JP6957523B2 - コア/シェル触媒粒子および製作方法 - Google Patents
コア/シェル触媒粒子および製作方法 Download PDFInfo
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- JP6957523B2 JP6957523B2 JP2018562074A JP2018562074A JP6957523B2 JP 6957523 B2 JP6957523 B2 JP 6957523B2 JP 2018562074 A JP2018562074 A JP 2018562074A JP 2018562074 A JP2018562074 A JP 2018562074A JP 6957523 B2 JP6957523 B2 JP 6957523B2
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- 239000003054 catalyst Substances 0.000 title claims description 133
- 238000000034 method Methods 0.000 title claims description 28
- 238000004519 manufacturing process Methods 0.000 title claims description 10
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 129
- 239000011258 core-shell material Substances 0.000 claims description 98
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 92
- 229910044991 metal oxide Inorganic materials 0.000 claims description 92
- 150000004706 metal oxides Chemical class 0.000 claims description 92
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 claims description 82
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 claims description 70
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 claims description 69
- 239000010410 layer Substances 0.000 claims description 69
- 239000000463 material Substances 0.000 claims description 69
- 239000010948 rhodium Substances 0.000 claims description 64
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims description 50
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- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 claims description 3
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- UIWYJDYFSGRHKR-UHFFFAOYSA-N gadolinium atom Chemical compound [Gd] UIWYJDYFSGRHKR-UHFFFAOYSA-N 0.000 claims description 2
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Description
自動車用触媒複合体は、コアとコアを取り囲むシェルとを含む複数のコアシェル支持体粒子を含む。コアは、通常、最大約5μmの一次粒度分布d90を有する複数の粒子を含み、コアの粒子は、1種または複数の金属酸化物の粒子を含む。上記に認められるように、コア構造は、所望の寸法:約0.1μm〜約5μmの範囲の一次粒度分布d90(好ましくは約0.25〜約3μmの範囲のd90)の、金属酸化物粒子を含む。一次粒子の所望の寸法範囲を達成するために、コアの粒子はより大きな粒子(例えば凝集粒子)から混練されてもよい。典型的にはスラリー状の、粒子の混練は、ボールミルまたは他の類似装置で達成されてもよく、混練中のスラリーの固形分は、例えば約10〜50質量%、とりわけ約10〜40質量%であってもよい。
基材
本発明は、また、本明細書に記載される触媒組成物を組み込んだ排出物質処理システムを提供する。本発明の触媒組成物を含む触媒物品は、通常、排気ガス排出物質処理のための1種または複数の追加の成分を含む統合された排出物質処理システムに使用される。排出物質処理システムの様々な成分の相対的な配置は変えることができる。例えば、排出物質処理システムは、選択接触還元(SCR)の触媒物品をさらに含んでよい。処理システムは、アンモニア酸化(AMOx)材料、アンモニア発生触媒、ならびにNOx蓄積および/またはトラッピング成分(LNT)などのさらなる成分を含むことができる。成分の先の列挙は単に例示であり、本発明の範囲の限定として見るべきでない。
以下の非限定的な実施例は、本発明の様々な実施形態を例証するのに役立つと予想される。
La2O3−ZrO2コアの粒子は8%のLa2O3および92%のZrO2で構成される。コロイド性CeO2(20%のCeO2)750グラムを水約1630グラムに加える。La2O3(8%)/ZrO(92%)粒子1369グラムをゆっくり加える。非常によく混合する。90%の元の粒度分布(すなわちD90)は65〜70μm未満である。スラリーを混練して90%で4〜5μm未満の粒度分布にする。最終のスラリー特性は、pH=6.3、固形分34.7%および粘度=12.5cpである。スラリーを噴霧乾燥して粉末にし、10%のCeO2を含むCeO2シェル、および90%のLa2O3−ZrO2のコアを形成する。110℃で2時間乾燥し、550℃で2時間焼成する。図2Aおよび2Bに示すように、コアシェル構造を求めるために走査型電子顕微鏡を使用した。
コロイド性CeO2(20%のCeO2)2250グラムを水約435グラムに加える。La2O3(8%)/ZrO(92%)1064グラムをゆっくり加える。非常によく混合する。90%の元の粒度分布は65μm未満である。スラリーを混練して90%で4〜5μm未満の粒度分布にする。最終のスラリー特性は、pH=5.26、固形分37.9%および粘度=9cpである。スラリーを噴霧乾燥して粉末にし、30%のCeO2を含むCeO2シェル、および70%のLa2O3−ZrO2のコアを形成する。110℃で2時間乾燥し、550℃で2時間焼成する。図3Aおよび3Bに示すように、走査型電子顕微鏡をコアシェル構造を求めるために使用した。
この実施例は、実施例1に記載した発明の材料を使用する、2層ウォッシュコート設計の形態の三元変換(TWC)触媒の製造を記載する。別個のPdおよびRhウォッシュコートを、モノリス基材(600セル/in2および4ミルの壁厚)に塗布した。PdおよびRhの装填率はそれぞれ47および3g/ft3である。同じモノリス基材をすべての実施例に使用した。
実施例3〜5および比較例1〜4の被覆した基材を、10%の水蒸気中950℃または1050℃で5時間エージングにかけた。反応器は直径1インチ長さ1.5インチの基材を使用した。触媒は、室温の反応器にしっかりと配置した。ガス組成は、C3H8、CO/H2、NO、O2、SO2、CO2およびH2Oで構成されていた。COおよびO2は試験中に変えて、車両シミュレーションに基づくラムダ条件を調整した。反応器に供給した後、触媒温度は、欧州走行サイクルを模したプロファイルを維持ながら上げた。次いで、HC、COおよびNOxについて累積した排出を時間に対してプロットした。
Claims (39)
- 担体上の、コアと前記コアを取り囲むシェルとを含む複数のコアシェル支持体粒子を含む触媒材料、および
前記コアシェル支持体上の1種または複数の白金族金属(PGM)
を含む自動車用触媒複合体であって、
前記コアは、最大約5μmの一次粒度分布d90を有する複数の粒子を含み、前記コアの粒子は、1種または複数の金属酸化物の粒子を含み、
前記シェルは、1種または複数の金属酸化物のナノ粒子を含み、前記ナノ粒子は、約5nm〜約1000nm(1μm)の範囲の一次粒度分布d90を有し、及び
前記シェルが1〜10μmの範囲の厚さを有し、
前記触媒材料は、自動車排気ガス流中の一酸化炭素、炭化水素およびNOx排出の緩和に効果的である、自動車用触媒複合体。 - 前記シェルが約2〜約6μmの範囲の厚さを有する、請求項1に記載の自動車用触媒複合体。
- 前記シェルが前記コアシェル支持体の平均粒子直径の約10〜約50%の厚さを有する、請求項1に記載の自動車用触媒複合体。
- 前記コアが約5〜約20μmの範囲の直径を有する、請求項1に記載の自動車用触媒複合体。
- 前記コアシェル支持体が、前記コアシェル支持体の合計質量に対して、約50〜約95質量%の前記コアおよび約5〜約50質量%の前記シェルを含む、請求項1に記載の自動車用触媒複合体。
- 前記コアシェル支持体が、約8μm〜約30μmの範囲の平均粒子直径を有する、請求項1に記載の自動車用触媒複合体。
- 前記コアが、約0.1〜約5μmの範囲の一次粒度分布d90を有する1種または複数の金属酸化物の粒子を含む、請求項1に記載の自動車用触媒複合体。
- 前記コアの金属酸化物が、アルミナ、ジルコニア、チタニア、シリカおよびその組合せからなる群から選択される金属酸化物を含み、前記シェルの金属酸化物が1種または複数のPGMをその上に支持し、前記シェルの金属酸化物は、ジルコニア、チタニア、セリア、プラセオジミア、酸化マンガン、ランタナ、バリア、酸化ガリウム、酸化鉄、酸化コバルト、酸化ニッケル、酸化亜鉛およびその組合せからなる群から選択される金属酸化物を含む、請求項1に記載の自動車用触媒複合体。
- 前記シェルの金属酸化物および前記コアの金属酸化物が、アルミナ、ジルコニア、チタニア、セリア、酸化マンガン、ジルコニアアルミナ、セリアジルコニア、セリアアルミナ、ランタナアルミナ、バリアアルミナ、シリカ、シリカアルミナおよびその組合せからなる群から独立して選択される、請求項1に記載の自動車用触媒複合体。
- 前記シェルが、ランタン、バリウム、プラセオジム、ネオジム、サマリウム、ストロンチウム、カルシウム、マグネシウム、ニオブ、ハフニウム、ガドリニウム、マンガン、鉄、スズ、亜鉛およびその組合せの酸化物からなる群から選択される卑金属酸化物をさらに含む、請求項1に記載の自動車用触媒複合体。
- 前記卑金属酸化物が、前記コアシェル支持体の質量に対して約1〜約20質量%の量で存在する、請求項10に記載の自動車用触媒複合体。
- 前記コアシェル支持体が、N2多孔度測定法によって測定して約30Åより大きい平均細孔半径を有する、請求項1に記載の自動車用触媒複合体。
- 1種または複数のPGMが前記シェルに堆積され、前記PGMが、白金(Pt)、ロジウム(Rh)、パラジウム(Pd)、イリジウム(Ir)、ルテニウム(Ru)およびその組合せからなる群から選択される、請求項1に記載の自動車用触媒複合体。
- 前記PGMが、Pt成分、Pd成分、Rh成分またはその組合せを含む、請求項13に記載の自動車用触媒複合体。
- PtとPdの質量比が約5:1〜約1:5の範囲にある、請求項14に記載の自動車用触媒複合体。
- PtおよびPdの合計量が、コアシェル支持体の合計質量に対して約0.1〜約5質量%である、請求項14に記載の自動車用触媒複合体。
- 前記シェルがセリアを含み、前記コアが、ジルコニア、アルミナ、セリアジルコニアおよびランタナジルコニアの少なくとも1つを含み、前記シェルは前記1種または複数のPGMを含む、請求項1に記載の自動車用触媒複合体。
- 前記シェルがジルコニアおよびアルミナの少なくとも1つを含み、前記コアがセリアまたはセリアジルコニアを含み、前記シェルは1種または複数のPGMを含む、請求項1に記載の自動車用触媒複合体。
- 前記担体がフロースルー基材または壁面流フィルターである、請求項1に記載の自動車用触媒複合体。
- 前記担体上の前記コアシェル支持体粒子の装填率が、約0.5〜約3.0g/in3である、請求項1に記載の自動車用触媒複合体。
- 金属酸化物結合剤をさらに含む、請求項1に記載の自動車用触媒複合体。
- 前記金属酸化物結合剤がアルミナ、ジルコニア、セリアジルコニアまたはその混合物を含む、請求項21に記載の自動車用触媒複合体。
- 前記コアシェル支持体粒子と混合された別の金属酸化物成分をさらに含み、前記別の金属酸化物成分は、任意にPGMで含浸された、請求項1に記載の自動車用触媒複合体。
- 前記別の金属酸化物成分が、任意にPt成分、Rh成分、Pd成分またはその組合せで含浸された、アルミナ、ジルコニア、セリアおよびセリアジルコニアからなる群から選択される、請求項23に記載の自動車用触媒複合体。
- 前記コアシェル支持体粒子と混合された別の成分をさらに含み、前記別の成分は、任意にPGMで含浸されたアルミナ、セリアまたはセリアジルコニア粒子を含む、請求項1に記載の自動車用触媒複合体。
- 単層のガソリン触媒の形態である、請求項1に記載の自動車用触媒複合体。
- 第1の層としてのコアシェル支持体粒子、および前記第1の層の上に重なる金属酸化物とPGMで含浸された酸素蓄積成分とを含む第2の層を含む、多層ガソリン三元触媒(TWC触媒)の形態である、請求項1に記載の自動車用触媒複合体。
- 前記第2の層のPGMが、Pt成分、Pd成分、Rh成分およびその組合せからなる群から選択される、請求項27に記載の自動車用触媒複合体。
- 多層ガソリン三元触媒(TWC触媒)の形態であり、前記三元触媒は、第1の層としてのコアシェル支持体粒子、および前記第1の層の上に重なる、PGMを含浸させた金属酸化物の第2の層、および前記第2の層の上に重なる、金属酸化物とPGMを含浸させた酸素蓄積成分との混合物を含む第3の層を含む、請求項1に記載の自動車用触媒複合体。
- 前記第3の層のPGMが、Pt成分、Pd成分、Rh成分およびその組合せからなる群から選択される、請求項29に記載の自動車用触媒複合体。
- 前記触媒材料が、担体の長手に沿って異なる触媒材料を含むゾーンで構成されている、請求項1に記載の自動車用触媒複合体。
- 前記触媒材料が前記担体に異なる触媒材料で階層化されている、請求項1に記載の自動車用触媒複合体。
- 前記コアシェル支持体粒子を含有する触媒材料が、ガソリン排気システムの、接近して連結した、または床下の位置にある、請求項1に記載の自動車用触媒複合体。
- 炭化水素(HC)、一酸化炭素(CO)およびNOxを変換する触媒として効果的な形態であり、
前記コアが、約0.1μm〜約5μmの範囲の一次粒度分布d90を有する1種または複数の金属酸化物の粒子を含み;
前記シェルが、約5nm〜約100nm(0.1μm)の範囲の一次粒度分布d90を有する1種または複数の金属酸化物のナノ粒子を含み;
前記複合体が、前記コアシェル支持体に堆積された、1種または複数の白金族金属(PGM)をさらに含み;
前記コアシェル支持体粒子は、N2多孔度測定法によって測定して約30Åより大きい平均細孔半径を有する、請求項1に記載の自動車用触媒複合体。 - 内燃機関の下流に位置する、請求項1から34のいずれか一項に記載の自動車用触媒複合体を含む排気ガス処理システム。
- 前記内燃機関がガソリンエンジンである、請求項35に記載の排気ガス処理システム。
- 炭化水素および一酸化炭素を含む排気ガスを処理する方法であって、前記排気ガスを、請求項1から34のいずれか一項に記載の自動車用触媒複合体と接触させることを含む方法。
- 自動車用触媒複合体を製造する方法であって、
コア構造用の水性懸濁液中の、最大約5μmの一次粒度分布d90を有し、1種または複数の金属酸化物を含む複数の粒子を得ることと;
約5nm〜約1000nm(1μm)の範囲の一次粒度分布d90を有する、1種または複数の金属酸化物のナノ粒子の溶液を得ることと;
コア構造用の前記水性懸濁液と前記ナノ粒子の溶液とを混合して混合物を形成することと;
前記混合物を噴霧乾燥して、複数のコアシェル支持体粒子を形成することと;
前記コアシェル支持体粒子を1種または複数の白金族金属(PGM)で処理して触媒材料を形成することと;
担体に触媒材料を堆積させることと
を含む方法。 - 1種または複数のPGMが、前記コアシェル支持体に堆積されており、白金(Pt)、ロジウム(Rh)、パラジウム(Pd)、イリジウム(Ir)、ルテニウム(Ru)およびその組合せからなる群から選択される、請求項38に記載の方法。
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WO2017205042A2 (en) | 2017-11-30 |
BR112018073996A2 (pt) | 2019-02-26 |
RU2018145993A3 (ja) | 2020-06-26 |
CA3025299A1 (en) | 2017-11-30 |
RU2018145993A (ru) | 2020-06-26 |
WO2017205042A3 (en) | 2018-07-26 |
KR20190003799A (ko) | 2019-01-09 |
CN109153009A (zh) | 2019-01-04 |
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