JP5938819B2 - 排気ガス処理用酸化触媒 - Google Patents
排気ガス処理用酸化触媒 Download PDFInfo
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- JP5938819B2 JP5938819B2 JP2011221896A JP2011221896A JP5938819B2 JP 5938819 B2 JP5938819 B2 JP 5938819B2 JP 2011221896 A JP2011221896 A JP 2011221896A JP 2011221896 A JP2011221896 A JP 2011221896A JP 5938819 B2 JP5938819 B2 JP 5938819B2
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- Prior art keywords
- catalyst
- catalyst layer
- active metal
- hydrocarbon adsorbent
- layer
- Prior art date
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- 239000003054 catalyst Substances 0.000 title claims description 170
- 238000007254 oxidation reaction Methods 0.000 title claims description 18
- 230000003647 oxidation Effects 0.000 title claims description 17
- 239000010410 layer Substances 0.000 claims description 117
- 229910052751 metal Inorganic materials 0.000 claims description 69
- 239000002184 metal Substances 0.000 claims description 69
- 229930195733 hydrocarbon Natural products 0.000 claims description 61
- 150000002430 hydrocarbons Chemical class 0.000 claims description 61
- 239000004215 Carbon black (E152) Substances 0.000 claims description 52
- 239000003463 adsorbent Substances 0.000 claims description 46
- 239000000463 material Substances 0.000 claims description 23
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 claims description 17
- 229910002091 carbon monoxide Inorganic materials 0.000 claims description 17
- 239000000758 substrate Substances 0.000 claims description 16
- 239000002344 surface layer Substances 0.000 claims description 13
- 239000011248 coating agent Substances 0.000 claims description 7
- 238000000576 coating method Methods 0.000 claims description 7
- 239000010457 zeolite Substances 0.000 description 28
- 229910021536 Zeolite Inorganic materials 0.000 description 26
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 26
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 20
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 15
- 239000007789 gas Substances 0.000 description 15
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 14
- 239000002002 slurry Substances 0.000 description 14
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 13
- 238000002485 combustion reaction Methods 0.000 description 12
- 230000000052 comparative effect Effects 0.000 description 12
- 238000002360 preparation method Methods 0.000 description 12
- 229910052763 palladium Inorganic materials 0.000 description 10
- 229910052697 platinum Inorganic materials 0.000 description 10
- 238000012360 testing method Methods 0.000 description 9
- 238000002156 mixing Methods 0.000 description 8
- 239000000446 fuel Substances 0.000 description 6
- 150000002739 metals Chemical class 0.000 description 6
- 229910000510 noble metal Inorganic materials 0.000 description 6
- 230000006835 compression Effects 0.000 description 5
- 238000007906 compression Methods 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- 238000000746 purification Methods 0.000 description 5
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 4
- 230000003197 catalytic effect Effects 0.000 description 4
- 239000000919 ceramic Substances 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 239000003921 oil Substances 0.000 description 4
- 239000013618 particulate matter Substances 0.000 description 4
- 229910052717 sulfur Inorganic materials 0.000 description 4
- 239000011593 sulfur Substances 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 3
- 230000010718 Oxidation Activity Effects 0.000 description 3
- 229910004298 SiO 2 Inorganic materials 0.000 description 3
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 3
- 239000010953 base metal Substances 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000011156 evaluation Methods 0.000 description 3
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 3
- 229910052737 gold Inorganic materials 0.000 description 3
- 239000010931 gold Substances 0.000 description 3
- 231100000572 poisoning Toxicity 0.000 description 3
- 230000000607 poisoning effect Effects 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- 238000001179 sorption measurement Methods 0.000 description 3
- 230000001052 transient effect Effects 0.000 description 3
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- 229910020203 CeO Inorganic materials 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 229910010413 TiO 2 Inorganic materials 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 229910052878 cordierite Inorganic materials 0.000 description 2
- 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 2
- TXKMVPPZCYKFAC-UHFFFAOYSA-N disulfur monoxide Inorganic materials O=S=S TXKMVPPZCYKFAC-UHFFFAOYSA-N 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 238000010304 firing Methods 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 239000000395 magnesium oxide Substances 0.000 description 2
- 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 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- -1 niobia Chemical compound 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
- XTQHKBHJIVJGKJ-UHFFFAOYSA-N sulfur monoxide Chemical compound S=O XTQHKBHJIVJGKJ-UHFFFAOYSA-N 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 1
- ODINCKMPIJJUCX-UHFFFAOYSA-N Calcium oxide Chemical compound [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910002061 Ni-Cr-Al alloy Inorganic materials 0.000 description 1
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 description 1
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 1
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000000292 calcium oxide Substances 0.000 description 1
- 235000012255 calcium oxide Nutrition 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-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
- 238000006243 chemical reaction Methods 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000003795 desorption Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 229910052675 erionite Inorganic materials 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 229910052733 gallium Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 229910052738 indium Inorganic materials 0.000 description 1
- 230000005764 inhibitory process Effects 0.000 description 1
- 229910052741 iridium Inorganic materials 0.000 description 1
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 229910052747 lanthanoid Inorganic materials 0.000 description 1
- 150000002602 lanthanoids Chemical class 0.000 description 1
- 230000003137 locomotive effect Effects 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 229910052961 molybdenite Inorganic materials 0.000 description 1
- CWQXQMHSOZUFJS-UHFFFAOYSA-N molybdenum disulfide Chemical compound S=[Mo]=S CWQXQMHSOZUFJS-UHFFFAOYSA-N 0.000 description 1
- 229910052680 mordenite Inorganic materials 0.000 description 1
- 229910052762 osmium Inorganic materials 0.000 description 1
- SYQBFIAQOQZEGI-UHFFFAOYSA-N osmium atom Chemical compound [Os] SYQBFIAQOQZEGI-UHFFFAOYSA-N 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 229910052574 oxide ceramic Inorganic materials 0.000 description 1
- 239000011224 oxide ceramic Substances 0.000 description 1
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 description 1
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- 239000010970 precious metal Substances 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000010948 rhodium Substances 0.000 description 1
- 229910052703 rhodium Inorganic materials 0.000 description 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 1
- 229910052707 ruthenium Inorganic materials 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- 238000002336 sorption--desorption measurement Methods 0.000 description 1
- 229910001256 stainless steel alloy Inorganic materials 0.000 description 1
- 229910052712 strontium Inorganic materials 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
Classifications
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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
- B01D53/9459—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts
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- B01D53/944—Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts
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- B01J20/10—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising silica or silicate
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Description
前記複数の触媒層が、ウォッシュコート材と、活性金属と、炭化水素吸着材とを含んでなるものであり
触媒表層側に一の触媒層が存在し、前記一の触媒層よりも下層側に他の触媒層が存在してなり、
前記一の触媒層における前記炭化水素吸着材の量が、他の触媒層における前記炭化水素吸着材の濃度よりも多いものであり、
前記一の触媒層における前記活性金属の濃度が前記他の触媒層における前記活性金属の濃度が少ないものであり、
排気ガス中の炭化水素(HC)と一酸化炭素(CO)を酸化処理する、酸化触媒を提供する。
本発明による触媒は、触媒層が複数層で構成されてなるものである。
本発明にあっては、複数の触媒層において、任意の「一の触媒層」と、任意の「他の触媒層」を決めた際に、複数の触媒層において、「一の触媒層」が触媒表層側に存在し、「他の触媒層」が「一の触媒層」よりも下層側(担体基材側)に存在してなるというものである。本発明の好ましい態様によれば、複数層は、「他の触媒層」と「一の触媒層」の二層で構成されてなるものが好ましくは用いられる。
「一の触媒層」における炭化水素吸着材の存在量が「他の触媒層」における炭化水素吸着材の存在量よりも多いものであり、かつ、「一の触媒層」における前記活性金属の存在濃度が「他の触媒層」における前記活性金属の存在濃度より少ないものである、という特徴を有する。また、触媒層は、「一の触媒層」と、「他の触媒層」とが隣り合わせとなって積層されてなるものであってもよく、また中間触媒層(又は他の層、同一又は異なる構成の層)を介在させてなるものであってもよい。また、本発明にあっては、複数の触媒層において、任意の二種の触媒層を選択し、かつ、「一の触媒層」が触媒表層側に存在し、「他の触媒層」が「一の触媒層」よりも下層側(担体基材側)に存在するとの位置決めをするものであり、「一の触媒層」が定まれば、他方は必ず「他の触媒層」として定まるものである。ここで、活性金属の存在濃度とは、活性金属の質量の、各触媒層の合計質量に対する割合であり、質量パーセントで表される。
活性金属は、酸化触媒の触媒活性成分して働くものである。活性金属としては、貴金属、卑金属が挙げられ、好ましくは貴金属である。貴金属の具体例としては、白金、パラジウム、ロジウム、ルテニウム、イリジウム、オスミウム、金、または銀が挙げられ、好ましくは、白金、パラジウム、または金である。また、これらの貴金属は、一種または二種以上の混合物として用いることができ、本願発明の好ましい態様によれば、白金とパラジウムの混同、白金とパラジウムと金の混合が望ましい。卑金属の具体例としては、ニッケル、銅、マンガン、鉄、コバルト、亜鉛等が挙げられ、好ましくは、ニッケル、マンガン、または鉄である。また、これらの卑金属は、一種または二種以上の混合物として用いることができる。
炭化水素吸着材は、炭化水素を吸着されるものであり、一般には排気ガスとの接触面積を拡大することが可能な高い比表面積を有した部材が使用される。高い比表面積とは、より具体的には、50〜1500m2/gであり、好ましくは200〜1000m2/g、さらに好ましくは、200〜900m2/g程度のものである。比表面積が上記範囲内にあることにより、触媒性能を十分に発揮させることが可能となる。比表面積は、吸脱着の気体として窒素を用いたBET窒素吸着法によって測定される値である。
ゼオライトとしては、天然ゼオライト、合成ゼオライト、これらに類するゼオライトが挙げられる。天然ゼオライトの具体例としては、方沸石、リョウ沸石、毛沸石、ソーダ沸石、モルデン沸石、輝沸石、束沸石、濁沸石、などを挙げることができる。合成ゼオライトの具体例としては、A型ゼオライト、Y型ゼオライト、X型ゼオライト、L型ゼオライト、エリオナイト、モルデナイト、ベータゼオライト、ZSM−5ゼオライト、等を挙げることができる。
ウォッシュコート材は、触媒成分を担持、分散する等の働きを担うものであり、そのような材料としては、酸化物セラミックが挙げられる。ウォッシュコート材としては、Mg、Si、Ca、Sr、Ba、Al、Ga、In、Sn、遷移元素、ランタニドからなる群から選択される金属酸化物又はこれらの複合酸化物、並びにこれらの二種以上の混合物が例示され、好ましくは、SiO2、Al2O3、CeO2、TiO2が挙げられ、SiO2、Al2O3、CeO2、TiO2を主成分とした複合酸化物を用いることもできる。
その他の成分としては、助触媒が挙げられる。助触媒としては、酸化セリウム、酸化ジルコニウム、酸化チタン等が挙げられる。助触媒の添加量は、適宜定めることができる。
担体基材は、触媒成分(活性金属、炭化水素吸着材、助触媒等)を、担体にキャリングするものである。担体基材は、圧力損失の問題などでエンジンの燃焼効率を低下させず、耐久性と信頼性をかなえ備えたものであれば、いずれのものであってもよい。担体基材は、セラミックまたは金属によって構成されてなり、円筒状、繊維状、粒子状、等の形態のものが挙げられる。セラミックまたは金属は一般的なもの、または市販されているものを用いることができ、好ましくはコージェライト(SiO2−Al2O3−MgO)、シリコンカーバイド(SiC)などの耐熱性セラミックやFe−Cr−Al系、Ni−Cr−Al系合金、ステンレス合金などがあげられる。また、担体基材の形態の具体例としては、モノリスハニカム型コーディエライト型、モノリスハニカム型SiC型、ファイバー積層または編物型、フォーム型、クロスフロー型積層型、メタルワイヤメッシュ型、金属多孔体型、セラミック粒子型等が挙げられる。
本発明による方法および装置は、内燃機関、特に、ディーゼルエンジンに好ましくは使用することができる。また、本発明の好ましい態様によれば、内燃機関を搭載した車両の排気系に本発明による方法および装置を用いることができる。内燃機関を用いる車両の具体例としては、例えば、自動車、バス、トラック、機関車、オートバイ、原動機付き自転車、重機等;飛行機等の運送機;耕耘機、トラクター、コンバイン、チェンソー、トロッコ、木材運搬機などの農林産業機械;船舶、漁船、モーターボート等の船舶;クレーン、圧搾機、掘削機等の土木作業機械;発電機;が挙げられる。しかしながら、これらのものに限定されるものではない。
ウォッシュコート材としてのアルミナ(Al2O3)、炭化水素吸着材としてのゼオライトと、活性金属としてのPtおよびPd(2:1)を混合し、「一の触媒層」のスラリーを調製した。炭化水素吸着材の存在量は担体1Lあたり12g、および活性金属の存在濃度は0.4質量%であった。担体1Lあたりの触媒質量は50g(活性金属0.2g)であった。
2)他の触媒層の調製(担体側)
ウォッシュコート材としてのアルミナ(Al2O3)、炭化水素吸着材としてのゼオライトと、活性金属としてのPtおよびPd(2:1)を混合し、「他の触媒層」のスラリーを調製した。炭化水素吸着材の存在量は担体1Lあたり30g、および活性金属の存在濃度は1.7質量%であった。担体1Lあたりの触媒質量は105g(活性金属1.785g)とした。
3)担体基材への被覆
先ず、「他の触媒層」用スラリーで,NGK製1.3Lのハニカム担体基材を被覆した。その後に、焼成を行った。次に、「他の触媒層」の上に「一の触媒層」用スラリーを被覆した。その後に、焼成を行い、実施例1を得た。
ウォッシュコート材としてのアルミナ(Al2O3)、炭化水素吸着材としてのゼオライトと、活性金属としてのPtおよびPd(2:1)を混合し、「一の触媒層」のスラリーを調製した。炭化水素吸着材の存在量は担体1Lあたり12g、および活性金属の存在濃度は2質量%であった。担体1Lあたりの触媒質量は90g(活性金属1.8g)とした。
2)他の触媒層の調製(担体側)
ウォッシュコート材としてのアルミナ(Al2O3)、炭化水素吸着材としてのゼオライトと、活性金属としてのPtおよびPd(2:1)を混合し、「他の触媒層」のスラリーを調製した。炭化水素吸着材の存在量は担体1Lあたり30g、および活性金属の存在濃度は0.3質量%であった。担体1Lあたりの触媒質量は65g(活性金属0.195g)とした。
3)担体基材への被覆
実施例1と同様にして比較例1を得た。
完成触媒を800℃、20時間オーブンで熱処理した後、直列4気筒ディーゼルエンジンの排ガス管に搭載した。市販の軽油(JIS 2)を用い、実際の排ガス中で過渡式の活性試験を実施し触媒の性能を評価した。
試験結果1
結果を表1に示す。比較例1のCOのT50(転化率が50%に到達する際の触媒入口温度。T50の数値が低い程、触媒性能が高いことを示す)が低い、つまり、実施例1の触媒活性が比較例1よりも高いことが示唆された。したがって、炭化水素吸着材の存在量が等しい触媒間において、一の触媒層における活性金属の存在濃度が他の触媒層における前記活性金属の存在濃度より少ない触媒構造により、COの酸化活性が向上したことが示された。
表1
ウォッシュコート材としてのアルミナ(Al2O3)、炭化水素吸着材としてのゼオライトと、活性金属としてのPtおよびPd(2:1)を混合し、「一の触媒層」のスラリーを調製した。炭化水素吸着材の存在量は担体1Lあたり30g、および活性金属の存在濃度は1.7質量%であった。担体1Lあたりの触媒質量は105g(活性金属1.785g)であった。
2)他の触媒層の調製(担体側)
ウォッシュコート材としてのアルミナ(Al2O3)、炭化水素吸着材としてのゼオライトと、活性金属としてのPtおよびPd(2:1)を混合し、「他の触媒層」のスラリーを調製した。炭化水素吸着材の存在量は担体1Lあたり12g、および活性金属の存在濃度は0.4質量%であった。担体1Lあたりの触媒質量は50g(活性金属0.2g)とした。
3)担体基材への被覆
実施例1と同様にして実施例2を得た。
完成触媒を800℃、20時間オーブンで熱処理した後、直列4気筒ディーゼルエンジンの排ガス管に搭載した。市販の軽油(JIS 2)を用い、実際の排ガス中で過渡式の活性試験を実施し触媒の性能を評価した。
試験結果2
結果を表2に示す。実施例2の触媒活性が比較例2よりも高いことが示唆された。したがって、活性金属の存在濃度の存在濃度がほぼ等しい触媒間において、一の触媒層における炭化水素吸着材の存在量が他の触媒層における炭化水素吸着剤より多い触媒構造により、COの酸化活性が向上したことが示された。
表2
ウォッシュコート材としてのアルミナ(Al2O3)、炭化水素吸着材としてのゼオライトと、活性金属としてのPtを混合し、「一の触媒層」のスラリーを調製した。炭化水素吸着材の存在量は担体1Lあたり24g、および活性金属の存在濃度は0.2質量%であった。担体1Lあたりの触媒質量は90g(活性金属0.18g)とした。
2)他の触媒層の調製(担体側)
ウォッシュコート材としてのアルミナ(Al2O3)、炭化水素吸着材としてのゼオライトと、活性金属としてのPtを混合し、「他の触媒層」のスラリーを調製した。炭化水素吸着材の存在量は担体1Lあたり6g、および活性金属の存在濃度は2.2質量%であった。担体1Lあたりの触媒質量は90g(活性金属1.98g)とした。
3)担体基材への被覆
実施例1と同様にして実施例3を得た。
ウォッシュコート材としてのアルミナ(Al2O3)、炭化水素吸着材としてのゼオライトと、活性金属としてのPtを混合し、「一の触媒層」のスラリーを調製した。炭化水素吸着材の存在量は担体1Lあたり15g、および活性金属の存在濃度は1.2質量%であった。担体1Lあたりの触媒質量は90g(活性金属1.08g)とした。
2)他の触媒層の調製(担体側)
ウォッシュコート材としてのアルミナ(Al2O3)、炭化水素吸着材としてのゼオライトと、活性金属としてのPtを混合し、「他の触媒層」のスラリーを調製した。炭化水素吸着材の存在量は担体1Lあたり15g、および活性金属の存在濃度は1.2質量%であった。担体1Lあたりの触媒質量は90g(活性金属1.08g)とした。
3)担体基材への被覆
実施例1と同様にして比較例3を得た。
ウォッシュコート材としてのアルミナ(Al2O3)、炭化水素吸着材としてのゼオライトと、活性金属としてのPtを混合し、「一の触媒層」のスラリーを調製した。炭化水素吸着材の存在量は担体1Lあたり6g、および活性金属の存在濃度は2.2質量%であった。担体1Lあたりの触媒質量は90g(活性金属1.98g)とした。
2)他の触媒層の調製(担体側)
ウォッシュコート材としてのアルミナ(Al2O3)、炭化水素吸着材としてのゼオライトと、活性金属としてのPtを混合し、「他の触媒層」のスラリーを調製した。炭化水素吸着材の存在量は担体1Lあたり24g、および活性金属の存在濃度は0.2質量%であった。担体1Lあたりの触媒質量は90g(活性金属0.18g)とした。
3)担体基材への被覆
実施例1と同様にして比較例4を得た。
完成触媒を800℃、20時間オーブンで熱処理した後、直列4気筒ディーゼルエンジンの排ガス管に搭載した。市販の軽油(JIS 2)を用い、実際の排ガス中で過渡式の活性試験を実施し触媒の性能を評価した。
試験結果3
結果を表3に示す。実施例3の触媒活性が明らかに比較例3および4よりも高いことが示唆された。したがって、一の触媒層および他の触媒層の触媒質量を揃えた比較において、一の触媒層における前記炭化水素吸着材の存在量、他の触媒層の存在濃度よりも多く、かつ、一の触媒層における活性金属の存在濃度が他の触媒層における前記活性金属の存在濃度が少ない触媒構造により、COの酸化活性が向上したことが示された。
表3
Claims (1)
- 担体基材と、該担体基材に担持された複数の触媒層とを備えてなる、排気ガス処理用酸化触媒であって、
前記複数の触媒層が、ウォッシュコート材と、活性金属と、炭化水素吸着材とを含んでなるものであり、
触媒表層側に一の触媒層が存在し、前記一の触媒層よりも下層側に他の触媒層が存在してなり、この一の触媒層および他の触媒層のそれぞれの触媒層が、ウォッシュコート材と、活性金属と、炭化水素吸着材とを含んでなるものであり、
前記一の触媒層における前記炭化水素吸着材の存在量(担体1リットルあたりの重量)が、他の触媒層における前記炭化水素吸着材の存在量(担体1リットルあたりの重量)よりも多いものであり、
前記一の触媒層における前記活性金属の存在濃度が0.05〜0.3質量%であって、前記他の触媒層における前記活性金属の存在濃度(質量%)よりも少ないものであり、前記他の触媒層における前記活性金属の存在濃度が0.5〜3質量%であり、排気ガス中の炭化水素(HC)と一酸化炭素(CO)を酸化処理する、酸化触媒。
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