JPWO2017006720A1 - 排ガス浄化フィルタの製造方法、排ガス浄化フィルタ及び排ガス浄化装置 - Google Patents
排ガス浄化フィルタの製造方法、排ガス浄化フィルタ及び排ガス浄化装置 Download PDFInfo
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- JPWO2017006720A1 JPWO2017006720A1 JP2017527149A JP2017527149A JPWO2017006720A1 JP WO2017006720 A1 JPWO2017006720 A1 JP WO2017006720A1 JP 2017527149 A JP2017527149 A JP 2017527149A JP 2017527149 A JP2017527149 A JP 2017527149A JP WO2017006720 A1 JPWO2017006720 A1 JP WO2017006720A1
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- Prior art keywords
- exhaust gas
- gas purification
- purification filter
- zeolite
- catalyst
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000000746 purification Methods 0.000 title claims abstract description 87
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 23
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 claims abstract description 65
- 229910021536 Zeolite Inorganic materials 0.000 claims abstract description 64
- 239000010457 zeolite Substances 0.000 claims abstract description 64
- 239000003054 catalyst Substances 0.000 claims abstract description 36
- 239000002245 particle Substances 0.000 claims abstract description 27
- 238000000034 method Methods 0.000 claims abstract description 18
- 239000003513 alkali Substances 0.000 claims abstract description 16
- 239000002994 raw material Substances 0.000 claims abstract description 16
- 238000011282 treatment Methods 0.000 claims abstract description 16
- 238000005342 ion exchange Methods 0.000 claims abstract description 13
- 229910052723 transition metal Inorganic materials 0.000 claims abstract description 11
- 150000003624 transition metals Chemical class 0.000 claims abstract description 11
- 238000010304 firing Methods 0.000 claims abstract description 9
- 239000000203 mixture Substances 0.000 claims abstract description 8
- 239000007789 gas Substances 0.000 claims description 99
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 claims description 65
- 229910000505 Al2TiO5 Inorganic materials 0.000 claims description 17
- 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 claims description 17
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 6
- 229910052757 nitrogen Inorganic materials 0.000 claims description 4
- 239000012876 carrier material Substances 0.000 claims 1
- 239000013618 particulate matter Substances 0.000 description 34
- 210000004027 cell Anatomy 0.000 description 28
- 239000004115 Sodium Silicate Substances 0.000 description 24
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 24
- 229910052911 sodium silicate Inorganic materials 0.000 description 24
- 239000007864 aqueous solution Substances 0.000 description 20
- 239000002002 slurry Substances 0.000 description 18
- 230000015572 biosynthetic process Effects 0.000 description 17
- 238000003786 synthesis reaction Methods 0.000 description 17
- 239000011734 sodium Substances 0.000 description 16
- 239000000243 solution Substances 0.000 description 15
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 15
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 12
- 239000011148 porous material Substances 0.000 description 11
- 239000007787 solid Substances 0.000 description 11
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 8
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 8
- 238000006722 reduction reaction Methods 0.000 description 8
- 238000002485 combustion reaction Methods 0.000 description 7
- 238000000151 deposition Methods 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- 229910008484 TiSi Inorganic materials 0.000 description 6
- 229910006249 ZrSi Inorganic materials 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 6
- 239000000654 additive Substances 0.000 description 5
- 239000013078 crystal Substances 0.000 description 5
- 230000008021 deposition Effects 0.000 description 5
- 238000001125 extrusion Methods 0.000 description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 4
- 229910052783 alkali metal Inorganic materials 0.000 description 4
- 150000001340 alkali metals Chemical class 0.000 description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 4
- 229910021529 ammonia Inorganic materials 0.000 description 4
- 239000003638 chemical reducing agent Substances 0.000 description 4
- OPQARKPSCNTWTJ-UHFFFAOYSA-L copper(ii) acetate Chemical compound [Cu+2].CC([O-])=O.CC([O-])=O OPQARKPSCNTWTJ-UHFFFAOYSA-L 0.000 description 4
- 235000014113 dietary fatty acids Nutrition 0.000 description 4
- 239000000194 fatty acid Substances 0.000 description 4
- 229930195729 fatty acid Natural products 0.000 description 4
- 150000004665 fatty acids Chemical class 0.000 description 4
- 239000010439 graphite Substances 0.000 description 4
- 229910002804 graphite Inorganic materials 0.000 description 4
- 229920000609 methyl cellulose Polymers 0.000 description 4
- 239000001923 methylcellulose Substances 0.000 description 4
- 235000010981 methylcellulose Nutrition 0.000 description 4
- 230000003647 oxidation Effects 0.000 description 4
- 238000007254 oxidation reaction Methods 0.000 description 4
- 238000005192 partition Methods 0.000 description 4
- 230000008929 regeneration Effects 0.000 description 4
- 238000011069 regeneration method Methods 0.000 description 4
- 239000000344 soap Substances 0.000 description 4
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 3
- 229910006501 ZrSiO Inorganic materials 0.000 description 3
- 239000012670 alkaline solution Substances 0.000 description 3
- 239000004202 carbamide Substances 0.000 description 3
- 239000000919 ceramic Substances 0.000 description 3
- 239000004927 clay Substances 0.000 description 3
- 229910052802 copper Inorganic materials 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- 238000011156 evaluation Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 229910052700 potassium Inorganic materials 0.000 description 3
- 229910052710 silicon Inorganic materials 0.000 description 3
- 239000000377 silicon dioxide Substances 0.000 description 3
- 229910052708 sodium Inorganic materials 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 239000004034 viscosity adjusting agent Substances 0.000 description 3
- ATRRKUHOCOJYRX-UHFFFAOYSA-N Ammonium bicarbonate Chemical compound [NH4+].OC([O-])=O ATRRKUHOCOJYRX-UHFFFAOYSA-N 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- OAKJQQAXSVQMHS-UHFFFAOYSA-N Hydrazine Chemical compound NN OAKJQQAXSVQMHS-UHFFFAOYSA-N 0.000 description 2
- 229910010100 LiAlSi Inorganic materials 0.000 description 2
- LRHPLDYGYMQRHN-UHFFFAOYSA-N N-Butanol Chemical compound CCCCO LRHPLDYGYMQRHN-UHFFFAOYSA-N 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- 239000001099 ammonium carbonate Substances 0.000 description 2
- 229910052792 caesium Inorganic materials 0.000 description 2
- 230000003197 catalytic effect Effects 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 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 2
- 239000012013 faujasite Substances 0.000 description 2
- -1 for example Substances 0.000 description 2
- 238000005470 impregnation Methods 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 229910052744 lithium Inorganic materials 0.000 description 2
- 229910052680 mordenite Inorganic materials 0.000 description 2
- 229910052863 mullite Inorganic materials 0.000 description 2
- BWHMMNNQKKPAPP-UHFFFAOYSA-L potassium carbonate Substances [K+].[K+].[O-]C([O-])=O BWHMMNNQKKPAPP-UHFFFAOYSA-L 0.000 description 2
- 239000002243 precursor Substances 0.000 description 2
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 2
- 229910052814 silicon oxide Inorganic materials 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 229910000029 sodium carbonate Inorganic materials 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 229910052719 titanium Inorganic materials 0.000 description 2
- 238000005406 washing Methods 0.000 description 2
- 229910052726 zirconium Inorganic materials 0.000 description 2
- 229910000013 Ammonium bicarbonate Inorganic materials 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- 235000006481 Colocasia esculenta Nutrition 0.000 description 1
- 240000004270 Colocasia esculenta var. antiquorum Species 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 238000002441 X-ray diffraction Methods 0.000 description 1
- 150000001242 acetic acid derivatives Chemical class 0.000 description 1
- 238000003915 air pollution Methods 0.000 description 1
- 150000001298 alcohols Chemical class 0.000 description 1
- 229910001413 alkali metal ion Inorganic materials 0.000 description 1
- 229910000272 alkali metal oxide Inorganic materials 0.000 description 1
- 229910000287 alkaline earth metal oxide Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- 235000012538 ammonium bicarbonate Nutrition 0.000 description 1
- 235000012501 ammonium carbonate Nutrition 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 238000010531 catalytic reduction reaction Methods 0.000 description 1
- 210000002421 cell wall Anatomy 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 229910052878 cordierite Inorganic materials 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 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 1
- 238000007598 dipping method Methods 0.000 description 1
- 239000002270 dispersing agent Substances 0.000 description 1
- 238000010828 elution Methods 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 229910052730 francium Inorganic materials 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 150000002500 ions Chemical group 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 239000012046 mixed solvent Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 229910000027 potassium carbonate Inorganic materials 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- BDERNNFJNOPAEC-UHFFFAOYSA-N propan-1-ol Chemical compound CCCO BDERNNFJNOPAEC-UHFFFAOYSA-N 0.000 description 1
- 229910052703 rhodium Inorganic materials 0.000 description 1
- 229910052701 rubidium Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 229910002001 transition metal nitrate Inorganic materials 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- 230000004580 weight loss Effects 0.000 description 1
Classifications
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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
- B01J37/0018—Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat)
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- 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
- B01J29/40—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
- B01J29/42—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively containing iron group metals, noble metals or copper
- B01J29/46—Iron group metals or copper
-
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
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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
- B01D53/9404—Removing only nitrogen compounds
- B01D53/9409—Nitrogen oxides
- B01D53/9413—Processes characterised by a specific catalyst
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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
- B01D53/9404—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
-
- 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
- B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
- B01J21/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
- B01J21/063—Titanium; Oxides or hydroxides thereof
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
- B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
- B01J29/064—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof containing iron group metals, noble metals or copper
- B01J29/072—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
- B01J29/40—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
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- B01J35/56—
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- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
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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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- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/02—Impregnation, coating or precipitation
- B01J37/0201—Impregnation
- B01J37/0207—Pretreatment of the support
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
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- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
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- B01J37/08—Heat treatment
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/30—Ion-exchange
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/46—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates
- C04B35/462—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates based on titanates
- C04B35/478—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates based on titanates based on aluminium titanates
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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Abstract
Description
本発明の排ガス浄化装置は、上記本発明の排ガス浄化フィルタを備えている。上記本発明の排ガス浄化フィルタの他に、例えば、排ガス浄化フィルタに還元剤等を供給する手段をさらに備えている。又は、本発明の排ガス浄化フィルタにPMを燃焼させる触媒が含まれている場合は、堆積したPMを分解するため排ガス浄化フィルタを加熱する手段等をさらに備えている。
(合成例1)
10質量%酢酸銅水溶液1000mlとZSM−5型ゼオライト(HSZ−840NHA、東ソー株式会社製)400gとを混合し、60℃で12時間撹拌することでスラリーを調製した。調製したスラリーの固形分を濾別し、1000mlのイオン交換水で洗浄した後、110℃にて6時間乾燥した。
(合成例2)
炭酸ナトリウム32.3質量部、酸化アルミニウム31.1質量部、及び酸化ケイ素36.6質量部を混合し、1200℃で4時間焼成した。得られた粒子状固体が、X線回折によりNaAlSiO4の単相であることを確認した。
(実施例1)
ZSM‐5型ゼオライト(HSZ‐840NHA:東ソー株式会社製)20質量部に対し、チタン酸アルミニウム(丸ス釉薬社製)80質量部、合成例2で製造したNaAlSiO4を10質量部、黒鉛3質量部、メチルセルロース10質量部、及び脂肪酸石鹸0.5質量部を配合し、さらに水を適当量添加して混練し、押出成形可能な坏土を得た。
pH10.0に調整したケイ酸ナトリウム水溶液を、pHを11.0に調整したケイ酸ナトリウム水溶液に変更した以外は、実施例1と同様の方法で排ガス浄化フィルタを製造した。
pH10.0に調整したケイ酸ナトリウム水溶液を、pHを12.0に調整したケイ酸ナトリウム水溶液に変更した以外は、実施例1と同様の方法で排ガス浄化フィルタを製造した。
pH10.0に調整したケイ酸ナトリウム水溶液を、pHを10.0に調整した水酸化ナトリウム水溶液に変更した以外は、実施例1と同様の方法で行った。
pH10.0に調整したケイ酸ナトリウム水溶液を、pHを10.0に調整した水酸化カリウム水溶液に変更した以外は、実施例1と同様の方法で排ガス浄化フィルタを製造した。
合成例2で製造したNaAlSiO4を、TISMO−N(大塚化学株式会社製)に変更した以外は、実施例1と同様の方法で排ガス浄化フィルタを製造した。
合成例2で製造したNaAlSiO4を、TISMO−N(大塚化学株式会社製)に変更し、pH10.0に調整したケイ酸ナトリウム水溶液を、pHを11.0に調整したケイ酸ナトリウム水溶液に変更した以外は、実施例1と同様の方法で排ガス浄化フィルタを製造した。
合成例2で製造したNaAlSiO4を、TISMO−N(大塚化学株式会社製)に変更し、pH10.0に調整したケイ酸ナトリウム水溶液を、pHを12.0に調整したケイ酸ナトリウム水溶液に変更した以外は、実施例1と同様の方法で排ガス浄化フィルタを製造した。
合成例2で製造したNaAlSiO4を、TISMO−N(大塚化学株式会社製)に変更し、pH10.0に調整したケイ酸ナトリウム水溶液を、pHを10.0に調整した水酸化ナトリウム水溶液に変更した以外は、実施例1と同様の方法で排ガス浄化フィルタを製造した。
合成例2で製造したNaAlSiO4を、TISMO−N(大塚化学株式会社製)に変更し、pH10.0に調整したケイ酸ナトリウム水溶液を、pHを10.0に調整した水酸化カリウム水溶液に変更した以外は、実施例1と同様の方法で排ガス浄化フィルタを製造した。
合成例2で製造したNaAlSiO4を、TISMO−D(大塚化学株式会社製)に変更した以外は、実施例1と同様の方法で排ガス浄化フィルタを製造した。
合成例2で製造したNaAlSiO4を、TISMO−D(大塚化学株式会社製)に変更し、pH10.0に調整したケイ酸ナトリウム水溶液を、pHを11.0に調整したケイ酸ナトリウム水溶液に変更した以外は、実施例1と同様の方法で排ガス浄化フィルタを製造した。
合成例2で製造したNaAlSiO4を、TISMO−D(大塚化学株式会社製)に変更し、pH10.0に調整したケイ酸ナトリウム水溶液を、pHを12.0に調整したケイ酸ナトリウム水溶液に変更した以外は、実施例1と同様の方法で排ガス浄化フィルタを製造した。
合成例2で製造したNaAlSiO4を、TISMO−D(大塚化学株式会社製)に変更し、pH10.0に調整したケイ酸ナトリウム水溶液を、pHを10.0に調整した水酸化ナトリウム水溶液に変更した以外は、実施例1と同様の方法で排ガス浄化フィルタを製造した。
合成例2で製造したNaAlSiO4を、TISMO−D(大塚化学株式会社製)に変更し、pH10.0に調整したケイ酸ナトリウム水溶液を、pHを10.0に調整した水酸化カリウム水溶液に変更した以外は、実施例1と同様の方法で排ガス浄化フィルタを製造した。
ZSM‐5型ゼオライト(HSZ‐840NHA:東ソー株式会社製)20質量部に対し、チタン酸アルミニウム(丸ス釉薬社製)80質量部、合成例2で製造したNaAlSiO4を10質量部、黒鉛3質量部、メチルセルロース10質量部、及び脂肪酸石鹸0.5質量部を配合し、さらに水を適当量添加して混練し、押出成形可能な坏土を得た。
pH10.0に調整したケイ酸ナトリウム水溶液を、pHを9.0に調整したケイ酸ナトリウム水溶液に変更した以外は、実施例1と同様の方法で排ガス浄化フィルタを製造した。
ZSM−5型ゼオライト(HSZ−840NHA:東ソー株式会社製)20質量部に対し、チタン酸アルミニウム(丸ス釉薬社製)80質量部、合成例2で製造したNaAlSiO4を10質量部、黒鉛3質量部、メチルセルロース10質量部、及び脂肪酸石鹸0.5質量部を配合し、さらに水を適当量添加して混練し、押出成形可能な坏土を得た。
チタン酸アルミニウム(丸ス釉薬社製)90質量部、黒鉛10質量部、メチルセルロース10質量部、及び脂肪酸石鹸0.5質量部を配合し、さらに水を適当量添加して混練し、押出成形可能な坏土を得た。
(NOx濃度評価)
予め排ガス浄化フィルタを尿素水溶液に含浸し、50℃にて乾燥しておき、排ガス浄化フィルタを模擬排ガス排気ラインに設置する。その後、模擬排ガス(O2:10%、N2:90%、NO:200ppm、NO2:200ppm)を300℃まで上昇させ、NOx濃度を測定した。結果を表1に示した。
予め排ガス浄化フィルタの初期重量を測定しておき、ディーゼルエンジンの排気ラインに、酸化触媒(DOC)と排ガス浄化フィルタを順に設置する。次いで、ディーゼルエンジンを始動させ、低温でPMを所定量(約4g/L)堆積させた後、排ガス浄化フィルタを取り外し、堆積したPMの重量を確認した後、圧力損失を測定した。結果を表1に示した。
予め排ガス浄化フィルタの初期重量を測定しておき、ディーゼルエンジンの排気ラインに、酸化触媒(DOC)と排ガス浄化フィルタを順に設置する。次いで、ディーゼルエンジンを始動させ、低温でPMを所定量(約8g/L)堆積させた後、一度排ガス浄化フィルタを取り外し、堆積したPMの重量を測定する。
Claims (7)
- ゼオライトと担体の原料粒子とを含む混合物を押出成形して成形体を作製する工程と、
前記成形体を焼成して焼結体を作製する工程と、
前記焼結体をpH9.5以上の条件下でアルカリ処理する工程と、
前記アルカリ処理後に焼結体に含まれるゼオライトのイオン交換サイトの元素を遷移金属に交換する工程とを備えることを特徴とする、排ガス浄化フィルタの製造方法。 - 前記ゼオライトを、窒素酸化物を窒素に還元する触媒として含むことを特徴とする、請求項1に記載の排ガス浄化フィルタの製造方法。
- 前記ゼオライトが、モルデナイト型ゼオライト、フォージャサイト型ゼオライト、A型ゼオライト、L型ゼオライト、βゼオライト、及びZSM−5型ゼオライトから選ばれる1種又は2種以上であることを特徴とする、請求項1又は2に記載の排ガス浄化フィルタの製造方法。
- 前記担体の原料粒子がチタン酸アルミニウムであることを特徴とする、請求項1〜3のいずれか一項に記載の排ガス浄化フィルタの製造方法。
- 前記成形体が、ハニカムフィルタの成形体であることを特徴とする、請求項1〜4のいずれか一項に記載の排ガス浄化フィルタの製造方法。
- 請求項1〜5のいずれか一項に記載の排ガス浄化フィルタの製造方法で製造されたことを特徴とする、排ガス浄化フィルタ。
- 請求項6に記載の排ガス浄化フィルタを備えることを特徴とする、排ガス浄化装置。
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