JP6635819B2 - ハニカム構造体 - Google Patents
ハニカム構造体 Download PDFInfo
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- JP6635819B2 JP6635819B2 JP2016027240A JP2016027240A JP6635819B2 JP 6635819 B2 JP6635819 B2 JP 6635819B2 JP 2016027240 A JP2016027240 A JP 2016027240A JP 2016027240 A JP2016027240 A JP 2016027240A JP 6635819 B2 JP6635819 B2 JP 6635819B2
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- 239000003054 catalyst Substances 0.000 claims description 99
- 238000005192 partition Methods 0.000 claims description 95
- 239000000758 substrate Substances 0.000 claims description 39
- 239000007789 gas Substances 0.000 description 46
- 238000000746 purification Methods 0.000 description 16
- 239000013618 particulate matter Substances 0.000 description 15
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 12
- 239000000243 solution Substances 0.000 description 12
- 230000000052 comparative effect Effects 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
- 229930195733 hydrocarbon Natural products 0.000 description 9
- 150000002430 hydrocarbons Chemical class 0.000 description 9
- 238000011156 evaluation Methods 0.000 description 8
- 238000002347 injection Methods 0.000 description 7
- 239000007924 injection Substances 0.000 description 7
- 238000000034 method Methods 0.000 description 7
- 239000011148 porous material Substances 0.000 description 6
- 230000009467 reduction Effects 0.000 description 5
- 238000012360 testing method Methods 0.000 description 5
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 4
- 229910010293 ceramic material Inorganic materials 0.000 description 4
- 238000007598 dipping method Methods 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 239000000446 fuel Substances 0.000 description 4
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 230000009471 action Effects 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 229910002092 carbon dioxide Inorganic materials 0.000 description 2
- 239000001569 carbon dioxide Substances 0.000 description 2
- 230000003197 catalytic effect Effects 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 238000007654 immersion Methods 0.000 description 2
- 238000000691 measurement method Methods 0.000 description 2
- 239000010948 rhodium Substances 0.000 description 2
- 239000004071 soot Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 229910001868 water Inorganic materials 0.000 description 2
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 239000002803 fossil fuel Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 239000012466 permeate Substances 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000001105 regulatory effect Effects 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
- 238000001878 scanning electron micrograph Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
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- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
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- F01N3/24—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 constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
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- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
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- 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
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- 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]
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
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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
- B01D53/9445—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
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- B01J37/0201—Impregnation
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- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
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- F01N3/101—Three-way catalysts
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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
- F01N3/24—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 constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
- F01N3/2842—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration specially adapted for monolithic supports, e.g. of honeycomb type
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- B01D2258/012—Diesel engines and lean burn gasoline engines
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- F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction
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Description
本実施形態のハニカム構造体1は、図1及び図2に主として示されるように、一方の端面2aから他方の端面2bまで延びる複数のセル3を区画形成する多孔質性のセラミックス材料によって形成された格子状の隔壁4を有する略円柱状のハニカム基材10と、一方の端面2aにおけるセル3を予め規定した配設基準に従って目封止した片側目封止部11と備えて主に構成されている。
本実施形態のハニカム構造体1において、隔壁内部4aに含浸及び隔壁表面4bに塗布される触媒Cとして、例えば、「三元触媒」を用いることができる。三元触媒は、主に炭化水素(HC)、一酸化炭素(CO)、及び窒素酸化物(NOx)を浄化する触媒であり、例えば、白金(Pt)、パラジウム(Pd)、ロジウム(Rh)を含むものであっても構わない。三元触媒により、炭化水素は水と二酸化炭素に、一酸化炭素は二酸化炭素に、窒素酸化物は窒素にそれぞれ酸化または還元反応によって浄化される。
更に、本発明のハニカム構造体は、上記第一領域R1及び第二領域R2の間に、第三領域R3を有するものであっても構わない。例えば、本発明の別例構成のハニカム構造体1’は、図4に示すように、触媒含浸隔壁12及び触媒層隔壁13が互いに重なり合うように形成された触媒共有部15を有する第三領域R3を備えるものである。触媒共有部15を有することによって、触媒含浸隔壁12及び触媒層隔壁13のいずれの作用効果も奏することができる。しかしながら、隔壁表面4bに形成された触媒層14によって、第三領域R3では、排気ガスEGの隔壁内部4aの通過が阻害され、圧力損失が上昇する可能性を有している。
上記の実施例及び比較例、及び基準ハニカムに係るハニカム構造体を装着した排気ガス浄化装置を、排気量2.0リットルの直噴式ガソリンエンジンを搭載した乗用車の排気系にそれぞれ装着する。その後、シャシダイナモによる車両試験として、国際調和排ガス試験モード(WLTC)の運転条件に従って運転した際の排気ガス中の一酸化炭素(CO)、炭化水素(HC)、及び窒素酸化物(NOx)のエミッションを測定し、エミッション値を得た。得られたエミッション値を、基準体のハニカム構造体の値と対比し、一酸化炭素、炭化水素、及び窒素酸化物の全ての成分の上昇値が0〜10%未満であるものを“A”とし、10〜20%未満の範囲のものを“B”とし、20%以上のものを“C”とした。なお、表2において、浄化率の測定に係る評価項目を“浄化率(CO,HC,NOx)”を表している。
実施例及び比較例、及び基準ハニカムに係るハニカム構造体を装着した排気ガス浄化装置を、排気量2.0リットルの直噴式ガソリンエンジンを搭載した乗用車の排気系に装着する。その後、シャシダイナモによる車両試験として、国際調和排ガス試験モード(WLTC)の運転条件に従って運転した際の排気ガス中のPM排出個数を欧州EURO6規制案に沿った方法に基づいて測定する。ここで、PM排出個数が3×1011個/km以下のものを“A”とし、3×1011〜6×1011個/km未満の範囲のものを“B”とし、6×1011個/km以上を“C”とした。
排気量2.0リットルの直噴式ガソリンエンジンの台上試験において、始めに、排気系にセル密度:46.5個/cm2、隔壁厚さ:216μm、ハニカム径:118.4mm、ハニカム長さ:127mm、触媒コート量:100g/lの両端を目封止したハニカム構造体(基準ハニカム)を装着する。このときのエンジンフルロード運転時の圧力損失を測定し、これを圧力損失の基準値とする。実施例及び比較例に係るハニカム構造体を使用した排気ガス浄化装置を同様に排気量2.0リットルの直噴式ガソリンエンジンを搭載した乗用車の排気径に装着し、上記と同条件のエンジンフルロード運転時の圧力損失を測定した。その後、基準体によって得られた圧力損失の基準値に対して、圧力損失の低減量が40%以上の場合を“A”とし、圧力損失の低減量が20%〜40%未満の場合を“B”とし、圧力損失の低減量が20%以下の場合を“C”とした。
上記浄化率(CO,HC,NOx)、(2)PM排出個数、及び(3)圧力損失における各評価項目において、全ての評価項目が“A”若しくは二つ以上が“A”の場合は、総合判断として“A”とし、二つの評価項目で“B”がある場合は“B”とし、“C”が一項目でもある場合を“C”とする。総合判断において、“A”,“B”を合格とし、”C”は不合格とする。
Claims (3)
- 一方の端面から他方の端面まで延びる複数のセルを区画形成する多孔質の隔壁を有するハニカム基材と、
前記一方の端面における前記セルを所定の配設基準に従って目封止した片側目封止部と
を備え、
前記隔壁は、
前記片側目封止部の設けられた前記一方の端面から前記ハニカム基材の軸方向に沿って延びた所定長さの第一領域に形成され、隔壁内部に触媒を含浸して形成された触媒含浸隔壁と、
前記他方の端面から前記ハニカム基材の軸方向に沿って延びた所定長さの第二領域に形成され、隔壁表面に前記触媒を層状に塗布した触媒層を有する触媒層隔壁と
を具備し、
前記第一領域及び前記第二領域の間に、前記ハニカム基材の軸方向に沿って延びた所定長さの第三領域を更に有し、
前記第三領域は、
前記触媒含浸隔壁及び前記触媒層隔壁をいずれも含んで構成され、または、前記触媒含浸隔壁及び前記触媒層隔壁をいずれも含まないで構成されているハニカム構造体。 - 前記ハニカム基材の軸方向の全長に対する前記第一領域の長さの比率は、
1/3〜2/3の範囲であり、
前記ハニカム基材の軸方向の全長に対する前記第二領域の長さの比率は、
1/3〜2/3の範囲である請求項1に記載のハニカム構造体。 - 前記触媒は、
三元触媒が用いられる請求項1または2に記載のハニカム構造体。
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