Exhaust gas purification catalyst, and exhaust gas purification filter and exhaust gas purification method using the same

Inactive Publication Date: 2015-10-08
TOYOTA JIDOSHA KK
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

This patent is about a new exhaust gas purification filter for vehicles that uses a special catalyst to remove harmful particulate matter from exhaust gas. The catalyst is supported on a substrate made of air-permeable material, which allows for a large surface area for contact with the exhaust gas. The method of supporting the catalyst on the substrate can be done in various ways, such as using a support containing alumina and an active species fine particle containing silver sulfate. The resulting exhaust gas purification filter has the ability to oxidize and remove particulate matter from exhaust gas, which can help reduce air pollution and improve engine performance.

Problems solved by technology

Gas exhausted from an internal combustion engine contains harmful materials, for example, particulate matter (PM) produced by combustion and ash including additives in oil.
Among the harmful materials, particulate matter is known as an air pollutant having an adverse effect on animals and plants.
However, the exhaust gas purification catalyst disclosed in JP 2009-45584 A has a problem in that the activity of the Ag catalyst is significantly decreased due to poisoning by a sulfur component contained in fuel or oil.
In particular, in a catalyst using a highly basic support such as ceria, the activity is extremely high in the initial stage, but a decrease in the activity due to the sulfur component is significant.
Therefore, when this highly basic support is exposed to gas containing sulfur, the PM oxidation activity thereof is not sufficient.
However, in the exhaust gas purification filter disclosed in JP 2011-218295 A, the dispersibility of the Ag catalyst supported on alumina is low, and an Ag particle is coarse.
Accordingly, when the Ag catalyst is exposed to gas containing sulfur, the PM oxidation activity thereof is not sufficient.

Method used

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  • Exhaust gas purification catalyst, and exhaust gas purification filter and exhaust gas purification method using the same
  • Exhaust gas purification catalyst, and exhaust gas purification filter and exhaust gas purification method using the same
  • Exhaust gas purification catalyst, and exhaust gas purification filter and exhaust gas purification method using the same

Examples

Experimental program
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Effect test

example 1

[0060]1.44 g of silver sulfate (manufactured by Wako Pure Chemical Industries Ltd.) was dissolved in ion exchange water (250 g) at 80° C. to prepare a silver sulfate aqueous solution. Next, 8.56 g of γ-Al2O3 powder (manufactured by Nikki-Universal Co., Ltd., TN4, specific surface area: 150 m2 / g) as a support was impregnated with the obtained silver sulfate aqueous solution and was evaporated to dryness. The obtained material was dried at 110° C. overnight and was fired at 500° C. for three hours to cause silver sulfate to be supported on the γ-Al2O3 support. As a result, a catalyst powder was obtained. Next, this powder was mixed in a mortar and was molded into a pellet shape having a particle size of 0.3 mm to 0.5 mm using an ordinary method (cold isostatic pressing (CIP)). As a result, a pellet catalyst (Ag2SO4 / γ-Al2O3) was obtained. The support amount of silver sulfate was 10.0 mass % in terms of Ag with respect to the total amount of the γ-Al2O3 support and the active species fi...

example 2

[0061]A pellet catalyst (Ag2SO4 / α-Al2O3) was obtained in the same procedure as that of Example 1, except that α-Al2O3 powder (8.56 g, manufactured by Wako Pure Chemical Industries Ltd., α-Al2O3, specific surface area: 8 m2 / g) was used instead of γ-Al2O3 as the support. The support amount of silver sulfate was 10.0 mass % in terms of Ag with respect to the total amount of the α-Al2O3 support and the active species fine particle formed of silver sulfate.

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Abstract

An exhaust gas purification catalyst includes: a support containing alumina as a major component; and an active species fine particle containing silver sulfate as a major component and having an average crystallite size of 3 nm to less than 100 nm, in which the active species fine particle is supported on a surface of the support.

Description

INCORPORATION BY REFERENCE[0001]The disclosure of Japanese Patent Application No. 2014-075965 filed on Apr. 2, 2014 including the specification, drawings and abstract is incorporated herein by reference in its entirety.BACKGROUND OF THE INVENTION[0002]1. Field of the Invention[0003]The present invention relates to an exhaust gas purification catalyst, and an exhaust gas purification filter and an exhaust gas purification method using the same.[0004]2. Description of Related Art[0005]Gas exhausted from an internal combustion engine contains harmful materials, for example, particulate matter (PM) produced by combustion and ash including additives in oil. Among the harmful materials, particulate matter is known as an air pollutant having an adverse effect on animals and plants. Therefore, a purification filter (Diesel Particulate Filter; DPF) is used in order to collect particulate matter which is contained in exhaust gas exhausted from an internal combustion engine. Since the PM colle...

Claims

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Application Information

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IPC IPC(8): F01N3/20
CPCF01N3/20B01J23/50B01J37/0201B01J37/0236B01J38/12F01N3/103F01N3/035F01N2570/04B01D53/944B01D2255/104B01D2255/2092B01D2255/9202B01D2255/9207B01D2258/012B01J27/055B01J37/0009B01J35/393B01J35/30B01J35/23B01J35/40B01J35/612B01J35/615
InventorKIKUGAWA, MASASHIYAMAZAKI, KIYOSHISOBUE, YUICHIOKAWARA, SEIJI
OwnerTOYOTA JIDOSHA KK