JP6379166B2 - 触媒すすフィルタの製造およびシステム - Google Patents
触媒すすフィルタの製造およびシステム Download PDFInfo
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- JP6379166B2 JP6379166B2 JP2016240090A JP2016240090A JP6379166B2 JP 6379166 B2 JP6379166 B2 JP 6379166B2 JP 2016240090 A JP2016240090 A JP 2016240090A JP 2016240090 A JP2016240090 A JP 2016240090A JP 6379166 B2 JP6379166 B2 JP 6379166B2
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- Prior art keywords
- soot filter
- particles
- wall flow
- slurry
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 10
- 229910000505 Al2TiO5 Inorganic materials 0.000 claims description 8
- 229910000510 noble metal Inorganic materials 0.000 claims description 8
- 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 claims description 8
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 claims description 6
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- QQONPFPTGQHPMA-UHFFFAOYSA-N Propene Chemical compound CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 claims description 4
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- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 1
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- 238000005839 oxidative dehydrogenation reaction Methods 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
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- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
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- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 1
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- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
- B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
- B01J23/44—Palladium
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2330/00—Structure of catalyst support or particle filter
- F01N2330/06—Ceramic, e.g. monoliths
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2510/00—Surface coverings
- F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction
- F01N2510/065—Surface coverings for exhaust purification, e.g. catalytic reaction for reducing soot ignition temperature
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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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
-
- 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
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49345—Catalytic device making
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- Oil, Petroleum & Natural Gas (AREA)
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- Exhaust Gas Treatment By Means Of Catalyst (AREA)
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- Exhaust Gas After Treatment (AREA)
Description
下記試料のためのフィルタ基板は、14〜15μmの間の平均粒径の51%の空隙率、300cpsi、および、13ミルの壁厚を有するチタン酸アルミニウムでできている。当該基板は周囲2インチ×6インチの寸法を有する。
当該参照例触媒は下記の組成を有する:33.3g/ft3のPt、16.7g/ft3のPd、0.5g/in3のSiralox1.5/100(Al2O3上に1.5%のSi)、および0.1g/in3のβ沸石。当該組成は当該フィルタの全長にわたって同一である。
この実施例のために、D90<4μmを有するCe/Zr合成物を用いた。その粒径をさらに減少させることなくそのCe/Zr粉末を用いた。実施例Aと同様の方法でそのスラリーをウォッシュコートした。
この実施例のために、D90<13μmを有するZSM−5のアンモニウム形態(0.3g/in3)を用いた。その粒径をさらに減少させることなくその沸石粉末を用いた。実施例Aと同様の方法でそのスラリーをウォッシュコートした。
この実施例のために、D90<5μmに粉砕したSiralox1.5粉末(0.1g/in3)を用いた。実施例Aと同様の方法でそのスラリーをウォッシュコートした。
この実施例のために、Siralox1.5粉末(0.3g/in3)を用いた。粉砕する前に酒石酸を添加しながら、その粉末をD90<6μmに粉砕した。その入口側と出口側の両方からそのスラリーをウォッシュコートし、合計0.3g/in3のウォッシュコート荷重を得た。
D90<7μmを有する、ジェットミルにより粉砕したアルミナ粉末を用いた。このアルミナ粉末を連続粉砕機内でさらにD90<5μmに粉砕した。その入口側からそのスラリーを被覆し、0.40g/in3のウォッシュコートを得た。
D90<7μmを有するジェットミルにより粉砕したアルミナ粉末を、機械的に3つの切片にさらに分類した:細かい切片(実施例G)、中間の切片(実施例H)、および粗い切片(実施例I)。その粒径分布(PSD)を図5に示す。細かい粉末である実施例Gは、10%の約1.1μm未満の大きさを有する粒子(90%が1.1μm超過)を有する。中間の粉末である実施例Hは、10%の約1.7μm未満の大きさを有する粒子(90%が1.7μm超過)を有する。粗い粉末である実施例Iは、10%の約2.0μm未満の大きさを有する粒子(つまり、90%が2.0μm超過)を有する。
テトラモノエタノールアミン水酸化白金溶液を、遊星混合器中で初期湿潤法によってSiralox粉末上に浸透させた。酢酸(粉末と比較して5重量%)をその粉末に添加した。その後、その貴金属が浸透した粉末を水中に分散させてスラリーを作成した。連続粉砕機を用いてこのスラリーを粉砕し、その粒径を90%4μm未満に減少させた(D90<4μm)。粉砕の完了前に、Ce/Zr粉末をそのスラリーに添加した。その後、その基板の入口側を下に向け、その出口側をそのスラリー面の真上(約1/4インチ)に向けた状態でフィルタ基板をそのスラリー中に含浸させることによって、そのスラリーをウォッシュコートした。その基板をそのスラリーから取り出し、ウォッシュコートスラリーが全く出てこなくなるまで、その出口側から空気流を流した。その後、その被覆した試料を110℃で2時間乾燥し、450℃で2時間空気中にて焼成した。同一のスラリーで3種類の基板を被覆し、下記の触媒組成を得た:5g/ft3、0.2g/in3のSiralox、0.1g/in3のCe/Zr。3種類の基板の特性を表1に記載する。
当該被覆のために乾式粉砕したアルミナ粉末を用いた。このアルミナ粉末は下記の粒径分布(PSD)を有する:90%の粒子が5μm未満であり、90%の粒子が1.1μmより大きい。湿式粉砕したスラリー(実施例J〜Lから)と、乾式粉砕アルミナ(本実施例)との間のPSD比較を図7で図示する。
試料PおよびQのための触媒ウォッシュコートは、同量の貴金属(50g/ft3、Pt/Pd=2:1)および卑金属成分(0.4g/in3の担持体、0.1g/in3のβ沸石)を含む。同種のフィルタ基板(SiC、空隙率50%、平均粒径=20μm、300cpsi、壁厚12ミル)上に両試料を被覆した。しかしながら、異なる方法によってそのウォッシュコートスラリーを作成した。試料Aと同一の方法によって試料Pを作成した。試料Mと同一の方法によって試料Qを作成した。
Claims (11)
- 壁流モノリスと該壁流モノリスの壁の内部に配置されたウォッシュコートを含む触媒すすフィルタであって、
前記壁流モノリスは、複数の縦方向に延びる流路を有し、且つこの流路は、当該流路を拘束および画定する縦方向に延びる壁によって形成されており、前記流路が、開いた入口端および閉じた出口端を有する入口流路と、閉じた入口端および開いた出口端を有する出口流路とを備え、そして前記壁流モノリスが、0.4μm未満の平均幅を有する微小亀裂と、10〜25μmの範囲内の平均孔径を有する細孔とを含み、
前記ウォッシュコートが、予め少なくとも1種の貴金属が含浸されている担持粒子を含む触媒を含み、且つ、前記担持粒子の合計個数に対し、前記担持粒子の少なくとも90%が前記微小亀裂の平均の大きさより大きい粒径を有し、前記担持粒子の少なくとも90%が前記壁流モノリスの平均孔径より小さい粒径を有し、及び7.5μm未満であることを特徴とする触媒すすフィルタ。 - 前記担持粒子の合計個数に対し、前記担持粒子の少なくとも90%が5μm未満であることを特徴とする請求項1に記載の触媒すすフィルタ。
- 前記担持粒子の合計個数に対し、前記担持粒子の90%の大きさが0.5μmより大きい、請求項1又は2に記載の触媒すすフィルタ。
- 前記担持粒子の合計個数に対し、前記担持粒子の90%の大きさが1μmより大きい、請求項1又は2に記載の触媒すすフィルタ。
- 前記担持粒子の合計個数に対し、前記担持粒子の60%超過の大きさが1〜5μmである、請求項1又は2に記載の触媒すすフィルタ。
- 前記担持粒子が、アルミニウム化合物、ジルコニウム化合物、セリウム化合物、ゼオライト、ケイ素化合物、卑金属酸化物、およびこれらの混合物から成る群から選択される、請求項1又は2に記載の触媒すすフィルタ。
- 前記壁流モノリスが、40〜70体積%の範囲内の空隙率を有するチタン酸アルミニウムを含む、請求項1又は2に記載の触媒すすフィルタ。
- 前記すすフィルタが、1,000℃で測定される場合、25×10−7/℃未満の熱膨張係数を示す、請求項1又は2に記載の触媒すすフィルタ。
- 前記すすフィルタが、800℃で測定される場合、5×10−7/℃未満の熱膨張係数を示す、請求項8に記載の触媒すすフィルタ。
- 前記フィルタを、空気および10体積%の蒸気を流しながら装置内にて700℃で4時間熟成し、その後800℃でさらに4時間熟成し、1,000ppmのCO、C1基準で450ppmの炭化水素、100ppmのNO、10体積%のO2、7体積%の水、5体積%のCO2を含む供給物を有する、供給物の残部をN2で補った流反応器システムにおいて試験し、前記炭化水素の構成が、C1基準で、等しい割合のプロペン、トルエン、およびデカンであり、前記試験が、前記フィルタを前記供給物の気体で90℃にて90秒間飽和させ、その後、前記温度を20℃/分の割合で300℃まで増加させる工程の後に行われる場合において、前記フィルタが炭化水素に関して180℃未満のT70温度を示す、請求項1又は2に記載の触媒すすフィルタ。
- 請求項1に記載の触媒すすフィルタを製造するための方法であって、以下の工程、
i)少なくとも1種の貴金属を、初期湿潤法を使用して担持粒子に含浸させる工程、
ii)工程i)で得られた担体粒子を溶媒に分散させてスラリーを作成する工程、
iii)工程ii)で得られたスラリーを壁流モノリスの壁に施す工程、
を含むことを特徴とする方法。
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US11/959,090 US8114354B2 (en) | 2007-12-18 | 2007-12-18 | Catalyzed soot filter manufacture and systems |
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US12/336,070 US8038956B2 (en) | 2007-12-18 | 2008-12-16 | Catalyzed soot filter manufacture and systems |
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US8038956B2 (en) | 2011-10-18 |
CN101970088A (zh) | 2011-02-09 |
US20090155135A1 (en) | 2009-06-18 |
US20090155134A1 (en) | 2009-06-18 |
CA2708235A1 (en) | 2009-06-25 |
KR101629034B1 (ko) | 2016-06-09 |
JP2011506095A (ja) | 2011-03-03 |
JP2015157285A (ja) | 2015-09-03 |
JP2017121624A (ja) | 2017-07-13 |
US8114354B2 (en) | 2012-02-14 |
EP2240259A1 (en) | 2010-10-20 |
CN101970088B (zh) | 2013-10-16 |
ZA201005017B (en) | 2011-09-28 |
BRPI0820724A2 (pt) | 2015-06-16 |
KR20100106497A (ko) | 2010-10-01 |
WO2009079590A1 (en) | 2009-06-25 |
CA2708235C (en) | 2016-06-21 |
MY152756A (en) | 2014-11-28 |
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