WO2020141188A1 - Procédé de fabrication de filtres de type "wall-flow" catalytiquement actifs - Google Patents

Procédé de fabrication de filtres de type "wall-flow" catalytiquement actifs Download PDF

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Publication number
WO2020141188A1
WO2020141188A1 PCT/EP2020/050007 EP2020050007W WO2020141188A1 WO 2020141188 A1 WO2020141188 A1 WO 2020141188A1 EP 2020050007 W EP2020050007 W EP 2020050007W WO 2020141188 A1 WO2020141188 A1 WO 2020141188A1
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WO
WIPO (PCT)
Prior art keywords
filter
coating
wall flow
flow filter
face
Prior art date
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PCT/EP2020/050007
Other languages
German (de)
English (en)
Inventor
Astrid Mueller
Meike Antonia GOTTHARDT
Martin Foerster
Stephanie SPIESS
Yannic WEIGL
Carsten HERZOG
Original Assignee
Umicore Ag & Co. Kg
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Umicore Ag & Co. Kg filed Critical Umicore Ag & Co. Kg
Priority to CN202080007835.3A priority Critical patent/CN113226547B/zh
Publication of WO2020141188A1 publication Critical patent/WO2020141188A1/fr

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Classifications

    • 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
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/033—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices
    • F01N3/035—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters in combination with other devices with catalytic reactors, e.g. catalysed diesel particulate filters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/50—Zeolites
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/911—NH3-storage component incorporated in the catalyst
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/915—Catalyst supported on particulate filters
    • B01D2255/9155—Wall flow filters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/40—Nitrogen compounds
    • B01D2257/404—Nitrogen oxides other than dinitrogen oxide
    • 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
    • B01D53/9418—Processes characterised by a specific catalyst for removing nitrogen oxides by selective catalytic reduction [SCR] using a reducing agent in a lean exhaust gas
    • 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
    • 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 is directed to a method for producing particle filters.
  • the particulate filters are commonly used to filter exhaust gases from a combustion process. New filter substrates and their specific use in exhaust gas aftertreatment are also specified.
  • Internal combustion engines in motor vehicles typically contain the harmful gases carbon monoxide (CO) and hydrocarbons (HC), nitrogen oxides (NO x ) and optionally sulfur oxides (SO x ), as well as particles that consist predominantly of soot residues and possibly adhering organic agglomerates. These are referred to as primary emissions.
  • CO, HC and particles are products of the incomplete combustion of the fuel in the engine's combustion chamber.
  • Nitrogen oxides are generated in the cylinder from nitrogen and oxygen in the intake air when the combustion temperatures locally exceed 1400 ° C. Sulfur oxides result from the combustion of organic sulfur compounds, which are always contained in small amounts in non-synthetic fuels.
  • catalytic exhaust gas purification technologies have been developed to remove these emissions, which are harmful to the environment and health, from motor vehicles, the basic principle of which is usually based on the fact that the exhaust gas to be cleaned is passed over a catalytic converter which consists of a flow or wall flow honeycomb body (Wall flow filter) and a catalytically active coating applied thereon and / or therein.
  • the catalyst promotes the chemical reaction of various exhaust gas components with the formation of harmless products such as carbon dioxide and water. Particles can be removed from the exhaust gas very effectively using particle filters.
  • Wall-flow filters made from ceramic materials have proven particularly useful.
  • first channels are formed which are open on the first side of the filter and closed on the second side of the filter, and second channels which are closed on the first side of the filter and open on the second side of the filter.
  • the exhaust gas flowing into the first channels can only leave the filter again via the second channels, and for this purpose must flow through the porous walls between the first and second channels. When the exhaust gas passes through the wall, the particles are retained.
  • Wall flow filters can be catalytically active.
  • the catalytic activity is achieved by coating the filter with catalytically active material. Contacting the catalytically active materials with the wall flow filter is referred to in the trade as "coating". This term is generally understood to mean the application of catalytically active materials and / or storage components to a largely inert support body / substrate.
  • the coating takes on the actual catalytic function and often contains storage materials and / or catalytically active metals, which are usually deposited in highly dispersed form on temperature-stable, high-surface metal compounds, in particular oxides.
  • the coating usually takes place by applying an aqueous suspension of the storage materials and catalytically active components - also called washcoat - to or in the wall of the wall flow filter.
  • the carrier is generally dried and, if appropriate, calcined at elevated temperature.
  • the coating may consist of one layer or be composed of several layers which are applied to one another on a corresponding filter (multilayer) and / or offset from one another (as zones).
  • the catalytically active material can be applied to the porous walls between the channels (so-called effort coating). However, this can lead to an unacceptable increase in the back pressure of the filter.
  • JPH01-151706 and W02005016497A1 propose to coat a wall flow filter with a catalyst in such a way that the latter penetrates the porous walls (so-called in-wall coating tung).
  • Three-way catalytic converters are used to reduce emissions in stoichiometric combustion engines.
  • Three-way catalysts are well known to those skilled in the art and have been required by law since the 1980s.
  • the actual catalyst mass here mostly consists of a high-surface metal compound, especially oxidic support. germ material on which the catalytically active components are separated in the finest distribution.
  • the noble metals of the platinum group, platinum, palladium and / or rhodium are particularly suitable as catalytically active components for the purification of stoichiometrically composed exhaust gases.
  • Suitable substrates are, for example, aluminum oxide, silicon dioxide, titanium oxide, zirconium oxide, cerium oxide and their mixed oxides and zeolites.
  • three-way catalysts also contain oxygen-storing components. These include cerium / zirconium mixed oxides, which may contain lanthanum oxide, praseodymium oxide and / or yttrium oxide. Zoned and multi-layer systems with three-way activity are now known (US8557204; US8394348). If such a three-way catalytic converter is located on or in a particle filter, one speaks of a cGPF (catalyzed gasoline particle filter; e.g. EP2650042B1).
  • cGPF catalyzed gasoline particle filter
  • the particle filter has in common that it has to be regenerated at certain time intervals. This means that the accumulated soot particles have to be burned off in order to keep the exhaust gas back pressure in an acceptable range.
  • Exhaust gas temperatures of approx. 600 ° C are required for filter regeneration and the initiation of soot combustion. Very high temperatures can occur during the burn-up, which can be> 800 ° C.
  • the targeted loading of a porous filter with a coating suspension is described in EP2727640A1.
  • the pores on the upstream side of the filter have particles inside that completely fill the pores at least across their cross-section, essentially transversely to the direction of flow, and due to this porous filling, the pore volume of the filled pores is 50 to 90% of the pore volume of unfilled pores .
  • the pore volume of the filled pores on the upstream side of the Filter is less than the pore volume of the filled pores in the flow direction further away from the upstream side of the filter and the pore volume of the filled pores in the flow direction increases the further away the pores are from the upstream side of the filter.
  • EP1716903B1 proposes a method for coating filter bodies, in which, after coating, the filter is freed from too much coating dispersion by repeatedly applying pressure pulses to one end of the filter body in such a way that excess coating suspension is forced out of the filter body. until it has reached its optimal coating weight. Aim seems among others here too the reduction in exhaust back pressure of the filter. This is obviously an in-wall coating.
  • US20040254071A1 describes a method for coating a wall flow filter.
  • a coating suspension is introduced into a wall flow filter and an excess is removed.
  • Zoned coatings can be obtained in or on wall flow filter channels. It is not explicitly stated from which side the coating is carried out.
  • the aim here is to obtain a specific coating geometry through the solids content of the coating suspension.
  • the coating concentration is usually increased on the side through which the coating is introduced into the wall flow filter.
  • the W02006042699A1 is also based on a process for coating e.g. Wall flow filters directed.
  • a support body is contacted with a suspension after vertical alignment from below. Excess suspension is then removed from the support body.
  • additional coating suspension can be applied to the support body from above via a spray nozzle.
  • the object of the present invention is to provide a manufacturing process for catalytically coated, ceramic wall-flow filter substrates, which in particular enables it to be able to generate improved wall-flow filter substrates compared to the prior art.
  • the wall-flow filters produced in this way should be superior to the substrates produced according to the prior art, especially with regard to the requirement of the lowest possible exhaust gas back pressure while still having sufficient catalytic activity and filtration efficiency.
  • Another object of the present invention was to specify filter substrates produced by the above process and their use in exhaust gas aftertreatment.
  • the wall flow filter having a first end face, a second end face and a length L and a porosity of at least 50% to a maximum of 80 % (DIN 66133 - latest version on the filing date) and an average pore diameter of 5 - 50 pm (DIN 66134 - newest version on the filing date), so that: i) a Sus.
  • the yield point is determined in accordance with DIN EN ISO 3219-1 (latest version on the filing date). It is defined as the smallest shear stress g above which a sample behaves like a liquid and can flow. Below the yield point, it behaves more like a solid. Suspensions are advantageously used which, as a filter cake, that is to say as a coating applied to the wall of the wall-flow filter, have such a high yield point that the pores opened by the pressure pulse are not closed again by a flowing suspension. Due to the increase in the concentration of the coating suspension caused by the water absorption of the porous filter from, for example, approximately 35% to greater than 45%, the yield point rises significantly (Chateau et al., J. Rheol. 52, 489-506 (2008)).
  • the yield point for suspensions with correspondingly high solids concentrations after coating in the filter cake is advantageously between 1 Pa and 300 Pa, preferably between 5 and 200 Pa and very preferably between 10 and 100 Pa.
  • the yield point of suspensions is usually determined using a plate-cone or plate-plate rheometer (for example the HAAKE RheoStress 600).
  • the density of the suspensions used can preferably be between 1050 kg / m 3 to 1700kg / m 3 , more preferably between 1100kg / m 3 and 1600kg / m 3 and particularly preferably between 1100kg / m 3 and 1550kg / m 3 .
  • the value of the surface tension and the contact angle for water can be assumed for the surface tension of the ceramic suspensions.
  • the surface tension value is 72.75 mN / m at 20 ° C and the contact angle is around 20 °. If this amount is put into the equation, the minimum pressure pulse required for emptying pores with a pore diameter of, for example, 10 pm to 280 mbar plus the value of the flow limit [g] of 3 to 10 mbar to 283-290 mbar is calculated. If you want to open the pores> 30pm, the minimum pressure pulse at the same yield point drops to approx. 100mbar.
  • These pressure pulse indications mean that the wall flow filter is treated with an appropriate suppressor. As a rule, the pressure pulse Dr described above will not be increased over a certain intensity.
  • the pressure pulse described under iii) is, in particular, a measure which is sufficient to largely free the larger channels or pores (for example> d50 of the pore diameter) through the wall from the catalytically active material applied to these pores .
  • a measure which is sufficient to largely free the larger channels or pores (for example> d50 of the pore diameter) through the wall from the catalytically active material applied to these pores As a rule, only the large, continuous pores or channels that reach through the wall are “blown free” or “sucked free” as already shown above. However, the catalytically active substance remains predominantly present on the smaller pores of the filter walls. To further discriminate between large and smaller pores, it may be beneficial for the pressure pulse to develop fully in a relatively short period of time.
  • the maximum pressure difference should be reached within ⁇ 0.5 s, more preferably ⁇ 0.2 s and very preferably ⁇ 0.1 s.
  • the total duration of the pressure pulse should also not exceed a value of 2 s, preferably 1 s and particularly preferably 0.5 s.
  • the pressure pulse should not exceed 350 mbar, more preferably 370 mbar and very preferably 400 mbar, since otherwise too much oxide mass will be removed.
  • the solid constituents of the suspension can penetrate the wall of the filter to less than 15% by weight, more preferably less than 10% by weight, based on the amount of solid constituents.
  • scanning electron microscope images are evaluated with the aid of a statistical gray scale evaluation. Free pores / air appear black in a catalytically coated filter, while the heaviest items appear white.
  • Expensive coatings are preferably achieved in that the catalytically active material contains high-surface metal compounds, in particular oxides, whose average particle diameter (DIN 66160 - latest version on the filing date) d50 of the Q3 distribution in relation to the average pore diameter of the filter d50 of the Q3 method.
  • division is preferably> 1: 6 and ⁇ 1: 1 and particularly preferably> 1: 3 and ⁇ 1: 2 (https://de.wikipedia.org/wiki/Pellegr%C3%B6%C3%9Fen Distribution).
  • An upper limit is generally the value which can be assessed as meaningful by the person skilled in the art with the appropriate cost coatings.
  • the catalytically active materials By choosing the right particle size, you can control how much of the catalytically active materials should be positioned in the wall or on the wall of the wall-flow filter.
  • the ratio of preferably oxidic components present on the wall to the wall naturally also has a significant influence on the exhaust gas back pressure of the filter substrate produced in this way.
  • the holding time can be adapted to the requirements of the wall flow filter. If more backflowing liquid is desired in the pressure reversal, the holding time is increased accordingly.
  • the holding time is preferably between 0s and 10s, more preferably between 0s and 5s and particularly preferably between 0 and 2s.
  • a suspension which has catalytically active materials is introduced into the filter via the lower end face of the wall-flow filter.
  • the pressure difference used for filling is preferably between 0.05 bar and 4 bar, more preferably between 0.1 and 3 bar and particularly preferably between 0.5 and 2.5 bar. This pressure difference is dependent on
  • the viscosity of the suspension and the cell dimensions of the wall flow filter are preferably chosen such that the filling speed in the cells is between 10 mm / s up to 250 mm / s, preferably between 20 mm / s and 200 mm / s and very preferably between 30 mm / s and 180 mm / s.
  • an expense coating is created according to the invention, which is less than the maximum length of the wall flow filter.
  • the zone length can be> 15%, more preferably 20% - 85%, very preferably 25% - 75% and most preferably 30% - 70% of the length L of the wall flow filter.
  • this coating can also extend only at least 1.25 cm from the lower end face.
  • the catalytic coating of the wall flow filter thus produced has a positive gradient for the amount of catalytically active material in the coating direction.
  • the expense zone created according to the invention has an amount of material, measured in material / unit length, which, after the plugs have been removed, is 20% to 70% less than in a subsequent area over a range of 15 to 40 mm from the coating inlet end.
  • the amount of active components in the coating direction over the length of 80 mm of the substrate has a positive concentration gradient in the range from 20% to 100%, more preferably 25% to 90%.
  • the concentration gradient due to the different amount and distribution of the catalytically active materials can be determined, for example, gravimetrically, by evaluating X-ray absorption data (XRF measurement) or by measuring the BET surface area of certain filter sections along the longitudinal axis of the filter.
  • XRF measurement X-ray absorption data
  • the coating method according to the invention can advantageously be carried out several times in succession with the same or different catalytically active materials. It is important here that an appropriate pressure pulse according to the invention is set in between while still moist, which ensures that the large pores are blocked as little as possible by the coating components of the catalytically active material. It should be mentioned that the coating can be carried out with the same or different catalytically active materials, with and without intermediate drying. So for Example, a first catalytically active material is specifically introduced into the pores of the wall of the filter substrate and, in a subsequent coating, a second catalytically active material is applied to the wall of the filter substrate in accordance with steps i) - iii) according to the invention.
  • steps i) - iii) are carried out and then carried out again from the other side after turning the wall flow filter.
  • Architectures can thus be achieved, as shown by way of example in FIG. 3.
  • the layers (10a) can overlap in the longitudinal direction of the wall flow filter, then preferably for more than 5%, more preferably up to 20% and very preferably for 7% -15% of the length L of the wall flow filter.
  • the coating can be carried out using the same or different catalytically active materials or amounts, with or without intermediate drying.
  • a method is carried out as previously described. Without rotating the wall flow filter in its direction, a certain amount of a suspension comprising a catalytically active material (identical or different from the first) is applied to the upper end face during or afterwards - with or without intermediate drying - and this is applied by applying one Pressure increase on the upper end face and / or the pressure decrease on the lower end face of the wall flow filter is introduced into the vertically locked wall flow filter, so that this coating extends to less than 100% of the length of the wall flow filter.
  • the length of this zone coating in the channels adjacent to the first coating can be determined by a person skilled in the art. It is at least 20% and a maximum of 95% of the length L of the wall flow filter,. preferably 40% to 85%, particularly preferably 50% to 70%.
  • the layers (400 or 500) can overlap in the longitudinal direction of the wall flow filter.
  • the zones formed by the two coatings do not have to overlap.
  • the filtration efficiency of the free area can then be specifically adjusted to the requirements of the wall-flow filter after drying by means of a subsequent powder coating.
  • the powder coating for increasing the filtration efficiency is known to the person skilled in the filter technology under the term precoat (US4010013).
  • the last washcoat coating preferably overlaps with the coating according to steps i) -iii) at least 5%, more preferably up to 20% and very preferably for 7% -15% of the length L of the wall-flow filter.
  • the process steps i) - iii) according to the invention are connected to the process step just mentioned in such a way that the introduction of the suspension from the upper end face and the treatment of the coating according to steps i) - iii) happens with the at least one pressure pulse at the same time.
  • the suspension applied to the upper end face of the wall flow filter is simultaneously sucked or pressed into the wall flow filter. So you proceed step by step so that first the suspension is inserted into the wall flow filter from below, then the suspension is applied to the upper face and then both suspensions are treated with the at least one pressure pulse.
  • the zone on the wall created with steps i) to iii) can additionally be combined with a zone in the porous wall which was also created by the sequence of steps i) to iii) after the substrate was rotated through 180 ° ( Fig. 5).
  • the order of the zone application is arbitrary.
  • the particle diameter d99 of the Q3 distribution in the suspension in relation to the mean pore diameter of the pores in the filter walls should be preferably ⁇ 0.6: 1, more preferably ⁇ 0.5: 1 and particularly preferably ⁇ 0.4: 1. So it is possible to make the suspension large Share of> 80%, more preferably> 90% and very preferably> 95% and more in the pores of the wall of a wall flow filter. Wall flow filters, which are shown, for example, in FIG. 5, can then be produced in this way.
  • the two zones (10a, 10b) do not have to overlap.
  • This last coating preferably overlaps with the coating according to steps i) -iii) but at least 5%, more preferably up to 20% and very preferably for 7% -15% of the length L of the wall flow filter.
  • the zone on the wall applied from above, with a comparable load, a comparable zone length and a comparable particle size distribution in the coating, has a significantly lower permeability overall than the zone on the wall, which over the lower end face with pressure pulse according to steps i) - iii) has been introduced, see also Table 2.
  • Powder coatings for increasing filtration efficiency have long been state of the art in filters for air pollution control (The Effects of Newly Formulated Filter Aids Material Loading on Pressure Drop and Particle Penetration, S. Hajar, M. Rashid, A. Nurnadia, MR Ammar, International Conference on Mechanics, Materials and Structural Engineering (ICMMSE 2016)).
  • the wall-flow filter produced as indicated above can be dried between the processes for applying the catalytically active coatings, if necessary, but it does not have to - as already indicated. As a rule, calcination does not follow in the usual way until the application of the final coating has been completed.
  • the present invention also relates to a catalytically coated ceramic wall-flow filter produced according to the invention for the treatment of exhaust gases from a combustion process.
  • the catalytic coating of the wall flow filter produced according to steps i) - iii) has a positive gradient of the coating concentration (g / l) in the coating direction (see above). This preferably results in a negative gradient (decrease) with regard to the permeability in the coating direction.
  • a very preferred wall flow filter - as described - has a catalytically active coating in the channels when viewed from both sides, of which at least one coating represents a porous expense coating (e.g. Fig. 4/5).
  • the filter has no preferred direction.
  • it is preferably installed in the exhaust line of a vehicle with a stoichiometrically operated internal combustion engine in such a way that the cost coating according to the invention of steps i) - iii) is located in the outlet duct, as seen in the direction of flow (FIG. 1).
  • Special wall flow filters can be manufactured by the method according to the invention. These have a unique permeability distribution in the direction of the longitudinal axis of the wall flow filter, which is due to the manufacturing process but is very advantageous. Precisely if one couples the combination of an application of a suspension with catalytically active materials over the lower end face of the wall flow filter in accordance with the invention with the coating over the upper end face, a wall flow filter that is particularly advantageous for use in the exhaust system of a stoichiometrically burning automobile engine is created.
  • the wall coating from above is particularly preferably in the inlet channel (E) of the exhaust gas flow, while the expense coating is from below in the outlet channel (A) of the exhaust gas flow (FIG. 1).
  • a wall flow filter in which the permeability curve along the longitudinal axis of the wall flow filter from the first end face of the exhaust gas inlet to the second end face (outlet of the exhaust gas) behaves as follows: a) Permeability in the area of the coating starting from the first End face remains constant within the scope of the error accuracy or falls in the coating direction; b) permeability in the overlap area of the coatings is equal to or less than in the area under a); c) Permeability continuously increasing in the area of the remaining coating. It is very particularly advantageous if the two coatings are expenditure coatings and the permeability on the second end face, the end face of the gas outlet, has the highest permeability of the filter.
  • the present invention also relates to the use of the wall flow filter according to the invention in a process for the oxidation of hydrocarbons and / or carbon monoxide and / or in a process for nitrogen oxide reduction.
  • This method is preferably the one that takes place in a three-way catalyst in the stoichiometric exhaust gas. It is preferred if, in addition to this wall flow filter, there is also a three-way catalytic converter on the downstream side or placed on the upstream side in the exhaust system. Possibly. there are also 2 separate three-way catalysts, particularly preferably one on the upstream side and one on the downstream side of the wall-flow filter according to the invention in the exhaust system.
  • the wall flow filter is very particularly preferably used as a cGPF with a three-way function.
  • the coatings considered here mostly contain platinum group metals, such as Pt, Pd and Rh, as catalytically active components, with Pd and Rh being particularly preferred.
  • the catalytically active metals are often highly dispersed on combatoberflä-containing oxides of aluminum, cerium, zirconium and titanium or mixtures or mixed oxides thereof, which by further transition elements such. B.
  • Such three-way catalysts also contain oxygen storage materials (e.g. Ce / Zr mixed oxides; see below).
  • oxygen storage materials e.g. Ce / Zr mixed oxides; see below.
  • a suitable three-way catalytic coating is described for example in EP1181970B1, EP1541220B1, W020081 13445A1, W02008000449A2, to which reference is hereby made with regard to the use of catalytically active powders (see also introduction).
  • Diesel engines without DPF can have up to ten times higher particle emissions, based on the particle mass, than petrol engines without GPF (Maricq et al., SAE 1999-01-01530).
  • Emissions in gasoline engines range from particle sizes smaller than 200 nm (Hall et al., SAE 1999-01-3530) to 400 nm (Mathis et al., Atmospheric Environment 38 4347) with the maximum in the range of around 60 nm to 80 nm.
  • the three-way catalysts just mentioned can be equipped with a nitrogen oxide storage functionality in powder (TWNSC).
  • TWNSC nitrogen oxide storage functionality in powder
  • These catalytic converters consist of materials that give the catalytic converter the function of a three-way catalytic converter under stoichiometric exhaust gas conditions and that have a function for storing nitrogen oxides under lean exhaust gas conditions. These stored nitrogen oxides are regenerated during short, rich operating phases in order to restore their storage capacity.
  • a corresponding TWNSC is preferably produced by combining materials which are used for the construction of a three-way catalytic converter and a nitrogen oxide storage catalytic converter.
  • a particularly preferred embodiment for such a catalyst is described for example in WO2010097146A1 or WO2015143191A1.
  • an air-fuel mixture is maintained during the regeneration, which one l corresponds to 0.8 to 1. This value is particularly preferably between 0.85 and 0.99, very particularly preferably between 0.95 and 0.99.
  • Porous wall flow filter substrates made of cordierite, silicon carbide or aluminum titanate are preferably used. These wall-mounted flow filter substrates have inflow and outflow channels, the outflow-side ends of the inflow channels and the upstream-side ends of the outflow channels being closed off from one another with gas-tight “plugs”.
  • the exhaust gas to be cleaned which flows through the filter substrate, is forced to pass through the porous wall between the inflow and outflow channels, which requires an excellent particle filter effect.
  • the filters can be symmetrical or asymmetrical.
  • the inflow channels are either the same size as the outflow channels or the inflow channels are enlarged compared to the outflow channels, i.e. they have a larger so-called "open frontal area” (OFA) compared to the outflow channels.
  • OFA open frontal area
  • the open porosity of the uncoated wall-flow filter is usually more than 50% to a maximum of 80%, generally from 50% to 75%, especially from 50% to 70% [measured according to DIN 66133 - latest version on the filing date].
  • the average pore diameter (average pore diameter; d50) of the uncoated filter is at least 5 pm, e.g. B.
  • the finished filters with an average pore diameter (d50) of generally 10 pm to 20 pm and a porosity of 50% to 65% are particularly preferred.
  • the wall flow filter considered here has acquired its significant character due to the manner of the coating, that is to say the application with the one or more catalytically active materials.
  • the starting point is a special coating applied to the filter, which is made porous by the application of a pressure pulse and therefore has a desired high permeability. This coating can be combined with a coating in the adjacent ducts as an in-wall or an outlay.
  • the wall flow filter thus produced has a special permeability profile along its longitudinal axis. This has surprising advantages over "normal" coated wall flow filters.
  • particulate filters are optimized with such configurations according to the invention producible that can be tailored precisely to the respective application or exhaust gas problem. Against the background of the known prior art, this was not to be expected.
  • Fig. 1 shows an example of the effect of various combinations of various coating architectures using patterns 1 (top) - 4 (bottom). With regard to their effect in the exhaust gas flow.
  • the combination of two coatings with a high permeability has the lowest pressure loss, but is otherwise weaker than the other samples according to the invention in terms of filtration efficiency, light-off temperature and OSC (oxygen storage).
  • the combination of two coatings with low permeability shows very good values in terms of light-off temperature, OSC and filtration efficiency, but does result in an enormous increase in pressure.
  • the best combination of all features is shown by the combination of a coating with low permeability in the entry line (inlet side of the filter in the exhaust gas; E) with a porous coating according to the invention with a high permeability in the Output line (outlet side of the filter in the exhaust gas; A).
  • the optimal setting of the two zone lengths depends on the requirements of the respective motor. You can set the quality criteria of the coated filter over the zone length like with a slider.
  • the filter 2 describes the process step of filling the filter with a suspension (washcoat) from below.
  • the coating suspension is used in excess and is more in quantity than is required in the finished filter.
  • the filter has cells 10 lying in parallel, which are separated by a wall 100.
  • the wall has a high open porosity.
  • the cells are alternately closed with plugs 160.
  • the cells that are open at the top can have different dimensions than the cells that are open at the bottom.
  • the suspension 140 moves through the application of a pressure difference between the upper end face 20 and the lower end face 30 into the cells 10 which are open at the bottom. Due to the pressure difference and the capillary forces, more or less liquid of the suspension 130 possibly penetrates with a small proportion of particles the open porous walls 100 and accumulates in the neighboring cell 40.
  • Fig. 3 shows schematically the product with two application zones (10a), which result from the coating method according to the invention with steps i) - iii) over the respective lower end face of the filter.
  • Fig. 4 shows schematically the product with two application zones, which result from the combination of the coating processes over the lower end face according to steps i) - iii) and over the upper end face of the filter.
  • porous coating 400 also called filter cake
  • a porous coating 400 also called filter cake
  • the exhaust gas 600 flows over the coating 500 and flows through the porous matrix of the filter 100 and the open-porous coating 400.
  • the layer 400 is also flowed over after the flow.
  • 5 relates to the combination of an expense coating (10a) produced according to the invention and an additional in-wall coating (10b) coming from the other side.
  • the preferred embodiment is shown with an overlap.
  • FIG. 7 shows the coating concentration along the longitudinal direction of two wall flow filters manufactured according to the invention (samples 1 and 3) and a wall filter (sample 4) not according to the invention. All three variants have the same total coating quantity for loading. The five panes per variant were shown (standardized) relative to the loading of the first pane on the left. The distribution of the washcoat load over the length of the filter measured by determining the BET surface area is shown by way of example for different combinations of coatings for two zones on the wall.
  • Fig. 8a shows the filtering process when filling the cells of the vertically locked wall flow filter through the lower end face with a suspension (step i. Invention) in detail.
  • the suspension 140 moves into the cell, the air, or more generally, by applying a pressure difference between the two faces of the filter Gas 110 escapes through the porous wall into the neighboring cell and is carried upwards.
  • the particles 120 are deposited on the porous surface of the filter 100 and form a filter cake 50, which supports further filtration.
  • the liquid 130 flows with at most a small proportion of particles through the porous wall and collects in the neighboring cell (150). It is a surface filtration with the formation of a filter cake.
  • FIG. 8b shows the local detachment of the particle layer when the pressure pulse according to the invention is applied.
  • This method is known to the person skilled in the art when used for water filters and exhaust air filters.
  • the filters and the process run under the name of backwash filter (EP154726A2, EP656223A1).
  • the suspension 140, Fig. 8a is removed from the cell by reversing the pressure difference compared to coating.
  • Air or gas (200) and the liquid 150 flows as flow 210 from the neighboring cell (150) from the previous coating step against the contact surface of the filter layer 50 through the porous wall 100.
  • Particles 70 are released from the filter layer 50.
  • the detachment occurs when the resistance of the particles caused by the liquid or gas flow or the force resulting from the pressure difference exceeds the adhesive force of the layer. This makes the layer more porous.
  • the particles 70 are discharged downwards together with the liquid 210 and the gas 200 (170).
  • 9 shows the permeability distribution of two effort zones produced according to the invention
  • Aluminum oxide stabilized with lanthanum oxide was combined with a first oxygen storage component, which comprised 40% by weight cerium oxide, zirconium oxide, lanthanum oxide and prase odymoxide, and a second oxygen storage component, which comprised 24% by weight cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide. suspended in water. Both oxygen storage components were used in equal parts. The suspension thus obtained was then mixed with a palladium nitrate solution and a rhodium nitrate solution with constant stirring. The resulting coating suspension (washcoat) was used directly to coat a commercially available wall-flow filter substrate.
  • a first oxygen storage component which comprised 40% by weight cerium oxide, zirconium oxide, lanthanum oxide and prase odymoxide
  • a second oxygen storage component which comprised 24% by weight cerium oxide, zirconium oxide, lanthanum oxide and yttrium oxide.
  • the methods for producing products are described below, each of which has two application zones, which have been coated from different end faces of the filter and each extend over approximately 60% of the length of the filter.
  • the ratio of ceramic oxides to precious metals is the same in the washcoat of both zones and constant across the filter.
  • the total amount of oxide and noble metal is distributed evenly between the two zones during the coating, which ideally means that an oxide amount of 83.55 g and a noble metal amount of 1.07 g are applied in each zone coating step.
  • Pattern 1 Both washcoat zones a) and b) of pattern 1 (FIG. 6a) were produced using the same coating method, the ceramic suspension being first brought into the filter by applying a pressure difference (pressure from below) becomes. The excess of oxides is then reversed by a pressure difference, i.e. the renewed application of a pressure difference (suction from below), which is opposite to the first, is removed.
  • a pressure difference pressure from below
  • zone a is coated from below from front face A.
  • the suspension has a solids content of around 33% and is pressed into the substrate until 60% of the substrate length is filled with washcoat from bottom to top.
  • the excess washcoat is then removed from the filter with a short suction pulse in the opposite direction to the coating (approx. 330 mbar suppression, 1.5 sec.).
  • the filter is coated from the front side B from below to produce zone b).
  • the coating is carried out analogously to the coating of zone a), only the coating parameters differ slightly (solids concentration around 35%, suction pulse vacuum around 210 mbar, suction pulse duration around 0.5 sec., The suction pulse rose within 0.2 sec the maximum).
  • the filter is then dried and calcined. Pattern 2 and Pattern 3
  • Pattern 2 (FIG. 6b) and pattern 3 (FIG. 6c) were produced according to a procedure where the coating of zone a) and zone b) each have a different coating process.
  • zone a) is coated from below from front face A.
  • the suspension has a solids content of around 34% and is pressed into the substrate until 60% of the substrate length is filled with washcoat from bottom to top.
  • the excess washcoat is removed from the filter with a short suction pulse (around 330 mbar suppression, 1.5 sec. Suction pulse duration, increase of the suction pulse within 0.2 sec to the maximum).
  • the filter is coated from the front side B from above to produce zone b).
  • a measured amount of washcoat (solids content approx. 44%) is added to face B from above and a short suction pulse (250 mbar suppression, 3 sec.) Is applied to distribute the washcoat in the filter.
  • the filter is then dried and calcined.
  • Both washcoat zones a) and b) of sample 4 were produced using the same coating method, with the ceramic suspension being applied to the wall-flow filter from above and brought into the filter by applying a pressure difference (suction from below) was (not according to the invention).
  • zone a) is coated from above from front face A.
  • the suspension has a solids content of around 43-45% and is added in a measured amount from the top to face A.
  • a pressure difference in the form of a short suction pulse 250 mbar negative pressure, 1 sec. Is applied in order to distribute the washcoat in the filter.
  • the filter is coated from the front side B from above to produce zone b). The coating parameters for this are analogous to those for zone a).
  • the filter is then dried and calcined. Characterization:
  • the effectiveness of a catalytically active filter is determined by the interplay of the functional parameters of catalytic performance, filtration efficiency and exhaust back pressure, which essentially result from the distribution of the catalytic material and the permeability of the washcoat layers.
  • the distribution and amount of the catalytically active material in the direction of flow through the filter is determined by measuring the BET surface area (DIN 66132 - latest version on the filing date) and the permeability by measuring the back pressure on filter samples of samples 1 to 4.
  • the samples for the analyzes with a view to determining the gradients were produced as follows after coating and calcining: Cut off the filter plugs on both sides (filter shortened by 2x 10 mm)
  • a block with 10mmx10mmx20mm was sawn out of each disc in the middle. Every second channel was mutually blocked, so that a small mini filter was created.
  • the pressure loss is measured at an air flow of 6 l / min. In a first approximation, the pressure loss is set to be proportional to the permeability.
  • the suspension 7 shows, by way of example, the differences in the wash coat loading (gradients in the disks) between the five filter sections with respect to the BET surface area, which can be seen when using the different methods a) coating with a wash coat excess and changing direction of the pressure difference and b) coating without and only with a slight washcoat excess without changing pressure difference for the combination result of the expenditure zones.
  • the suspensions used had identical particle size distributions and identical Pd to oxide ratios. Due to the different processes, the suspensions had different viscosities and different solids concentrations. The gradient was always standardized with the value of the disc on the left.
  • All 3 variants (pattern 1, pattern 2/3, pattern 4) have the same amount of washcoat as a load.
  • Fig. 9 shows the course of the permeability by way of example for the combination of two wall zones, the zone on the left having a washcoat excess and a change in the pressure difference during the coating being produced according to process steps i) to iii), while the right zone without washcoat excess and was generated without changing the pressure difference. Both zones contain the same amount of oxides and both cover 60% of the length of the filter.
  • the plugs of the filter were first removed. The rest was divided into 5 equally long discs with a length of approx. 26mm. Small blocks with a base area of 10mm x 10mm and a height of 26mm were made from the panes. The channels were provided with plugs so that 5 small filter bodies were created. A pressure difference volume flow curve was now determined for the small filters and the permeability was calculated using the Darcy equation. The left zone was used to standardize the permeability of the five small filters.
  • the first pane of the zone hereinafter referred to as area A, which was produced with a washcoat excess and a change in the pressure difference during the coating, has a 4 to 20 times higher permeability in the first 15 to 50 mm than the zone in has the following mm.
  • the length L was measured from the end face after removing the stopper that had the first contact with the washcoat when coating with excess washcoat and a change in pressure difference.
  • the zone that was created without excess washcoat and without reversing the pressure difference during coating has a permeability with the same grain size distribution of the oxides in the washcoat, the same amount of oxide in the zone, which corresponds to only 5% to 25% of the permeability of area A.
  • Tab. 2 shows the different permeabilities of the coatings from above (without excess and without pressure reversal) and below, (the length measurement starts behind the stopper). The area 0-26mm of the coating from below was used for standardization to 100% Tab. 2
  • samples 1 to 4 were characterized with regard to the distribution of the catalytic material and the permeability in the preceding explanations, who subsequently determines the catalytic effectiveness, the filtration efficiency and the exhaust gas back pressure of the four different samples.
  • the particle filters samples 1 to 4 were subjected to an engine test bench aging. This consists of a fuel cut-off switch with 950 ° C exhaust gas temperature in front of the catalyst inlet (maximum bed temperature 1030 ° C). The aging time was 19 hours (see Motortechnische Zeitschrift, 1994, 55, 214-218).
  • Table 3 below contains the temperatures T70 of samples 1 to 4, at which 70% of the components considered are converted in each case.
  • the particle filter pattern 2 shows a slight improvement in the light-off behavior compared to pattern 1 in the aged state.
  • the particulate filter patterns 3 and 4 show a significant improvement in the light-off behavior compared to pattern 1 in the aged state.
  • Samples 3 and 4 show a significantly increased ability to store oxygen after aging compared to sample 1.
  • the particle filter samples 1 to 4 were compared on a cold blow test bench with regard to the exhaust gas back pressure.
  • Table 5 contains pressure loss data which were determined at an air temperature of 21 ° C and a volume flow of 300 m 3 / h.
  • the two patterns in which the coating processes for zone a) and zone b) differ have an acceptable increase in pressure loss with respect to sample 1, but have a significantly lower pressure loss compared to sample 4.
  • the particle filters described were examined on the engine test bench in the real exhaust gas of an engine operated with an average stoichiometric air / fuel mixture with regard to the fresh filtration efficiency.
  • the driving cycle used was WLTC Class 3.
  • the particulate filter was installed 30 cm after a conventional three-way catalytic converter, which was the same for all measured particulate filters.
  • a particle counter was installed in front of the three-way catalytic converter and after the particle filter. Table 6 shows the results of the filtration efficiency measurement. Tab. 6
  • sample 1 The lowest filtration efficiency is shown in sample 1, in which both zones were produced using the same coating method in accordance with steps i) - iii).
  • sample 4 in which both zones were also produced by the same coating method, but different from sample 1, with the exclusion of steps i) - iii), has the highest filtration efficiency.
  • the two samples 2 and 3, in which the coating processes for zone a) and zone b) differ, have a lower filtration efficiency than sample 4, but they result in a significant increase in filtration efficiency compared to sample 1.
  • the best combination of all features surprisingly shows the combination of a layer in the entry line (upstream side of the filter in the exhaust gas) with low permeability, which was produced according to the invention by applying a pressure difference with one layer in the output line (outflow side of the filter in the exhaust gas) with a high permeability, which was produced via a coating process according to the invention with process steps i) to iii).
  • the optimal setting of the two zone lengths depends on the requirements of the respective motor. You can set the quality criteria of the coated filter over the zone length like with a slide control.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Catalysts (AREA)
  • Filtering Materials (AREA)

Abstract

Procédé de fabrication de filtres à particules. Les filtres à particules sont communément utilisés pour filtrer les gaz d'échappement issus d'un processus de combustion. La présente invention concerne un procédé de fabrication d'un filtre de type "wall-flow" revêtu, un filtre de type "wall-flow" fabriqué selon ce procédé et l'utilisation du filtre de type "wall-flow" dans un procédé permettant de réduire les polluants contenus dans un flux gazeux. L'invention concerne également de nouveaux substrats filtrants ainsi que leur utilisation spécifique dans le post-traitement des gaz d'échappement
PCT/EP2020/050007 2019-01-04 2020-01-02 Procédé de fabrication de filtres de type "wall-flow" catalytiquement actifs WO2020141188A1 (fr)

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DE102019100097.1A DE102019100097B4 (de) 2019-01-04 2019-01-04 Verfahren zur Herstellung von katalytisch aktiven Wandflussfiltern
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