WO2002083309A1 - Corps structural de support catalytique - Google Patents

Corps structural de support catalytique Download PDF

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Publication number
WO2002083309A1
WO2002083309A1 PCT/JP2002/003439 JP0203439W WO02083309A1 WO 2002083309 A1 WO2002083309 A1 WO 2002083309A1 JP 0203439 W JP0203439 W JP 0203439W WO 02083309 A1 WO02083309 A1 WO 02083309A1
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Prior art keywords
ceramic
exhaust gas
catalyst
catalyst carrier
ceramic wire
Prior art date
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PCT/JP2002/003439
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English (en)
Japanese (ja)
Inventor
Norihiro Murakawa
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Mitsui Chemicals, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mitsui Chemicals, Inc. filed Critical Mitsui Chemicals, Inc.
Priority to PCT/JP2002/010219 priority Critical patent/WO2003045553A1/fr
Priority to AU2002343939A priority patent/AU2002343939A1/en
Publication of WO2002083309A1 publication Critical patent/WO2002083309A1/fr

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    • 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
    • F01N3/24Exhaust 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
    • F01N3/28Construction of catalytic reactors
    • F01N3/2803Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2825Ceramics
    • 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
    • B01D53/9445Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
    • B01D53/9454Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific device
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00Catalysts, in general, characterised by their form or physical properties
    • B01J35/50Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
    • B01J35/56Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00Catalysts, in general, characterised by their form or physical properties
    • B01J35/50Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
    • B01J35/58Fabrics or filaments
    • CCHEMISTRY; METALLURGY
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    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/453Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on zinc, tin, or bismuth oxides or solid solutions thereof with other oxides, e.g. zincates, stannates or bismuthates
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    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/495Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on vanadium, niobium, tantalum, molybdenum or tungsten oxides or solid solutions thereof with other oxides, e.g. vanadates, niobates, tantalates, molybdates or tungstates
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    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
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    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632Organic additives
    • C04B35/634Polymers
    • 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
    • F01N3/022Exhaust 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 characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
    • F01N3/0222Exhaust 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 characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous the structure being monolithic, e.g. honeycombs
    • CCHEMISTRY; METALLURGY
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3205Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
    • C04B2235/3215Barium oxides or oxide-forming salts thereof
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3231Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
    • C04B2235/3251Niobium oxides, niobates, tantalum oxides, tantalates, or oxide-forming salts thereof
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/327Iron group oxides, their mixed metal oxides, or oxide-forming salts thereof
    • C04B2235/3275Cobalt oxides, cobaltates or cobaltites or oxide forming salts thereof, e.g. bismuth cobaltate, zinc cobaltite
    • CCHEMISTRY; METALLURGY
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/327Iron group oxides, their mixed metal oxides, or oxide-forming salts thereof
    • C04B2235/3279Nickel oxides, nickalates, or oxide-forming salts thereof
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3284Zinc oxides, zincates, cadmium oxides, cadmiates, mercury oxides, mercurates or oxide forming salts thereof
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3294Antimony oxides, antimonates, antimonites or oxide forming salts thereof, indium antimonate
    • 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 a catalyst carrier structure, and more particularly, to a catalyst carrier structure suitably used for an exhaust gas purifying catalyst for purifying exhaust gas of an internal combustion engine such as an automobile engine.
  • Exhaust gas emitted from internal combustion engines such as automobile engines contains nitrogen oxides (NO x ), carbon monoxide (CO), and hydrocarbons (HC), as well as lean-burn internal combustion engines such as diesel engines.
  • Engine exhaust gases contain particulate matter particulates. It is required to reduce these harmful substances as early as possible in terms of environmental protection.
  • Such NO x, CO, exhaust gas containing HC are generally Kiyoshii spoon by the exhaust gas SuKiyoshii ⁇ catalyst such as a three-way catalyst
  • the exhaust gas purifying catalyst is generally a group having a honeycomb shape
  • a catalyst carrier made of a ceramic material is fixed on a material (honeycomb substrate) to form a catalyst carrier structure, and a catalyst component such as platinum is supported on the catalyst carrier structure.
  • such a honeycomb substrate is not limited to a ceramic material, and may be made of a metal material as described in JP-A-8-243406 and JP-A-5-138040.
  • metal non-cam bases of various shapes have been proposed by utilizing the easy workability of metal materials.
  • the high temperature atmosphere when operated for a long time car at high speed, NO x, for corrosive atmosphere by SO x, generally used is a ceramic honeycomb substrate, the thermal expansion or contraction due to variations in exhaust gas temperature Since it is necessary to avoid damage such as cracks due to cracks, cordierite mosquitoes with extremely low thermal expansion coefficient Honeycomb base material is used.
  • the exhaust gas in addition to lean-burn internal combustion engine includes particulates such as NO x, likewise, ha - exhaust gas was responsible lifting a catalyst component such as platinum catalyst support structure using a cam base Kiyoshi Efforts are being made to purify the catalyst using a catalyst for fuel cells.
  • a honeycomb base material having a particulate filtration function by alternately plugging cells is used.
  • the catalyst component In order for such an exhaust gas purifying catalyst to exhibit high exhaust gas purification performance, the catalyst component must be in sufficient contact with the exhaust gas. Therefore, the catalyst component is carried on the catalyst carrier over a wide area. It is necessary. For this reason, it is desired that the honeycomb substrate has as many cells as possible per unit cross-sectional area.
  • a ceramic material of the catalyst carrier fixed to the honeycomb substrate generally, about 18 Om 2 Zg is used. ⁇ -alumina having a high specific surface area is used.
  • the ceramic material on the side fixed to the honeycomb substrate does not participate in the contact with the gas, so that the active surface of the ceramic material is effectively used. It is hard to say that there is.
  • ceramic materials such as various oxides, composite oxides, nitrides, and carbides exhibit functions such as oxygen storage capacity, oxygen ion conductivity, acid-base sites, and adsorbability under an exhaust gas atmosphere.
  • functional ceramic materials There are specific ceramic materials that have a catalytic or co-catalytic effect (hereinafter sometimes referred to as “functional ceramic materials”).
  • the honeycomb substrate In order to enhance the purification performance of the exhaust gas purifying catalyst, the honeycomb substrate There is a limit to the further reduction in the size of the honeycomb structure in terms of extrusion technology for manufacturing honeycomb substrates.
  • the distance between the cell centers is currently reduced to several mm or less, but if the cell diameter is further reduced, the cross-sectional area of the cell wall that blocks the flow of exhaust gas increases, and the pressure of the exhaust gas increases. There is a problem that fuel loss will be worsened due to increased losses.
  • the catalytic activity of the above-mentioned specific functional ceramic material is lower than that of a noble metal such as platinum, so that a large amount of active surface area is required to ensure sufficient exhaust gas purification performance to achieve sufficient exhaust gas purification performance. It is necessary to use a ceramic material, but fixing it on a honeycomb substrate has limitations in terms of the volume of the honeycomb substrate. In addition, these functional ceramic materials generally have a problem that it is difficult to obtain a material having a specific surface area high enough to support a catalyst component such as platinum.
  • the present invention can use the active surface of these ceramic materials efficiently by remarkably increasing the absolute amount (filled amount per unit space) and surface area of the catalyst support ceramic material or the functional ceramic material. Accordingly, it is an object of the present invention to provide a catalyst carrier structure that significantly improves the purification performance of an exhaust gas purification catalyst. Disclosure of the invention
  • the gist of the present invention to achieve such an object is as follows.
  • a catalyst carrier structure comprising a plurality of ceramic wire layers made of a plurality of ceramic wires mutually TO, and a spacer disposed between the ceramic wire layers.
  • the ceramic wire is 10 ⁇ ! It has a diameter of ⁇ 1 mm and the spacer is 30 At ⁇ !
  • the catalyst carrier structure according to any one of (1) to (7), having a diameter of 3 mm.
  • the oxide ceramic is alumina, zirconia, ceria, zirconia-ceria, alumina-ceria-zirconia, ceria-zirconia-yttria, zirconia-potassium, perovskite-type composite oxide, aluminate-type composite oxide
  • the catalyst support structure according to (9) or (10) which is at least one oxide ceramic selected from the group consisting of spinel-type composite oxides.
  • a catalyst support structure according to any one of (1) to (12), wherein at least one catalyst component selected from the group consisting of platinum, palladium, and rhodium is supported. Exhaust gas purification catalyst.
  • An exhaust gas purifying catalyst device comprising the exhaust gas purifying catalyst according to (13) or (14) loaded in a cylindrical member, wherein an axis of the cylindrical member and the ceramic wire layer are provided. And the axis of the cylindrical member and the axis of the ceramic wire are arranged so as to be perpendicular to each other.
  • FIGS. 1 to 3 are model diagrams illustrating the configuration of the catalyst carrier structure of the present invention.
  • FIG. 4 is a model diagram illustrating another configuration of the catalyst carrier structure of the present invention.
  • FIG. 5 is a model diagram illustrating another configuration of the catalyst carrier structure of the present invention.
  • FIG. 6 is a model diagram of an exhaust gas purifying catalyst device using the catalyst carrier structure of the present invention.
  • FIG. 1 to 3 are model diagrams illustrating the configuration of the catalyst carrier structure (1) of the present invention.
  • FIG. 1 is a schematic perspective view of the catalyst carrier structure (1)
  • FIG. 2 is a cross-sectional view taken along line AA of FIG. 1
  • FIG. 3 is a cross-sectional view taken along line BB of FIG.
  • the catalyst carrier structure (1) comprises a plurality of ceramic wire layers (2) each comprising a plurality of ceramic wires (3) parallel to each other; It works with spacers (4) arranged between each layer of the wire rod layer (2).
  • the exhaust gas G is supplied by the ceramic wire layer (2) and the spacer (4).
  • the formed flow path flows in the direction shown in FIG. That is, when the exhaust gas G flows, it flows between the ceramic wire layers (2) perpendicularly to the axial direction of the ceramic wire (3).
  • the catalyst carrier structure (1) of the present invention the absolute amount and the surface area of the ceramic material family or the functional ceramic material for the catalyst carrier are remarkably reduced as compared with the catalyst carrier structure using the honeycomb substrate of the prior art. Thus, the utilization rate of the active surface of these ceramic materials can be significantly increased.
  • the space volume of these ceramic materials in the unit space volume of the catalyst support structure (1) is significantly increased.
  • Another major factor is that exhaust gas can contact substantially all outer surfaces of the ceramic wire layer (2) and the spacer ( 4 ). That is, in the conventional catalyst carrier structure using the honeycomb substrate, the exhaust gas does not flow near the cell wall of the ceramic material fixed to the honeycomb substrate. Although the exhaust gas does not contact, in the catalyst carrier structure (1) of the present invention, the exhaust gas can contact all the outer surfaces of the ceramic wire layer (2) and the spacer (4).
  • the active area of ceramic wire (3) and spacer (4) can be increased due to less restrictions on the diameter from the viewpoint of manufacturing technology. This is because ceramic wires (3) and spacers (4) can be made much smaller than the cell wall thickness of the honeycomb substrate manufactured by extrusion, and can be as thin as a few meters in diameter. .
  • the material family of the ceramic wire (3) and the spacer (4) is not limited to a material having a low coefficient of thermal expansion, and various materials suitable as a ceramic material for a catalyst carrier or a functional ceramic material. It can be a ceramic material selected from a wide range of oxides and composite oxides. According to the configuration of the present invention, the individual ceramic wires (3) and spacers (4) have a simple shape and a remarkably small volume, so that even if the material has a high coefficient of thermal expansion, it has a low temperature. This is because the thermal stress caused by the fluctuation is extremely small. Therefore, the influence of the heat cycle is small, and the material margin is increased.
  • the catalyst carrier structure (1) of the present invention includes a plurality of ceramic wire layers (2) and a plurality of spacers (4) interposed between the ceramic wire layers (2).
  • the ceramic wire layer (2) is constituted by a plurality of mutually parallel ceramic wire rods (3).
  • the “ceramic wire layer” refers to a “layer” formed by a plurality of ceramic wires (3).
  • Ceramic wire refers to a “wire” formed of a ceramic material, regardless of whether it is linear or curved.
  • spacer refers to a material interposed between the ceramic wire layers (2) for providing a gap between the ceramic wire layers (2), and preferably extends in one direction. It consists of a linear member.
  • the ceramic wire layer (2) is formed by a ceramic material (3) having substantially the same diameter, and similarly, the spacer (4) comprises a wire material having substantially the same diameter, Each of the plurality of ceramic wire layers (2) is arranged substantially parallel to each other via the plurality of spacers (4).
  • the ceramic wire rod (3) is durable in an exhaust gas atmosphere and is formed of any ceramic material suitable as a ceramic material for a catalyst carrier or a functional ceramic material. It may be formed to include.
  • the ceramic wire (3) is made of alumina, zirconia, ceria, zirconia-ceria, alumina-ceria-zirconia, ceria-zirconia-yttria, zirconia-capacitor, perovskite-type composite oxide, It is formed of a ceramic material selected from an aluminate-type composite oxide, a spinel-type composite oxide, or a mixture of these oxide ceramics.
  • the spacer (4) can be formed of any material that is durable in an exhaust gas atmosphere, and can be formed of not only a ceramic material but also a metal material.
  • the spacer (4) like the ceramic wire (3), is made of alumina, zirconia, ceria, di / reconia-ceria, a / remina-ceria-reconia, ceria-zisconnea.
  • the formed ceramic wire (3) and spacer (4) may be the same material or different materials.
  • the ceramic wire (3) is 10 ⁇ ! ⁇ 1mm diameter, more preferred Has a diameter of 20 to 500 m.
  • the diameter of the spacer (4) is appropriately selected in consideration of the pressure loss of the exhaust gas, but is preferably 30 ⁇ ! 33 mm, more preferably 50 111-2111111.
  • the ceramic wire (3) and spacer (4) need not have a precise circular cross section, and the "diameter" of the ceramic wire (3) and spacer (4) is the diameter of the ceramic wire (3). ) Or means the average of the longest and shortest diameters of the cross section perpendicular to the longitudinal direction of the spacer (4).
  • the ceramic wire (3) has a density of 20% to 80% of the theoretical density, more preferably a density of 30% to 70% of the theoretical density, so as to provide a wide loading area for the catalyst component.
  • the porous body has a specific surface area of 1 O m 2 nog or more, more preferably 5 O m 2 "g or more.
  • a ceramic wire (3) for example, an aqueous dispersion slurry of ceramic powder is prepared, and a ceramic precursor and a polymer having high spinnability such as polybutyl alcohol and polyacrylamide are added to the slurry as necessary. Then, the slurry is extruded while being extruded from a nozzle having a diameter of several mm or less to produce an unfired ceramic wire rod (3), which is a ceramic powder compact formed into a linear shape, and then dried and fired.
  • a ceramic precursor and a polymer having high spinnability such as polybutyl alcohol and polyacrylamide
  • the term “ceramic precursor” refers to a substance that forms a ceramic material upon firing, and is suitably a substance that is liquid at room temperature or a substance that forms a liquid solution at room temperature.
  • alumina sol Ceramic sols such as dissoles, or soluble metal compounds such as aluminum nitrate and aluminum chloride.
  • Such a ceramic precursor can enhance the strength and integrity of the ceramic wire (3) obtained by binding and firing the ceramic powder.
  • the diameter, density and specific surface area of the ceramic wire (3) thus obtained can be controlled by the type of the raw material powder, the extrusion speed and the stretching speed, the temperature and the time for firing, and the like.
  • the ceramic wire (3) can be produced, for example, by obtaining a separately prepared ceramic fiber and coating the ceramic fiber with a ceramic material.
  • a ceramic material for example, an aqueous dispersion slurry of a ceramic powder is prepared, and the slurry to which the above-mentioned ceramic precursor is added is coated with ceramic fibers by immersion or the like as necessary.
  • an unfired ceramic wire which is a ceramic powder molded body using ceramic fibers as a core material, is prepared, and then fired to produce a non-fired ceramic wire.
  • the diameter, density, and specific surface area of the ceramic wire (3) thus obtained can be controlled by the raw material powder, coating thickness, firing temperature and time, and the like.
  • the ceramic wire (3) can also be made using metal fibers.
  • the metal fiber is subjected to ceramic spraying, and then, in the same manner as the above-mentioned ceramic fiber, using a slurry containing ceramic powder, an unfired ceramic wire, which is a ceramic powder molded body having metal fiber as a core material And then baking it.
  • the ceramic wire (3) when the ceramic wire (3) is formed by coating a ceramic material on a ceramic fiber or a metal fiber, the ceramic ; the ceramic material outside the fiber or the metal fiber preferably has a theoretical density. It has a density of 20 to 80%, more preferably a density of 30 to 70% of the theoretical density, and preferably has a specific surface area of 10 m 2 Zg or more, more preferably 5 O m It has a specific surface area of 2 / g or more.
  • a ceramic material When a ceramic material is coated on a ceramic fiber, it is preferable to select a ceramic fiber having a density of at least 70% of the theoretical density in order to produce a high-strength ceramic wire (3).
  • the ceramic fiber a commercially available high-strength ceramic fiber made of a material such as alumina, silica, and silicon carbide can be used. Many of these commercially available ceramic fibers are manufactured by a melting method or the like with the aim of obtaining a dense wire without defects, and the specific surface area is generally only 0.1 lm 2 Zg.
  • Spacer (4) uses ceramic powder, ceramic fiber and ceramic powder, or metal fiber and ceramic powder, as in ceramic wire (3), to produce unfired ceramic wires, respectively. Next, it is made by firing. Can be Alternatively, ceramic fibers or metal fibers in some cases can be used as they are as spacers (4).
  • the location of the spacer (4) is not particularly limited as long as the flow path of the exhaust gas G can be secured. However, in order to stabilize the gas flow, it is preferable that the spacer (4) is formed of a linear member and is arranged in parallel with each other at intervals. Further, in order to efficiently make contact between the air gas G and the ceramic wire (3), the spacer (4) is arranged perpendicular to the axial direction of the ceramic wire (3). Is preferred. In this case, the axis of the spacer (4) and the flow direction of the exhaust gas G are the same as shown in FIG.
  • the spacer (4) is shorter than the length of the catalyst support structure (1) as shown in Fig. 5, and reaches the length of the catalyst support structure (1) by a plurality of spacers. That's okay.
  • the catalyst carrier structure (1) of the present invention is composed of a ceramic wire layer (2) made of such a semic wire and a spacer (4).
  • the ceramic wire layer (2) constituting the catalyst carrier structure (1) of the present invention is formed by a plurality of ceramic wires (3) parallel to each other, and these ceramic wires (3) are substantially mutually mutually independent. May be arranged in contact with each other, or may be arranged separately from each other.
  • the ceramic wire layer (2) is used for a lean burn internal combustion engine such as diesel engine. It can exhibit the function of collecting particulates contained in exhaust gas.
  • the contact portion becomes a groove-like depression.
  • turbulent flow of the exhaust gas occurs in the depression between the contacting ceramic wires, and the particulates collide with each other to form a secondary aggregate in which a large number of particulates are aggregated.
  • a local region with extremely low flow velocity occurs in the depression.
  • the particulates are collected as secondary aggregates in local regions where the flow velocity is extremely low.
  • a speed above a certain speed accompanied by exhaust gas above a certain speed Due to its inertial force, the curate collides with the surface of the depression in the region where the flow velocity is extremely low under turbulent flow, adheres to the surface, and is collected.
  • the catalyst carrier structure (1) is composed of the ceramic wire layer (2) by a plurality of ceramic and steel materials substantially in contact with each other and a plurality of mutually separated ceramic wires
  • the catalyst The exhaust gas purifying catalyst prepared by supporting the components can have a region having a particulate trapping function and a region not having the particulate trapping function. For this reason, for example, by carrying a catalyst component that promotes particulate combustion purification in an area that does not have a particulate trapping function upstream of the gas flow, and by placing an area that has a particulate trapping function downstream thereof, that Do possible overall purification design of the exhaust gas purifying catalyst for the purpose of the harmful substances such as particulate and NO x.
  • Such a catalyst carrier structure (1) of the present invention supports a catalyst component such as platinum as required to constitute a catalyst for exhaust gas purification.
  • a catalyst component such as platinum
  • the problem that occurs when the pressure loss of the flowing exhaust gas increases is remarkably reduced.
  • the honeycomb base material having no catalytic ability itself impedes the flow of exhaust gas, resulting in a large pressure loss.
  • no material other than the material capable of supporting the catalyst component is present in the flow path of the exhaust gas, and the flow path of the exhaust gas is connected to the ceramic wire layer (2) and the space. Formed by the spacer (4), the size of this flow path can be adjusted over a wide range by means of the diameter of the spacer and the gap between the spacers so that the pressure drop is sufficiently low. is there.
  • FIG. 1 there is a catalyst carrier structure in which a ceramic wire layer (2) is formed by a plurality of substantially parallel ceramic wire forests (3) extending in one direction.
  • the length of the ceramic wire (3), The length of the spacer (4) and the number of ceramic wire layers ( 2 ) vary depending on the amount of exhaust gas to be treated and the intended purification rate.
  • the length of the Sato spacer (4) is generally 20 to 50 Omm, and the number of ceramic wire layers (2) is roughly a standard of 50 to 100 layers. It is.
  • the shape also differs depending on the exhaust gas treatment amount and the target purification rate.
  • the outer diameter of the circle is 30 to 30 O mm
  • the length of the cylindrical or oval cylinder is 20 to 500 mm
  • the number of ceramic wire layers (2) outward from the center of the circle or oval is Each of the 500 to 100 layers is a rough guide.
  • the axial direction of the ceramic wire (3) is defined by a plane formed by one wound ceramic wire (3). Any direction. Therefore, in the embodiment shown in FIG. 4, the exhaust gas flows in a direction perpendicular to the paper surface.
  • the gap L between the adjacent spacers can be appropriately selected in consideration of the pressure loss of the exhaust gas, and D is the diameter of the spacer (4).
  • L L 20 XD is a rough guide.
  • a plurality of mutually parallel ceramic wires (3) forming the ceramic wire layer (2) can be arranged substantially in contact with each other, or They can be arranged at intervals.
  • the catalyst carrier structure of the embodiment shown in FIG. 1 is integrally formed from the ceramic wire (3) and the spacer (4), for example, for a ceramic wire rod which is formed into a linear shape as described above.
  • a large number of unsintered ceramic wires and a large number of unsintered ceramic wires for a spacer are arranged as shown in Fig. 1 to form a rectangular parallelepiped molded body, and a small number such as 0-l to 100 kPa is obtained.
  • This pressure is applied to the upper surface of the rectangular parallelepiped, and the rectangular parallelepiped compact is uniaxially pressed while firing at a temperature of about 500 ° C. or more.
  • the ceramic precursor contained in the unfired ceramic wire acts as a binder for the ceramic wire and the spacer, and after firing, an integrated catalyst carrier structure (1) can be obtained.
  • a pressure such as 10 kPa to 10 MPa is applied to the upper surface of the rectangular parallelepiped to temporarily uniaxially apply the rectangular compact.
  • deformation can be produced in the ceramic wire and unsintered ceramic wire for spacers to the extent that they interlock with each other, and then, by firing, the more rigid ceramic wire and spacer are pressed.
  • an integral structure can be obtained.
  • an unfired ceramic wire or a fired ceramic wire and a spacer are arranged as shown in FIG. 1, and the rectangular parallelepiped molded body is immersed in the above-mentioned ceramic precursor liquid and then fired, thereby being integrally fired. You can also make it dagger.
  • an unfired ceramic for a ceramic wire processed into a linear shape is used.
  • the wires are arranged in parallel, and an unsintered ceramic wire for a spacer is arranged at a right angle to the unsintered ceramic wire at an interval.Then, with the axial direction of the unsintered ceramic wire for the spacer as an axis, By winding these, a cylindrical or long cylindrical shaped body is produced.
  • the ceramic wire and the spacer are integrated by firing at a temperature of about 500 ° C. or more. be able to.
  • the catalyst carrier structure (1) of the present invention is a structure composed of a ceramic material, but is composed of a ceramic wire (3) having a simple shape and a spacer (4).
  • the production is relatively easy and suitable for industrial production.
  • Such a catalyst support structure (1) of the present invention optionally, platinum, palladium, catalyst component selected from Rojiumu etc., about per mass of the catalyst support structure (1) from 0.2 to 5 weight 0
  • the exhaust gas purifying catalyst may be configured to be carried in the amount of / 0 .
  • This loading can be carried out by a usual evaporative drying method, impregnation method, adsorption method, ion exchange method, reduction precipitation method, or the like.
  • the exhaust gas purifying catalyst including the catalyst carrier structure (1) as described above is loaded on a tubular member (5) and used as an exhaust gas purifying catalyst device (10).
  • Exhaust gas and ceramic In order to secure a contact area with the wire (3), when loading the exhaust gas purifying catalyst into the tubular member, the axis of the tubular member and the surface of the ceramic wire layer (2) are parallel.
  • the ceramic wire (3) is arranged so that the axis of the cylindrical member and the axis of the ceramic wire (3) are perpendicular to each other.
  • the axis of the cylindrical member is the illustrated y-axis
  • the surface of the ceramic wire layer (2) is a yz plane. Therefore, the y-axis (the axis of the cylindrical member) and the yz plane (the plane of the ceramic wire layer (2)) are parallel.
  • the axis of the ceramic wire (3) is the z-axis shown. Therefore, the y-axis (the axis of the cylindrical member) and the z-axis (the axis of the ceramic wire (3)) are perpendicular.
  • the surface of the ceramic wire layer (2) is a substantially cylindrical surface wound around the y-axis. Therefore, the y-axis (the axis of the cylindrical member) is parallel to the substantially cylindrical surface wound around the y-axis.
  • the axial direction of the ceramic wire (3) is an arbitrary direction defined by a plane Z plane formed by a single wound ceramic wire (3). Therefore, the y-axis (the axis of the cylindrical member) and any direction in the Xz plane (the direction of the axis of the ceramic wire (3)) are perpendicular to each other.
  • Such an exhaust gas purifying catalyst device is mounted on a desired exhaust gas flow path of an internal combustion engine such that the y-axis direction is a gas flow path G. That is, in the states shown in FIGS. 3 and 4, the exhaust gas flows in a direction perpendicular to the paper surface.
  • the gas purification method according to the present invention is characterized in that, when the exhaust gas is circulated between the ceramic wire layers, the exhaust gas is circulated perpendicularly to the axial direction of the ceramic wire.
  • Example 1 the present invention will be described based on examples, but the present invention is not limited to these examples.
  • Example 1 the present invention is not limited to these examples.
  • ⁇ -alumina powder (specific surface area: 19 Om 2 / g) is dispersed in ion-exchanged water, and alumina sol and an aqueous solution of polyacrylamide having a molecular weight of about 1,000,000 are added to the dispersion to make ⁇ -alumina powder about 30% by mass.
  • alumina sol about 10 wt% as a solid content
  • poly acrylamide about 0.1 weight 0/0 containing slurry one was prepared.
  • the slurry was extruded from a hole having a diameter of 1 mm while being extruded and cut, and a large number of unfired ceramic wires having a diameter of about 50 ⁇ and a length of 50 mm were prepared for a ceramic wire.
  • this slurry was extruded while stretching from a hole with a diameter of lmm at a stretching speed lower than that of the unfired ceramic wire, and then cut.
  • unfired ceramic wire rods Of unfired ceramic wire rods. Then, about 2,000 unfired ceramic wires having a diameter of about 50 imX and a length of 50 mm were contacted in parallel and arranged at a width of 10 Omm to form a first unfired ceramic wire layer having a size of 5 OmmX 10 Omm. .
  • the first unsintered ceramic wire layer was arranged on the entirety of the first unsintered ceramic wire layer with an interval of mm.
  • a second unfired ceramic wire layer is formed on the unfired ceramic wire for the spacer in the same manner as the first unfired ceramic wire layer, and a spacer is further formed thereon.
  • Unfired ceramic wires were placed at intervals of 1 mm, and these operations were repeated until the height reached 5 Omm, thereby producing a rectangular parallelepiped structure having a size of 5 OmmX10 OmmX50 mm.
  • Example 3 The catalyst support structure obtained in Example 1 was impregnated with an aqueous solution of a dutrodiammine platinum complex in an amount of 0.1% by mass as platinum, dried, and calcined in an air atmosphere to remove the catalyst component platinum.
  • the supported exhaust gas purifying catalyst of the present invention was obtained.
  • ⁇ / -Alumina and alumina sol were dispersed in ion-exchanged water to prepare a slurry containing about 30% by mass of T / -alumina and 10% by mass of alumina sol as a solid content.
  • Theoretical density is 98. /.
  • Alumina fiber with a diameter of about 30 ⁇ m is immersed in this slurry and dried, coated with ceramic material on the alumina fiber, cut, and used for ceramic wire rods. An unfired ceramic wire was created.
  • the above alumina fiber with a diameter of about 30 // m is repeatedly immersed and dried in the above slurry, coated with a ceramic material, cut and then used as a spacer for a diameter of about 350 A number of unfired ceramic wires with mX length of 100 mm were produced.
  • Example 4 In the same manner as in Example 1 except that these unfired ceramic wires for the ceramic wire layer and the unfired ceramic wires for the spacer were used, a rectangular parallelepiped structure having a size of about 5 OmmX 100 mmX 50 mm was used. After the body was prepared, it was fired to obtain the catalyst carrier structure of the present invention in the embodiment shown in FIG. Example 4
  • Example 5 To the catalyst carrier structure obtained in Example 3, 0.1 mass of palladium was evaporated to dryness using an aqueous solution of palladium nitrate. /. , And then calcined in an air atmosphere to carry palladium to obtain an exhaust gas purifying catalyst of the present invention.
  • Example 5 To the catalyst carrier structure obtained in Example 3, 0.1 mass of palladium was evaporated to dryness using an aqueous solution of palladium nitrate. /. , And then calcined in an air atmosphere to carry palladium to obtain an exhaust gas purifying catalyst of the present invention.
  • the green ceramic wire A catalyst carrier structure of the present invention was obtained in the same manner as in Example 1 except that phenol was used. The invention's effect
  • the utilization rate of the active surface of the catalyst carrier ceramic material or the functional ceramic material is significantly increased, and thereby the purification performance of the exhaust gas purification catalyst is significantly improved.
  • a catalyst support structure can be provided.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Structural Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Analytical Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Environmental & Geological Engineering (AREA)
  • Biomedical Technology (AREA)
  • Toxicology (AREA)
  • Processes For Solid Components From Exhaust (AREA)
  • Filtering Of Dispersed Particles In Gases (AREA)
  • Catalysts (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)

Abstract

L'invention concerne un corps structural de support catalytique (1) permettant une utilisation efficace de la surface active d'un matériau céramique de support catalytique ou d'un matériau céramique fonctionnel pour augmenter, de manière remarquable, les performances de purification d'émission de gaz d'échappement d'un catalyseur destiné à purifier une émission de gaz d'échappement. Ledit corps structural de support catalytique (1) comprend une pluralité de couches de matériaux constitués de fils céramiques (2) présentant une pluralité de matériaux constitués de fils céramiques (3) parallèles entre eux, et des espaceurs (4) disposés entre les couches de matériaux constitués de fils céramiques (2). Lors de l'utilisation du catalyseur destiné à purifier une émission d'échappement et faisant appel audit corps structural de support catalytique (1), une émission de gaz d'échappement doit de préférence circuler de manière verticale par rapport à la direction axiale des matériaux constitués de fils céramiques (3) lorsque l'émission de gaz d'échappement s'effectue entre les couches de matériaux constitués de fils céramiques (2).
PCT/JP2002/003439 2001-04-06 2002-04-05 Corps structural de support catalytique WO2002083309A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
PCT/JP2002/010219 WO2003045553A1 (fr) 2001-11-20 2002-10-01 Corps structural d'un support catalytique, procede de fabrication du corps structural, catalyseur et procede de controle d'emission de gaz d'echappement
AU2002343939A AU2002343939A1 (en) 2001-11-20 2002-10-01 Catalyst carrier structural body and method of manufacturing the structural body, and catalyst and method for exhaust emission control

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JP2001-143942 2001-04-06
JP2001143942 2001-04-06
JP2001-392819 2001-11-20
JP2001392819 2001-11-20

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2719371C1 (ru) * 2018-05-08 2020-04-17 Тойота Дзидося Кабусики Кайся Конструкция катализатора

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JPS5973053A (ja) * 1982-10-15 1984-04-25 Matsushita Electric Ind Co Ltd 触媒担体
JPS63302953A (ja) * 1987-05-30 1988-12-09 Aichi Steel Works Ltd 排気ガス触媒用金属担体
JPH07158433A (ja) * 1993-12-06 1995-06-20 Yutaka Giken Co Ltd 排ガスの浄化装置
JPH11267520A (ja) * 1998-03-23 1999-10-05 Petroleum Energy Center Found 触媒担体
JPH11290695A (ja) * 1998-04-10 1999-10-26 Sumitomo Electric Ind Ltd 光触媒フィルタ

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Publication number Priority date Publication date Assignee Title
JPH084696B2 (ja) * 1993-07-09 1996-01-24 日本金網商工株式会社 金網製積層フィルター及びその製造方法
EP0884457B1 (fr) * 1997-06-12 2003-09-03 Kabushiki Kaisha Toyota Chuo Kenkyusho Filtre de particules
JP2000130150A (ja) * 1998-10-26 2000-05-09 Isuzu Ceramics Res Inst Co Ltd デイーゼル機関の排気微粒子フイルタ

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Publication number Priority date Publication date Assignee Title
JPS5973053A (ja) * 1982-10-15 1984-04-25 Matsushita Electric Ind Co Ltd 触媒担体
JPS63302953A (ja) * 1987-05-30 1988-12-09 Aichi Steel Works Ltd 排気ガス触媒用金属担体
JPH07158433A (ja) * 1993-12-06 1995-06-20 Yutaka Giken Co Ltd 排ガスの浄化装置
JPH11267520A (ja) * 1998-03-23 1999-10-05 Petroleum Energy Center Found 触媒担体
JPH11290695A (ja) * 1998-04-10 1999-10-26 Sumitomo Electric Ind Ltd 光触媒フィルタ

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2719371C1 (ru) * 2018-05-08 2020-04-17 Тойота Дзидося Кабусики Кайся Конструкция катализатора

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