JPH0338893B2 - - Google Patents
Info
- Publication number
- JPH0338893B2 JPH0338893B2 JP60211634A JP21163485A JPH0338893B2 JP H0338893 B2 JPH0338893 B2 JP H0338893B2 JP 60211634 A JP60211634 A JP 60211634A JP 21163485 A JP21163485 A JP 21163485A JP H0338893 B2 JPH0338893 B2 JP H0338893B2
- Authority
- JP
- Japan
- Prior art keywords
- catalyst
- alumina
- coating layer
- exhaust gas
- layer
- Prior art date
- Legal status (The legal status 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 status listed.)
- Expired - Lifetime
Links
- 239000003054 catalyst Substances 0.000 claims description 130
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 60
- 239000011247 coating layer Substances 0.000 claims description 55
- 239000003795 chemical substances by application Substances 0.000 claims description 44
- 239000007789 gas Substances 0.000 claims description 42
- 239000010410 layer Substances 0.000 claims description 33
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims description 32
- 229910000420 cerium oxide Inorganic materials 0.000 claims description 28
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 claims description 28
- 239000010948 rhodium Substances 0.000 claims description 24
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 claims description 21
- 229910052697 platinum Inorganic materials 0.000 claims description 17
- 229910052703 rhodium Inorganic materials 0.000 claims description 16
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 claims description 14
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 claims description 7
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 6
- 229910000480 nickel oxide Inorganic materials 0.000 claims description 6
- 239000001301 oxygen Substances 0.000 claims description 6
- 229910052760 oxygen Inorganic materials 0.000 claims description 6
- GNRSAWUEBMWBQH-UHFFFAOYSA-N oxonickel Chemical compound [Ni]=O GNRSAWUEBMWBQH-UHFFFAOYSA-N 0.000 claims description 5
- 238000003860 storage Methods 0.000 claims description 5
- 229910003445 palladium oxide Inorganic materials 0.000 claims 1
- 238000000746 purification Methods 0.000 description 38
- 238000012360 testing method Methods 0.000 description 28
- 239000002002 slurry Substances 0.000 description 20
- 230000000052 comparative effect Effects 0.000 description 19
- 238000000034 method Methods 0.000 description 17
- 239000011241 protective layer Substances 0.000 description 17
- 238000011156 evaluation Methods 0.000 description 15
- 230000000694 effects Effects 0.000 description 12
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 11
- 230000007423 decrease Effects 0.000 description 10
- 239000011248 coating agent Substances 0.000 description 9
- 238000000576 coating method Methods 0.000 description 9
- 229910052763 palladium Inorganic materials 0.000 description 8
- 229910000510 noble metal Inorganic materials 0.000 description 7
- 238000007664 blowing Methods 0.000 description 6
- 238000010586 diagram Methods 0.000 description 6
- 239000000446 fuel Substances 0.000 description 6
- 238000005259 measurement Methods 0.000 description 6
- 239000000203 mixture Substances 0.000 description 6
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 5
- 230000006866 deterioration Effects 0.000 description 5
- 229910017604 nitric acid Inorganic materials 0.000 description 5
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 4
- 150000001342 alkaline earth metals Chemical class 0.000 description 4
- 238000001035 drying Methods 0.000 description 4
- 239000010970 precious metal Substances 0.000 description 4
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 3
- 230000004913 activation Effects 0.000 description 3
- 229910001593 boehmite Inorganic materials 0.000 description 3
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 3
- 229910052878 cordierite Inorganic materials 0.000 description 3
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 3
- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- MWUXSHHQAYIFBG-UHFFFAOYSA-N nitrogen oxide Inorganic materials O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 3
- 229910052698 phosphorus Inorganic materials 0.000 description 3
- 239000011574 phosphorus Substances 0.000 description 3
- 239000002994 raw material Substances 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- 239000002253 acid Substances 0.000 description 2
- 239000007864 aqueous solution Substances 0.000 description 2
- 239000010953 base metal Substances 0.000 description 2
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 2
- 239000000292 calcium oxide Substances 0.000 description 2
- 230000003197 catalytic effect Effects 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000010304 firing Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 238000005470 impregnation Methods 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229940057995 liquid paraffin Drugs 0.000 description 2
- 238000001465 metallisation Methods 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000010705 motor oil Substances 0.000 description 2
- PIBWKRNGBLPSSY-UHFFFAOYSA-L palladium(II) chloride Chemical compound Cl[Pd]Cl PIBWKRNGBLPSSY-UHFFFAOYSA-L 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
- 231100000572 poisoning Toxicity 0.000 description 2
- 230000000607 poisoning effect Effects 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 230000002265 prevention Effects 0.000 description 2
- SONJTKJMTWTJCT-UHFFFAOYSA-K rhodium(iii) chloride Chemical compound [Cl-].[Cl-].[Cl-].[Rh+3] SONJTKJMTWTJCT-UHFFFAOYSA-K 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000010998 test method Methods 0.000 description 2
- 238000004017 vitrification Methods 0.000 description 2
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- VSGNNIFQASZAOI-UHFFFAOYSA-L calcium acetate Chemical compound [Ca+2].CC([O-])=O.CC([O-])=O VSGNNIFQASZAOI-UHFFFAOYSA-L 0.000 description 1
- 235000011092 calcium acetate Nutrition 0.000 description 1
- 239000001639 calcium acetate Substances 0.000 description 1
- 229960005147 calcium acetate Drugs 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 description 1
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 239000002270 dispersing agent Substances 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 239000003112 inhibitor Substances 0.000 description 1
- 239000012784 inorganic fiber Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- JKQOBWVOAYFWKG-UHFFFAOYSA-N molybdenum trioxide Chemical compound O=[Mo](=O)=O JKQOBWVOAYFWKG-UHFFFAOYSA-N 0.000 description 1
- 231100000614 poison Toxicity 0.000 description 1
- 230000007096 poisonous effect Effects 0.000 description 1
- 238000003878 thermal aging Methods 0.000 description 1
Landscapes
- Catalysts (AREA)
- Exhaust Gas Treatment By Means Of Catalyst (AREA)
Description
(産業上の利用分野)
本発明は、内燃機関等、特に自動車から排出さ
れる排気ガス中の一酸化炭素(以下、COとい
う)、炭化水素(以下、HCという)および酸化
窒素(以下、NOxという)を低減せしめるため
に用いられるエンジンの排気ガス浄化用触媒に関
するものである。
(従来技術)
従来より、自動車排気ガス中のCO、HC、
NOxを浄化する触媒として、白金(Pt)、ロジウ
ム(Rh)、パラジウム(Pd)等の貴金属をアル
ミナ(Al2O3)に担持したものが用いられてい
る。又、これら貴金属の触媒性能を向上させるた
めに、酸素貯蔵能効果(排気ガス中の酸素を取り
込み、この酸素を触媒の浄化に寄与させる効果)
がある酸化セリウム(CeO2)を、貴金属といつ
しよにアルミナコート層に含有させ、排気ガスの
浄化率を高めようとした触媒が製造されてきてい
る。
しかし、貴金属および卑金属の触媒成分と、酸
化セリウム等の酸素貯蔵能付与剤(以下、OSC
剤という)とをアルミナコート層に共存させて担
持する方法には、以下に述べるような問題があつ
た。
(a) OSC剤はアルミナコート層に均一に担持さ
れているため、必ずしもポア付近の排気ガスと
接触しやすい領域に担持されていない。つま
り、OSC剤の多くは、排気ガスの拡散しずら
い部分に担持されており、浄化反応に関与せ
ず、高浄化率が得られない。
(b) OSC剤と、触媒成分およびアルミナとの直
接的な接触が多くなるため、OSC剤の熱不安
定性がこれらに悪影響をおよぼす。
(c) OSC剤が触媒成分といつしよに担持されて
いるため、両者が化合物をつくり、触媒成分の
分散性を低下させ、排気ガス浄化性能が低下す
る。また、触媒担体に、Pt、Pdなどを含有す
る触媒層を設け、該触媒層の保護のためにアル
ミナまたはアルミナと酸化セリウム(アルミナ
に対して重量比で0.1〜0.5%)の混合物からな
る酸化物の被覆層を設けるようにしたものが提
案されている(特開昭60−5230号公報参照)。
この公知技術の場合、微量の酸化セリウムを含
む被覆層は、触媒層を保護する目的で設けられ
ているものであり、OSC剤として作用する酸
化セリウムの濃度が極めて低いため、酸素貯蔵
能効果を殆ど期待できないものであつた。
(発明の目的)
本発明は、上記の問題点に鑑みてなされたもの
で、貴金属あるいは卑金属からなる触媒成分を含
む触媒層の上面にOSC剤を多量に含む被覆層を
形成させることにより、触媒の浄化性能の大幅な
改善を図ることを目的とするものである。
(目的を達成するための手段)
本発明では、上記目的を達成するための手段と
して、触媒担体に担持され、触媒成分を含有した
触媒層の上面に、OSC剤を多量に含む被覆層を
設けている。
ここで、触媒成分としては、Pt、Rh、Pdなど
の公知成分およびそれらの二種以上の混合物が使
用される。
また、OSC剤の成分としては、酸化セリウム
(CeO2)、酸化ニツケル(NiO)、酸化鉄(Fe2O3
あるいはFeO)などの公知成分およびそれらの二
種以上の混合物が使用されるが、CeO2が最も効
果的である。
さらに、前記被覆層の組成は、50〜95重量%の
OSC剤と残部の活性アルミナとからなつており、
そのコーテイングは、OSC剤、活性アルミナ、
水和アルミナ、その他分散剤からなる水性スラリ
ーを用いて行う。最も簡単な方法としては、
OSC剤と水和アルミナとの二成分を用いたスラ
リーをコーテイングすることによつて被覆層を形
成することができる。
かくして形成された排気ガス浄化用触媒の一例
が第1図に拡大して示されている。ここで、符号
1は触媒担体、2は触媒層、3は被覆層をそれぞ
れ示している。該触媒担体1としては、コージラ
イト等のセラミツクスからなるハニカム構造体あ
るいは耐熱金属、耐熱無機繊維からなる各種担体
が使用される。
(作用)
上記のような構造を有する触媒は、従来のよう
に、活性触媒成分とOSC剤とを同一層に含浸せ
しめた触媒に比べて非常に優れた排気ガス浄化性
能を示す。
一般に、被覆層中のOSC剤含有量が減少する
に従つて触媒性能は次第に低下し、50%以下では
急激に低下する。その理由は、OSC剤の濃度が
低下すると、活性触媒成分との相互作用が得られ
なくなるからである。ちなみに、OSC剤として
CeO2を用いた被覆層中におけるCeO2の含有量
(重量%)に対する400℃におけるCOの浄化率
(%)の変化を測定した結果が第2図に示されて
いる。ここで使用された触媒成分は、白金(Pt)
およびロジウム(Rh)からなるもの(後述する
実施例1のものと同様)であり、酸化セリウムと
ベーマイトの重量比(全重量は930gに固定)を
変えることによりCeO2の含有量を変化させるよ
うにしている。本結果は、活性測定条件を、空燃
比A/F=14.7±0.9、空間速度S.V=60000/Hr
とし、台上エンジンにおいて、排気ガス温度850
℃で300Hr運転した耐久テスト後の触媒を用いて
評価したものである。これによれば、CeO2が50
%以下になるとCO浄化率が大幅に低下している。
なお、他のOSC剤もこれと同様な傾向を示すこ
とは自明であろう。
一方、OSC剤の含有量が高くなると、触媒活
性は向上するが、OSC剤自体の結合力が弱いた
めに、物理的強度(耐剥離性)が減少し、耐久性
が低減する。ちなみに、OSC剤としてCeO2を用
いた被覆層中におけるCeO2の含有量(重量%)
を変化させて、剥離テストを行つたところ、表−
1に示す結果が得られた。ここで、剥離量=(テ
スト前のコート付着量−テスト後のコート付着
量)/(テスト前のコート付着量)、また、テス
ト方法としては、直径1インチ、高さ1インチの
円筒テストピースを600℃で30分間加熱、次に25
℃の水中で冷却という手順を三回繰り返した後、
充分乾燥し、剥離量を測定する方法が採用され
た。
(Industrial Application Field) The present invention deals with carbon monoxide (hereinafter referred to as CO), hydrocarbons (hereinafter referred to as HC), and nitrogen oxides (hereinafter referred to as NOx) in exhaust gas emitted from internal combustion engines, etc., especially automobiles. This invention relates to a catalyst for purifying engine exhaust gas, which is used to reduce emissions. (Conventional technology) Conventionally, CO, HC,
As a catalyst for purifying NOx, alumina (Al 2 O 3 ) supported on noble metals such as platinum (Pt), rhodium (Rh), and palladium (Pd) is used. In addition, in order to improve the catalytic performance of these precious metals, we have developed an oxygen storage effect (the effect of capturing oxygen from exhaust gas and contributing to the purification of the catalyst).
Catalysts have been manufactured in which cerium oxide (CeO 2 ), which is a certain substance, is contained in an alumina coating layer along with precious metals to improve the purification rate of exhaust gas. However, catalyst components of noble metals and base metals, and oxygen storage capacity imparting agents (hereinafter referred to as OSC) such as cerium oxide
The method of coexisting and supporting the alumina coating layer has the following problems. (a) Since the OSC agent is uniformly supported on the alumina coat layer, it is not necessarily supported in areas near the pores that are likely to come into contact with exhaust gas. In other words, most of the OSC agents are carried in parts of the exhaust gas that are difficult to diffuse, and do not participate in the purification reaction, making it impossible to obtain a high purification rate. (b) The thermal instability of the OSC agent adversely affects the catalyst components and alumina due to the increased direct contact between the agent and the catalyst components. (c) Since the OSC agent and the catalyst component are supported together, the two form a compound, reducing the dispersibility of the catalyst component and reducing exhaust gas purification performance. In addition, a catalyst layer containing Pt, Pd, etc. is provided on the catalyst carrier, and in order to protect the catalyst layer, an oxide consisting of alumina or a mixture of alumina and cerium oxide (0.1 to 0.5% by weight relative to alumina) is used. A method in which a coating layer is provided has been proposed (see Japanese Patent Application Laid-Open No. 60-5230).
In the case of this known technology, the coating layer containing a trace amount of cerium oxide is provided for the purpose of protecting the catalyst layer, and since the concentration of cerium oxide that acts as an OSC agent is extremely low, it does not affect the oxygen storage capacity effect. It was hardly what I expected. (Object of the Invention) The present invention has been made in view of the above-mentioned problems, and by forming a coating layer containing a large amount of OSC agent on the upper surface of the catalyst layer containing a catalyst component made of noble metal or base metal, catalyst The purpose is to significantly improve the purification performance of (Means for achieving the object) In the present invention, as a means for achieving the above object, a coating layer containing a large amount of OSC agent is provided on the upper surface of the catalyst layer supported on a catalyst carrier and containing a catalyst component. ing. Here, as the catalyst component, known components such as Pt, Rh, and Pd, and mixtures of two or more thereof are used. In addition, the ingredients of the OSC agent include cerium oxide (CeO 2 ), nickel oxide (NiO), and iron oxide (Fe 2 O 3
Alternatively, known components such as FeO) and mixtures of two or more thereof are used, but CeO2 is the most effective. Furthermore, the composition of the coating layer is 50 to 95% by weight.
It consists of an OSC agent and the remainder activated alumina.
The coating consists of OSC agent, activated alumina,
It is carried out using an aqueous slurry consisting of hydrated alumina and other dispersants. The easiest way is to
The coating layer can be formed by coating a slurry using two components: OSC agent and hydrated alumina. An example of the thus formed exhaust gas purifying catalyst is shown enlarged in FIG. Here, reference numeral 1 indicates a catalyst carrier, 2 indicates a catalyst layer, and 3 indicates a coating layer. As the catalyst carrier 1, a honeycomb structure made of ceramics such as cordierite, a heat-resistant metal, or various carriers made of heat-resistant inorganic fibers are used. (Operation) A catalyst having the above structure exhibits extremely superior exhaust gas purification performance compared to a conventional catalyst in which an active catalyst component and an OSC agent are impregnated in the same layer. Generally, as the OSC agent content in the coating layer decreases, the catalyst performance gradually decreases, and below 50%, the catalyst performance decreases rapidly. The reason is that as the concentration of the OSC agent decreases, it is no longer able to interact with the active catalyst components. By the way, as an OSC agent
Figure 2 shows the results of measuring the change in CO purification rate (%) at 400°C with respect to the content (wt%) of CeO 2 in the coating layer using CeO 2 . The catalyst component used here was platinum (Pt)
and rhodium (Rh) (same as in Example 1 described later), and the content of CeO 2 can be changed by changing the weight ratio of cerium oxide and boehmite (total weight fixed at 930 g). I have to. In this result, the activation measurement conditions were air-fuel ratio A/F = 14.7 ± 0.9, space velocity SV = 60000/Hr.
In a bench engine, the exhaust gas temperature is 850.
This is an evaluation using a catalyst after a durability test operated at ℃ for 300 hours. According to this, CeO 2 is 50
% or less, the CO purification rate drops significantly.
It is obvious that other OSC agents also exhibit a similar tendency. On the other hand, when the content of the OSC agent increases, the catalytic activity improves, but because the bonding force of the OSC agent itself is weak, the physical strength (peeling resistance) decreases and the durability decreases. By the way, the content (wt%) of CeO 2 in the coating layer using CeO 2 as the OSC agent
When we performed a peel test by changing the
The results shown in 1 were obtained. Here, peeling amount = (coat adhesion amount before test - coat adhesion amount after test) / (coat adhesion amount before test) Also, as a test method, use a cylindrical test piece with a diameter of 1 inch and a height of 1 inch. Heat at 600℃ for 30 minutes, then 25
After repeating the procedure of cooling in water at ℃ three times,
A method of thoroughly drying and measuring the amount of peeling was adopted.
【表】
上記剥離テストの結果から、被覆層中のCeO2
含有量は、95%以下とするのが好ましいことがわ
かる。なお、他のOSC剤もこれと同様な傾向を
示すことは自明であろう。
前記被覆層の触媒担体に対する付着割合が5重
量%以下では触媒層の表面を効果的に被覆するこ
とができなくなるため、触媒性能が急激に低下
し、40重量%を越えると、活性成分と排気ガスと
の接触が阻害されるため、急激に触媒性能が低下
する。このことを勘案すると、被覆層の付着割合
を5〜40重量%とするのが望ましい。なお、被覆
層の厚さは、20〜40μとするのが望ましい。
以下、本発明の幾つかの好適な実施例を説明す
る。
実施例 1
γ−アルミナ160g、ベーマイト160g、水500
c.c.、濃硝酸4c.c.をホモミキサーにより10時間混合
撹拌し、アルミナウオツシユコート用スラリーを
得た。このスラリーにハニカム触媒担体(コージ
ライト製)を浸漬して引き上げた後、余分のスラ
リーを高圧エアブローで除去し、昇温速度200
℃/Hrにセツトした電気炉中に置いて600℃まで
焼成した。
このアルミナコートした触媒担体を、Ptが200
g/である塩化白金酸と、Rhが100g/であ
る塩化ロジウムとを水200c.c.に混合して得られた
混合水溶液に約15秒浸漬して引き上げた後、200
℃で1時間乾燥し、次いで600℃で2時間焼成し
た。焼成後の貴金属含有量は白金(Pt)1.0g/
、ロジウム(Rh)0.2g/であつた。この時
得られた触媒層2の付着量は、触媒担体1に対し
て14重量%であつた。
次いで、酸化セリウム810g、ベーマイト120
g、水600c.c.をホモミキサーにより混合撹拌し、
OSC剤コート用スラリーを得た。このスラリー
に、先のアルミナ及び貴金属を付着させた触媒担
体を約20秒浸漬して引き上げた後、余分のスラリ
ーを高圧エアブローで除去し、前記アルミナコー
ト時と同じ条件で乾燥焼成した。これによつて、
触媒担体1上に形成された触媒層2(Pt、Rhを
含む)の上面に、90重量%の酸化セリウムと10重
量%のγ−アルミナとからなる被覆層3が形成さ
れてなる排気ガス浄化用触媒が得られた(第1図
参照)。なお、被覆層3の付着量は触媒担体1に
対して25重量%であつた。
実施例 2
活性触媒成分含浸過程(即ち、アルミナコート
された触媒担体に貴金属を含浸させる過程)にお
いて、塩化白金酸、塩化ロジウム、塩化パラジウ
ム混合水溶液を用いて、触媒担体に白金(Pt)
0.28g/、ロジウム(Rh)0.14g/、パラジ
ウム(Pd)0.98g/を付着させた以外は、前記
実施例1とまつたく同一の方法で調製して、触媒
担体1上に形成された触媒層2(Pt、Rh、Pdを
含む)の上面に90重量%の酸化セリウムと10重量
%のγ−アルミナとからなる被覆層3が形成され
てなる排気ガス浄化用触媒が得られた(第1図参
照)。なお、本実施例においても、被覆層3の付
着量は触媒担体1に対して25重量%であつた。
実施例 3
活性触媒成分含浸過程(即ち、アルミナコート
された触媒担体に貴金属を含浸させる過程)にお
いて、塩化パラジウム水溶液を用いて、触媒担体
にパラジウム(Pd)1.4g/を付着させた以外
は、前記実施例1とまつたく同一の方法で調製し
て、触媒担体1上に形成された触媒層2(Pdを
含む)の上面に90重量%の酸化セリウムと10重量
%のγ−アルミナとからなる被覆層3が形成され
てなる排気ガス浄化用触媒が得られた(第1図参
照)。なお、本実施例においても、被覆層3の付
着量は触媒担体1に対して25重量%であつた。
実施例 4
OSC剤コート用スラリーにおいて、酸化セリ
ウムの代わりに酸化ニツケルを用いた以外は、前
記実施例1とまつたく同一の方法で調製して、触
媒担体1上に形成された触媒層2(Pt、Phを含
む)の上面に90重量%の酸化ニツケルと10重量%
のγ−アルミナとからなる被覆層3が形成されて
なる排気ガス浄化用触媒が得られた(第1図参
照)。なお、本実施例においても、被覆層3の付
着量は触媒担体1に対して25重量%であつた。
実施例 5
OSC剤コート用スラリーにおいて、酸化セリ
ウムの代わりに酸化鉄(例えば、Fe2O3)を用い
た以外は、前記実施例1とまつたく同一の方法で
調製して、触媒担体1上に形成された触媒層2
(Pt、Rhを含む)の上面に90重量%の酸化鉄と10
重量%のγ−アルミナとからなる被覆層3が形成
されてなる排気ガス浄化用触媒が得られた(第1
図参照)。なお、本実施例においても、被覆層3
の付着量は触媒担体1に対して25重量%であつ
た。
上記各実施例で得られた排気ガス浄化用触媒の
浄化性能を、従来公知の触媒、即ち、活性触媒成
分とOSC剤とを混在せしめてなる触媒と比較し
て浄化性能評価テストを行つたところ、第3図な
いし第5図に示す結果が得られた。
ここで、比較例1〜3は次のようにして調製さ
れた。
比較例 1
活性アルミナ315g、酸化セリウム100g、濃硝
酸4c.c.、水700c.c.をホモミキサーにより混合撹拌
し、アルミナ及びOSC剤コート用のスラリーを
得た。このスラリーを用いて、前記各実施例と同
一方法でハニカム触媒担体にアルミナ及びOSC
剤をコーテイングした。このコート層の付着量は
触媒担体に対して25重量%、酸化セリウムのコー
ト層中での割合は25重量%であつた。
この触媒担体に、さらに前記実施例1と同様な
方法を用いて、白金(Pt)1.0g/、ロジウム
(Rh)0.2g/を上記コート層に含浸させるこ
とにより触媒を得た。
比較例 2
前記比較例1と同一の方法、条件によりアルミ
ナとOSC剤とをコーテイングした後、前記実施
例2と同じ方法、条件によりPt、Rh、PdをOSC
剤を含有したコート層に含浸させ、実施例2と同
じ貴金属付着量(即ち、Pt0.28g/、Rh0.14
g/、Pd0.98g/)の触媒を得た。
比較例 3
前記比較例1と同一の方法、条件によりアルミ
ナとOSC剤とをコーテイングした後、前記実施
例3と同じ方法、条件によりPdをOSC剤を含有
したコート層に含浸させ、実施例3と同じ貴金属
付着量(即ち、Pd1.4g/)の触媒を得た。
なお、活性測定条件を、空燃比A/F=14.7±
0.9、空間速度S.V=60000/Hrとし、台上エンジ
ン300Hr耐久テスト後の触媒を用いて評価テスト
を行つた。
上記評価テストの結果によると、本発明の各実
施例による排気ガス浄化用触媒は、従来公知の触
媒、即ち、比較例1〜3のものに比較して排気ガ
ス温度の低い状態から大幅に浄化性能が改善され
ていることがわかる。
実施例 6
第6図図示の如く、円筒状に形成された触媒担
体1上に、前記実施例1と同様な方法によりγ−
アルミナと触媒成分(PtおよびRh)とを担持し
て得られたものを、まず半分流動パラフイン溶液
中に浸漬させ、次いで、酸化セリウム440g、水
和アルミナ110g、水500c.c.、濃硝酸5c.c.からなる
スラリー液中に約20秒浸漬させた後、余分なスラ
リー液を高圧エアブローにより除去する。その
後、130℃で1時間乾燥後、600℃で1時間焼成す
ることにより、流動パラフインが付着しない半分
側にのみ酸化セリウムを多量に含む被覆層3が形
成された排気ガス浄化用触媒が得られた。この触
媒は、被覆層3が形成された側を出口側として使
用すると、高温となる入口側に比較的耐熱性に劣
る酸化セリウムを含む被覆層が存在しないことと
なり、酸化セリウムの熱劣化を防止することが可
能となる。なお、被覆層3を形成する範囲は、被
覆層形成部長さおよび被覆層非形成部長さを、そ
れぞれA1、A2とするとき、A2/A1=7/3〜
3/7とされるが、A1/A2=1とするのが好ま
しい。
実施例 7
第7図図示の如く、円筒状に形成された触媒担
体1上に、実施例と同様な方法によりγ−アルミ
ナと触媒成分(PtおよびRh)とを担持して得ら
れたものにおいて、その開口部両側に開口径の1/
2の径を有するラベルを貼り、次いで、酸化セリ
ウム440g、水和アルミナ110g、水500c.c.、濃硝
酸5c.c.からなるスラリー液中に浸漬させた後、余
分なスラリー液を高圧エアブローにより除去す
る。その後、前記ラベルを取り除き、130℃で1
時間乾燥後、600℃で1時間焼成することにより、
前記ラベルが貼られていない外周部にのみ酸化セ
リウムを多量に含む被覆層3が形成された排気ガ
ス浄化用触媒が得られた。この触媒は、高温の排
気ガスと直接接触する内周側に被覆層3が形成さ
れていないため、比較的耐熱性に劣る酸化セリウ
ムの熱劣化を防止することが可能となる。なお、
被覆層3を形成する範囲は、被覆層形成部の巾お
よび被覆層非形成部の巾を、それぞれB1、B2と
するとき、B2/2B1=7/3〜3/7とされる
が、B2/2B1=1とするのが好ましい。
上記実施例6、7の排気ガス浄化用触媒の浄化
性能の評価テストを行ない、触媒担体の全体に酸
化セリウムを多量に含む被覆層を形成してなる比
較例(本発明実施例の一例である)と比較した結
果が第8図ないし第10図に示されている。前記
評価テストは、エンジンエージング(排気ガス温
度:900℃、100時間運転)後に測定されたもので
あり、活性測定条件としては、空燃比A/F=
14.7±0.9、空間速度S.V=60000/Hrである。
上記の結果によれば、実施例6、7の触媒は、
比較例のものに比べて若干浄化性能が向上してお
り、このことから、熱劣化し易い部分に被覆層を
形成しなくとも、浄化性能の低下がないことが分
かる。したがつて、被覆層形成に必要な原料
(OSC剤等)の節約が可能となるのである。
実施例 8
前記実施例1〜5と同様な方法により触媒担体
1上に形成された触媒層2(PtおよびRhを含む)
の上面に、酸化セリウムを多量に含む被覆層3を
形成してなる触媒を、水和アルミナ70g、γ−ア
ルミナ70g、水200c.c.からなるアルミナスラリー
液中に約20秒浸漬させて引き上げたのち、高圧エ
アブローにより余分なアルミナスラリーを除去
し、130℃で1時間乾燥後、550℃の電気炉で1時
間焼成した。これにより、第11図図示の如く、
触媒担体1上に、PtおよびRhからなる活性触媒
成分を含む触媒層2、酸化セリウムを多量に含む
被覆層3、アルミナ成分のみの保護層4を有する
三重層の排気ガス浄化用触媒を得ることができ
た。この時得られた保護層4の厚さは約30μであ
つた。かく構成することによつて、被覆層3に含
まれるCeO2の熱劣化が保護層4によつて防止さ
れる。又、該保護層4は、被覆層3に対する被毒
防止作用をも有している。なお、前記保護層4の
厚さは、20〜40μが適切であり、20μ以下では熱
及び被毒に対する保護層としての効果が得られ
ず、40μ以上では厚すぎて、排気ガスのウオツシ
ユコート内での拡散が不充分となり、浄化性能が
低下する。
上記実施例8の排気ガス浄化用触媒の浄化性能
の評価テストを行ない、比較例(本発明実施例の
一例であり、保護層4を形成しないもの)と比較
した結果が第12図ないし第14図に示されてい
る。前記評価テストは、200時間実車走行後に測
定されたものであり、活性測定条件としては、空
燃比A/F=14.7±0.9、空間速度S.V=60000/
Hrとされた。これによれば、本実施例のものが、
保護層4を形成していない比較例のものに比べ
て、浄化性能が優れていることがわかる。
実施例 9
本実施例の排気ガス浄化用触媒は、前記実施例
8のものと同様に、触媒担体1上に、触媒層2、
被覆層3、保護層4を設けた三重層構造とされて
おり、且つ該保護層4にアルカリ土類金属の酸化
物(本実施例ではCaO)を含有せしめている。
即ち、前記実施例におけるアルミナスラリーの
組成を、水和アルミナ50g、γ−アルミナ60g、
酢酸カルシウム50g、水200c.c.とした以外は、前
記実施例8と同様な方法、条件で調製して、前記
保護層4中に酸化カルシウムが含有された三重層
構造の触媒を得た。この時得られた保護層4の厚
さは約30μであつた。このように、保護層4内に
アルカリ土類金属を含有せしめることによつて、
エンジンオイル中に含有されている被毒物である
リン(P)が、コート表面上でガラス化するのを
防止することができるのである。なお、ガラス化
防止剤としては、アルカリ土類金属中では特に酸
化カルシウム(CaO)が効果的である。又、添加
するアルカリ土類金属量は、焼成後において、保
護層4の重量中10〜30重量%が適切であり、10重
量%以下ではガラス化防止効果が充分でなく、30
重量%以上ではウオツシユコートの物理的強度が
低下し、剥離しやすくなつてしまう。
なお、前記保護層4の厚さは、前記実施例8と
同様に20〜40μが適切である。
上記実施例9の排気ガス浄化用触媒の浄化性能
の評価テストを行い、比較例(本発明実施例の一
例であり、保護層4を形成しないもの)と比較し
た結果が第15図ないし第17図に示されてい
る。前記評価テストは、200時間実車走行後に測
定されたものであり、活性測定条件としては、空
燃比A/F=14.7±0.9、空間速度S.V=60000/
Hrとされた。ただし、触媒に付着するリンの量
を高めるため、LOCが20000Km/であるエンジ
ンにおいて、エンジンオイル中のリン量を添加剤
を加えて1.0重量%に増やしたものを使用した。
これによれば、本実施例のものが、保護層4を形
成していない比較例のものに比べて、浄化性能が
優れていることがわかる。
実施例 10
本実施例の排気ガス浄化用触媒においては、触
媒層はγ−アルミナから構成されるが、OSC剤
を多量に含む被覆層の原料は、α−アルミナ/水
和アルミナ=95/5〜60/40(重量比)であるア
ルミナ組成からなつている。
即ち、従来方法によりコージライト製触媒担体
上に約40μのγ−アルミナコートを設け、これに
触媒成分(Pt1.0g/、Rh0.2g/)を担持
し、これを、α−アルミナ100g、水和アルミナ
10g、酸化セリウム440g、水500c.c.、濃硝酸3c.c.
からなるスラリー液中に約20秒浸漬して引き上
げ、余分なスラリー液を高圧エアブローで除去
し、130℃で1時間乾燥後、550℃の電気炉で1時
間焼成して、上記構造の触媒を得た。
この触媒は、熱によつてもアルミナ結晶変化が
少なく、ポア減少もほとんどないため、高温にお
ける物理的強度(触媒のクラツク、コードの剥離
等)が改善され、耐久性が向上する。
なお、水和アルミナ量がα−アルミナ/水和ア
ルミナ=95/5より少なくなると、アルミナ同志
及びアルミナとOSC剤との結合力が弱くなり、
剥離しやすくなる。又、α−アルミナ量がα−ア
ルミナ/水和アルミナ=60/40より少なくなる
と、α−アルミナの特性である高温における物理
的強度、耐久性が得られなくなる。
上記実施例10の排気ガス浄化用触媒の浄化性能
評価テストを行い、比較例(本発明の実施例の一
例であり、OSC剤を含む被覆層の原料がγ−ア
ルミナのみからなる触媒)と比較した結果が第1
8図ないし第20図に示されている。前記評価テ
ストは、大気中1100℃で50時間熱エージングした
後に測定されたものであり、活性測定条件として
は、空燃比A/F=14.7±0.9、空間速度S.V=
60000/Hrとされた。
又、被覆層の剥離テストを行つた結果、表−2
に示す結果が得られた。
剥離テスト方法としては、直径1インチ、高さ
1インチの円柱テストピースを、600℃で30分間
加熱し、次に25℃の水中で冷却するという手順を
3回繰り返した後、充分乾燥して剥離量を測定す
るという方法が採用される。[Table] From the results of the above peel test, CeO 2 in the coating layer
It can be seen that the content is preferably 95% or less. It is obvious that other OSC agents also exhibit a similar tendency. If the adhesion ratio of the coating layer to the catalyst carrier is less than 5% by weight, the surface of the catalyst layer cannot be effectively coated, resulting in a rapid decline in catalyst performance, and if it exceeds 40% by weight, active components and exhaust gas Since contact with gas is inhibited, catalyst performance rapidly decreases. Taking this into consideration, it is desirable that the adhesion ratio of the coating layer be 5 to 40% by weight. Note that the thickness of the coating layer is preferably 20 to 40 μm. Some preferred embodiments of the present invention will be described below. Example 1 γ-alumina 160g, boehmite 160g, water 500g
cc. and 4 c.c. of concentrated nitric acid were mixed and stirred for 10 hours using a homomixer to obtain a slurry for coating an alumina wash. After immersing a honeycomb catalyst carrier (made of cordierite) in this slurry and pulling it up, the excess slurry was removed by high-pressure air blowing, and the heating rate was 200.
It was placed in an electric furnace set at °C/Hr and fired to 600 °C. This alumina-coated catalyst carrier is coated with Pt of 200
After immersing for about 15 seconds in a mixed aqueous solution obtained by mixing chloroplatinic acid with a Rh content of 100 g/ and rhodium chloride with an Rh content of 100 g/c.
It was dried at 600°C for 1 hour and then fired at 600°C for 2 hours. Precious metal content after firing is platinum (Pt) 1.0g/
, Rhodium (Rh) 0.2g/. The amount of the catalyst layer 2 thus obtained was 14% by weight based on the catalyst carrier 1. Next, cerium oxide 810g, boehmite 120g
g and 600 c.c. of water were mixed and stirred using a homomixer,
A slurry for coating with an OSC agent was obtained. The catalyst carrier to which alumina and precious metals were attached was immersed in this slurry for about 20 seconds and then pulled out. Excess slurry was removed by high-pressure air blowing, and the carrier was dried and fired under the same conditions as the alumina coating. By this,
Exhaust gas purification in which a coating layer 3 consisting of 90% by weight cerium oxide and 10% by weight γ-alumina is formed on the upper surface of a catalyst layer 2 (containing Pt and Rh) formed on a catalyst carrier 1. A catalyst was obtained (see Figure 1). The amount of the coating layer 3 deposited was 25% by weight based on the catalyst carrier 1. Example 2 In the active catalyst component impregnation process (i.e., the process of impregnating an alumina-coated catalyst carrier with a noble metal), platinum (Pt) was added to the catalyst carrier using a mixed aqueous solution of chloroplatinic acid, rhodium chloride, and palladium chloride.
A catalyst formed on catalyst carrier 1 was prepared in exactly the same manner as in Example 1, except that 0.28 g/, rhodium (Rh) 0.14 g/, and palladium (Pd) 0.98 g/ were deposited. An exhaust gas purification catalyst was obtained in which a coating layer 3 consisting of 90% by weight cerium oxide and 10% by weight γ-alumina was formed on the upper surface of layer 2 (containing Pt, Rh, and Pd). (See Figure 1). In this example as well, the amount of the coating layer 3 deposited was 25% by weight based on the catalyst carrier 1. Example 3 In the active catalyst component impregnation process (i.e., the process of impregnating the alumina-coated catalyst support with a noble metal), palladium (Pd) 1.4 g/m was deposited on the catalyst support using an aqueous palladium chloride solution. The catalyst layer 2 (containing Pd) formed on the catalyst carrier 1 was prepared by the same method as in Example 1, and was coated with 90% by weight of cerium oxide and 10% by weight of γ-alumina. An exhaust gas purifying catalyst having a coating layer 3 formed thereon was obtained (see FIG. 1). In this example as well, the amount of the coating layer 3 deposited was 25% by weight based on the catalyst carrier 1. Example 4 Catalyst layer 2 ( 90 wt% nickel oxide and 10 wt% on the top surface (including Pt, Ph)
An exhaust gas purifying catalyst was obtained in which a coating layer 3 made of γ-alumina was formed (see FIG. 1). In this example as well, the amount of the coating layer 3 deposited was 25% by weight based on the catalyst carrier 1. Example 5 A slurry for coating an OSC agent was prepared in the same manner as in Example 1 above, except that iron oxide (e.g., Fe 2 O 3 ) was used instead of cerium oxide, and a slurry was coated on the catalyst carrier 1. Catalyst layer 2 formed on
90 wt% iron oxide and 10 on the top surface (including Pt, Rh)
An exhaust gas purifying catalyst was obtained in which a coating layer 3 consisting of γ-alumina of % by weight was formed (first
(see figure). In addition, also in this example, the coating layer 3
The amount of adhesion was 25% by weight based on the catalyst carrier 1. A purification performance evaluation test was conducted by comparing the purification performance of the exhaust gas purification catalyst obtained in each of the above examples with a conventionally known catalyst, that is, a catalyst made by mixing an active catalyst component and an OSC agent. , the results shown in FIGS. 3 to 5 were obtained. Here, Comparative Examples 1 to 3 were prepared as follows. Comparative Example 1 315 g of activated alumina, 100 g of cerium oxide, 4 c.c. of concentrated nitric acid, and 700 c.c. of water were mixed and stirred using a homomixer to obtain a slurry for coating alumina and OSC agent. Using this slurry, alumina and OSC were applied to a honeycomb catalyst carrier in the same manner as in each of the above examples.
coated with the agent. The amount of this coating layer deposited was 25% by weight based on the catalyst carrier, and the proportion of cerium oxide in the coating layer was 25% by weight. Using the same method as in Example 1, this catalyst carrier was further impregnated with 1.0 g of platinum (Pt) and 0.2 g of rhodium (Rh) into the coating layer to obtain a catalyst. Comparative Example 2 After coating alumina and OSC agent using the same method and conditions as in Comparative Example 1, Pt, Rh, and Pd were coated with OSC using the same method and conditions as in Example 2.
The coating layer containing the agent was impregnated with the same noble metal deposition amount as in Example 2 (i.e., Pt0.28g/, Rh0.14
A catalyst of 0.98 g/Pd/) was obtained. Comparative Example 3 After coating alumina and an OSC agent using the same method and conditions as in Comparative Example 1, Pd was impregnated into the OSC agent-containing coating layer using the same method and conditions as in Example 3. A catalyst with the same noble metal deposition amount (ie, Pd 1.4 g/) was obtained. In addition, the activity measurement conditions are air-fuel ratio A/F = 14.7±
0.9, space velocity SV = 60000/Hr, and an evaluation test was conducted using the catalyst after a 300Hr endurance test on a bench engine. According to the results of the above evaluation tests, the exhaust gas purifying catalysts according to the embodiments of the present invention significantly purify exhaust gas from a low temperature state compared to conventionally known catalysts, that is, those of Comparative Examples 1 to 3. It can be seen that the performance has been improved. Example 6 As shown in FIG. 6, γ-
The product obtained by supporting alumina and catalyst components (Pt and Rh) was first immersed in a semi-liquid paraffin solution, and then 440 g of cerium oxide, 110 g of hydrated alumina, 500 c.c. of water, and 5 c. of concentrated nitric acid. After being immersed in the slurry liquid consisting of c. for about 20 seconds, excess slurry liquid is removed by high-pressure air blowing. Thereafter, by drying at 130°C for 1 hour and baking at 600°C for 1 hour, an exhaust gas purifying catalyst was obtained in which the coating layer 3 containing a large amount of cerium oxide was formed only on the half side to which the liquid paraffin did not adhere. Ta. When this catalyst is used with the side on which the coating layer 3 is formed as the outlet side, there is no coating layer containing cerium oxide, which has relatively poor heat resistance, on the inlet side where the temperature is high, preventing thermal deterioration of the cerium oxide. It becomes possible to do so. The range in which the covering layer 3 is formed is A 2 /A 1 = 7/3 to A 2 /A 1 when the length of the part with the covering layer formed and the length of the part without the covering layer are respectively A 1 and A 2 .
Although it is assumed to be 3/7, it is preferable to set A 1 /A 2 =1. Example 7 As shown in Figure 7, γ-alumina and catalyst components (Pt and Rh) were supported on a cylindrical catalyst carrier 1 in the same manner as in Example. , 1/ of the opening diameter on both sides of the opening.
After pasting a label with a diameter of 2, immersing it in a slurry consisting of 440 g of cerium oxide, 110 g of hydrated alumina, 500 c.c. of water, and 5 c.c. of concentrated nitric acid, the excess slurry was removed by high-pressure air blowing. Remove by. After that, remove the label and heat at 130℃ for 1 hour.
After drying for an hour, by baking at 600℃ for 1 hour,
An exhaust gas purifying catalyst was obtained in which the coating layer 3 containing a large amount of cerium oxide was formed only on the outer peripheral portion where the label was not attached. Since this catalyst does not have the coating layer 3 formed on the inner peripheral side that comes into direct contact with high-temperature exhaust gas, it is possible to prevent thermal deterioration of cerium oxide, which has relatively poor heat resistance. In addition,
The range in which the coating layer 3 is formed is B 2 /2B 1 =7/3 to 3/7, where the width of the coating layer forming part and the width of the coating layer non-forming part are B1 and B2 , respectively. However, it is preferable to set B 2 / 2 B 1 =1. A comparative example (an example of an example of the present invention) in which a coating layer containing a large amount of cerium oxide was formed over the entire catalyst carrier was conducted to evaluate the purification performance of the exhaust gas purifying catalysts of Examples 6 and 7. ) are shown in FIGS. 8 to 10. The above evaluation test was measured after engine aging (exhaust gas temperature: 900°C, 100 hours of operation), and the activity measurement conditions were: air-fuel ratio A/F =
14.7±0.9, space velocity SV=60000/Hr. According to the above results, the catalysts of Examples 6 and 7 were
The purification performance is slightly improved compared to that of the comparative example, and this shows that there is no deterioration in the purification performance even if no coating layer is formed on the portions that are prone to thermal deterioration. Therefore, it is possible to save raw materials (OSC agent, etc.) necessary for forming the coating layer. Example 8 Catalyst layer 2 (containing Pt and Rh) formed on catalyst carrier 1 by the same method as in Examples 1 to 5 above
A catalyst having a coating layer 3 containing a large amount of cerium oxide formed on its upper surface is immersed in an alumina slurry solution consisting of 70 g of hydrated alumina, 70 g of γ-alumina, and 200 c.c. of water for about 20 seconds and then pulled up. Thereafter, excess alumina slurry was removed by high-pressure air blowing, dried at 130°C for 1 hour, and then fired in an electric furnace at 550°C for 1 hour. As a result, as shown in FIG. 11,
To obtain a triple-layer exhaust gas purifying catalyst having, on a catalyst carrier 1, a catalyst layer 2 containing an active catalyst component consisting of Pt and Rh, a coating layer 3 containing a large amount of cerium oxide, and a protective layer 4 containing only an alumina component. was completed. The thickness of the protective layer 4 obtained at this time was about 30μ. With this configuration, thermal deterioration of CeO 2 contained in the coating layer 3 is prevented by the protective layer 4. Further, the protective layer 4 also has a poisoning prevention effect on the coating layer 3. The appropriate thickness of the protective layer 4 is 20 to 40 μm. If it is less than 20 μm, it will not be effective as a protective layer against heat and poisoning, and if it is more than 40 μm, it will be too thick and will not be used as a wash coat for exhaust gas. Diffusion within the tank becomes insufficient, and purification performance deteriorates. An evaluation test was conducted on the purification performance of the exhaust gas purification catalyst of Example 8, and the results of comparison with a comparative example (an example of an example of the present invention, in which no protective layer 4 was formed) are shown in Figures 12 to 14. As shown in the figure. The above evaluation test was conducted after driving the actual vehicle for 200 hours, and the activation measurement conditions were: air-fuel ratio A/F = 14.7 ± 0.9, space velocity SV = 60000/
It was considered Hr. According to this, the one of this example is
It can be seen that the purification performance is superior to that of the comparative example in which the protective layer 4 is not formed. Example 9 The exhaust gas purifying catalyst of this example has a catalyst layer 2, a catalyst layer 2,
It has a triple-layer structure including a covering layer 3 and a protective layer 4, and the protective layer 4 contains an oxide of an alkaline earth metal (CaO in this example). That is, the composition of the alumina slurry in the above example was 50 g of hydrated alumina, 60 g of γ-alumina,
A catalyst having a triple layer structure in which calcium oxide was contained in the protective layer 4 was obtained by using the same method and conditions as in Example 8 except that 50 g of calcium acetate and 200 c.c. of water were used. The thickness of the protective layer 4 obtained at this time was about 30μ. In this way, by containing the alkaline earth metal in the protective layer 4,
This can prevent phosphorus (P), a poisonous substance contained in engine oil, from vitrifying on the coated surface. Note that, among alkaline earth metals, calcium oxide (CaO) is particularly effective as a vitrification inhibitor. In addition, the amount of alkaline earth metal to be added is appropriately 10 to 30% by weight based on the weight of the protective layer 4 after firing, and if it is less than 10% by weight, the vitrification prevention effect will not be sufficient;
If it exceeds % by weight, the physical strength of the wash coat decreases and it becomes easy to peel off. Note that the thickness of the protective layer 4 is suitably 20 to 40 μm, as in Example 8. An evaluation test was conducted on the purification performance of the exhaust gas purification catalyst of Example 9, and the results of comparison with a comparative example (an example of an example of the present invention, in which no protective layer 4 was formed) are shown in Figures 15 to 17. As shown in the figure. The above evaluation test was conducted after driving the actual vehicle for 200 hours, and the activation measurement conditions were: air-fuel ratio A/F = 14.7 ± 0.9, space velocity SV = 60000/
It was considered Hr. However, in order to increase the amount of phosphorus adhering to the catalyst, an additive was added to increase the amount of phosphorus in the engine oil to 1.0% by weight for an engine with a LOC of 20,000 km/.
According to this, it can be seen that the cleaning performance of this example is superior to that of the comparative example in which the protective layer 4 is not formed. Example 10 In the exhaust gas purification catalyst of this example, the catalyst layer is composed of γ-alumina, but the raw material for the coating layer containing a large amount of OSC agent is α-alumina/hydrated alumina = 95/5. It has an alumina composition of ~60/40 (weight ratio). That is, a γ-alumina coat of about 40 μm was provided on a cordierite catalyst carrier by a conventional method, and catalyst components (Pt 1.0 g/, Rh 0.2 g/) were supported on this, and this was coated with 100 g of α-alumina and water. Japanese alumina
10g, cerium oxide 440g, water 500c.c., concentrated nitric acid 3c.c.
The catalyst with the above structure was immersed in a slurry liquid for about 20 seconds, removed by high-pressure air blowing, dried at 130°C for 1 hour, and fired in an electric furnace at 550°C for 1 hour. Obtained. This catalyst has little change in alumina crystals even when exposed to heat, and there is almost no decrease in pores, so physical strength at high temperatures (catalyst cracking, cord peeling, etc.) is improved, and durability is improved. In addition, when the amount of hydrated alumina is less than α-alumina/hydrated alumina = 95/5, the bonding strength between alumina and the alumina and the OSC agent becomes weaker.
It becomes easier to peel off. Furthermore, if the amount of α-alumina is less than α-alumina/hydrated alumina=60/40, the physical strength and durability at high temperatures, which are the characteristics of α-alumina, cannot be obtained. A purification performance evaluation test was conducted on the exhaust gas purification catalyst of Example 10 above, and comparison was made with a comparative example (an example of an example of the present invention, a catalyst in which the raw material of the coating layer containing the OSC agent is only γ-alumina). The first result is
This is shown in FIGS. 8 to 20. The above evaluation test was measured after thermal aging at 1100°C in the atmosphere for 50 hours, and the activity measurement conditions were: air-fuel ratio A/F = 14.7 ± 0.9, space velocity SV =
It was set as 60000/Hr. In addition, as a result of the peeling test of the coating layer, Table 2
The results shown are obtained. The peel test method involved heating a cylindrical test piece with a diameter of 1 inch and a height of 1 inch at 600℃ for 30 minutes, then cooling it in water at 25℃ three times, and then thoroughly drying it. A method of measuring the amount of peeling is adopted.
【表】
ここで、剥離量=(テスト前のコート付着量−
テスト後のコート付着量)/(テスト前のコート
付着量)とされている。
上記各テストの結果からみると、本実施例のも
のが、比較例のものに比べて、浄化性能において
若干劣つているが、耐剥離性において非常に優れ
ていることがわかる。
なお、上記各実施例では、OSC剤として酸化
セリウム、酸化ニツケル、酸化鉄を用いたものに
ついて説明しているが、これらのOSC剤に酸化
モリブデン(MoO3)を添加する場合もある。
(発明の効果)
叙上の如く、本発明によれば、活性触媒成分で
ある白金、ロジウム、パラジウムよりなる群から
選ばれた少なくとも一種類を含有する触媒層と、
OSC剤である酸化セリウム、酸化ニツケル、酸
化鉄よりなる群から選ばれた少なくとも一種類を
含有する被覆層とを分離して形成しているので、
活性触媒成分とOSC剤とが化合物を形成するこ
とがなくなり、従来の活性触媒成分とOSC剤と
を混在させたものに比べて、排気ガス浄化性能が
向上するという優れた効果がある。
また、OSC剤の被覆層中における含有量を50
〜95重量%として、OSC剤による酸素貯蔵能効
果を大幅に増大せしめるようにしたので、排気ガ
ス浄化性能を著しく向上せしめることができると
いう効果もある。
さらに、触媒層上面をOSC剤を含有する被覆
層で被覆するようにしているので、触媒層が還元
雰囲気になり易くなり、排気ガス中のNOxの浄
化性能が一段と向上するという利点もある。[Table] Here, peeling amount = (coat adhesion amount before test -
Coat adhesion amount after test)/(coat adhesion amount before test). From the results of the above tests, it can be seen that the samples of this example are slightly inferior in purification performance compared to those of comparative examples, but are very superior in peeling resistance. In the above embodiments, cerium oxide, nickel oxide, and iron oxide are used as OSC agents, but molybdenum oxide (MoO 3 ) may be added to these OSC agents. (Effects of the Invention) As described above, according to the present invention, a catalyst layer containing at least one active catalyst component selected from the group consisting of platinum, rhodium, and palladium;
Since it is formed separately from the coating layer containing at least one OSC agent selected from the group consisting of cerium oxide, nickel oxide, and iron oxide,
The active catalyst component and the OSC agent no longer form a compound, which has the excellent effect of improving exhaust gas purification performance compared to the conventional combination of the active catalyst component and the OSC agent. In addition, the content of the OSC agent in the coating layer was increased to 50%.
~95% by weight, which greatly increases the oxygen storage effect of the OSC agent, which also has the effect of significantly improving exhaust gas purification performance. Furthermore, since the upper surface of the catalyst layer is coated with a coating layer containing an OSC agent, the catalyst layer is easily exposed to a reducing atmosphere, which has the advantage of further improving the NOx purification performance in exhaust gas.
第1図は、本発明にかかる排気ガス浄化用触媒
の一例を示す拡大図、第2図は、本発明にかかる
排気ガス浄化用触媒における被覆層中のCeO2含
有量(重量%)に対する排気ガス中のCO浄化率
(%)の変化を示す特性図、第3図、第4図及び
第5図は、本発明の実施例1〜5と比較例1〜3
との浄化性能評価テストの結果を示す特性図、第
6図は、本発明の実施例6にかかる排気ガス浄化
用触媒の斜視図、第7図は、本発明の実施例7に
かかる排気ガス浄化用触媒の端面図、第8図、第
9図及び第10図は、本発明の実施例6、7と比
較例との浄化性能評価テストの結果を示す特性
図、第11図は、本発明の実施例8、9にかかる
排気ガス浄化用触媒の一例を示す拡大図、第12
図、第13図及び第14図は、本発明の実施例8
と比較例との浄化性能評価テストの結果を示す特
性図、第15図、第16図及び第17図は、本発
明の実施例9と比較例との浄化性能評価テストの
結果を示す特性図、第18図、第19図及び第2
0図は、本発明の実施例10と比較例との浄化性能
評価テストの結果を示す特性図である。
1……触媒担体、2……触媒層、3……被覆
層。
FIG. 1 is an enlarged view showing an example of the exhaust gas purification catalyst according to the present invention, and FIG. 2 is a graph showing the exhaust gas relative to the CeO 2 content (wt%) in the coating layer of the exhaust gas purification catalyst according to the present invention. Characteristic diagrams showing changes in CO purification rate (%) in gas, Figures 3, 4 and 5 are for Examples 1 to 5 of the present invention and Comparative Examples 1 to 3.
FIG. 6 is a perspective view of the exhaust gas purifying catalyst according to Example 6 of the present invention, and FIG. 7 is a characteristic diagram showing the results of the purification performance evaluation test with Example 7 of the present invention. The end view of the purification catalyst, FIGS. 8, 9, and 10 are characteristic diagrams showing the results of the purification performance evaluation test of Examples 6 and 7 of the present invention and the comparative example, and FIG. 11 is the characteristic diagram of the present invention. Enlarged view showing an example of the exhaust gas purifying catalyst according to Examples 8 and 9 of the invention, No. 12
FIG. 13 and FIG. 14 show Example 8 of the present invention.
FIG. 15, FIG. 16, and FIG. 17 are characteristic diagrams showing the results of the purification performance evaluation test of Example 9 of the present invention and the comparative example. , Fig. 18, Fig. 19 and Fig. 2
FIG. 0 is a characteristic diagram showing the results of a purification performance evaluation test of Example 10 of the present invention and a comparative example. 1...Catalyst carrier, 2...Catalyst layer, 3...Coating layer.
Claims (1)
パラジウムよりなる群から選ばれた少なくとも一
種類の触媒成分を含有する触媒層と、該触媒層上
に設けられ、酸素貯蔵能付与剤として作用する酸
化セリウム、酸化ニツケルおよび酸化鉄よりなる
群から選ばれた少なくとも一種類の酸化物を50〜
95重量%含有するアルミナの被覆層とを備えてい
ることを特徴とするエンジンの排気ガス浄化用触
媒。1. A catalyst layer supported on a catalyst carrier and containing at least one catalyst component selected from the group consisting of platinum, rhodium, and palladium, and cerium oxide provided on the catalyst layer and acting as an oxygen storage ability imparting agent. , at least one oxide selected from the group consisting of nickel oxide and iron oxide.
A catalyst for purifying exhaust gas from an engine, comprising a coating layer of alumina containing 95% by weight.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP60211634A JPS6271537A (en) | 1985-09-24 | 1985-09-24 | Catalyst for cleaning up exhaust gas of engine |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP60211634A JPS6271537A (en) | 1985-09-24 | 1985-09-24 | Catalyst for cleaning up exhaust gas of engine |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS6271537A JPS6271537A (en) | 1987-04-02 |
| JPH0338893B2 true JPH0338893B2 (en) | 1991-06-12 |
Family
ID=16609025
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP60211634A Granted JPS6271537A (en) | 1985-09-24 | 1985-09-24 | Catalyst for cleaning up exhaust gas of engine |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS6271537A (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS63240949A (en) * | 1987-03-27 | 1988-10-06 | Nissan Motor Co Ltd | Catalyst for purifying exhaust gas |
-
1985
- 1985-09-24 JP JP60211634A patent/JPS6271537A/en active Granted
Also Published As
| Publication number | Publication date |
|---|---|
| JPS6271537A (en) | 1987-04-02 |
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