリックス成分、及び5-90重量%のゼオライトモレキュラシーブ、非ゼオライトモレキュラシーブ又はこれらのうち2つ以上の混合物、及び0-80重量%の場合によって安定化されたセリアを含有するように前記出発物質の比率を選択し、前記ソリッド押出し体の表面を少なくとも1つの貴金属でコーティングし、場合によって前記ソリッド押出し体の表面を少なくとも1つの金属で含浸する段階を含む製造工程を提供する。
押出しゼオライトモノリス基材がUS7,507,684に開示されたものと類似の方法で製造された。水素形態の商業的に利用可能な粉末βゼオライトがガラス繊維、カオリンフィラー及び粉末合成ベーマイト(Pural SB)と混合され、5-6のpH値を有する水溶液で処理され、セルロース(CMC-QP10000H)、可塑剤Zusoplast(Zschimmer&Schwarz GmbH&Co KGのブランド名)と有機補助剤PEOアルコックス(ポリエチレン酸化物)の混合物により成形可能であり、流動可能なスリップに製造される。前記出発物質の量的比率は、最終ソリッド触媒体の活性物質が69重量%のゼオライト、23重量%のγ-Al2O3及び5重量%のガラス繊維及び3重量%のカオリンを含むように選択される。前記成形可能な混合物は、300cpsi又は400cpsiのセル密度を有する2.54cm直径×7.62cm長さ(1”直径×3”長さ)のフロースルーハニカム触媒体(即ち、連続したチャネルと円形の断面を有する)内に押し出される。次に、前記触媒体は、WO2009/080155(全体内容が参照としてここに含まれる)に説明された方法により1時間2mbarで冷却乾燥し、ソリッド触媒体を形成するために、580℃の温度で焼成される。
実施形態1の300cpsi及び400cpi 2.54cm×7.62cm(1”×3”)押出しゼオライトモノリス基材サンプルは、WO99/47260(ここで全体内容が参照として含まれる)に開示された方法(即ち、(a)モノリス式支持体の上部に保持手段を位置させる段階、(b)前記保持手段内に予め設定された量の液体成分を提供する段階((a)と(b)の順序は、(a)の次(b)、又は(b)の次(a))、(c)前記液体成分の全体を前記モノリス式支持体の少なくとも一部に吸い込むために真空を加え、前記液体成分の全体を前記モノリス式支持体内に再生なしに維持させる段階を含むモノリス式支持体のコーティング方法。)を用いて大部分のγ-アルミナとパラジウム(大部分)とロジウムを担持するセリア-ジルコニアの混合酸化物の混合物を含む三元触媒組成物の単一層でウォッシュコートされる。結果物は乾燥し、600℃で焼成される。
商業的に利用可能な300cpsiのコーディエライトモノリス基材が乾燥及び600℃での焼成後にβゼオライトとコロイド性シリカを含む第1層で(WO99/47260の技術によって)ウォッシュコートされた。実施形態2に係る第2の三元触媒層が前記第1のβゼオライト層の上を覆う層であって、ウォッシュコートで塗布された。結果物は乾燥し、600℃で焼成された。2.54cm×7.62cm(1”×3”)のコアがコーティングされたモノリス基材から得られる。
実施形態2の触媒サンプルと比較実施形態3が、次の段階によって実験室SCAT(Synthetic Catalyst Activity Test)リグ(rig)を用いてテストされた:
(i)N2(バランス)内5%の酸素で15分間希薄事前-処理後にN2で30℃に冷却、
(ii)0.15%HC(17体積%のトルエン、24体積%のイソペンタン、59体積%のプロピレン)、0.1%CO、10%H2O蒸気及びバランス圧縮空気の16L/min(25K/h SV)での触媒バイパスにベースラインの供給導入、
(iii)データ収集開始及び30秒待機、
(iv)HCの供給を30秒間サンプルに送り、30℃-40℃で吸着維持、
(iv)ガス供給を触媒バイパスを介して送る、
(v)供給から空気、HC及びCOの除去及び16L/minを維持するためにN2でリバランス、
(vi)ガス供給をサンプルに再び提供し、30℃から550℃まで40℃/minで温度を変化、
(vii)データ収集終了、N2をサンプルを貫通させて30℃に冷却、及び
(viii)ガスの流れをバイパスに転換
実施形態1で他の押出しゼオライトモノリス基材がUS7,507,684に開示された方法と類似の方法により製造された。水素形態(Tosoh)の商業的に利用可能な粉末βゼオライトがガラス繊維(Vetrotex 4、5mm(Saint-Gobain))、低アルカリクレーフィラー及び粉末合成ベーマイト(Pural SB)と混合され、5-6のpH値を有する水溶液で処理され、8重量%のセルロース(全体無機ソリッド成分に基づく)(CVP-M-5280(Dow Wolff Cellulosics))により成形可能であり、流動可能なスリップに製造される。前記出発物質の量的比率は、最終ソリッド触媒体の活性物質が60重量%のゼオライト、25重量%のクレー、7重量%のγ-Al2O3及び8重量%のガラス繊維を含むように選択される。前記成形可能な混合物は、適切なセル密度を有するフロースルーハニカム触媒体(即ち、連続したチャネルと円形の断面を有する)内に押し出される。次に、前記触媒体は、WO2009/080155(全体内容が参照としてここに含まれる)に説明された方法により1時間2mbarで冷却乾燥し、ソリッド触媒体を形成するために、580℃の温度で焼成される。
混練可能なペーストを製造するために、表1に記載された成分A、B、FとSを水と混合することで、参照押出しV2O5/WOx-TiO2ソリッド体が実施形態1及び5と類似に用意された。添加剤H(孔隙変更剤)が追加され、前記物質は孔隙変更剤を分散させるために、10分間混練された。結果組成物は、実施形態1及び5で説明されたように押し出され、乾燥し、焼成された。最終的に焼成された製品に存在する無機ソリッド量の百分率は100%である。焼成過程で燃焼により除去される添加剤(HとS)の量は、100%無機ソリッド成分に対して重量%で提供される。
A2=V2O5 from AMV(78%V2O5、GFE)
B1=ベントナイト(90%、ACE/Mizuka)
B2=カオリン(97、9%、TK0177/Thiele)
B3=SiO2(100%、Tixosil/Novus)
F1=ガラス繊維(Vetrotex 4、5mm/Saint Cobain)
H1=セルロース(QP10000H/Nordmann)
H2=PEO(Alkox/Alroko)
H3=Zusoplast(Zschimmer & Schwarz)
S1=MEA(Imhoff & Stahl)
S2=NH3
S3=C3H6O3(fauth)
これは例示的な実施形態である。触媒ウォールフローフィルタモノリス基材が以下のように製造され得る。適切な量のCeO2-ZrO2混合酸化物が、ガラス繊維、粉末合成ベーマイト(Pural SB)及びβゼオライトと混合され、3.5のpH値を有する水溶液で処理され、1.5重量%のセルロース(CMC-QP1000H)、1.0重量%の有機補助剤PEOアルコックス(ポリエチレン酸化物)及び孔隙変更剤Rettenmaier BC200とポリアクリロニトリル(PAN)繊維の混合物13重量%を含む成形可能であり、流動可能なスリップに製造される。前記出発物質の量的比率は、最終ソリッド触媒体の活性物質が25重量%のCeO2、15重量%のβゼオライト、52重量%のγ-Al2O3及び8重量%のガラス繊維を含むように選択される。前記成形可能な混合物は、300cpsiのセル密度を備え、連続したチャネルと円形の断面を有するフロースルーハニカム触媒体内に押し出される。次に、前記触媒体は、WO2009/080155(全体内容が参照としてここに含まれる)に説明された方法により1時間2mbarで冷却乾燥し、ソリッド触媒体を形成するために、580℃の温度で焼成される。結果製品は一般に約10μmの平均孔隙サイズを有するようになる。
Claims (19)
- 押出しソリッド体を備えた三元触媒であって、前記押出しソリッド体が、
10-95重量%の少なくとも1つのマトリックス成分、
それぞれが最大リング孔隙開口構造として、10と等しいか、それより大きいリング孔隙開口構造を有し、10から150のシリカ-アルミナ比を有する、5-90重量%の合成アルミノ珪酸塩ゼオライトモレキュラシーブ、又は前記ゼオライトモレキュラシーブと非ゼオライトモレキュラシーブとの混合物、及び
0-80重量%の場合によって安定化されたセリア
を含んでなり、
前記触媒が、少なくとも1つの貴金属と、場合によって少なくとも1つの非貴金属を含んでなり、
(i)前記少なくとも1つの貴金属が、前記押出しソリッド体の表面上の1つ以上のコーティング層に収容されてなり、
(ii)少なくとも1つの金属が、前記押出しソリッド体の全体に渡って存在し、少なくとも1つの貴金属も前記押出しソリッド体の表面上の1つ以上のコーティング層に収容されてなり、又は
(iii)少なくとも1つの金属が前記押出しソリッド体の全体に渡って存在し、前記押出しソリッド体の表面に更に高い濃度で存在し、及び少なくとも1つの貴金属も前記押出しソリッド体の表面上の1つ以上のコーティング層に収容されてなる、三元触媒。 - 前記少なくとも1つの金属が、前記ゼオライトモレキュラシーブ成分に結合される、請求項1に記載の三元触媒。
- 前記押出しソリッド体が、前記ゼオライトモレキュラシーブ成分に結合される少なくとも1つの第1金属と、
前記ゼオライトモレキュラシーブ成分に結合されていない少なくとも1つの第2金属とを含んでなる、請求項2に記載の三元触媒。 - 前記押出しソリッド体の全体に渡って存在するが、前記ゼオライトモレキュラシーブ成分に結合されないものであるか、
前記押出しソリッド体の表面上の1つ以上のコーティング層に存在するか、
又は前記押出しソリッド体の表面に更に高い濃度で存在する、
前記少なくとも1つの金属が、
アルカリ金属、アルカリ土金属、ランタナイド又はこれらのうち2つ以上の混合物からなる群より選択される少なくとも1つの金属を含んでなる、請求項3に記載の三元触媒。 - 前記貴金属が、Pt、Au、Ag、Ir、Ru、Rh、Pd及びOsからなる群より選択される、請求項1〜4の何れか一項に記載の三元触媒。
- 前記押出しソリッド体が、
10-95重量%のコーディエライト、窒化物、炭化物、ホウ化物、合金、リチウムアルミノ珪酸塩、場合によってドーピングされたアルミナ、シリカソース、チタニア、ジルコニア、チタニア-ジルコニア、ジルコン及びこれらのうち2つ以上の混合物、
0-80重量%のスピネル、
それぞれが1つ以上の金属を場合によって含有する、5-90重量%のゼオライトモレキュラシーブ、又は前記ゼオライトモレキュラシーブと非ゼオライトモレキュラシーブとの混合物、
0-80重量%の場合によって安定化したセリア、及び
0-25重量%の無機繊維を含んでなる、請求項1〜5の何れか一項に記載の三元触媒。 - ウォールフローフィルタの形態である、請求項1〜6の何れか一項による三元触媒。
- 前記少なくとも1つのマトリックス成分が、コーディエライト、窒化物、炭化物、ホウ化物、合金、リチウムアルミノ珪酸塩、スピネル、場合によってドーピングされたアルミナ、シリカソース、チタニア、ジルコニア、チタニア-ジルコニア、ジルコン及びこれらのうち2つ以上の混合物からなる群より選択される、請求項1〜7の何れか一項に記載の三元触媒。
- 前記ゼオライトモレキュラシーブが、下記のフレームワーク形態のコード:
国際ゼオライト協会の構造委員会により定義された
ABW、AEL、AET、AFG、AFI、AFO、AFR、AFS、AFY、AHT、AST、ASV、ATN、ATO、ATS、ATV、AWO、AWW、BCT、BEA、BEC、BIK、BOF、BOG、BPH、BRE、BSV、CAN、CAS、CFI、CGF、CGS、-CHI、-CLO、CON、CZP、DAC、DFO、DOH、DON、EMT、EON、ESV、ETR、EUO、EZT、FAR、FAU、FER、FRA、GIU、GME、GON、HEU、IFR、IMF、ISV、ITH、ITR、IWR、IWS、IWV、IWW、JBW、JRY、LAU、LIO、-LIT、LOS、LOV、LTF、LTL、LTN、MAR、MAZ、MEI、MEL、MEP、MFI、MFS、MOR、MOZ、MRE、MSE、MSO、MTF、MTN、MTT、MTW、MWW、NAB、NAT、NES、NON、NPO、OBW、OFF、OSI、OSO、-PAR、PON、-RON、RRO、RSN、RTE、RUT、RWR、RWY、SAO、SAS、SBE、SBS、SBT、SFE、SFF、SFG、SFH、SFN、SFO、SFS、SGT、SOD、SOF、SOS、SSF、SSY、STF、STI、STO、STT、STW、-SVR、SZR、TER、TOL、TON、TUN、UOS、UOZ、USI、UTL、VET、VFI、VSV、WEI又は-WEN
及びこれらのうち2つ以上の混合物を有する、請求項1〜8の何れか一項に記載の三元触媒。 - 前記ゼオライトモレキュラシーブが、ZSM-5、ベータ、フェリエライト及びこれらのうち2つ以上の混合物からなる群より選択される、請求項1〜9の何れか一項に記載の三元触媒。
- 前記セリア成分が、ジルコニウム、ランタナイド及びそれらのうち2つ以上の混合物からなる群から選択される少なくとも1つの非セリウム成分により安定化されている、請求項1〜10の何れか一項に記載の三元触媒。
- 請求項1〜11の何れか一項による三元触媒を製造する方法であって、
粉末の出発物質を混合し、ここで、前記粉末の出発物質は、少なくとも1つのマトリックス成分又はこれの1つ以上の前駆体、場合によって少なくとも1つの金属に結合される合成アルミノ珪酸塩ゼオライトモレキュラシーブ、又は前記ゼオライトモレキュラシーブと非ゼオライトモレキュラシーブとの混合物であってそれぞれが最大リング孔隙開口構造として、10と等しいか、それより大きいリング孔隙開口構造を有し、10から150のシリカ-アルミナ比を有するもの、場合によって安定化されたセリア、及び場合によって少なくとも1つの金属化合物であり;場合によって無機繊維と共に混合し、場合によって有機補助剤を添加し、
混合物を形成するように、少なくとも1つの金属の金属塩を場合によって含有する酸又はアルカリ水溶液と、混合された粉末の出発原料とを混合及び/又は混練を通じて処理し、
前記混合物が触媒体に押し出し、前記触媒体を乾燥させ、ソリッド押出し体を形成するために焼成し、
前記ソリッド押出し体が、10-95重量%の少なくとも1つのマトリックス成分、及びそれぞれが最大リング孔隙開口構造として、10と等しいか、それより大きいリング孔隙開口構造を有し、10から150のシリカ-アルミナ比を有する5-90重量%の合成アルミノ珪酸塩ゼオライトモレキュラシーブ、又は前記ゼオライトモレキュラシーブと非ゼオライトモレキュラシーブとの混合物、及び0-80重量%の場合によって安定化されたセリアを含有するように前記出発物質の量的比率を選択し、
前記ソリッド押出し体の表面を少なくとも1つの貴金属を含む少なくとも1つのコーティング層でコーティングし、且つ場合によって前記ソリッド押出し体の表面を少なくとも1つの金属で含浸することも含んでなる、製造方法。 - 固定型発生源又は車両の内燃機関から発生した排気ガスを処理する方法であって、
前記排気ガスを請求項1〜11の何れか一項による三元触媒と接触させることを含んでなる、方法。 - 請求項1〜11の何れか一項による三元触媒を含んでなる、内燃機関用排気システム。
- 内燃機関及び請求項14による排気システムを備えてなる、車両。
- 前記少なくとも1つの金属が、前記ゼオライトモレキュラシーブ成分、又は前記混合物中の前記ゼオライトモレキュラシーブ成分と前記非ゼオライトモレキュラシーブ成分のうちの一方もしくは双方と結合している、請求項1〜11の何れか一項に記載の三元触媒。
- 前記少なくとも1つの金属が、遷移金属、ランタナイド又はこれらのうち2つ以上の混合物からなる群より選択される1つ以上の金属を含んでなる、請求項16に記載の三元触媒。
- 前記遷移金属が、Cu、Pd及びAgからなる群より選択される、請求項17に記載の三元触媒。
- 前記少なくとも1つの金属の全体金属含有量が、0.1〜20重量%である、請求項16、17又は18に記載の三元触媒。
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