JP6808007B2 - 触媒を製造するための方法及び触媒物品 - Google Patents
触媒を製造するための方法及び触媒物品 Download PDFInfo
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- JP6808007B2 JP6808007B2 JP2019223401A JP2019223401A JP6808007B2 JP 6808007 B2 JP6808007 B2 JP 6808007B2 JP 2019223401 A JP2019223401 A JP 2019223401A JP 2019223401 A JP2019223401 A JP 2019223401A JP 6808007 B2 JP6808007 B2 JP 6808007B2
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Images
Classifications
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- 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
- B01D53/9404—Removing only nitrogen compounds
- B01D53/9409—Nitrogen oxides
- B01D53/9413—Processes characterised by a specific catalyst
- B01D53/9418—Processes characterised by a specific catalyst for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
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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
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
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- 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
- B01J29/76—Iron group metals or copper
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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
- B01J29/76—Iron group metals or copper
- B01J29/763—CHA-type, e.g. Chabazite, LZ-218
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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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Description
−機能粒子中で細孔成形剤により形成され、
−更に無機粒子を含むマトリクス中に埋め込まれ、
−細孔構造を形成し、かつ
−機能粒子の触媒的に活性な材料の層を含む活性な界面層により少なくとも部分的に囲まれる
多孔性の触媒的に不活性なセル、
を少なくとも含むセラミック体を形成するように、触媒組成物は、最終的に触媒を形成するような熱的処理に供される。
−触媒からなる押出成形触媒物品、
−触媒からなるハニカム、
−触媒からなるプレート触媒コンバーター、
−触媒からなるペレット、
−触媒からなるウォッシュコートでコーティングされたモノリス支持体、
−ハニカムを含むウォールフローフィルターであって、ハニカムが触媒からなりかつ/又はハニカムが触媒から構成されるウォッシュコートでコーティングされたウォールフローフィルター、
の何れかである成形体である。
4 細孔成形剤
5 層
6 粉末粒子
8 機能粒子
10 バインダー成分
12 触媒組成物
14 成形体
17 触媒物品
18 細孔構造
20 セル
22 活性界面層
24 マトリクス
Claims (31)
- セラミック触媒(2)を製造するための方法であって、
a)触媒的に活性な材料の層(5)により囲まれている支持体として触媒的に不活性な細孔成形剤(4)を有する機能粒子(8)を提供し、
b)機能粒子(8)を、更なる無機粒子(10)で処理して触媒組成物(12)を与え、
c)触媒組成物(12)を、熱的に処理してセラミック触媒(2)を形成することにおいて、触媒(2)が、
− 機能粒子(8)中の細孔成形剤(4)により形成され、
− 更なる無機粒子(10)を含むマトリクス(24)中に埋め込まれ、
− 多孔性構造(18)を形成し、かつ
− 機能粒子(8)の層(5)の触媒的に活性な材料を含む活性な界面層(22)により少なくとも部分的に囲まれている、
少なくとも多孔性の触媒的に不活性なセル(20)を含む、セラミック触媒(2)を形成する、方法。 - セラミック触媒(2)が排気ガス処理のためのセラミック触媒(2)である、請求項1に記載の方法。
- 細孔成形剤(4)が、セルが細孔(20)として形成されるように、触媒組成物(12)の熱処理の過程で漏れる有機材料からなる、請求項1又は2に記載の方法。
- 細孔成形剤(4)が熱可塑物又はエラストマーを含む有機材料からなる、請求項3に記載の方法。
- 細孔成形剤(4)が少なくともメソ多孔性を有する無機多孔性材料からなる、請求項1に記載の方法。
- 細孔成形剤(4)がマクロ多孔性を有する無機多孔性材料からなる、請求項5に記載の方法。
- 無機多孔性材料が、クレイ鉱物、珪藻土、シリカゲル及び多孔性ガラスから選択される、請求項5又は6に記載の方法。
- クレイ鉱物がピラードクレイ鉱物である、請求項7に記載の方法。
- 触媒的に活性な材料の粉末粒子(6)が細孔成形剤(4)に塗布される、請求項1から8の何れか一項に記載の方法。
- 粉末粒子(6)が粘着により塗布される、請求項9に記載の方法。
- 粉末粒子(6)が粘着により塗布され、かつこの目的のために、有機材料からなっていてもよい細孔成形剤(4)が、それが柔らかくなりかつ粉末粒子(6)が細孔成形剤の表面に付着したままであるように加熱されるか、又は細孔成形剤(4)に接着剤を塗布することにより塗布される、請求項10に記載の方法。
- 触媒的に活性な層(5)への触媒的に不活性な細孔成形剤(4)の外部層の変換により、層(5)が形成される、請求項1から8の何れか一項に記載の方法。
- 細孔成形剤(4)が10μmから200μmの範囲内の粒径を有する、請求項1から12の何れか一項に記載の方法。
- 細孔成形剤(4)が30−150μmの範囲内の粒径を有する、請求項13に記載の方法。
- 更なる無機粒子が、工程c)での処理後にセラミックマトリクス(24)を形成するバインダー成分(10)を有する、請求項1から14の何れか一項に記載の方法。
- 成形体(14)が押出成形により触媒組成物から形成され、かつその後、成形体(14)が熱的に処理される、請求項1から15の何れか一項に記載の方法。
- 触媒(2)が、熱処理の後に、触媒的に活性な材料を含むウォッシュコートでコーティングされる、請求項16に記載の方法。
- 触媒組成物(12)がウォッシュコートとしてモノリス支持体に塗布され、かつその後、このコーティングされた支持体が熱的に処理される、請求項1から16の何れか一項に記載の方法。
- 機能粒子(8)の形成のための細孔成形剤(4)への層(5)の塗布、及び触媒組成物(12)の処理が、単一の処理工程で行われる、請求項1から18の何れか一項に記載の方法。
- 細孔成形剤(4)が乾燥触媒組成物(12)ベースで40体積%から80体積%の範囲内の割合を占める、請求項1から19の何れか一項に記載の方法。
- 細孔成形剤(4)が乾燥触媒組成物(12)ベースで50−60体積%の範囲内の割合を占める、請求項20に記載の方法。
- 使用される触媒的に活性な材料が、
− 結晶性モレキュラーシーブ
− 卑金属ベースの触媒システム
− タングステン/セリウム−ベースの触媒システム
− 金属酸化物若しくは混合酸化物
− 卑金属ベースの触媒システム、及び
− 白金族金属(PGM)−ベースのシステム
のいずれか又は組み合わせである、請求項1から21の何れか一項に記載の方法。 - 結晶性モレキュラーシーブが、(イオン交換)ゼオライトである、請求項22に記載の方法。
- 卑金属ベースの触媒システムが、チタンベースのシステムである、請求項22又は23に記載の方法。
- 結晶性モレキュラーシーブが個々の結晶子として存在する、請求項22から24の何れか一項に記載の方法。
- 結晶性モレキュラーシーブが、それらの固有のミクロ多孔性に加えて、IUPAC規格により規定される少なくともメソ多孔性を有する、請求項22から25の何れか一項に記載の方法。
- 工程b)で触媒組成物中に導入される更なる粒子が、更なる触媒的に活性な材料である、請求項1から26の何れか一項に記載の方法。
- 異なる粒径分布の種々の細孔成形剤(4)が使用される、請求項1から27の何れか一項に記載の方法。
- 触媒組成物(12)が、層(5)に使用されている触媒的に活性な材料の面で異なる2以上の異なる機能粒子(8)を含み、
− 2以上の異なる触媒的に活性な材料の混合物が層(5)に使用され、かつ/又は
− 異なる触媒的に活性な材料が、混合され触媒組成物(12)を形成する第一及び第二の機能粒子(8)を得るように、個々の細孔成形剤(4)のそれぞれに塗布される、
請求項1から28の何れか一項に記載の方法。 - 異なる粉末粒子(6)の混合物が層(5)に使用される、請求項29に記載の方法。
- 混合され触媒組成物(12)を形成する第一及び第二の機能粒子(8)を得るように、第一の細孔成形剤(4)に第一の粉末粒子(6a)を塗布すること及び第二の細孔成形剤(4)に第二の粉末粒子(6b)を塗布することにより、異なる触媒的に活性な材料が、個々の細孔成形剤(4)のそれぞれに塗布される、
請求項29又は30に記載の方法。
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