WO2007040348A1 - Support catalytique en céramique - Google Patents

Support catalytique en céramique Download PDF

Info

Publication number
WO2007040348A1
WO2007040348A1 PCT/KR2006/004008 KR2006004008W WO2007040348A1 WO 2007040348 A1 WO2007040348 A1 WO 2007040348A1 KR 2006004008 W KR2006004008 W KR 2006004008W WO 2007040348 A1 WO2007040348 A1 WO 2007040348A1
Authority
WO
WIPO (PCT)
Prior art keywords
cell
catalyst support
cross
section
catalyzer
Prior art date
Application number
PCT/KR2006/004008
Other languages
English (en)
Inventor
Sang Wook Lee
Original Assignee
Sang Wook Lee
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 Sang Wook Lee filed Critical Sang Wook Lee
Priority claimed from KR1020060097651A external-priority patent/KR20070038021A/ko
Publication of WO2007040348A1 publication Critical patent/WO2007040348A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
    • B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2803—Construction of catalytic reactors characterised by structure, by material or by manufacturing of catalyst support
    • F01N3/2825—Ceramics
    • F01N3/2828—Ceramic multi-channel monoliths, e.g. honeycombs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/06—Ceramic, e.g. monoliths
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/30—Honeycomb supports characterised by their structural details
    • F01N2330/34—Honeycomb supports characterised by their structural details with flow channels of polygonal cross section

Definitions

  • the present invention generally relates to a ceramic catalyst support, and more particularly to a ceramic catalyst support wherein corners of a cell partition are roundly formed for efficient application of catalytic layer on the inner surface of cells while improving the structural strength.
  • a ceramic catalyst support is generally used as a filter to remove impurities of gas or liquid. It can also be used as a catalytic structure to purify harmful gas or liquid by chemical reaction as well as to discharge harmless gas or liquid.
  • the inner surfaces of each cell partition of the ceramic catalyst support are coated with catalyzer to oxidize or deoxidize said fluid passing therethrough.
  • the ceramic catalyst support coated with the oxidization or deoxidization catalyst is used as a catalyst, wherein catalysis occurs on the surface of its pipe through which the fluid passes.
  • it is used as a catalyst or filter of wall flow type.
  • such ceramic catalyst support is used for purifying liquid for purposes of VOC (Volatile organic compounds) or water-purity control. It can also be used for purifying gas such as exhaust gas of a vehicle.
  • the type of catalyzer can be selected depending on the use of the catalyst support.
  • the above catalyst support can be used with an exhaust system of a vehicle.
  • a catalytic converter can be attached to the exhaust pipe.
  • a ceramic catalyst support which is applied with a catalyzer on the inner surfaces of each cell partition, can be used as the converter.
  • the catalytic converter can be an oxidizing converter, which oxidizes carbon monoxide (CO) and hydro carbon (HC) into carbon dioxide (CO ) and water (H O).
  • it can be a deoxidizing converter, which deoxidizes nitrogen oxide (NO ) into nitrogen (N ) and oxygen (O ).
  • NO nitrogen oxide
  • N nitrogen
  • O oxygen
  • a back pressure preferably becomes low according to the same exhaust gas contact area. This is because the higher the exhaust pressure, the lower the engine power output will be during the exhaust process.
  • each cell in such ceramic catalyst support may be a circular shape or a polygonal shape such as triangle, quadrangle, hexagon or the like.
  • Figs. 1 and 3 are cross-sectional views illustrating a prior art ceramic catalyst support, wherein the cell partitions have quadrangled and hexagonal cross-sections. Further, Figs. 2 and 4 are cross-sectional views illustrating that a catalytic layer is formed by applying catalyzer on the inner surface of the cell partition shown in Figs. 1 and 3.
  • the prior art ceramic catalyst support includes quadrangle- shaped cell partitions 1 and a through-hole 2 surrounded by the cell partition.
  • the catalyzer is applied upon the inner surfaces 3 of such partitioned structure to thereby form a catalytic layer 4.
  • the cross-section of the through-hole 12 in the cell partition 11 has a hexagonal shape to thereby alleviate the cohesiveness of the catalyzer at the corner portions 15 of the catalytic layer 14.
  • the corner portions 15 of the catalytic layer 14 are still thicker than the side portions 16 thereof since the cross-sectioned shape of the cell partition surface 13 is hexagonal. In other words, so long as the cross- sectioned shape of the cell partition surface is polygonal, it is inevitable that the corner portions 15 of the catalytic layer 14 are thicker than the side portions 16 thereof.
  • FIG. 5 is a cross-sectional view of the catalytic layer where the catalyzer is applied on the circular cell partitions according to the prior art.
  • the thickness of the catalytic layer 24 may be uniform around the through-hole.
  • the thickness of the cell partition 21 will not be uniform.
  • a circular cell has the disadvantage of higher back pressure compared with the polygonal cell when the cells have the same area. Disclosure of Invention
  • the object of the present invention is to provide a ceramic catalyst support, wherein the cross-section of each cell is in a shape of a polygon and the corners of a partition of each cell are roundly formed, thereby maximizing a through-hole area while not wasting the catalyzer.
  • Another object of the present invention is to provide a ceramic catalyst support, which is structurally reinforced and has the same cross-sectional area of the through- hole by roundly forming the structurally fragile corner portions of the partition.
  • the present invention provides a ceramic catalyst support comprising partitions and a number of cells defined by such partitions, each of which has a polygonal cross-section with rounded corners.
  • the present invention further provides a catalyst support having a number of cells arranged parallel to each other and forming a plurality of cell rows when observed from the cross-sectional view of the catalyst support. It is preferable that the plurality of cell rows are arranged in such a manner that a center of each cell in one cell row and each partition between two adjacent cells in another cell row adjacent to the one cell row correspond to each other.
  • the cross-section of each cell may be a triangle, e.g., right, regular or isosceles triangle, etc. In the case of rectangular cross-section, such configured arrangement is particularly effective in terms of structural strength.
  • each cell is hexagonal so that the cells are arranged in a honeycomb structure.
  • the present invention is efficient since it can reduce the waste of an expensive catalyzer by using the rounded cell corners of a ceramic catalyst support, which has a generally polygonal cell cross-section.
  • the present invention can further maximize the total area of the through-holes while preventing the cohesiveness of excessive catalyzer at the corner.
  • the present invention is further efficient in that the weak portion is reinforced since the corners of a cell, on which the stress is concentrated, are thicker than the previous ones.
  • the present invention is additionally efficient in that although the cell cross-section is rectangular, the catalyst support can stand cleavage in a special direction by the zigzag arrangement of the cells as the brickwork.
  • Fig. 1 is a cross-sectional view illustrating the cell partitions of a ceramic catalyst support having a quadrangle cross-section according to the prior art.
  • Fig. 2 is a cross-sectional view illustrating that the catalytic layer is formed on the inner surface of the cell partition shown in Fig. 1 by applying a catalyzer thereon.
  • Fig. 3 is a cross-sectional view illustrating the cell partitions of the ceramic catalyst support having a hexagonal cross-section according to the prior art.
  • Fig. 4 is a cross-sectional view illustrating that the catalytic layer is formed on the inner surface of the cell partition shown in Fig. 3 by applying a catalyzer thereon.
  • FIG. 5 is a cross-sectional view of the catalytic layer wherein the catalyzer is applied on a circular cell partitions according to the prior art.
  • FIG. 6 is a cross-sectional view of an embodiment of the present invention, which illustrates the cell partitions of the ceramic catalyst support having a quadrangle cross- section.
  • Fig. 7 is a cross-sectional view illustrating that the catalytic layer is formed on the inner surface of the cell partition shown in Fig. 6 by applying a catalyzer thereon.
  • Fig. 8 is a cross-sectional view illustrating a zigzag arrangement of the rectangular cells.
  • FIG. 9 is a cross-sectional view of another embodiment of the present invention, which illustrates the cell partitions of the ceramic catalyst support having a hexagonal cross-section.
  • Fig. 10 is a cross-sectional view illustrating that the catalytic layer is formed on the inner surface of the cell partition shown in Fig. 9 by applying a catalyzer thereon. Best Mode for Carrying Out the Invention
  • Fig. 6 is a cross-sectional view of an embodiment of the present invention, which illustrates the cell partitions of a ceramic catalyst support having a quadrangle cross- section.
  • Fig. 7 is a cross-sectional view illustrating that the catalytic layer is formed on the inner surface of the cell partition shown in Fig. 6 by applying a catalyzer thereon.
  • Fig. 8 is a cross-sectional view illustrating the zigzag arrangement of the rectangular cells, wherein each cell in one cell row and each cell in another adjacent cell row are arranged in a zigzag configuration.
  • the catalyst support has rectangular cells. Further, the rectangular cross-sectioned cell partitions 101 with rounded corners form through-holes 102.
  • the catalyst support of the present invention also has catalytic layers 104 formed by a catalyzer such as an oxidizing or deoxidizing agent applied upon the inner surface 103 of the through-holes 102 surrounded by the cell partitions. As such, the catalyst support of the present invention can purify the fluid passing through the through-holes 102 of the cells.
  • the structure having a cell with a polygonal cross-section is not isotropic. Thus, it does not satisfy the structural compatibility condition. Specifically, as shown in Figs. 6 and 7, if the cross-sections of the inner surface 103 of the cell partitions are rectangular and the cells are arranged in a check pattern, then the catalyst support has a low structural compatibility. As such, it should be weak in some directions, as is apt to split up in a horizontal or vertical direction in Figs. 6 and 7.
  • the cross-sectional shape of the inner surface 113 of cell partitions 111, through-hole 112 and catalytic layer 114 are identical to the embodiment shown in Figs. 6 and 7.
  • this embodiment arranges the cell rows to be zigzag like brickwork such that the cells in each cell row and the cells in adjacent cell rows are in a zigzag configuration. That is, the number of cell rows is placed in such a manner that each center of the cells in one cell row corresponds to the partitions between the two adjacent cells in other cell rows adjacent to the one cell row.
  • Such cell arrangement makes the catalyst support more approximate to the compatibility condition compared to the check-patterned arrangement, as shown in Figs. 6 and 7. For example, it is more difficult to split up in a zigzag direction of the cells.
  • Fig. 9 is a cross-sectional view of another embodiment of the present invention, which illustrates the cell partitions of the ceramic catalyst support having a hexagonal cross-section.
  • Fig. 10 is a cross-sectional view illustrating that the catalytic layer is formed on the inner surface of the cell partition shown in Fig. 9 by applying a catalyzer thereon.
  • the embodiment shown in Figs. 9 and 10 is essentially identical to the embodiment shown in Figs. 6 and 7.
  • the cross-section of cells is formed to be hexagonal. That is, the through-hole 122 is formed by the hexagonal inner surface 123 of the cell partitions 121 with rounded corners, wherein the catalytic layer 124 formed by applying the catalyzer upon the inner surface 123 of the partitions is disposed.
  • the catalyzer of the catalytic layer can be selected from an oxidizing agent, deoxidizing agent or both depending on the type of fluid that must be purified.
  • the rounded corner means purposely forming the corners rounded with a specific curvature in order to substantially alleviate the accumulation of catalyzer at the corners. This is so that it is very different from the conventional rounding or tolerance in manufacturing. Further, the radius and range of curvature of cell corners are larger than those of common rounding or tolerance inevitably obtained in manufacturing. To uniform the thickness of the catalytic layer at both the corner and side of the cell as well as to maximize the through-hole area, the radius and range of curvature can be varied according to the size of the cell, the amount of the catalyzer, the applying position, the method of the catalyzer application, etc.
  • the cross-sections of the cells are rectangular or hexagonal in the above embodiments, the present invention should not be limited by such example.
  • the cross-section can be a triangle such as a regular, isosceles or right triangle, or other polygonal shapes that can form a pattern.
  • each cell does not have a sharp corner so that the cohesiveness of the catalyzer caused by the viscosity does not occur and the thickness of the sides 106, 116, 126 and corners 105, 115, 125 of the catalytic layers 104, 114, 124 are uniform. Therefore, the expensive catalyzer would not be wasted unnecessarily and the contact area of the through-holes 102, 112, 122, which the fluid passes through, can be maximized so that the fluid can be purified efficiently.
  • the catalyst support on which a number of the polygonal cells are arranged, is not isotropic to the external force.
  • the structural characteristic can be improved by arranging the rectangular cells to be zigzag or by forming the cell cross-section to be hexagonal.
  • the catalyst support can be sized from tens of CPSI (Cells Per Square Inch) to about 1200 CSPI according to the purpose at hand.
  • CPSI Cells Per Square Inch
  • the catalyst support with hexagonal cell relatively has the compatibility condition close to the isotropic material, which can achieve lighter and more efficient catalyst support. However, it is somewhat complex for precise manufacturing.
  • the catalyst support with rectangular cells has low compatibility while it is relatively easy to manufacture. Therefore, the manufacturer must select an optimal cell cross-section by considering both use and cost.
  • the catalyst support structure which is constructed in accordance with the present invention, can be manufactured by extrusion, the process of which includes feeding ceramic materials to an extruder and extruding the materials in a mold, the cross- section of which corresponds to the above-mentioned cell cross-section, so as to form continuous patterns.
  • the rounded corner means that the cell cross-section is still generally polygonal, while the cross-section of cells involves the shapes formed by cutting the corner obliquely to the partitions. Further, it involves the shapes formed by numerously cutting the corner obliquely to the partitions so as to form an arc shape, or cutting the corner in the shape of an arc.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Ceramic Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • Toxicology (AREA)
  • Health & Medical Sciences (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Catalysts (AREA)
  • Exhaust Gas After Treatment (AREA)

Abstract

La présente invention vise à produire un support catalytique en céramique, dans lequel la section transversale de chaque alvéole a une forme polygonale et les angles des cloisons d'alvéoles sont de forme arrondie de façon à accroître la surface de canal et l'efficacité du catalyseur. Pour remplir l'objectif visé, l'invention propose un support catalytique comprenant des cloisons qui déterminent un certain nombre d'alvéoles, chacune de ces alvéoles possédant une section transversale polygonale à coins arrondis.
PCT/KR2006/004008 2005-10-04 2006-10-04 Support catalytique en céramique WO2007040348A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
KR20050092749 2005-10-04
KR10-2005-0092749 2005-10-04
KR10-2006-0097651 2006-10-04
KR1020060097651A KR20070038021A (ko) 2005-10-04 2006-10-04 세라믹 담체

Publications (1)

Publication Number Publication Date
WO2007040348A1 true WO2007040348A1 (fr) 2007-04-12

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ID=37906371

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/KR2006/004008 WO2007040348A1 (fr) 2005-10-04 2006-10-04 Support catalytique en céramique

Country Status (1)

Country Link
WO (1) WO2007040348A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011121562A1 (fr) * 2010-04-01 2011-10-06 Basf Se Procédé de préparation de monolithes recouverts
WO2013082336A1 (fr) * 2011-11-30 2013-06-06 Corning Incorporated Substrat catalytique de traversée comprenant des canaux d'écoulemen possédant des parties d'angle chanfreinées et procédés de fabrication correspondant
JP2016084775A (ja) * 2014-10-28 2016-05-19 イビデン株式会社 電気加熱式触媒コンバータ
US9808794B2 (en) 2013-09-23 2017-11-07 Corning Incorporated Honeycomb ceramic substrates, honeycomb extrusion dies, and methods of making honeycomb ceramic substrates

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4335023A (en) * 1980-01-24 1982-06-15 Engelhard Corporation Monolithic catalyst member and support therefor
JPH07124428A (ja) * 1993-11-08 1995-05-16 Noritake Co Ltd モノリス型セラミックフィルター
US5714228A (en) * 1995-12-18 1998-02-03 General Motors Corporation Ceramic catalytic converter substrate
EP1184077A1 (fr) * 2000-08-30 2002-03-06 Haldor Topsoe A/S Particules de catalyseur d'hydrotraitement
JP2003269132A (ja) * 2002-03-13 2003-09-25 Ngk Insulators Ltd 排ガス浄化用フィルター

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4335023A (en) * 1980-01-24 1982-06-15 Engelhard Corporation Monolithic catalyst member and support therefor
JPH07124428A (ja) * 1993-11-08 1995-05-16 Noritake Co Ltd モノリス型セラミックフィルター
US5714228A (en) * 1995-12-18 1998-02-03 General Motors Corporation Ceramic catalytic converter substrate
EP1184077A1 (fr) * 2000-08-30 2002-03-06 Haldor Topsoe A/S Particules de catalyseur d'hydrotraitement
JP2003269132A (ja) * 2002-03-13 2003-09-25 Ngk Insulators Ltd 排ガス浄化用フィルター

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2011121562A1 (fr) * 2010-04-01 2011-10-06 Basf Se Procédé de préparation de monolithes recouverts
CN102933299A (zh) * 2010-04-01 2013-02-13 巴斯夫欧洲公司 制备经涂覆的整料的方法
US9550180B2 (en) 2010-04-01 2017-01-24 Basf Se Process for the preparation of coated monoliths
EP3673998A1 (fr) * 2010-04-01 2020-07-01 Basf Se Monolithes revêtus
WO2013082336A1 (fr) * 2011-11-30 2013-06-06 Corning Incorporated Substrat catalytique de traversée comprenant des canaux d'écoulemen possédant des parties d'angle chanfreinées et procédés de fabrication correspondant
US8865084B2 (en) 2011-11-30 2014-10-21 Corning Incorporated Pass-through catalytic substrate including porous ceramic beveled corner portions and methods
CN104245134A (zh) * 2011-11-30 2014-12-24 康宁股份有限公司 包含具有斜面角的流动通道的流通催化基材以及制造方法
US8992821B2 (en) 2011-11-30 2015-03-31 Corning Incorporated Pass-through catalytic substrate including porous ceramic beveled corner portions and methods
CN104245134B (zh) * 2011-11-30 2016-11-16 康宁股份有限公司 包含具有斜面角的流动通道的流通催化基材以及制造方法
US9808794B2 (en) 2013-09-23 2017-11-07 Corning Incorporated Honeycomb ceramic substrates, honeycomb extrusion dies, and methods of making honeycomb ceramic substrates
JP2016084775A (ja) * 2014-10-28 2016-05-19 イビデン株式会社 電気加熱式触媒コンバータ

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