JP7481485B2 - 触媒担体及び誘導加熱触媒システム - Google Patents
触媒担体及び誘導加熱触媒システム Download PDFInfo
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- JP7481485B2 JP7481485B2 JP2022560651A JP2022560651A JP7481485B2 JP 7481485 B2 JP7481485 B2 JP 7481485B2 JP 2022560651 A JP2022560651 A JP 2022560651A JP 2022560651 A JP2022560651 A JP 2022560651A JP 7481485 B2 JP7481485 B2 JP 7481485B2
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- catalyst
- catalyst carrier
- gas flow
- induction heating
- flow direction
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Images
Classifications
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- F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
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- F01N3/2013—Periodically heating or cooling catalytic reactors, e.g. at cold starting or overheating using electric or magnetic heating means
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- 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
- F01N3/2066—Selective catalytic reduction [SCR]
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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
- 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
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2251/00—Reactants
- B01D2251/20—Reductants
- B01D2251/206—Ammonium compounds
- B01D2251/2062—Ammonia
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/90—Physical characteristics of catalysts
- B01D2255/911—NH3-storage component incorporated in the catalyst
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2258/00—Sources of waste gases
- B01D2258/01—Engine exhaust gases
- B01D2258/012—Diesel engines and lean burn gasoline engines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- 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
- 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
- B01D53/9495—Controlling the catalytic process
-
- 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
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
- B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
-
- 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
- F01N2240/00—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
- F01N2240/16—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being an electric heater, i.e. a resistance heater
-
- 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
- F01N2330/06—Ceramic, e.g. monoliths
-
- 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
- F01N2330/30—Honeycomb supports characterised by their structural details
- F01N2330/34—Honeycomb supports characterised by their structural details with flow channels of polygonal cross section
-
- 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
- F01N2510/00—Surface coverings
- F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction
- F01N2510/068—Surface coverings for exhaust purification, e.g. catalytic reaction characterised by the distribution of the catalytic coatings
-
- 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
- F01N2570/00—Exhaust treating apparatus eliminating, absorbing or adsorbing specific elements or compounds
- F01N2570/14—Nitrogen oxides
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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
- F01N2610/00—Adding substances to exhaust gases
- F01N2610/02—Adding substances to exhaust gases the substance being ammonia or urea
-
- 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
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
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- Exhaust Gas After Treatment (AREA)
Description
(1)外周壁と、前記外周壁の内側に配設され、ガス流れ方向入口側の端面から出口側の端面まで延びて流路を形成する複数のセルを区画形成する隔壁と、を有する柱状ハニカム構造部を備えるハニカム構造体と、
前記隔壁の内部に担持された触媒と、
前記ハニカム構造体内に設けられた磁性体と、
を有する誘導加熱用の触媒担体であって、
前記触媒担体の、少なくともガス流れ方向入口側の端面側に、前記触媒を担持しない領域Aを有し、
ガス流れ方向において前記磁性体が少なくとも前記領域Aに配置されている、誘導加熱用の触媒担体。
(2)(1)に記載の誘導加熱用の触媒担体と、前記触媒担体の外周に設けられたコイルと、を有する誘導加熱触媒システム。
図1は、本発明の実施形態における、触媒担体10のセル13の延伸方向に平行な断面模式図である。図2は、図1における触媒担体10のL1-L1断面の模式図である。
次に、本発明の実施形態に係る触媒担体の製造方法を説明する。まず、セラミックス製の隔壁を有し、隔壁によって複数のセルが区画形成されたハニカム構造体を作製する。例えば、コージェライトからなるハニカム構造体を作製する場合には、まず、坏土用材料としてコージェライト化原料を用意する。コージェライト化原料は、コージェライト結晶の理論組成となるように各成分を配合するため、シリカ源成分、マグネシア源成分、及びアルミナ源成分等を配合する。このうちシリカ源成分としては、石英、溶融シリカを用いることが好ましく、更に、このシリカ源成分の粒径を100~150μmとすることが好ましい。
まず、磁性粉体、及び、ガラス等で構成された固着材を混在させた材料で表面層形成用スラリーを作製する。具体的には、例えば、磁性粉体とガラス粉末を配合し、これにバインダ、分散剤、水を配合して表面層形成用スラリーを作製する。磁性粉体とガラス粉体の配合比としては、体積基準で1:1以上、20:1以下である。
磁性粉体と、金属又はガラスを主成分とする結合材とを含むスラリーをハニカム乾燥体のセル内に流し込み、当該金属の融点、又は、ガラスの軟化点以上の温度で加熱して固める。または、磁性粉体と、シリカ又はアルミナを主成分とする接着材料とを含むスラリーをハニカム乾燥体のセル内に流し込み、加熱してシリカ又はアルミナを固化する。
アルミナやシリカを主成分とする接着材料を用いる場合においては、スラリーをセル内に流し込む工程はハニカム成形、乾燥体の段階で行っても良い。この場合は、スラリーをハニカム成形体のセル内に流し込んだ後、ハニカム成形体を乾燥し、ハニカム乾燥体の焼成工程において、磁性体が接着材料に固定する工程が同時に行われる。シリカ又はアルミナは、乾燥により固化する効果を発現することが好ましい。
まず、磁性体を充填するハニカム乾燥体のセルの断面形状及びセルの長さを考慮して、所定の板状、棒状、ワイヤ状、または繊維状の磁性体を準備する。次に、ハニカム乾燥体の所定のセルに、上流側の端面から所定の長さまで磁性体を差し込むことで、セル内に磁性体を充填する。また、磁性体がリング状である場合は、ハニカム乾燥体の上流側の端面を所定の深さだけ切削除去して溝部を形成しておき、当該溝部にリング状の磁性体を差し込む。または、溝部を形成した生のハニカム成形体を作製しておき、これを乾燥させてハニカム乾燥体を作製した後、当該溝部にリング状の磁性体を差し込む。
図8に、本発明の実施形態における、誘導加熱触媒システム100のガス流れ方向に平行な断面模式図を示す。誘導加熱触媒システム100は、本発明の実施形態に係る触媒担体10、及び、触媒担体10の外周に設けられたコイル19を有する。
図9に、実施例1で準備した誘導加熱触媒システムのガス流れ方向に平行な断面模式図を示す。図9において、それぞれ、「SCR」は選択還元触媒を示し、「DOC」は酸化触媒を示し、「DPF」はディーゼルパティキュレートフィルターを示し、「CC-」はエンジン直下を示し、「UF」は床下を示す。
<初期条件>
・ハニカム構造体温度:300K
・初期アンモニア吸蔵量:CC-SCR、UF-SCR共に0g/L
<通電条件>
・誘電加熱方法:30kWの誘電加熱相当の熱量をCC-SCR全域に均一付与
・通電時間:FTP走行モード開始から500秒間
<供給排ガス条件>
・NH3濃度:入りガスNOx濃度の1.5倍になるように0~500秒で供給
比較例1として、実施例1に対し、CC-SCRの触媒配置領域をコージェライト担体のガス流れ方向の入口側の端面から出口側の端面まで全域に設けた以外は、同様の条件でシミュレーションを実施した。
参考例1として、比較例1に対し、CC-SCRに磁性体を配置せず、さらにCC-SCRの周囲にコイルを設けず、誘導加熱をしなかった以外は、同様の構成とした。そして、このような構成の参考例1のNOxエミッションを基準値100%とした。
実施例2として、実施例1に対し、CC-SCRのコージェライト担体のガス流れ方向において、前段と後段とに同じ距離だけ2等分し、前段にのみ実施例1と同様の磁性体及びコイルを設け、後段にのみ触媒を担持させた。
すなわち、実施例2のコージェライト担体は実施例1のコージェライト担体と同様であり、セルの延伸方向の長さが152.4mmである。また、後段の触媒配置領域のセルの延伸方向の長さが76.2mmである。ガス流れ方向において磁性体が配置されている領域Aは、コージェライト担体のガス流れ方向入口側の端面からコージェライト担体の長さの50%の位置まで配置されている。このように、実施例2のCC-SCRのコージェライト担体のガス流れ方向において、触媒が設けられた領域と磁性体が設けられた領域とが重なる部分αは無い。
また、誘導加熱の際の電力を10kWとした。それら以外は、実施例1と同様の条件でシミュレーションを実施した。
実施例3として、実施例2に対し、CC-SCRのコージェライト担体のガス流れ方向において、磁性体及びコイルを設けた領域を触媒配置領域へ22.9mmだけ延長して、触媒配置領域と磁性体が設けられた領域とが重なる部分αが触媒配置領域全体の30%となるようにした以外は、実施例2と同様の条件でシミュレーションを実施した。このとき、ガス流れ方向において磁性体が配置されている領域Aは、コージェライト担体のガス流れ方向入口側の端面からコージェライト担体の長さの65%の位置まで配置されている。
実施例4として、実施例2に対し、CC-SCRのコージェライト担体のガス流れ方向において、磁性体及びコイルを設けた領域を触媒配置領域へ38.1mmだけ延長して、触媒配置領域と磁性体が設けられた領域とが重なる部分αが触媒配置領域全体の50%となるようにした以外は、実施例2と同様の条件でシミュレーションを実施した。このとき、ガス流れ方向において磁性体が配置されている領域Aは、コージェライト担体のガス流れ方向入口側の端面からコージェライト担体の長さの75%の位置まで配置されている。
実施例5として、実施例2に対し、CC-SCRのコージェライト担体のガス流れ方向において、磁性体及びコイルを設けた領域を触媒配置領域へ60.96mmだけ延長して、触媒配置領域と磁性体が設けられた領域とが重なる部分αが触媒配置領域全体の80%となるようにした以外は、実施例2と同様の条件でシミュレーションを実施した。このとき、ガス流れ方向において磁性体が配置されている領域Aは、コージェライト担体のガス流れ方向入口側の端面からコージェライト担体の長さの90%の位置まで配置されている。
11、21、31、41、51 ハニカム構造体
12 触媒
13 セル
14 外周壁
15 隔壁
16 柱状ハニカム構造部
17 磁性体
18 表面層
19 コイル
22 無機マット材
23 金属管
61 CC-SCR
62 DOC
63 DPF
64 ミキサー
65 UF-SCR
66 無機マット材
67 金属管
68 コイル
100 誘導加熱触媒システム
Claims (7)
- 外周壁と、前記外周壁の内側に配設され、ガス流れ方向入口側の端面から出口側の端面まで延びて流路を形成する複数のセルを区画形成する隔壁と、を有する柱状ハニカム構造部を備えるハニカム構造体と、
前記隔壁の内部に担持された触媒と、
前記ハニカム構造体内に設けられた磁性体と、
を有する誘導加熱用の触媒担体であって、
前記触媒担体の、少なくともガス流れ方向入口側の端面側に、前記触媒を担持しない領域Aを有し、
ガス流れ方向において前記磁性体が少なくとも前記領域Aに配置されており、
前記磁性体が、リング状であり、前記触媒担体のガス流れ方向入口側の端面に設けられた溝部に、前記リング状の磁性体が埋め込まれている、誘導加熱用の触媒担体。 - 前記領域Aは、前記触媒担体のガス流れ方向入口側の端面から前記触媒担体の長さの10%~70%の位置まで配置されている、請求項1に記載の誘導加熱用の触媒担体。
- ガス流れ方向において、前記触媒が担持された領域と前記磁性体が設けられた領域とが重なる部分を有する、請求項1または2に記載の誘導加熱用の触媒担体。
- 前記触媒が、SCR触媒である、請求項1~3のいずれか一項に記載の誘導加熱用の触媒担体。
- 前記磁性体が、磁性粉体が分散されてなる、請求項1~4のいずれか一項に記載の誘導加熱用の触媒担体。
- 請求項1~5のいずれか一項に記載の誘導加熱用の触媒担体と、前記触媒担体の外周に設けられたコイルと、を有する誘導加熱触媒システム。
- 前記コイルが、前記触媒担体のガス流れ方向において、前記磁性体が設けられた領域に対応する位置に設けられている、請求項6に記載の誘導加熱触媒システム。
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