JP6920304B2 - ガソリン微粒子フィルタ - Google Patents
ガソリン微粒子フィルタ Download PDFInfo
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- JP6920304B2 JP6920304B2 JP2018533092A JP2018533092A JP6920304B2 JP 6920304 B2 JP6920304 B2 JP 6920304B2 JP 2018533092 A JP2018533092 A JP 2018533092A JP 2018533092 A JP2018533092 A JP 2018533092A JP 6920304 B2 JP6920304 B2 JP 6920304B2
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- 239000010419 fine particle Substances 0.000 title description 17
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 claims description 83
- 238000000576 coating method Methods 0.000 claims description 68
- 239000003054 catalyst Substances 0.000 claims description 62
- 239000011248 coating agent Substances 0.000 claims description 60
- 230000003197 catalytic effect Effects 0.000 claims description 57
- 239000007789 gas Substances 0.000 claims description 56
- 239000000758 substrate Substances 0.000 claims description 56
- 239000000463 material Substances 0.000 claims description 40
- 238000000034 method Methods 0.000 claims description 40
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Substances [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims description 35
- 229910052751 metal Inorganic materials 0.000 claims description 29
- 239000002184 metal Substances 0.000 claims description 29
- 229910052703 rhodium Inorganic materials 0.000 claims description 28
- -1 platinum group metals Chemical class 0.000 claims description 25
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 24
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 claims description 23
- 229910002091 carbon monoxide Inorganic materials 0.000 claims description 23
- 229930195733 hydrocarbon Natural products 0.000 claims description 22
- 150000002430 hydrocarbons Chemical class 0.000 claims description 21
- 229910052760 oxygen Inorganic materials 0.000 claims description 21
- 239000001301 oxygen Substances 0.000 claims description 20
- 229910052763 palladium Inorganic materials 0.000 claims description 20
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 19
- 238000002485 combustion reaction Methods 0.000 claims description 17
- 229910052684 Cerium Inorganic materials 0.000 claims description 14
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 claims description 14
- 238000003860 storage Methods 0.000 claims description 14
- 229910052697 platinum Inorganic materials 0.000 claims description 13
- 239000013618 particulate matter Substances 0.000 claims description 12
- 229910052777 Praseodymium Inorganic materials 0.000 claims description 11
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 11
- 239000000446 fuel Substances 0.000 claims description 11
- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 claims description 11
- 229910052726 zirconium Inorganic materials 0.000 claims description 11
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 claims description 10
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 claims description 10
- 238000001354 calcination Methods 0.000 claims description 8
- 229910052779 Neodymium Inorganic materials 0.000 claims description 4
- 238000002156 mixing Methods 0.000 claims description 4
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 claims description 4
- 238000002360 preparation method Methods 0.000 claims description 4
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- 239000004215 Carbon black (E152) Substances 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 claims description 3
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 46
- 239000010948 rhodium Substances 0.000 description 44
- 239000010410 layer Substances 0.000 description 30
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 25
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- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 6
- 229910052878 cordierite Inorganic materials 0.000 description 6
- 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 6
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- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 4
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 4
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 4
- 239000003870 refractory metal Substances 0.000 description 4
- 238000011144 upstream manufacturing Methods 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- GQPLMRYTRLFLPF-UHFFFAOYSA-N Nitrous Oxide Chemical compound [O-][N+]#N GQPLMRYTRLFLPF-UHFFFAOYSA-N 0.000 description 3
- 239000003638 chemical reducing agent Substances 0.000 description 3
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 3
- 230000009970 fire resistant effect Effects 0.000 description 3
- 229910052757 nitrogen Inorganic materials 0.000 description 3
- 230000001590 oxidative effect Effects 0.000 description 3
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229910021536 Zeolite Inorganic materials 0.000 description 2
- 238000004026 adhesive bonding Methods 0.000 description 2
- 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 2
- 229910021529 ammonia Inorganic materials 0.000 description 2
- 239000010953 base metal Substances 0.000 description 2
- 230000033228 biological regulation Effects 0.000 description 2
- WUKWITHWXAAZEY-UHFFFAOYSA-L calcium difluoride Chemical compound [F-].[F-].[Ca+2] WUKWITHWXAAZEY-UHFFFAOYSA-L 0.000 description 2
- 229910002092 carbon dioxide Inorganic materials 0.000 description 2
- 239000001569 carbon dioxide Substances 0.000 description 2
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- 150000001768 cations Chemical class 0.000 description 2
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- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- QSHDDOUJBYECFT-UHFFFAOYSA-N mercury Chemical compound [Hg] QSHDDOUJBYECFT-UHFFFAOYSA-N 0.000 description 2
- 229910052753 mercury Inorganic materials 0.000 description 2
- 238000000386 microscopy Methods 0.000 description 2
- 239000004570 mortar (masonry) Substances 0.000 description 2
- 231100000719 pollutant Toxicity 0.000 description 2
- 239000011164 primary particle Substances 0.000 description 2
- 238000000746 purification Methods 0.000 description 2
- 229910052761 rare earth metal Inorganic materials 0.000 description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
- 229910010271 silicon carbide Inorganic materials 0.000 description 2
- 241000894007 species Species 0.000 description 2
- 229910052642 spodumene Inorganic materials 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000010998 test method Methods 0.000 description 2
- 239000010457 zeolite Substances 0.000 description 2
- 229910000505 Al2TiO5 Inorganic materials 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229920002907 Guar gum Polymers 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 230000001133 acceleration Effects 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000002457 bidirectional effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
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- 239000000969 carrier Substances 0.000 description 1
- 238000010531 catalytic reduction reaction Methods 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
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- 229910052802 copper Inorganic materials 0.000 description 1
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- 238000010586 diagram Methods 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
- 238000007598 dipping method Methods 0.000 description 1
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- 239000003517 fume Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
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- 239000000665 guar gum Substances 0.000 description 1
- 229960002154 guar gum Drugs 0.000 description 1
- 235000010417 guar gum Nutrition 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000005342 ion exchange Methods 0.000 description 1
- 229910052741 iridium Inorganic materials 0.000 description 1
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Natural products C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- VUZPPFZMUPKLLV-UHFFFAOYSA-N methane;hydrate Chemical compound C.O VUZPPFZMUPKLLV-UHFFFAOYSA-N 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
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- 239000002808 molecular sieve Substances 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 239000001272 nitrous oxide Substances 0.000 description 1
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- 238000003921 particle size analysis Methods 0.000 description 1
- 230000003094 perturbing effect Effects 0.000 description 1
- 238000002459 porosimetry Methods 0.000 description 1
- 239000010970 precious metal Substances 0.000 description 1
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- 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
- 230000008929 regeneration Effects 0.000 description 1
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- 229910052702 rhenium Inorganic materials 0.000 description 1
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 description 1
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- 239000000565 sealant Substances 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
- URGAHOPLAPQHLN-UHFFFAOYSA-N sodium aluminosilicate Chemical compound [Na+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O URGAHOPLAPQHLN-UHFFFAOYSA-N 0.000 description 1
- 239000006104 solid solution Substances 0.000 description 1
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- 238000003325 tomography Methods 0.000 description 1
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- 229910052727 yttrium Inorganic materials 0.000 description 1
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 1
- 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
- B01J23/46—Ruthenium, rhodium, osmium or iridium
- B01J23/464—Rhodium
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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
- B01D53/9459—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts
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- B01J23/54—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
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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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- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
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- B01J37/02—Impregnation, coating or precipitation
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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
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
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- 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
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/033—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices
- F01N3/035—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
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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
- 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
- F01N3/101—Three-way catalysts
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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
- 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
- F01N3/20—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 specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
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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
- 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
- F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
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- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01D2255/00—Catalysts
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- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/10—Noble metals or compounds thereof
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- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01D2255/20—Metals or compounds thereof
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- B01D2255/2066—Praseodymium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01D2255/20—Metals or compounds thereof
- B01D2255/209—Other metals
- B01D2255/2092—Aluminium
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B—PERFORMING OPERATIONS; TRANSPORTING
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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
- F01N2330/02—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
- 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
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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
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- F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction
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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
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
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- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
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- Y02A50/20—Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
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- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
Description
(i)アルミナ;
(ii)一又は複数種の白金族金属;及び
(iii)酸素貯蔵成分(OSC)
を含み、
前記OSCは、セリア又はセリウムを含む一もしくは複数種の混合酸化物を含み、65:35〜85:15のOSC対アルミナの重量比で存在する。
ある層厚を有する触媒材料を含む壁上コーティングが第二の複数のチャネルのチャネル壁面上に存在し、
第二の複数のチャネルのチャネル壁面上の触媒材料が、(i)ロジウム(Rh)のみ;(ii)パラジウム(Pd)のみ;(iii)白金(Pt)及びロジウム(Rh);(iv)パラジウム(Pd)及びロジウム(Rh);及び(v)白金(Pt)、パラジウム(Pd)及びロジウム(Rh)からなる群から選択される一又は複数種の白金族金属と耐火性金属酸化物担体を含み、
(i)第二の複数のチャネルのチャネル壁面上に存在する壁上コーティングの単位体積当たりの一又は複数種の白金族金属の重量が、長手方向に沿って連続的に変わり;及び/又は
(ii)第二の複数のチャネルのチャネル壁面上に存在する壁上コーティングの層厚が長手方向に沿って連続的に変わる。
(i)第一の複数のチャネルのチャネル壁面上に存在する壁上コーティングの単位体積当たりの一又は複数種の白金族金属の重量が、長手方向に沿って連続的に変わり;及び/又は
(ii)第一の複数のチャネルのチャネル壁面上に存在する第二の壁上コーティングの層厚が、長手方向に沿って連続的に変わる、
製品を得ることができる。
長手方向が間に画定される第一の面及び第二の面と、前記長手方向に延びる第一及び第二の複数のチャネルを有する多孔質基材を提供する工程であって、第一の複数のチャネルが第一の面において開口し、第二の面において閉塞し、第二の複数のチャネルが第二の面において開口し、第一の面において閉塞している工程;
触媒材料を含むウォッシュコートを前記多孔質基材に浸透させる工程;及び
前記多孔質基材内で前記触媒材料をか焼する工程
を含み、
前記触媒材料が、
(i)アルミナ;
(ii)一又は複数種の白金族金属;及び
(iii)酸素貯蔵成分(OSC)
を含み、
前記OSCが、セリア又はセリウムを含む一もしくは複数種の混合酸化物を含み、65:35〜85:15のOSC対アルミナの重量比で存在する、方法が提供される。
4つのフロースルー基材(4×5”及び600/4セル密度)を、40[g/ft−3]/0:9:1[Pt:Pd:Rh重量比]の白金族金属(PGM)組成を有するTWCでコーティングした。各TWCは、異なる重量比のAl2O3対CeZrO4を含んでいた。
結果は次の通りであった:
表から分かるように、CeZrO4:Al2O3比を1:1より増加させることは、コーティングされたスルーフローモノリスのNOx転化能に有害であることが見出された。
4つのウォールフローフィルタ(4.66×4.5”及び300/8セル密度)を、PGM60/0.57:3を有するTWCでコーティングした。各TWCは、異なる重量比のAl2O3対CeZrO4を含んでいた。コーティングしたフィルタをか焼し、エージングした(水熱、10%のH2Oを加えた空気中で1100℃、5時間)。
表から分かるように、CeZrO4:Al2O3の重量比が1:2から3:1に増加するにつれて、相対NOx排出量が減少した。
3つのウォールフローフィルタ(4.66×4.5”及び300/8セル密度)を、PGM22/0:20:2を有するTWCでコーティングした。各TWCは、異なる重量比のAl2O3対CeZrO4を含んでいた。コーティングしたフィルタを、実施例2におけるようにか焼し、エージングさせた。
それぞれ希土類元素がドープされ、以下の表に示された組成を有する二種のセリア−ジルコニア混合酸化物を、CATLAB−PCS複合マイクロリアクタ・質量分析計実験装置(Hiden Analytical)を使用してそのスート燃焼活性について試験した。コーディエライトサンプルを対照として試験した。セリア−ジルコニア混合酸化物とコーディエライト対照を500℃で2時間予備焼成した。
4.66インチ(直径)×6インチ(長さ)の寸法、セル密度/壁厚300/8(セル/平方インチ/ミル(1000分の1インチのチャネル壁厚))を有する基材と、第一の複数のチャネルと第二の複数のチャネルとの間で50:50に分けられた1.6g/in3の充填量でセリア−ジルコニア系混合酸化物OSC及びアルミナ系耐火性酸化物担体をまた含む10g/ft3の重量比70:30でPd/Rhを含む完全に処方された三元触媒ウォッシュコートに基づいてウォールフローフィルタを調製した。前記ウォッシュコートは、2〜4ミクロンのD50と<10ミクロンのD90を含んでいた。使用したウォッシュコート固形分は19%であり、これは、Brookfield RV DVII+Extra Pro粘度計で50rpmスピンドル速度にてSC4−27スピンドルを使用して20℃で測定して、900〜1000cPの目標粘度まで当業者に知られている増粘剤を使用して増粘した。使用したコーティング法は、英国特許公報第2524662号に開示された第一の方法、すなわち予め決められた量の液体をフィルタ基材の上端の収容手段に導入し、フィルタ基材の下端に真空を適用する方法に従った。使用した真空は上記の説明に記載された通りであるが、より短い持続時間とより低い真空強度の組み合わせを使用した。コーティングした生成物を乾燥させ、通常の方法でか焼した。
実施例4とその参照例(比較例)のコーティングされエージングされたフィルタの低温フロー背圧解析を、http://www.superflow.com/Flowbenches/sf1020.phpで市販されているSuperflow SF1020装置を使用して行った。
実施例4=92.82mbar@700m3/hr(9.28KPa);及び
参照例4(比較例)=116.56mbar@700m3/hr(11.66KPa)
疑義を避けるために、ここに引用した全ての文献の内容全体を出典明示によりここに援用する。
Claims (19)
- 排気処理システムにおいて使用するための触媒ウォールフローモノリスであって、モノリスが多孔質基材と三元触媒(TWC)とを含み、TWCが実質的に多孔質基材全体に分布し、TWCが、
(i)アルミナ;
(ii)一又は複数種の白金族金属;及び
(iii)酸素貯蔵成分(OSC)
を含み、OSCが、セリア又はセリウムを含む一もしくは複数種の混合酸化物を含み、70:30〜85:15のOSC対アルミナの重量比で存在する、触媒ウォールフローモノリス。 - OSCがセリアを含む、請求項1に記載の触媒ウォールフローモノリス。
- OSCが、セリウムとジルコニウムの混合酸化物;セリウム、ジルコニウム、及びネオジムの混合酸化物;プラセオジムとジルコニウムの混合酸化物;セリウム、ジルコニウム、及びプラセオジムの混合酸化物;又はプラセオジム、セリウム、ランタン、イットリウム、ジルコニウム、及びネオジムの混合酸化物を含む、請求項2に記載の触媒ウォールフローモノリス。
- OSCがプラセオジムを含み、2〜10重量%で存在する、請求項3に記載の触媒ウォールフローモノリス。
- OSCがプラセオジムを含み、第一の複数のチャネルが、プラセオジムを含むOSCを含む壁上TWCコーティングを含む、請求項3又は4に記載の触媒ウォールフローモノリス。
- OSC対アルミナの重量比が約75:25である、請求項1から5の何れか一項に記載の触媒ウォールフローモノリス。
- 一又は複数種の白金族金属が、Pt、Pd及びRh、又はそれらの二種以上の組み合わせから選択される、請求項1から6の何れか一項に記載の触媒ウォールフローモノリス。
- TWCが、多孔質基材全体にわたって均質である、請求項1から7の何れか一項に記載の触媒ウォールフローモノリス。
- モノリスが、第一の面及び第二の面を有し、それらの間に長手方向を画定し、かつ長手方向に延びる第一及び第二の複数のチャネルを有し、
第一の複数のチャネルは第一の面において開口し、第二の面において閉塞し、第二の複数のチャネルは第二の面において開口し、第一の面において閉塞し、
TWCは、第一及び第二の複数のチャネルの少なくとも一つの表面上にコーティングとして更に存在する、請求項1から8の何れか一項に記載の触媒ウォールフローモノリス。 - 隣接するチャネル間の基材の平均最小厚が8〜20ミル(0.02〜0.05cm)である、請求項9に記載の触媒ウォールフローモノリス。
- (a)第一の複数のチャネルのチャネル壁面上に存在する壁上コーティングの単位体積当たりの一又は複数種の白金族金属の重量が、長手方向に沿って連続的に変化し;かつ/又は(b)第一の複数のチャネルのチャネル壁面上に存在する壁上コーティング−又は実質的に壁上コーティング−の層厚が長手方向に沿って連続的に変化する、請求項9又は10に記載の触媒ウォールフローモノリス。
- 燃焼排気ガスの流れを処理するための排気処理システムであって、請求項1から11の何れか一項に記載の触媒ウォールフローモノリスを備える、システム。
- 請求項12に記載の排気処理システムを備えるポジティブ点火エンジン。
- 請求項13に記載のエンジンを備える自動車。
- 触媒ウォールフローモノリスの製造方法であって、
長手方向が間に画定される第一の面及び第二の面と、長手方向に延びる第一及び第二の複数のチャネルとを有する多孔質基材を提供する工程であって、第一の複数のチャネルが第一の面において開口し、第二の面において閉塞し、第二の複数のチャネルが第二の面において開口し、第一の面において閉塞している工程;
触媒材料を含むウォッシュコートを多孔質基材に浸透させる工程;及び
多孔質基材内で触媒材料をか焼する工程
を含み、
触媒材料が、
(i)アルミナ;
(ii)一又は複数種の白金族金属;及び
(iii)酸素貯蔵成分(OSC)
を含み、
OSCが、セリア又は、セリウムを含む一もしくは複数種の混合酸化物を含み、70:30〜85:15のOSC対アルミナの重量比で存在する、方法。 - 多孔質基材に浸透させる前のウォッシュコートの調製が、
Pt及び/又はPdをアルミナと混合し、か焼して触媒材料の第一の部分を形成する工程
を含む、請求項15に記載の方法。 - 多孔質基材に浸透させる前のウォッシュコートの調製が、
RhをOSCと混合し、か焼して触媒材料の第二の部分を形成する工程
を含む、請求項15又は請求項16に記載の方法。 - 触媒ウォールフローモノリスが請求項1から11の何れか一項に記載のモノリスである、請求項15から17の何れか一項に記載の方法。
- 窒素酸化物(NOx)、一酸化炭素(CO)未燃炭化水素燃料(HC)及び粒子状物質(PM)を含むポジティブ点火内燃機関からの燃焼排気ガスを処理する方法であって、請求項1から11の何れか一項に記載の触媒ウォールフローフィルタに排気ガスを接触させることを含む、方法。
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GB1522917.2A GB2545747A (en) | 2015-12-24 | 2015-12-24 | Gasoline particulate filter |
GBGB1604915.7A GB201604915D0 (en) | 2015-12-24 | 2016-03-23 | Gasoline particulate filter |
GB1604915.7 | 2016-03-23 | ||
PCT/GB2016/054070 WO2017109514A1 (en) | 2015-12-24 | 2016-12-23 | Gasoline particulate filter |
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EP3393654A1 (en) | 2018-10-31 |
JP2019509166A (ja) | 2019-04-04 |
RU2732400C2 (ru) | 2020-09-16 |
CN108602050A (zh) | 2018-09-28 |
GB201522917D0 (en) | 2016-02-10 |
KR20180098600A (ko) | 2018-09-04 |
BR112018012782A2 (pt) | 2018-12-04 |
GB2545747A (en) | 2017-06-28 |
CN108602050B (zh) | 2021-09-21 |
US20190009254A1 (en) | 2019-01-10 |
GB201604915D0 (en) | 2016-05-04 |
DE112016005997T5 (de) | 2018-08-30 |
EP3393654B1 (en) | 2020-08-12 |
GB201707959D0 (en) | 2017-07-05 |
US10625243B2 (en) | 2020-04-21 |
RU2018126874A3 (ja) | 2020-04-16 |
BR112018012782B1 (pt) | 2021-10-26 |
WO2017109514A1 (en) | 2017-06-29 |
RU2018126874A (ru) | 2020-01-24 |
GB2558332B (en) | 2020-10-28 |
GB2558332A (en) | 2018-07-11 |
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