JP6240370B2 - 触媒粉末の製造方法 - Google Patents
触媒粉末の製造方法 Download PDFInfo
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- JP6240370B2 JP6240370B2 JP2010286857A JP2010286857A JP6240370B2 JP 6240370 B2 JP6240370 B2 JP 6240370B2 JP 2010286857 A JP2010286857 A JP 2010286857A JP 2010286857 A JP2010286857 A JP 2010286857A JP 6240370 B2 JP6240370 B2 JP 6240370B2
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- catalyst
- catalyst powder
- powder
- calcined
- slurry
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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
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- B01D53/9409—Nitrogen oxides
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- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/90—Physical characteristics of catalysts
- B01D2255/92—Dimensions
- B01D2255/9205—Porosity
-
- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/90—Physical characteristics of catalysts
- B01D2255/92—Dimensions
- B01D2255/9207—Specific surface
-
- 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
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
- B01J37/0027—Powdering
- B01J37/0045—Drying a slurry, e.g. spray drying
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/02—Impregnation, coating or precipitation
- B01J37/0215—Coating
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Description
[実験室規模の合成]
銀を含有する鋳型金属酸化物の代表的な製造方法は以下の工程を含む。機械式攪拌機、還流冷却器及び滴下ロートを備えた5Lの3つ口フラスコに250mLの2−プロパノール、TRITON X−114(68.7g、0.16モル)及びアセト酢酸エチル(13.2g、0.1モル)を入れた。Al(OsecBu)3(249.8g、1.02モル)を1Lの2−プロパノールに溶解又は懸濁してフラスコに添加した。内容物を30分間撹拌した。所定量の硝酸銀(AgNO3)を水(37mL、2.06モル)に溶解した。硝酸銀溶液は以下のように使用した。AgNO3の量は、触媒生成物1の場合、5.383g(0.0317モル)のAgNO3から6%の銀構造規制されたアルミナ触媒組成物を生成し、触媒生成物2の場合、2.6g(0.0158モル)のAgNO3から3%の銀構造規制されたアルミナ触媒組成物を生成する。硝酸銀溶液を500mLの2−プロパノールと混合して、滴下ロートに入れた。滴下ロートの内容物を75分間かけて5Lフラスコに添加した。撹拌溶液を24時間還流した。
[大規模な合成]
この実験には、窒素ブランケットにて循環熱油加熱器、後退カーブ形撹拌機、熱電対プローブ付きバッフル、窒素スイープ及び還流/蒸留冷却器を備えた100ガロン(380L)容量のガラス内張りスチール反応器を使用した。窒素ブランケット下95RPMで撹拌しながら反応器に約60.5kgのアセト酢酸エチル(130g/モル)及び約2.6kgのTRITON(商標)X−114(426g/モル)を入れた。連続撹拌下約15kgのアルミニウムsec−ブトキシド(246g/モル)を反応器に添加した。
60 加熱管
72 実験室規模の6%銀触媒のNOx転換活性率曲線
74 実験室規模の3%銀触媒のNOx転換活性率曲線
76 大規模の6%銀触媒のNOx転換活性率曲線
78 大規模の3%銀触媒のNOx転換活性率曲線
82 乾燥工程後にエタノール抽出を行った6%銀触媒のNOx転換活性率曲線
84 エタノール抽出なしの3%銀触媒のNOx転換活性率曲線
86 噴霧乾燥前にエタノール抽出を行った3%銀触媒のNOx転換活性率曲線
88 噴霧乾燥後にエタノール抽出を行った3%銀触媒のNOx転換活性率曲線
Claims (13)
- 触媒、液体キャリア、鋳型剤及び触媒基材を含有する触媒スラリーを調製する工程と、
触媒スラリーを噴霧乾燥して触媒粉末原料を得る工程と、
触媒粉末原料を第1制御雰囲気で加熱して熱分解した触媒粉末を得る工程と、
熱分解触媒粉末を第2制御雰囲気で焼成して焼成触媒粉末を得る工程と
を含む、触媒粉末の製造方法であって、第1制御雰囲気が不活性雰囲気又は真空であり、第2制御雰囲気が酸素を含む制御酸素雰囲気であり、得られる焼成触媒粉末のバッチ量の中央値が5kg超である、方法。 - 前記加熱が、150℃未満の温度での脱水工程である第1工程と、700℃未満の温度での熱分解工程である第2工程とを含む、請求項1記載の方法。
- 第2制御雰囲気の酸素濃度が第2制御雰囲気の全気体含量の1モル%超である、請求項1又は請求項2記載の方法。
- 酸素濃度が5モル%超である、請求項3記載の方法。
- 焼成前に、熱分解触媒粉末を100℃未満の第2制御雰囲気にさらすことをさらに含む、請求項1乃至請求項4のいずれか1項記載の方法。
- 焼成が、第2制御雰囲気で熱分解触媒粉末の温度を約500℃超の温度に上げることを含む、請求項1乃至請求項5のいずれか1項記載の方法。
- 触媒が銀である、請求項1乃至請求項6のいずれか1項記載の方法。
- 触媒基材がメソポーラスアルミナである、請求項1乃至請求項7のいずれか1項記載の方法。
- 液体キャリアがアルコールである、請求項1乃至請求項8のいずれか1項記載の方法。
- 得られた焼成触媒粉末のメジアン径が10μm未満である、請求項1乃至請求項9のいずれか1項記載の方法。
- 焼成触媒粉末の比表面積が200m2/g超である、請求項1乃至請求項10のいずれか1項記載の方法。
- 触媒コンバータの製造方法であって、
請求項1乃至請求項11のいずれか1項記載の方法で焼成触媒粉末を得る工程と、
焼成触媒粉末からなる触媒表面を製造する工程と
を含む方法。 - 銀、アルミナ、アルコール及び鋳型剤を含有する触媒スラリーを調製する工程と、
触媒スラリーを噴霧乾燥して触媒粉末原料を得る工程と、
触媒粉末原料を不活性雰囲気で加熱して熱分解した触媒粉末を得る工程と、
熱分解触媒粉末を制御酸素雰囲気で焼成して銀鋳型メソポーラスアルミナ(Ag−TA)を含む焼成触媒粉末を得る工程であって、得られる焼成触媒粉末のバッチ量の中央値が5kg超である工程と、
焼成触媒粉末を液体と混合して焼成触媒粉末スラリーを形成する工程と、
焼成触媒粉末スラリーをモノリス支持体上にウォッシュコートする工程と
を含む、NOx触媒コンバータの製造方法。
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US12/652,808 | 2010-01-06 | ||
US12/652,808 US8476187B2 (en) | 2010-01-06 | 2010-01-06 | Process for preparing catalyst powder |
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EP (1) | EP2343120A3 (ja) |
JP (1) | JP6240370B2 (ja) |
CN (1) | CN102151587B (ja) |
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US9375710B2 (en) | 2007-09-19 | 2016-06-28 | General Electric Company | Catalyst and method of manufacture |
US20090263297A1 (en) * | 2007-09-19 | 2009-10-22 | General Electric Company | Catalyst and method of manufacture |
US9272271B2 (en) | 2007-09-19 | 2016-03-01 | General Electric Company | Manufacture of catalyst compositions and systems |
US20110047995A1 (en) * | 2009-08-31 | 2011-03-03 | General Electric Company | Catalyst and method of manufacture |
US20100196236A1 (en) | 2009-01-30 | 2010-08-05 | General Electric Company | Templated catalyst composition and associated method |
US20100196237A1 (en) | 2009-01-30 | 2010-08-05 | General Electric Company | Templated catalyst composition and associated method |
US8889587B2 (en) | 2009-08-31 | 2014-11-18 | General Electric Company | Catalyst and method of manufacture |
US20120329644A1 (en) | 2011-06-21 | 2012-12-27 | General Electric Company | Catalyst composition and catalytic reduction system |
KR102321224B1 (ko) * | 2017-07-14 | 2021-11-03 | 아사히 가세이 가부시키가이샤 | 촉매의 제조 방법 및 불포화 니트릴의 제조 방법 |
US11493274B2 (en) * | 2019-12-04 | 2022-11-08 | Greyrock Technology, Llc | Process for the commercial production of high-quality catalyst materials |
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US5785946A (en) | 1994-08-22 | 1998-07-28 | Board Of Trustees Operating Michigan State University | Crystalline inorganic oxide compositions prepared by neutral templating route |
US5840264A (en) | 1994-08-22 | 1998-11-24 | Board Of Trustees Operating Michigan State University | Crystalline inorganic oxide compositions prepared by neutral templating route |
US5622684A (en) | 1995-06-06 | 1997-04-22 | Board Of Trustees Operating Michigan State University | Porous inorganic oxide materials prepared by non-ionic surfactant templating route |
AU7226296A (en) | 1996-10-10 | 1998-05-05 | Massachusetts Institute Of Technology | Compositions and methods for preparing porous metal oxides |
US6027706A (en) | 1998-05-05 | 2000-02-22 | Board Of Trustees Operating Michigan State University | Porous aluminum oxide materials prepared by non-ionic surfactant assembly route |
US6146602A (en) * | 1999-02-08 | 2000-11-14 | Ford Global Technologies, Inc. | Mesoporous oxide molecular sieves for absorbing nitrogen oxides in oxidizing engine exhaust gas |
US6746659B2 (en) | 2000-05-25 | 2004-06-08 | Board Of Trustees Of Michigan State University | Ultrastable porous aluminosilicate structures |
US6585952B1 (en) | 2000-05-25 | 2003-07-01 | Board Of Trustees Operating Michigan State University | Ultrastable hexagonal, cubic and wormhole aluminosilicate mesostructures |
GB0227081D0 (en) | 2002-11-20 | 2002-12-24 | Exxonmobil Res & Eng Co | Methods for preparing catalysts |
US7304011B2 (en) * | 2004-04-15 | 2007-12-04 | W.R. Grace & Co. -Conn. | Compositions and processes for reducing NOx emissions during fluid catalytic cracking |
US7153810B2 (en) * | 2004-06-24 | 2006-12-26 | Caterpillar Inc | Silver doped catalysts for treatment of exhaust |
US7431905B2 (en) * | 2005-10-04 | 2008-10-07 | General Electric Company | Catalyst system and method for the reduction of NOx |
EP1832345A1 (en) * | 2006-03-10 | 2007-09-12 | Asahi Kasei Kabushiki Kaisha | Catalyst for exhaust gas purification |
US8173574B2 (en) * | 2006-09-20 | 2012-05-08 | Basf Corporation | Catalysts to reduce NOx in an exhaust gas stream and methods of preparation |
US8530369B2 (en) * | 2007-09-19 | 2013-09-10 | General Electric Company | Catalyst and method of manufacture |
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CA2726622A1 (en) | 2011-07-06 |
CN102151587A (zh) | 2011-08-17 |
US20110166015A1 (en) | 2011-07-07 |
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