JP5628413B2 - 触媒化煤煙フィルターおよび排出処理システムおよび方法 - Google Patents
触媒化煤煙フィルターおよび排出処理システムおよび方法 Download PDFInfo
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- 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
- B01D53/9431—Processes characterised by a specific device
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
- B01D46/2429—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material of the honeycomb walls or cells
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
- B01D46/24492—Pore diameter
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- 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
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
- F01N13/009—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00 having two or more separate purifying devices arranged in series
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- 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
- F01N3/022—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 characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/18—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control
- F01N3/20—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by methods of operation; Control specially adapted for catalytic conversion ; Methods of operation or control of catalytic converters
- F01N3/2066—Selective catalytic reduction [SCR]
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/90—Physical characteristics of catalysts
- B01D2255/915—Catalyst supported on particulate filters
- B01D2255/9155—Wall flow filters
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2255/00—Catalysts
- B01D2255/90—Physical characteristics of catalysts
- B01D2255/92—Dimensions
- B01D2255/9202—Linear dimensions
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2258/00—Sources of waste gases
- B01D2258/01—Engine exhaust gases
- B01D2258/012—Diesel engines and lean burn gasoline engines
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2279/00—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses
- B01D2279/30—Filters adapted for separating dispersed particles from gases or vapours specially modified for specific uses for treatment of exhaust gases from IC Engines
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2510/00—Surface coverings
- F01N2510/06—Surface coverings for exhaust purification, e.g. catalytic reaction
- F01N2510/068—Surface coverings for exhaust purification, e.g. catalytic reaction characterised by the distribution of the catalytic coatings
- F01N2510/0684—Surface coverings for exhaust purification, e.g. catalytic reaction characterised by the distribution of the catalytic coatings having more than one coating layer, e.g. multi-layered coatings
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
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Description
1つまたは複数の実施形態によれば、触媒のための基材は、自動車触媒の調製に通常使用される材料のいずれでもよく、通常、金属またはセラミック壁流フィルター構造を含む。特定の実施形態において、フィルターは壁流フィルター(「壁流モノリス」とも呼ばれる)である。図2および3は、縦方向に伸びる複数の通路52を有する壁流フィルター30を説明する。通路は、フィルター基材の内壁53によって管状に包囲されている。基材は、入口端部54および出口端部56を有する。通路は、1つおきに、入口栓58で入口端部が、出口栓60で出口端部が塞がれ、入口54および出口56で逆のチェス盤パターンを形成する。ガス流れ62は、栓のない流路入口64を通して進入し、出口栓60によって遮られ、出口側66から流路壁53(多孔性である)を通して拡散する。ガスは、入口栓58のために壁の入口側へ戻ることができない。
本発明の1つまたは複数の実施形態によると、SCR機能(本明細書において「SCR成分」と称される)を触媒するのに有効な成分は、NOx低減触媒組成物の一部としての被覆に使用される。通常、SCR成分は、被覆中に他の成分を含む組成物の一部である。しかし、1つまたは複数の実施形態において、NOx低減触媒組成物は、SCR成分のみを含んでいてもよい。特定の実施形態において、第1のSCR触媒および第2のSCR触媒は共に、白金族金属成分を実質的に含まない。本明細書において論じられる様々なSCR組成物は、第1のSCR触媒および/または第2のSCR触媒のために、別々に、または組み合わせて使用することができる。
本発明の1つまたは複数の実施形態による触媒または触媒物品は、2ステップのプロセスで調製され得る。第1のステップで、特定の実施形態において、多孔質壁を有し、約100流路/inから1000流路/inの範囲の次元の流路を含むハニカム基材である担体基材は、第1のSCR触媒で被覆される。基材は、乾燥され、か焼され、基材の多孔質壁に第1のSCR触媒を固定する。次いで、基材は第2のSCR触媒で被覆される。基材は、乾燥され、か焼され、基材の壁に第2のSCR触媒を固定する。
排出処理システム
Claims (31)
- 入口端部、出口端部、交互の入口流路および出口流路、ならびに出口流路から入口流路を分離する多孔質壁を有する壁流フィルターを含む触媒物品であって、
入口流路は出口端部に栓を有し、出口流路は入口端部に栓を有し、
多孔質壁は平均細孔直径および細孔サイズ分布を有し、
第1の平均粒子サイズおよび第1の粒子サイズ分布を有する第1のアンモニアSCR触媒物質が、前記多孔質壁に第1の装填で包埋され、且つ
第2の装填で第2のアンモニアSCR触媒物質が前記多孔質壁の表面上にあり、該第2のアンモニアSCR触媒物質は第2の平均粒子サイズおよび第2の粒子サイズ分布を有し、
第1および第2のSCR触媒物質は共に白金族金属成分が添加されておらず、
第2の平均粒子サイズは、第1の平均粒子サイズよりも大きい、触媒物品。 - 第2のアンモニアSCR触媒が壁流フィルターの入口流路上にある、請求項1に記載の触媒物品。
- 第1の装填および第2の装填が異なる、請求項1に記載の触媒物品。
- 第1の触媒物質および第2の触媒物質が異なる、請求項1に記載の触媒物品。
- 第1の装填および第2の装填が異なる、請求項4に記載の触媒物品。
- 入口流路に隣接する触媒化多孔質壁の表面での細孔率が壁内の細孔率より低い、請求項1に記載の触媒物品。
- 平均細孔直径と第1のアンモニアSCR組成物粒子サイズD90との比が、0.5から50の範囲である、請求項1に記載の触媒物品。
- 平均細孔直径と第1のアンモニアSCR組成物粒子サイズD90との比が、1.5から15の範囲である、請求項7に記載の触媒物品。
- 平均細孔直径と第2のアンモニアSCR組成物粒子サイズD90との比が、0.05から5の範囲である、請求項1に記載の触媒物品。
- 平均細孔直径と第2のアンモニアSCR組成物粒子サイズD90との比が、0.2から0.75の範囲である、請求項9に記載の触媒物品。
- 触媒煤煙フィルターの製造方法であって、
第1のアンモニアSCR触媒、第1のスラリー固形分装填、第1の平均粒子サイズ、第1の粒子サイズ分布および第1の粘度を有し、白金族金属を実質的に含まない第1のアンモニアSCR触媒スラリーを調製するステップと;
壁流フィルター基材を前記第1のアンモニアSCR触媒スラリーで被覆するステップであって、該基材は、入口端部、出口端部、入口流路、出口流路および出口流路から入口流路を分離する多孔質壁を有し、入口流路は出口端部に栓を有し、出口流路は入口端部に栓を有し、第1のアンモニアSCR触媒スラリーは前記基材の多孔質壁に浸透し、多孔質壁は平均細孔サイズを有するステップと;
第2のアンモニアSCR触媒、第2のスラリー固形分装填、第2の平均粒子サイズ、第2の粒子サイズ分布および第2の粘性を有し、白金族金属を実質的に含まない第2のアンモニアSCR触媒スラリーを調製するステップと;および
第2のアンモニアSCR触媒が入口流路に隣接する前記基材の多孔質壁の表面に塗布されるように、第2のアンモニアSCR触媒スラリーで前記基材を被覆するステップと
を含み、
第2の平均粒子サイズは、第1の平均粒子サイズよりも大きい、製造方法。 - 第2の粘性が第1の粘性より大きい、請求項11に記載の製造方法。
- 第2の平均粒子サイズが第1の平均粒子サイズより大きい、請求項11に記載の製造方法。
- 第2のスラリー固形分装填が第1のスラリー固形分装填より大きい、請求項11に記載の製造方法。
- 第1のアンモニアSCR触媒スラリー及び第2のアンモニアSCR触媒スラリーの一方若しくは双方で被覆した後に、前記基材をか焼するステップをさらに含む、請求項11に記載の方法。
- 第1のアンモニアSCR触媒スラリーを調製するステップが、第1の平均粒子サイズおよび第1の粒子サイズ分布を低下させるためにそのスラリーを粉砕するステップをさらに含む、請求項11に記載の方法。
- 第2のアンモニアSCR触媒スラリーを調製するステップが、第2の平均粒子サイズおよび第2の粒子サイズ分布を低下させるためにそのスラリーを粉砕するステップをさらに含む、請求項11に記載の方法。
- 平均細孔直径と第1の平均粒子サイズD90との比が、0.5から50の範囲となるように、前記スラリーを粉砕して、第1の粒子サイズ分布を低下させる、請求項16に記載の方法。
- 請求項1に記載の触媒物品に排気ガスを通すステップを含む、ディーゼルエンジンからの排気ガス流れを処理する方法。
- ディーゼルエンジンと、該エンジンの下流に位置し且つ該エンジンと流体連通している請求項1に記載の触媒物品とを含む排気ガス処理システム。
- 酸化触媒、還元触媒、NOx貯蔵成分、NOx捕捉成分のうち1種以上及びエンジンの下流に位置し且つ該エンジンと流体連通した還元噴射器を更に含む、請求項20に記載の排気ガス処理システム。
- 第1及び第2のアンモニアSCR触媒材料は、ゼオライト又は非ゼオライトモレキュラーシーブを含む、請求項1に記載の触媒物品。
- 前記モレキュラーシーブは、該モレキュラーシーブ上に又は内側に配置された周期表のVB、VIB、VIIB、VIIIB、IBまたはIIB族の1つからの金属を含み、該金属は、前記モレキュラーシーブの0.1〜10重量%の量で存在する、請求項22に記載の触媒物品。
- 前記金属は、銅、鉄、及びこれらの混合物又は組み合わせから選択される、請求項23に記載の触媒物品。
- 前記金属は銅である、請求項23に記載の触媒物品。
- 前記金属は鉄である、請求項23に記載の触媒物品。
- 前記第1及び第2のSCR触媒スラリーは、ゼオライト又は非ゼオライトモレキュラーシーブを含む、請求項11に記載の方法。
- 前記モレキュラーシーブは、該モレキュラーシーブ上に又は内側に配置された周期表のVB、VIB、VIIB、VIIIB、IBまたはIIB族の1つからの金属を含み、該金属は、前記モレキュラーシーブの0.1〜10重量%の量で存在する、請求項27に記載の方法。
- 前記金属は、銅、鉄、及びこれらの混合物又は組み合わせから選択される、請求項28に記載の方法。
- 前記金属は銅である、請求項28に記載の方法。
- 前記金属は鉄である、請求項28に記載の方法。
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US33144510P | 2010-05-05 | 2010-05-05 | |
US61/331,445 | 2010-05-05 | ||
PCT/US2011/035230 WO2011140248A2 (en) | 2010-05-05 | 2011-05-04 | Catalyzed soot filter and emissions treatment systems and methods |
US13/100,663 | 2011-05-04 | ||
US13/100,663 US8663587B2 (en) | 2010-05-05 | 2011-05-04 | Catalyzed soot filter and emissions treatment systems and methods |
Publications (3)
Publication Number | Publication Date |
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JP2013532049A JP2013532049A (ja) | 2013-08-15 |
JP2013532049A5 JP2013532049A5 (ja) | 2014-02-20 |
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US (1) | US8663587B2 (ja) |
EP (1) | EP2567078B1 (ja) |
JP (1) | JP5628413B2 (ja) |
KR (1) | KR101476901B1 (ja) |
CN (1) | CN102959191B (ja) |
BR (1) | BR112012028302A2 (ja) |
CA (1) | CA2798326C (ja) |
MX (1) | MX350977B (ja) |
MY (1) | MY163935A (ja) |
WO (1) | WO2011140248A2 (ja) |
ZA (1) | ZA201209016B (ja) |
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EP2567078B1 (en) | 2017-09-27 |
MX350977B (es) | 2017-09-27 |
MX2012012828A (es) | 2013-01-28 |
CA2798326A1 (en) | 2011-11-10 |
US8663587B2 (en) | 2014-03-04 |
MY163935A (en) | 2017-11-15 |
CN102959191A (zh) | 2013-03-06 |
US20110274601A1 (en) | 2011-11-10 |
WO2011140248A2 (en) | 2011-11-10 |
EP2567078A4 (en) | 2014-09-17 |
WO2011140248A3 (en) | 2012-03-15 |
CA2798326C (en) | 2014-11-04 |
KR101476901B1 (ko) | 2014-12-26 |
JP2013532049A (ja) | 2013-08-15 |
BR112012028302A2 (pt) | 2016-11-01 |
KR20130064075A (ko) | 2013-06-17 |
EP2567078A2 (en) | 2013-03-13 |
CN102959191B (zh) | 2015-05-13 |
ZA201209016B (en) | 2014-03-26 |
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