Metal-supported crystalline silica aluminophosphate catalyst and process for producing the same

a technology of crystalline silica aluminophosphate and catalyst, which is applied in the direction of metal/metal-oxide/metal-hydroxide catalyst, physical/chemical process catalyst, separation process, etc., can solve the problems of reducing crystallinity and specific surface area, reducing activity, and impregnating crystalline silicoaluminophosphate, etc., to achieve high hydrothermal stability and maintain high activity

Inactive Publication Date: 2011-08-25
JGC CATALYSTS & CHEM LTD
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0014]An object of the present invention is to provide a process for producing a metal-supported catalyst, which has high

Problems solved by technology

Conventional crystalline porous material catalysts such as the above-described zeolites, when used at 700° C. or above in a reaction that produces water, cause lowered crystallinity and specific surface area that in turn results in lowered activity.
The following facts, however, have been found: (1) a method in which ion-exchange is carried out in an aqueous metal salt solution is disadvantageous in that a metal in an amount large enough to provide satisfactory activity cannot be supported, (2) a method in which a cry

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

Preparation of Metal-Supported Crystalline Silicoaluminophosphate Catalyst (1)

Preparation of Crystalline Silicoaluminophosphate (1)

[0147]807.3 g of an aqueous phosphoric acid solution having a concentration of 75% by weight and 2060.7 g of pure water were mixed together to prepare 2868 g of an aqueous phosphoric acid solution having a concentration of 21.1% by weight. 974.9 g of tetraethylammonium hydroxide (TEAH) having a concentration of 35% by weight was mixed thereinto. 440.5 g of pseudo-boehmite powder (Al2O3 content: 74% by weight) as an aluminum source was then dispersed in the mixture over a period of 10 minutes, and the dispersion was stirred for 15 minutes.

[0148]216.5 g of silica sol (manufactured by JGC Catalysts and Chemicals Ltd.: Sl-30, SiO2 concentration: 30% by weight) as a silica source was then added to the dispersion over a period of about 10 minutes to prepare a slurry (1) for crystalline silicoaluminophosphate synthesis.

[0149]The slurry (1) for crystalline silic...

example 2

Preparation of Metal-Supported Crystalline Silicoaluminophosphate Catalyst (2)

[0163]A crystalline silicoaluminophosphate (2) was prepared in the same manner as in Example 1, except that, after the washing, drying and calcining were not carried out.

[0164]3000 g of a dispersion having a solid content of 16.7% by weight was then prepared from the crystalline silicoaluminophosphate (2) obtained by washing and was colloid-milled to prepare a dispersion of the crystalline silicoaluminophosphate (2).

[0165]Separately, 68.6 g of cupric nitrate trihydrate was dissolved in 2500 g of water to prepare an aqueous copper nitrate solution.

[0166]An aqueous copper nitrate solution was then mixed into the dispersion of the crystalline silicoaluminophosphate (2) while maintaining the dispersion of the crystalline silicoaluminophosphate (2) to pH 3.5 by the addition of dilute nitric acid to prepare a mixed dispersion for spray drying.

[0167]The dispersion of the crystalline silicoaluminophosphate (2) was...

example 3

Preparation of Metal-Supported Crystalline Silicoaluminophosphate Catalyst (3)

[0170]A metal-supported crystalline silicoaluminophosphate catalyst (3) was prepared in the same manner as in Example 1, except that the amount of cupric nitrate trihydrate was changed to 25.5 g.

[0171]The content of copper as Cu in the resultant metal-supported crystalline silicoaluminophosphate catalyst (3) and the specific surface area of the metal-supported crystalline silicoaluminophosphate catalyst (3) were then measured, and the results are shown in Table 1 below.

[0172]Further, for the metal-supported crystalline silicoaluminophosphate catalyst (3), a NOx removing test and a hydrothermal resistance test were carried out in the same manner as in Example 1, and the results are shown in Table 2 below.

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Abstract

Disclosed is a metal-supported catalyst produced by (a) preparing a dispersion of crystalline silicoaluminophosphate particles; (b) mixing an aqueous active ingredient metal compound solution into the dispersion; (c) spray-drying the mixture; (d) washing the spray-dried product and (e) heat-treating (calcining) the washed product at 400 to 900° C.
Also disclosed is an aluminum phosphate-modified metal-supported crystalline silicoaluminophosphate catalyst having a content of aluminum phosphate in the catalyst of 0.1 to 40% by weight in terms of Al2O3+P2O5 based on the metal-supported crystalline silicoaluminophosphate particles.

Description

TECHNICAL FIELD[0001]The present invention relates to a metal-supported catalyst suitable for use in exhaust gas treatment in internal combustion engines with an enhanced exhaust gas treatment efficiency and a process for producing the same.BACKGROUND ART[0002]Contaminants such as HC (hydrocarbons), CO (carbon monoxide), NOx (nitrogen oxide), and PM (particulate matter) are contained in exhaust gases discharged from diesel engines. Among these contaminants, NOx cannot be purified by three-way catalysts, which have been put to practical use in oxidation catalysts and gasoline automobiles, without difficulties, and, thus, selective reduction-type NOx catalysts (hereinafter referred, to as “SCR catalysts”) are under development as promising NOx-purifying catalysts.[0003]Catalysts that have a honeycomb structure and comprise an active ingredient such as V (vanadium), Cr (chromium), Mo (molybdenum), Mn (manganese), Fe (iron), Ni (nickel), Cu (copper), Ag (silver), Au (gold), Pd (palladiu...

Claims

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Application Information

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IPC IPC(8): B01J29/85B01J37/08B01J37/04B01J37/06
CPCB01D53/9418B01J37/10B01D2255/1021B01D2255/1023B01D2255/1025B01D2255/1026B01D2255/1028B01D2255/104B01D2255/106B01D2255/20746B01D2255/50B01D2255/9202B01D2255/9207B01D2258/012B01J29/85B01D2251/2062B01D53/56B01D53/58B01J23/72B01J23/745B01J29/7065B01J29/723B01J29/763B01J29/83B01J35/0006B01J35/023B01J35/026B01J2229/186
Inventor MITSUI, TOMOHIROMORISHITA, YUKAMIZUNO, TAKAKIKOYANAGI, TSUGUO
Owner JGC CATALYSTS & CHEM LTD
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