US20080124264A1 - Oxidation Catalyst and Exhaust-Gas Purification System Using the Same - Google Patents

Oxidation Catalyst and Exhaust-Gas Purification System Using the Same Download PDF

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US20080124264A1
US20080124264A1 US11/946,620 US94662007A US2008124264A1 US 20080124264 A1 US20080124264 A1 US 20080124264A1 US 94662007 A US94662007 A US 94662007A US 2008124264 A1 US2008124264 A1 US 2008124264A1
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exhaust gas
catalyst
exhaust
oxidation catalyst
reducing agent
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Masanori Ikeda
Naohiro Kato
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ICT Co Ltd
International Catalyst Technology Inc
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ICT Co Ltd
International Catalyst Technology Inc
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Publication of US20080124264A1 publication Critical patent/US20080124264A1/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D53/00Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/92Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9404Removing only nitrogen compounds
    • B01D53/9409Nitrogen oxides
    • B01D53/9413Processes characterised by a specific catalyst
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B01J23/00Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B01J23/44Palladium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D53/00Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/92Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/944Simultaneously removing carbon monoxide, hydrocarbons or carbon making use of oxidation catalysts
    • B01J35/19
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/0009Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
    • B01J37/0027Powdering
    • B01J37/0036Grinding
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B01J37/00Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02Impregnation, coating or precipitation
    • B01J37/024Multiple impregnation or coating
    • B01J37/0248Coatings comprising impregnated particles
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10Exhaust 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
    • F01N3/105General auxiliary catalysts, e.g. upstream or downstream of the main catalyst
    • F01N3/106Auxiliary oxidation catalysts
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10Exhaust 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
    • F01N3/18Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
    • F01N3/206Adding periodically or continuously substances to exhaust gases for promoting purification, e.g. catalytic material in liquid form, NOx reducing agents
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10Exhaust 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
    • F01N3/18Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
    • F01N3/20Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
    • F01N3/2066Selective catalytic reduction [SCR]
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2251/00Reactants
    • B01D2251/20Reductants
    • B01D2251/206Ammonium compounds
    • B01D2251/2062Ammonia
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2255/00Catalysts
    • B01D2255/10Noble metals or compounds thereof
    • B01D2255/102Platinum group metals
    • B01D2255/1021Platinum
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2255/00Catalysts
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    • B01D2255/102Platinum group metals
    • B01D2255/1023Palladium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2257/00Components to be removed
    • B01D2257/40Nitrogen compounds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D2258/00Sources of waste gases
    • B01D2258/01Engine exhaust gases
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D53/00Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/92Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9404Removing only nitrogen compounds
    • B01D53/9409Nitrogen oxides
    • B01D53/9413Processes characterised by a specific catalyst
    • B01D53/9418Processes characterised by a specific catalyst for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D53/00Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/92Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9459Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts
    • B01D53/9477Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts with catalysts positioned on separate bricks, e.g. exhaust systems
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/70Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
    • B01J23/74Iron group metals
    • B01J23/745Iron
    • B01J35/56
    • B01J35/60
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02Impregnation, coating or precipitation
    • B01J37/024Multiple impregnation or coating
    • B01J37/0246Coatings comprising a zeolite
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2240/00Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
    • F01N2240/40Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being a hydrolysis catalyst
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01NGAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2250/00Combinations of different methods of purification
    • F01N2250/02Combinations of different methods of purification filtering and catalytic conversion
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • F01N2330/00Structure of catalyst support or particle filter
    • F01N2330/02Metallic plates or honeycombs, e.g. superposed or rolled-up corrugated or otherwise deformed sheet metal
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • F01N2370/00Selection of materials for exhaust purification
    • F01N2370/02Selection of materials for exhaust purification used in catalytic reactors
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
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    • F01N2370/00Selection of materials for exhaust purification
    • F01N2370/02Selection of materials for exhaust purification used in catalytic reactors
    • F01N2370/04Zeolitic material
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/10Internal combustion engine [ICE] based vehicles
    • Y02T10/12Improving ICE efficiencies

Definitions

  • the present invention relates to an oxidation catalyst and an exhaust-gas purification system using the same, and in particular, to an exhaust-gas purification system having excellent performance in purifying particularly nitrogen oxides from an internal combustion engine such as a diesel engine.
  • a method of making use of plasma is known as a technology for forming NO 2 .
  • a method for decreasing particulate matters in an exhaust gas by using nitrogen dioxide and ozone formed by means of generating plasma in the exhaust gas is disclosed (US-A-2004-168429 (JP-A-2004-169643)).
  • Another technology for forming NO 2 is a technology of using an oxidation catalyst to promote the reaction of the above formula (5).
  • platinum (Pt), palladium (Pd), ruthenium (Ru), rhodium (Rh) and the like are proposed as a active component of a catalyst for oxidizing NO in the exhaust gas to NO 2 in pursuit of removing diesel particulates (particulate matters) in U.S. Pat. No. 4,902,487 (JP-A-1-318715).
  • JP-A-1-318715 Specific data on the metals other than Pt, however, are not disclosed.
  • Pat. No. 4,902,487 or US-A-2002-039550 is used that sufficient effect for purifying nitrogen oxides and particulate matters has not been obtained.
  • the temperature of exhaust gases is low, it has been necessary in a conventional method to elevate the temperature of the exhaust gas, which sometimes has made a system complicated.
  • an object of the present invention is to provide an oxidation catalyst for efficiently promoting oxidation of NO to NO 2 even in a low temperature range.
  • Another object of the present invention is to provide an exhaust-gas purification system and method for efficiently removing nitrogen oxides or particulate matters even in a low temperature range.
  • the present inventors have found, after having intensively studied a way to solve the above problem, that an oxidation catalyst containing platinum and palladium as catalytically active components which contains 1 to 55% by weight of the palladium relative to 100% by weight of the platinum, efficiently promotes oxidation of NO to NO 2 even in a low temperature range, and completed the present invention.
  • the present invention provides an oxidation catalyst comprising platinum and palladium as catalytically active components, which promotes oxidation of nitrogen monoxide to nitrogen dioxide, wherein the oxidation catalyst comprises 1 to 55% by weight of the palladium relative to 100% by weight of the platinum.
  • the present invention provides an exhaust-gas purification system, which comprises an oxidation catalyst containing platinum and palladium as catalytically active components and promoting oxidation of nitrogen monoxide to nitrogen dioxide which contains 1 to 55% by weight of the palladium relative to 100% by weight of the platinum, in the exhaust-gas passage of an internal-combustion engine.
  • the present invention provides an exhaust-gas purification method for purifying the exhaust gas discharged from an internal-combustion engine, having (1) a step for converting nitrogen monoxide in the exhaust gas to nitrogen dioxide by bringing the exhaust gas into contact with an oxidation catalyst containing platinum and palladium as catalytically active components which contains 1 to 55% by weight of the palladium relative to 100% by weight of the platinum, and (2) a step for reducing the nitrogen oxides in the exhaust gas by bringing the exhaust gas obtained in the step (1) into contact with a NO X reduction catalyst in the presence of a reducing agent.
  • the present invention provides an exhaust-gas purification method for purifying the exhaust gas discharged from an internal-combustion engine, having (1) a step for converting nitrogen monoxide in the exhaust gas to nitrogen dioxide by bringing the exhaust gas into contact with an oxidation catalyst containing platinum and palladium as catalytically active components which contains 1 to 55% by weight of the above palladium relative to 100% by weight of the platinum, (2) a step for reducing the nitrogen oxides in the exhaust gas by bringing the exhaust gas obtained in the step (1) into contact with a NO X reduction catalyst in the presence of a reducing agent, and (3) a step for removing at least a part of particulate matters.
  • the oxidation catalyst of the present invention can form NO 2 even when an exhaust gas is at low temperature, it can efficiently promote a reaction of a substance to be reacted with NO 2 even when an exhaust gas is at low temperature.
  • FIG. 1 is a drawing showing the result of Evaluation Example 1.
  • FIG. 2 is a schematic drawing showing an example of the exhaust-gas purification system of the present invention.
  • FIG. 3 is a schematic drawing showing an example of the exhaust-gas purification system of the present invention.
  • FIG. 4 is a schematic drawing showing an example of the exhaust-gas purification system of the present invention.
  • FIG. 5 is a schematic drawing showing an example of the exhaust-gas purification system of the present invention.
  • FIG. 6 is a schematic drawing showing an example of the exhaust-gas purification system of the present invention.
  • FIG. 7 is a schematic drawing showing an example of the exhaust-gas purification system of the present invention.
  • FIG. 8 is a schematic drawing showing an example of the exhaust-gas purification system of the present invention.
  • the first aspect of the present invention is an oxidation catalyst containing platinum and palladium as catalytically active components and promoting oxidation of nitrogen monoxide to nitrogen dioxide, which is characterized by containing 1 to 55% by weight of the above palladium relative to 100% by weight of the above platinum.
  • Pt, Pd, Ru, Rh and the like are disclosed as a catalytically active component for promoting oxidation of NO to NO 2 , for example, in U.S. Pat. No. 4,902,487.
  • Pt has been usually used as an active component for forming NO 2 , because Pd used alone as a catalytically active component has much poorer oxidation activity compared with Pt used alone as described in “Barry J. Cooper, et al., Role of NO in Diesel Particulate Emission Control, SAE paper, 890404”.
  • the present invention has found that a catalyst made of a combination of Pt and Pd has a synergistic effect on promotion of nitrogen dioxide formation and also has found the range where an oxidation catalyst functions effectively by specifying contents of the Pt and Pd even under a low temperature condition.
  • the oxidation catalyst has an adequate activity after the oxidation catalyst is used for a long period.
  • the ratio of the contents of Pt and Pd by weight is 1 to 55% by weight of Pd relative to 100% by weight of Pt. Further, it is preferably that the ratio of the contents of Pt and Pd by weight is 1 to 45% by weight, 1 to 35% by weight, 1 to 20% by weight, 4 to 20% by weight, 4 to 12% by weight, 5 to 12% by weight of Pd relative to 100% by weight of Pt, in this order.
  • An oxidation catalyst containing these ranges of Pt and Pd promotes conversion of NO to NO 2 very efficiently even in a low temperature range.
  • the amount (sum) of Pt and Pd to be used is preferably 0.1 to 20 g, more preferably 0.5 to 10 g per liter of a three-dimensional structure. This range of the amount gives excellent catalyst activity in initial and endurance operation.
  • the oxidation catalyst of the present invention may contain other metals and oxides thereof as catalytically active components as long as the catalyst contains Pt and Pd at the above specified ratio.
  • the metal includes specifically a metal such as ruthenium, rhodium, iridium, gold, cobalt, nickel and copper, and an alloy thereof, and the like.
  • the content of other metals and oxides thereof is usually 0 to 2000% by weight relative to 100% by weight of catalytically active components.
  • the oxidation catalyst of the present invention has a structure where a catalytically active component is supported on a refractory inorganic oxide to form a catalytically active component-supporting inorganic oxide which is further supported on a three-dimensional structure.
  • the catalytically active component which is supported on a refractory inorganic oxide is not particularly limited, and preferably is present in the state of catalyst metal particles having a mean particle diameter of preferably 1 to 50 nm.
  • the refractory inorganic oxide to be used in the present invention is not particularly limited as long as it is usually used as a catalyst carrier, and includes activated alumina such as ⁇ -, ⁇ -, ⁇ -, ⁇ - and ⁇ -alumina; zirconia, titania, zeolite, silica; or a composite oxide of these oxides such as alumina-silica, alumina-titania, alumina-zirconia and titania-zirconia. From the standpoint of improving catalyst performance, activated alumina, alumina-silica, zirconia, titania and zeolite are preferable and activated alumina is more preferable.
  • the above inorganic oxide may be used alone or in combination of two or more.
  • the shape of the refractory inorganic oxide is a powder.
  • the amount of the refractory inorganic oxide (excluding active components) to be used is preferably 10 to 300 g, more preferably 20 to 150 g per liter of a three-dimensional structure. This range of the amount gives sufficient dispersion of a noble metal and satisfactory durability.
  • the BET specific surface area of the refractory inorganic oxide is preferably 50 to 750 m 2 /g, more preferably 150 to 750 m 2 /g.
  • the mean primary particle diameter of the refractory inorganic oxide powder is 0.5 to 150 ⁇ m, preferably 1 to 100 ⁇ m.
  • the three-dimensional structure to be used in the present invention includes a heat-resistant carrier such as a honeycomb carrier, and particularly, a honeycomb structure of an integrally molded type is preferable, for example, a monolithic honeycomb carrier, a metal honeycomb carrier, a plug honeycomb carrier and a pellet carrier are included.
  • the monolithic carrier includes a carrier that is usually called a ceramic honeycomb carrier, and particularly, a honeycomb carrier made of material such as cordierite, mullite, ⁇ -alumina, zirconia, titania, titanium phosphate, aluminum titanate, betallite, spondumene, aluminosilicate, magnesium silicate is preferable, and cordierite-base is particularly preferable among these.
  • a three-dimensional structure made of a heat-resistant metal of oxidation resistance such as stainless steel and a Fe—Cr—Al alloy is used.
  • These monolithic carriers are manufactured by an extrusion molding method, a method of rolling up a sheet-shaped element, and the like.
  • the shape of a gas passage may be any of a hexagon, a quadrangle, a triangle and a corrugated shape.
  • the carrier having a cell density (number of cell/cross-sectional area) of 100 to 600 cells/square inch can be satisfactorily used, and preferably 200 to 500 cells/square inch.
  • the oxidation catalyst of the present invention may contain an alkaline metal such as potassium, an alkaline-earth metal such as magnesium and barium, a rare-earth metal such as lanthanum and cerium, and an metal oxide thereof, or zeolite, and the content thereof is usually 0 to 100 g per liter of a three-dimensional structure.
  • the production method for the oxidation catalyst of the present invention is not particularly limited, and will be described below with specific examples.
  • inorganic salts such as a chloride (halide), a nitrate, a sulfate, an ammonium salt, an amine, a carbonate, a bicarbonate, a nitrite and an oxalate of Pt and Pd; a carboxylate such as a formate, a hydroxide, an alkoxide, and an oxide of Pt and Pd; preferably a chloride, a nitrate, an ammonium salt, an amine and a carbonate are prepared.
  • the active component is Pt
  • dinitrodiammine platinate nitrate, chloroplatinic acid (hexachloroplatinic acid), platinum nitrate and the like are included
  • the active component is Pd
  • palladium nitrate, palladium chloride are included.
  • the above raw material and a refractory inorganic oxide powder are subjected to wet milling to prepare an aqueous slurry.
  • a three-dimensional structure is coated with the slurry, dried usually at 50 to 150° C. for 30 minutes to 8 hours and then calcined at usually 300 to 800° C., preferably 400 to 600° C.
  • oxidation catalyst having a metal-particle diameter of a catalytically active component of 1 to 50 nm gives excellent oxidation performance.
  • the oxidation performance of the oxidation catalyst having a metal-particle diameter smaller than 1 nm is undesirably impaired due to interaction with a carrier, whereas the oxidation catalyst having a metal-particle diameter larger than 50 nm has undesirably less metal surface area resulting in less numbers of metal atoms to be used for catalytic reaction.
  • the second aspect of the present invention is an exhaust-gas purification system wherein the oxidation catalyst of the first aspect of the present invention is installed in the exhaust-gas passage of an internal-combustion engine. Since the oxidation catalyst of the first aspect of the present invention efficiently converts NO to NO 2 even in a low temperature range as described above, the exhaust-gas purification system of the second aspect of the present invention can efficiently remove nitrogen oxides even under a low temperature condition.
  • FIG. 2 is a schematic drawing showing an embodiment of the exhaust-gas purification system of the second aspect of the present invention.
  • the exhaust-gas purification system shown in FIG. 2 is equipped with an oxidation catalyst 2 installed in the exhaust-gas passage of an internal-combustion engine, a apparatus (reducing agent injection nozzle 8 , pump 9 , reducing agent tank 10 ) supplying a reducing agent to latter stage of the oxidation catalyst, and a NO X reduction catalyst 3 in the exhaust-gas passage at latter stage of the reducing agent supplying apparatus.
  • the internal-combustion engine 1 and the pump 9 are controlled by a controller 4 .
  • a temperature controller is composed of the controller 4 and thermocouples 5 to 7 .
  • the exhaust gas discharged from the internal-combustion engine 1 is introduced through the exhaust-gas passage to the oxidation catalyst 2 installed in the exhaust-gas passage.
  • the exhaust gas contains NO and NO 2 as nitrogen oxides, most of which is NO under a low temperature condition.
  • the reducing agent stored in the reducing agent tank 10 is then supplied from the reducing agent injection nozzle 8 to the exhaust-gas passage with actuation of the pump 9 .
  • Ammonia, urea, a hydrocarbon such as light oil, an alcohol of 1 to 3 carbon atoms and an ether of 2 to 6 carbon atoms can be used as the reducing agent, but from the standpoint of handling, preferably at least one selected from urea, light oil, dimethyl ether, methane, ethane, propane, hexane, ethylene, propylene, hexene, gasoline, kerosene, fuel oil A (JIS), fuel oil C (JIS), methanol, ethanol and propanol, more preferably at least one kind selected from urea, ammonia, light oil, dimethyl ether, methanol, ethanol and propanol, still more preferably urea, light oil, dimethyl ether and ethanol, and particularly preferably urea and light oil are used.
  • JIS fuel oil A
  • JIS fuel oil C
  • methanol, ethanol and propanol more preferably at least one kind selected from urea, ammonia, light oil,
  • a catalyst for hydrolyzing urea 14 is installed downstream as shown in FIG. 3 or the NO X reduction catalyst to be described later has a function for hydrolyzing urea.
  • urea water is injected from the injection nozzle 8 as shown in FIG. 3 .
  • the temperature controller composed of the controller 4 and the thermocouples 5 to 7 shown in FIG. 2 can control the temperature of the exhaust gas at each stage.
  • the temperature of the exhaust gas may be controlled to be preferably 140° C. or higher, more preferably 160° C. or higher before the exhaust gas is introduced to the oxidation catalyst 2 .
  • the temperature of the exhaust gas is controlled to be preferably 135° C. or higher, more preferably 160° C. or higher before the exhaust gas is introduced to the reduction catalyst 3 .
  • thermal decomposition of urea represented by the following formula (6) or hydrolysis of isocyanic acid, which is generated by the thermal decomposition of urea, represented by the following formula (7) proceeds easily.
  • the temperature of the exhaust gas before the exhaust gas is introduced to the NO X reduction catalyst 3 is preferably the boiling point of the hydrocarbon or higher.
  • the temperature of the exhaust gas is controlled to be preferably 200° C. or higher, more preferably 250 to 550° C. In such a temperature range, preferably, the liquid hydrocarbon hardly sticks to the surface of the reduction catalyst leading to efficient removal of NO X .
  • the NO X reduction catalyst is not particularly limited as long as it is usually known, and may be selected as appropriate according to the vehicle weight, the engine displacement and the like, to be mounted.
  • the reducing agent is urea
  • a zeolite catalyst exchanged by a specific transition metal is preferably used.
  • the reducing agent is a hydrocarbon such as light oil, an alcohol of 1 to 3 carbon atoms and an ether of 2 to 6 carbon atoms
  • a noble metal such as Pt, Pd and Rh supported on an inorganic carrier such as alumina, silica and alumina-silica is preferably used in a low temperature range of 300° C. or lower
  • a zeolite catalyst exchanged by a specific transition metal is preferably used in a high temperature range of 300° C. or higher.
  • the zeolite catalyst exchanged by a transition metal is preferably supported on a three-dimensional structure.
  • the three-dimensional structure the structure described in column of the above oxidation catalyst can be used.
  • the transition metal is not limited, and includes copper, iron, cerium, vanadium, chromium, nickel and oxides thereof, preferably copper, iron, vanadium and oxides thereof.
  • the amount of the transition metal to be used is preferably 1 to 80 g, more preferably 2 to 40 g per liter of a three-dimensional structure. This range of the amount gives excellent catalyst activity in initial and endurance operation.
  • the zeolite catalyst exchanged by a transition metal includes not only the zeolite having the form where a transition metal is ion exchanged, but also the zeolite having both of the form where a transition metal is ion exchanged and the form where a transition metal is coated.
  • the above amount of the transition metal to be used indicates the sum of the ion-exchanged transition metal and the transition metal coated on the zeolite.
  • the zeolite to be used is not particularly limited, and includes BEA type, MFI type, FER type, FAU type and MOR type zeolite, preferably BEA type and MFI type zeolite.
  • the amount of zeolite to be used is preferably 10 to 300 g, preferably 50 to 300 g per liter of a three-dimensional structure. This range of the amount gives sufficient dispersion of a transition metal and satisfactory durability.
  • the BET specific surface area of zeolite is preferably 50 to 750 m 2 /g, more preferably 150 to 750 m 2 /g.
  • the mean primary particle diameter of zeolite is preferably 0.5 to 150 ⁇ m, more preferably 1 to 100 ⁇ m.
  • the NO X reduction catalyst to be used in the present invention may contain an alkaline metal such as potassium, an alkaline-earth metal such as magnesium and barium, a rare-earth element such as lanthanum and cerium, and oxides thereof or zeolite.
  • the production method for the NO X reduction catalyst that can be used in the present invention is not particularly limited. As one example, a production method for a zeolite catalyst exchanged by a specific transition metal will be specifically described below.
  • a transition metal salt such as iron nitrate, iron acetate and iron sulfate is prepared as a raw material of a transition metal.
  • the above raw material and zeolite are then subjected to wet milling to prepare an aqueous slurry.
  • a three-dimensional structure is coated with this slurry, dried usually at 50 to 150° C. for 30 minutes to 8 hours and then calcined at 300 to 800° C., preferably 400 to 600° C. for 15 minutes to 2 hours, preferably 30 minutes to 1 hour to obtain a NO X reduction catalyst.
  • the purification system of the present invention includes various improved embodiments that use the oxidation catalyst of the first aspect of the present invention, preferably have a supplying apparatus of a reducing agent at the latter stage of the oxidation catalyst and further have a NO X reduction catalyst at the latter stage of the supplying apparatus of a reducing agent.
  • a catalyst of suppressing slip of a reducing agent 11 at the latter stage of the NO X reduction catalyst 3 FIG. 4
  • an embodiment having a diesel particulate filter 13 at the latter stage of the NO X reduction catalyst 3 FIG. 8
  • an embodiment including a diesel particulate filter 13 at the latter stage of the oxidation catalyst 2 FIG.
  • FIG. 5 an embodiment including a catalyst for hydrolyzing urea 14 ( FIG. 3 ) and a combination ( FIG. 6 and FIG. 7 ) of these embodiments are included.
  • Thermocouple 12 is installed after the NO X reduction catalyst 3 in the embodiment of FIG. 5 or FIG. 6 .
  • the reducing agent is urea or ammonia
  • an embodiment having a catalyst of suppressing slip of a reducing agent 11 installed as shown in FIG. 4 is preferable.
  • the catalyst of suppressing slip of a reducing agent indicates a catalyst for preventing discharge of extra ammonia, for which a conventionally known oxidizing catalyst can be used.
  • a diesel particulate filter can remove at least a part of particulate matters.
  • a fuel supplying apparatus composed of a fuel injection nozzle 17 , a pump 18 and a fuel tank 19 may be installed before the diesel particulate filter 13 as shown in FIG. 5 or FIG. 7 .
  • the filter requires processing for regeneration when particulates are accumulated.
  • the system of FIG. 7 is described as follows: Fuel is supplied from the fuel supplying apparatus to the oxidation catalyst 16 through the exhaust-gas passage and the temperature of the exhaust gas is controlled to be high enough to burn the particulates.
  • Thermocouple 15 is installed after the diesel particulate filter 13 in the embodiment of FIG. 7 .
  • the fuel necessary for regeneration of the diesel particulate filter may be supplied either to the exhaust-gas passage as shown above or before an exhaust-gas discharge step after fuel combustion in an engine cylinder.
  • the temperature of the exhaust gas to be introduced to the diesel particulate filter is not too low, specifically 200° C. or higher in view of regeneration of the diesel particulate filter.
  • Various kinds of diesel particulate filters are available and a known filter such as a filter made of cordierite and a filter made of heat-resistant silicon carbide can be used.
  • the diesel particulate filter may contain a catalyst component.
  • the catalyst component is not limited and includes one that at least one kind of catalytically active component such as platinum, palladium, rhodium, iridium, gold, silver, iron, copper and manganese is supported on a refractory inorganic oxide.
  • the refractory inorganic oxide includes activated alumina; zirconia, titania, zeolite, silica, ceria, magnesia, silica-alumina, ceria-zirconia, and the mixture thereof.
  • the amount of the catalytically active component is preferably 0.1-10 g per liter of the catalyst, and the amount of the refractory inorganic oxide is preferably 5-100 g per liter of the catalyst.
  • a catalyst of suppressing slip of a reducing agent and a catalyst for hydrolyzing urea that are conventionally known can be used.
  • the third aspect of the present invention is an exhaust-gas purification method for purifying an exhaust gas discharged from an internal-combustion engine.
  • the exhaust-gas purification method is characterized by comprising (1) a step for converting nitrogen monoxide in the exhaust gas to nitrogen dioxide by bringing the exhaust gas into contact with the oxidation catalyst of the first aspect of the present invention and (2) a step for reducing the nitrogen oxides in the exhaust gas by bringing the exhaust gas obtained in the step (1) into contact with a NO X reduction catalyst in the presence of a reducing agent.
  • the method comprises further (3) a step for purifying at least a part of particulate matters. The details of each step are as described above.
  • the oxidation catalyst of the present invention and the purification system using it can purify nitrogen oxides discharged from various internal-combustion engines such as a diesel engine, a gasoline engine and a compressed-natural-gas engine, and are preferably applied to a diesel engine among the above engines or to a vehicle driven by a diesel engine.
  • various internal-combustion engines such as a diesel engine, a gasoline engine and a compressed-natural-gas engine, and are preferably applied to a diesel engine among the above engines or to a vehicle driven by a diesel engine.
  • the calcination at 700° C. for 11 hours is a durable treatment for evaluating a catalyst performance after long-period use.
  • the conversion ratio of NO to NO 2 was calculated by the following equation and plotted against the temperature at the catalyst-bed inlet. The results are shown in FIG. 1 .
  • the oxidation catalyst of the present invention which contains a specific amount of Pd and Pt as catalytically active components shows a higher conversion ratio of NO to NO 2 than an oxidation catalyst which contains only Pt as a catalytically active component.
  • the aqueous slurry (F) was prepared in 15 times as many amounts by weight as that in Example 4.
  • a cylindrical honeycomb carrier made of cordierite of 10.5 inches in diameter and 6 inches in length having 300 cells per square inch of cross-sectional area was coated (wash coat) with this slurry so that the sum of platinum, palladium and alumina is 124 g per liter of the honeycomb carrier, dried at 120° C. for 8 hours and then calcined at 500° C. for an hour to obtain catalyst J.
  • the aqueous slurry (I) was prepared in 15 times as many amounts by weight as that in Comparative Example 3.
  • a cylindrical honeycomb carrier made of cordierite of 10.5 inches in diameter and 6 inches in length having 300 cells per square inch of cross-sectional area was coated (wash coat) with this slurry so that the sum of platinum and alumina is 124 g per liter of the honeycomb carrier, dried at 120° C. for 8 hours and then calcined at 500° C. for an hour to obtain catalyst K.
  • An aqueous solution of iron nitrate of the amount corresponding to 48 g of iron and 1,600 g of MFI type zeolite (BET specific surface area: 380 m 2 /g, mean primary particle diameter: 15 ⁇ m) were subjected to wet milling by a ballmill to prepare 4,500 g in total of an aqueous slurry (L).
  • a cylindrical honeycomb carrier made of cordierite of 10.5 inches in diameter and 6 inches in length having 400 cells per square inch of cross-sectional area was coated (wash coat) with this slurry so that the sum of iron and zeolite is 164.8 g per liter of the honeycomb carrier, dried at 120° C. for 8 hours and then calcined at 500° C. for an hour to obtain catalyst L.
  • An exhaust-gas discharge apparatus was fabricated by installing catalyst J after an engine 1 and reduction catalyst L after the catalyst as shown in FIG. 2 .
  • a direct-injection diesel engine of 9.8 L was used as the internal-combustion engine.
  • An exhaust-gas discharge apparatus was fabricated by installing catalyst K after an engine 1 and reduction catalyst L after the catalyst as shown in FIG. 2 .
  • a direct-injection diesel engine of 9.8 L was used as the internal-combustion engine.
  • An exhaust-gas discharge apparatus was fabricated in the same way as Comparative Example 5 except that a cylindrical honeycomb carrier made of cordierite of 10.5 inches in diameter and 6 inches in length having 300 cells per square inch of cross-sectional area was installed instead of catalyst K.
  • a direct-injection diesel engine of 9.8 L was used as the internal-combustion engine.
  • thermocouple 5 before the oxidation catalyst (the thermocouple 5 before the reduction catalyst in Comparative Example 6) indicated 400° C. and the exhaust gas was passed through the oxidation catalyst for 15 minutes. The engine was then run so that the thermocouple 5 before the oxidation catalyst indicates 180° C. on average and 200° C.
  • NO X ⁇ ⁇ Conversion ⁇ ⁇ Ratio ⁇ ⁇ ( % ) NO X ⁇ ⁇ concentration ⁇ ⁇ after ⁇ ⁇ reduction ⁇ ⁇ catalyst NO X ⁇ ⁇ concentration ⁇ ⁇ before ⁇ ⁇ oxidation ⁇ ⁇ catalyst ⁇ 100
  • the aqueous slurry (A) was prepared in 5 times as many amounts by weight as that in Example 1.
  • a cylindrical honeycomb carrier made of cordierite of 5.7 inches in diameter and 6 inches in length having 400 cells per square inch of cross-sectional area was coated (wash coat) with this slurry so that the sum of platinum, palladium and alumina is 124 g per liter of the honeycomb carrier, dried at 120° C. for 8 hours and then calcined at 500° C. for an hour to obtain catalyst M.
  • the aqueous slurry (D) was prepared in 5 times as many amounts by weight as that in Comparative Example 1.
  • a cylindrical honeycomb carrier made of cordierite of 5.7 inches in diameter and 6 inches in length having 400 cells per square inch of cross-sectional area was coated (wash coat) with this slurry so that the sum of platinum and alumina is 124 g per liter of the honeycomb carrier, dried at 120° C. for 8 hours and then calcined at 500° C. for an hour to obtain catalyst N.
  • An exhaust-gas discharge apparatus was fabricated by installing catalyst M after a direct-injection diesel engine of 2.2 L and a cylindrical diesel particulate filter made of SiC of 5.2 inches in diameter and 9 inches in length having 316 cells per square inch of cross-sectional area in which 9 g of particulate matters discharged from the engine accumulated, after the catalyst.
  • An exhaust-gas discharge apparatus was fabricated by installing catalyst N after a direct-injection diesel engine of 2.2 L and a cylindrical diesel particulate filter made of SiC of 5.2 inches in diameter and 9 inches in length having 316 cells per square inch of cross-sectional area in which 9 g of particulate matters discharged from the engine accumulated, after the catalyst.
  • the removal ratio of particulate matters was evaluated using the exhaust-gas discharge apparatuses of Example 10 and Comparative Example 7.
  • the weight change of the diesel particulate filter from before to after the temperature indicated by the thermocouple before the oxidation catalyst was raised from 115° C. to 400° C. in 100 minutes was measured and thus the weight of the particulate matters remaining on the diesel particulate filter was calculated.
  • the diesel particulate filter was weighed after it was dried at 150° C. for an hour.
  • the removal ratio of particulate matters was determined from the weight of the remaining particulate matters using the following equation. The results are shown in Table 3.
  • Removal ⁇ ⁇ ratio ⁇ ⁇ of ⁇ ⁇ particulate ⁇ ⁇ matters ⁇ ⁇ ( % ) 100 - ⁇ Weight ⁇ ⁇ of ⁇ ⁇ remaining ⁇ ⁇ particulate matters ⁇ ⁇ after ⁇ ⁇ heated ⁇ ⁇ to ⁇ ⁇ ⁇ 400 ⁇ ° ⁇ ⁇ C . 9 ⁇ 100

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