WO2014115420A1 - 触媒コンバーター - Google Patents
触媒コンバーター Download PDFInfo
- Publication number
- WO2014115420A1 WO2014115420A1 PCT/JP2013/081729 JP2013081729W WO2014115420A1 WO 2014115420 A1 WO2014115420 A1 WO 2014115420A1 JP 2013081729 W JP2013081729 W JP 2013081729W WO 2014115420 A1 WO2014115420 A1 WO 2014115420A1
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- WIPO (PCT)
- Prior art keywords
- length
- catalyst layer
- catalytic converter
- cell density
- longitudinal direction
- Prior art date
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- 230000003197 catalytic effect Effects 0.000 title claims abstract description 44
- 239000003054 catalyst Substances 0.000 claims abstract description 91
- 210000004027 cell Anatomy 0.000 claims abstract description 72
- 230000002093 peripheral effect Effects 0.000 claims abstract description 60
- 239000000758 substrate Substances 0.000 claims abstract description 28
- 210000002421 cell wall Anatomy 0.000 claims abstract description 23
- 229910000510 noble metal Inorganic materials 0.000 claims abstract description 8
- 239000000463 material Substances 0.000 claims description 58
- 239000007789 gas Substances 0.000 abstract description 55
- RWSOTUBLDIXVET-UHFFFAOYSA-N Dihydrogen sulfide Chemical compound S RWSOTUBLDIXVET-UHFFFAOYSA-N 0.000 abstract description 21
- 229910000037 hydrogen sulfide Inorganic materials 0.000 abstract description 21
- 239000000470 constituent Substances 0.000 abstract description 2
- 239000010410 layer Substances 0.000 description 113
- 230000000052 comparative effect Effects 0.000 description 15
- 238000000746 purification Methods 0.000 description 15
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 5
- 238000010586 diagram Methods 0.000 description 5
- 238000002474 experimental method Methods 0.000 description 5
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 5
- 230000001629 suppression Effects 0.000 description 5
- 238000012360 testing method Methods 0.000 description 5
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 229910010293 ceramic material Inorganic materials 0.000 description 4
- 229910052763 palladium Inorganic materials 0.000 description 4
- 229910052697 platinum Inorganic materials 0.000 description 4
- 239000002131 composite material Substances 0.000 description 3
- 229910052878 cordierite Inorganic materials 0.000 description 3
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 3
- 238000005485 electric heating Methods 0.000 description 3
- 238000000034 method Methods 0.000 description 3
- 229910052703 rhodium Inorganic materials 0.000 description 3
- 239000010948 rhodium Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 239000000395 magnesium oxide Substances 0.000 description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 2
- 239000007769 metal material Substances 0.000 description 2
- 235000019645 odor Nutrition 0.000 description 2
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 2
- 239000010970 precious metal Substances 0.000 description 2
- 238000004904 shortening Methods 0.000 description 2
- 229910010271 silicon carbide Inorganic materials 0.000 description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- 235000012239 silicon dioxide Nutrition 0.000 description 2
- 239000012855 volatile organic compound Substances 0.000 description 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 230000003213 activating effect Effects 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 description 1
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 230000003203 everyday effect Effects 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- -1 silicon carbide Chemical compound 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 239000011206 ternary composite Substances 0.000 description 1
- 239000002912 waste gas Substances 0.000 description 1
Images
Classifications
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- B01J35/56—
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- 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
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
- B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
- B01J23/42—Platinum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation 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
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation 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
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
- B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
- B01D53/9445—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC]
- B01D53/945—Simultaneously removing carbon monoxide, hydrocarbons or nitrogen oxides making use of three-way catalysts [TWC] or four-way-catalysts [FWC] characterised by a specific catalyst
-
- 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
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
- B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
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- 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
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
- B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
- B01J23/46—Ruthenium, rhodium, osmium or iridium
- B01J23/464—Rhodium
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- 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
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
- B01J23/54—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
- B01J23/56—Platinum group metals
- B01J23/63—Platinum group metals with rare earths or actinides
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- B01J35/19—
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/02—Impregnation, coating or precipitation
- B01J37/024—Multiple impregnation or coating
- B01J37/0244—Coatings comprising several layers
-
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01D2255/902—Multilayered catalyst
- B01D2255/9022—Two layers
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- B01D2255/903—Multi-zoned catalysts
- B01D2255/9032—Two zones
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2330/00—Structure of catalyst support or particle filter
- F01N2330/30—Honeycomb supports characterised by their structural details
- F01N2330/48—Honeycomb supports characterised by their structural details characterised by the number of flow passages, e.g. cell density
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2510/00—Surface coverings
- F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction
- F01N2510/068—Surface coverings for exhaust purification, e.g. catalytic reaction characterised by the distribution of the catalytic coatings
- F01N2510/0682—Surface coverings for exhaust purification, e.g. catalytic reaction characterised by the distribution of the catalytic coatings having a discontinuous, uneven or partially overlapping coating of catalytic material, e.g. higher amount of material upstream than downstream or vice versa
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2510/00—Surface coverings
- F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction
- F01N2510/068—Surface coverings for exhaust purification, e.g. catalytic reaction characterised by the distribution of the catalytic coatings
- F01N2510/0684—Surface coverings for exhaust purification, e.g. catalytic reaction characterised by the distribution of the catalytic coatings having more than one coating layer, e.g. multi-layered coatings
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- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
Definitions
- the present invention relates to a catalytic converter that is housed and fixed in a pipe constituting an exhaust gas exhaust system.
- a catalytic converter for purifying exhaust gas is generally provided in an exhaust gas exhaust system connecting the vehicle engine and the muffler.
- Engines may emit substances that are harmful to the environment, such as CO, NOx, unburned HC, and VOCs.
- Catalysts made of precious metal catalysts such as palladium and platinum to convert these harmful substances into acceptable substances
- the layer is formed on the cell wall surface of the substrate having a large number of cells. More specifically, on the cell wall surface of a large number of cells, a catalyst layer is formed in the longitudinal direction of the base material and in the direction in which the exhaust gas circulates. By passing the exhaust gas through the gas, CO is converted to CO 2 , NOx is converted to N 2 and O 2 , and VOC is burned to generate CO 2 and H 2 O.
- a catalytic converter in which the cell density of the base material is uniform is common, but the exhaust gas flow velocity distribution in the central region of the cross section of the base material is larger than that in the peripheral region. Since it becomes high, there exists a subject that the catalyst layer of the whole base material is not fully utilized. Therefore, considering the flow velocity distribution of the exhaust gas, a difference in flow velocity distribution in the cross section of the substrate is made possible by using a catalytic converter having a cell density in the central region higher than that in the peripheral region of the substrate. It is possible to reduce the amount of exhaust gas, and it is possible to perform exhaust gas purification that effectively uses the catalyst layer of the entire catalytic converter.
- Patent Document 1 discloses that a catalytic converter (here, a catalyst body) has a uniform cell density as a whole, for example, a honeycomb structure base material, a central region (here central portion) and a peripheral region (here). Discloses a technique for improving exhaust gas purification performance by changing the amount of noble metal catalyst supported on the outer periphery. More specifically, among the catalyst bodies, the amount of catalyst per unit volume carried in the central part where the gas flow is large is 1.1 times or more that of the outer peripheral part.
- the present invention has been made in view of the above-described problems, and can effectively purify exhaust gas by effectively utilizing the entire catalyst constituting the catalytic converter, and can further suppress the release of hydrogen sulfide.
- the purpose is to provide.
- the catalytic converter according to the present invention is a catalytic converter in which a catalyst layer made of a noble metal catalyst is formed in the longitudinal direction of the base material through which gas flows on the cell wall surface of the base material of the cell structure,
- the substrate is composed of a central region having a relatively high cell density and a peripheral region having a relatively low cell density, and the longitudinal lengths of the catalyst layers in the central region and the peripheral region are the same, or The length in the longitudinal direction of the catalyst layer in the peripheral region is shorter than that in the central region.
- a substrate having a large number of cells is composed of a central region and a peripheral region having different cell densities, and the cell density in the central region is relatively high, whereby a uniform cell density is achieved.
- the difference in the flow velocity distribution of the exhaust gas between the central region and the peripheral region can be reduced as compared with the material, and exhaust gas purification can be performed by effectively utilizing the entire catalyst constituting the catalytic converter.
- the lengths in the longitudinal direction of the catalyst layers in the central region and the peripheral region are the same or longer than the central region in the longitudinal direction of the catalyst layer in the peripheral region.
- the cell density in the central region is relatively high with respect to the substrate having a uniform cell density per unit volume.
- the amount of exhaust gas flowing into the peripheral area having a relatively low density increases.
- the length of the catalyst layer formed in the longitudinal direction of the substrate on the cell wall surface is set at various ratios relative to the length of the substrate in the longitudinal direction
- a peripheral region having a low cell density is compared with a base material having a uniform cell density. Therefore, the amount of exhaust gas flowing in (the amount of exhaust gas to be purified) is large, and therefore sufficient purification performance cannot be obtained.
- the contact area between the catalyst layer and the exhaust gas in the peripheral region is increased by increasing the longitudinal length of the catalyst layer in the peripheral region as compared to the central region.
- the exhaust gas purification performance can be improved.
- the precious metal catalyst has a problem that hydrogen sulfide that causes bad odor is easily released in the process of purifying exhaust gas. Therefore, the amount of hydrogen sulfide discharged increases as the length of the catalyst layer increases. That is, the exhaust gas purification performance and the hydrogen sulfide emission suppression performance are in a trade-off relationship.
- the longitudinal lengths of the catalyst layers in the central region and the peripheral region are the same or in the central region. In comparison, the length in the longitudinal direction of the catalyst layer in the peripheral region is shortened.
- the catalyst layer formed on the cell wall surface has a two-layer structure composed of a lower layer on the cell wall side and an upper layer above the cell wall side, and each layer is any one of Pd, Pt and Rh which are noble metal catalysts or Forms formed from two or more types can be applied.
- the base material of the cell structure to be used in addition to ceramic materials such as cordierite and silicon carbide composed of a composite oxide of magnesium oxide, aluminum oxide and silicon dioxide, other than ceramic materials such as metal materials Material may be used.
- a so-called honeycomb structure having a large number of lattice contour cells such as a quadrangle, a hexagon, and an octagon can be applied.
- the ratio of the catalyst layer there can be mentioned a catalytic converter in which the ratio of the length in the longitudinal direction of the catalyst layer in the central region to the length in the longitudinal direction of the base material is 70% to 90%.
- the ratio of the length in the longitudinal direction of the catalyst layer in the central region to the length in the longitudinal direction of the substrate is 80%, and the length in the longitudinal direction of the substrate
- a catalytic converter having a form in which the ratio of the length in the longitudinal direction of the catalyst layer in the peripheral region is 50 to 80% can be given.
- the cell density in the central region is greater than 1 and less than or equal to 2 times the cell density in the peripheral region.
- the control of the amount of exhaust gas flowing into the cells in each area due to the difference in cell density between the central area and the peripheral area will be insufficient, and the cell density ratio will be 2 If it exceeds twice, the amount of exhaust gas flowing into the surrounding area becomes too large, and the purification performance may be lowered.
- the catalytic converter of the present invention preferably has a cordierite honeycomb carrier excellent in thermal shock resistance, but may be an electric heating type catalytic converter (EHC: “Electrically-Heated” Converter).
- EHC Electric heating type catalytic converter
- This electric heating type catalytic converter attaches a pair of electrodes to a honeycomb catalyst and heats the honeycomb catalyst by energizing the electrodes, thereby increasing the activity of the honeycomb catalyst and detoxifying the exhaust gas passing therethrough.
- the exhaust gas can be purified by activating the catalyst by electric heating when cold, in addition to purifying the exhaust gas at normal temperature, by applying it to an exhaust gas exhaust system that connects the vehicle engine and the muffler.
- the base material that is a constituent element is composed of a central region having a relatively high cell density and a peripheral region having a relatively low cell density, Furthermore, the longitudinal length of each of the catalyst layers in the central region and the peripheral region is the same, or the longitudinal length of the catalyst layer in the peripheral region is shorter than that in the central region. It is possible to provide a catalytic converter that has excellent hydrogen sulfide release suppression performance.
- (A) is the schematic diagram explaining the length of the longitudinal direction of the cell wall surface of the peripheral region of a base material, and the length of the longitudinal direction of the upper layer and lower layer of a catalyst layer of 2 layer structure
- (b) is the center of a base material
- (b) is the schematic diagram explaining the length of the longitudinal direction of the cell wall surface of an area
- exhaust gas exhaust system in which the catalytic converter of the present invention is interposed will be outlined.
- the exhaust system of the exhaust gas to which the catalytic converter of the present invention is applied includes an engine, a catalytic converter, a three-way catalytic converter, a sub muffler and a main muffler which are connected to each other through a system pipe, and the exhaust gas generated by the engine is Each part is circulated through a pipe and exhausted.
- FIG. 1 is a schematic view illustrating an embodiment of the catalytic converter of the present invention.
- FIG. 2a is a longitudinal direction of the cell wall surface in the peripheral region of the substrate and the longitudinal direction of the upper and lower layers of the catalyst layer having a two-layer structure.
- 2b is a schematic diagram illustrating the length in the longitudinal direction of the cell wall surface in the central region of the substrate and the length in the longitudinal direction of the upper and lower layers of the catalyst layer having a two-layer structure. is there.
- FIG. 3 is a diagram for explaining the flow velocity distribution of the exhaust gas of the base material having a uniform cell density and the base material having a different cell density in the central region and the peripheral region.
- the catalytic converter 10 shown in FIG. 1 is roughly composed of a cylindrical base material 1 having a large number of cells and a two-layered catalyst layer formed on the cell wall surface constituting the cells.
- examples of the material for the substrate 1 include materials other than ceramic materials such as cordierite and ceramic materials such as silicon carbide, and metal materials made of a composite oxide of magnesium oxide, aluminum oxide and silicon dioxide.
- examples of the carrier constituting the catalyst layer formed on the cell wall surface of the substrate include oxides mainly composed of at least one of CeO 2 , ZrO 2 and Al 2 O 3 which are porous oxides.
- CZ material CeO 2 -ZrO 2 compounds Al 2 O 3 -CeO 2 -ZrO 2 ternary composite oxide Al 2 O 3 was introduced as a diffusion barrier (ACZ material), etc.
- the substrate 1 is made of a honeycomb structure having a large number of lattice contour cells such as a quadrangle, a hexagon, and an octagon, and an exhaust gas flows through each cell (X1 direction).
- the base material 1 is composed of two regions, a central region 1A having a relatively high cell density and a peripheral region 1B having a relatively low cell density.
- the flow velocity distribution of the exhaust gas will be described with reference to FIG.
- the flow velocity distribution shown in FIG. 3 is such that the two end points of the diameter are ⁇ 1 and 1 around the center 0 of the base material having a circular cross section, the intermediate positions are indicated by the ratio to the radius, and the exhaust gas flow velocity at each position is shown.
- the ratio of the cell density of the base material to the flow rate at the center of the base material of the catalytic converter is shown.
- the flow velocity distribution of the exhaust gas in the central region of the cross section of the base material is significantly higher than the peripheral region as shown by the dotted line in FIG. For this reason, there is a problem that it is difficult to fully utilize the catalyst layer of the entire substrate.
- the base material 1 is formed from two regions having different cell densities as in the catalytic converter 10 of the present invention, and the cell density in the peripheral region 1B is relatively lowered, so that the solid line shown in FIG. As described above, the difference in flow velocity distribution between the central region 1A and the peripheral region 1B of the base material 1 can be remarkably reduced, and the exhaust gas purification using the entire catalyst layer of the catalytic converter 10 can be performed effectively.
- the length of the catalyst layer formed on the cell wall surface of each region is changed in the peripheral region 1B and the central region 1A of the substrate 1.
- the catalyst layer 2B formed on the surface of the cell wall surface 1Ba in the peripheral region 1B shown in FIG. 2a has a two-layer structure composed of a lower layer 2Ba on the cell wall surface 1Ba side and an upper layer 2Bb directly above the exhaust gas. Each layer is formed of one or more of Pd, Pt and Rh which are noble metal catalysts.
- the catalyst layer 2A formed on the surface of the cell wall surface 1Aa in the central region 1A shown in FIG. 2b also has a two-layer structure including a lower layer 2Aa on the cell wall surface 1Aa side and an upper layer 2Ab above the catalyst layer 2Aa. It is formed from one or more of Pd, Pt and Rh which are noble metal catalysts.
- the cell wall surfaces 1Aa and 1Ba are similarly t1, and the catalyst layers 2A and 2B have the same length. While the lengths of the upper layers 2Ab and 2Bb are both t1, the lengths of the lower layers 2Aa and 2Ba of the catalyst layers 2A and 2B are t3 and t2, respectively, so that t1> t3> t2.
- the catalyst layer 2B (the lower layer 2Ba) in the peripheral region 1B as compared to the catalyst layer 2A (the lower layer 2Aa) in the central region 1A.
- the cell density of the central region 1A it is preferable to set the cell density of the central region 1A to be greater than 1 and less than 2 times the cell density of the peripheral region 1B.
- the cell density ratio is less than 1 time, the control of the amount of exhaust gas flowing into the cells in each area due to the difference in cell density between the central area 1A and the peripheral area 1B becomes insufficient, and the cell density ratio If the value exceeds twice, the amount of exhaust gas flowing into the peripheral region 1B becomes excessive, and the purification performance may be lowered.
- the catalyst layer may have a single layer structure, a three-layer structure, or the like other than the two-layer structure as illustrated.
- Example 1 A cordierite-made honeycomb structure base material was produced by extrusion molding, and the cell density was made different between the central region and the peripheral region.
- the size of the honeycomb structure is such that the diameter of the circular cross section orthogonal to the flow direction of the exhaust gas is ⁇ 103 mm, the length t1 in the longitudinal direction is 105 mm, and the cell density in the peripheral region where the cell density is relatively low is 400 cpsi (62 cells / cm 2 ), the cell density of the central region where the cell density is relatively high is 600 cpsi (93 cells / cm 2 ), the switching line between the central region and the peripheral region is at a position of ⁇ 70 mm, and the lattice shape of the cell is rectangular It is.
- the catalyst layer has a two-layer structure, the lower layer is a Pt-supported layer and the supported amount is 0.7 g / L, the upper layer is the Rh-supported layer and the supported amount is 0.2 g / L, and the length of the catalyst layer is In both the peripheral areas, the upper layer is the same length as the base material (ratio to the base material length t1 is 100%). Regarding the lower layer length, the peripheral area is 70% of the base material length. Is 80% of the substrate length.
- Example 2 Regarding the length of the catalyst layer, it is the same as in Example 1 except that the length of the lower layer in the peripheral region is 60% of the length of the base material.
- Example 3 Regarding the length of the catalyst layer, the length of the lower layer in the peripheral region is 80% of the base material length (therefore, the length of the lower layer of the catalyst layer in the peripheral region and the central region is the same) as in Example 1. It is the same.
- Example 4 Regarding the length of the catalyst layer, it is the same as in Example 1 except that the length of the lower layer in the peripheral region is 50% of the base material length.
- FIG. 1 A cordierite-made honeycomb structure substrate was produced by extrusion molding, and the cell density was uniform in cross section.
- the size of the honeycomb structure is such that the diameter of the circular cross section perpendicular to the flow direction of the exhaust gas is ⁇ 103 mm, the length t1 in the longitudinal direction is 105 mm, the cell density is 400 cpsi (62 cells / cm 2 ), and the cell lattice shape is It is a rectangle.
- the catalyst layer has a two-layer structure, the lower layer is a Pt-supported layer and the supported amount is 0.7 g / L, the upper layer is the Rh-supported layer and the supported amount is 0.2 g / L, and the upper layer is based on the length of the catalyst layer.
- the length is the same as the material length (100%), and the lower layer is 80% of the base material length.
- Comparative Example 2 Regarding the length of the catalyst layer, it is the same as in Example 1 except that the length of the lower layer in the peripheral region is 90% of the base material length.
- Example 3 Regarding the length of the catalyst layer, it is the same as in Example 1 except that the length of the lower layer in the peripheral region is 100% of the base material length.
- the vehicle was driven at a constant speed of 40 km / hour to adsorb sulfur, accelerated to 100 km / hour with a wide open throttle, and after reaching 100 km / hour, the throttle was closed.
- the hydrogen sulfide emission was measured when the vehicle was stopped and the engine was left idle for a certain period of time.
- the discharge amount of Comparative Example 1 was set to 100%, and the discharge amounts of the other test specimens were obtained as a ratio relative thereto.
- the ratio range of the length of the catalyst layer in the central region with respect to the base material in which each example is superior to Comparative Example 1 can be defined as 70% to 90%.
- SYMBOLS 1 Base material, 1A ... Center area
Abstract
Description
まず、本発明の触媒コンバーターが介在する排ガスの排気系統を概説する。本発明の触媒コンバーターが適用される排ガスの排気系統は、エンジン、触媒コンバーター、三元触媒コンバーター、サブマフラーおよびメインマフラーが配されて相互に系統管で繋がれ、エンジンで生成された排ガスが系統管を介して各部を流通し、排気されるようになっている。次に、以下、触媒コンバーターの実施の形態を説明する。
図1は本発明の触媒コンバーターの実施の形態を説明した模式図であり、図2aは基材の周辺領域のセル壁面の長手方向の長さと2層構造の触媒層の上層および下層の長手方向の長さを説明した模式図であり、図2bは基材の中央領域のセル壁面の長手方向の長さと2層構造の触媒層の上層および下層の長手方向の長さを説明した模式図である。また、図3はセル密度一様の基材と中央領域と周辺領域でセル密度が異なる基材の排ガスの流速分布を説明した図である。
本発明者等は、以下で示す実施例1~6および比較例1~7のハニカム構造基材を製作して、周辺領域の触媒層の長さ(基材の長さに対する比率)を変化させた際の硫化水素排出量を測定した実験、および周辺領域の触媒層の長さを変化させた際のNOx排出量を測定した実験をおこなった。
押出成形によってコージェライト製のハニカム構造基材を作製し、中央領域と周辺領域でセル密度を相違させた。ハニカム構造体のサイズは排ガスの流れ方向に直交する円形断面の直径がφ103mmで長手方向の長さt1が105mmであり、セル密度が相対的に低い周辺領域のセル密度が400cpsi(62個/cm2)であり、セル密度が相対的に高い中央領域のセル密度が600cpsi(93個/cm2)であり、中央領域と周辺領域の切替ラインがφ70mmの位置であり、セルの格子形状は四角形である。さらに、触媒層は2層構造であって下層がPt担持層で担持量は0.7g/L、上層がRh担持層で担持量は0.2g/L、触媒層の長さに関しては、中央領域と周辺領域ともにそれらの上層は基材長さと同じ長さ(基材長さt1に対する比率が100%)であり、下層の長さに関しては周辺領域が基材長さの70%であり、中央領域が基材長さの80%である。
触媒層の長さに関し、周辺領域の下層の長さが基材長さの60%であること以外は実施例1と同様である。
触媒層の長さに関し、周辺領域の下層の長さが基材長さの80%であること(したがって、周辺領域と中央領域の触媒層の下層の長さが同じ)以外は実施例1と同様である。
触媒層の長さに関し、周辺領域の下層の長さが基材長さの50%であること以外は実施例1と同様である。
押出成形によってコージェライト製のハニカム構造基材を作製し、セル密度は断面均一とした。ハニカム構造体のサイズは排ガスの流れ方向に直交する円形断面の直径がφ103mmで長手方向の長さt1が105mmであり、セル密度が400cpsi(62個/cm2)であり、セルの格子形状は四角形である。さらに、触媒層は2層構造であって下層がPt担持層で担持量は0.7g/L、上層がRh担持層で担持量は0.2g/L、触媒層の長さに関しては、上層は基材長さと同じ長さ(100%)であり、下層は基材長さの80%である。
触媒層の長さに関し、周辺領域の下層の長さが基材長さの90%であること以外は実施例1と同様である。
触媒層の長さに関し、周辺領域の下層の長さが基材長さの100%であること以外は実施例1と同様である。
浄化性能評価試験では、実機エンジンを使用し、A/Fをリーン側(15.1)からリッチ側(14.1)に反転させ、リッチ雰囲気を保持した際のNOx排出量を測定した。そして、比較例1の排出量を100%として、他の試験体の排出量をそれに対する比率で求めた。
Claims (4)
- セル構造の基材のセル壁面においてガスが流通する基材の長手方向に貴金属触媒からなる触媒層が形成されてなる触媒コンバーターであって、
基材は、セル密度が相対的に高い中央領域と、セル密度が相対的に低い周辺領域とから構成され、
中央領域と周辺領域の触媒層のそれぞれの前記長手方向の長さが同じか、中央領域に比して周辺領域の触媒層の前記長手方向の長さが短くなっている触媒コンバーター。 - 基材の前記長手方向の長さに対する中央領域の触媒層の該長手方向の長さの比率が70%~90%である請求項1に記載の触媒コンバーター。
- 基材の前記長手方向の長さに対する中央領域の触媒層の該長手方向の長さの比率が80%であり、
基材の前記長手方向の長さに対する周辺領域の触媒層の長手方向の長さの比率が50~80%である請求項1または2に記載の触媒コンバーター。 - 周辺領域のセル密度に対する中央領域のセル密度が1倍より大きくて2倍以下の範囲である請求項1~3のいずれかに記載の触媒コンバーター。
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BR112015017245-8A BR112015017245B1 (pt) | 2013-01-23 | 2013-11-26 | Conversor catalítico |
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