JP6509738B2 - 触媒組成物、触媒物品、並びに大きい粒子の分子ふるいを利用するシステム及び方法 - Google Patents
触媒組成物、触媒物品、並びに大きい粒子の分子ふるいを利用するシステム及び方法 Download PDFInfo
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- JP6509738B2 JP6509738B2 JP2015547557A JP2015547557A JP6509738B2 JP 6509738 B2 JP6509738 B2 JP 6509738B2 JP 2015547557 A JP2015547557 A JP 2015547557A JP 2015547557 A JP2015547557 A JP 2015547557A JP 6509738 B2 JP6509738 B2 JP 6509738B2
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- catalyst
- molecular sieve
- zeolite
- particles
- catalyst composition
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- 239000003054 catalyst Substances 0.000 title claims description 135
- 239000002245 particle Substances 0.000 title claims description 122
- 239000002808 molecular sieve Substances 0.000 title claims description 70
- URGAHOPLAPQHLN-UHFFFAOYSA-N sodium aluminosilicate Chemical compound [Na+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O URGAHOPLAPQHLN-UHFFFAOYSA-N 0.000 title claims description 70
- 239000000203 mixture Substances 0.000 title claims description 40
- 238000000034 method Methods 0.000 title claims description 25
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 claims description 78
- 239000010457 zeolite Substances 0.000 claims description 78
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 claims description 75
- 229910021536 Zeolite Inorganic materials 0.000 claims description 68
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical group [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims description 60
- 229910052751 metal Inorganic materials 0.000 claims description 42
- 239000002184 metal Substances 0.000 claims description 42
- 239000007789 gas Substances 0.000 claims description 34
- 229930195733 hydrocarbon Natural products 0.000 claims description 32
- 150000002430 hydrocarbons Chemical class 0.000 claims description 32
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 claims description 26
- 239000000758 substrate Substances 0.000 claims description 26
- 239000000463 material Substances 0.000 claims description 24
- 230000003197 catalytic effect Effects 0.000 claims description 21
- 230000003647 oxidation Effects 0.000 claims description 21
- 238000007254 oxidation reaction Methods 0.000 claims description 21
- 239000011230 binding agent Substances 0.000 claims description 16
- 238000009826 distribution Methods 0.000 claims description 15
- 239000013078 crystal Substances 0.000 claims description 12
- 229910052697 platinum Inorganic materials 0.000 claims description 12
- -1 silicalite Inorganic materials 0.000 claims description 11
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 claims description 10
- 229910002091 carbon monoxide Inorganic materials 0.000 claims description 10
- 229910052763 palladium Inorganic materials 0.000 claims description 10
- 239000004215 Carbon black (E152) Substances 0.000 claims description 8
- 229910044991 metal oxide Inorganic materials 0.000 claims description 8
- 150000004706 metal oxides Chemical class 0.000 claims description 8
- JYIBXUUINYLWLR-UHFFFAOYSA-N aluminum;calcium;potassium;silicon;sodium;trihydrate Chemical compound O.O.O.[Na].[Al].[Si].[K].[Ca] JYIBXUUINYLWLR-UHFFFAOYSA-N 0.000 claims description 2
- 229910001603 clinoptilolite Inorganic materials 0.000 claims description 2
- 239000012013 faujasite Substances 0.000 claims description 2
- 229910052680 mordenite Inorganic materials 0.000 claims description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 29
- 239000002002 slurry Substances 0.000 description 24
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 20
- 239000010410 layer Substances 0.000 description 14
- 238000006243 chemical reaction Methods 0.000 description 13
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 12
- 238000002485 combustion reaction Methods 0.000 description 11
- 230000004048 modification Effects 0.000 description 11
- 238000012986 modification Methods 0.000 description 11
- 239000000377 silicon dioxide Substances 0.000 description 11
- 230000000052 comparative effect Effects 0.000 description 10
- 238000000576 coating method Methods 0.000 description 9
- 230000003993 interaction Effects 0.000 description 8
- 238000004519 manufacturing process Methods 0.000 description 8
- 238000002360 preparation method Methods 0.000 description 8
- 239000004071 soot Substances 0.000 description 8
- 239000011248 coating agent Substances 0.000 description 7
- 239000000446 fuel Substances 0.000 description 7
- 239000003870 refractory metal Substances 0.000 description 7
- 238000004220 aggregation Methods 0.000 description 6
- 230000002776 aggregation Effects 0.000 description 6
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 description 5
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 description 5
- 239000011247 coating layer Substances 0.000 description 5
- 150000002739 metals Chemical class 0.000 description 5
- 239000011148 porous material Substances 0.000 description 5
- 230000008569 process Effects 0.000 description 5
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- 230000032683 aging Effects 0.000 description 4
- 229910052788 barium Inorganic materials 0.000 description 4
- 239000011575 calcium Substances 0.000 description 4
- 239000003344 environmental pollutant Substances 0.000 description 4
- 239000011777 magnesium Substances 0.000 description 4
- 239000013618 particulate matter Substances 0.000 description 4
- 231100000719 pollutant Toxicity 0.000 description 4
- 239000007921 spray Substances 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 3
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 238000004458 analytical method Methods 0.000 description 3
- 229910052791 calcium Inorganic materials 0.000 description 3
- 239000000919 ceramic Substances 0.000 description 3
- 238000000151 deposition Methods 0.000 description 3
- 239000012530 fluid Substances 0.000 description 3
- 238000002356 laser light scattering Methods 0.000 description 3
- 229910052749 magnesium Inorganic materials 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 230000000737 periodic effect Effects 0.000 description 3
- 229910052761 rare earth metal Inorganic materials 0.000 description 3
- 150000002910 rare earth metals Chemical class 0.000 description 3
- 230000008929 regeneration Effects 0.000 description 3
- 238000011069 regeneration method Methods 0.000 description 3
- 238000001694 spray drying Methods 0.000 description 3
- 229910052712 strontium Inorganic materials 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 229910052684 Cerium Inorganic materials 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 2
- 238000005033 Fourier transform infrared spectroscopy Methods 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229910052779 Neodymium Inorganic materials 0.000 description 2
- 229910019142 PO4 Inorganic materials 0.000 description 2
- 229910052777 Praseodymium Inorganic materials 0.000 description 2
- 238000002441 X-ray diffraction Methods 0.000 description 2
- 239000003463 adsorbent Substances 0.000 description 2
- 229910052783 alkali metal Inorganic materials 0.000 description 2
- 150000001340 alkali metals Chemical class 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 2
- 238000001354 calcination Methods 0.000 description 2
- 239000000969 carrier Substances 0.000 description 2
- 229910052804 chromium Inorganic materials 0.000 description 2
- 239000011651 chromium Substances 0.000 description 2
- 229910052878 cordierite Inorganic materials 0.000 description 2
- DIOQZVSQGTUSAI-UHFFFAOYSA-N decane Chemical compound CCCCCCCCCC DIOQZVSQGTUSAI-UHFFFAOYSA-N 0.000 description 2
- 230000008021 deposition Effects 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
- 239000002355 dual-layer Substances 0.000 description 2
- 238000002149 energy-dispersive X-ray emission spectroscopy Methods 0.000 description 2
- 229910052746 lanthanum Inorganic materials 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 229910001092 metal group alloy Inorganic materials 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 238000003921 particle size analysis Methods 0.000 description 2
- 235000021317 phosphate Nutrition 0.000 description 2
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 229910052703 rhodium Inorganic materials 0.000 description 2
- 239000010948 rhodium Substances 0.000 description 2
- 238000001878 scanning electron micrograph Methods 0.000 description 2
- 239000011734 sodium Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 239000002594 sorbent Substances 0.000 description 2
- 238000011144 upstream manufacturing Methods 0.000 description 2
- 229910052845 zircon Inorganic materials 0.000 description 2
- MGWGWNFMUOTEHG-UHFFFAOYSA-N 4-(3,5-dimethylphenyl)-1,3-thiazol-2-amine Chemical compound CC1=CC(C)=CC(C=2N=C(N)SC=2)=C1 MGWGWNFMUOTEHG-UHFFFAOYSA-N 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004593 Epoxy Substances 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
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 229910002089 NOx Inorganic materials 0.000 description 1
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- 229910052772 Samarium Inorganic materials 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- 229910052769 Ytterbium Inorganic materials 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 229910000287 alkaline earth metal oxide Inorganic materials 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- HEHRHMRHPUNLIR-UHFFFAOYSA-N aluminum;hydroxy-[hydroxy(oxo)silyl]oxy-oxosilane;lithium Chemical compound [Li].[Al].O[Si](=O)O[Si](O)=O.O[Si](=O)O[Si](O)=O HEHRHMRHPUNLIR-UHFFFAOYSA-N 0.000 description 1
- CNLWCVNCHLKFHK-UHFFFAOYSA-N aluminum;lithium;dioxido(oxo)silane Chemical compound [Li+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O CNLWCVNCHLKFHK-UHFFFAOYSA-N 0.000 description 1
- 239000003125 aqueous solvent Substances 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 239000010953 base metal Substances 0.000 description 1
- 229910052790 beryllium Inorganic materials 0.000 description 1
- ATBAMAFKBVZNFJ-UHFFFAOYSA-N beryllium atom Chemical compound [Be] ATBAMAFKBVZNFJ-UHFFFAOYSA-N 0.000 description 1
- 230000027455 binding Effects 0.000 description 1
- 238000009739 binding Methods 0.000 description 1
- 229910052792 caesium Inorganic materials 0.000 description 1
- TVFDJXOCXUVLDH-UHFFFAOYSA-N caesium atom Chemical compound [Cs] TVFDJXOCXUVLDH-UHFFFAOYSA-N 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- ZMIGMASIKSOYAM-UHFFFAOYSA-N cerium Chemical compound [Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce][Ce] ZMIGMASIKSOYAM-UHFFFAOYSA-N 0.000 description 1
- 229910000420 cerium oxide Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 229910052729 chemical element Inorganic materials 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
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- 239000008367 deionised water Substances 0.000 description 1
- 229910021641 deionized water Inorganic materials 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 239000002283 diesel fuel Substances 0.000 description 1
- 238000007865 diluting Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 230000003311 flocculating effect Effects 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 229910052730 francium Inorganic materials 0.000 description 1
- KLMCZVJOEAUDNE-UHFFFAOYSA-N francium atom Chemical compound [Fr] KLMCZVJOEAUDNE-UHFFFAOYSA-N 0.000 description 1
- 238000010191 image analysis Methods 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 150000002603 lanthanum Chemical class 0.000 description 1
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- HCWCAKKEBCNQJP-UHFFFAOYSA-N magnesium orthosilicate Chemical compound [Mg+2].[Mg+2].[O-][Si]([O-])([O-])[O-] HCWCAKKEBCNQJP-UHFFFAOYSA-N 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- 239000000391 magnesium silicate Substances 0.000 description 1
- 229910052919 magnesium silicate Inorganic materials 0.000 description 1
- 235000019792 magnesium silicate Nutrition 0.000 description 1
- 238000001465 metallisation Methods 0.000 description 1
- 239000013081 microcrystal Substances 0.000 description 1
- 238000000386 microscopy Methods 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 239000003595 mist Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 1
- 229910017604 nitric acid Inorganic materials 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- JCXJVPUVTGWSNB-UHFFFAOYSA-N nitrogen dioxide Inorganic materials O=[N]=O JCXJVPUVTGWSNB-UHFFFAOYSA-N 0.000 description 1
- 229910000510 noble metal Inorganic materials 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- GPNDARIEYHPYAY-UHFFFAOYSA-N palladium(ii) nitrate Chemical compound [Pd+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O GPNDARIEYHPYAY-UHFFFAOYSA-N 0.000 description 1
- 229910052670 petalite Inorganic materials 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 1
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
- 238000000746 purification Methods 0.000 description 1
- 229910052705 radium Inorganic materials 0.000 description 1
- HCWPIIXVSYCSAN-UHFFFAOYSA-N radium atom Chemical compound [Ra] HCWPIIXVSYCSAN-UHFFFAOYSA-N 0.000 description 1
- 229910001404 rare earth metal oxide Inorganic materials 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000011819 refractory material Substances 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 1
- 229910052701 rubidium Inorganic materials 0.000 description 1
- IGLNJRXAVVLDKE-UHFFFAOYSA-N rubidium atom Chemical compound [Rb] IGLNJRXAVVLDKE-UHFFFAOYSA-N 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 229910052851 sillimanite Inorganic materials 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000008247 solid mixture Substances 0.000 description 1
- 238000001179 sorption measurement Methods 0.000 description 1
- 229910052642 spodumene Inorganic materials 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 description 1
- 230000001052 transient effect Effects 0.000 description 1
Images
Classifications
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- 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
- B01J29/70—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65
- B01J29/72—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65 containing iron group metals, noble metals or copper
- B01J29/74—Noble metals
- B01J29/7415—Zeolite Beta
-
- 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
-
- 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
- B01D53/944—Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts
-
- 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
- B01D53/9445—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
- B01D53/945—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] 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
- 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
- B01J23/42—Platinum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
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Description
希薄状態(捕捉モード):
2NO + O2 → 2NO2 (1)
4NO2 + 2MCO3 + O2 →2M(NO3)2 + 2CO2 (2)
リッチ状態(再生モード):
M(NO3)2 + 2 CO → MCO3 + NO2 + NO + CO2 (3)
NO2 + CO → NO + CO2 (4)
2 NO + 2 CO → N2 + 2 CO2 (5)
2 NO + 2 H2 → N2 + 2 H2O (6)
流体入口から流体出口までの基本的に直線的な通り道である流路は、流路を通って流れる気体が触媒物質に接触するように、触媒物質がウォッシュコートとして被覆された壁によって定義される。モノリス基材の流路は、薄肉の導管であり、それは、どんな好適な断面の形状及び大きさ、例えば、台形型、長方形型、正方形型、正弦型、六角形型、楕円型、円形等も可能である。そのような構造は、断面平方インチ当たり、約60〜約900、又はそれ以上の気体注入口(すなわち、セル))を有してもよい。
BET表面積が約150m2/g、細孔容積が約0.85cc/g、平均細孔半径が約100Åである高表面積ガンマアルミナを、標準的な初期湿潤法(incipient wetness techniques)を使用して硝酸パラジウム溶液に含浸した。厚いペーストを形成するための追加のDI水(脱イオン水)を加えた後に、白金“A”溶液を加えた。さらに、DI水で希釈し、硝酸を加えることでpHを4に減少させた後に、生成したスラリーを技術において公知の方法を使用して粒径90%を約20μm未満に粉砕した。商業的サプライヤから入手した高いシリカ対アルミナ比を有するベータゼオライト(ゼオライトA)を、その後、混合物中に分散させる。最後のスラリーを、この技術分野において公知の堆積方法を使用して、1“3による直径”の長いコージェライト基材上に被覆させる。被覆されたモノリスを、120℃で乾燥させ、450℃で空気中で1時間焼成させる。焼成後の合計ウォッシュコート堆積量は、ベータゼオライト0.5g/in3(0.5g/1.6387× 10−5 m3)を含む約2.0g/in3(2.0g/1.6387× 10−5 m3)であった。白金族金属の堆積物の合計は、Pt/Pd質量比が2:1である80g/ft3(80g/2.8317×10−2m2)である。
ゼオライトAのように名目上同じ組成であるが、異なる粒径分布を有する同一のサプライヤから得られる高いシリカ:アルミナ比のベータゼオライトを使用した(ゼオライトB)ことを除き、触媒Bを触媒Aと同様に製造した。
触媒Bを、触媒Aと同様に製造した。ゼオライトAのための、希釈水溶性スラリー中のレーザー光散乱法(Sympatec Quixel製、HD23型)による粒径測定では、以下の粒子分布:14%<1μm及び52%<2μm(d50=2μm)を示した。対照的に、ゼオライトBは、以下の粒子分布を有する:4%<1μm及び15%<2μm(d50=5μm)。明らかに、ゼオライトAは、2μm未満の小さい粒子のより大きな粒子を有し、実際には、非常に多くのサブミクロン粒子を有していた(図.1参照)。異なる粒径のゼオライトパウダーA及びBを示す比較のSEM写真は、図2及び3で示す。
10%のセリア結合剤(ゼオライトC)を使用するより大きな粒径にする噴霧乾燥による凝集後であるが、同一の、高いシリカ対アルミナ比を有するベータゼオライト(ゼオライトA)を使用して触媒Cを触媒Aと同様に製造した。ゼオライトCのための、希釈水溶性スラリー中のレーザー光散乱法(Sympatec Quixel製、HD23型)による粒径測定では、以下の粒子分布:0.7%<1μm、1.5%<2μm、4.1%<5μm及び10%<11μm(d50=22μm)を示した。ゼオライトA、B及びCのための粒径分布プロットのまとめを図4に示す。ゼオライトA及びBと比較して、ゼオライトCの粒径は非常に大きい。噴霧乾燥されたゼオライト粉末Cの大きな粒径を示すSEM写真を図5に示す。
触媒Dを、ゼオライトBとCの間の粒径分布を有する、異なる高いシリカ対アルミナの比を有するベータゼオライト(ゼオライトD)を使用した点を除いて、触媒Aと同様に製造した。ゼオライトDのための、希釈水溶性スラリー中のレーザー光散乱法(Sympatec Quixel製、HD23型)による粒径測定では、以下の粒子分布:0.5%<1μm、12%<3μm、及び27%<4.5μm(d50=7μm)を示した。ゼオライトB、C及びDのための粒径分布プロットのまとめを図6に示す。ゼオライトDは、ゼオライトBよりも大きい粒径分布を有するが、ゼオライトCより小さい。
SEM画像は、ウォッシュコートされた触媒A,C及びDから得られた(図7〜9)。被覆されたコアをエポキシ中に固定し、その後、モノリスを通るガス流の方向に対して垂直に切断することで、断面に、ウォッシュコートされた導管を露出させた。1μmより小さい粒子の大きなフラクションを有するゼオライトを使用した比較触媒Aのために、ウォッシュコート中の個々のゼオライト粒子を特定することは困難である。しかし、噴霧乾燥されたゼオライトを使用した触媒D、及び、特に触媒Cにとって、ゼオライト粒子がはっきりと見える(図8及び9)。
触媒Eを、2種の異なるスラリーを使用して2つの異なる層において触媒を被覆することを除いて実施例1で記載された工程に類似する工程によって製造した。トップ層を被覆するために使用されるスラリーは、Pt、Pd、アルミナ及びゼオライトA、触媒Aを製造するために使用される同一の小さい粒径のゼオライトを含有していたのに対し、ボトム層を被覆するために使用されるスラリーは、Pt、Pd及びアルミナのみ含んでいた。ボトム層における白金族金属の堆積量は、2:1のPt/Pd質量比で、53g/ft3(53g/2.8317×10−2m2)であった。同一の2:1のPt/Pd質量比がゼオライトともにトップ層で使用されたが、27g/ft3(27g/2.8317×10−2m2)の低い堆積量である。合計白金族金属堆積量は2:1のPt/Pd質量比を有する80g/ft3(80g/2.8317×10−2m2)であった。焼成後の合計ウォッシュコート堆積量は、ベータゼオライトをトップ層に0.5g/in3(0.5g/1.6387× 10−5 m3)含む約2.6g/in3(2.6g/1.6387× 10−5 m3)である。
触媒Fを噴霧乾燥ゼオライトCをゼオライトAの代わりに使用したことを除いて触媒Eと同様に製造した。
実施例1〜7で製造された被覆されたPt/Pd触媒モノリス組成物を以下のように試験した。最初に、被覆されたモノリスを25時間750℃でディーゼルエンジン排気流中で老化(age)させた。排気流の温度を、上流のバーナーDOC上で噴射されたディーゼル燃料を燃焼させることで750℃まで上昇させた。エージング後に、徐々に温度が上昇する間に、小さな試料の上をシミュレートされたディーゼルエンジン排気を通過させることのできる実験室用の反応システムを使用して、被覆されたモノリスについて一酸化炭素(CO)の着火(LO)のための評価をした。ガス流組成物は、COを1600ppm、C1基(basis)上の合計炭化水素を550ppm(プロピレン250ppm、デカン150ppm及びトルエン150ppm)、O210%、NO100ppm、CO24.5%、H2O4%、及び平衡窒素を含有する。試験の試料を15℃/分のランプ率で315℃にランピングする前に、100℃で流れるガスの下で、2〜3分間平衡させた。総ガス流空間速度は、70000h−1であった。触媒アウトレット(outlet)CO濃度を、フーリエ変換赤外(FTIR)分析器を使用して測定し、CO変換を温度の関数として計算した。発生したCOの50%変換時の温度を表1の触媒A〜Fにまとめた。
750℃のエンジンエージングの後、小さな粒径のゼオライトAを使用した単層の比較触媒Aを参照するためのCOLO温度は、全て、大きな粒径を有するゼオライトを使用した触媒B、C及びDよりも6〜9℃高かった。同様に、小さな粒径のゼオライトAを使用した2重層の比較触媒Eを参照するためのCOLO温度は、噴霧乾燥ゼオライトCを使用した触媒Fよりも4℃高かった。明らかに、小さな粒径を有するベータゼオライトの使用は、非常に高いCOLO温度と悪いパフォーマンスという結果になった。
触媒A、C、E及びFを、また、車両の過渡挙動をシミュレートするために設計された実験反応器上でCO及びHC変換性能のために評価した。より具体的には、反応器は、特定の認可ドライブサイクルの下で運転する時のディーゼル車両の排気ガス流、排出量及び温度をシミュレートするために設計された。表2は、新しい排出ドライブサイクル(NEDC)を使用して試験したときのそれぞれの触媒のためのCO及びHC排出量をまとめている。総CO及びHC排出量は、それぞれ、1.03g/km/L‐cat及び0.27g/km/L‐catであったのに対し、この試験のための平均NEDC排気温度は163℃であった。750℃のエンジンエージングの後、噴霧乾燥された(大きい粒径の)ゼオライトCで製造された単層の触媒CのためのCO及びHC変換は、小さな粒径のゼオライトAで製造された比較触媒AのCO及びHC変換よりも少なくとも5%高かった。同様に、ゼオライトCを含む二重層の触媒FのためのCO及びHC変換は、ゼオライトAで製造された比較触媒Eよりも4%高かった。明らかに、大きな粒径を有するベータゼオライトの使用は、非常に高い触媒能力を示す結果となった。
Claims (14)
- 窒素酸化物、ハイドロカーボン及び一酸化炭素を含有するガスの処理用の触媒組成物であって、
ウォッシュコートを含み、
当該ウォッシュコートは、耐熱性金属酸化物担体上に担持された白金族金属と、分子ふるい粒子と、を含有し、
90%を超える前記分子ふるい粒子が1μmより大きい粒径及び50μm未満のd50を有し、
前記分子ふるい粒子が一次結晶の凝集体であり、
前記分子ふるい粒子の90%を超える粒子が、1μmより大きいサイズを有する一次結晶を有することを特徴とする触媒組成物。 - 前記白金族金属の一部が、分子ふるい粒子上に担持されていることを特徴とする請求項1に記載の触媒組成物。
- 95%を超える前記分子ふるい粒子が、1μmより大きい粒径を有することを特徴とする請求項1又は2に記載の触媒組成物。
- 前記分子ふるい粒子が、結合剤と混合された噴霧乾燥粒子であることを特徴とする請求項1〜3の何れか一項に記載の触媒組成物。
- 前記白金族金属が、白金及びパラジウムを含有することを特徴とする請求項1〜4の何れか一項に記載の触媒組成物。
- 96%を超える前記分子ふるい粒子が、1μmより大きい粒径を有することを特徴とする請求項1〜5のいずれか1項に記載の触媒組成物。
- 前記分子ふるい粒子成分が、1μmより大きい粒子を96%及び、2μmより大きい粒子を95%含有することを特徴とする請求項1〜6の何れか一項に記載の触媒組成物。
- 前記分子ふるい粒子成分が、1μm〜10μmの範囲にある粒子を96%含有することを特徴とする請求項1〜7の何れか一項に記載の触媒組成物。
- 前記分子ふるい粒子が、フォージャサイト、チャバサイト、クリノプチロライト、モルデナイト、シリカライト、ゼオライトX、ゼオライトY、超安定ゼオライトY、ZSM−5、ZSM−12、SSZ−13、SAPO−5、SAPO−37、オフレタイト、ベータゼオライト及びそれらの組み合わせからなる群から選択されるゼオライトであることを特徴とする請求項1〜8の何れか一項に記載の触媒組成物。
- 前記ゼオライトが、H−ベータであることを特徴とする請求項9に記載の触媒組成物。
- 前記ゼオライトが、モノモーダルな粒径分布を有することを特徴とする請求項9又は10に記載の触媒組成物。
- ハイドロカーボン、一酸化炭素及び、窒素酸化物を含有するリーンバーンエンジンからの排気ガス処理用の触媒物品であって、長さ、入口端及び出口端を有する担体基材と、該担体上の酸化触媒物質を有し、前記酸化触媒物質は、請求項1〜11の何れか一項に記載の前記触媒組成物を含有することを特徴とする触媒物品。
- 前記物品が、LNT、DOC及びCSFからなる群から選択されることを特徴とする請求項12に記載の触媒物品。
- 前記排気ガスを、請求項12又は13に記載の触媒物品上を流す工程を有することを特徴とするハイドロカーボン、一酸化炭素及び窒素酸化物を含有するリーンバーンエンジンからの排気ガスの処理方法。
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201261736387P | 2012-12-12 | 2012-12-12 | |
US61/736,387 | 2012-12-12 | ||
PCT/US2013/074750 WO2014093666A1 (en) | 2012-12-12 | 2013-12-12 | Catalyst compositions, catalytic articles, systems and processes using large particle molecular sieves |
US14/104,716 US9321042B2 (en) | 2012-12-12 | 2013-12-12 | Catalyst compositions, catalytic articles, systems and processes using large particle molecular sieves |
US14/104,716 | 2013-12-12 |
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EP2931423B1 (en) | 2021-10-27 |
JP2016506294A (ja) | 2016-03-03 |
CA2892683A1 (en) | 2014-06-19 |
PL2931423T3 (pl) | 2022-01-31 |
CN104837557B (zh) | 2018-06-01 |
US9321042B2 (en) | 2016-04-26 |
EP2931423A1 (en) | 2015-10-21 |
WO2014093666A1 (en) | 2014-06-19 |
US20140170043A1 (en) | 2014-06-19 |
KR20150093693A (ko) | 2015-08-18 |
KR102194065B1 (ko) | 2020-12-22 |
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