MXPA98002442A - Cleaning of environmental air through the movement of a vehicle that has a surface of treatment of contaminants - Google Patents

Cleaning of environmental air through the movement of a vehicle that has a surface of treatment of contaminants

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Publication number
MXPA98002442A
MXPA98002442A MXPA/A/1998/002442A MX9802442A MXPA98002442A MX PA98002442 A MXPA98002442 A MX PA98002442A MX 9802442 A MX9802442 A MX 9802442A MX PA98002442 A MXPA98002442 A MX PA98002442A
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MX
Mexico
Prior art keywords
composition
atmosphere
catalyst
component
platinum
Prior art date
Application number
MXPA/A/1998/002442A
Other languages
Spanish (es)
Inventor
W Blosser Patrick
Hu Zhicheng
B Hoke Jeffrey
M Heck Ronald
M Allen Fred
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Engelhard Corporation
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Publication date
Application filed by Engelhard Corporation filed Critical Engelhard Corporation
Publication of MXPA98002442A publication Critical patent/MXPA98002442A/en

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Abstract

A method and apparatus for treating the atmosphere comprising moving a vehicle through the atmosphere is described, the vehicle has at least one surface contact with the atmosphere and a contaminant treatment composition located on the surface. A specific embodiment comprises coating a motor vehicle radiator with a contaminant treatment catalyst.

Description

ENVIRONMENTAL AIR CLEANING THROUGH THE MOVEMENT OF A VEHICLE WHICH HAS A CONTAMINANT TREATMENT SURFACE DESCRIPTION OF THE INVENTION This is a continuation in part of the United States application Serial No. 08 / 589,182 filed on January 19, 1996 , which is a continuation in part of the United States Application No. 08 / 537,206 filed September 29, 1995 which is a continuation in part of the United States Application Serial No. 08 / 410,445 filed on March 24, 1995, which is a continuation in part of the United States Application Serial No. 08 / 376,332 filed on January 20, 1995, all of these applications are incorporated herein by reference. The present invention relates to an apparatus for cleaning the atmosphere; and more particularly to a vehicle comprising at least one contact surface with the atmosphere having a contaminant treatment composition thereon, and a related method and composition. A review of the literature regarding pollution control reveals that the general aspect is to reactively clean waste streams entering the environment. If much more than one contaminant is detected or discharged, the tendency has been to focus on the source of the contaminant, the cause of the contaminant or the waste stream containing the contaminant. For most of the gas streams they are treated to reduce the pollutants before entering the atmosphere. The treatment of atmospheric air directed towards a confined space to remove unwanted components in the air has been described. However, very little effort has been made to treat contaminants, which are in the environment; the environment has been left to its own cleaning systems. References are known that describe proactively cleaning the environment. U.S. Patent No. 3,738,088 discloses an air filtration assembly for cleaning the ambient air contamination using a vehicle as a mobile cleaning device. A variety of elements are described that will be used in combination with a vehicle to clean the ambient air as the vehicle is driven through the environment. In particular, duct formation is described to control the air stream velocity and direct the air to various filter media. The filter media may include filters and electronic precipitators. Catalyzed post-filters are described which are useful for treating particulate or aerosolized contamination, such as carbon monoxide, unburned hydrocarbons, nitrous oxide and / or sulfur oxides, and the like. German Patent No. DE 43 18 738 Cl also describes a procedure for physical and chemical cleaning of external air. Vehicles with engines are used as carriers for conventional filters and / or catalysts, which do not constitute operational components of the vehicle, but are used to clean atmospheric air directly. Another aspect is described in U.S. Patent No. 5,147,429. There is described an air cleaning station suspended in the moving air. In particular, this patent presents an airship to collect air. The airship has a plurality of different types of air cleaning devices contained therein. The described air cleaning devices include wet scrubbers, filtration machines and cyclonic spray washers. The difficulty with the aforementioned devices described for proactively cleaning atmospheric air is that they require new and additional equipment. Even the modified vehicle described in U.S. Patent No. 3,738,088 requires the formation of ducts and filters, which may include catalytic filters. DE 40 07 965 C2 by Klaus Hager describes a catalyst comprising copper oxides for converting ozone and a mixture of copper oxides and manganese oxides to convert carbon monoxide. The catalyst can be applied as a coating to a self-heating radiator, oil coolers or air-charged coolers. The catalyst coating comprises heat resistant binders, which are also gas permeable. It is indicated that copper oxides and manganese oxides are widely used in filters to mask gas and have the disadvantage of being poisoned by water vapor. However, the heating of the surfaces of the car during the operation evaporates the water. In this way, the continuous use of the catalyst is possible, since no drying agent is necessary. Manganese oxides are known to catalyze the oxidation of ozone to form oxygen. Many commercially available types of manganese compound and compositions, including alpha-manganese oxide, are described to catalyze the reaction of ozone to form oxygen. In particular, it is known to use the crypomelanic form of alpha-manganese oxide to catalyze the reaction of ozone to form oxygen. The alpha-manganese oxides are described in references, such as 0 'Young, Hydrothermal Synthesis of Manganese Oxides with Tunnel Structures, Modern Analytical Techniques for Analysis of Petroleum, presented at the Symposium on Advances in Zeolites and Pillared Clay Structures before the Division of Petroleum Chemistry, Inc. American Chemical Society New York City Meeting, August 25-30, 1991 beginning on page 348. Such materials are also described in U.S. Patent No. 5,340,562 to O'Young, et al. In addition, the forms of a-Mn? 2 are described by McKenzie, the Synthesis of Birnessite, Cryptomelane, and Some Other Oxides and Hydroxides of Manganese, Mineralogical Magazine, December 1971, Vol. 38, p. 493-502. For the purposes of the present invention, a? 2 is defined as including holandite (BaM sOig.xH20), crypomelano (K nsOxg. XH2O), manjiorite (aMngOig • xH2 °) and coronary (P MngOig. XH2O). O'Yong describes these materials as having a three-dimensional frame tunnel structure (U.S. Patent No. 5,340,562 and 0 'Young Hydrothermal Synthesis of Manganese Oxides with Tunnel Structures both incorporated herein by reference). For the purposes of the present invention, a-Mn? 2 is considered to have a 2 x 2 tunnel structure and includes Dutch, cryptomelanus, manjiorite, and coronary. The present invention relates to an apparatus, method and composition for treating the atmosphere. For the purposes of the present invention, the atmosphere is defined as the mass of air surrounding the earth. The present invention is directed to an apparatus and a related method for treating the atmosphere, comprising a vehicle and means such as a motor for moving the vehicle from one place to another through the atmosphere. The vehicle comprises at least one vehicle surface that is in contact with the atmosphere and a contaminant treatment composition located on that surface. The contact surface with the atmosphere is a surface of a component of the vehicle that is in direct contact with the atmosphere. Preferred and useful atmosphere contact surfaces include body surfaces, wind deflector surfaces, grid surfaces, mirror backs and "under the deck" component surfaces. The preferred atmosphere contact surfaces are located within the body of the motor vehicle, typically close to the engine, i.e., the engine compartment. The surfaces are preferably the surfaces of the cooling means, which comprise a flow path for liquids or gases through a cooling wall enclosure such as tubes or a housing and an external surface on which fins are located for cooling. Improve thermal transfer. Preferred atmosphere contact surfaces comprise an external surface with fins and are selected from the radiator's outer surfaces, air conditioning condenser, radiator fin surfaces, engine oil cooler, transmission oil cooler, Power steering fluid cooler and air charge cooler also referred to as an intercooler or aftercooler. The most preferred atmosphere contact surfaces are the external surfaces of the air conditioner and radiator condenser due to its relatively high surface area and ambient operating temperatures, from about 40 ° C to 135 ° C and typically up to 110 ° C. ° C. An advantage of the present invention is that the contact surface with the atmosphere useful for supporting a composition for the treatment of contaminants can be the surface of existing vehicle components. No additional filter or apparatus is required to support a contaminant treatment composition. Accordingly, the apparatus and method of the present invention can be located in existing new car components or retrofitted in used cars. The retrofix can comprise the coating of a suitable contaminant treatment composition that is placed on an existing vehicle surface, which is brought into contact with atmospheric air as the vehicle is driven through the atmosphere. The present invention is directed to compositions, methods and articles for treating pollutants in the air. Such contaminants typically can comprise from 0 to 400 parts, typically from 1 to 300, and even more typically from 1 to 200 parts per billion (ppb) of ozone, -0 to 30 parts and more typically from 1 to 20 parts per million ( ppm) of carbon monoxide; and from 2 to 3000 ppb of unsaturated hydrocarbon compounds such as C2 olefins at about C20 and partially oxygenated hydrocarbons such as alcohols, aldehydes, esters, ethers, ketones and the like. Typical hydrocarbons, which can be treated include, but are not limited to propylene, butylene, formaldehyde and other hydrocarbon gases and vapors found in the air. Other contaminants present may include nitrogen oxides and sulfur oxides. The National Environmental Air Quality Standard for ozone is 120 ppb, and for carbon monoxide it is 9 ppm.
Compositions for the treatment of contaminants include catalyst compositions useful for catalyzing the conversion of contaminants present in the atmosphere to non-objectionable materials. Alternatively, adsorption compositions can be used as the composition for treating contaminants to absorb contaminants, which can be destroyed after adsorption, or stored for further treatment at a later time. Catalyst compositions can be used, which can assist in the conversion of contaminants to non-hazardous compounds or less hazardous compounds. Useful and preferred catalyst compositions include compositions that catalyze the reaction of ozone to form oxygen, catalyze the reaction of carbon monoxide to form carbon dioxide, and / or catalyze the reaction of hydrocarbons to form water and carbon dioxide. Specific and preferred catalysts for catalyzing hydrocarbon reactions are useful for catalyzing the reaction of low molecular weight unsaturated hydrocarbons having from 2 to 20 carbon atoms and at least one double bond, such as C2 monoolefins at about Cg. Such low molecular weight hydrocarbons have been identified as being sufficiently reactive to cause smog. Particular olefins that can be reacted include propylene and butylene. A useful and preferred catalyst can catalyze the reactions of both ozone and carbon monoxide; and preferably of ozone, carbon monoxide and hydrocarbons. Ozone - Useful and preferred catalyst compositions for treating ozone include a composition comprising manganese compounds including oxides such as Mn2 3 3 and Mn 2 2 with a preferred composition comprising α-Mn 2 2, and cryptomelane which is most preferred . Other useful and preferred compositions include a mixture of n? 2 and CuO. Specific and preferred compositions comprise hopcalite which contains CuO and n? 2 and more preferably Carulite.RTM. Which contains Mn? 2, CuO and AI2O3 and which is sold by Carus Chemical Co. An alternative composition comprises a refractory metal oxide support, on which a catalytically effective amount of a palladium component is dispersed and preferably also includes a manganese component. Also useful is a catalyst comprising a precious metal component, preferably a platinum component on a coprecipitated zirconia support and manganese oxide. The use of this coprecipitated support has been found to be particularly effective in allowing a platinum component to be used to treat ozone. Still another composition, which can result in the conversion of ozone to oxygen, comprises carbon and palladium or platinum supported on carbon, manganese dioxide, Carulite® and / or hopcalite. Manganese supported on a refractory oxide such as alumina has also been found to be useful. Carbon Monoxide - Useful and preferred catalyst compositions for treating carbon monoxide include a composition comprising a refractory metal oxide support on which is dispersed a catalytically effective amount of a platinum and / or palladium component, preferably a platinum component. A highly preferred catalyst composition for treating carbon monoxide comprises a component of the reduced platinum group supported on a refractory metal oxide, preferably titania. Useful catalyst materials include precious metal components including platinum group components, which include the metals and their compounds. Such metals can be selected from components of platinum, palladium, rhodium and ruthenium, gold and / or silver. The platinum one will result in the catalytic reaction of ozone. Also useful is a catalyst that comprises a precious metal component, preferably a platinum component on a support of coprecipitated zirconia and manganese dioxide. Preferably, this catalyst mode is reduced. Other useful compositions that can convert carbon monoxide to carbon dioxide include a platinum component supported on carbon or a support comprising manganese dioxide. The preferred catalysts for treating such contaminants are reduced. Another composition useful for treating carbon monoxide comprises a metal component of the platinum group, preferably a platinum component, a refractory oxide support, preferably alumina and titania and at least one metal component selected from a tungsten component and a rhenium component, preferably in the form of metal oxide.
Hydrocarbons - Useful and preferred catalyst compositions for treating unsaturated hydrocarbons including olefins from C to about C20 and typically C2 to CQ monoolefins, such as propylene and partially oxygenated hydrocarbons, have been found to be of the same type established for use in catalysis of the reaction of the carbon monoxide with the preferred compositions for unsaturated hydrocarbons comprising a reduced component of platinum and / or palladium and a refractory metal oxide support for the platinum component. A preferred refractory metal oxide support is titania. Other useful compositions, which can convert hydrocarbons to carbon dioxide and water, include a platinum component supported on carbon or a support comprising manganese dioxide. The preferred catalysts for treating such contaminants are reduced. Another useful composition for converting hydrocarbons comprises a metal component of the platinum group, preferably a platinum component, a refractory oxide support, preferably alumina and titania and at least one metal component selected from a tungsten component and a component of rhenium, preferably in the form of metal oxide. A combination of a platinum component and a palladium component results in an improved CO conversion in an increase in cost and is highly preferred when the higher conversion is desired and the cost increase is acceptable. Ozone and Carbon Monoxide - A useful and preferred catalyst that can treat both ozone and carbon monoxide, comprises a support such as a refractory metal oxide support on which a precious metal component is dispersed. The refractory oxide support may comprise a support component selected from the group consisting of ceria, alumina, silica, titania, zirconium and mixtures thereof. Also useful as a support for precious metal catalyst components is a coprecipitation of zirconia and manganese oxides. Most preferably, this support is used as a platinum component and the catalyst is in reduced form. This unique catalyst has been found to effectively treat both ozone and carbon monoxide. Other useful and preferred precious metal components are composed of precious metal components selected from palladium and also platinum components, with palladium being preferred. A combination of a ceria support with a palladium component results in an effective catalyst for treating both ozone and carbon monoxide. Other useful and preferred catalysts for treating both ozone and carbon monoxide include a platinum group component, preferably a platinum component and / or a palladium component, and most preferably a platinum component, on titania or on a combination of zirconia and silica. A combination of a platinum component and a palladium component results in an improved CO conversion in an increase in cost and is highly preferred when a larger conversion is desired and the cost increase is acceptable. Other useful compositions that can convert ozone to oxygen and carbon monoxide to carbon dioxide include a platinum component supported on carbon or on a support comprising manganese dioxide. The preferred catalysts are reduced. Ozone, Carbon Monoxide and Hydrocarbons - A useful and preferred catalyst, which can treat ozone, carbon monoxide and hydrocarbons, typically low molecular weight olefins (from C2 to approximately C20) and typically C2 to Cg monoolefins, and partially hydrocarbons oxygenated as described above, comprising a support, preferably a refractory metal oxide support on which a precious metal component is dispersed. The support of refractory metal oxide, may comprise a support component selected from the group consisting of ceria, alumina, titania, zirconia and mixtures thereof, with titania being preferred. The useful and preferred precious metal components are comprised of precious metal components of the platinum group components, including palladium and / or platinum components, with platinum being preferred. It has been found that a combination of a titania support with a platinum component results in a more effective catalyst for the treatment of low molecular weight ozone, carbon monoxide and gaseous olefin compounds. A combination of a platinum component and a palladium component results in an improved conversion of CO and hydrocarbon to an increase in cost and is highly preferred when a higher conversion is desired and the increase in cost is acceptable. It is preferred to reduce the platinum group components with a suitable reducing agent. Other useful compositions that can convert ozone to oxygen, carbon monoxide to carbon dioxide, and hydrocarbons to carbon dioxide include a platinum component supported on carbon, a support comprising manganese dioxide, or a support comprising a coprecipitate of manganese oxides. and zirconia. The preferred catalysts are reduced. The above compositions can be applied as a coating to at least one contact vehicle surface with the atmosphere. Particularly preferred compositions catalyze the destruction of unsaturated ozone, carbon monoxide and / or low molecular weight olefinic compounds at ambient conditions or environmental operating conditions. The environmental conditions are the conditions of the atmosphere. By environmental operating conditions is meant the conditions, such as temperature, of the contact surface with the atmosphere during normal operation of the vehicle without the use of additional directed energy to heat the contaminant treatment composition. Certain atmospheric contact surfaces such as a grid or wind deflector can be at the same temperature or at a temperature similar to that of the atmosphere. It has been found that preferred catalysts that catalyze the ozone reaction can catalyze the reaction of ozone to environmental conditions at scales as low as 5 ° C to 30 ° C. The contact surfaces with the atmosphere can have higher temperatures than ambient atmospheric temperatures due to the nature of the operation of the component that is below the surface. For example, the preferred atmosphere contact surfaces are the surfaces of the air conditioning condenser and the radiator, due to their high surface area. When vehicles use air charge chillers, these are preferred due to the high surface area and ambient operating temperatures at 121.1 (250 ° F). Normally, during environmental operating conditions, the surface of these components increases to higher temperature levels than the environment, due to the nature of their operation. After the vehicle engine has been heated, these components are typically at temperatures ranging from about 130 ° C and typically from 40 ° C to 110 ° C. The temperature scale of these contact surfaces with the atmosphere helps to improve the conversion rates of ozone, carbon monoxide and hydrocarbon catalysts supported on such surfaces. Air charge chillers operate at temperatures up to about 130 ° C, and typically from 60 to 130 ° C. Several of the catalyst compositions can be combined, and a combined coating can be applied to the atmosphere contact surface. Alternatively, different surfaces or different parts of the same surface they can be coated with different catalyst compositions. The method and apparatus of the present invention are designed so that contaminants can be treated at ambient atmospheric conditions or at ambient operating conditions of the contact surface with the vehicle's atmosphere. The present invention is particularly useful for the treatment of ozone by coating the contact surfaces with the atmosphere of the motor vehicle with suitable catalysts useful for destroying such pollutants even at environmental conditions, and at vehicle surface temperatures typically of at least 0 ° C, preferably from 10 ° C to 105 ° C, and most preferably from 40 ° C to 100 ° C. Carbon monoxide is preferably treated at surface contact temperatures with the atmosphere from 40 ° C to 105 ° C. Low molecular weight hydrocarbons, typically unsaturated hydrocarbons having at least one unsaturated bond, such as C2 olefins at about C20 'and typically C2 to Cg monoolefins, are preferably treated at atmospheric surface contact temperatures of 40 to 105 ° C. The percentage conversion of ozone, carbon monoxide and / or hydrocarbons depends on the temperature and space velocity of the atmospheric air "in relation to the contact surface, and the temperature of the contact surface with the atmosphere. , the present invention, in the highly preferred embodiments can result in at least the reduction of the levels of ozone, carbon monoxide and / or hydrocarbon present in the atmosphere without the addition of any mechanical aspect or energy source in existing vehicles , - particularly motor vehicles In addition, the catalytic reaction is presented at normal environmental operating conditions experienced by the surfaces of these motor vehicle elements, so that no change in the construction or method of operation of the vehicle is required. motor since the apparatus and method of the present invention are generally directed for the treatment of In view of the atmosphere, it will be appreciated that variations of the apparatus are contemplated for use in the treatment of air volumes in enclosed spaces. For example, a motor vehicle having a surface contact with the atmosphere supporting a treatment composition with aminants can be used to treat air within factories, mines and tunnels. Such apparatuses may include vehicles used in such environments. Since the preferred embodiments of the present invention are directed to the destruction of contaminants at ambient operating temperatures of the atmosphere contact surface, it is also desirable to treat contaminants having a catalyzed reaction temperature greater than room temperature or temperature. environmental operating temperature of the contact surface with the atmosphere. Such contaminants include hydrocarbons and nitrogen oxides and any carbon monoxide that exceeds or is not treated at the surface contact with the atmosphere. These contaminants can be treated at higher temperatures, typically on the scale of at least 100 ° C to 450 ° C. This can be achieved, for example, through the use of an auxiliary hot catalysed surface. By an auxiliary hot surface, it is meant to mean that there are supplementary means for heating the surface. A preferred auxiliary hot surface is the surface of an electrically heated catalyzed monolith, such as a heated electrically catalyzed metal honeycomb of the type known to those skilled in the art. Electricity can be provided through batteries or a generator as it is presented in motor vehicles. The catalyst composition can be any well-known oxidation and / or reduction catalyst, preferably a three-step catalyst (T C) comprising metals of the precious group such as platinum, palladium, rhodium and the like, supported on refractory oxide supports. An auxiliary hot catalyzed surface may be used in combination with, and preferably downstream of, the contact surface with the vehicle's atmosphere to further treat the contaminants. As previously stated, adsorption compositions can also be used to adsorb contaminants such as hydrocarbons and / or particulate matter, for subsequent oxidation or subsequent removal. Useful and preferred adsorption compositions include zeolites, other molecular sieves, carbon and alkaline earth metal oxides of group IIA such as calcium oxide. Hydrocarbons and particulate matter can be adsorbed from 0 ° C to 110 ° C and subsequently treated by desorption followed by catalytic reaction or incineration. It is preferred to coat the areas of the vehicle having a relatively high surface area exposed to a large velocity of atmospheric air flow as the engine is driven through the environment. For motor vehicles of terrestrial use, the particularly preferred atmospheric contact surfaces include the radiator, fan blades, air conditioning condenser or heat exchanger, air charge cooler, engine oil cooler, oil cooler of transmission and wind deflectors of the type used in the roof of truck cabins. More preferably, the contact surface with the atmosphere is a surface of a radiator. The radiator has a large surface area to better cool the internal combustion engine fluid coolers. The application of a catalyst that will be supported on the surface of the radiator may have advantage taken from the surface area of the large honeycomb type, usually with little or no effect on the cooling function of the radiator. The high honeycomb type surface area allows the maximum increase of the catalyst with the air passing through the radiator-type honeycomb design. In addition, radiators in many automobiles can be located behind the air conditioning condenser and thus are protected by the air conditioning condenser.
The present invention includes methods for coating the compositions for treating contaminants on surfaces of contact with the atmosphere of motor vehicles. In particular, the present invention includes a method for coating catalyst compositions on finned elements such as radiators, air conditioning condensers, and air charge coolers. The calculations suggest that in congested areas of motor vehicle traffic there is a sufficient number of motor vehicles that significantly impact the pollutants treated in accordance with the present invention. For example, in Southern California's South Coast Air Quality Management District, there are approximately eight million cars. It has been calculated if each car travels 38.18 kilometers (20 miles) per day, all the air in that region at an altitude of 3048 - centimeter (100 feet) can be cycled through radiators in a week. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic side view of a truck showing a grid, an air conditioner condenser, electrically heated catalyst, air charge cooler, radiator, fan and motor with a wind deflector on the roof of the truck cabin. Figure 2 is a partial schematic view of a motor vehicle showing the grid, the air conditioning condenser, the radiator and the fan. Figure 3 is a front view of the radiator. Figure 4 is a front view of the air conditioning condenser. Figure 5 is a front view of a wind deflector of the type illustrated in Figure 1. Figure 6 is a front view of the truck of Figure 1. Figure 7 is a partial schematic sectional view of the finned cooling element. , coated. Figure 8 is a photograph of the coated radiator of Examples 1 and 2. Figures 9-14 and 16-17 are graphs of CO conversion against temperature to use different catalysts in Examples 4, 9-12, 14 and 15.
Figure 15 is a plot of propylene conversion against temperature based on Example 14. Figure 18 is a graph of the conversion of ozone against temperature based on Example 17. Figure 19 is an IR spectrum for criptomelano. Figure 20 is an XRD pattern for cryptomelane shown as beads using a square root scale against the Bragg angle, 2 ?. Figure 21 is a graph of the conversion of CO and hydrocarbon against temperature based on Example 30. DETAILED DESCRIPTION OF THE PREFERRED MODALITIES The present invention relates to an apparatus and methods for cleaning the atmosphere, useful with vehicles having means to transport the vehicle through the atmosphere. As the vehicle moves through the atmosphere, at least one contact surface with the atmosphere comprises a treatment composition for contaminants (eg, a catalyst or an adsorb) located thereon is contacted with the atmospheric air. As the atmospheric air encounters the contaminant treatment composition, various contaminants, including particulate matter and / or gaseous pollutants, carried in the air, can be catalytically reacted or adsorbed by the contaminant treatment composition located on the surface of the air. contact with the atmosphere. It will be appreciated by those skilled in the art that the vehicle can be any vehicle having movement means for propelling the vehicle such as wheels, sails, bands, rails or the like. Such means can be driven through any suitable energy means, including engines which use fossil fuels, such as gasoline or diesel fuel, ethanol, methanol, gas engines powered by fuels such as methane gas, wind energy such as wind powered sails or propellers, solar energy or electric power, such as in cars operated with batteries. Vehicles include automobiles, trucks, trailers, trains, boats, ships, aircraft, airships, balloons, and the like. The surface of contact with the atmosphere, can be any suitable surface that finds and puts in contact with the air as the vehicle moves through the atmosphere. Preferably, in a motor vehicle, preferably trucks, trailers and trucks, the contact means is a surface located toward the front of the vehicle and can be in contact with the air as the vehicle proceeds in the forward direction. Useful contact surfaces must have a relatively large surface area. Preferred contact surfaces are at least partly enclosed in the vehicle. Preferred atmosphere contact surfaces are located below the cover and are located within the body of the motor vehicle, typically near the engine. That is, the engineer's compartment. The surfaces preferably are the external surfaces of cooling means, which comprise a flow path for liquids or gases through an enclosure with a cooler wall, such as pipes or a housing and an external surface on which fins are located for Improve heat transfer. Useful contact surfaces include the external surfaces of means for cooling fluids, including liquids and / or gases, used in the vehicle, such as the air conditioning condenser, the radiator, the air charge cooler, the oil cooler engine, transmission oil cooler, power steering fluid cooler, fan cover, and radiator fan, which are all located and supported within the vehicle housing. A useful contact surface outside the vehicle may be the grid typically located and supported on the front of the housing, and wind deflectors commonly supported on the roof of large truck cabins. It is preferred that the contact surface be a forward facing surface, a side facing surface or a surface facing the top or bottom of the vehicle. Front facing surfaces are facing the front of the vehicle, surfaces such as the radiator fins and condenser elements face the top, top and bottom of the vehicle. Even the surfaces directed to look away from the front and towards the rear of the vehicle, which are in contact with the air, can be surfaces of contact with the atmosphere, such as the back surface of fan blades. The surfaces of airplane engines such as wings, propellers, or jet engine parts, including turbine engines and / or stators, can be coated. The surfaces that are in contact with the surface preferred in motor vehicles, are located in the cooling elements of the motor, such as motor vehicle radiators, air conditioning condensers, air charge coolers, also known as intercoolers. or rear coolers, engine oil coolers and transmission oil coolers. Such elements typically have large surface area structures associated with them to have an improved heat transfer. The high surface areas are useful to maximize the contact of atmospheric air with the composition for the treatment of pollutants. All these elements are well known in. the automotive technique. Reference is made to Bosch Automotive Handbook. Second Edition, pages 301-303, 320 and 349-351, published by Robert Bosch GmbH, 1986, incorporated herein by reference. This reference illustrates a truck diesel engine with a radiator, an interenf iador and a fan. Such elements may be coated with a contaminant treatment surface of the present invention. The radiator and the intercooler typically operate at higher temperatures than that of atmospheric air. Reference is also made to Taylor, The Internal Combustion Engine in Theory and Practice, Vol. 1: Thermo Dynamics, Fluid Flow, Prefor ance, Second Edition, Rev. The MIT Press, 1985 to pages 304-306 for radiator and fin design; and page 392 for rear coolers. Taylor's previous pages are incorporated here for reference. Reference is also made to a document collection in 1993 Vehicle Thermal Management Systems Conference Proceedings, SAE P: 263 published by the Society of Automotive Engineers, Inc., 1993. The following documents are incorporated herein for reference. SAE Paper No. 931088 to page 157 entitled, Calculation and Design of Cooling Systems by Eichlseder and Raab of Steyr Damon Puchag and Charge Air Cooler for Passenger Cars by Collette of Valeo Thermique Moteur, - SAE Paper No. 931092 entitled, State of the Art and Future Developments of Aluminum Radiators for Cars and Trucks by Kern and Eitel of Behr GmbH and Co. being to page 187; SAE Paper 931112 entitled, Air Mix vs. Coolant Flow to Control Discharge Air Temperature and Vehicle Heating Air Conditioning Sys ems by Rolling and Cummings of Behr of America, Inc. and Schweizer of Behr GmbH & Co. The above documents include descriptions of the radiator, air conditioner and air charge cooler structures for use in motor vehicles. Additional reference is made to SAE Paper 931115 Engine Cooling Module Development Using Air Flow Management Techniques by El-Bourini and Chen of Calsonic Technical Center to page 379 and incorporated herein for reference. Of interest are appendices 1 and 2, which illustrate typical radiator and condenser structures useful in motor vehicle applications. Reference is also made to SAE Paper 931125 entitled, Durabili and 'Concerns of Aluminum Air to Air Charged Coolers by Smith, Valeo Engine Cooling Inc. which describes air charge chillers and is thus incorporated herein for reference.
The present invention will be better understood by those skilled in the art, with reference to the accompanying drawings 1-7. Figure 1 illustrates a truck 10 schematically containing a variety of vehicle components comprising atmospheric contact surfaces. These surfaces include the grid surfaces 12, the air conditioning condenser 14, an air charge cooler 25, the radiator 16, and the radiator fan 18. Also shown in this truck, is a wind deflector 20 which it has a front deflection surface 22. It is recognized that the various components can have different relative locations on different vehicles. Referring to Figures 1 to 4, the preferred contact surfaces include the surface of the front surfaces 13 and side 15 of the air conditioning condenser 14, the front 17 and side 19 surfaces of the radiator 16, corresponding to the surfaces of the air charge cooler 25 and the front surfaces 21 and rear 23 of the radiator fan 18. These surfaces are located within the housing 24 of the truck. Typically they are under the cover 24 of the truck between the front part 26 of the truck and the engine 28. The air conditioning condenser, the air charge cooler, the radiator, and the radiator fan can be directly or indirectly supported by the housing 24 or a frame (not shown) within the housing. Figure 2 generally shows a schematic view of an automobile assembly. The corresponding elements in Figures 1 and 2 have common reference characters. The automobile comprises a housing 30. There is a front part 32 of a motor vehicle, having a grid 12 supported on the front part of the housing 30. An air conditioning condenser 14, a radiator 16 and a radiator fan 18 can be located inside. of the housing 30. Referring to the embodiments of Figures 1, 2 and 6, the contact surface on the front and sides of at least the grid 12, the air conditioning condenser 14, the air cooler air charge 25 and radiator 16; the front and rear of the radiator fan 18; and the front part of the wind deflector 20 can have a contaminant treatment composition located therein. The grid 12 may have a suitable grid type design, which provides the openings 36, through which the air passes as the truck 12 is operated and moves through the atmosphere. The openings are defined by the grate 38. The grate 38 has a front grill surface 40 and a side grill surface 42. The front and side grill surfaces 40 and 42 can be used as the surfaces of. contact with the atmosphere on which the pollutant treatment compositions are located. Referring to Figures 1 and 4, the air conditioning condenser 14, comprises a plurality of air conditioning condenser fins 44. In addition, there is an air conditioning fluid conduit 46, which conducts the air by conditioning the air. fluid through the condenser 14. The front and side surfaces of the air conditioning vanes 44, as well as the front surface of the air conditioning duct 46, may be the surfaces in contact with the atmosphere, on which a composition for the treatment of pollutants. As indicated, both the front 21 and rear 23 surfaces of the radiator fan 18 may be a contact surface for supporting a composition for the treatment of contaminants. The highly preferred atmosphere contact surface is on the radiator 16 as shown in Figure 3. A typical radiator 16 has a front radiator surface 17, as well as a plurality of radiator corrugated plates or fins 50 located on the radiator. Radiator plate or fin channels 52corresponding, which pass through the radiator 16. It is preferred to coat the front surface 17, as well as the side surfaces of the radiator plates 50 and the channel surfaces 52. The radiator is very preferred, since it is located inside the housing 23 or 30, and is protected from the front through by 1 or less the grid 12 and preferably an air conditioning condenser 14. In addition to the air entering into the roof chamber 34, as the vehicle of motor moves through the atmosphere. The radiator fan 38 expels air in and through the channels 52. Therefore, the radiator 16 is located and protected by the grate 12, the air conditioning condenser 19 and is in front of the radiator fan 18. Furthermore, as As already indicated, the radiator has a large surface area for heat transfer purposes. In accordance with the present invention, the contaminant treatment composition can be effectively located on, and with advantage of, such a large surface area without significantly and adversely impacting the heat transfer function of the radiator. The above description is particularly directed to, and illustrates the use of surfaces for the treatment of the atmosphere in an apparatus such as a radiator 16 and an air conditioning condenser 14. As indicated, the contact surface with the atmosphere may be on other suitable means for cooling engine fluids, - including well-known articles such as the air charge cooler shown above, as well as engine oil coolers, transmission oil coolers and power steering oil coolers. A common aspect of all cooling means is a housing and conduit through which the fluid passes. The housing comprises a wall having an internal surface in contact with the fluid and an external surface typically in contact with the atmosphere within the vehicle frame typically within the engine compartment. In order to efficiently transfer heat from the fluid in these various apparatuses, fins or plates extend from the external surface of the cooling, housing or conduit. A useful and preferred embodiment with each of these cooling means is illustrated in Figure 7. Figure 7 is a schematic sectional view of a coated finned cooling element 60. The element comprises a housing or conduit defined by a wall airing or conduit 62. Located within the conduit is a passageway or chamber 64, through which fluid, such as oils or "cooling liquids or air conditioning fluids, pass through. Such fluids are known to the character of reference 66. The housing wall comprises an inner surface 68 and an outer surface 70. Plates or fins 72 are located and attached to the outer surface.
According to the present invention, there is a contaminant treatment composition 74, which can be located on the outer surface 70 in the fins or plates 72. During the operation of the air streams, the contact of the treatment composition of the pollutants, causes several of the pollutants to be treated. The applicant hereby incorporates for reference the commonly assigned patent application entitled, "Pollution Treating Device and Methods of Making the Same", attorney's file 3794/3810, filed as in Series No. 08 / 537,208 of the United States. Additionally, any of the embodiments of the present invention and method of use thereof may optionally also incorporate a replaceable contaminant treatment device, as described therein. Contaminant treatment compositions can also be located on external surfaces of the vehicle. As indicated, such compositions can be located on the gate 12 and in the case of the truck shown in Figures 1 and 6, on the wind deflector 20 and the front wind deflector surface 22. In addition, the treatment compositions of contaminants can be located on the front of the mirror 54 as well as any of a variety of facing surfaces. The use of an air charge cooler 25 represents a particularly effective atmosphere contact surface, on which contaminant treatment compositions can be supported. Operating temperatures can reach temperatures as high as 250 ° F. At such temperatures, the catalyst compositions of the present invention can more effectively treat ozone, hydrocarbon, and carbon monoxide contaminants. Particularly useful are compositions containing precious metals, such as platinum, palladium, or oxo or silver components. Alternatively, the catalyst may include manganese compounds such as manganese dioxide and copper compounds, including copper oxide such as Carulite or hopcalite. During normal operation, the vehicle moves in a forward direction with the front part 26 of the vehicle 10 initially in contact with the atmospheric air. Typically, vehicles move through the air at speeds of up to approximately 1,000 miles per hour for airplanes. Land vehicles and water vehicles typically move at speeds of up to 300 miles per hour, more typically up to 200 miles per hour with motor vehicles moving at speeds up to 100 miles per hour, and typically from 5 to 75 miles per hour. Sea vehicles, such as boats, typically move through water at speeds of up to 30 miles per hour, and typically from 2 to 20 miles per hour. According to the method of the present invention, the relative velocity (or face velocity) between the contact surface with the atmosphere and the atmosphere, such as the vehicle, typically a car or a land vehicle, moves through the atmosphere it is from 0 to 100 miles per hour, typically from 2 to 75 miles per hour in a car typically from 5 to 60 miles per hour. The face velocity is the air velocity relative to the pollutant treatment surface. In motor vehicles, such as trucks 10, which have a radiator fan 18, the ventilator expels atmospheric air through the grate 12, the air conditioning condenser 14, the air charge cooler 25, and / or the radiator 16 in addition to the air passing through these elements, as the motor vehicle moves through the atmosphere. When the motor vehicle is at rest, the relative face velocity of the air expelled to the radiator typically varies from about 5 to 15 mph. The radiator fan moderates the speed of air flow through the radiator as the motor vehicle moves through the atmosphere. When a typical car moves through the atmosphere at speeds approaching 70 mph, the air inlet face velocity is about 25 mph. Depending on the design of a motor vehicle that uses a radiator fan, the cars have a face velocity as low as when the fan is used during the idle time of up to approximately 100% of the face velocity corresponding to the speed of the motor vehicle. However, typically, the face velocity of the air relative to the contact surface with the atmosphere is equal to the idle face velocity of more than 0.1 to 1.0 and more typically 0.2 to 0.8 times of the vehicle speed.
According to the invention, large volumes of "air at relatively low temperatures can be treated." This occurs as vehicles move through the atmosphere.The high surface area components of vehicles including radiators, conditioning condensers. air and charge air coolers, typically have a large front surface area, which meets the air stream.However, these devices are relatively narrow, typically ranging from approximately 1.9 to a depth of 2.54 cm. approximately a speed of 5.8 cm and usually on the scale of 1.9 to 3.81 cm (3/4 to 1 1/2 inches) of depth ". The linear velocity of atmospheric air that comes into contact with the front surface of such devices typically is in the range of up to 20, and more typically from 5 to 15 miles per hour. An indication of the amount of air that is being treated as it passes through the catalyzed vehicle component is commonly referred to as space velocity, more precisely space velocity in hours, in volume (VHSV). This is measured as the volume (corresponding to the volume of the catalyzed element) of air per hour, which passes through the volume of the catalytic article. It is based on cubic feet per hour of air divided by cubic feet of catalyst substrate. The volume of the catalyst substrate is times the front area of the axial depth or length in the direction of the air flow. Alternatively, the space velocity per volume hour is the number of catalyst volumes based on the volume of the catalytic article being treated per hour. Due to the relatively short axial depth of the catalyzed elements of the present invention. Space speeds are relatively high. The space-time velocities in air volume, which can be treated in accordance with the present invention, can be of one million or more reciprocal hours. An air face velocity against one of these elements at 5 miles per hour can result in a space velocity as high as 300,000 reciprocal hours. In accordance with the present invention, the catalysts are designed to treat contaminants in the atmosphere at varying space velocities that are as high as 250,000 to 750,000, and typically from 300,000 to 600,000 reciprocal hours. This is achieved even at relatively low ambient temperatures, and at ambient operating temperatures of the vehicle elements containing the contaminant treatment compositions, in accordance with the present invention. The operating temperature of the atmosphere contact surfaces with atmosphere, may vary depending on whether they are located near the thermal sources in the vehicle or are the surfaces of elements that work to cool the parts of the vehicle. However, the contact surfaces such as the grid 12, the wind deflector 20 are at ambient conditions. During the typical operation, the means for cooling operate at approximately the ambient atmospheric temperature, with the contact surfaces such as the surfaces of the air conditioning condenser 14, and radiator 16 and the air charge cooler 25, may vary up to 130. ° C and typically up to 105 ° C, and typically are in the range of 10 ° C to 105 ° C, more typically, 40 ° C to 100 ° C and can be 10 ° C to 75 ° C. The air charge cooler 25 typically operates at temperatures of 75 ° to 130 ° C. The amount of contact surface may vary with air conditioning condensers, radiators, and air charge chillers, typically ranging from 20 to 2,000 square feet and fan blades 18 typically ranging from 0.2 to approximately 40 square feet, when considered the front and back surfaces. The contaminant treatment composition is preferably a catalyst composition or adsorption composition. Useful and preferred catalyst compositions are compositions, which can catalytically cause the reaction of the target pollutants to the air space velocity as it comes into contact with the surface, and to the surface temperature at the point of contact. Typically, these catalyzed reactions will be on the temperature scale of the contact surface or with the atmosphere from 0 ° to 130 ° C, more typically from 20 ° C to 105 ° C and still typically from about 40 ° C to 100 ° C. C. There is no limit with respect to the efficiency of the reaction, since some reaction occurs. Preferably, there is at least a conversion efficiency of 1% with a conversion efficiency as high as possible. Useful conversion efficiencies are preferably at least about 5% in a preferably at least about 10%. The preferred conversions depend on the particular contaminant and the particular contaminant treatment composition. When treating ozone with a catalytic composition on an atmosphere contact surface, it is preferred that the conversion efficiency be greater than about 30% to 40%, preferably greater than 50%, and more preferably greater than 70%. The preferred conversion for carbon monoxide is greater than 30% and preferably greater than 50%. The preferred conversion efficiency for hydrocarbons and partially oxygenated hydrocarbons is at least 10%, preferably at least 15%, and more preferably at least 25%. These conversion rates are particularly preferred when the contact surface with the atmosphere is at ambient operating conditions of up to about 110 ° C. These temperatures are the surface temperatures typically experienced during the normal operation of the contact surfaces with the vehicle's atmosphere, including the surfaces of the radiator and the air conditioning condenser. When there is a supplemental heating of the contact surface with the atmosphere, such as having a monolith, grating, sieve, gauze, electrically heated, catalytic, or the like, it is preferred that the conversion efficiency be greater than 90% and more preferably higher than 95% The conversion efficiency is based on the molar percentage of the particular pollutants in the air, which react in the presence of the catalyst composition. Ozone treatment catalyst compositions comprise manganese compounds that include manganese dioxide, including non-stoichiometric manganese dioxide (for example, MnO (^ .5-2.0)> Y / ° M12O3. The preferred manganese oxides, which are nominally referred to as Mn? 2, have a chemical form, wherein the molar ratio of manganese to oxide is from about 1.5 to 2.0, such as MngOig Up to 100 weight percent Manganese Dioxide No. 2 can be used in catalyst compositions for treating ozone Alternative compositions, which are commercially available, comprise manganese dioxide and compounds such as copper oxide alone or copper oxide and alumina.The preferred and useful manganese dioxides are alpha-manganese dioxides nominally having a manganese to oxygen molar ratio of 1 to 2. Useful alpha-manganese dioxides are described in U.S. Patent No. 5,340,562 to O 'Young, et al., also in O' Young, Hydrothermal Synthesis of Manganese Oxides with Tunnel Structures presented in the Symposium on Advances in Z eolites and Pillared Clay Structures fiwith the Division of Petroleum Chemistry, Inc. American Chemical Society New York City Meeting, August 25-30, 1991 beginning on page 342, and McKenzie, the Synthesis of Birnessite, Cryptomelane, and Some Other Oxides and Hydroxides of Manganese, Mineralogical Magazine, December 1971, Vol. 38, p. 493-502. For the purpose of the present invention, the preferred alpha-manganese dioxide is a 2 × 2 tunnel structure, which may be hollandite (BamN Oig • xH2 °) »crypomelano (KMn8016, xH20), manjiroite (NaMn Oi - xH20) and coronary (PbMn Oig. XH2O).
The manganese dioxides of the present invention preferably have a surface area, measured through BET adsorption, greater than 150 m2 / g, more preferably greater than 200 m2 / g, and more preferably greater than 220 m2 / g. . The upper scale can be as high as 300 m2 / g, 325 m2 / g, and even 350 m2 / g. Preferred materials are in the range of 200-350 m2 / g, preferably 200-275 m2 / g, and more preferably 220-250 m2 / g. The composition preferably comprises a binder as described below, the preferred binders are polymeric binders. The composition may further comprise precious metal components with preferred precious metal components being the precious metal oxides, preferably the metal oxides of J. platinum group and more preferably palladium and platinum oxides also referred to as palladium black or platinum black. The amount of palladium black or platinum may vary from 0 to 25%, with useful amounts being in the range of 1 to 25 and 5 to 15% by weight based on the weight of the manganese component and the precious component.
It has been found that the use of compositions comprising the cryptomelane form of alpha-manganese oxide, which also contain a polymeric binder, can result in more than 50%, preferably more than 60% and more preferably 75%. -85% of ozone conversion on a concentration scale of 0 to 400 parts per billion (ppb) and an air stream moving through a radiator at a space velocity of 300,000 to 650,000 reciprocal hours. When a portion of the cryptomelane is replaced by up to 25%, and preferably 15-25% parts by weight of palladium black (PdO), the conversion rates of ozone to the above conditions vary from 95-100%, using a powder reactor. The manganese dioxide, preferred cryptomelane, has 1.0 to 3.0 weight percent potassium, typically as K2O, and a crystallite size varying from 2 to 10 and preferably less than 5 nm. It can be calcined on a temperature scale ranging from 250 ° C to 550 ° C, and preferably below 500 ° C and greater than 300 ° C for at least 1.5 hours and preferably at least 2 hours until approximately 6 hours .
The preferred crypomelano can be made in accordance with the articles presented above and the O'Young and McKenzie patents. Crypomelano can be made by reacting a manganese salt including salts selected from the group consisting of MnCl2, Mn (N03) 2 / MnS04 and Mn (CH3COO) 2 with a permanganate compound. Cryptomelano is made using potassium permanganate; the Dutchman is made using barium permanganate; the coronaadita is made using lead permanganate; and manjiroite is made using sodium permanganate. It is recognized that the alpha manganese useful in the present invention may contain one or more of the compounds of dutchite, cryptomelane, manjiroite or coronaadite. Even when the cryptomelane is made, smaller amounts of other metal ions such as sodium may be present. Useful methods for forming alpha-manganese dioxide are described in the above references, which are incorporated herein by reference. The preferred alpha-manganese to be used according to the present invention is cryptomelane. The preferred crypomelano is "clean" or substantially free of organic anions, particularly on the surface. Such anions can include chlorides, sulfates and nitrates, which are introduced during the method to form cryptomelane. An alternative method for making the cleaning cryptomelane is to react a manganese carboxylate, preferably manganese acetate with potassium permanganate. It has been found that the use of such material, which has been calcined, is "clean" the use of the material containing inorganic anions can result in the conversion of oxygen ozone of up to about 60%. The use of crypomelano with a "clean" surface results in conversions of up to about 80%. It is believed that the carboxylates are burned during the calcination process. However, the inorganic anions remain on the surface even during calcination. The inorganic anions such as sulfates can be washed with an aqueous solution or a slightly acidic aqueous solution. Preferably, the alpha-manganese dioxide is a "clean" alpha-manganese dioxide. The cryptomelane can be washed from about 60 ° C to 100 ° C for half an hour to remove a significant amount of sulfate anions. Washing also reduces the level of potassium present. Nitrate anions can be removed in a similar way. The "clean" alpha-manganese dioxide is characterized by having an IR spectrum as illustrated in Figure 19, and an X-ray diffraction pattern (XRD) as illustrated in Figure 20. Such a crypomelano preferably has an area of surface greater than 200 m / g, and more preferably greater than 250 m2 / g. A review of the IR spectrum for the most preferred cryptomelane, shown in Figure 19, is characterized by the absence of peaks assignable to the carbonate, sulfate and nitrate groups. The peaks expected for the carbonate groups appear on the scale of 1320 to 1520 wave numbers, and for the sulphate groups appear on the scale of 950 to 1250 wave numbers. Figure 20 is a powder X-ray diffraction pattern for crypomelano with a high surface area, prepared in Example 23. The X-ray pattern for cryptomelane useful in the present invention is characterized by large peaks resulting from the small crystallite size (-5-10 nm). Approximate peak positions (± 0.15 ° 2?) And approximate relative intensities (± 5) for the crypomelano using CuKß radiation, are: 2? / Relative Intensities 12.1 / 9; 18/9; 28.3 / 10; 37.5 / 100; 41.8 / 32; 49.7 / 16; 53.8 / 5; 60.1 / 13; 55.7 / 38; and 68.0 / 23. A preferred method for making cryptomelane useful in the present invention comprises mixing a solution of aqueous aqueous manganese salt with a solution of potassium permanganate. The acid manganese salt solution preferably has a pH of 0.5 to 3.0, and can be made acidic by using any common acid, preferably acetic acid at a concentration of 0.5 to 5.0 normal and more preferably 1.0 to 2.0 normal. The mixture forms a slurry, which is stirred at a temperature range of 50 ° C to 110 ° C. The sludge is filtered and the filtrate is dried at a temperature range of 75 ° C to 200 ° C. The resulting crypomelano crystals have a surface area typically on the scale of 200 m2 / g to 350 m2 / g. Another useful composition comprising manganese dioxide is a composition having manganese dioxide and minor amounts of silica, typically up to 2%, more typically up to 1%, preferred amounts are from 0.4 to 0.8%, based on the weight of manganese dioxide and silica. The presence of silica in preferred amounts has been found to affect the crystalline morphology of manganese dioxide, particularly the cryptomelane form of manganese dioxide. It is speculated that the presence of minor amounts of silica, particularly on the preferred scale, may provide certain advantages to the composition of the present invention. The presence of silica is believed to make the composition more hydrophobic, particularly when used as a coating on a substrate such as a coating on a radiator. Secondly, it is believed that the presence of silica in coating compositions comprising manganese dioxide, increases the pH to assist the compatibility of manganese dioxide with latex binders. A preferred and useful composition for use as a coating material comprises cryptomelane and silica. Such material comprises crypomelano having a surface area of 200 to 340, and preferably 220 to 250 m2 / g, a weight percent of potassium of 1 to 3% less than 0.1% of sulfur and a measured loss in ignition of 13 to 18% by weight, mainly due to humidity. The pH of the composition is approximately 3. The surface area is measured by a BET nitrogen adsorption and desorption test. As the amount of sulfur is reduced, the pH typically increases slightly. In addition, the pH typically increases with the amount of potassium present with preferred amounts of potassium, being from 1.2 to 2.8 percent by weight. Other useful compositions comprise manganese dioxide and optionally copper oxide and alumina, and at least one precious metal component, such as a metal of the platinum group supported on manganese dioxide and wherein copper oxide and alumina is present. Useful compositions contain up to 100, from 40 to 80 and preferably from 50 to 70 percent by weight manganese dioxide and from 10 to 60, and typically from 30 to 50 percent copper oxide. Useful compositions include hopcalite, which is about 60 weight percent manganese dioxide and about 40 weight percent copper oxide; and Carulite® 200 (sold by Carus Chemical Co.), which is reported to have 60 to 75 percent by weight manganese dioxide, 11 to 14 percent copper oxide and 15 to 16 percent oxide. aluminum. The surface area of CaruliteR is reported to be approximately 180 m2 / g. Calcination at 450 ° C reduces the surface area of the Carulite® to approximately fifty percent (50%) without significantly affecting activity. It is preferred to calcinate the manganese compounds from 300 ° C to 500 ° C and more preferably from 350 ° C to 450 ° C. Calcination at 550 ° C causes a large loss of the surface area of the ozone treatment activity. The calcination of Carulite® after the ball milling with acetic acid and the coating on a substrate can improve the adhesion of the coating to the substrate. Other compositions for treating ozone may comprise a component of manganese dioxide and precious metal components such as metal components of the platinum group. Since both components are catalytically active, manganese dioxide can also support the precious metal component. The metal component of the platinum group is preferably a palladium and / or platinum component. The amount of the platinum group metal compound preferably ranges from about 0.1 to 10 percent by weight (based on the weight of the platinum group metal) of the composition. Preferably, when platinum is present, it is in amounts of 0.1 to 5 percent by weight, the useful and preferred amounts in a volume of catalyst for the treatment of contaminants, based on the volume of the support article, varying from about 0.5 to about 70 g / ft3. The amount of the palladium components preferably ranges from about 2 to about 10 percent by weight of the composition, with useful and preferred amounts in a volume of pollutant treatment catalyst ranging from about 10 to about 250 g / ft3. The various catalyst compositions for the treatment of useful and preferred contaminants, especially those containing a precious metal catalyst component, may comprise a suitable support material such as a refractory oxide support. The preferred refractory oxide can be selected from the group consisting of silica, alumina, titania, seria, zirconia and chromia, and mixtures thereof. More preferably, the support is at least one high active surface area compound selected from the group consisting of alumina, silica, titania, silica-alumina, lycopene, alumina silicates, alumina zirconia, alumina- chromia and alumina ceria. The refractory oxide may be in a suitable form, including a bulky particulate form typically having particle sizes ranging from about 0.1 to about 100, and preferably 1 to 10, or in the form of sol having a varying particle size. from about 1 to about 50 and preferably from about 1 to about 10 nm. A preferred titania sol support comprises titania having a particle size ranging from about 1 to about 10, and typically from about 2 to 5 nm. Also useful as a preferred support, is a co-precipitate of a manganese oxide and zirconia. This composition can be made as presented in U.S. Patent No. 5,283,041 incorporated herein for reference. Briefly, this co-precipitated support material, preferably comprises in a weight-based ratio, manganese metals and zirconia from 5:95 to 95: 5; preferably from 10:90 to 75:25; more preferably from 10:90 to 50:50; and more preferably from 15:85 to 50:50. A useful and preferred embodiment comprises a weight ratio of Mn: Zr of 20:80. U.S. Patent No. 5,283,041 discloses a preferred method for co-precipitating a manganese oxide component and a zirconia component. As presented in U.S. Patent No. 5, 283,041, a material of zirconia oxide and manganese oxide can be prepared by mixing aqueous solutions of suitable zirconium oxide precursors, such as zirconium oxynitrate, zirconium acetate, zirconium oxychloride, or zirconium oxysulfate and a precursor of suitable manganese oxide such as manganese nitrate, manganese acetate, manganese dichloride or manganese dibromide, by adding a sufficient amount of a base such as ammonium hydroxide to obtain a pH of 8-9, filtering the resulting precipitate, washing with water and drying at 450 ° -500 ° C. A useful support for a catalyst for treating ozone is selected from a support of refractory oxide, preferably alumina and silica-alumina with a preferred support being a silica-alumina support comprising from about 1 to 10% by weight of silica and 90 % to 99% by weight of alumina. Refractory oxide supports useful for a catalyst comprising a platinum group metal for the treatment of carbon monoxide, are selected from alumina, titania, silica-zirconia, and manganese-zirconia. Preferred supports for a catalyst composition for treating carbon monoxide is a zirconia-silica support as presented in U.S. Patent No. 5,145,825, a manganese-zirconia support as presented in U.S. Pat. No. 5,283,041 and an alumina of high surface area. More preferred for the treatment of carbon monoxide is titania. Reduced catalysts having titania supports result in a higher conversion of carbon monoxide than the corresponding non-reduced catalysts. Support for the catalyst for treating hydrocarbons, such as low molecular weight hydrocarbons, particularly low molecular weight olefinic hydrocarbons having from about two to about twenty carbons, and typically from two to about eight carbon atoms, as well as partially hydrogenated hydrocarbons , preferably selected from refractory metal oxides, including alumina and titania. As with the catalysts for treating carbon monoxide, the reduced catalysts result in a higher hydrocarbon conversion. Particularly preferred is a titania support, which has been found to be useful as it results in a catalyst composition having an improved ozone conversion, as well as a significant conversion of carbon monoxide and low molecular weight olefins. Also useful are microporous refractory oxides of high surface area, preferably alumina and titania having a surface area greater than 150 m2 / g and preferably ranging from 150 to 350, preferably from 200 to 300, and more preferably from 225 at 275 m2 / g, - a porosity greater than 0.5 cc / g, typically varying from 0.5 to 4.0 and preferably from approximately 1 to 2 cc / g, measured based on mercury porosimetry; and particle sizes ranging from 0.1 to 10 μm. A useful material is Versal GL alumina which has a surface area of approximately 260 m / g, a porosity of 1.4 to 1.5 cc / g and is supplied by LaRoche Industries. A preferred refractory support for metals of the platinum group, preferably of platinum platinum and / or palladium for use in the treatment of carbon monoxide and / or hydrocarbons is titania dioxide. The titania can be used in the form of voluminous powder or in the form of sol of titania dioxide. Also useful is a nano-sized particle size (nanometer) titania. The catalyst composition can be prepared by adding a platinum group metal in a liquid medium preferably in 1 to a solution such as platinum nitrate with the titania sol, with the sun very preferred. The sludge obtained can then be placed as a coating on a suitable substrate, such as an atmosphere treatment surface such as a radiator, metal monolith substrate or ceramic substrate. The metal of the preferred platinum group is a platinum compound. The platinum titania sol catalyst obtained from the above process has a high activity for the oxidation of carbon monoxide and / or hydrocarbon at an ambient operating temperature. Metal components other than platinum components, which can be combined with the titania sol, include gold, palladium, rhodium, silver, and mixtures thereof. A component of the reduced platinum group, preferably a platinum component on a titanium catalyst, which is indicated as being preferred for the treatment of carbon monoxide, has also been found to be useful and preferred for the treatment of hydrocarbons, particularly hydrocarbons olefinic A preferred titania sol support comprises titania having a particle size ranging from about 1 to about 10, and typically about 2 to 5 nm. A titania of preferred volume has a surface area of about 25 to 120 m / g, and preferably 50 to 100 m2 / g; and a particle size of about 0.1 to 10 μm. A specific and preferred bulky titania support has a surface area of 45-50 m2 / g, a particle size of about 1 μm, and is sold by DeGussa as P-25. The titanium of useful nanoparticle size comprises, having a particle size ranging from about 5 to 100 and typically greater than 10 to about 50 nm.
A preferred ice-zirconia support comprises 1 to 10 percent silica and 90 to 99 percent zirconia. Preferred support particles have a high surface area, for example from 100 to 500 square meters per gram (m2 / g) of surface area, preferably from 150 to 450 m2 / g, and more preferably from 200 to 400 m2 / g, to improve the dispersion of the catalytic metal component or components thereon. The preferred refractory metal oxide support also has a high pore porosity with a radius of up to about 145 nm, for example from about 0.75 to 1.5 cubic centimeters per gram (cm3 / g), preferably from about 0.9 to 1.2 cm / g , and a pore size varying from at least about 50% of the porosity being provided by the pores from 4 to 100 nm in radius. A catalyst for the treatment of useful ozone comprises at least one precious metal component, preferably a palladium component dispersed on a suitable support such as a refractory oxide support. The composition comprises 0.1 to 20.0 percent by weight, and preferably 0.5 to 15 percent by weight of the precious metal on the support, such as a refractory oxide support, based on the weight of the precious metal (metal and non-oxide). and the support. Palladium is preferably used in amounts of 2 to 15, more preferably 5 to 15 and even more preferably 8 to 12 weight percent. The platinum one is preferably used from 0.1 to 10, more preferably from 0.1 to 5.0 and even more preferably from 2 to 5 weight percent. Palladium is most preferred to catalyze the reaction of ozone to form oxygen. The support materials can be selected from the group presented above. In preferred embodiments, there may furthermore be a bulky manganese component as noted above, or a manganese component dispersed on the same or a different refractory oxide support, such as the precious metal, preferably the palladium component. It can exist up to 80, preferably up to 50, and most preferably from 1 to 40, and still more preferably from 5 to 35 weight percent of a manganese component based on the weight of the palladium and manganese metal in the composition of treatment of pollutants. Established otherwise, preferably there are from 2 to 30, and preferably from 2 to 10 percent by weight of a manganese component. The catalyst load of 20 to 250 grams and preferably 50 to 250 grams of palladium per cubic foot (g / ft3) of the volume of catalyst. The volume of the catalyst is the total volume of the composition of the finished catalyst and therefore includes the total volume of the air conditioning condenser or radiator, including hollow spaces provided by the gas flow passages. Generally, the higher palladium load results in a higher ozone conversion, ie a greater percentage of the decomposition of ozone in the treated air stream. Conversions of ozone to oxygen obtained with a palladium / manganese catalyst on alumina support compositions at a temperature of about 40 ° C to 50 ° C have been about 50 mole percent, when ozone concentrations vary from 0.1 to 0.4 ppm and the face velocity was 10 miles per hour. Lower conversions were obtained using a platinum on alumina catalyst. Of particular interest is the use of a support comprising the co-precipitated product described above of a manganese oxide, and zirconia, which is used to support a precious metal, preferably selected from platinum and palladium, and more preferably from platinum. . The platinum one is of particular interest, since it has been found that it is particularly effective when used on this co-precipitated support. The amount of platinum can vary from 0.1 to 6, preferably from 0.5 to 4, more preferably from 1 to 4, and still more preferably from 2 to 4 percent by weight based on that of platinum metal and the co-precipitated support. The use of platinum to treat ozone has been found to be particularly effective on this support. In addition, as discussed below, this catalyst is useful for treating carbon monoxide, preferably, the precious metal is platinum and the catalyst is reduced. Other catalysts useful for catalytically converting ozone to oxygen are described in U.S. Patent Nos. 4,343,776 and 4,405,507, both incorporated herein by reference. A useful and more preferred composition is disclosed in commonly assigned United States Patent Application, Serial No. 08 / 202,397, filed on February 25, 1994, and now U.S. Patent No. 5,422,331 and entitled "Light Weight, Low Pressure Drop Ozone Decomposition Catalyst for Aircraft Applicatons "incorporated here for reference. Still other compositions, which can result in the conversion of ozone to oxygen, comprise carbon, and palladium or platinum supported on carbon, manganese dioxide, Carulite® and / or hopcalite. Manganese supported on a refractory oxide as presented above has also been found to be useful. The carbon monoxide treatment catalysts preferably comprise at least one precious metal component, preferably selected from platinum and / or palladium components, with platinum components being more preferred. A combination of a platinum component and a palladium component results in an improved CO conversion at a cost increase and is highly preferred when the highest conversion is desired and the cost increase is acceptable. The composition comprises 0.1 to 20 percent by weight, preferably 0.5 to 15 percent by weight of the precious metal component on a suitable support such as a refractory oxide support, with the amount of the precious metal, based on the weight of the metal. precious metal (metal and non-metal component) and support. Platinum is most preferred and is preferably used in amounts of 0.01 to 10 percent by weight, and preferably 0.1 to 5 percent by weight, and more preferably 1.0 to 5.0 percent by weight. Palladium is useful in amounts of 2 to 15, preferably 5 to 15 and more preferably 8 to 12 percent by weight. The preferred support is titania, the titania sol being more preferred as presented above. When loaded onto a monolithic structure, such as a radiator or other atmospheric contact surfaces, the catalyst load preferably ranges from 1 to 150, approximately, and more preferably 10 to 100 grams of platinum per cubic foot (g / ft3). ) of the catalyst volume and / or 20 to 250 and preferably 50 to 250 grams of palladium per g / ft3 of the catalyst volume. When platinum and palladium are used in combination, these are approximately 25 to 100 g / ft3 of palladium and 50 or 250 g / ft3 of palladium. A preferred composition comprises 50 to 90 g / ft3 of platinum and 100 to 225 g / ft3 of palladium. The preferred catalysts are reduced. Conversions of 5 to 80 mole percent of carbon monoxide to carbon dioxide were obtained using core samples coated with an automotive radiator having 1 to 6 percent by weight based on the metal) of platinum on titania compositions. temperatures from 25 ° to 90 ° C, when the concentration of carbon monoxide was 15 to 25 parts per million and the space velocity was 300,000 to 500,000 reciprocal hours. Also, conversions of 5 to 65 mole percent of carbon monoxide to carbon dioxide were obtained, using 1.5 to 4.0 percent by weight of platinum on alumina support compositions at a temperature of about 95 ° C., where the concentration of carbon monoxide was approximately 15 parts per million and the space velocity was approximately 300,000 reciprocal hours. Lower conversions were obtained with palladium on a ceria support. An alternative and preferred catalyst composition for treating carbon monoxide comprises a precious metal component supported on a previously described co-precipitate of a manganese oxide and zirconia. The co-precipitate is formed as described above. The preferred manganese to zirconia ratios are from 5:95 to 95: 5; 10:90 to 75:25; 10:90 to 50:50, and 45:85 to 25:75, with a preferred coprecipitate having a ratio of manganese oxides to zirconia of 20:80. The percentage of platinum is supported on the co-precipitate based on the platinum metal ranging from 0.1 to 6, preferably from 0.5 to 4, preferably from 1 to 4, and more preferably 2-4 percent by weight. Preferably, the catalyst is reduced. The catalyst can be reduced in powder form or after it has been placed as a coating on a support substrate. Other useful compositions, those which can convert carbon monoxide to carbon dioxide include a platinum component supported on carbon or a support comprising manganese dioxide. Catalysts for treating hydrocarbons, typically unsaturated hydrocarbons, more typically unsaturated monoolefins have from two to about twenty carbon atoms and, in particular, two to eight carbon atoms, and partially hydrogenated hydrocarbons of the type referred to above, comprise at least one precious metal component, preferably selected from platinum and palladium, with platinum being more preferred. A combination of a platinum component and a palladium component results in an improved hydrocarbon conversion, an increase in cost and is highly preferred when a higher conversion is desired and the cost increase is acceptable. Useful catalyst compositions include those described for use to treat carbon monoxide. The composition for treating hydrocarbons comprises from 0.01 to 20% by weight, and preferably from 0.5 to 15% by weight of the precious metal component on a suitable support such as a refractory oxide support, the amount of precious metal is based on the weight of the precious metal (not in the metal component) and the support. Platinum is most preferred, and is preferably used in amounts of 0.01 to 10% by weight and most preferably 0.1 to 5% by weight and more preferably 1.0 to 5% by weight. When loaded on a monolithic structure such as a motor vehicle radiator, or on other atmospheric contact surfaces, the catalyst load is preferably from about 1 to 150, and more preferably from 10 to 100 grams of platinum per cubic foot ( g / ft3) of the catalyst volume. When using platinum and palladium in combination, one finds about 25 to 100 g / ft3 of platinum and 50 to 250 g / ft3 of palladium. A preferred composition comprises about 50 to 90 g / ft3 of platinum and 100 to 225 g / ft3 of palladium. The preferred refractory oxide support is a metal oxide refractory, which is preferably selected from ceria, silica, zirconia, alumina, titania and mixtures thereof, with alumina and titania being more preferred. The preferred titania is characterized by what was presented above, the titania sol being more preferred. The preferred catalyst is reduced. Treatment in a coated automotive radiator resulted in conversions of a low molecular weight olefin, such as propylene, to water and carbon dioxide with 1.5 to 4% by weight of platinum in an alumina or titania support, has been between and 25%, where the propylene concentration was about 10 parts per million propylene and the space velocity was about 320,000 reciprocal. These catalysts were not reduced. The reduction of the catalyst improves the conversion.
Catalysts useful for the oxidation of both carbon monoxide and hydrocarbons, generally include those presented above as useful for treating carbon monoxide as hydrocarbons. Most preferred catalysts that have been found to have a good activity for the treatment of carbon monoxide and hydrocarbon, such as unsaturated olefins, comprise a platinum component supported on a preferred titania support. The composition preferably comprises a binder and can be coated on a suitable support structure in amounts of 0.8 to 1.0 g / inch. A preferred platinum concentration ranges from 2 to 6% and preferably from 3 to 5% by weight of the platinum metal on the titania support. Useful and preferred substrate cell densities are equivalent to about 300 to 400 cells per 6.45 cm 2 (square inch). The catalyst is preferably reduced as a powder or on the coated article using a suitable reducing agent. Preferably, the catalyst is reduced in the gas stream comprising about 7% hydrogen with the remainder being nitrogen of 200 ° to 500 ° C or 1 to 12 hours.
The most preferred reduction or formation temperature is 400 ° C is 2-6 hours. This catalyst has been found to maintain high activity in air and humidified air at elevated temperatures of up to 100 ° C after prolonged exposure. Useful catalysts, which can treat both ozone and carbon monoxide, comprise at least one precious metal component, more preferably a precious metal selected from palladium, platinum and mixtures thereof, on a suitable support such as an oxide support. refractory. A combination of a platinum component and a palladium component results in an improved conversion of CO to an increase in cost, and is highly preferred when a higher conversion is desired and the increase in cost is acceptable. Useful refractory oxide supports include ceria, zirconia, alumina, titania, silica and mixtures thereof, including a mixture of zirconia and silica as presented above. Also useful and preferred as a support are the above described co-precipitates of manganese oxide and zirconia. The composition comprises from 0.1 to 20.0, preferably from 0.5 to 15, and more preferably from 1 to 10 weight percent of the precious metal component on the support based on the weight of the precious metal and support. Palladium is preferably used in amounts of 2 to 15, and more preferably 3 to 8 percent by weight. The platinum one is preferably used in amounts of 0.1 to 6 percent and more preferably 2 to 5 percent by weight. A preferred composition is a composition wherein the refractory component comprises ceria and the precious metal component comprises palladium. This composition has resulted in relatively high ozone and carbon monoxide conversions. More particularly, testing this composition on a coated radiator has resulted in a 21% conversion of carbon monoxide into an air stream comprising 16 ppm of carbon monoxide in contact with a surface at 95 ° C, with a high speed face of the gas flow of 5 miles per hour. The same catalyst resulted in a 55% conversion where the stream contained 0.25 ppm ozone and the treatment surface was at 25 ° C with an air flow face velocity of 10 miles per hour. Also preferred is a composition comprising a precious metal, preferably a platinum metal group, more preferably selected from components of platinum and palladium components, and more preferably from a platinum component and the aforementioned co-precipitated manganese oxide. and zirconia. This catalyst containing a precious metal mentioned above in the form of a catalyst powder or a coating on a suitable substrate, it is in reduced form. Preferred reduction conditions include those expressed above, the most preferred condition being 250 ° to 350 ° C for 2 to 4 hours in a reduction gas comprising 7% hydrogen and 93% nitrogen. This catalyst has been found to be particularly useful in the treatment of both carbon monoxide and ozone. Other compositions useful for converting ozone to oxygen and carbon monoxide comprise a platinum component supported on carbon, manganese dioxide, or a refractory oxide support, and optionally having an additional manganese component. A useful and preferred catalyst, which can treat ozone, carbon monoxide and hydrocarbons, as well as partially oxygenated hydrocarbons, comprises a precious metal component, preferably a platinum component on a suitable support, such as a refractory oxide support. A combination of a platinum component and a palladium component results in an improved conversion of CO to an increase in cost, and is more preferred when a higher conversion is desired and an increase in cost is acceptable. Useful refractory oxide supports include ceria, zirconia, alumina, titania, silica and mixtures thereof, including a mixture of zirconia and silica as presented above. Also useful is a support that includes the aforementioned co-precipitate of manganese oxide and zirconia. The composition comprises from 0.1 to 20, preferably from 0.5 to 15, and more preferably from 1 to 10% by weight of the precious metal component on the refractory support based on the weight of the precious metal and support. When it is desired that the hydrocarbon component be converted to carbon dioxide and water, platinum is the most preferred catalyst, and preferably used in amounts of 0.1 to 5% and more preferably 2 to 5% by weight.
In specific embodiments, there may be a combination of catalysts, including the aforementioned catalyst, as well as a catalyst, which is particularly preferred for the treatment of ozone, such as a catalyst comprising a manganese component. The manganese component can optionally be combined as a platinum component. Manganese and platinum can be in the same supports or in different supports. There can exist up to 80, preferably up to 50, more preferably from 1 to 40 and even more preferably from 10 to 35% by weight, of the manganese component based on the weight of the precious metal and manganese in the treatment composition of pollutants The catalyst loading is the same as that presented above with respect to the ozone catalyst. A preferred composition is a composition wherein the refractory component comprises a support of alumina or titania and the precious metal component comprises a platinum component. The test of such composition placed as a coating on a radiator, resulted in a conversion of 68 to 72% of carbon monoxide, a conversion of 8 to 15% of ozone and a conversion of 17 to 18% of propylene, when placed in contact with a surface at 95 ° C with a face velocity of the gas stream of approximately ten miles per hour (space velocities per hour of 320,000 per reciprocal hours), with an air dew point at 35 ° F. Generally, as the contact surface temperature is reduced and the space velocity or face velocity of the atmosphere air flow over the contact surface with the contaminant increases, the conversion percentage is reduced. The activity of the catalyst, particularly for treating carbon monoxide and hydrocarbons can be further improved by reducing the catalyst in a formation gas such as hydrogen, carbon monoxide, methane or hydrocarbon plus nitrogen gas. Alternatively, the reducing agent may be in the form of a liquid such as a hydrazine, formic acid and formate salts, such as a solution of sodium formate. The catalyst can be reduced as a powder or after being coated on a substrate. The reduction can be conducted in gas of 150 ° -500 ° C, preferably 200 ° -400 ° C, for 1 to 12 hours, preferably 2 to 8 hours. In a preferred process, the coated article or powder can be reduced in a gas comprising 7% hydrogen in nitrogen at 275 ° -350 ° C, for 2 to 4 hours. An alternative composition for use in the method and apparatus of the present invention comprises a catalytically active material selected from the group consisting of precious metal components including metal components of the platinum group, gold components and silver components, and a component of metal selected from the group consisting of tungsten components and rhenium components. The relative amounts of the catalytically active material to the tungsten component and / or rhenium component based on the weight of the metal, are from 1 to 25, to 15 to 1. The composition contains a tungsten component and / or a component of Rhenium preferably comprises tungsten and / or rhenium in the oxide form. The oxide can be obtained by forming the composition using tungsten or rhenium salts, and the composition can be subsequently calcined to form tungsten oxide and / or rhenium. The composition may comprise other components such as supports, including refractory oxide supports, manganese components, carbon and co-precipitates of a manganese oxide and zirconia. Suitable refractory metal oxides include alumina, silica, titania, ceria, zirconia, chromia, and mixtures thereof. The composition may further comprise a binder material, such as metal sols including alumina and titania sols or a polymeric binder., which can be provided in the form of a polymeric latex binder. In preferred compositions, there is from 0.5 to 15, preferably 1 to 10 and more preferably from 3 to 5 weight percent of the catalytically active material. Preferred catalytically active materials are metals of the platinum group with palladium and platinum being very preferred, and platinum is most preferred. The amount of the tungsten and / or rhenium component based on the metals, ranges from 1 to 25, preferably from 2 to 15, and more preferably from 3 to 10 percent by weight. The amount of binder can vary from 0 to 20 percent by weight, preferably from 0.5 to 20, more preferably from 2 to 10 and more preferably from 2 to 5 percent by weight. Depending on the support material, a binder is not necessary in this composition. Preferred compositions comprise from 60 to 98.5 percent by weight of a refractory oxide support, from 0.5 to 15 percent by weight 5 of the catalytically active material, from 1 to 25 by weight of the tungsten and / or rhenium component, and from 0 10 by weight of the binder. The compositions containing the tungsten component and the rhenium component K) can be calcined under the conditions presented above. In addition, the composition can be reduced. However, as shown in the following examples, the compositions do not need to be reduced and the presence of the The tungsten and / or rhenium component can result in conversions of carbon monoxide and hydrocarbons comparable to platinum group containing compositions, which have been reduced. The compositions for the treatment of contaminants of the present invention, preferably comprise a binder, which acts to adhere the composition and to provide adhesion to the contact surface with the atmosphere. It has been found that a preferred binder is a peripheral binder used in amounts of 0.5 to 20, more preferably 2 to 10, and more preferably 2 to 5 percent by weight of the binder based on the weight of the composition. Preferably, the binder is a polymeric binder, which may be a thermoplastic or thermoplastic polymer binder. The polymeric binder may have suitable stabilizers and aging resistors known in the polymeric art. The polymer can be a plastic or elastomeric polymer. More preferred are thermosetting, elastomeric polymers, introduced as a latex to the catalyst to a slurry of the catalyst composition, preferably an aqueous slurry. After the application of the composition and heating of the binder material, it can be interlaced providing a suitable support, which improves the integrity of the coating, its adhesion to the surface of contact with the atmosphere, and provides structural stability under vibrations found in motor vehicles. . The use of a preferred polymeric binder allows the contaminant treatment composition to adhere to the contact surface with the atmosphere without the need for a coating layer. The binder may comprise water resistant additives to improve water resistance and improve adhesion. Such additives may include luorocarbon f emulsions and waxy petroleum emulsions. Useful polymeric compositions include polyethylene, polypropylene, polyolefin copolymers, polyisoprene, polybutadiene, polybutadiene copolymers, chlorinated rubber, nitrile rubber, polychloroprene, ethylene-propylene-diene elastomers, polystyrene, polyacrylate, polymethacrylate, polyacrylonitrile, poly (vinyl) esters yarns), poly (vinyl) halides, polyamides, cellulose polymers, polyimides, acrylics, vinyl acrylics and styrene acrylics, polyvinyl alcohol, thermoplastic polyesters, heat-setting polyesters, poly (phenylene) oxide, poly (phenylene) sulfide , fluorinated polymers, such as poly (tet raf luoroethylene) polyvinylidene fluoride, and copolymers of poly (vinyl) fluoride and chlorine / fluorine, such as copolymers of ethylene trichloroethane, polyamide, phenolic resins and epoxy resins, polyurethane and polymers of silicone. A more preferred polymeric material is a polymeric acrylic latex as described in the appended examples. Particularly preferred polymers and copolymers are vinyl acrylic polymers and ethylene-vinyl acetate copolymers. An acrylic vinyl polymer is an entanglement polymer sold by National Starch and Chemical Company as Xlink 2833. It is described as a vinyl acrylic polymer having a Tg of -15 ° C, 45% solids, a pH of 4.5 and a viscosity of 300 cps. In particular, it is indicated that it has CAS No. 108-05-4 vinyl acetate on a concentration scale of less than 0.5 percent. It is indicated that it is a vinyl acetate copolymer. Other preferred vinyl acetate copolymers sold by the National Starch and Chemical Company include Dur-O-Set E-623 and Dur-O-Set E-646. Dur-0-Set E-623 is indicated to be ethylene-vinyl acetate copolymers having a Tg of -0 ° C, 52% solids, a pH of 5.5 and a viscosity of 200 cps. Dur-O-Set E-646 is indicated to be an ethylene-vinyl acetate copolymer with a Tg of -12 ° C, 52% solids, a pH of 5.5 and a viscosity of 300 cps. A useful and preferred binder is an entangled acrylic copolymer sold by National Starch and Chemical Company as X-4280. It is described as a milky white aqueous emulsion having a pH of 2.6; a boiling point of 212 ° F, a freezing point of 32 ° F, - a specific gravity of 1.060; and a viscosity of 100 cps. An alternative and useful agglutination material is the use of a zirconium compound. Zirconyl acetate is the preferred zirconium compound, which is used. It is believed that zirconia acts as a high temperature stabilizer, tests the catalytic activity and improves catalyst adhesion. After calcination, zirconyl compounds such as zirconyl acetate are converted to Zr 2 / which is believed to be the agglutination material. Various useful zirconium compounds include acetates, hydroxides, nitrates, etc., to generate r 2 in the catalysts. In the case of using zirconyl acetate as a binder for the catalysts herein, Zr 2 will not be formed unless the radiator coating is calcined. Since good adhesion has been achieved through a "calcination" temperature of only 120 ° C, it is believed that zirconium acetate has not decomposed to zirconium oxide, but rather has formed a network interlaced with the contaminant treatment material, such as Carulite® particles, and acetates, which were formed from ball milling with acetic acid. Accordingly, the use of any of the zirconium-containing compounds in the catalysts herein is not restricted to zirconia only. In addition, the zirconium components can be used with other binders such as the polymeric binder described above. A catalyst composition for the treatment of alternative contaminants may comprise an activated carbon composition. The carbon composition comprises activated carbon, a binder, such as a polymeric binder, and optionally conventional additives, such as defoamers and the like. A useful activated carbon composition comprises from 75 to 85 percent by weight of activated carbon, such as "coconut shell carbon" or wood carbon and a binder such as an acrylic binder with a defoamer. Useful sludges comprise from 10 to 50 percent by weight of solids. Activated carbon can catalyze the reduction of ozone to oxygen, as well as to adsorb other pollutants. The catalyst compositions for the treatment of contaminants of the present invention can be prepared in any suitable process. A preferred process is described in U.S. Patent No. 4,134,860, incorporated herein by reference. According to this method, the refractory oxide support such as activated alumina, titania or activated silica-alumina is milled by jet, impregnated with a catalytic metal salt, preferably a precious metal salt solution and calcined at a temperature suitable, typically from about 300 ° C to about 600 ° C, preferably from about 350 ° C to 550 ° C, more preferably from about 400 ° C to about 500 ° C, during 0.5 to about 12 hours. The palladium salts are preferably a palladium nitrate or a palladium amine, such as palladium tertiary ramine-acetate, or palladium-tet raminine hydroxide. The platinum salts preferably include platinum hydroxide solubilized in an amine. In specific and preferred embodiments, the calcined catalyst is reduced as expressed above. In a composition for the treatment of ozone, a manganese salt, such as manganese nitrate, can then be mixed with the palladium supported with dry alumina and calcined in presence in deionized water. The amount of water added must be an amount up to the point of incipient humidity. Reference is made to the method reviewed in U.S. Patent No. 4,134,860 previously incorporated and referenced. The incipient moisture point is the point at which the amount of liquid added is at the most concentration at which the powder mixture is sufficiently dry in order to absorb essentially all of the liquid. In this way, the soluble manganese salt such as Mn (Ü3) 3 in water, can be added to the calcined supported catalytic precious metal. The mixture is then dried and calcined at a suitable temperature, preferably 400 to 500 ° C for 0.5 to 12 hours. Alternatively, the supported catalyst powder (ie, palladium supported on alumina) can be combined with a liquid, preferably water, to form a slurry to which a solution of a manganese salt such as Mn (N03 >) is added.2- Preferably, the manganese ~ component and the palladium supported on a refractory support such as activated alumina, more preferably activated silica-alumina, is mixed with a suitable amount of water to result in a sludge having 15 to 40%, and preferably 20 to 35 percent by weight of solids. The combined mixture can be placed as a coating on a vehicle such as a radiator and the radiator is air dried at suitable conditions such as 50 ° C to 150 ° C for 1 to 12 hours. The substrate that supports the coating can then be heated in an oven to suitable conditions typically from 300 ° C to 550 ° C, preferably 350 ° C to 550 ° C, more preferably 350 ° C to 450 ° C, and more preferably from 400 ° C to 500 ° C, in an atmosphere containing oxygen, preferably air of about 0.5 to 12 hours, to calcine the components and help to secure the coating to the contact surface with the atmosphere of the substrate. When the composition further comprises a precious metal component, it is preferably reduced after calcination.
One method of the present invention includes forming a mixture comprising a catalytically active material selected from at least one platinum group metal component, a gold component, a silver component, a manganese component and mixtures thereof, and water . The catalytically active material can be on a suitable support, preferably a refractory oxide support. The mixture can be milled, and then optionally can be calcined and reduced when a precious metal catalytic material is used. The calcination step can be conducted before milling and addition of the polymeric binder. It is also preferred to reduce the catalytically active material before milling, calcination and addition of the polymeric binder. The sludge comprises a carboxylic acid compound or a polymer containing carboxylic acid groups or their derivatives, in an amount which results in a pH of from about 3 to 7, typically from 3 to 6. Preferably, the acid comprises from 0.5 to 15 percent by weight of glacial acetic acid based on the catalytically active material and acetic acid. The amount of water can be added as appropriate to obtain a sludge of the desired solids concentration and / or viscosity. The percentage of solids is typically from 20 to 50, and preferably from 30 to 40 percent by weight. The preferred vehicle is deionized water (A.D). The acetic acid can be added after the formation of the mixture of the catalytically active material, which has been calcined, with water. Alternatively, the acetic acid can be added with the polymeric binder. A preferred composition for treating ozone using manganese dioxide as the catalyst can be made using about 1,500 g of manganese dioxide, which is mixed with 2,250 g of deionized water and 75 g of acetic acid. The mixture is combined in a 3-gallon (3-gallon) ball mill and ground into balls for about 4 hours, until about 90% of the particles are less t8 microns. The ball mill is drained and 150 g of polymeric binder are added. The mixture is then combined in a roller mill for 30 minutes. The resulting mixture is ready to be coated on a suitable substrate, such as a car radiator according to the methods described below.
It has been found that the compatibility of the compounds of a sludge comprising a catalytic material and a polymeric binder, such as a latex emulsion, is desirable to maintain the stability and uniformity of the sludge. For the purpose of the present invention, compatibility means that the binder and the catalytic material remain as a mixture of separated particles in the slurry. It is believed that when the polymeric binder is a latex emulsion and the catalytic material has electrical charges, which cause them to repel each other, are compatible and the slurry is stable and has a uniform distribution of the catalytic material and the polymer latex in the liquid vehicle, for example, aqueous fluid such as water. If the catalytic material and the latex emulsion particles do not mutually repel each other, the irreversible agglomeration of the latex will occur on the catalytic material. These materials, therefore, are incompatible and the latex is left out of the emulsion. The compatibility of a high surface area catalyst with the organic latex binder is a key property for preparing a stable, uniform slurry. If the catalyst and the latex emulsion particles do not mutually repel each other, irreversible agglomeration will occur. The result of this will be an unstable, non-uniform mud, which will produce a poorly adherent coating. Although the mutual repulsion of the catalyst and the binder particles is controlled through a variety of physical factors, surface loading plays an important role. Since the latex emulsion particles are typically negatively charged, the catalyst particles must be similarly charged. However, measurements of the zeta potential have shown that catalyst particles such as Mn? 2 are only slightly negative or even positively charged as a result, irreversible coagulation of the catalyst and latex occurs (ie, catalyst and latex are not compatible). It has been found that although the above-described method of adding acetic acid provides certain advantages to the sludge of the present invention, such as viscosity control, it does not improve the compatibility and may still be dangerous for the stability of the aged sludge.
KM) When the catalytic material is positive or slightly negatively charged, improved compatibility can be obtained, making the mud more basic. The pH of the sludge can be controlled depending on the acidity of the catalytic material, with preferred pH levels being at least 6, preferably at least 7, more preferably at least 8.5. Generally, the mud should not be too caustic and a preferred upper limit is about 11. A preferred scale is 8.5 to 11. Maintaining a pH > 8.5 of a sludge comprising a latex emulsion and Mn? 2 (crypomelano) is critical. If the pH falls below 8.15 for an extended period (days), the binder and the catalyst will irreversibly coagulate. Despite the large negative charge on the cryptomelane particles at this pH, it has been difficult to obtain long-term stability - of the sludge containing cryptomelane. Preferred binders are binders based on poly (acrylic acid) derivative with a particularly preferred binder, which has long term stability under these conditions, with an acrylic latex sold by National Starch as acrylic latex x-4280. The difficulty to achieve a long-term compatibility even with basic sludge containing negatively charged latex and catalyst particles, indicates that although surface loading is important, it is not the only factor in determining the compatibility of the binder / catalyst. Other factors that play an important role include the particle size of the emulsion, the packaging of the surfactant, etc. The method of the present invention involves increasing the pH of the milled catalyst slurry in a ball mill at a pH of > 8.5 and preferably 9, to improve stability. An alternative method for improving mud stability involves adding a surfactant such as a polymeric dispersant to the mud, instead of, or in addition to increasing the pH. In the second case, the binder / catalyst compatibility is achieved by adding a dispersant derived from polymeric acrylate (approximately 3% solids as a base) instead of increasing the pH. However, the result is the same, since the particle size of the catalyst is given as a large negative charge, which can repel similar charged latex particles. The dispersant can be added during the grinding operation in a ball mill, or after. Despite the generation of a large negative charge on the catalyst particles, not all dispersants work equally well. Preferred dispersants comprise polymers containing carboxylic acid groups or derivatives thereof such as esters and salts. Preferred dispersants include Accusol 445 (from Rohm &Haas) and Colloid 226/35 (from Rhone-Poulenc). Useful dispersants and a review of dispersion technology are presented in, Additives for Dispersion Technology, published by Rhone-Poulenc, Surfactants & Specialties incorporated here for reference. Useful polymeric dispersants include, but are not limited to, partial sodium salts of polyacrylic acid, and sodium salts of anionic copolymer, sold by Rhone-Poulenc, as polymeric dispersants of Colloid ™. Again, although surface loading is an important factor in determining the compatibility of the catalyst / binder, it is not the only factor. In addition, the dispersant (particularly Colloid 226) has a good role in the stability of the sludge, since a wide variety of latex binders (eg, acrylics, styrene acrylics and EVA) are compatible. Long-term compatibility problems can be addressed by increasing the amount of dispersant, raising the pH a little, or both. The methods presented above, improve compatibility and result in a stable catalyst slurry. Both methods generate a large negative surface charge on the catalyst particle, which in turn stabilizes the catalyst in the presence of equally charged latex (anionic) emulsion particles. For both systems good adhesion has been observed (ie, the catalyst can not be cleaned from the surface of a coated monolith), cpn a load of 10% by weight (solid base) of the polymeric binder. At 5%, adhesion is not good, so the optimal load is probably between this calculation. Since these methods have been shown to improve the compatibility of Mn? 2 / latex muds, the present invention is not limited to systems using negatively charged latex emulsions. Those skilled in the art will understand that mud compatibility can also be achieved by using cationic latex emulsions, using cationic surfactants and / or dispersant packs to stabilize the catalyst particles. The polymeric slurries of the present, particularly the polymer latex sludge, may contain conventional additives, such as thickeners, biocides, antioxidants and the like. The composition for the treatment of contaminants can be applied to the vehicle contact surface with the atmosphere through any suitable means, such as spray coating, powder coating, or brushing or immersing the surface in a catalyst slurry. The contact surface with the atmosphere is preferably cleaned to remove dust from the surface, particularly oils that can result in poor adhesion of the composition for the treatment of contaminants to the surface. When possible, it is preferred to heat the substrate on which the surface is to be located, at a temperature high enough to volatilize or burn the waste and oils from the surface. When the substrate on which a contact surface is to be made with the atmosphere of a material that can withstand high temperatures, such as an aluminum radiator, the surface of the substrate can be treated in such a way that it improves the adhesion of the catalyst composition, preferably carbon monoxide to ozone, and / or the hydrocarbon catalyst composition. One method is to heat the aluminum substrate such as the radiator, at a sufficient temperature in air for a sufficient time to form a thin layer of aluminum oxide on the surface. This helps clean the surface by removing the oils, which can be dangerous for adhesion. In addition, if the surface is aluminum, it has been found that a sufficient layer of oxidized aluminum is capable of being formed by heating the radiator in the air for 0.5 to 24 hours, preferably 8 to 12, and more preferably 12 to 20 hours to 350 ° C to 500 ° C, preferably 400 ° C to 500 ° C and more preferably 425 ° C to 475 ° C. In some cases, sufficient adhesion has been obtained without the use of a subcoat layer, where an aluminum radiator has been heated at 450 ° C for 16 hours in the air. This method is particularly useful when the coating is applied to new surfaces such as radiators or air conditioning condensers prior to assembly in a motor vehicle, either as an original equipment or as a replacement. Adhesion can be improved by applying a subcoat or pre-coating to the substrate. Useful sub-coatings or pre-coatings include refractory oxide supports of the type described above, with alumina being preferred. A preferred undercoat for increasing the adhesion between the contact surface with the atmosphere, and an overcoat of an ozone catalyst composition is disclosed in commonly assigned U.S. Patent No. 5,422,331 incorporated herein by reference . The sub-coating layer is described as comprising a mixture of refractory metal oxide in fine particles and a sol selected from silica sols, alumina, zirconia and titania. According to the method of the present invention, the surfaces on existing vehicles can be coated, while the substrate, such as the radiator, radiator fan or air conditioning condenser, is located on the vehicle. The catalyst composition can be applied directly to the surface. When additional adhesion is required, a subcoat may be used, as mentioned above. When it is practical to separate the radiator from the vehicle, a support material such as activated alumina, silica-alumina, bulky titania, titania sol, lice-zirconia, manganese-zirconia and others, as presented above, can be made into a slurry and being coated on the substrate, preferably with a silica sol, to improve adhesion, the pre-coated substrate can subsequently be coated with soluble precious metal salts, such as the platinum and / or palladium salts, and optionally manganese nitrate. The coated substrate can then be heated in an air oven for a sufficient time (0.5 to 12 hours from 350 ° C to 550 ° C) to calcinate the palladium and manganese components to form its oxides. The present invention may comprise adsorption compositions supported on the surface of contact with the atmosphere. The adsorption compositions can be used to adsorb gaseous contaminants such as hydrocarbons and sulfur dioxide as well as particulate matter, such as particulate hydrocarbons, soot, pollen, bacteria and germs. Useful supported compositions may include adsorbents such as zeolite to adsorb hydrocarbons. Useful zeolitic compositions are described in Publication No. WO 94/27709 published December 8, 1994, and entitled Nitrous Oxide Decomposition Catalyst incorporated herein by reference. Particularly preferred zeolites are Beta zeolite, and dealuminated Zeolite Y. The carbon, preferably activated carbon, can be formed in carbon adsorption compositions comprising activated carbon and binders such as the polymers shown in the prior art. The carbon adsorption composition can be applied to the surface of contact with the atmosphere. Activated carbon can adsorb hydrocarbons, volatile organic compounds, bacteria, pollen, and the like. Still another adsorption composition may include components, which adsorb SO3. A particularly useful SO3 adsorbent is calcium oxide. The calcium oxide is converted to calcium sulfate. The calcium oxide adsorbent compositions may also contain a vanadium or platinum catalyst, which can be used to convert sulfur dioxide to sulfur trioxide, which can then be adsorbed onto the calcium oxide to form calcium sulfate. In addition to a treatment of the atmospheric air containing contaminants to the environmental condition or environmental operating conditions, the present invention contemplates the catalytic oxidation and / or reduction of hydrocarbons, nitrogen oxides and residual carbon monoxide, using three conventional catalysts supported on electrically heated catalysts, such as is known in the art. The electrically heated catalysts can be located on the monolith 56 the electrically heated catalyst illustrated in Figure 1. Such electrically heated catalyst substrates are known in the art and are described in references such as U.S. Patent Nos. 5,308,591 and 5,317,869, incorporated herein by reference. For the purposes of the present invention, the electrically heated catalyst is a metal honeycomb having a thickness suitable for fixing in the direction of flow, preferably from 0.3175 cm to 3.81 cm (1/8 inch to 12 inches), and preferably from 1.27 to 7.62 cm (0.5 to 3 inches). When the electrically heated catalyst must be fixed in a narrow space, it may have a thickness of 0.635 cm to 3.81 cm (0.25 to 1.5 inches). Preferred supports are monolithic vehicles of the type having a plurality of fine, parallel gas flow passages extending therethrough from an entrance face to an exit face of the vehicle so that the passages are opened so that the flow enters from the front part 26 and passes through the monolith 56 in the direction towards the fan 20. Preferably, the passages are essentially straight from their entrance to their outlet, and are defined by walls, in which the material The catalyst is placed as a coating, such as a wash coating, so that the gases flowing through the passages come into contact with the catalytic material. The flow passages of the vehicle lll monolithic are thin-walled channels, which can be of any suitable cross-sectional shape and size, such as trapezoidal, rectangular, square, sinusoidal, hexagonal, oval, circular or formed from metal components, which are corrugated and they are flat, as is known in the art. Such structures may contain from about 60 to 600 or more gas inlet openings ("cells") per square centimeter of cross section. The monolith can be made of any suitable material and preferably is capable of being heated after the application of an electric current. A useful catalyst to apply is the three-way catalyst (TWC) as presented above, which can improve the oxidation of hydrocarbons and carbon monoxide as well as the reduction of nitrogen oxides. Useful TWC catalysts are presented in U.S. Patent Nos. 4,714,694; 4,738,947; 5,010,051; 5,057,483; and 5,139,992. The present invention is further illustrated by the following examples, which are not intended to limit the scope of the invention.
EXAMPLES Example 1 A radiator core of a Nissan Alti to 1993 (Nissan part number 1460, 1E400) was heat treated in air at 450 ° C for 16 hours to clean and oxidize the surface and then a portion was placed as a coating with a sub-coating of silica-alumina of high surface area (dry load = 0.23 g / centimeter) emptying a mud of water containing the silica-alumina through the channels of the radiator, blowing the excess with a spray gun. air, drying at room temperature with a fan, and then calcining at 450 ° C. The alumina-alumina slurry was prepared by grinding the calcined SRS-II alumina with high surface area (Davison) with acetic acid (0.5% based on alumina) and water (total solids approximately 20%) in a ball mill. a particle size of 90% of < 4 μm. The material milled in a ball mill was then mixed with Nalco silica sol (# 91SJ06S - 28% solids) in a ratio of 25% / 75%. The SRS-II alumina was specified to have a structure of xSiO2.yAl2O3.zH2O with 92-95% by weight of AI2O3 and 4-7% by weight of SIO2 after activation. The surface area of BET was specified as a minimum of 260 ~ m2 / g after calcination. A Pd / Mn / Al2? 3 catalyst slurry (nominally 10% by weight of palladium on alumina) was prepared by impregnating the alumina SRS-II of high surface area (Davison) to the point of incipient humidity with a water solution containing palladium tetraaminacetate, sufficient. The resulting powder was dried and then calcined for one hour at 450 ° C. The powder was subsequently mixed under high shear with a solution of manganese nitrate water (amount equivalent to 5.5% by weight of Mn? 2 on alumina powder) and sufficient dilution water to produce a sludge of 32-34%. solid The radiator was coated with mud, dried in air using a fan, and calcined in air at 450 ° C for 16 hours. This ozone destruction catalyst contained palladium (dry filler = 263 g / ft3 of radiator volume) and manganese dioxide (dry filler = 142 g / ft3) of high surface area SRS-II alumina. The partially coated radiator was re-assembled with the cooling tanks, also referred to as the heads, as shown in Figure 8.
The ozone destruction performance of the coated catalyst was determined by blowing an ozone-containing air stream through the radiator channels at typical face velocities of driving velocities and then measuring the concentration of ozone leaving the rear face of the radiator. The air used was approximately 20 ° C and had a dew point of approximately 35 ° F. The coolant fluid was recirculated through the radiator at a temperature of about 50 ° C. Ozone concentrations ranged from 0.1-0.4 ppm. The conversion of ozone to linear air velocities (face velocities) equivalent to 12.5 miles per hour was measured as 43%; at 25 mph as 33%; at 37.5 mph as 30% and at 49 mph as 24%. Example 2 (Comparative) A portion of the same radiator used in Example 1, which was not coated with the catalyst, was similarly evaluated for ozone destruction performance (i.e., control experiment). No conversion of ozone was observed.
Example After heat treatment for 60 hours in air at 450 ° C, a radiator core of a Lincoln Town car (part # F1VY-8005 -A) was sequentially coated in square patches of 15.24 x 15.24 cm (6 x 6 inches) with a variety of different ozone destruction catalyst compositions (ie, different catalysts, catalyst fillers, binder formulations, and heat treatments). Several of the radiator patches were pre-coated with alumina or silica-alumina of high surface area and calcined at 450 ° C before coating with the catalyst. The current coating was achieved similarly to Example 1 by emptying a water slurry containing the specific catalyst formulation through the radiator channels, blowing, the excess with an air gun, and drying at room temperature with a fan. The core of the radiator was then dried at 120 ° C, or dried at 120 ° C and then calcined at 400 to 450 ° C. The core of the radiator was then reattached to its plastic tanks and the ozone destruction performance of the various catalysts was determined at a radiator surface temperature of about 40 ° C to 50 ° C and a face velocity of 10. mph as described in Example 1. Table I summarizes the variety of catalyst coating in the radiator. Details of the catalyst solution preparations are given in the following. A catalyst Pt / Al203 (nominally 2% by weight of Pt on A1203 is prepared by impregnating 114g of a solution of platinum salt derived from H2Pt (OH) 6 solubilized in an amine (17.9% Pt), dissolved in 520 g of water to 1000 g of Condea SBA-150 of high surface area (specified to be approximately 150 m2 / g) of alumina powder Subsequently 49.5 g of acetic acid was added, the powder was then dried at 110 ° C during 1 hour and calcined at 550 ° C for 2 hours A catalyst solution was then prepared, adding 875g of the powder to 1069g of water and 44.6g of acetic acid in a ball mill and grinding the mixture to a 90% particle size < 10 μm. (Patches i and 4) A carbon catalyst solution was a formulation (29% solids) obtained from Grant Industries, Inc. Wood Park, NJ Coal is derived from coconut bark. Acrylic binder and a defoamer. (Patches 8 and 12) The Carulit catalyst is prepared e 200 (CuO / Mn02) first by ball mill lOOOg of Carulite 200 (obtained from Carus Chemical Co; Chicago, IL) with 1500g of water at a particle size 90% < 6μm. Carulite 200 is specified to contain 60 to 75 percent by weight of Mn02, 11-14 percent of CuO and 15-16 percent of A1203. The resulting solution was diluted to ca. 28% solids and then mixed with either 3% silica sol (solid base) of Nalco # 1056 or 2% acrylic copolymer (solid base) Nat ional Starch # x4260 (Patches 5,9 and 10) . The catalyst solution was prepared Pd / Mn / Al203 (nominally 10% by weight of palladium on alumina), as described in Example 1. (Patches 2.3 and 6). A 'Pd / Mn / Al203 I catalyst was similarly prepared. (wet start) (nominally 8% by weight of palladium and 5.5% of Mn02 on alumina), first impregnated the high surface area of alumina SRS-II (Davison) to the wet start point with a water solution that It contains palladium tetraamine acetate. After it was dried and then the powder was calcined for two hours at 450 ° C, the powder was reimpregnated to the wet start point with a water solution containing manganese nitrate. Again, after drying and calcination at 450 ° C for two hours, the powder was mixed in a ball mill in acetic acid (3% by weight of the catalyst powder) and enough water to create a slurry of 35% solids. . Then, the mixture was milled until the particle size was 90% < 8 μm. (Patches 7 and 11). The precoat slurry of SIO2 / I2O3 was prepared as described in Example 1. (Patches 3 and 11) The precoat slurry of AI2O3 was prepared by grinding in a ball mill, alumina SBA-150 high surface area with acetic acid (5% by weight based on alumina) and water (total solids, approximately 44%) at a particle size of 90% by <10 μm, (Patches 9 and 12) The results are summarized in Table I. Conversion of carbon monoxide after being on the car for 5,000 miles was also measured at the conditions presented in Example 1 for patch # 4. At the radiator temperature of 50 ° C, and at a linear speed of 10 mph, no conversion was observed. TABLE I - CATALYST SUMMARY PATCH # CATALYZER OZONE CONVERSION (%) 1 Pt / Al203 12 0.67 g / inch3 (23 g / ft3 Pt) Without coating Without calcining (120 ° C only) 2 Pd / Mn / Al203 25 0.97 g / inch3 (171 g / ft3 Pd) Without coating Calcinated 450 ° C 3 Pd / Mn / Al203 24 1.19 g / inch3 (209 g / ft3 Pd) SIO2 / AI2O3 Pre-coated (0.16 g / inch3) 4 Pt / Al203 8 0.79 g / inch3 (27 g / ft3 Pt) Without coating Calcinated 450 ° C 5 Carulite 200 50 0.49 g / inch3 3% Si02 / Al2O3 Binder Without coating Calcined 400 ° C Pd / Mn / Al203"28 0.39 g / inch3 (70 g / ft3 Pd) Uncoated Calcinated 450 ° C IW Pd / Mn / Al203 50 0.69 g / in3 (95 g / ft3 Pd) Uncoated Uncalcined (120 ° C only) Carbon 22 0.80 g / in3 Without shrinkage Without calcining (120 ° C only) Carulite 200 38 0.65 g / inch3 3% of SIO2 / AI2O3 Binder AI2O3 Pre-coated (0.25 g / in3) Calcinated 450 ° C 10 Carulite 200 42 0.70 g / inch3 2% Binder of latex Without coating Without calcining (120 ° C only) 11 I.W. Pd / Mn / Al203 46 0.59 g / inch3 (82 g / ft3 Pd) SÍO2 / AI2O3 pre-coated (0.59 g / in3) Without calcining or coated (120 ° C only) 12 Carbon 17 1.07 g / inch3 AI2O3 Pre-coated (0.52 g / in3) calcined at 450 ° C Upper lining not calcined (120 ° C only) Example 4 A radiator core of a Nissan Altima 1993, (Nissan part number 21460-1E400) was heat treated in air at 400 ° C for 16 hours and then a portion was coated with alumina SBA-150 of high surface area Condea (dry load = 0.86 g / centimeter 3) by pouring sludge containing the alumina through the radiator channels, blowing the excess with an air gun, drying at room temperature with a fan, and then calcining at 400 ° C. The alumina pre-coated slurry was prepared as described in Example 3. Next, the radiator was sequentially coated in square patches of 5.08 cm x 50.8 cm_ (2 inches x 2 inches) with CO kill calibrators (Table II) . Each coating was applied by draining a slurry of water containing the specific catalyst formulation through the radiator channels, blowing the excess with an air gun and drying at room temperature with a fan. The Carulite.RTM. And 2% Pt / Al.sub.2.sub.3 catalysts (Patch # 4 and # 6, respectively) were prepared according to the procedure described in Example 3. The 3% Pt / Zr02 / SiO2 catalyst (Patch # 3 ) was first made by burning 510 g of zirconia / solder frying (95% of Zr? 2/5% of SiO2 - Magnesium Elektron XZO678 / 01) for 1 hour at 500 ° C. Then, a catalyst slurry was prepared by adding to 480 g of deionized water, 468 g of the resulting powder, 42 g of glacial acetic acid and 79.2 g of a platinum salt solution (18.2% Pt) derived from H Pt (OH) g solubilized with an amine. The resulting mixture was milled in a ball mill for 8 hours at a particle size of 90% less than 3 μm. The 3% Pt / Ti02 catalyst (Patch # 7) was prepared by mixing in a conventional mixer 500g of TiO2 (Degussa P25), 500g of deionized water, 12g of concentrated ammonium hydroxide, and 82g of a solution of platinum salt (18.2% Pt) derived from H2Pt (OH) 6, solubilized with an amine. After mixing for 5 minutes at 90% particle size less than 5 μm, 32.7 g of Nalco 1056 silica sol and sufficient deionized water were used to reduce the solid contents to about 22%. The resulting mixture was mixed on a roller mill to mix all the ingredients. The catalyst slurry of 3% Pt / Mn / Zr? 2 (Patch # 5) was prepared by combining in a ball mill 70 g of manganese / zirconia frying, comprising a co-precipitate of 20 weight percent manganese and 80 weight percent zirconia, based on the weight of metal (Magnesium Elektron XZO719 / 01), 100 g of deionized water, 3.5 g of acetic acid and 11.7 g of a platinum salt solution (18.2% of Pt), derived from H2Pt (OH) 6 solubilized with an amine. The resulting mixture was milled for 16 hours at a particle size of 90% less than 10 μm. The 2% Pt / Ce02 catalyst (Patch # 1) was prepared by impregnating 490 g of ceria of high surface area stabilized with alumina (Rhone Poulenc) with 43.9 g of a platinum salt solution (18.2% Pt) derived from H2Pt / (OH) 6 solubilized with an amine and dissolved in deionized water (total volume - 155 ml). The powder was dried at 110 ° C for 6 hours and calcined at 400 ° C for 2 hours. Then, a catalyst slurry was prepared by adding 491 g of the powder to 593 g of deionized water in a volume of beads and then milling the mixture for 2 hours at a particle size of 90% less than 4 μm. The 4.6% Pd / Ce? 2 catalyst (Patch # 2) was similarly prepared by incipient wet impregnation using 209.5 g (180 ml) of a tetraamylacetate solution. After the seven catalysts were applied, the radiator was calcined for approximately 16 hours at 400 ° C. After joining the radiator core to the plastic tanks, the CO destruction performance of the various catalysts was determined by blowing an air stream containing CO (approximately 16 ppm) through the radiator channels at a linear face velocity of 5 mph (space velocity of 315,000 / h) and then measuring the concentration of CO that leaves the rear face of the radiator. The radiator temperature was about 95 ° C, and the air flow had a dew point of about 35 ° F. The results are summarized in Table II. The ozone destruction performance was measured as described in Example 1 at 25 ° C, 0.25 ppm ozone, and at a linear face velocity of 10 mph with a flow of 135.2 1 / minutes and a space velocity per hour of 640,000 / h. The air used had a dew point of 35 ° F. The results are summarized in Table II. Figure 9 illustrates the conversion of CO to temperature for patches Nos. 3, 6 and 7. The catalysts were also tested for the destruction of propylene by blowing a stream of air containing propylene (approximately 10 ppm) through the radiator channels at a linear face velocity of 5 mph, with a flow velocity of 68.2 1 / min and a space velocity per hour of 320,000 / h, and then measuring the concentration of propylene that leaves the rear face of the radiator. The radiator temperature was about 95 ° C, and the air flow had a dew point of about 35 ° F. The results are summarized in Table II. TABLE II - SUMMARY OF THE CONVERSION OF CO / HC / OZONE PATCH # CATALYZER CONVERSION CONVERSION CONVERSION MONOXIDE OZONE (%) 2 PROPYLENE (%) 3 CARBON (%) 1 2% Pt / Ce02 2 14 0.7 g / inch3 (24 g / ft3 Pt) 4.6% Pd / Ce02 21 55 0.5 g / inch3 (40 g / ft3 Pd) 3% Pt / Zr02 / Si02 67 14 0.5 g / inch3 (26 g / ft3 Pt) Carulite 200 56 0.5 g / inch3 3% Si02 / Al203 binder 3% Pt / Mn / Zr02 41 0.7 g / inch3 (36 g / ft3 Pt) 2% Pt / Al203 72 17 0.5 g / inch3 (17 g / ft3 Pt) 7 3% Pt / Ti02 68 15 18 0.7 g / inch3 (36 g / ft3 Pt) ) 3% Si02 / Al-203 binder ^ -Conditions of Test: 16 ppm of CO; 95 ° C, 5 mph face speed; 68.2 1 / minute. LHSV (space velocity per hour) = 320,000 / ti; Air dew point = 35 ° F. Test Conditions: 0.25 ppm O3, - 25 ° C; face speed 10 mph; 145.2 1 / minute; LHSV (space velocity per hour) = 640,000 / h; Air dew point = 35 ° F. Test conditions: 10 ppm propylene; 95 ° C; 5 mph face speed; 68.2 1 / minutes; LHSV (space velocity per hour) = 320,000 / h; Air dew point = 35 ° F. Example 5 This example summarizes the technical results of the vehicle test on the highway conducted in February and March 1995 in the Los Angeles area. The purpose of the test was to measure the decomposition efficiency of catalytic ozone over a catalysed radiator under real driving conditions. The Los Angeles (LA) area was chosen as the most appropriate test site, primarily because of ~ its measurable ozone levels during this test period in March. In addition, specific management routes are defined in the LA area, which are typical for peak and non-peak management of AM and PM. Two different catalyst compositions were evaluated: 1) Carulite® 200 (CuO / Mn ?2 / Al2 ?3, sold from Carus Chemical Company); and 2) Pd / Mn / Al2? 3 (77 g / ft3 Pd) prepared as described in Example 3. Both catalysts were placed as patched coatings on an aluminum V-6 engine radiator of a late Cadillac model. The radiator was an aluminum replacement for the cobrébronce OEM radiator, which was placed on a Chevrolet brand Caprice test vehicle. The car was fixed with 0.635 cm (1/4 inch) Teflon® PTFE sampling lines, located directly below each catalyst patch and below an uncoated portion of the radiator (control patch). Ozone levels in the environment (in catalyst) were measured through a sampling line in front of the radiator. Ozone concentrations were measured with two Dasibi Model 1003AH ozone monitors, located in the rear seat of the vehicle. Temperature probes (with epoxy) were mounted directly on each radiator test patch in a few centimeters of the sampling line. An individual air velocity probe was mounted on the front face of the radiator in the middle of the two patches. The data from the ozone analyzers, temperature probes, air velocity probe, and vehicle speedometer were collected with a personal computer located on the trunk and discharged on flexible disks. All the results of the test are summarized in Table III below. For each catalyst (CaruliteR &Pd / n / Al2? 3), the results for cold rest, hot rest and road handling were reported. The data was collected in two separate trips to LA in February and March 1995. The first trip was short after only two days, due to the low levels of ozone in the environment. Although a little more - high during the second trip in March, the environmental levels only averaged approximately 40 ppb. The last three days of the test (March 17-20), had the highest ozone levels found. The peak levels were approximately 100 ppb. In general, no tendency was observed in the conversion against ozone concentration. Except for cold resting results, those reported in Table III are averages of at least eleven different operations (the actual scale of the values appears in parentheses). Only the data corresponding to the input ozone concentration, greater than or equal to 30 ppb, were included. The free data were not included since the levels in the environment fell to 20 ppb or less. Only two operations were completed for the tests in cold rest. Cold rest refers to data collected immediately after ignition of the vehicle during rest before the thermostat drives and the pumps heat the coolant fluid to the radiator. In summary, all ozone conversions were very good for both catalysts with the highest levels obtained "during warm rest." This can be attributed to the higher temperatures and lower face velocities associated with rest. gave the lowest conversion due to the lowest ambient temperature of the radiator surface.The driving results were intermediate of the results of hot and cold rest.Although the radiator was heated, the temperature was lower and the face velocity more In general, the measured ozone conversions for CaruliteR were greater than those measured for Pd / Mn / Al2? 3 (for example, 78.1 versus 63.0% while driving). for hot rest and handling operations, the average temperature of the Carulite® catalyst was typically 40 ° F higher than the Pd / Mn / Al203 catalyst while The radiator face velocity was typically 1 mph lower. In summary, the results indicate that ozone can be decomposed at high conversion rates under typical handling conditions.
In general, the results of the motor tests are consistent with the recent activity measured in the laboratory before the installation of the radiator. The ambient temperature (approximately 25 ° C) 20% relative humidity (0.7% absolute water vapor), and an equivalent face velocity of 10 mph, with the laboratory conversions for Pd / Mn / Al 03 and CaruliteR were 55 and 69% respectively. The increase of RH to 70% at room temperature (approximately 25 ° C) (2.3% absolute water vapor), reduced the conversions to 38 and 52% respectively. Since cold-rest (70 ° F) conversions measured at a face velocity of 9 mph were 48 and 67%, respectively, it could appear that the moisture levels encountered during the test were low. The face velocity of the air entering the radiator was low. At an average driving speed of absolutely 20 mph (typical for 'local driving'), the radiator face velocity was only around 13 mph. Even at free speeds in excess of 60 mph, the radiator face velocity was only about 25 mph. The fan significantly affects the control of the air flowing through the radiator. While at rest, the fan typically drives around 8 mph. Example 6 A Pd catalyst was prepared on Carulite® 8 percent by weight, impregnating 100 g of Carulite® powder (ground in a mixer) to the point of incipient humidity with 69.0 g of a solution containing palladium tetraaminacetate (12.6% Pd). The powder was dried overnight at 90 ° C and then calcined at 450 ° C or 550 ° C for 2 hours. Then 92 g of the resulting calcined catalyst was combined with 171 g of deionized water in a ball mill to create a slurry of 35% solids. After grinding for 30 minutes at a particle size of 90% of < 9 μm, 3.1 g of National Starch x4260 acrylic latex binder (50% solids) was added and the resulting mixture was ground for 30 minutes to disperse the binder. Similarly, compositions containing 2, 4 and 6 percent by weight of Pd catalysts on Carulite® were prepared and evaluated. The catalysts were evaluated for the decomposition of ozone at room temperature and at a space velocity of 630,000 / h using ceramic-coated channels by washing 21.09 kg / cm2 (300 cpsi) (cells per square centimeter). The catalyst samples were prepared as indicated above. The results are summarized in Table IV. As can be easily seen, the 4 and 8% Pd / Carulite® catalysts, which were calcined at 450 ° C, gave equivalent initial ozone conversions of 45 minutes (approximately 62 and 60%, respectively). These results are equivalent to those of CaruliteR only under identical test conditions. The catalysts of 2 and 4% of Pd which are calcined at 550 ° C, gave significantly lower conversions after 45 minutes (47%). This was attributed to a loss in the surface area at the highest calcination temperature.
The 6% catalyst was also calcined at 550 ° C, but showed absolutely no activity drop. TABLE IV: OZONE RESULTS (Honeycomb of 21.09 kg / cm2, (300 cpsi), Space Speed 630,000 / h) CATALYZER LOAD CONVERSION (%) CONVERSION (%) (g / inch3) Initial 45 minutes Pd on Carulite 200 4% Pd / Carulite (calcinated 450 ° C) 1.8 64 59 8 % Pd / Carulite (calcined 450 ° C) 2.0 61 60 2% Pd / Carulite (calcined 550 ° C) 2.1 57 48 4% Pd / Carulite (calcined 550 ° C) 1.9 57 46 6% of Pd / Carulite 2.3 59 53 Example 7 A series of tests were conducted to evaluate a variety of catalyst compositions comprising a palladium component for treating air containing 0.25 ppm ozone. The air was at ambient conditions (23 ° C, 0.6% water). The compositions were coated on a ceramic flow of 300 cells per 2.54 cm (cordierite) through the honeycomb at loads of approximately 2 g of wash coating per 16.38 cm3 of substrate. The coated monoliths containing the various supported palladium catalysts, were loaded into a stainless steel pipe with a diameter of (1 inch) 2.54 cm, and the air stream was passed perpendicularly to the open face of the honeycomb at a space velocity of 630,000 / h. The concentration of ozone at the entrance and exit of the catalyst was measured. An alumina support used was gamma alumina SRS-II (purchased from Davison), characterized as described in Example 1 (surface area of approximately 300 m2 / g). A tetraalumine of low surface area characterized by a surface area of 58 m2 / g and an average pore radius of about 80 Angstrom was also used. Alumina E-160 is a gamma alumina characterized by a surface area of approximately 180 m2 / g and an average pore radius of approximately 47 Angstrom. The ceria used had a surface area of approximately 120 m2 / g and an average pore radius of approximately 28 Angstrom. A dealuminated beta zeolite with a silica alumina ratio of approximately 250 to 1 and a surface area of approximately 430 m2 / g was also used. Carbon, a microporous wood carbon, characterized by a surface area of about 850 m / g, was also used as a support. Finally, a titania purchased at Rhone-Poulenc (grade DT51) and characterized by a surface area of approximately 110 m2 / g was used as a support. The results are summarized in Table V which includes the relative weight percentage of various catalyst components, the charge in the honeycomb, the initial conversion of ozone and the conversion after 45 minutes.
TABLE V: OZONE RESULTS - (Honeycomb of 21.09 kg / cm2 (300 cpsi), Space Velocity 630,000 / h, 0.6% of Water, approximately 0.25 ppm of Ozone) CATALYST LOAD CONVERSION (%) CONVERSION (%) (g / inch3) Initial 45 Minutes I.W. 8% Pd / 5% Mn / Al203 1.8 60 55 i.w. 8% Pd / 5% Mn / Superfie Low Area AI2O3. 1.9 64 60 8% of Pd / Low Surface Area AI2O3 1.9 56 44 8% of Pd / E-160 A1203 2.2 61 57 4. 6% of Pd / Ce? 2 1.99 59 58 8% Pd / BETA Zeolite (dazzled) 1.9 38 32 % Pd / C 0.5 63 61 8% Pd / DT-51 Ti02 1.8 39 20 Example 8 The following is a Carulite® preparation that includes vinyl acetate latex binder and was used to coat radiators, which resulted in Excellent adhesion of the catalyst to an aluminum radiator. 1000 g of Carulite® 200, 1500 g of deionized water, and 50 g of acetic acid (5% based on Carulite) were combined in a 2.78 liter (1 gallon) ball mill and ground for 4 hours at a particle size. of 90% of < 7 μm. After draining the resulting sludge from the mill, 104 g (5% solids base) of National Starch Inter-EVA copolymer Dur-O-Set E-646 (48% solids) was added. Although the binder mixture was achieved by rolling the slurry in a mill without a milling medium for several hours. After coating this sludge on a piece of aluminum substrate (eg, radiator), excellent adhesion was obtained (ie, the coating could not be rubbed), after 30 minutes drying at 30 ° C. If desired, higher curing temperatures (up to 150 ° C) can be used.
The conversion of carbon monoxide was tested by coating a variety of platinum compositions supported with titania on ceramic panels, as described in Example 6. The catalyst loads were approximately 2 g / inch3, and the test was conducted using a current having 16 ppm carbon monoxide (35 ° F dew point) and at a space velocity of 215,000 / h. The catalyst compositions were conducted on the panel using a forming gas, having 7% H2 and 93% N2 at 300 ° C for 3 hours. The compositions contained TIO2, included 2 and 3 percent by weight of the platinum component on titania P25; and 2 and 3 percent by weight of the platinum component on the titanium of grade DT52. The DT51 grade titania was purchased at Rhone-Poulenc and had a surface area of approximately 110 m2 / g. The titania of grade DT52 was a tungsten containing titania of Rhone-Poulenc and which had a surface area of approximately 210 m2 / g. Titania grade P25 was grade in Degussa and was characterized as having a particle size of approximately 1 μm and a surface area of approximately 45-50 m2 / g. The results are illustrated in Figure 10. Example 10 Example 10 refers to the evaluation of the CO conversion for compositions containing alumina, ceria and zeolite. The supports were characterized as described in Example 7. The compositions evaluated included 2 percent by weight of platinum on tetraalumina with a low surface area; 2 percent by weight of platinum and ceria; 2 percent by weight of platinum on gamma alumina SRS-II, and 2 percent by weight of platinum on Beta zeolite. The results are illustrated in Figure 11. Example 11 The conversion of CO to temperature was measured for the compositions containing 2 percent by weight of platinum on gamma alumina of SRS-II and on zeolite ZSM-5, which were "placed as a coating on a radiator of an Altima Nissan 1993, as presented in Example 4 and tested using the same procedure to test the CO as used in Example 4. The results are illustrated in Figure 9.
Example 12 0.659 g of a solubilized platinum hydroxide solution with amine having 17.75 percent by weight of platinum (based on platinum metal) was slowly added to 20 g of an aqueous slurry of 11.7 percent by weight of a sol of titania in a glass precipitate and stirred with a magnetic stirrer. A core sample of metal monolith with a diameter of 2.54 cm by 400 cells with a length of 2.54 cm by 6.45 cm2, he immersed himself in the mud. Air was blown on the coated monolith to clean the channels and the monolith was dried for three hours at 110 ° C. At this time, the monolith was again immersed in the mud once more and the steps of blowing into the channels and drying at 110 ° C were repeated. The monolith coated twice was calcined at 300 ° C for two hours. The monolith made of uncoated metal weighing 12.36 g. After the first dive, weighed 14.06 g, after the first drying 12.6 g, after the second dive 14.38 g and after calcination weighed 13.05 g indicating a total weight gain of 0.69 g. The coated monolith had 72 g / ft3 of platinum based on the metal and was designated as 72 Pt / Ti. The catalyst was evaluated in an air stream containing 20 ppm carbon monoxide at a gas flow rate of 36.6 liters per minute. After this initial evaluation, the catalyst core is reduced in a formation gas having 7% hydrogen and 93% nitrogen at 300 ° C for 12 hours and the evaluation was repeated to treat an air stream containing 20 ppm of monoxide of carbon. The reduced coated monolith was designated as 72 Pt / Ti / R. The aforementioned sludge was then evaluated using a core sample of a ceramic monolith having 400 cells per 6.45 cm2, which was pre-coated with 40 g per cubic feet, of a weight ratio of 5: 1 from platinum to rhodium plus 2.0 g per cubic centimeter of ES-160 (alumina) and the core had a monolith of 11 cells per 10 cells for a length of 1.9 cm (0.75 inches) and was designated as 33 Pt / 7Rh / Al, submerged in the mud previously presented, and blew with air to clean the channels. This monolith was dried at 110 ° C for three hours and calcined at 300 ° C for two hours. The catalyst substrate included the first layer of platinum and rhodium weight 2.19 g. After the first immersion, weight 3.40 g and after calcination 2.38 g, showing a total weight gain of 0.19 g, which is equal to 0.90 g per cubic centimeter of the platinum / titania sludge. The submerged ceramic core contained 74 per cubic foot of platinum based on the platinum metal and designated as 74 Pt / Ti / Pt / Rh. The results are illustrated in Figure 12. EXAMPLE 13 A platinum titanium catalyst was described in Example 12 above as an air stream containing 4 ppm of propane and 4 ppm of propylene. In an air stream at a space velocity of 650,000 space velocity per normal hour. The platinum and titanium catalyst had 72 g of platinum per cubic foot of the total catalyst and substrate used. It was evaluated in a ceramic honeycomb as presented in Example 13. The measured results for propylene conversion were 16.7% at 65 ° C; 19% - at 70 ° C; 23.8% at 75 ° C; 28.6% at 80 ° C; 35.7% at 85 ° C; 40.5% at 95 ° C and 47.6% at 105 ° C. Example 14 Example 14 is an illustration of a platinum component on a titania support. This Example illustrates the excellent activity of platinum supported on titania for the oxidation of carbon monoxide and hydrocarbon. The evaluation was performed using a catalyst prepared from the colloidal titania sol to form a composition comprising 5.0 by weight of the platinum component based on the weight of the platinum metal and titania. The platinum was added to titania in the form of a platinum hydrogen solution solubilized with amine. It was added to the colloidal titania mud or to the titania powders to prepare a mud containing platinum and titania. The mud was placed as a coating on a ceramic monolith having 400 cells per 6.45 cm3. The samples had coating amounts, varying from 0.8-1.0 g / 2.54 cm. The coated monoliths were calcined at 300 ° C for 2 hours in the air and then reduced. The reduction was carried out at 300 ° C in a gas containing 7% hydrogen and 93% nitrogen for 12 hours. The colloidal titania sludge contained 10% by weight of titania in an aqueous medium. The titania had a nominal particle size of 2-5 nm. The conversion of carbon monoxide into an air stream containing 20 ppm CO was measured. The flow rate of carbon monoxide in various experiments ranged from speeds of 300,000 VHSV to 650,000 VHSV at an ambient temperature of 110 ° C. The air used was air purified from an air cylinder and where moisture was added to the air that passed through the water bath. When moisture was studied, the relative humidity varied from 0-100% humidity at room temperature (25 ° C). The carbon monoxide containing the air stream was passed through the ceramic monolith coated with the catalyst compositions using a space velocity of 650,000 / h. Figure 13 represents a study using air with 20 ppm CO measuring the conversion of carbon monoxide against temperature, comparing that of platinum supported on titania, which was reduced (Pt / Ti-R) at 300 ° C using a gas of reduction containing 7% hydrogen and 93% nitrogen for 12 hours, as shown above, with a non-reduced platinum supported on the titania catalyst coating (Pt / Ti). Figure 13 illustrates a significant advantage when using a reduced catalyst.
Figure 14 illustrates a comparison of platinum over titania, which was reduced with variable supports including platinum on tin oxide (Pt / Sn), platinum on zinc oxide (Pt / Zn) and platinum on ceria (Pt / Ce) for comparison. All samples were reduced to the conditions indicated above. The flow velocity of carbon monoxide in the air was 650,000 shsv. As can be seen, the reduced platinum on colloidal titania had conversion results significantly higher than that of platinum on the various other support materials. The hydrocarbon oxidation was measured using an air mixture of 6 ppm propylene. The propylene air stream was passed through the catalyst monolith at a space velocity of 300,000 vhsv at a temperature ranging from room temperature to 0 ° C. The concentration of propylene was determined using an ionized detector called before and after the catalyst. The results are summarized in Figure 15. The support used was 5% by weight based on the weight of the platinum metal and lithium oxide? 2 ° 2 • The comparison was between reduced and unreduced catalyst. As shown in Figure 15, the reduction of the catalyst resulted in a significant improvement in propylene conversion. The above-presented platinum supported on a titania catalyst was reduced in a formation gas containing 7% hydrogen and 93% nitrogen at 500 ° C for 1 hour. The conversion of carbon monoxide was evaluated in air with a relative humidity of Opor cent at a flow rate of 500,000 vhsv. The evaluation was conducted to determine if the catalyst reduction was reversible. Initially, the catalyst was evaluated for the ability to convert carbon monoxide to 22 ° C. As shown in Figure 16, the catalyst was initially converted to approximately 53% carbon monoxide and reduced to 30% after about 200 minutes. At 200 minutes, air and carbon monoxide were heated to 50 ° C, and carbon monoxide conversion was increased to 65%. The catalyst was further heated to 100 ° C in the air and carbon monoxide and kept at 100 ° C for one hour, and then cooled with air at room temperature (about 25 ° C). Initially, the conversion fell to approximately 30% in the period of around 225-400 minutes. The evaluation was continued at 100 ° C to 1200 minutes, at which time, the conversion was measured at approximately 40%. A parallel study was conducted at 50 ° C. At approximately 225 minutes, the conversion was around 65%. After 1200 minutes, the conversion actually increased to approximately 75%. This example shows that the reduction of the catalyst permanently improves the activity of the catalysis. Example 15 Example 15 was used to illustrate the conversion of ozone to room temperature for platinum and / or palladium components supported on co-precipitated manganese oxide / zirconia. This example also shows a platinum catalyst, which catalyzes the conversion of ozone to oxygen, and at the same time, oxidizes carbon monoxide and hydrocarbons. Manganese oxide / zirconia oxide powders were made, having 1: 1 and 1: 4 based on weight of metals Mn and Zr. The co-precipitate was made according to the procedure described in the aforementioned U.S. Patent No. 5,283,041. 3% and 6% Pt were prepared on manganese / zirconia catalysts (1: 4 basis weight of Mn to Zr), as described in Example 4. Gamma alumina SBA-150 (10% based on weight) was added. of the compound oxide powder), as a binder in the form of a 40% water sludge containing acetic acid (5% by weight alumina powder) and ground to a particle size of 90% by <; 10 μm. The 6 wt% Pd catalyst was prepared by impregnating manganese / zirconia frit (1: 1 basis weight from Mn to Zr) to the point of incipient humidity, with a water solution containing palladium tetraaminacetate. After drying and after calcining the powder for two hours at 450 ° C, the catalyst was mixed in a ball mill with silica sol Nalco # 1056 (10% by weight of the catalyst powder) and sufficient water to create a sludge approximately 35% solids. The mixture was then milled until the particle size was 90% < 10 μm. Several samples were reduced using a formation gas, having 7% H2 and 93% N2 at 300 ° C for 3 hours. The evaluations were conducted to determine the conversion of ozone onto radiator mininuclei coated with an Altima radiator from 1993, which have a depth of approximately 1.27 cm x 3.4 cm by 2.54 cm (1/2 inch by 7 / 8__ inch by 1 inch) . The evaluation was conducted at room temperature using a stainless steel pipe with a diameter of 2.54 cm (one inch) as described in Example 7 with domestic air (air supplied in laboratory) at a space velocity of 630,000 / h at a speed of space of 630,000 / h with an input ozone concentration of 0.25 ppm. The results are given in Table VI.
As can be seen from Table VI, Nuclei 1 and 2 have only 3% platinum resulted in an excellent conversion of ozone, initially and after 45 minutes both for a reduced and not reduced catalyst. The Cores 3 and 4 have a concentration of 6% platinum, they also had excellent results, but not as good as 3% platinum results. Cores 5-7 illustrate a variety of other support materials used, which resulted in the conversion of ozone. Nucleus 5 had a palladium on a co-precipitate of manganese oxide / zirconia and resulted in a conversion of ozone lower than that expected, but still significant. The Nuclei 6 and 7 in the evaluations used the co-precipitate without the precious metal and also resulted in significant ozone conversions, but in the present not as good as when platinum was used as a catalyst. Core 8 was made of platinum on a zirconia support / core, which was calcined but not reduced, and Core 9 was platinum on a zirconia support / core, which was reduced. Both Nuclei 8 and 9 gave some conversion, but not as good as the conversion obtained with platinum on the co-precipitate. In addition, the conversion of carbon monoxide evaluated in mininuclei of radiator of 39 cpsi, as explained for 3% and 6% of platinum on manganese / zirconia supports. Reduced and non-reduced samples were evaluated. For illustrative purposes, platinum is also presented on zirconia / silica and platinum supports on reduced and unreduced Carulite®. As can be seen from Figure 17, the results of 3% reduced platinum on a manganese / zirconia support were higher when compared to other modalities. Example 16 (Comparative) Ozone conversion was measured in a radiator of a Ford Contour 1995 car at room temperature and 80 ° C by blowing a stream of air containing ozone (0.25 ppm) through the radiator channels at a linear velocity of 10 mph (speed of ^ space of 630,000 / h) and then the concentration of ozone leaving the rear face of the radiator was measured. The air stream had a dew point of approximately 35 ° F. The hot cooler was not circulated through the radiator, but the air stream was heated as necessary with a heating tape to obtain the desired radiator temperature. An additional test was completed with a "mini-core" Ford Taurus radiator with a length of 1.905 cm (L) xl.27 cm (W) x 2.54 cm (D) (0.75 inch 1L) X0.5 inches (W) x 1.0 inch (D) uncoated diameter (1 inch) in a stainless steel pipe with a diameter of 2.54 cm (1 inch) as described in Example 7. The air stream was heated with a heating tape to obtain the desired temperature of the radiator. For both tests, no decomposition of ozone up to 120 ° C was observed. Example 17 The conversion of ozone at various temperatures to a 3% Pt / Ti? 2 catalyst reduced in the absence and in the presence of 15 ppm CO was measured. Titania Degussa of grade P25 was used as the support and was characterized as having a particle size of approximately 1 μm and a surface area of approximately 45-50 m2 / g. The catalyst was coated on a 300 cpsi ceramic honeycomb (cordierite) and reduced on the honeycomb using a forming gas having 7% H2 and 93% N2 at 300 ° C for 3 hours. The test was accomplished as previously described in Example 7. The air stream (35 ° F dew) was heated with heating tape to obtain the desired temperature. As can be seen in Fig. 18, an approximate increase of 5% in the absolute conversion of ozone from 25 to 80 ° C was observed. The presence of CO improves the conversion of ozone. Example 18 100 g of Versal GL alumina obtained from LaRoche Industries Inc. was impregnated with approximately 28 g of Pt amine hydroxide (Pt (A) salt) diluted in water to approximately 80 g of the solution. 5 g of acetic acid were added to fix the Pt on the surface of alumina. After mixing for half an hour, the catalyst impregnated with Pt was made as mud by adding water to be approximately 40% solids. The sludge was milled in a ball mill for 2 hours. The particle size was measured and was 90% less than 10 microns. The catalyst was coated on a ceramic substrate of 400 cpsi with a diameter of 3.81 cm (1.5 inches) with a length of 2.54 cm (1 inch) to give a load of wash coating after drying at approximately 0.65 g / inch3. The catalyst was then dried at 100 ° C and calcined at 550 ° C for 2 hours. This catalyst was treated for the oxidation of C3Hg at temperatures between 60 and 100 ° C in dry air as described in Example 21. Some of the calcined Pt / Al2? 3 sample, described above, was reduced by 7% H2 / N2 at 400 ° C for 1 hour. The reduction step was performed by ramping the catalyst temperature from 25 to 400 ° C at a gas flow rate of H2 / N2 of 500 cc / minute. The ramp temperature was about 5 ° C / min. The catalyst was cooled to room temperature and the catalyst was tested for the oxidation of 3H6 as described in Example 21. Example 19 6.8 g of ammonium tungstate were dissolved in 30 cc of water and the pH was adjusted to 10 and the The solution was placed in the form of impregnation on 50 g of alumina from Versal GL (LaRoche Industries Inc.). The material was dried at 100 ° C and calcined for 2 hours at 550 ° C. At about 10% by weight of the metal of about AI2O3 it was cooled to room temperature and impregnated with 13.7 g of the Pt-amine hydroxide (18.3% Pt): 2.5 g of acetic acid was added and mixed well. The catalyst was then made in a slurry containing 35% solid by adding water. The sludge was then placed as a coating on a ceramic substrate with a diameter of 3.81 cm x 2.54 cm (1.5 inches x 1 inch) 400 cpsi, resulting after drying, a catalyst wash coating with a load 5 of 0.79 g / inch3. The coated catalyst was then dried and calcined at 550 ° C for 2 hours. The catalyst was tested calcined in C3H5 and dry air in the temperature range of 60 to 100 ° C. Example 20 10 6.8 g of perrhenic acid were further diluted (36% of Re in solution) to make 10 g of a perrhenic acid solution. The solution was impregnated on 25 g of Versal GL alumina. The impregnated alumina was dried and the powder was calcined to 550 ° C for 2 hours. The 10 percent by weight base metal impregnated with Re on AI2O3 powder was further impregnated with 6.85 g of a Pt-amine hydroxide solution (Pt metal in solution which was 18.3%). 5 g of 0 acetic acid were added and mixed for half an hour. A mud was made by adding water to make 28% solid. The slurry was milled in a ball mill for 2 hours and placed as a coating on a ceramic substrate of 400 cpsi with a diameter of 3.81 cm x a length of 2.54 cm to give a back-loading of the catalyst wash. 0.51 g / inch3 after drying. The substrate coated with the catalyst was dried at 100 ° C and calcined at 550 ° C for 2 hours. The catalyst was tested in the calcined form using 60 ppm of C3Hg and dried with air at a temperature range of 60 to 100 ° C. Example 21 The catalyst of Examples 18, 19 and 20 was tested in a micro-reactor. The size of the catalyst samples was of a diameter of 1.27 cm (0.5 inch) and a length of 1.016 cm (0.4 inch). The feed was composed of 60 ppm of C3Hg in dry air at a temperature range of 25 to 100 ° C. The C3Hg was measured at 60, 70, 80, 90 and 100 ° C at a steady state condition. The results are summarized in Table VII. TABLE VII - SUMMARY OF THE RESULTS OF THE CONVERSION OF C3H6 Name of Pt / Al 03 Pt / Al203 Pt / 10% W / A1203 Pt / 10% Re / Al2O3 calcined calcinated calcined calcined catalyst (Ex. 18) and reductive (Ex. 19) (Ex 20) do (Ex 18)% C3H6 Conversion @ 60 ° C 0 10 9 11 70 ° C 7 22 17 27 80 ° C 20 50 39 45 90 ° C 38 70 65 64 100 ° C 60 83 82 83 It is evident from the Table that the addition of W or Re oxide has increased the capacity of Pt / Al2? 3 in the calcined form. The conversion of C3Hg from the calcined Pt / Al2? 3 was significantly improved when the catalyst was reduced to 400 ° C for 1 hour. Improved activity was also observed for the calcined catalyst through the incorporation of Re or o-oxides. Example 22 This is an example for preparing high surface area cryptomelane using MnS04. Molar ratios: KMn? 4: MnSÜ4: acetic acid were 1: 1.43: 5.72 Molarities of Mn in solutions before mixing were: 0.44 M of Kmn? 4 0.50 M of MnS04 FW KMn04 = 158.04 g / mol FW MnS0 .H20 = 169.01 g / mol FW C2H402 = 60.0 g / mol The following steps were carried out: 1. Make a solution of 3.50 mol (553 grams) of K n? 4 in 8.05 L of deionized water and heat to 68 ° C. 2. Make 10.5 L of 2N acetic acid using 1260 grams of glacial acetic acid and diluting to 10.5 L with deionized water. The density of this solution is 1.01 g / ml. 3. Weigh 5.00 moles (846 grams) of manganous sulfate hydrate (nS? 4-H2?) And dissolved in ,115 g of the above 2N acetic acid solution and heated to 40 ° C. 4. Add the solution of 3. to the solution of 1. for 15 mis, while stirring is continued. After completing the addition, start heating the sludge according to the following heating rate: 1:06 pm 69.4 ° C 1:07 pm 71.2 ° C 1: 11 pm 74.5 ° C 1:15 pm 77.3 ° C 1: 18 pm 80.2 ° C 1:23 pm 83.9 ° C 1: 25 p.m. 86.7 ° C 1:28 p.m. 88.9 ° C 5. At 1:28 p.m. of about 100 ml of mud were removed from the container and quickly filtered over a funnel from Büchner, was washed with 2 liters of deionized water and then dried in an oven at 100 ° C. The sample was determined to have a BET multiple point surface area of 259 m2 / g. Example 23 This is an example for preparing high surface area crypomelano using Mn (CH3COO) 2 • Molar ratios: KMn04: n (CH3C02) 2: acetic acid where: 1: 1.43: 5.72 FW KMn0 = 158.04 g / moles Lot Aldrich # 8824MG FW Mn (CH3C02) 2 -H2 ° = 245.09 g / moles Lot Aldrich # 08722HG FW C H40 = 60.0 g / moles l. Make a solution of 2.0 moles (316 grams) of KMn? 4 in 4.6 L of deionized water and heat to 60 ° C by heating on hot plates. 2. Make 6.0 g of 2N acetic acid using 720 grams of glacial acetic acid and diluting to 6.0 L with deionized water. The density of this solution is 1.01 g / ml. 3. 2.86 moles (700 grams) of manganese acetate ahydrate (II) were weighed [Mn (CH3CO2) 2 • 4H2 ° J and were dissolved in 5780 g of the above 2N acetic acid solution (in the above vessel). It was heated to 60 ° C in the reactor vessel. 4. Add the solution of 1. to the solution of 3. while maintaining the mud at 62-63 ° C. After finishing the addition, the mud was heated moderately according to the following: 82.0 ° C to 3: 58 p.m. 86.5 ° C to 4:02 p.m. 87.0 ° C to 4:06 p.m. 87.1 ° C to 4:08 p.m. the heat after extinguishing the mud by pumping 10 L of deionized water into the container. This cooled the mud to 58 ° C at 4:13 pm. The mud was filtered over Büchner's funnel. The resulting filter cakes were again made in mud in 12 L of deionized water, and then stirred overnight in a 18.9 liter (5 gallon) bucket using a mechanical stirrer. The washed product was refiltered in the morning and dried in an oven at 100 ° C. The sample was determined to have a BET multiple point surface area of 296 m2 / g. The resulting cryptomelane was characterized by the XRD pattern of Figure 20. It was expected to have an IR spectrum similar to that shown in Figure 19. Example 24 The following is a description of the ozone test method to determine the percentage of decomposition of ozone used in this Example. A test apparatus comprised of an ozone generator, gas flow control equipment, a water bubbler, a frozen mirror dew point hygrometer, and an ozone detector was used to measure the percentage destroyed by the samples of catalyst. The ozone was generated in situ using the ozone generator in a stream of flowing gas composed of water vapor air. The ozone concentration was measured using the ozone detector and the water content was determined using a dew point hygrometer. Samples were tested at 25 ° C using inlet ozone concentrations of 4.5 to 7 parts per thousand-l (ppm) in a gas stream, flowing at approximately 1.5 L / minute with a dew point of between 15 ° C and 17 ° C. The samples were tested as particles sized at 25 / + 45 maintained between glass wool shutters in a PyrexR glass tube with an internal diameter of 0.635 cm (1/4 inch). The tested samples were filled to a 1 cm portion of the glass tube. The sample test generally required between 2 to 16 hours to achieve a stable state of conversion. Samples typically came very close to a 100% conversion, when the test started and were slowly reduced to an "out of level" conversion that remained fixed for extended periods (48 hours). After obtaining a stable state, conversions of the equation were calculated:% conversion of ozone = [(concentration of ozone after passing over the catalyst) / (concentration of ozone before passing over the catalyst)] * 100. The test of ozone destruction in the sample of Example 22 showed a conversion of 58%.
The ozone destruction test in the sample of Example 23 showed a conversion of 85%. EXAMPLE 25 This example is intended to illustrate that the method of Example 23 generated "clean" high surface area cryptomelane for which the ozone destruction performance was not further improved through calcination and washing. A 20 gram portion of the sample represented by Example 23 was calcined in air at 200 ° C for 1 hour, cooled to room temperature, then washed at 100 ° C in 200 ml of deionized water, stirring the slurry for 30 minutes. The resulting product was filtered and dried at 100 ° C in an oven. The sample was determined to have a BET multiple point surface area of 265 m2 / g.
The ozone destruction test over & the sample showed a conversion of 85%. A comparison of the test sample of Example 23 showed that there was no benefit in the conversion of ozone from the washing and the calcination of the sample of Example 23. Example 26 High surface area cryptomelane samples were obtained of commercial suppliers and were modified through calcination and / or washing. As established, powders modified for ozone decomposition performance were tested according to the method of Example 24 and characterized by powder X-ray diffraction, infrared spectroscopy, and BET surface area measurements through absorption. of nitrogen. Example 26a A commercially available sample of cryptomelane with a high surface area (Chemetals, Inc., Baltimore, MD) was washed for 30 minutes in deionized water at 60 ° C, filtered, rinsed and dried in a oven to 100 ° C. The ozone conversion of the received sample was 64% compared to 79% for the washed material. The wash did not change the glass structure surface area of this material (223 m2 / g crypomelano) as determined by the 0 nitrogen adsorption and powder X-ray diffraction measurements, respectively. However, infrared spectroscopy showed the disappearance of the peaks at 1220 and 1320 wave numbers in the spectrum of the washed sample indicating the removal of the anions from the sulfate group.
Example 26fc > Commercially-supplied samples of cryptomelane with a high surface area (Chemetals, Inc., Baltimore, MD) were calcined at 300 ° C for 4 hours and 400 ° C for 8 hours. The ozone conversion of the material received was 44% compared to 71% for the sample calcined at 300 ° C, and 75% for the sample calcined at 400 ° C. The calcination did not significantly change the surface area or the crystal structure of the samples at 300 ° C or 400 ° C (334 m2 / g of cryptomelane). A trace of Mn2? 3 was detected in the sample at 400 ° C. The calcination caused the dehydroxylation of these samples. Infrared spectroscopy showed a reduction in the intensity of the band between wave numbers 2700 and 3700 assigned to the hydroxyl groups on the surface. Example 27 It was found that the addition of Pd black (containing Pd metal and oxide) to high surface area cryptomelane significantly improves the ozone decomposition performance. Samples were prepared comprising black powder of Pd physically mixed with powders of (1) a commercially obtained cryptomelane (the sample calcined at 300 ° C described in Example 26b) and (2) the high surface area cryptomelane synthesized in Example 23 calcined at 200 ° C for 1 hour. The samples were prepared by mixing in a dry state, Pd black powder and cryptomelane in a ratio of 1: 4 by weight. The dried mixture was stirred until homogeneous in color. An amount of deionized water was added to the mixture in a stirrer to produce 20-30% solids content, thus forming a suspension, the aggregates in the suspension were mechanically broken with a stir bar. The sound was applied to the suspension in a BransonicR ultrasound cleaner, model 5210 for 10 minutes and then dried in an oven at 120-140 ° C for approximately 8 hours. The ozone conversion for the commercially obtained cryptomelane calcined at 300 ° C was 71% as measured in the powder reactor (Example 26b). A sample of this product was mixed with 20% Pd black and produced an 88% conversion. The cryptomelane sample prepared in Example 23 was calcined at 200 ° C and had a conversion of 85%. The yield was improved to 97% with 20 percent by weight of Pd black added.
Example 28 - 1500 g of manganese dioxide of high surface area (criptomelane purchased from Chemetals) and 2250 g of deionized water were combined in a 3.78 liter ball mill and ground for 1.5 hours at a particle size of 90% of <7 μm. After draining the resulting sludge from the mill to a separate container of 3.78 liters (1 gallon), sufficient KOH (20% deionized water solution) was added to increase the pH to about 9.5. Additional KOH was added during the following days to maintain the pH of 9.5. Subsequently, 294 g (10% solid bases) of the National Starch acrylic latex polymer x-4280 (51% solids) were added. Consistent mixing of the binder was achieved, by winding the container containing the sludge over a two-roll mill. The container did not contain any grinding media such as ceramic grinding balls. The sludge made in accordance with this procedure was coated on a variety of sulfates and exhibited excellent adhesion. Such substrates included a porous monolithic support (e.g., ceramic panels) on which the coating was applied by immersing the honeycomb in the mud. The mud was also coated as a spray on an aluminum radiator. It was also dipped coated on the small radiator mininuclei of the type previously presented. In addition, polyfiber filter media of the type used to filter the air was coated by dipping or spraying. Typically, the mixtures were coated with fillers that could vary from 0.15 to 1.5 grams per cubic centimeter. The samples were dried with air at 30 ° C until dried, typically at least two hours. Excellent adhesion of the catalyst was obtained in each case (ie, the coating could not be washed). Higher drying temperatures (up to 150 ° C) can be used if desired. The latex is cured during drying. Example 29 To 96.56 g of the ground catalyst sludge in a ball mill obtained in Example 1 (before addition of KOH) was added 3.20 g (3% of base in solid) of the polymer dispersant of Rhone-Poulenc Colloid 226 After rolling the mixture in a roller mill for several hours, 7.31 g (10% solids bases) of the National Starch acrylic latex polymer x-4280 (51% solids) were added. As in Example 28, thorough mixing of the binder was achieved by winding the container containing the sludge over a two-roll mill. The container did not contain any grinding media such as ceramic grinding balls. The mud made in accordance with this procedure was coated on a variety of substrates and exhibited excellent adhesion. Such substrates included a porous monolithic support (e.g., ceramic honeycomb) on which the coating was applied by immersing the honeycomb in the mud. The mud was also placed as a coating in immersion on the small mininuclei of the radiator of the type cited above. Typically, the mixtures were coated with charges that could vary from 0.15 to 1.5 grams per cubic centimeter. The samples were air dried at 30 ° C until dried, typically, for two hours. The excellent adhesion of the catalyst was obtained in each case (ie, the coating could not be cleaned). Higher drying temperatures can be used (up to 150 ° C) if desired. The latex is cured during drying.
EXAMPLE 30 8.9 grams of deionized water was added to 1.1 grams of nano Ti02 powder in a beaker. An ammonia / water concentrate was added to adjust the pH to 9.5. A solution of platinum hydroxide solubilized with amine having 17.75 percent by weight of platinum (based on that of platinum metal) was added slowly, with mixing, to obtain 5% by weight of platinum on titania. Then, a palladium nitrate solution containing 20% by weight based on the palladium metal was added, with mixing to obtain 14.3% palladium on titania. A sample of a metal monolith core with a diameter of 2.54 cm (one inch) for a length of 2.54 cm (one inch) of 400 cells per square centimeter (cm2) was immersed in the mud. The air was blown on the coated monolith to clean the channels and the monolith was dried for 3 hours at 110 ° C. At this time, the monolith was submerged again in the mud once and the air blowing passages of the channels were repeated and the drying at 110 ° C. The twice coated monolith was calcined at 300 ° C for two hours. After this initial evaluation, the catalyst core was reduced in a formation gas having 7% hydrogen and 93% nitrogen at 300 ° C for 12 hours. The catalyst is evaluated in an air stream containing 20 ppm of carbon monoxide and 20 ppm of hydrocarbons with Ci base. The hydrocarbons were evaluated in the presence of 20 ppm of CO. The hydrocarbons evaluated were ethylene C2 =; propylene C3 =; and pentene C? = at a gas flow rate of 36.6 liters per minute, which corresponds to 300,000 speed per hour of normal space (SHSV). The air stream was at a relative humidity of 30% (RH). The results are illustrated in Figure 21.

Claims (47)

  1. REJVINPTC? CTO ES 1. A method for treating the atmosphere, characterized in that it comprises moving a vehicle through the atmosphere, the vehicle has at least one contact surface to an atmosphere and a pollutant treatment composition, comprising a material active selected from the group consisting of a catalyst composition and an adsorption composition, located on the surface, a polymeric binder and a dispersant.
  2. 2. The method for treating the atmosphere, characterized in that it comprises moving a vehicle through the atmosphere, the vehicle has at least one contact surface with the atmosphere and a pollutant treatment composition, comprising an active material selected from the group that it consists of a catalyst composition and an adsorption composition, the contaminant treatment composition located on the surface, and wherein the catalyst composition comprises a catalytically active material selected from the platinum component and a palladium component.
  3. 3. The confounding method with claim 2, characterized in that the contaminant treatment composition is at least one composition selected from the group consisting of a catalyst composition and an adsorption composition.
  4. 4. The method according to claim 3, characterized in that it further comprises the step of adding a polymeric binder to the contaminant treatment composition.
  5. The method according to claim 1 or 4, characterized in that it further comprises the step of adding a polymeric latex binder to the contaminant treatment composition.
  6. 6. The method according to claim 5, characterized in that the polymeric binder comprises a polymer composition, which comprises a polymer selected from the group consisting of thermoplastic polymer and thermofixation.
  7. The method according to claim 5, characterized in that the polymeric binder comprises a polymer composition comprising a polymer selected from the group consisting of polyethylene, polypropylene, polyolefin copolymers, polyisoprene, polybutadiene, polybutadiene copolymers, chlorinated rubber, nitrile rubber, polychloroprene, ethylene-propylene-diene elastomers, polystyrene, polyacrylate, polymethacrylate, polyacrylonitrile, polyvinyl esters, polyvinyl halides, polyamides, cellulosic polymers, thermoplastic polyesters, thermosetting polyesters, polyphenylene oxide, poly sulfide (phenylene), fluorinated polymers, polyamide, phenolic resins and epoxy resins, polyurethane, silicone polymers, polyimides, acrylic acrylics of styrene, poly (vinyl alcohol), and ethylene-vinyl acetate copolymers.
  8. The method according to claim 1 or 3, characterized in that the catalyst composition comprises a support material selected from the group consisting of a refractory oxide support, a manganese component, carbon and co-precipitated from a manganese oxide. and zirconia.
  9. The method according to claim 8, characterized in that the catalytically active material is selected from at least one metal component of the platinum group, gold component, silver component, and the method further comprises the step of reducing the catalyst composition.
  10. The method according to claim 9, characterized in that the catalytically active material is selected from palladium and platinum components and mixtures thereof.
  11. The method according to claim 8, characterized in that the refractory oxide is selected from the group consisting of alumina, silica, titania, ceria, zirconia, chromia and mixtures thereof.
  12. 12. The method according to claim 11, characterized in that the refractory oxide is a titania sol.
  13. 13. The method according to claim 1 or 3, characterized in that in addition the step of calcining the catalyst composition.
  14. The method according to claim 1, characterized in that the catalyst composition comprises a manganese component.
  15. 15. The method according to claim 1 or 3, characterized in that it comprises the step of catalytically reacting at least one pollutant in the atmosphere, selected from the group consisting of ozone, carbon monoxide and hydrocarbons.
  16. The method according to claim 1 or 3, characterized in that the step of maintaining the surface at a temperature of about 20 to about 105 ° C.
  17. 17. The method according to claim 1 or 3, characterized in that the contact surface with the atmosphere is directly in contact with the atmosphere as the vehicle moves through the atmosphere.
  18. 18. The method according to claim 1 or 3, characterized in that the relative velocity of the contact surface with the atmosphere and the atmosphere as the vehicle moves through the atmosphere is up to 100 miles per hour.
  19. The method according to claim 1 or 3, characterized in that the steps of heating the contact surface with the atmosphere, and catalytically reacting the carbon monoxide and / or hydrocarbons in the atmosphere.
  20. 20. The method according to claims 1 6 3, characterized in that the contact surface with the atmosphere is selected from the group consisting of the external surface of an air conditioning condenser, a radiator, a radiator fan, a charge cooler of air, a wind deflector, a motor oil cooler, a transmission oil cooler and a power steering fluid cooler.
  21. 21. The method according to claim 1, characterized in that the dispersion is a polymeric acid or a derivative thereof.
  22. 22. An apparatus for treating the atmosphere, comprising: a vehicle, the vehicle is characterized in that it comprises means of movement, at least one vehicle surface contacting the atmosphere, and a composition for treating pollutants located on said surface , the contaminant treatment composition comprises an active material selected from the group consisting of a catalyst composition and an adsorption composition located on said surface, a polymeric binder and a dispersant.
  23. 23. An apparatus for the treatment of the atmosphere which is characterized in that it comprises: a vehicle, the vehicle comprises, means of translation, at least one surface of vehicle in contact with the atmosphere, and a composition for the treatment of pollutants comprising a material active selected from the group consisting of a catalyst composition and an adsorption composition, the contaminant treatment composition is located on the surface, wherein the catalyst composition comprises a catalytically active material comprising a platinum component and a component of palladium.
  24. 24. The apparatus according to claim 22 or 23, wherein the catalyst composition comprises a support material selected from the group consisting of a refractory oxide support, a manganese component, carbon and an oxide co-precipitate. manganese and zirconia.
  25. 25. The apparatus according to claim 24, characterized in that the refractory oxide support is titania.
  26. 26. A method is characterized in that it comprises the steps of: forming a mixture comprising a platinum component and a palladium component supported on a catalyst support, the mixture is sufficiently dried to absorb essentially all the solution, dry the mixture, calcined the composition, forming a sludge comprising the mixture and a liquid, and coating a contact surface with the atmosphere of the motor vehicle with the sludge.
  27. 27. The method according to claim 26, characterized in that it also comprises the step of reducing the composition.
  28. 28. A composition which is characterized in that it comprises a catalytic material selected from the group consisting of a manganese oxide and a precious metal component, a support selected from the group consisting of a refractory oxide support and a co-precipitate of a manganese oxide and zirconia; a binder; and a dispersant.
  29. 29. The composition according to claim 28, characterized in that it also comprises a water-resistant additive, selected from the group consisting of waxes and luorocarbons.
  30. The composition according to claim 28, characterized in that at least one catalytic material is selected from the group consisting of manganese oxide, a platinum component, and palladium components and mixtures thereof.
  31. 31. The composition according to claim 28, characterized in that the dispersant is a polymeric acid derived therefrom.
  32. 32. The composition according to claim 28, characterized in that the binder is a polymeric binder selected from the group consisting of acrylic polymers and vinyl acetate and copolymers.
  33. 33. The composition according to claim 28, wherein the binder is characterized in that it comprises a polymer composition comprising a polymer selected from the group consisting of polyethylene, polypropylene, polyolefin copolymers, polyisoprene, polybutadiene, polybutadiene copolymers, chlorinated rubber, nitrile rubber, polychloroprene, ethylene elastomers. -propylene-diene, polyacrylate, polymethacrylate, polyacrylonitrile, poly (vinyl) esters, poly (vinyl) halides, polyamides, cellulose polymers, thermoplastic polyethers, heat-setting polyesters, poly (phenylene) oxide, poly (phenylene) sulfide , fluorinated polymers, polyamide, phenolic resins and epoxy resins, polyurethane, silicone polymers, polyamides, acrylics, styrene acrylics, poly (vinyl alcohol), and ethylene-vinyl acetate copolymers.
  34. 34. An apparatus for treating the atmosphere characterized in that it comprises: a vehicle, the vehicle comprises, translating means, at least one contact vehicle surface of the atmosphere, and a composition for the treatment of pollutants located on that surface, the composition of, treatment of contaminants comprises Mn? 2, a polymeric binder and a dispersant.
  35. 35. The apparatus according to claim 34, characterized in that the contamination treatment composition further comprises a component of the platinum group.
  36. 36. The apparatus according to claim 35, characterized in that the platinum group component is reduced.
  37. 37. The apparatus according to claim 35, characterized in that the contaminant treatment composition further comprises a refractory support.
  38. 38. The apparatus according to claim 34, characterized in that the n? 2 is a-Mn? 2 •
  39. 39. The apparatus according to claim 38, characterized in that the a-Mn? 2 comprises 2% by weight of silica .
  40. 40. The apparatus according to claim 38, characterized in that the a-Mn? 2 is selected from the group consisting of dutchite, cryptomelane, manjiroite and coronadite.
  41. 41. The apparatus according to claim 40, characterized in that the a-Mn? 2 is crypomelano having a surface area of about 200 to 350 m2 / g.
  42. 42. A method is characterized in that it comprises the steps of: forming a mixture comprising: a catalytically active material selected from at least one component of the platinum group metal, a gold component, a silver component and a manganese component; and water; grind the mixture, - adjust the pH of the composition to at least 8.5; and adding the polymeric binder to the mixture.
  43. 43. A method is characterized in that it comprises the steps of: forming a mixture comprising, a catalytically active material selected from at least one metal component of the platinum group, a gold component, a silver component and a manganese component , - and water, - add a dispersant; grind the mixture, - and add the polymeric binder to the mixture.
  44. 44. The method according to claim 42 or 43 is characterized in that it further comprises the steps of: forming a sludge comprising the mixture and a liquid; and coating an atmosphere contact surface of the motor vehicle with the sludge. ~
  45. 45. The method according to claim 44, characterized in that the catalytically active material also comprises a support.
  46. 46. The method according to claim 45, characterized in that it further comprises the step of calcining the catalytically active material before adding the polymeric binder.
  47. 47. The method according to claim 46, characterized in that it further comprises the step of reducing the catalytically active material.
MXPA/A/1998/002442A 1995-09-29 1998-03-27 Cleaning of environmental air through the movement of a vehicle that has a surface of treatment of contaminants MXPA98002442A (en)

Applications Claiming Priority (8)

Application Number Priority Date Filing Date Title
US537208 1995-09-29
US537206 1995-09-29
US549996 1995-10-27
US589182 1996-01-19
US08588972 1996-01-19
US08589030 1996-01-19
US08589032 1996-01-19
US08682174 1996-07-16

Publications (1)

Publication Number Publication Date
MXPA98002442A true MXPA98002442A (en) 1998-11-12

Family

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