RU2018139516A - Способ покрытия подложки стабилизированной частицами пеной - Google Patents

Способ покрытия подложки стабилизированной частицами пеной Download PDF

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RU2018139516A
RU2018139516A RU2018139516A RU2018139516A RU2018139516A RU 2018139516 A RU2018139516 A RU 2018139516A RU 2018139516 A RU2018139516 A RU 2018139516A RU 2018139516 A RU2018139516 A RU 2018139516A RU 2018139516 A RU2018139516 A RU 2018139516A
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foam
substrate
layer
paragraphs
oxide
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RU2018139516A
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RU2746160C2 (ru
RU2018139516A3 (ru
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Сесилия БЕРНАРДИНИ
Томас КЭМПБЕЛЛ
Гай Ричард ЧЭНДЛЕР
Кристофер ДЭЛИ
Катарин ХАРДСТОУН
Томас ХОТЧКИСС
Дэвид ТОМПСЕТТ
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Джонсон Мэтти Паблик Лимитед Компани
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2825—Ceramics
    • F01N3/2828—Ceramic multi-channel monoliths, e.g. honeycombs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/207—Transition metals
    • B01D2255/20761—Copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/209—Other metals
    • B01D2255/2092—Aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/50—Zeolites
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2250/00—Combinations of different methods of purification
    • F01N2250/02—Combinations of different methods of purification filtering and catalytic conversion
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00—Structure of catalyst support or particle filter
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/06—Ceramic, e.g. monoliths
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/22—Metal foam
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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Claims (38)

1. Способ нанесения на подложку покрытия из пены, причем способ включает:
(а) введение пены в подложку, включающую множество каналов, через открытые концы каналов на первом конце подложки; и
(b) необязательно, создание (i) вакуума у открытых концов каналов на втором конце подложки, и/или (ii) давления у открытых концов каналов на первом конце подложки;
причем пена включает дисперсный материал, и причем пена стабилизирована частицами.
2. Способ по п.1, в котором стадия (а) включает стадии (i) удерживания подложки по существу вертикально, и (ii) вдавливания или нагнетания пены в подложку через открытые концы каналов на первом конце.
3. Способ по п.2, в котором стадия (ii) вдавливания или нагнетания пены в подложку тогда может представлять собой (ii) вдавливание или нагнетание пены с использованием поршня.
4. Способ по п.1, в котором стадия (а) включает стадии: (i) размещения вмещающего средства поверх первого конца подложки, (ii) дозирования пены во вмещающее средство, и (iii) создания [1] вакуума у открытых концов каналов на втором конце подложки и/или [2] давления у открытых концов каналов на первом конце подложки.
5. Способ по любому из предшествующих пунктов, в котором стадия (а) дополнительно включает введение пены в предварительно заданном количестве.
6. Способ по любому из предшествующих пунктов, дополнительно включающий стадию (с) высушивания и/или кальцинирования подложки, содержащей стабилизированную частицами пену, для получения слоя твердой пены, размещенного на подложке или нанесенного на нее как на носитель.
7. Способ по п.6, в котором слой твердой пены включает открытоячеистую структуру.
8. Способ по п.6 или 7, в котором слой твердой пены имеет объем ячеек, причем более 20% объема ячеек являются взаимосвязанными.
9. Способ по любому из предшествующих пунктов, в котором пену получают или пена является получаемой способом, включающим стадии: (i) приготовления суспензии дисперсного материала в водной среде; и (ii) вспенивания суспензии введением газа в суспензию для генерирования стабилизированной частицами пены.
10. Способ по п.9, в котором стадия (i) представляет собой стадию получения суспензии дисперсного материала в водной среде, содержащей амфифильное вещество.
11. Способ по любому из предшествующих пунктов, в котором дисперсный материал имеет медианный размер частиц от 1 нм до 50 мкм.
12. Способ по любому из предшествующих пунктов, в котором пена содержит пузырьки, имеющие диаметр от 1 мкм до 1 мм.
13. Устройство для регулирования выбросов для обработки или удаления загрязнителей из выхлопного газа, образованного двигателем внутреннего сгорания, причем устройство для регулирования выбросов включает слой твердой пены, размещенный на подложке, и причем слой твердой пены, размещенный на подложке:
получен или является получаемым способом по любому из пп. 6-12; и/или
имеет открытоячеистую структуру.
14. Устройство по п.13, причем слой твердой пены имеет объем ячеек, причем более 20% объема ячеек являются взаимосвязанными.
15. Устройство по п. 13 или 14, в котором слой твердой пены имеет медианный диаметр пор 1-100 мкм.
16. Устройство по любому из пп. 13-15, в котором слой твердой пены включает пузырчатые структуры, имеющие распределение по величине в диапазоне 5 мкм-500 мкм.
17. Устройство по любому из пп. 13-16, в котором слой твердой пены включает частично схлопнутую структуру.
18. Устройство по любому из пп. 13-17, в котором толщина слоя твердой пены составляет не более 500 мкм.
19. Устройство по любому из пп. 13-18, в котором слой твердой пены по существу локализован на стенках каналов.
20. Устройство по любому из пп. 13-15, в котором подложка представляет собой пористый монолит.
21. Устройство по любому из пп. 13-20, в котором слой твердой пены включает дисперсный материал.
22. Устройство по п.21, в котором дисперсный материал представляет собой керамический материал, каталитический материал или материал сорбента.
23. Устройство по п.22, в котором дисперсный материал представляет собой каталитический материал, содержащий каталитически активный металл, нанесенный на материал носителя.
24. Устройство по п.23, в котором каталитически активный металл представляет собой по меньшей мере один переходный металл, выбранный из железа, меди, никеля, золота, платины, палладия, родия и рутения.
25. Устройство по п.23 или 24, в котором материал носителя представляет собой жаростойкий оксид, алюминат металла или цеолит.
26. Устройство по п.23 или 25, в котором материал носителя представляет собой жаростойкий оксид, который выбирается из группы, состоящей из оксида алюминия, оксида кремния, оксида титана, оксида магния, оксида циркония, оксида церия, оксида лантана, и смешанного или сложного оксид двух или более из них, такого как оксид кремния-оксид алюминия, оксид титана-оксид алюминия, оксид циркония-оксид алюминия, оксид церия-оксид алюминия, оксид титана-оксид кремния, оксид циркония-оксид кремния, оксид циркония-оксид титана, оксид церия-оксид циркония, оксид церия-оксид циркония-оксид алюминия, или оксид алюминия-оксид магния.
27. Устройство по любому из пп. 21-25, в котором дисперсный материал представляет собой композицию SCR-катализатора на основе оксида металла, композицию SCR-катализатора на основе молекулярного сита, или их смесь.
28. Устройство по п.27, в котором дисперсный материал представляет собой композицию SCR-катализатора на основе молекулярного сита, предпочтительно композицию SCR-катализатора на основе молекулярного сита, включающую образованное обменом на переходный металл молекулярное сито.
29. Устройство по п.28, в котором переходный металл образованного обменом на переходный металл молекулярного сита представляет собой медь, и молекулярное сито представляет собой цеолит, имеющий структуру каркаса, представляемую инструкцией Framework Type Code как CHA.
30. Устройство по любому из пп. 21-25, в котором дисперсный материал представляет собой улавливающий материал для улетучившейся Pt, который включает частицы жаростойкого оксида и/или частицы Pt-легируемого металла.
31. Устройство по п.30, дополнительно включающее каталитический материал, причем каталитический материал включает платину (Pt), и причем слой твердой пены размещен в контакте с выхлопным газом после контактирования выхлопного газа с каталитическим материалом, содержащим платину (Pt).
32. Применение устройства для регулирования выбросов по любому из пп. 13-31 в выхлопной системе двигателя внутреннего сгорания для предотвращения повышения противодавления внутри выхлопной системы.
33. Применение слоя твердой пены для улавливания улетучившейся платины (Pt) в выхлопной системе для обработки выхлопного газа, образованного двигателем внутреннего сгорания с воспламенением, причем слой твердой пены представляет собой слой по п. 30 или 31.
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