Substituted Aluminum Borate Carrier for Pd Exhaust Catalyst

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Solution Overview

Problem

Existing exhaust gas purification catalysts face challenges with Pd sintering at high temperatures, leading to impaired performance, and aluminum borate whiskers with small specific surface areas cause noble metal particle aggregation, affecting durability and NOx removal efficiency.

Innovation Solution

Employing a substituted aluminum borate compound, such as Fe or Ni-substituted aluminum borate, as a carrier for Pd, which enhances oxygen storage capacity and NOx removal performance under rich conditions, even after long-term high-temperature use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If Pd is used as a catalytically active component to reduce production cost, then production cost is reduced, but Pd sintering occurs at high temperatures leading to impaired exhaust gas purification performance

Engineering Contradiction:

Improveproduction costVSAvoidexhaust gas purification performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention changes the chemical composition parameters of the carrier material by substituting Al atoms with Fe, Co, Ga, or Ni atoms in the aluminum borate structure. This substitution modifies the carrier's properties to suppress Pd sintering at high temperatures while maintaining catalytic activity, thus resolving the contradiction between using inexpensive Pd and maintaining performance reliability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite catalyst system combining Pd with substituted aluminum borate (containing Fe, Co, Ga, or Ni). This composite structure leverages the synergistic effects where the substituted aluminum borate carrier provides both structural support and active sites that prevent Pd aggregation, thereby maintaining exhaust gas purification performance while using cost-effective Pd.

Inventive Principle:

Principle #40Composite materials

2Productivity

If aluminum borate whiskers are used as a carrier to improve gas diffusibility, then gas diffusibility is improved, but the small specific surface area causes noble metal particle aggregation reducing durability

Engineering Contradiction:

Improvegas diffusibilityVSAvoiddurability

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The invention changes the physical and chemical parameters of the aluminum borate carrier by substituting Al atoms with other metal atoms. This substitution increases the specific surface area of the carrier while maintaining its gas diffusibility properties, thereby preventing noble metal aggregation and improving long-term durability without sacrificing productivity.

Inventive Principle:

Principle #35Parameter changes

3Quantity of substance

If substituted aluminum borate is used as a carrier to suppress Pd sintering, then oxygen storage capacity is improved, but the catalyst structure becomes more complex

Engineering Contradiction:

Improveoxygen storage capacityVSAvoidcatalyst structure

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The invention modifies the chemical composition of the aluminum borate carrier through controlled substitution of Al atoms with Fe, Co, Ga, or Ni atoms. This parameter change enhances oxygen storage capacity by creating oxygen vacancies and modifying the electronic structure, while the substitution process can be integrated into existing manufacturing workflows, limiting the increase in structural complexity.

Inventive Principle:

Principle #35Parameter changes

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 catalyst exhibits improved oxygen storage capacity and sustained NOx removal performance under high-temperature conditions, maintaining durability and efficiency.

Implementation Method 1

the resultant catalyst exhibits oxygen storage capacity

Methodology Applied

Scientific EffectOxygen storage capacity: Absorption (physical)

Implementation Method 2

Pd supported on the carrier... exhibits excellent exhaust gas purification performance (in particular, excellent NOx removal performance under a rich condition)

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS9199221B2Exhaust gas purification catalyst, and exhaust gas purification catalyst structure

Publication Date: 2015.12.01 MITSUI MINING & SMELTING CO LTD

AI summary

Provided are an exhaust gas purification catalyst including a carrier containing substituted aluminum borate in which 2.5 to 11.5 at. % of aluminum atoms contained therein are substituted by Fe, Co, Ga, or Ni, and Pd supported on the carrier; and an exhaust gas purification catalyst product including a catalyst support made of a ceramic or metallic material, and a layer of the aforementioned exhaust gas purification catalyst and which is supported on the catalyst support.