WO2014125733A1 - 触媒コンバーター - Google Patents
触媒コンバーター Download PDFInfo
- Publication number
- WO2014125733A1 WO2014125733A1 PCT/JP2013/084080 JP2013084080W WO2014125733A1 WO 2014125733 A1 WO2014125733 A1 WO 2014125733A1 JP 2013084080 W JP2013084080 W JP 2013084080W WO 2014125733 A1 WO2014125733 A1 WO 2014125733A1
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- Prior art keywords
- region
- catalytic converter
- catalyst layer
- cell density
- base material
- Prior art date
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- 230000003197 catalytic effect Effects 0.000 title claims abstract description 58
- 239000003054 catalyst Substances 0.000 claims abstract description 67
- 210000004027 cell Anatomy 0.000 claims abstract description 66
- 239000000758 substrate Substances 0.000 claims abstract description 21
- 210000002421 cell wall Anatomy 0.000 claims abstract description 14
- 229910000510 noble metal Inorganic materials 0.000 claims abstract description 6
- 239000000463 material Substances 0.000 claims description 45
- 230000002093 peripheral effect Effects 0.000 claims description 22
- 238000000746 purification Methods 0.000 abstract description 11
- 239000007789 gas Substances 0.000 description 44
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 8
- 230000000052 comparative effect Effects 0.000 description 6
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 6
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 4
- 229910010293 ceramic material Inorganic materials 0.000 description 4
- 239000002131 composite material Substances 0.000 description 4
- 229910052878 cordierite Inorganic materials 0.000 description 4
- 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 4
- 238000010586 diagram Methods 0.000 description 3
- 238000005485 electric heating Methods 0.000 description 3
- 238000011156 evaluation Methods 0.000 description 3
- 229910052763 palladium Inorganic materials 0.000 description 3
- 229910052697 platinum Inorganic materials 0.000 description 3
- 239000010948 rhodium Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 230000004888 barrier function Effects 0.000 description 2
- 239000000969 carrier Substances 0.000 description 2
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 description 2
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000009792 diffusion process Methods 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 239000000446 fuel Substances 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
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 2
- 229910052703 rhodium Inorganic materials 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
- 239000011206 ternary composite Substances 0.000 description 2
- 238000010998 test method Methods 0.000 description 2
- 239000012855 volatile organic compound Substances 0.000 description 2
- 230000003213 activating effect Effects 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000003203 everyday effect Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 239000010970 precious metal Substances 0.000 description 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- -1 silicon carbide Chemical compound 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 238000012795 verification Methods 0.000 description 1
- 239000002912 waste gas Substances 0.000 description 1
Images
Classifications
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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
-
- 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
- B01D53/9404—Removing only nitrogen compounds
- B01D53/9409—Nitrogen oxides
- B01D53/9413—Processes characterised by a specific catalyst
-
- 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
- B01D53/9404—Removing only nitrogen compounds
- B01D53/9409—Nitrogen oxides
- B01D53/9413—Processes characterised by a specific catalyst
- B01D53/9422—Processes characterised by a specific catalyst for removing nitrogen oxides by NOx storage or reduction by cyclic switching between lean and rich exhaust gases (LNT, NSC, NSR)
-
- 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
- B01J23/54—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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- 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
- B01J35/19—Catalysts containing parts with different compositions
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/10—Noble metals or compounds thereof
- B01D2255/102—Platinum group metals
- B01D2255/1021—Platinum
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
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- B01D2255/10—Noble metals or compounds thereof
- B01D2255/102—Platinum group metals
- B01D2255/1023—Palladium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01D2255/10—Noble metals or compounds thereof
- B01D2255/102—Platinum group metals
- B01D2255/1025—Rhodium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/90—Physical characteristics of catalysts
- B01D2255/903—Multi-zoned catalysts
- B01D2255/9032—Two zones
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2258/00—Sources of waste gases
- B01D2258/01—Engine exhaust gases
-
- 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
- B01J35/40—Catalysts, in general, characterised by their form or physical properties characterised by dimensions, e.g. grain size
-
- 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
- F01N2330/48—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
- F01N2330/00—Structure of catalyst support or particle filter
- F01N2330/60—Discontinuous, uneven properties of filter material, e.g. different material thickness along the longitudinal direction; Higher filter capacity upstream than downstream in same housing
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 apparent catalyst coating amount is often different between a region where the cell density is high and a region where the cell density is low. This is because even if the amount of catalyst is the same, the thickness of the catalyst layer supported on one cell is different. More specifically, the region where the cell density is high is higher than the region where the cell density is low. It relies on the reduced thickness of the catalyst layer due to its large academic surface area (GSA). At this time, the thickness of the catalyst layer is relatively thick in the region where the cell density is low, but in this case, the gas diffusibility to the deep portion of the catalyst layer is reduced, and sufficient exhaust gas is generated in the region where the cell density is low. The purification performance cannot be expected. This problem is not the problem raised by the catalytic converter disclosed in Patent Document 1 described above, and cannot be solved even with this catalytic converter.
- the present invention has been made in view of the above-described problems, and relates to a catalytic converter having a base material composed of regions having different cell densities, and provides a catalytic converter having excellent exhaust gas purification performance in all regions of the base material. For the purpose.
- the catalytic converter according to the present invention is a catalyst in which a catalyst layer is formed in which a noble metal catalyst is supported on a support in the longitudinal direction of a base material through which gas flows on the cell wall surface of the base material of the cell structure.
- the base material is configured by a first region having a relatively high cell density and a second region having a relatively low cell density, and a second material with respect to the thickness of the catalyst layer in the first region. In this region, the ratio of the thickness of the catalyst layer is in the range from 0.95 times to 1.2 times.
- the ratio of the thickness of the catalyst layer in the second region having a relatively low cell density to the thickness of the catalyst layer in the first region having a relatively high cell density is greater than 0.95 times and 1.2.
- regions having different cell densities are formed in the central region and the peripheral region.
- the first region is the central region and the second region is the peripheral region.
- the cell density in the central region relatively high, the difference in the flow velocity distribution of the exhaust gas in the central region and the peripheral region can be reduced compared to a base material having a uniform cell density, and the catalyst constituting the catalytic converter
- the entire system can be used effectively for exhaust gas purification.
- the base material of the cell structure is made of a ceramic material such as cordierite or silicon carbide composed of a composite oxide of magnesium oxide, aluminum oxide and silicon dioxide, or a material other than a ceramic material such as a metal 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.
- 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. It can be made of oxides consisting of any one of ceria (CeO 2 ), zirconia (ZrO 2 ) and alumina (Al 2 O 3 ), or composite oxides consisting of two or more (so-called 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.) can be mentioned.
- One or more of noble metal catalysts such as rhodium, palladium and platinum are supported on these carriers to form a catalyst layer.
- 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 component of the first region has a relatively high cell density
- the second region has a relatively low cell density.
- the ratio of the thickness of the catalyst layer in the second region to the thickness of the catalyst layer in the first region is in the range of more than 0.95 and less than or equal to 1.2 times.
- a converter can be provided.
- FIG. 1 is the figure which expanded the cell wall surface of the 1st area
- (b) is the figure which expanded the cell wall surface of the 2nd 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 diagram illustrating an embodiment of a catalytic converter of the present invention
- FIG. 2a is an enlarged view of a cell wall surface in a first region (central region) of the substrate
- FIG. It is the figure which expanded the cell wall surface of the 2nd field (peripheral field).
- 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.
- a catalytic converter 10 shown in FIG. 1 is generally composed of a cylindrical base material 1 having a large number of cells and a catalyst layer 3 formed on the surface of a cell wall 2 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.
- the catalyst layer 3 is composed entirely of one or more of Pd, Pt, and Rh, which are noble metal catalysts, supported on these carriers.
- 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 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 thickness of the catalyst layer formed on the cell wall surface of each region is changed in the first region 1A and the second region 1B of the substrate 1.
- the thickness ratio is adjusted to a range greater than 0.95 times and less than 1.2 times.
- the thickness t1 of the four sides (general part) of the catalyst layer 3 is measured, and the thickness t2 of the four corners is measured.
- the average value obtained by dividing the sum of the two thicknesses by 8 is the thickness of the catalyst layer 3 in the first region 1A.
- the thickness t3 of the four sides (general part) of the catalyst layer 3A is measured, the thickness t4 of the four corners is measured, and the average value obtained by dividing the sum of the eight thicknesses by eight. Is the thickness of the catalyst layer 3A in the second region 1B.
- the average value obtained by dividing the sum of the measured values of the thickness of the six sides and the measured values of the thickness of the six corners by 12 is the target region.
- the thickness of the catalyst layer can be set.
- the ratio of the thickness of the catalyst layer 3A to the thickness of the catalyst layer 3 is adjusted to a range greater than 0.95 times and less than or equal to 1.2 times, so that the deep layer portion of the catalyst layer in any region of the substrate It has been demonstrated that a catalytic converter can be obtained that can improve the exhaust gas diffusibility to the surface, has excellent exhaust gas purification performance, and has a relatively small pressure loss. This pressure loss relies on the relatively thin catalyst layer in the second 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 L in the longitudinal direction is 105 mm, and the cell density in the peripheral region with a relatively low cell density is 400 cpsi (62 cells / cm 2 ), the cell density of the central region with a relatively high cell density 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 cell lattice shape is 2 Both areas are rectangular.
- the central region of the honeycomb structure 2 and the honeycomb structure 1 is 250 g / L, and the peripheral region of the honeycomb structure 1 differs depending on the examples and comparative examples.
- Pt is 1.0 g / L and Rh is 0.3 g / L.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Combustion & Propulsion (AREA)
- Health & Medical Sciences (AREA)
- Ceramic Engineering (AREA)
- Environmental & Geological Engineering (AREA)
- Analytical Chemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Biomedical Technology (AREA)
- Toxicology (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Exhaust Gas After Treatment (AREA)
- Catalysts (AREA)
- Exhaust Gas Treatment By Means Of Catalyst (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は基材の第1の領域(中央領域)のセル壁面を拡大した図であり、図2bは基材の第2の領域(周辺領域)のセル壁面を拡大した図である。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、2と比較例1~6の各触媒コンバーターを試作し、それぞれの触媒コンバーターの排ガスエミッション量と圧損量を測定し、エミッションに関しては比較例1の値に対する他の触媒コンバーターの値の比を求め、圧損に関しては比較例2の値に対する他の触媒コンバーターの値の比を求めてグラフ化した。以下、各触媒コンバーターの基材の仕様や触媒層の仕様と耐久評価試験方法の概要を説明する。
<ハニカム構造体1>
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L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2つの領域ともに四角形状である。
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、セル密度が均一である。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Lが105mmであり、セル密度が600cpsi(93個/cm2)であり、セルの格子形状は四角形である。
ハニカム構造体2およびハニカム構造体1の中央領域は250g/Lであり、ハニカム構造体1の周辺領域は実施例や比較例によって相違する。
Ptが1.0g/L、Rhが0.3g/Lである。
各触媒コンバーターをV型8気筒4.3リットルカ゛ソリンエンシ゛ンの排気系にそれぞれ装着し、触媒床温を1000℃で1分間にフィードバック、フューエルカット、リッチ、リーンを含む条件で50時間の耐久試験を施した。
各触媒コンバーターに6m3/分の空気を流した際の圧力損失(25℃換算)を測定し、比較例2の値に対する比率で評価した。
実機エンジンに各触媒コンバーターをセットし、A/Fをリッチ(14.1)、リーン(15.1)を1秒で切り替えた際のNOx排出量をそれぞれ測定し、比較例1の値に対する比率で評価した。以下、表1と図4に各触媒コンバーターの水準と圧損比、エミッション比に関する実験結果を示す。
Claims (2)
- 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が担体に担持されてなる触媒層が形成されてい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第1の領域と、セル密度が相対的に低い第2の領域とから構成され、
第1の領域における触媒層の厚みに対する第2の領域における触媒層の厚みの比率が0.95倍より大きく1.2倍以下の範囲である触媒コンバーター。 - 基材における、ガスが流通する方向に直交する断面において、中央領域とその周辺領域の2つの領域にセル密度の異なる領域が形成されており、
前記第1の領域が前記中央領域であり、前記第2の領域が前記周辺領域である請求項1に記載の触媒コンバーター。
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BR112015019300-5A BR112015019300B1 (pt) | 2013-02-13 | 2013-12-19 | Conversor catalítico |
CN201380072823.9A CN104994951A (zh) | 2013-02-13 | 2013-12-19 | 催化转换器 |
DE112013006663.7T DE112013006663B4 (de) | 2013-02-13 | 2013-12-19 | Katalytischer Wandler |
US14/767,123 US9782753B2 (en) | 2013-02-13 | 2013-12-19 | Catalytic converter |
ZA2015/06225A ZA201506225B (en) | 2013-02-13 | 2015-08-26 | Catalytic converter |
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US10598068B2 (en) | 2015-12-21 | 2020-03-24 | Emissol, Llc | Catalytic converters having non-linear flow channels |
JP6587565B2 (ja) * | 2016-03-17 | 2019-10-09 | 日本碍子株式会社 | ハニカム構造体 |
JP6625920B2 (ja) * | 2016-03-25 | 2019-12-25 | トヨタ自動車株式会社 | 触媒コンバーター |
JP6620049B2 (ja) * | 2016-03-25 | 2019-12-11 | 日本碍子株式会社 | ハニカム構造体 |
CN110785232B (zh) * | 2017-04-28 | 2022-09-23 | 优美科触媒日本有限公司 | 废气净化用催化剂及使用其的废气净化方法 |
JP2020040004A (ja) * | 2018-09-07 | 2020-03-19 | いすゞ自動車株式会社 | パティキュレートフィルタ及びその製造方法 |
JP2020044461A (ja) * | 2018-09-14 | 2020-03-26 | 三菱日立パワーシステムズ株式会社 | 脱硝装置 |
GB2581776B (en) * | 2019-02-19 | 2022-08-17 | Jaguar Land Rover Ltd | Catalytic converter core having first and second regions with different thermal inertia |
WO2020183496A1 (en) * | 2019-03-11 | 2020-09-17 | Hero MotoCorp Limited | Catalyst system for treatment of exhaust gas of automobile and process for making the same |
KR102211944B1 (ko) * | 2019-04-04 | 2021-02-03 | 희성촉매 주식회사 | 귀금속 박층을 최상층으로 포함하는 다층구조의 배기가스 정화용 촉매 및 이의 제조방법 |
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US20150375204A1 (en) | 2015-12-31 |
BR112015019300A2 (pt) | 2017-07-18 |
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DE112013006663T5 (de) | 2015-11-26 |
US9782753B2 (en) | 2017-10-10 |
JP5888259B2 (ja) | 2016-03-16 |
DE112013006663B4 (de) | 2021-11-25 |
JP2014151305A (ja) | 2014-08-25 |
ZA201506225B (en) | 2016-12-21 |
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