JP6577895B2 - ハニカム構造体 - Google Patents
ハニカム構造体 Download PDFInfo
- Publication number
- JP6577895B2 JP6577895B2 JP2016068417A JP2016068417A JP6577895B2 JP 6577895 B2 JP6577895 B2 JP 6577895B2 JP 2016068417 A JP2016068417 A JP 2016068417A JP 2016068417 A JP2016068417 A JP 2016068417A JP 6577895 B2 JP6577895 B2 JP 6577895B2
- Authority
- JP
- Japan
- Prior art keywords
- honeycomb structure
- oxidation catalyst
- exhaust gas
- catalyst
- cell
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 239000003054 catalyst Substances 0.000 claims description 102
- 238000005192 partition Methods 0.000 claims description 58
- 230000003647 oxidation Effects 0.000 claims description 53
- 238000007254 oxidation reaction Methods 0.000 claims description 53
- 229910000314 transition metal oxide Inorganic materials 0.000 claims description 28
- 238000006243 chemical reaction Methods 0.000 claims description 25
- 239000002245 particle Substances 0.000 claims description 25
- 239000011148 porous material Substances 0.000 claims description 23
- 229910020599 Co 3 O 4 Inorganic materials 0.000 claims description 8
- 238000011068 loading method Methods 0.000 claims description 2
- 210000004027 cell Anatomy 0.000 description 70
- 239000007789 gas Substances 0.000 description 62
- 230000003197 catalytic effect Effects 0.000 description 37
- 239000004202 carbamide Substances 0.000 description 20
- 238000000034 method Methods 0.000 description 20
- XSQUKJJJFZCRTK-UHFFFAOYSA-N urea group Chemical group NC(=O)N XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 20
- 238000000746 purification Methods 0.000 description 19
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 16
- 239000002002 slurry Substances 0.000 description 16
- 239000004071 soot Substances 0.000 description 16
- 239000002994 raw material Substances 0.000 description 15
- 239000000463 material Substances 0.000 description 12
- 239000013618 particulate matter Substances 0.000 description 11
- 238000011144 upstream manufacturing Methods 0.000 description 11
- 238000002485 combustion reaction Methods 0.000 description 10
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 9
- 229910002091 carbon monoxide Inorganic materials 0.000 description 9
- 229910021529 ammonia Inorganic materials 0.000 description 8
- 238000010304 firing Methods 0.000 description 8
- 239000011230 binding agent Substances 0.000 description 7
- 230000000052 comparative effect Effects 0.000 description 7
- 238000005259 measurement Methods 0.000 description 6
- 239000000919 ceramic Substances 0.000 description 5
- 239000004927 clay Substances 0.000 description 5
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 5
- 230000000007 visual effect Effects 0.000 description 5
- 229910052878 cordierite Inorganic materials 0.000 description 4
- 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 4
- 238000001035 drying Methods 0.000 description 4
- 239000012530 fluid Substances 0.000 description 4
- 229930195733 hydrocarbon Natural products 0.000 description 4
- 150000002430 hydrocarbons Chemical class 0.000 description 4
- 229910000510 noble metal Inorganic materials 0.000 description 4
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- 238000001878 scanning electron micrograph Methods 0.000 description 4
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
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- 239000013078 crystal Substances 0.000 description 3
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- 230000001590 oxidative effect Effects 0.000 description 3
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- 229910010271 silicon carbide Inorganic materials 0.000 description 3
- 239000011800 void material Substances 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 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 2
- 238000001354 calcination Methods 0.000 description 2
- 238000005238 degreasing Methods 0.000 description 2
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- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 2
- 229910052753 mercury Inorganic materials 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
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- 230000002093 peripheral effect Effects 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 239000010970 precious metal Substances 0.000 description 2
- 230000001737 promoting effect Effects 0.000 description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
- 229910052723 transition metal Inorganic materials 0.000 description 2
- 150000003624 transition metals Chemical class 0.000 description 2
- 239000002912 waste gas Substances 0.000 description 2
- 229910000505 Al2TiO5 Inorganic materials 0.000 description 1
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 238000007088 Archimedes method Methods 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000010531 catalytic reduction reaction Methods 0.000 description 1
- 210000002421 cell wall Anatomy 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 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
- 239000002612 dispersion medium Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 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 1
- 238000007561 laser diffraction method Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229920000609 methyl cellulose Polymers 0.000 description 1
- 239000001923 methylcellulose Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000005416 organic matter Substances 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 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 description 1
- 230000005855 radiation Effects 0.000 description 1
- 238000006722 reduction reaction Methods 0.000 description 1
- 230000008929 regeneration Effects 0.000 description 1
- 238000011069 regeneration method Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- SBEQWOXEGHQIMW-UHFFFAOYSA-N silicon Chemical compound [Si].[Si] SBEQWOXEGHQIMW-UHFFFAOYSA-N 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 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
- 238000005245 sintering Methods 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 238000001291 vacuum drying Methods 0.000 description 1
- 238000009777 vacuum freeze-drying Methods 0.000 description 1
Images
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- 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
- B01D53/9404—Removing only nitrogen compounds
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01J37/02—Impregnation, coating or precipitation
- B01J37/0215—Coating
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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
- F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
- F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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- F01N2330/00—Structure of catalyst support or particle filter
- F01N2330/02—Metallic plates or honeycombs, e.g. superposed or rolled-up corrugated or otherwise deformed sheet metal
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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- F01N2330/00—Structure of catalyst support or particle filter
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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- F01N2370/00—Selection of materials for exhaust purification
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F01N2570/00—Exhaust treating apparatus eliminating, absorbing or adsorbing specific elements or compounds
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F01N2610/00—Adding substances to exhaust gases
- F01N2610/14—Arrangements for the supply of substances, e.g. conduits
- F01N2610/1453—Sprayers or atomisers; Arrangement thereof in the exhaust apparatus
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- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
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Description
本発明のハニカム構造体の一実施形態を、図1、及び図2に示す。図1は、ハニカム構造体1を模式的に示す斜視図である。図2は、ハニカム構造体1のセル3の延びる方向に平行な断面を模式的に示す断面図である。ハニカム構造体1は、多数の細孔を有する多孔質の隔壁4を有し、隔壁4によって排ガスの流路となる複数のセル3が区画形成されたハニカム構造部10と、複数のセル3の排ガスの流入側となる一方の開口端部と排ガスの流出側となる他方の開口端部とを互い違いに目封止する目封止部8と、を備える。複数のセル3は、流入側の開口端部が開口した流入セル3aと、流出側の開口端部が開口した流出セル3bとから構成されている。目封止部8は、所定のセル3の流入端面2a側に配設された流入側目封止部8aと、残余のセル3の流出端面2b側に配設された流出側目封止部8bを含む。
隔壁4の厚さは、50〜500μmであることが好ましく、100〜450μmであることが更に好ましく、150〜450μmであることが特に好ましい。隔壁4の厚さが下限値以上であると、強度が十分である。上限値以下であると、圧力損失を抑制することができる。
ハニカム構造体1は、流入側目封止部8aと流出側目封止部8bとを備えている。これらの目封止部8を備えることにより、排ガス中の粒子状物質を良好に捕集することができる。ハニカム構造体1のハニカム構造部10において、流出側目封止部8bが配設されたセル3は流入セル3aであり、流入側目封止部8aが配設されたセル3は流出セル3bである。
本実施形態のハニカム構造体1の製造方法について説明する。まず、ハニカム構造体1を作製するための坏土を調整し、この坏土を成形して、ハニカム成形体を作製する(成形工程)。その後、流入端面における所定のセル3の開口部、及び流出端面における残余のセル3の開口部に目封止を施して、流入側目封止部及び流出側目封止部を形成する(目封止工程)。その後、交互に目封止部8が形成されたハニカム成形体を焼成して、ハニカム焼成体を作製する(焼成工程)。このようにしてハニカム構造体1を作製することができる。
成形工程は、セラミック原料を含有するセラミック成形原料からなる坏土を調製し、この坏土を成形して、流体の流路となる複数のセル3を区画形成するハニカム成形体を形成する工程である。
ハニカム成形体を焼成(本焼成)する前には、そのハニカム成形体を仮焼することが好ましい。仮焼は、脱脂のために行うものであり、その方法は、特に限定されるものではなく、中の有機物(有機バインダ、分散剤、造孔材等)を除去することができればよい。一般に、有機バインダの燃焼温度は100〜300℃程度、造孔材の燃焼温度は200〜800℃程度であるので、仮焼の条件としては、大気雰囲気において、200〜1000℃程度で、3〜100時間程度加熱することが好ましい。
目封止部8の形成方法については、所定のセル3の一方の開口部にマスクを配設し、残余のセル3の開口部に目封止スラリーを充填する方法を挙げることができる。なお、このような目封止部8の形成方法は、例えば、公知のハニカム構造体における目封止部8の作製方法に準じて行うことができる。
酸化触媒5を、ハニカム構造体1の隔壁4の流出セル3b側に担持する方法としては、例えば、酸化触媒5のスラリーが貯留された容器に、目封止部8が配設されたハニカム構造体1を、その流出端面2bから、浸漬させる。そして、流入セル3a側からスラリーを吸引する。目封止部8が配設される前であれば、ハニカム構造体1の端面に所定のセル3に対応する部分に孔が形成されたマスクを貼付して同様に行えばよい。
図5は、DPF30、SCR触媒コンバータ70を備える排ガス浄化システム100を示す。DPF30は、さらにDOC40(上流側酸化触媒)、CSF50を備える。本発明のハニカム構造体1は、CSF50として使用することができる。また、排ガス浄化システム100は、DPF30とSCR触媒コンバータ70との間に、尿素噴射器60を備える。
SOF+O2=CO,CO2,H2O (式2)
C(スス)+NO2=CO+NO (式4)
C(スス)+1/2O2+NO2=CO2+NO (式5)
NO+NO2+2NH3=2N2+3H2O (式7)
6NO2+8NH3=7N2+12H2O (式8)
タルク、カオリン、アルミナを主原料とするコージェライト化原料に、造孔材、有機バインダ、及び水を加えて、成形原料を調製した。造孔材としては平均粒子径が20μmの中空樹脂粒子を用いた。尚、この平均粒子径は、レーザー回折法で測定した値である。また、有機バインダとしては、メチルセルロース及びヒドロキシプロポキシルメチルセルロースを用いた。各原料の添加量は、コージェライト化原料100質量部に対して、造孔材15質量部、有機バインダ4質量部、水27質量部とした。
実施例2〜10、比較例1〜3についても、実施例1と同様にして、遷移金属酸化物5aの酸化触媒5が担持されたハニカム構造体1を得た。詳細は、表1に示す。なお、比較例3は、酸化触媒5の代わりにPtを用いた。
本明細書において、開気孔率は、水銀圧入法(JIS R 1655準拠)による全細孔容積(単位:cm3/g)とアルキメデス法により測定した見掛け密度(単位:g/cm3)から、算出した値である。開気孔率を算出する際には、「気孔率[%]=全細孔容積/{(1/見掛け密度)+全細孔容積}×100」という式を用いた。平均細孔径は、水銀圧入法(JIS R 1655準拠)で測定した値である。
結晶相は次のようにして同定した。X線回折装置を用いてX線回折パターンを得た。X線回折装置としては、回転対陰極型X線回折装置(理学電機製、RINT)を用いた。X線回折測定の条件は、CuKα線源、50kV、300mA、2θ=10〜60°とした。X線回折データの解析は、MDI社製の「X線データ解析ソフトJADE7」を用いて結晶相を同定した。
触媒粒子径は、次のようにして測定した。樹脂にて包含した本発明の多孔質材料をダイヤモンドスラリー等を用いて鏡面研磨したものを観察試料とした。この断面研磨面を1000倍の倍率で観察し得た微構造写真中の全ての触媒粒子を測定した。これを3視野分を行いその平均値を算出した。この平均値を触媒粒子径とした。
上記によって作製されたハニカム構造体(実施例1〜10、比較例1〜3)をそれぞれ、直径25.4mm×長さ50.8mmの試料片に加工し、加工した外周を基材の共材でコートした。これを測定試料として自動車排ガス分析装置を用いて評価を行った。このとき、昇温炉の中の反応管に上記測定試料をセットし、250℃に保持した。一方、250℃のガス温度に調整されたNO(一酸化窒素):200ppm、O2(酸素):10%の窒素バランスの混合ガスを作製し、反応管中にセットされた測定試料の中に導入した。このとき、測定試料から排出されたガス(排出ガス)を排気ガス測定装置(HORIBA製:MEXA−6000FT)を用いて分析し、それぞれの排出濃度(NO濃度、及びNO2濃度)の測定を行った。測定結果に基づいて、NO2変換率(1−(NO濃度/(NO濃度+NO2濃度)))を算出した。
隔壁厚さの1/2を占める触媒の割合は、次のようにして測定した。樹脂にて包含した本発明の多孔質材料をダイヤモンドスラリー等を用いて鏡面研磨したものを観察試料とし、この断面研磨面を100倍の倍率で観察し得た微構造写真中の全ての触媒粒子の個数を計測し、これを全触媒粒子数Naとした。次に隔壁の半分から出口側の触媒粒子の個数を計測し、これを隔壁厚さの1/2を占める触媒数N hとした。これらの測定値から隔壁厚さの1/2を占める触媒の割合(Nh/Na)を求めた。
Claims (4)
- 多数の細孔を有する多孔質の隔壁を有し、前記隔壁によって排ガスの流路となる複数のセルが区画形成されたハニカム構造部と、
前記複数のセルの排ガスの流入側となる一方の開口端部と排ガスの流出側となる他方の開口端部とを互い違いに目封止する目封止部と、を備え、
前記複数のセルは、前記流入側の前記開口端部が開口した流入セルと、前記流出側の前記開口端部が開口した流出セルとから構成され、
前記隔壁の気孔率は、70%以下であり、
前記隔壁の前記流出セル側に、NOガスを酸化する遷移金属酸化物の酸化触媒、またはCeO2に担持されたNOガスを酸化する遷移金属酸化物の酸化触媒が担持され、
前記遷移金属酸化物は、Fe 2 O 3 、MnO 2 、及びCo 3 O 4 のいずれかであり、
前記酸化触媒の粒子径は、1μmより大きく50.0μmより小さく、
前記酸化触媒の担持量は、5.0g/L以上50g/L以下であるハニカム構造体。 - NO2変換率が、250℃において3.0%より大きく35%より小さい請求項1に記載のハニカム構造体。
- CeO2に担持された前記遷移金属酸化物の前記酸化触媒は、Fe2O3/CeO2、MnO2/CeO2、及びCo3O4/CeO2のいずれかである請求項1または2に記載のハニカム構造体。
- 前記隔壁の厚さ方向において、厚さの1/2より前記流出セル側に60%以上の前記遷移金属酸化物が担持されている請求項1〜3のいずれか1項に記載のハニカム構造体。
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DE102017002807.9A DE102017002807A1 (de) | 2016-03-30 | 2017-03-22 | Wabenstruktur |
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