WO2015099114A1 - Method for producing catalyst structure, and catalyst structure - Google Patents

Method for producing catalyst structure, and catalyst structure Download PDF

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Publication number
WO2015099114A1
WO2015099114A1 PCT/JP2014/084482 JP2014084482W WO2015099114A1 WO 2015099114 A1 WO2015099114 A1 WO 2015099114A1 JP 2014084482 W JP2014084482 W JP 2014084482W WO 2015099114 A1 WO2015099114 A1 WO 2015099114A1
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catalyst
porous
catalyst structure
porous molded
molded member
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PCT/JP2014/084482
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French (fr)
Japanese (ja)
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健司 大橋
研亮 小栗
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株式会社エフ・シ－・シ－
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Publication of WO2015099114A1 publication Critical patent/WO2015099114A1/en

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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
    • B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
    • B01J23/74—Iron group metals
    • B01J23/755—Nickel
    • 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
    • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/02—Boron or aluminium; Oxides or hydroxides thereof
    • B01J21/04—Alumina
    • 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
    • B01J35/50—
    • B01J35/51—
    • B01J35/56—
    • B01J35/58—
    • 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
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
    • C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
    • C01B3/32—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air
    • C01B3/34—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents
    • C01B3/38—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents using catalysts
    • C01B3/40—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents using catalysts characterised by the 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
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/0201—Impregnation
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/02—Processes for making hydrogen or synthesis gas
    • C01B2203/0205—Processes for making hydrogen or synthesis gas containing a reforming step
    • C01B2203/0227—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step
    • C01B2203/0233—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step the reforming step being a steam reforming step
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/10—Catalysts for performing the hydrogen forming reactions
    • C01B2203/1041—Composition of the catalyst
    • C01B2203/1082—Composition of support materials
    • 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
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/50—Improvements relating to the production of bulk chemicals
    • Y02P20/52—Improvements relating to the production of bulk chemicals using catalysts, e.g. selective catalysts

Definitions

  • the present invention relates to a catalyst structure carrying a catalyst.
  • a catalyst structure called an industrial catalyst used in a chemical plant, etc. is formed by pressing a ceramic powder containing a catalyst capable of obtaining a desired reaction into a pellet, sphere, cylinder, or hollow cylinder. It was obtained by doing. That is, a ceramic powder containing a catalyst is pressed and hardened to obtain a desired shape. For example, it is used by filling a predetermined portion of a reaction tube through which a reaction gas flows.
  • Various methods for forming a catalyst structure have been proposed in the past, as shown in Non-Patent Document 1, for example.
  • the present invention has been made in view of such circumstances, and provides a catalyst structure manufacturing method and a catalyst structure capable of achieving both improvement in catalyst reactivity and improvement in durability while reducing costs. It is to provide.
  • the invention according to claim 1 is a method for producing a catalyst structure carrying a catalyst, wherein a papermaking process for forming a porous sheet-like member by forming a heat-resistant fiber into a sheet shape by a papermaking method is obtained in the papermaking process.
  • the heat-resistant fiber used in the paper making step is made of alumina fiber
  • the binding step uses a predetermined amount of solvent for the alumina powder.
  • the fibers are bound together by immersing the porous molded member in the alumina solution dissolved in (1).
  • the invention according to claim 3 is the method for producing a catalyst structure according to claim 2, wherein the amount of alumina filled in the pores of the porous molded member is adjusted by adjusting the concentration or immersion time of the alumina solution. Is arbitrarily adjustable.
  • the porous molded member obtained in the molding step is formed by forming the porous sheet-shaped member into a roll shape. It is characterized by comprising a cylindrical porous molded member wound around or a cubic or rectangular parallelepiped porous molded member obtained by forming the porous sheet-shaped member into a cube shape.
  • the invention according to claim 5 is a papermaking step for obtaining a porous sheet-like member by forming a heat-resistant fiber into a sheet by a papermaking method in a catalyst structure carrying a catalyst, and a porous material obtained by the papermaking step
  • the heat resistant fiber used in the paper making process is made of an alumina fiber
  • the binding step comprises dissolving the alumina powder with a predetermined amount of solvent.
  • the fibers are bonded together by immersing the porous molded member in the alumina solution.
  • the amount of alumina filled in the pores of the porous molded member can be arbitrarily set. It is characterized by being adjustable.
  • the invention according to claim 8 is the catalyst structure according to any one of claims 5 to 7, wherein the porous molded member obtained in the molding step is a roll of the porous sheet-shaped member. It is characterized by comprising a cylindrical porous molded member, or a cubic or rectangular parallelepiped porous molded member obtained by forming the porous sheet-shaped member into a cube shape.
  • the porous sheet-shaped member is molded to obtain the porous molded member, and then the fibers of the porous molded member are bound together. Since the catalyst is supported on the surface including the inner wall surface of the pores, it is possible to achieve both improvement in catalyst reactivity and improvement in durability while reducing costs.
  • the heat-resistant fiber used in the paper making process is made of alumina fiber
  • the binding process is performed by placing the porous molded member in an alumina solution obtained by dissolving alumina powder with a predetermined amount of solvent. Since the fibers are bound together by soaking, the fibers can be bound better and more reliably, and the strength can be further improved.
  • the amount of alumina filled in the pores of the porous molded member can be arbitrarily adjusted by adjusting the concentration of the alumina solution or the immersion time. In the process, the filling of the pores can be minimized, and both the improvement of the strength and the improvement of the catalytic reactivity can be favorably achieved.
  • molding process is a cylindrical porous shaping
  • the catalyst structure according to the present embodiment is composed of a catalyst structure supporting an industrial catalyst used in a chemical plant (for example, a catalyst for obtaining a desired product gas by catalytic reaction with a reaction gas).
  • a catalyst structure supporting an industrial catalyst used in a chemical plant for example, a catalyst for obtaining a desired product gas by catalytic reaction with a reaction gas.
  • it consists of a hollow cylindrical catalyst structure 1 (see FIG. 1) or a cubic or rectangular parallelepiped catalyst structure 2 (see FIG. 2).
  • These catalyst structures 1 and 2 are obtained by forming a porous sheet-like member into a predetermined shape, binding the fibers together, firing the catalyst, and then supporting the catalyst.
  • 1 is a fired cylindrical porous molded member obtained by winding a porous sheet-shaped member in a roll shape
  • the catalyst structure 2 is a cubic or cuboid porous material in which the porous sheet-shaped member is molded in a cube shape. A quality molded member is fired.
  • the catalyst structure according to the embodiment includes the steps shown in the flowchart of FIG. 3 (mainly the paper making step S1, the forming step S2, the binding step S3, the degreasing step S4, the high temperature firing step S5, and the catalyst supporting step. Step S6 and the baking step S7).
  • the papermaking step S1 is a step of obtaining a porous sheet-like member by forming heat-resistant fibers into a sheet shape by a papermaking method (wet papermaking method in the present embodiment).
  • the paper making method includes a slurry generation step in which an inorganic binder and alumina fibers as heat-resistant fibers are mixed in a predetermined amount of water to generate a slurry, and a flocculant is added to the slurry obtained in the slurry generation step to add a flocculant.
  • a flock generating step for producing a sheet a sheet forming step for producing a sheet-like porous structure by papermaking the flock obtained in the flock generating step, and a drying of the sheet-like porous structure obtained in the sheet forming step And a drying step for obtaining a porous sheet-like member.
  • the forming step S2 is a step for obtaining a porous formed member by forming the porous sheet-like member obtained in the paper making step S1 into a predetermined shape.
  • the porous molded member may have a hollow cylindrical shape, a cubic shape or a rectangular parallelepiped shape, or other shapes such as a spherical shape or a pellet shape.
  • a porous sheet-shaped member having a relatively large thickness is obtained by arbitrarily cutting in a vertical and horizontal direction, and a porous having a relatively small thickness. It may be obtained by laminating sheet-like members.
  • the binding step S3 is a step of binding the fibers of the porous molded member obtained in the molding step S2.
  • the porous step is performed in an alumina solution in which alumina powder is dissolved in a predetermined amount of solvent. It is comprised so that fibers may be bound together by immersing a forming member. More specifically, in the binding step S3, a slurry in which alumina powder is dispersed in a predetermined amount of water is prepared, and the porous molded member obtained in the molding step S2 is immersed in the slurry for a predetermined time. Then, it is performed by drying.
  • the heat resistant fiber used in the paper making step S1 is made of alumina fiber
  • the binding step S3 is porous in an alumina solution in which alumina powder is dissolved in a predetermined amount of water (solvent).
  • the fibers are bound together by dipping the quality molded member.
  • it is preferable to adjust the components of the slurry by adding a dispersant, a thickener, or the like to the alumina solution (slurry).
  • the amount of alumina filled in the pores of the porous molded member can be arbitrarily adjusted by adjusting the concentration of the alumina solution or the immersion time.
  • the alumina contained in the alumina solution can improve the strength by binding the fibers constituting the porous molded member, while filling the pores and reducing the specific surface area.
  • the pores are prevented from being excessively filled.
  • the degreasing step S4 is a step of eliminating the organic components contained in the porous molded member by heating the porous molded member that has undergone the binding step S3 in an air atmosphere for a predetermined time.
  • the heating temperature varies somewhat depending on the raw material components used, but is preferably about 500 to 600 ° C.
  • the high-temperature firing step S5 is a step of firing the porous molded member that has undergone the degreasing step S4 at a high temperature of about 1450 to 1550 ° C. for a predetermined time in an air atmosphere.
  • a catalyst structure having practical strength can be obtained through the high-temperature firing step S5.
  • the catalyst supporting step S6 is a step of supporting the catalyst on the surface of the porous molded member that has undergone the calcination step S5. For example, after immersing the porous molded member that has undergone the calcination step S5 in a catalyst supporting liquid that has been manufactured in advance, It is supposed to dry. By passing through such a catalyst supporting step S6, the catalyst can be supported substantially uniformly on the surface of the porous molded member (including the inner wall surfaces of the pores formed in the porous molded member).
  • the catalyst supporting liquid used in the catalyst supporting step S6 includes the following. That is, an aqueous solution containing a metal such as palladium, rhodium, platinum, or nickel is supported in the pores of the porous alumina powder by, for example, a pore filling method and dried, and then the powder is heated at about 600 to 900 ° C. for a predetermined time. To obtain catalyst powder. And the slurry (catalyst carrying liquid) is obtained by throwing the catalyst powder into a predetermined amount of water and uniformly diffusing it with a ball mill or the like. It is preferable to adjust the components of the slurry by adding a dispersant, a thickener or the like to the catalyst support liquid (slurry).
  • the firing step S7 is a step of firing the porous molded member carrying the catalyst in the catalyst carrying step S6 in an air atmosphere at a temperature of about 600 to 900 ° C. for a predetermined time.
  • a catalyst structure as a finished product can be obtained.
  • the fibers of the porous molded member are bound together, and the pores of the porous molded member Since the catalyst is supported on the surface including the inner wall surface, it is possible to achieve both improvement in catalyst reactivity and improvement in durability while reducing costs.
  • the heat-resistant fiber used in the paper making step S1 is made of alumina fiber
  • the binding step S3 is a step in which a porous molded member is placed in an alumina solution obtained by dissolving alumina powder with a predetermined amount of solvent. By soaking, the fibers are bound together, so it can be bound with the same material alumina as the alumina forming the porous molded member, and the fibers can be bound better and more reliably, and the strength is increased. Can be improved.
  • the amount of alumina filled in the pores of the porous molded member can be arbitrarily adjusted by adjusting the concentration or immersion time of the alumina solution. Further, it is possible to minimize the filling of the pores, and it is possible to satisfactorily achieve both improvement in strength and improvement in catalytic reactivity.
  • the porous molded member obtained in the molding step S2 according to the present embodiment is a cylindrical porous molded member obtained by winding the porous sheet-shaped member in a roll shape, or the porous sheet-shaped member is formed in a cube shape. Since it consists of a molded cubic or rectangular parallelepiped porous molded member, the catalytic reactivity can be further improved.
  • a first example comprising a hollow cylindrical catalyst structure
  • a second example comprising a cubic catalyst structure
  • a spherical comparative example were prepared.
  • the first embodiment and the second embodiment consist of the above-described manufacturing steps (paper making step S1, forming step S2, binding step S3, degreasing step S4, high temperature firing step S5, catalyst supporting step S6 and firing step S7.
  • the ceramic powder mixed with the catalyst is formed into a spherical shape by press working.
  • the reaction tube K into which the reaction gas G1 is introduced has a catalyst filling portion Ka for filling the catalyst.
  • the first embodiment (catalyst structure 1) is filled in the catalyst filling portion Ka of the reaction tube K as shown in FIG. 6, and the second embodiment (catalyst structure 2) is filled in the catalyst filling portion Ka. 7 and the comparative example (catalyst structure a) is filled as shown in FIG. 8 in the catalyst filling portion Ka.
  • the first example and the second example showed a higher methane conversion rate than the comparative example.
  • the catalyst structure was destroyed (pulverized) with carbon deposition, whereas in the first and second examples, the catalyst structure was not destroyed (pulverized). Therefore, it can be seen that the first and second examples are superior in catalytic reaction and higher in strength than the comparative examples.
  • it is a manufacturing method of a catalyst structure or a catalyst structure having a catalyst supporting step for supporting a catalyst on the surface, it can be applied to other forms.

Abstract

Provided are: a method for producing a catalyst structure, which is capable of achieving a good balance between improvement of the catalyst reactivity and improvement of the durability, while reducing the cost at the same time; and a catalyst structure. A method for producing a catalyst structure loaded with a catalyst, which comprises: a papermaking step (S1) for obtaining a porous sheet-like member by forming heat-resistant fibers into a sheet by a papermaking method; a shaping step (S2) for shaping the porous sheet-like member obtained in the papermaking step (S1) into a predetermined shape; a binding step (S3) for having the fibers in a porous shaped member obtained in the shaping step (S2) bound with each other; a firing step (S5) for firing the porous shaped member after the binding step (S3) at a predetermined temperature; and a catalyst loading step (S6) for loading the surface of the porous shaped member after the firing step (S5) with a catalyst.

Description

触媒構造体の製造方法及び触媒構造体Method for producing catalyst structure and catalyst structure
　本発明は、触媒を担持した触媒構造体に関するものである。 The present invention relates to a catalyst structure carrying a catalyst.
　化学プラント等で使用される工業触媒と称される触媒構造体は、従来より、所望の反応を得ることができる触媒を含有したセラミック粉末をペレット状、球状、円筒状又は中空円筒状にプレス成形等することで得られていた。すなわち、触媒を含有したセラミック粉末をプレス成形にて押し固めることで所望形状とし、例えば反応ガスが流通する反応管の所定部位に充填することにより用いられていた。なお、触媒構造体の成形方法については、例えば非特許文献１に示すように、従来より、種々のものが提案されている。 Conventionally, a catalyst structure called an industrial catalyst used in a chemical plant, etc., is formed by pressing a ceramic powder containing a catalyst capable of obtaining a desired reaction into a pellet, sphere, cylinder, or hollow cylinder. It was obtained by doing. That is, a ceramic powder containing a catalyst is pressed and hardened to obtain a desired shape. For example, it is used by filling a predetermined portion of a reaction tube through which a reaction gas flows. Various methods for forming a catalyst structure have been proposed in the past, as shown in Non-Patent Document 1, for example.
　しかしながら、上記従来技術においては、反応にほとんど寄与しない触媒構造体の内部に触媒を有しているとともに、触媒構造体の表面に担持された触媒のみが反応するので、反応に寄与しない触媒を必要としてコストが嵩んでしまい、且つ、触媒反応性に乏しいという問題があった。一方、湿式抄紙法を利用して得られたシート状の多孔質構造体に触媒を担持させることで当該多孔質構造体の細孔内の触媒も反応に寄与させることができるペーパー触媒と称される触媒構造体が提案されていることから、本出願人は、かかるペーパー触媒を任意形状に成形して用いることを検討するに至った。しかし、その場合、反応性の向上は期待できるものの、強度が十分でないことから、耐久性が不十分となってしまう虞がある。 However, in the above prior art, since the catalyst is contained inside the catalyst structure that hardly contributes to the reaction and only the catalyst supported on the surface of the catalyst structure reacts, a catalyst that does not contribute to the reaction is required. However, there is a problem that the cost increases and the catalytic reactivity is poor. On the other hand, the catalyst in the pores of the porous structure can be contributed to the reaction by supporting the catalyst on the sheet-like porous structure obtained by using the wet papermaking method. Therefore, the present applicant has come to consider using such a paper catalyst by shaping it into an arbitrary shape. However, in that case, although an improvement in reactivity can be expected, since the strength is not sufficient, the durability may be insufficient.
　本発明は、このような事情に鑑みてなされたもので、低コスト化を図りつつ触媒反応性の向上と耐久性の向上とを両立させることができる触媒構造体の製造方法及び触媒構造体を提供することにある。 The present invention has been made in view of such circumstances, and provides a catalyst structure manufacturing method and a catalyst structure capable of achieving both improvement in catalyst reactivity and improvement in durability while reducing costs. It is to provide.
　請求項１記載の発明は、触媒を担持した触媒構造体の製造方法において、抄紙法により耐熱性繊維をシート状に成形して多孔質シート状部材を得る抄紙工程と、該抄紙工程で得られた多孔質シート状部材を所定形状に成形する成形工程と、該成形工程で得られた多孔質成形部材の繊維同志を結着させる結着工程と、該結着工程を経た多孔質成形部材を所定温度にて焼成する焼成工程と、該焼成工程を経た多孔質成形部材の表面に触媒を担持させる触媒担持工程とを有したことを特徴とする。 The invention according to claim 1 is a method for producing a catalyst structure carrying a catalyst, wherein a papermaking process for forming a porous sheet-like member by forming a heat-resistant fiber into a sheet shape by a papermaking method is obtained in the papermaking process. A forming step for forming the porous sheet-like member into a predetermined shape, a binding step for binding fibers of the porous molding member obtained in the forming step, and a porous forming member that has undergone the binding step. It is characterized by having a firing step of firing at a predetermined temperature, and a catalyst supporting step of supporting a catalyst on the surface of the porous molded member that has undergone the firing step.
　請求項２記載の発明は、請求項１記載の触媒構造体の製造方法において、前記抄紙工程で用いられる耐熱性繊維がアルミナ繊維から成るとともに、前記結着工程は、アルミナ粉末を所定量の溶媒で溶解させたアルミナ溶液に前記多孔質成形部材を浸漬することで繊維同志を結着させることを特徴とする。 According to a second aspect of the present invention, in the method for producing a catalyst structure according to the first aspect, the heat-resistant fiber used in the paper making step is made of alumina fiber, and the binding step uses a predetermined amount of solvent for the alumina powder. The fibers are bound together by immersing the porous molded member in the alumina solution dissolved in (1).
　請求項３記載の発明は、請求項２記載の触媒構造体の製造方法において、前記アルミナ溶液の濃度又は浸漬時間を調整することにより、前記多孔質成形部材の細孔に充填されるアルミナの量を任意に調整可能とされたことを特徴とする。 The invention according to claim 3 is the method for producing a catalyst structure according to claim 2, wherein the amount of alumina filled in the pores of the porous molded member is adjusted by adjusting the concentration or immersion time of the alumina solution. Is arbitrarily adjustable.
　請求項４記載の発明は、請求項１～３の何れか１つに記載の触媒構造体の製造方法において、前記成形工程で得られる多孔質成形部材は、前記多孔質シート状部材をロール状に巻いた円筒状の多孔質成形部材、又は当該多孔質シート状部材をキューブ状に成形した立方体状若しくは直方体状の多孔質成形部材から成ることを特徴とする。 According to a fourth aspect of the present invention, in the method for producing a catalyst structure according to any one of the first to third aspects, the porous molded member obtained in the molding step is formed by forming the porous sheet-shaped member into a roll shape. It is characterized by comprising a cylindrical porous molded member wound around or a cubic or rectangular parallelepiped porous molded member obtained by forming the porous sheet-shaped member into a cube shape.
　請求項５記載の発明は、触媒を担持した触媒構造体において、抄紙法により耐熱性繊維をシート状に成形して多孔質シート状部材を得る抄紙工程と、該抄紙工程で得られた多孔質シート状部材を所定形状に成形する成形工程と、該成形工程で得られた多孔質成形部材の繊維同志を結着させる結着工程と、該結着工程を経た多孔質成形部材を所定温度にて焼成する焼成工程と、該焼成工程を経た多孔質成形部材の表面に触媒を担持させる触媒担持工程とを経て得られることを特徴とする。 The invention according to claim 5 is a papermaking step for obtaining a porous sheet-like member by forming a heat-resistant fiber into a sheet by a papermaking method in a catalyst structure carrying a catalyst, and a porous material obtained by the papermaking step A molding step for molding a sheet-like member into a predetermined shape, a binding step for binding fibers of the porous molding member obtained in the molding step, and a porous molding member that has undergone the binding step at a predetermined temperature It is characterized by being obtained through a firing step of firing and a catalyst supporting step of supporting a catalyst on the surface of the porous molded member that has undergone the firing step.
　請求項６記載の発明は、請求項５記載の触媒構造体において、前記抄紙工程で用いられる耐熱性繊維がアルミナ繊維から成るとともに、前記結着工程は、アルミナ粉末を所定量の溶媒で溶解させたアルミナ溶液に前記多孔質成形部材を浸漬することで繊維同士を結着させることを特徴とする。 According to a sixth aspect of the present invention, in the catalyst structure according to the fifth aspect, the heat resistant fiber used in the paper making process is made of an alumina fiber, and the binding step comprises dissolving the alumina powder with a predetermined amount of solvent. The fibers are bonded together by immersing the porous molded member in the alumina solution.
　請求項７記載の発明は、請求項６記載の触媒構造体において、前記アルミナ溶液の濃度又は浸漬時間を調整することにより、前記多孔質成形部材の細孔に充填されるアルミナの量を任意に調整可能とされたことを特徴とする。 According to a seventh aspect of the present invention, in the catalyst structure according to the sixth aspect, by adjusting the concentration or immersion time of the alumina solution, the amount of alumina filled in the pores of the porous molded member can be arbitrarily set. It is characterized by being adjustable.
　請求項８記載の発明は、請求項５～７の何れか１つに記載の触媒構造体において、前記成形工程で得られる多孔質成形部材は、前記多孔質シート状部材をロール状に巻いた円筒状の多孔質成形部材、又は当該多孔質シート状部材をキューブ状に成形した立方体状若しくは直方体状の多孔質成形部材から成ることを特徴とする。 The invention according to claim 8 is the catalyst structure according to any one of claims 5 to 7, wherein the porous molded member obtained in the molding step is a roll of the porous sheet-shaped member. It is characterized by comprising a cylindrical porous molded member, or a cubic or rectangular parallelepiped porous molded member obtained by forming the porous sheet-shaped member into a cube shape.
　請求項１、５の発明によれば、多孔質シート状部材を成形して多孔質成形部材を得た後、当該多孔質成形部材の繊維同志が結着されるとともに、その多孔質成形部材の細孔の内壁面を含む表面に触媒が担持されるので、低コスト化を図りつつ触媒反応性の向上と耐久性の向上とを両立させることができる。 According to the first and fifth aspects of the present invention, the porous sheet-shaped member is molded to obtain the porous molded member, and then the fibers of the porous molded member are bound together. Since the catalyst is supported on the surface including the inner wall surface of the pores, it is possible to achieve both improvement in catalyst reactivity and improvement in durability while reducing costs.
　請求項２、６の発明によれば、抄紙工程で用いられる耐熱性繊維がアルミナ繊維から成るとともに、結着工程は、アルミナ粉末を所定量の溶媒で溶解させたアルミナ溶液に多孔質成形部材を浸漬することで繊維同志を結着させるので、繊維同志をより良好且つ確実に結着させることができ、より強度の向上を図ることができる。 According to the second and sixth aspects of the invention, the heat-resistant fiber used in the paper making process is made of alumina fiber, and the binding process is performed by placing the porous molded member in an alumina solution obtained by dissolving alumina powder with a predetermined amount of solvent. Since the fibers are bound together by soaking, the fibers can be bound better and more reliably, and the strength can be further improved.
　請求項３、７の発明によれば、アルミナ溶液の濃度又は浸漬時間を調整することにより、多孔質成形部材の細孔に充填されるアルミナの量を任意に調整可能とされたので、結着工程において、細孔が埋まってしまうのを最小限に抑えることができ、強度の向上と触媒反応性の向上との両立を良好に図ることができる。 According to the inventions of claims 3 and 7, the amount of alumina filled in the pores of the porous molded member can be arbitrarily adjusted by adjusting the concentration of the alumina solution or the immersion time. In the process, the filling of the pores can be minimized, and both the improvement of the strength and the improvement of the catalytic reactivity can be favorably achieved.
　請求項４、８の発明によれば、成形工程で得られる多孔質成形部材は、多孔質シート状部材をロール状に巻いた円筒状の多孔質成形部材、又は当該多孔質シート状部材をキューブ状に成形した立方体状若しくは直方体状の多孔質成形部材から成るので、触媒反応性をより向上させることができる。 According to invention of Claim 4, 8, the porous shaping | molding member obtained by a shaping | molding process is a cylindrical porous shaping | molding member which wound the porous sheet-like member in roll shape, or the said porous sheet-like member is cubed. Since it is formed of a cubic or rectangular parallelepiped porous molded member, the catalytic reactivity can be further improved.
本発明の実施形態に係る触媒構造体を示す外観図External view showing a catalyst structure according to an embodiment of the present invention 本発明の他の実施形態に係る触媒構造体を示す外観図External view showing a catalyst structure according to another embodiment of the present invention 本発明の触媒構造体の製造方法を示すフローチャートThe flowchart which shows the manufacturing method of the catalyst structure of this invention 本発明の触媒構造体の技術的優位性を示す実験で使用される設備を示す模式図The schematic diagram which shows the installation used in the experiment which shows the technical advantage of the catalyst structure of this invention 同実験で使用される設備の反応管を示す模式図Schematic diagram showing the reaction tube of the equipment used in the experiment 同反応管に充填される触媒構造体（第１実施例）を示す模式図Schematic diagram showing the catalyst structure (first embodiment) filled in the reaction tube 同反応管に充填される触媒構造体（第２実施例）を示す模式図Schematic diagram showing the catalyst structure (second embodiment) filled in the reaction tube 同反応管に充填される触媒構造体（比較例）を示す模式図Schematic diagram showing the catalyst structure (comparative example) filled in the reaction tube 同実験における触媒温度とメタン転化率との関係を示すグラフGraph showing the relationship between catalyst temperature and methane conversion in the same experiment
　以下、本発明の実施形態について図面を参照しながら具体的に説明する。
　本実施形態に係る触媒構造体は、化学プラントで使用される工業触媒（例えば反応ガスに対して触媒反応して所望の生成ガスを得るための触媒）を担持した触媒構造体から成るもので、例えば、中空円筒状の触媒構造体１（図１参照）又は立方体状若しくは直方体状の触媒構造体２（図２参照）から成る。 Hereinafter, embodiments of the present invention will be specifically described with reference to the drawings.
The catalyst structure according to the present embodiment is composed of a catalyst structure supporting an industrial catalyst used in a chemical plant (for example, a catalyst for obtaining a desired product gas by catalytic reaction with a reaction gas). For example, it consists of a hollow cylindrical catalyst structure 1 (see FIG. 1) or a cubic or rectangular parallelepiped catalyst structure 2 (see FIG. 2).
　これら触媒構造体１、２は、多孔質シート状部材を所定形状に成形するとともに、その繊維同志を結着させ、焼成した後、触媒を担持させることにより得られたものであり、触媒構造体１は、多孔質シート状部材をロール状に巻いた円筒状の多孔質成形部材を焼成したもの、触媒構造体２は、多孔質シート状部材をキューブ状に成形した立方体状若しくは直方体状の多孔質成形部材を焼成したものである。 These catalyst structures 1 and 2 are obtained by forming a porous sheet-like member into a predetermined shape, binding the fibers together, firing the catalyst, and then supporting the catalyst. 1 is a fired cylindrical porous molded member obtained by winding a porous sheet-shaped member in a roll shape, and the catalyst structure 2 is a cubic or cuboid porous material in which the porous sheet-shaped member is molded in a cube shape. A quality molded member is fired.
　具体的には、実施形態に係る触媒構造体は、図３のフローチャートで示す工程（主に、抄紙工程Ｓ１、成形工程Ｓ２、結着工程Ｓ３、脱脂工程Ｓ４、高温焼成工程Ｓ５、触媒担持工程Ｓ６及び焼成工程Ｓ７から成る工程）を経て製造される。
　抄紙工程Ｓ１は、抄紙法（本実施形態においては湿式抄紙法）により耐熱性繊維をシート状に成形して多孔質シート状部材を得る工程である。抄紙法は、例えば無機バインダ及び耐熱性繊維としてのアルミナ繊維などを所定量の水に混入させてスラリーを生成するスラリー生成工程と、スラリー生成工程で得られたスラリーに凝集剤を添加してフロックを生成するフロック生成工程と、フロック生成工程で得られたフロックを抄紙してシート状の多孔質構造体を得るシート化工程と、シート化工程で得られたシート状の多孔質構造体を乾燥して多孔質シート状部材を得る乾燥工程とを有している。 Specifically, the catalyst structure according to the embodiment includes the steps shown in the flowchart of FIG. 3 (mainly the paper making step S1, the forming step S2, the binding step S3, the degreasing step S4, the high temperature firing step S5, and the catalyst supporting step. Step S6 and the baking step S7).
The papermaking step S1 is a step of obtaining a porous sheet-like member by forming heat-resistant fibers into a sheet shape by a papermaking method (wet papermaking method in the present embodiment). For example, the paper making method includes a slurry generation step in which an inorganic binder and alumina fibers as heat-resistant fibers are mixed in a predetermined amount of water to generate a slurry, and a flocculant is added to the slurry obtained in the slurry generation step to add a flocculant. A flock generating step for producing a sheet, a sheet forming step for producing a sheet-like porous structure by papermaking the flock obtained in the flock generating step, and a drying of the sheet-like porous structure obtained in the sheet forming step And a drying step for obtaining a porous sheet-like member.
　成形工程Ｓ２は、抄紙工程Ｓ１で得られた多孔質シート状部材を所定形状に成形して多孔質成形部材を得るための工程である。かかる多孔質成形部材は、図１、２で示すように、中空円筒状や立方体状若しくは直方体状の他、球状やペレット状等、他の形状であってもよい。また、立方体状若しくは直方体状の多孔質成形部材とする場合、比較的厚さ寸法が大きい多孔質シート状部材を縦横方向に任意に切除して得るものの他、比較的厚さ寸法の小さい多孔質シート状部材を積層させて得るもの等であってもよい。 The forming step S2 is a step for obtaining a porous formed member by forming the porous sheet-like member obtained in the paper making step S1 into a predetermined shape. As shown in FIGS. 1 and 2, the porous molded member may have a hollow cylindrical shape, a cubic shape or a rectangular parallelepiped shape, or other shapes such as a spherical shape or a pellet shape. In addition, when a cube-shaped or rectangular parallelepiped porous molded member is used, a porous sheet-shaped member having a relatively large thickness is obtained by arbitrarily cutting in a vertical and horizontal direction, and a porous having a relatively small thickness. It may be obtained by laminating sheet-like members.
　結着工程Ｓ３は、成形工程Ｓ２で得られた多孔質成形部材の繊維同志を結着させる工程であり、本実施形態においては、アルミナ粉末を所定量の溶媒で溶解させたアルミナ溶液に多孔質成形部材を浸漬することで繊維同志を結着させるよう構成されている。より具体的には、結着工程Ｓ３は、アルミナ粉末を所定量の水に分散させたスラリーを用意しておき、そのスラリーに成形工程Ｓ２で得られた多孔質成形部材を所定時間浸漬させた後、乾燥させることにより行われる。 The binding step S3 is a step of binding the fibers of the porous molded member obtained in the molding step S2. In this embodiment, the porous step is performed in an alumina solution in which alumina powder is dissolved in a predetermined amount of solvent. It is comprised so that fibers may be bound together by immersing a forming member. More specifically, in the binding step S3, a slurry in which alumina powder is dispersed in a predetermined amount of water is prepared, and the porous molded member obtained in the molding step S2 is immersed in the slurry for a predetermined time. Then, it is performed by drying.
　このように、本実施形態においては、抄紙工程Ｓ１で用いられる耐熱性繊維がアルミナ繊維から成るとともに、結着工程Ｓ３は、アルミナ粉末を所定量の水（溶媒）で溶解させたアルミナ溶液に多孔質成形部材を浸漬することで繊維同志を結着させているのである。なお、アルミナ溶液（スラリー）に分散剤や増粘剤等を添加することで、スラリーの成分調整を図るのが好ましい。 Thus, in this embodiment, the heat resistant fiber used in the paper making step S1 is made of alumina fiber, and the binding step S3 is porous in an alumina solution in which alumina powder is dissolved in a predetermined amount of water (solvent). The fibers are bound together by dipping the quality molded member. In addition, it is preferable to adjust the components of the slurry by adding a dispersant, a thickener, or the like to the alumina solution (slurry).
　特に、本実施形態においては、アルミナ溶液の濃度又は浸漬時間を調整することにより、多孔質成形部材の細孔に充填されるアルミナの量を任意に調整可能とされている。すなわち、アルミナ溶液に含有するアルミナは、多孔質成形部材を構成する繊維同志を結着させて強度を向上させ得る一方、細孔を埋めてしまい、比表面積を低下させてしまうため、アルミナ溶液の濃度又は浸漬時間を調整することにより、細孔が過度に埋まってしまうのを回避しているのである。 In particular, in this embodiment, the amount of alumina filled in the pores of the porous molded member can be arbitrarily adjusted by adjusting the concentration of the alumina solution or the immersion time. In other words, the alumina contained in the alumina solution can improve the strength by binding the fibers constituting the porous molded member, while filling the pores and reducing the specific surface area. By adjusting the concentration or immersion time, the pores are prevented from being excessively filled.
　脱脂工程Ｓ４は、結着工程Ｓ３を経た多孔質成形部材をエア雰囲気下で所定時間加熱することにより、多孔質成形部材中に含有される有機成分を消失させる工程である。加熱温度は、使用する原材料成分により多少異なるが、概ね５００～６００℃程度が好ましい。高温焼成工程Ｓ５は、脱脂工程Ｓ４を経た多孔質成形部材をエア雰囲気下、約１４５０～１５５０℃の高温で所定時間焼成する工程である。かかる高温焼成工程Ｓ５を経ることで、実用強度を有する触媒構造体を得ることができる。 The degreasing step S4 is a step of eliminating the organic components contained in the porous molded member by heating the porous molded member that has undergone the binding step S3 in an air atmosphere for a predetermined time. The heating temperature varies somewhat depending on the raw material components used, but is preferably about 500 to 600 ° C. The high-temperature firing step S5 is a step of firing the porous molded member that has undergone the degreasing step S4 at a high temperature of about 1450 to 1550 ° C. for a predetermined time in an air atmosphere. A catalyst structure having practical strength can be obtained through the high-temperature firing step S5.
　触媒担持工程Ｓ６は、焼成工程Ｓ５を経た多孔質成形部材の表面に触媒を担持させる工程であり、例えば予め製造された触媒担持液中に焼成工程Ｓ５を経た多孔質成形部材を浸漬した後、乾燥するものとされている。このような触媒担持工程Ｓ６を経ることで、多孔質成形部材の表面（多孔質成形部材に形成された細孔の内壁面を含む）に対して略均一に触媒を担持させることができる。 The catalyst supporting step S6 is a step of supporting the catalyst on the surface of the porous molded member that has undergone the calcination step S5. For example, after immersing the porous molded member that has undergone the calcination step S5 in a catalyst supporting liquid that has been manufactured in advance, It is supposed to dry. By passing through such a catalyst supporting step S6, the catalyst can be supported substantially uniformly on the surface of the porous molded member (including the inner wall surfaces of the pores formed in the porous molded member).
　また、触媒担持工程Ｓ６で使用される触媒担持液は、以下のものが挙げられる。すなわち、多孔質アルミナ粉末の細孔内にパラジウム、ロジウム、プラチナ、ニッケルなどの金属を含む水溶液を例えばポアフィリング法により担持させて乾燥した後、その粉末を約６００～９００℃で所定時間加熱して触媒粉末を得る。そして、その触媒粉末を所定量の水に投入し、ボールミルなどにより均一に拡散させることによりスラリー（触媒担持液）を得る。なお、触媒担持液（スラリー）に分散剤や増粘剤等を添加することで、スラリーの成分調整を図るのが好ましい。 Further, the catalyst supporting liquid used in the catalyst supporting step S6 includes the following. That is, an aqueous solution containing a metal such as palladium, rhodium, platinum, or nickel is supported in the pores of the porous alumina powder by, for example, a pore filling method and dried, and then the powder is heated at about 600 to 900 ° C. for a predetermined time. To obtain catalyst powder. And the slurry (catalyst carrying liquid) is obtained by throwing the catalyst powder into a predetermined amount of water and uniformly diffusing it with a ball mill or the like. It is preferable to adjust the components of the slurry by adding a dispersant, a thickener or the like to the catalyst support liquid (slurry).
　焼成工程Ｓ７は、触媒担持工程Ｓ６にて触媒が担持された多孔質成形部材をエア雰囲気下、約６００～９００℃で所定時間焼成する工程であり、かかる工程を経ることで本実施形態に係る完成品としての触媒構造体を得ることができる。このような実施形態によれば、多孔質シート状部材を成形して多孔質成形部材を得た後、当該多孔質成形部材の繊維同志が結着されるとともに、その多孔質成形部材の細孔の内壁面を含む表面に触媒が担持されるので、低コスト化を図りつつ触媒反応性の向上と耐久性の向上とを両立させることができる。 The firing step S7 is a step of firing the porous molded member carrying the catalyst in the catalyst carrying step S6 in an air atmosphere at a temperature of about 600 to 900 ° C. for a predetermined time. A catalyst structure as a finished product can be obtained. According to such an embodiment, after the porous sheet-like member is molded to obtain the porous molded member, the fibers of the porous molded member are bound together, and the pores of the porous molded member Since the catalyst is supported on the surface including the inner wall surface, it is possible to achieve both improvement in catalyst reactivity and improvement in durability while reducing costs.
　また、本実施形態によれば、抄紙工程Ｓ１で用いられる耐熱性繊維がアルミナ繊維から成るとともに、結着工程Ｓ３は、アルミナ粉末を所定量の溶媒で溶解させたアルミナ溶液に多孔質成形部材を浸漬することで繊維同志を結着させるので、多孔質成形部材を構成するアルミナと同一材料のアルミナで結着させることができ、繊維同志をより良好且つ確実に結着させることができ、より強度の向上を図ることができる。 Further, according to the present embodiment, the heat-resistant fiber used in the paper making step S1 is made of alumina fiber, and the binding step S3 is a step in which a porous molded member is placed in an alumina solution obtained by dissolving alumina powder with a predetermined amount of solvent. By soaking, the fibers are bound together, so it can be bound with the same material alumina as the alumina forming the porous molded member, and the fibers can be bound better and more reliably, and the strength is increased. Can be improved.
　さらに、本実施形態によれば、アルミナ溶液の濃度又は浸漬時間を調整することにより、多孔質成形部材の細孔に充填されるアルミナの量を任意に調整可能とされたので、結着工程において、細孔が埋まってしまうのを最小限に抑えることができ、強度の向上と触媒反応性の向上との両立を良好に図ることができる。またさらに、本実施形態に係る成形工程Ｓ２で得られる多孔質成形部材は、多孔質シート状部材をロール状に巻いた円筒状の多孔質成形部材、又は当該多孔質シート状部材をキューブ状に成形した立方体状若しくは直方体状の多孔質成形部材から成るので、触媒反応性をより向上させることができる。 Furthermore, according to the present embodiment, the amount of alumina filled in the pores of the porous molded member can be arbitrarily adjusted by adjusting the concentration or immersion time of the alumina solution. Further, it is possible to minimize the filling of the pores, and it is possible to satisfactorily achieve both improvement in strength and improvement in catalytic reactivity. Furthermore, the porous molded member obtained in the molding step S2 according to the present embodiment is a cylindrical porous molded member obtained by winding the porous sheet-shaped member in a roll shape, or the porous sheet-shaped member is formed in a cube shape. Since it consists of a molded cubic or rectangular parallelepiped porous molded member, the catalytic reactivity can be further improved.
　次に、本発明に係る触媒構造体の技術的優位性を示すための実験について説明する。
　下記の表１に示すように、中空円筒状の触媒構造体から成る第１実施例、立方体状の触媒構造体から成る第２実施例及び球状の比較例を用意した。但し、第１実施例及び第２実施例は、上記した製造工程（抄紙工程Ｓ１、成形工程Ｓ２、結着工程Ｓ３、脱脂工程Ｓ４、高温焼成工程Ｓ５、触媒担持工程Ｓ６及び焼成工程Ｓ７から成る工程）を経たものであり、比較例は、触媒が混入されたセラミック粉末をプレス加工にて球状に成形したものである。 Next, an experiment for showing the technical superiority of the catalyst structure according to the present invention will be described.
As shown in Table 1 below, a first example comprising a hollow cylindrical catalyst structure, a second example comprising a cubic catalyst structure, and a spherical comparative example were prepared. However, the first embodiment and the second embodiment consist of the above-described manufacturing steps (paper making step S1, forming step S2, binding step S3, degreasing step S4, high temperature firing step S5, catalyst supporting step S6 and firing step S7. In the comparative example, the ceramic powder mixed with the catalyst is formed into a spherical shape by press working.
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
　そして、第１実施例、第２実施例及び比較例に対して、メタン水蒸気改質反応（８００℃、７００℃）を図４、５で示すような常圧固定床流通型反応装置で行い、メタン転化率を評価した。評価時の条件は、表１に示した通りであり、例えば大気圧下、Ｓ／Ｃ＝３．０、ＳＶ＝２８５０（１／ｈｒ）又は５６９０（１／ｈｒ）とされるとともに、生成ガスＧ２は、ＧＣ（ガスクロマトグラフィー）で分析して定量した。また、反応ガスＧ１が導入される反応管Ｋは、触媒を充填するための触媒充填部Ｋａを有している。そして、第１実施例（触媒構造体１）は、反応管Ｋの触媒充填部Ｋａにおいて図６に示す如く充填され、第２実施例（触媒構造体２）は、同触媒充填部Ｋａにおいて図７に示す如く充填されるとともに、比較例（触媒構造体ａ）は、同触媒充填部Ｋａにおいて図８に示す如く充填されている。 And with respect to 1st Example, 2nd Example, and a comparative example, a methane steam reforming reaction (800 degreeC, 700 degreeC) is performed with an atmospheric pressure fixed bed flow-type reaction apparatus as shown in FIG. Methane conversion was evaluated. Conditions at the time of evaluation are as shown in Table 1. For example, S / C = 3.0, SV = 2850 (1 / hr) or 5690 (1 / hr) under atmospheric pressure, and the generated gas G2 was analyzed and quantified by GC (gas chromatography). The reaction tube K into which the reaction gas G1 is introduced has a catalyst filling portion Ka for filling the catalyst. The first embodiment (catalyst structure 1) is filled in the catalyst filling portion Ka of the reaction tube K as shown in FIG. 6, and the second embodiment (catalyst structure 2) is filled in the catalyst filling portion Ka. 7 and the comparative example (catalyst structure a) is filled as shown in FIG. 8 in the catalyst filling portion Ka.
　上記条件下、反応結果については、図９に示すように、第１実施例及び第２実施例が比較例よりも高いメタン転化率を示した。また、比較例については、炭素析出とともに触媒構造体が破壊（粉化）されたのに対し、第１、２実施例については、触媒構造体の破壊（粉化）等は全く生じなかった。したがって、第１、２実施例は、比較例に比べて、触媒反応に優れ、且つ、強度が高いことが分かる。 Under the above conditions, as for the reaction results, as shown in FIG. 9, the first example and the second example showed a higher methane conversion rate than the comparative example. In the comparative example, the catalyst structure was destroyed (pulverized) with carbon deposition, whereas in the first and second examples, the catalyst structure was not destroyed (pulverized). Therefore, it can be seen that the first and second examples are superior in catalytic reaction and higher in strength than the comparative examples.
　以上、本実施形態について説明したが、本発明はこれに限定されず、結着工程Ｓ３においてアルミナと異なる材料で多孔質成形部材の繊維同志を結着するもの、或いは触媒担持工程Ｓ６において種々の触媒を担持させるものとしてもよい。また、脱脂工程Ｓ４、高温焼成工程Ｓ５及び焼成工程Ｓ７は、それぞれの作用を果たすものであれば、温度や雰囲気等の条件を他の条件としてもよい。なお、本実施形態においては、化学プラントに使用される触媒構造体に適用されているが、他の触媒構造体に適用してもよい。 As mentioned above, although this embodiment was described, this invention is not limited to this, What bind | concludes the fiber of a porous shaping | molding member with the material different from an alumina in binding process S3, or various in catalyst support process S6 A catalyst may be supported. Moreover, as long as the degreasing process S4, the high temperature baking process S5, and the baking process S7 perform each function, conditions, such as temperature and an atmosphere, may be made into other conditions. In addition, in this embodiment, although applied to the catalyst structure used for a chemical plant, you may apply to another catalyst structure.
　抄紙法により耐熱性繊維をシート状に成形して多孔質シート状部材を得る抄紙工程と、該抄紙工程で得られた多孔質シート状部材を所定形状に成形する成形工程と、該成形工程で得られた多孔質成形部材の繊維同志を結着させる結着工程と、該結着工程を経た多孔質成形部材を所定温度にて焼成する焼成工程と、該焼成工程を経た多孔質成形部材の表面に触媒を担持させる触媒担持工程とを有した触媒構造体の製造方法又は触媒構造体であれば、他の形態のものにも適用することができる。 A papermaking process for forming a porous sheet-like member by forming a heat-resistant fiber into a sheet by a papermaking method, a molding process for molding the porous sheet-like member obtained in the papermaking process into a predetermined shape, and A binding step for binding fibers of the obtained porous molded member, a firing step for firing the porous molded member that has undergone the binding step at a predetermined temperature, and a porous molded member that has undergone the firing step As long as it is a manufacturing method of a catalyst structure or a catalyst structure having a catalyst supporting step for supporting a catalyst on the surface, it can be applied to other forms.
Ｓ１　抄紙工程
Ｓ２　成形工程
Ｓ３　結着工程
Ｓ４　脱脂工程
Ｓ５　高温焼成工程
Ｓ６　触媒担持工程
Ｓ７　焼成工程 S1 Papermaking step S2 Molding step S3 Binding step S4 Degreasing step S5 High temperature firing step S6 Catalyst supporting step S7 Firing step

Claims (8)

  1. 　触媒を担持した触媒構造体の製造方法において、
    　抄紙法により耐熱性繊維をシート状に成形して多孔質シート状部材を得る抄紙工程と、
    　該抄紙工程で得られた多孔質シート状部材を所定形状に成形する成形工程と、
    　該成形工程で得られた多孔質成形部材の繊維同志を結着させる結着工程と、
    　該結着工程を経た多孔質成形部材を所定温度にて焼成する焼成工程と、
    　該焼成工程を経た多孔質成形部材の表面に触媒を担持させる触媒担持工程と、
    を有したことを特徴とする触媒構造体の製造方法。     In the method for producing a catalyst structure carrying a catalyst,
    A papermaking process in which a heat-resistant fiber is formed into a sheet by a papermaking method to obtain a porous sheet-like member;
    A molding step of molding the porous sheet-like member obtained in the paper making step into a predetermined shape;
    A binding step for binding fibers of the porous molded member obtained in the molding step;
    A firing step of firing the porous molded member that has undergone the binding step at a predetermined temperature;
    A catalyst supporting step of supporting a catalyst on the surface of the porous molded member that has undergone the firing step;
    The manufacturing method of the catalyst structure characterized by having.
  2. 　前記抄紙工程で用いられる耐熱性繊維がアルミナ繊維から成るとともに、前記結着工程は、アルミナ粉末を所定量の溶媒で溶解させたアルミナ溶液に前記多孔質成形部材を浸漬することで繊維同志を結着させることを特徴とする請求項１記載の触媒構造体の製造方法。 The heat-resistant fibers used in the paper making process are made of alumina fibers, and in the binding process, the porous molded members are immersed in an alumina solution in which alumina powder is dissolved in a predetermined amount of solvent to bind the fibers together. The method for producing a catalyst structure according to claim 1, wherein the catalyst structure is deposited.
  3. 　前記アルミナ溶液の濃度又は浸漬時間を調整することにより、前記多孔質成形部材の細孔に充填されるアルミナの量を任意に調整可能とされたことを特徴とする請求項２記載の触媒構造体の製造方法。 The catalyst structure according to claim 2, wherein the amount of alumina filled in the pores of the porous molded member can be arbitrarily adjusted by adjusting the concentration or immersion time of the alumina solution. Manufacturing method.
  4. 　前記成形工程で得られる多孔質成形部材は、前記多孔質シート状部材をロール状に巻いた円筒状の多孔質成形部材、又は当該多孔質シート状部材をキューブ状に成形した立方体状若しくは直方体状の多孔質成形部材から成ることを特徴とする請求項１～３の何れか１つに記載の触媒構造体の製造方法。 The porous molded member obtained in the molding step is a cylindrical porous molded member obtained by rolling the porous sheet-shaped member into a roll shape, or a cubic or rectangular parallelepiped shape obtained by forming the porous sheet-shaped member into a cube shape. The method for producing a catalyst structure according to any one of claims 1 to 3, wherein the catalyst structure is made of the following porous molded member.
  5. 　触媒を担持した触媒構造体において、
    　抄紙法により耐熱性繊維をシート状に成形して多孔質シート状部材を得る抄紙工程と、
    　該抄紙工程で得られた多孔質シート状部材を所定形状に成形する成形工程と、
    　該成形工程で得られた多孔質成形部材の繊維同志を結着させる結着工程と、
    　該結着工程を経た多孔質成形部材を所定温度にて焼成する焼成工程と、
    　該焼成工程を経た多孔質成形部材の表面に触媒を担持させる触媒担持工程と、
    を経て得られることを特徴とする触媒構造体。     In the catalyst structure carrying the catalyst,
    A papermaking process in which a heat-resistant fiber is formed into a sheet by a papermaking method to obtain a porous sheet-like member;
    A molding step of molding the porous sheet-like member obtained in the paper making step into a predetermined shape;
    A binding step for binding fibers of the porous molded member obtained in the molding step;
    A firing step of firing the porous molded member that has undergone the binding step at a predetermined temperature;
    A catalyst supporting step of supporting a catalyst on the surface of the porous molded member that has undergone the firing step;
    A catalyst structure obtained by passing through
  6. 　前記抄紙工程で用いられる耐熱性繊維がアルミナ繊維から成るとともに、前記結着工程は、アルミナ粉末を所定量の溶媒で溶解させたアルミナ溶液に前記多孔質成形部材を浸漬することで繊維同志を結着させることを特徴とする請求項５記載の触媒構造体。 The heat-resistant fibers used in the paper making process are made of alumina fibers, and in the binding process, the porous molded members are immersed in an alumina solution in which alumina powder is dissolved in a predetermined amount of solvent to bind the fibers together. The catalyst structure according to claim 5, wherein the catalyst structure is attached.
  7. 　前記アルミナ溶液の濃度又は浸漬時間を調整することにより、前記多孔質成形部材の細孔に充填されるアルミナの量を任意に調整可能とされたことを特徴とする請求項６記載の触媒構造体。 The catalyst structure according to claim 6, wherein the amount of alumina filled in the pores of the porous molded member can be arbitrarily adjusted by adjusting the concentration or immersion time of the alumina solution. .
  8. 　前記成形工程で得られる多孔質成形部材は、前記多孔質シート状部材をロール状に巻いた円筒状の多孔質成形部材、又は当該多孔質シート状部材をキューブ状に成形した立方体状若しくは直方体状の多孔質成形部材から成ることを特徴とする請求項５～７の何れか１つに記載の触媒構造体。 The porous molded member obtained in the molding step is a cylindrical porous molded member obtained by rolling the porous sheet-shaped member into a roll shape, or a cubic or rectangular parallelepiped shape obtained by forming the porous sheet-shaped member into a cube shape. The catalyst structure according to any one of claims 5 to 7, wherein the catalyst structure is formed of the following porous molded member.
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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5910345A (en) * 1983-06-06 1984-01-19 Nichias Corp Carrier of catalyst
JPS62153175A (en) * 1985-12-27 1987-07-08 ニチアス株式会社 Heat resistant honeycomb structure and manufacture
JPH119991A (en) * 1997-06-23 1999-01-19 Nippon Gasket Co Ltd Heat-resistant porous sheet and its manufacture
JP2005111331A (en) * 2003-10-06 2005-04-28 Matsushita Electric Ind Co Ltd Catalyst carrier and catalyst filter

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5910345A (en) * 1983-06-06 1984-01-19 Nichias Corp Carrier of catalyst
JPS62153175A (en) * 1985-12-27 1987-07-08 ニチアス株式会社 Heat resistant honeycomb structure and manufacture
JPH119991A (en) * 1997-06-23 1999-01-19 Nippon Gasket Co Ltd Heat-resistant porous sheet and its manufacture
JP2005111331A (en) * 2003-10-06 2005-04-28 Matsushita Electric Ind Co Ltd Catalyst carrier and catalyst filter

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