Honeycomb Structure Pore Optimization for Catalyst Loading
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Solution Overview
Problem
Conventional honeycomb structures face increased pressure loss and catalyst clogging when loaded with higher catalyst amounts to meet stricter exhaust gas regulations, compromising purification performance and exhaust gas diffusibility.
Innovation Solution
A honeycomb structure with specific porosity, pore density, and median opening diameter of 10 μm or more, along with a wet area of 16,500 μm2 or more, to enhance catalyst filling and prevent pressure loss, while maintaining isostatic strength and purification performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the catalyst loading amount is increased to meet stricter exhaust gas regulations, then the purification performance is improved, but the pressure loss increases and cell passages become clogged
Solution Approach 1:
The partition walls are designed with optimized porous structures, including specific porosity (30-70%), pore size distribution (D10: 1-10 μm, D50: 10-50 μm, D90: 50-200 μm), and pore shape characteristics (circularity: 0.4-2.0). This porous structure allows high catalyst loading (400 g/L or more) while maintaining exhaust gas diffusibility and preventing pressure loss increase, as the pores provide adequate pathways for gas flow even when catalyst is densely loaded.
Solution Approach 2:
The invention changes multiple structural parameters of the partition walls simultaneously: porosity, pore diameter distribution, pore shape (circularity), wet area (16,500 μm2 or more), and thickness (50-200 μm). By optimizing these parameters together, the honeycomb structure achieves high catalyst loading capacity while maintaining pressure loss below 100 Pa and preserving exhaust gas diffusibility.
2Reliability
If the catalyst loading amount is increased to meet stricter exhaust gas regulations, then the purification performance is improved, but the cell passages become clogged by catalyst
Solution Approach 1:
The partition walls are designed with optimized porous structures, including specific porosity (30-70%), pore size distribution (D10: 1-10 μm, D50: 10-50 μm, D90: 50-200 μm), and pore shape characteristics (circularity: 0.4-2.0). This porous structure allows high catalyst loading (400 g/L or more) while maintaining exhaust gas diffusibility and preventing pressure loss increase, as the pores provide adequate pathways for gas flow even when catalyst is densely loaded.
Solution Approach 2:
The invention transitions from considering only surface area to also considering the three-dimensional pore structure and volume. By controlling pore size distribution across different dimensions (small pores D10: 1-10 μm, medium pores D50: 10-50 μm, large pores D90: 50-200 μm) and optimizing the wet area (16,500 μm2 or more), the structure accommodates high catalyst loading without clogging cell passages.
3Quantity of substance
If the porosity of partition walls is increased to allow more catalyst loading, then the catalyst amount is increased, but the pressure loss increases
Solution Approach 1:
The invention changes multiple structural parameters of the partition walls simultaneously: porosity, pore diameter distribution, pore shape (circularity), wet area (16,500 μm2 or more), and thickness (50-200 μm). By optimizing these parameters together, the honeycomb structure achieves high catalyst loading capacity while maintaining pressure loss below 100 Pa and preserving exhaust gas diffusibility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The structure achieves improved exhaust gas diffusibility and purification performance with increased catalyst loading without significant pressure loss, ensuring effective NOx reduction and catalyst distribution.
Implementation Method 1
The present invention provides a honeycomb structure having an excellent exhaust gas diffusibility
Data Source
AI summary
A honeycomb structure includes a honeycomb structure body including porous partition walls defining a plurality of cells serving as fluid passages extending from an inflow end face to an outflow end face. The partition walls have a porosity of 45 to 65%; the open frontal area of the pores having an equivalent circle diameter of 10 μm or more, of the pores open on the surface of each partition wall, is 20 to 50%; the pore density of the pores having an equivalent circle diameter of 10 μm or more is 200 to 1,000 pores/mm2; the median opening diameter of the pores having an equivalent circle diameter of 10 μm or more is 40 to 60 μm; the circularity of the pores having an equivalent circle diameter of 10 μm or more is 1.8 to 4.0; and the partition walls have a wet area of 16,500 μm2 or more.