(19)
(11)EP 2 990 107 B1

(12)EUROPEAN PATENT SPECIFICATION

(45)Mention of the grant of the patent:
13.05.2020 Bulletin 2020/20

(21)Application number: 14788080.1

(22)Date of filing:  23.04.2014
(51)International Patent Classification (IPC): 
B01J 23/58(2006.01)
B01J 23/63(2006.01)
F01N 3/10(2006.01)
B01D 53/94(2006.01)
B01J 32/00(2006.01)
(86)International application number:
PCT/JP2014/061470
(87)International publication number:
WO 2014/175349 (30.10.2014 Gazette  2014/44)

(54)

SUPPORT FOR EXHAUST GAS PURIFICATION CATALYST, CATALYST FOR EXHAUST GAS PURIFICATION, AND CATALYST STRUCTURE FOR EXHAUST GAS PURIFICATION

TRÄGER FÜR ABGASREINIGUNGSKATALYSATOR, KATALYSATOR ZUR ABGASREINIGUNG UND KATALYSATORSTRUKTUR ZUR ABGASREINIGUNG

SUPPORT DE CATALYSEUR DE PURIFICATION DES GAZ D'ÉCHAPPEMENT, CATALYSEUR DE PURIFICATION DES GAZ D'ÉCHAPPEMENT ET STRUCTURE CATALYTIQUE POUR LA PURIFICATION DES GAZ D'ÉCHAPPEMENT


(84)Designated Contracting States:
AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

(30)Priority: 26.04.2013 JP 2013094197

(43)Date of publication of application:
02.03.2016 Bulletin 2016/09

(73)Proprietor: MITSUI MINING & SMELTING CO., LTD.
Tokyo 141-8584 (JP)

(72)Inventors:
  • NAKAHARA, Yunosuke
    Ageo-shi Saitama 362-0025 (JP)
  • HOUSHITO, Ohki
    Ageo-shi Saitama 362-0025 (JP)
  • IWAKURA, Hironori
    Ageo-shi Saitama 362-0025 (JP)
  • NAGAO, Yuki
    Ageo-shi Saitama 362-0025 (JP)
  • MACHIDA, Masato
    Kumamoto-shi Kumamoto 860-8555 (JP)

(74)Representative: Casalonga 
Casalonga & Partners Bayerstraße 71/73
80335 München
80335 München (DE)


(56)References cited: : 
EP-A1- 2 756 882
CN-A- 1 704 381
JP-A- 2012 016 685
US-A- 3 856 702
US-A- 3 954 670
US-A- 4 990 480
WO-A1-2013/039037
JP-A- 2001 172 626
US-A- 3 057 677
US-A- 3 856 705
US-A- 4 645 753
US-A- 5 043 308
  
  • MACDOWELL J F: "ALUMINOBORATE GLASS-CERAMICS WITH LOW THERMAL EXPANSIVITY", JOURNAL OF THE AMERICAN CERAMIC SOCIETY, BLACKWELL PUBLISHING, MALDEN, MA, US, vol. 73, no. 8, 1 August 1990 (1990-08-01) , pages 2287-2292, XP000162932, ISSN: 0002-7820, DOI: 10.1111/J.1151-2916.1990.TB07590.X
  • K. IKEUE ET AL.: 'Structure and Catalytic Properties of Pd/10Al2O3·2B2O3. Effect of Preparation Routes and Additives' BULL. CHEM. SOC. JPN. vol. 85, 2012, pages 468 - 474, XP008181730
 
Remarks:
The file contains technical information submitted after the application was filed and not included in this specification
 
Note: Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. Notice of opposition shall be filed in a written reasoned statement. It shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention).


Description

Technical Field



[0001] The present invention relates to a carrier for an exhaust gas purification catalyst (hereinafter referred to as an exhaust gas purification catalyst carrier), to an exhaust gas purification catalyst, and to an exhaust gas purification catalyst product. More particularly, the invention relates to an exhaust gas purification catalyst carrier, to an exhaust gas purification catalyst, and to an exhaust gas purification catalyst product, which exhibit excellent exhaust gas purification performance, (in particular CO removal performance), in a fuel-rich region (hereinafter referred to simply as a "rich region"), even after long-term use thereof under high-temperature conditions.

Background Art



[0002] Exhaust gas discharged from an internal combustion engine of, for example, an automobile contains toxic components such as hydrocarbons (HC), carbon monoxide (CO), and nitrogen oxides (NOx). Hitherto, three-way catalysts have been used for removing such toxic components for detoxifying the exhaust gas.

[0003] Such three-way catalysts include a noble metal (e.g., Pt, Pd, or Rh) serving as a catalytically active component; a material such as alumina, ceria, zirconia, or oxygen-occluding ceria-zirconia composite oxide, serving as a carrier; and a catalyst support made of a ceramic or metallic material and having a shape of honeycomb, plate, pellet, etc.

[0004] Recently, the regulation of automobile exhaust gas has become more strict, and the demand and prices of Pt and Rh, which are noble metals serving as a main catalytically active component of internal combustion engine exhaust gas purification catalysts, have risen. Since a rise in Rh price is a critical issue, efforts have been made on reduction of exhaust gas purification catalyst production cost by use of inexpensive Pd as a catalytically active component, and various means therefor have been proposed (see, for example, Patent Documents 1, 2, and 3). Meanwhile, there are some cases where a catalyst carrier made of aluminum borate is used. In one case of such a catalyst, a catalyst component is deposited on a powder compact which is covered with aluminum borate whiskers and which includes voids therein, whereby gas diffusivity is enhanced (see Patent Document 4).

[0005] However, it has been reported that Pd causes impairment in exhaust gas purification performance by sintering thereof at high temperature in a reducing atmosphere. Thus, suppression of Pd sintering is an inevitable issue for designing coming catalysts of a noble-metal saving format. Also, aluminum borate whiskers, having an acicular shape, have a small specific surface area, which causes cohesion of noble metal elements after long-term use of the relevant catalyst under high-temperature conditions. That is, durability of the catalyst is unsatisfactory.

[0006] In order to solve such problems, the present applicant previously developed an exhaust gas purification catalyst which exhibits excellent NOx purification performance, particularly in a rich region. The catalyst includes a carrier containing a substituted aluminum borate in which 2.5 to 11.5 at.% aluminum atoms are substituted by Fe, Co, Ga, or Ni atoms, and Pd supported on the carrier (see Patent Document 5).

Prior Art Documents


Patent Documents



[0007] 

Patent Document 1: Japanese Patent Application Laid-Open (kokai) No. Hei 06-099069

Patent Document 2: Japanese Patent Application Laid-Open (kokai) No. Hei 07-171392

Patent Document 3: Japanese Patent Application Laid-Open (kokai) No. Hei 08-281071

Patent Document 4: Japanese Patent Application Laid-Open (kokai) No. 2002-370035

Patent Document 5: WO 2012/005375



[0008] Other catalyst compositions are described in K. Ikeue et al, "Structure and catalytic properties of Pd/10 Al2O3 . 2B2O3. Effect of preparation routes and additives", Bull. Chem. Soc. JPN, Vol. 85, 2012, pages 468-474, and US 3 856 705. An aluminum borate of formula 10Al2O3 . 2B2O3 (10A2B) wherein additives selected from Mg, Ca, Sr, Ba, La and Ce, are added thereto, is used as support material for Pd catalysts in the article of K. Ikeue et al.

[0009] Further a catalyst composition comprising an aluminum borate wherein the B2O3/Al2O3 weight ratio is between 8/92 and 25/75, and active metal(s) is disclosed in US 3 856 705. The metals are zinc, cadmium, copper, silver, chromium, molybdenum, tungsten, manganese, rhenium, iron, cobalt, nickel, ruthenium, rhodium, palladium, osmium, iridium, and platinum.

Summary of the Invention


Problems to be Solved by the Invention



[0010] However, the exhaust gas purification catalyst disclosed in Patent Document 5, employing a substituted aluminum borate, exhibits somewhat lower purification performance after long-term use thereof in a rich region, although the catalyst exhibits excellent purification performance after long-term use thereof under a fuel-lean or a stoichiometric condition.

[0011]  In the meantime, the exhaust gas purification catalyst for automobiles is designed in accordance with the type of automobile. Specifically, automobiles mainly employing a combustion mode in a lean condition (at high air-fuel ratio) are provided with an exhaust gas purification catalyst which is durable in a lean condition, while automobiles mainly employing a combustion mode in a rich region (at low air-fuel ratio) are provided with an exhaust gas purification catalyst which is durable in a rich region.

[0012] Thus, an object of the present invention is to provide an exhaust gas purification catalyst carrier, an exhaust gas purification catalyst, and an exhaust gas purification catalyst product, which exhibit excellent exhaust gas purification performance, (in particular CO removal performance), in a rich region, even after long-term use thereof under high-temperature conditions.

Means for Solving the Problems



[0013] The present inventors have conducted extensive studies in order to attain the aforementioned object, and have found that the electronegativity of a catalyst carrier made of a modified aluminum borate to which a rare earth element as defined below has been added can be reduced, to thereby promote electron supply from noble metal elements to the carrier, whereby the noble metal elements are immobilized on the carrier even in a rich region, to thereby attain excellent Pd dispersion degree and catalytic activity, even after long-term use thereof in a rich region. The present invention has been accomplished on the basis of this finding.

[0014] Notably, characteristics, its production method, etc. of aluminum borate are disclosed in, for example, Siba P. Ray, "Preparation and Characterization of Aluminum Borate", J. Am. Ceram. Soc., 75[9], p. 2605-2609 (1992).

[0015] Conventionally, aluminum borate is represented by a formula 9Al2O3·2B2O3 (Al18B4O33), obtained through chemical analysis. However, a thesis (Martin et al., "Crystal-chemistry of mullite-type aluminoborates Al18B4O33 and Al5BO9: A stoichiometry puzzle", Journal of Solid State Chemistry 184(2011) p. 70 to 80), discloses crystal structure analyses revealing that aluminum borate is represented by Al5BO9 (5Al2O3:B2O3, Al20B4O36); i.e., formula 10Al2O3·2B2O3. The thesis also discloses that aluminum borate may be represented by either formula 9Al2O3·2B2O3 (Al18B4O33) or Al5BO9 (5Al2O3:B2O3, Al20B4O36), meaning that the two formulas represent a unique substance.

[0016] Thus, as used herein, the term "aluminum borate" encompasses aluminum borate represented by formula 10Al2O3·2B2O3 (5Al2O3:B2O3, Al20B4O36) and aluminum borate represented by formula 9Al2O3·2B2O3 (Al18B4O33).

[0017] Accordingly, a characteristic feature of the exhaust gas purification catalyst carrier of the present invention resides in that the catalyst carrier comprises a modified aluminum borate which contains aluminum borate (in particularly aluminum borate having a cage structure) as defined above and one addition element containing two elements which are La and Pr, the addition element being supported on the outer surface of aluminum borate entities as an addition element oxide, and the ratio (amount of addition element oxide)/(amount of aluminum borate+amount of addition element oxide) being 6 to 13 mass%. The aluminum borate employed in the present invention encompasses aluminum borate species having an aluminum oxide to boron oxide ratio of 10:2 to 9:2; i.e., an aluminum borate represented by formula 10Al2O3·2B2O3 (5Al2O3:B2O3, Al20B4O36) and an aluminum borate represented by formula 9Al2O3·2B2O3 (Al18B4O33). The aluminum borate employed in the present invention can be identified as an aluminum borate represented by formula 10Al2O3·2B2O3 through X-ray diffractometry. However, since the formula 9Al2O3·2B2O3 (Al18B4O33) is also given in an X-ray diffraction standard chart, the aluminum borate can also be identified as an aluminum borate represented by formula 9Al2O3·2B2O3 (Al18B4O33).

[0018] The aforementioned addition element contains two which are La and Pr.

[0019] The exhaust gas purification catalyst of the present invention includes the aforementioned exhaust gas purification catalyst carrier, and Pd supported on the carrier.

[0020] The exhaust gas purification catalyst product of the present invention includes a catalyst support formed of a ceramic or metallic material, and a layer of the aforementioned exhaust gas purification catalyst, the layer being supported on the catalyst support.

Effects of the Invention



[0021] The exhaust gas purification catalyst carrier, the exhaust gas purification catalyst, and the exhaust gas purification catalyst product according to the present invention exhibit excellent exhaust gas purification performance (in particular, CO removal performance) in a rich region, after long-term use thereof under high-temperature conditions.

Brief Description of the Drawings



[0022] [Fig. 1] An XRD pattern of aluminum borate produced in Referential Example 1.

Modes for Carrying Out the Invention



[0023] The carrier employed in the exhaust gas purification catalyst of the present invention comprises a modified aluminum borate which contains aluminum borate represented by formula 10Al2O3.2B2O3 or formula 9Al2O3.2B2O3 and one addition element containing two elements which are La and Pr, the addition element being supported on the outer surface of aluminum borate entities as an addition element oxide, and the ratio (amount of addition element oxide)/(amount of aluminum borate + amount of addition element oxide) being 6 to 13 mass %. When such a modified aluminum borate is employed, an exhaust gas purification catalyst containing Pd supported on the carrier exhibits excellent Pd dispersion degree and catalytic activity in a rich region after long-term use of the catalyst under high-temperature conditions.

[0024] The addition element contained in the modified aluminum borate of the present invention is not a partial substitution element with respect to boron or aluminum of aluminum borate, but is supported on aluminum borate or modifies aluminum borate. The addition element is present as an oxide or the like of the addition element such as a crystal grain boundary. When such an addition element is analyzed through XRD, no substantial shift is observed for the peak attributed to aluminum borate, but a peak attributed to the addition element is observed as a corresponding oxide peak.

[0025] Hereinafter, such aluminum borate species may also be referred to collectively as modified aluminum borate.

[0026] The aforementioned aluminum borate species may be produced through, for example, the following method.

<Solid-phase method>



[0027] Boric acid was weighed in such an amount that the compositional proportions of a target compound, aluminum borate (formula: Al20B4O36), were attained, and dissolved in ion-exchange water. Subsequently, the solution was mixed with a specifically weighed boehmite acetate sol, and the resultant mixture was heated under stirring. The thus-formed gel was dried at about 120°C for 12 hours or longer. After completion of drying, the dried product was fired at about 300°C for about one hour and then at about 1,000°C for about 5 hours, to thereby yield the target aluminum borate.

[0028] More specifically, boric acid was weighed in such an amount that the compositional proportions of the target aluminum borate (formula: Al20B4O36) were attained, and dissolved in ion-exchange water. Subsequently, the solution was mixed with a specifically weighed boehmite acetate sol, and the resultant mixture was heated under stirring. The thus-formed gel was dried at 120°C for 12 hours or longer. After completion of drying, the dried product was fired at 300°C for one hour and then at 1,000°C for 5 hours, to thereby yield the target aluminum borate.

<Reverse co-precipitation method>



[0029] Boric acid was weighed in such an amount that the compositional proportions of a target compound, aluminum borate (formula: Al20B4O36), were attained, and dissolved in hot pure water. Subsequently, the solution was mixed with a specifically weighed aluminum nitrate, to thereby prepare a solution. The solution was added dropwise to aqueous ammonium carbonate. The thus-formed precipitates were washed with pure water with filtration, and the solid was dried overnight at about 120°C and fired in air at about 300°C for about one hour. Thereafter, the dried product was fired at about 1,000°C for about 5 hours, to thereby yield the target aluminum borate.

[0030] More specifically, boric acid was weighed in such an amount that the compositional proportions of the target aluminum borate (formula: Al20B4O36) were attained, and dissolved in ion-exchange water. Subsequently, the solution was mixed with a specifically weighed aluminum nitrate nanohydrate, to thereby prepare a solution. The solution was added dropwise to aqueous ammonium carbonate. The thus-formed precipitates were washed with pure water with filtration, and the solid was dried at 120°C for 12 hours or longer and fired in air at 300°C for one hour. Thereafter, the dried product was fired in air at 1,000°C for 5 hours, to thereby yield the target aluminum borate. No significant difference was observed between the aluminum borate prepared through the above reverse co-precipitation and that prepared through the aforementioned solid-phase method.

[0031] The carrier of the exhaust gas purification catalyst of the present invention contains a modified aluminum borate prepared by modifying (or depositing) one addition element with (or on) the above-produced aluminum borate.

[0032]  In one mode of the method of producing such a modified aluminum borate, aluminum borate was immersed in a solution containing a specific amount of a compound of additional element (e.g., a nitrate salt, a sulfate salt, or an acetate salt), subjecting the mixture to evaporation to dryness, and firing the solid at a specific temperature (e.g., 400 to 1,000°C).

[0033] The addition element content, reduced to the corresponding oxide content; i.e., the ratio (amount of addition element oxide)/(sum of amount of aluminum borate + amount of addition element oxide) selected in the present invention, is 6 to 13 mass%, more preferably 7 to 13 mass%.

[0034] The modified aluminum borate contains one addition element containing two elements which are La and Pr, in the form of an oxide, in an amount of 6 to 13 mass%, preferably of 7 to 13 mass% based on the modified aluminum borate. When said one addition element is added as an oxide in an amount of 7 mass% or more, electrons are sufficiently supplied from noble metal elements to the carrier, whereby the noble metal elements are immobilized on the carrier even in a rich region, to thereby attain excellent Pd dispersion degree and catalytic activity, even after long-term use thereof in a rich region.

[0035] The exhaust gas purification catalyst of the present invention contains Pd supported on a carrier containing the aforementioned modified aluminum borate. By virtue of employing Pd supported on the modified aluminum borate, the exhaust gas purification catalyst exhibits excellent exhaust gas purification performance (in particular, CO removal performance) in a rich region, after long-term use thereof under high-temperature conditions. The amount of Pd supported on the carrier is preferably 0.05 to 5 mass%, based on the mass of the carrier, more preferably 0.4 to 3 mass%. When the amount of supported Pd based on the mass of the carrier is 0.05 mass% or more, durability of the catalyst increases, and when the amount is 5 mass% or less, Pd can be consistently supported in a highly dispersed state. In contrast, when the amount of supported Pd based on the mass of the carrier is less than 0.05 mass%, durability is poor due to a small absolute amount of noble metal, and when the amount is in excess of 5 mass%, supporting of Pd in a highly dispersion state may fail to be attained due to an excess amount of noble metal. In the present specification, the amount of supported Pd is reduced to the mass of metallic Pd.

[0036] In one mode of production, the exhaust gas purification catalyst of the present invention may be produced by mixing the modified aluminum borate with a solution of a Pd compound (a soluble Pd compound; e.g., Pd nitrate, Pd chloride, or Pd sulfate) so that the amount of supported Pd based on the mass of the carrier is adjusted to 0.2 to 3 mass%, and then subjecting the mixture to evaporation to dryness and firing the dried product at 450 to 650°C. Notably, in the specification and other attachments, no particular limitation is imposed on the solvent for forming the "solution," so long as the solvent can form the solution, and water is generally used. Notably, so long as the effects of the present invention are not impaired, the modified aluminum borate may be used in combination with an additional carrier, such as a porous body of a compound selected from the group consisting of silica, ceria, ceria-zirconia, alumina, and titania.

[0037] The exhaust gas purification catalyst product of the present invention includes a catalyst support formed of a ceramic or metallic material, and a layer of the aforementioned exhaust gas purification catalyst of the present invention, the layer being formed and supported on the catalyst support. In such an exhaust gas purification catalyst product, no particular limitation is imposed on the shape of the catalyst support formed of a ceramic or metallic material, and the support is generally in the form of honeycomb, plate, pellet, etc. In the case of a honeycomb shape support, the amount of exhaust gas purification catalyst supported is preferably 70 to 300 g/L, more preferably 100 to 200 g/L. When the catalyst amount is less than 70 g/L, durability of the catalyst tends to decrease due to an insufficient catalyst amount. Examples of the material of the catalyst support include ceramic materials such as alumina (Al2O3), mullite (3Al2O3-2SiO2), and cordierite (2MgO-2Al2O3-5SiO2), and metallic materials such as stainless steel.

[0038] The exhaust gas purification catalyst product of the present invention may be produced through the following method. A modified aluminum borate (50 to 70 parts by mass, preferably 50 to 60 parts by mass), La-stabilized alumina (20 to 40 parts by mass, preferably 20 to 30 parts by mass), barium hydroxide (0 to 3 parts by mass, preferably 1 to 3 parts by mass), and an alumina-bases binder (5 to 10 parts by mass) are mixed with a Pd compound solution, and the mixture is pulverized under wet conditions, to thereby prepare a slurry. The thus-prepared slurry is applied onto, through a widely known technique, a catalyst support formed of a ceramic or metallic material, preferably a honeycomb-shape catalyst support. The resultant structure is dried and then fired at 450 to 650°C, to thereby produce an exhaust gas purification catalyst product which includes a catalyst support, and a layer of the exhaust gas purification catalyst, the layer being supported on the catalyst support.

[0039] The present invention will next be described in detail by way of Referential Examples, Example, and Comparative Examples. Notably, the addition element content is derived as the ratio of amount of addition element oxide/total amount of aluminum borate and addition element oxide. In Tables 1 to 3, 10A2B denotes 10Al2O3·2B2O3.

Referential Example 1



[0040] An aluminum borate (Al20B4O36) was prepared through the following solid-phase method. Specifically, boric acid was weighed in such an amount that the compositional proportions of a target compound were attained, and dissolved in ion-exchange water. Subsequently, the solution was mixed with a specifically weighed boehmite acetate sol, and the resultant mixture was heated under stirring. The thus-formed gel was dried at 120°C for 12 hours or longer. After completion of drying, the dried product was fired in air at 300°C for one hour and then at 1,000°C for 5 hours, to thereby yield the aluminum borate of interest. The aluminum borate was found to have an XRD pattern shown in Fig. 1. As is clear from Fig. 1, the aluminum borate was identified as an aluminum borate represented by formula 10Al2O3·2B2O3, through X-ray diffraction analysis.

[0041] Notably, since the formula 9Al2O3·2B2O3 (Al18B4O33) is also given in an X-ray diffraction standard chart, the yielded product was also identified as an aluminum borate represented by formula 9Al2O3·2B2O3 (Al18B4O33).

Referential Example 2



[0042] An aluminum borate (Al20B4O36) was prepared through a reverse co-precipitation method. Specifically, boric acid was weighed in such an amount that the compositional proportions of a target compound were attained, and dissolved in ion-exchange water. Subsequently, the solution was mixed with a specifically weighed aluminum nitrate nanohydrate, to thereby prepare a solution. Then, the solution was added dropwise to aqueous ammonium carbonate, to thereby form precipitates. The precipitates were washed with pure water with filtration, and dried at 120°C for 12 hours or longer, followed by firing in air at 300°C for one hour and further in air at 1,000°C for 5 hours, to thereby yield the aluminum borate of interest. No significant difference was observed between the aluminum borate prepared through the above co-precipitation and that prepared through the solid-phase method of Referential Example 1.

Aluminum borate Production Example 1



[0043] To a three-neck flask dipped in a hot water bath at 50°C, 2-propanol (1.5 L), aluminum isopropoxide (200 g) pulverized by means of an agate mortar, and boron n-propoxide (40.9 g) were added, and the mixture was stirred under a flow of nitrogen gas. After complete dissolution of aluminum isopropoxide (confirmation of transparency of the solution), a mixture (24.6 g) of 2-propanol : water = 1 : 1 was gradually added dropwise to the solution for hydrolysis, to thereby form a white gel substance. The thus-formed precipitates were washed sequentially with ethanol and pure water, followed by filtration. Thereafter, the solid was dried overnight (for about 15 hours) at 120°C, and fired in air at 300°C for 3 hours and further in air at 1,000°C for 5 hours, to thereby yield an aluminum borate as a white product. Through X-ray diffractometry, this aluminum borate was identified as an aluminum borate represented by formula 10Al2O3·2B2O3

Comparative Example 1



[0044] The aluminum borate produced in Production Example 1 was immersed in aqueous lanthanum nitrate and in aqueous strontium nitrate. The amount of lanthanum nitrate in the aqueous solution and that of the strontium nitrate in the aqueous solution were adjusted such that the La2O3 content and the SrO content of the aluminum borate represented by 10Al2O3·2B2O3 modified with target La2O3 and SrO were attained as 5 mass% and 5 mass%, respectively. Thereafter, the mixture was dried overnight (for about 15 hours) at 120°C to dryness, and then fired in air at 600°C for 3 hours, to thereby yield an aluminum borate represented by 10Al2O3·2B2O3 modified with La2O3 and SrO at 5 mass% and 5 mass%, respectively.

[0045] To the aluminum borate (99 parts by mass) represented by 10Al2O3·2B2O3 modified with La2O3 and SrO at 5 mass% and 5 mass%, and palladium nitrate (1 part by mass, as reduced to Pd metal), an appropriate amount of ion-exchange water was added, and the resultant slurry was stirred, dried, and fired at 500°C for one hour.

Example 1



[0046] The aluminum borate produced in Production Example 1 was immersed in aqueous lanthanum nitrate and in aqueous praseodymium nitrate. The amount of lanthanum nitrate in the aqueous solution thereof and that of preseodymium nitrate in its aqueous solution were adjusted such that the La2O3 content and the Pr6O11 content of the aluminum borate represented by 10Al2O3·2B2O3 modified with target La2O3 and Pr6O11 were attained as 5 mass% and 5 mass%, respectively. Thereafter, the mixture was dried overnight (for about 15 hours) at 120°C to dryness, and then fired in air at 600°C for 3 hours, to thereby yield an aluminum borate represented by 10Al2O3·2B2O3 modified with La2O3 and Pr6O11 at 5 mass% and 5 mass%, respectively.

[0047] To the aluminum borate (99 parts by mass) represented by 10Al2O3·2B2O3 modified with La2O3 and Pr6O11 at 5 mass% and 5 mass%, and palladium nitrate (1 part by mass, as reduced to Pd metal), an appropriate amount of ion-exchange water was added, and the resultant slurry was stirred, dried, and fired at 500°C for one hour.

Comparative Example 2



[0048] The aluminum borate produced in Production Example 1 was immersed in aqueous lanthanum nitrate and in aqueous calcium nitrate. The amount of lanthanum nitrate in the aqueous solution and that of the calcium nitrate in its aqueous solution were adjusted such that the La2O3 content and the CaO content of the aluminum borate represented by 10Al2O3·2B2O3 modified with target La2O3 and CaO were attained as 5 mass% and 5 mass%, respectively. Thereafter, the mixture was dried overnight (for about 15 hours) at 120°C to dryness, and then fired in air at 600°C for 3 hours, to thereby yield an aluminum borate represented by 10Al2O3·2B2O3 modified with La2O3 and CaO at 5 mass% and 5 mass%, respectively. To the aluminum borate (99 parts by mass) represented by 10Al2O3·2B2O3 modified with La2O3 and CaO at 5 mass% and 5 mass%, and palladium nitrate (1 part by mass, as reduced to Pd metal), an appropriate amount of ion-exchange water was added, and the resultant slurry was stirred, dried, and fired at 500°C for one hour.

Comparative Example 3



[0049] The aluminum borate produced in Production Example 1 was immersed in aqueous lanthanum nitrate and in aqueous barium nitrate. The amount of lanthanum nitrate in the aqueous solution and that of the barium nitrate in its aqueous solution were adjusted such that the La2O3 content and the BaO content of the aluminum borate represented by 10Al2O3·2B2O3 modified with La2O3 and BaO were attained as 5 mass% and 5 mass%, respectively. Thereafter, the mixture was dried overnight (for about 15 hours) at 120°C to dryness, and then fired in air at 600°C for 3 hours, to thereby yield an aluminum borate represented by 10Al2O3·2B2O3 modified with La2O3 and BaO at 5 mass% and 5 mass%, respectively.

[0050] To the aluminum borate (99 parts by mass) represented by 10Al2O3·2B2O3 modified with La2O3 and BaO at 5 mass% and 5 mass%, and palladium nitrate (1 part by mass, as reduced to Pd metal), an appropriate amount of ion-exchange water was added, and the resultant slurry was stirred, dried, and fired at 500°C for one hour.

Comparative Example 4



[0051] γ-Al2O3 (99 parts by mass) and palladium nitrate (1 part by mass, as reduced to metallic Pd) were added to an appropriate amount of ion-exchange water, and the resultant slurry was stirred. Then, the slurry was dried and fired at 500°C for one hour.

Comparative Example 5



[0052] The aluminum borate produced in Production Example 1 was immersed in aqueous lanthanum nitrate. The amount of lanthanum nitrate in the aqueous solution was adjusted such that the La2O3 content of the aluminum borate represented by 10Al2O3·2B2O3 modified with target La2O3 was attained as 5 mass% based on the modified aluminum borate. Thereafter, the mixture was dried overnight (for about 15 hours) at 120°C to dryness, and then fired in air at 600°C for 3 hours, to thereby yield an aluminum borate represented by 10Al2O3·2B2O3 modified with La2O3 at 5 mass%.

[0053] To the aluminum borate (99 parts by mass) represented by 10Al2O3·2B2O3 modified with La2O3 at 5 mass% based on the modified aluminum borate, and palladium nitrate (1 part by mass, as reduced to Pd metal), an appropriate amount of ion-exchange water was added, and the resultant slurry was stirred, dried, and fired at 500°C for one hour.

Comparative Example 6



[0054] The aluminum borate produced in Production Example 1 was immersed in aqueous lanthanum nitrate and in aqueous barium nitrate. The amount of lanthanum nitrate in the aqueous solution thereof and that of the barium nitrate in its aqueous solution were adjusted such that the La2O3 content and the BaO content of the aluminum borate represented by 10Al2O3·2B2O3 modified with target La2O3 and BaO were attained as 1 mass% and 2 mass%, respectively. Thereafter, the mixture was dried overnight (for about 15 hours) at 120°C to dryness, and then fired in air at 600°C for 3 hours, to thereby yield an aluminum borate represented by 10Al2O3·2B2O3 modified with La2O3 and BaO at 1 mass% and 2 mass% based on the modified aluminum borate, respectively.

[0055] To the aluminum borate (99 parts by mass) represented by 10Al2O3·2B2O3 modified with La2O3 and BaO at 1 mass% and 2 mass% based on the modified aluminum borate, and palladium nitrate (1 part by mass, as reduced to Pd metal), an appropriate amount of ion-exchange water was added, and the resultant slurry was stirred, dried, and fired at 500°C for one hour.

<Catalytic performance evaluation method>



[0056] Each of the samples produced in the Example and Comparative Examples was assessed in terms of purification performance with respect to a simulated exhaust gas, by means of an immobilized bed flow-type reactor. Each catalyst powder (50 mg) was placed in the reactor tube, and a gas which simulated a complete combustion gas and which was composed of NO (0.05%), CO (0.39%), C3H6 (1,200 ppmC), O2 (0.4%), H2 (0.1%), and H2O (10%), the balance being N2, was fed to the catalyst powder at a total flow rate of 1,000 cc/min. The reactor tube was heated to 500°C at a temperature elevation rate of 10°C/min, and maintained at 500°C for 10 minutes, for carrying out a preliminary treatment. Subsequently, the reactor tube was cooled, and heated again from 100°C to 500°C at 10°C/min.

[0057] The outlet gas composition was determined by means of a CO/NO analyzer (model: PG240, product of Horiba) and an HC analyzer (model: VMF-1000F, product of Shimadzu Corporation).

[0058] Each catalyst was aged at 900°C and 25H in a rich region of A/F = 14.0 (H2O = 10%).

<Pd dispersion degree evaluation method>



[0059] The degree of Pd dispersion was measured according to the CO pulse adsorption method (i.e., a known technique) (T. Takeguchi, S. Manabe, R. Kikuchi, K. Eguchi, T. Kanazawa, S. Matsumoto, Applied Catalysis A: 293 (2005) 91). The degree of Pd dispersion was calculated by the following formula: degree of Pd dispersion = the amount (by mole) of Pd corresponding to the amount of CO adsorbed/the total amount (by mole) of Pd contained in the catalyst of interest.

<Catalytic performance evaluation results>



[0060] Table 1 shows the values of the temperature (T50) at which 50% removal of NO and HC was completed in the presence of each catalyst after aging, and the temperature (T70) at which 70% removal of CO was completed in the presence of the catalyst. As is clear from Table 1, the catalyst sample of Example 1 exhibited more excellent low-temperature catalytic activity, as compared with those of the Comparative Examples. Among three components, CO removal performance was remarkably excellent.
[Table 1]
 Carrier compositionNO-T50HC-T50CO-T70
Comp. Ex. 4 γ-Al2O3 392.2 360.2 374.1
Comp. Ex. 5 5 wt.% La2O3/10A2B 375.5 355.5 373.1
Comp. Ex. 6 (1 wt.% La2O3 + 2 wt.% BaO)/10A2B 371.5 353.7 372.1
Comp. Ex. 1 (5 wt.% La2O3 + 5 wt.% SrO)/10A2B 371.3 352.9 365.8
Ex. 1 (5 wt.% La2O3 + 5 wt.% Pr6O11)/10A2B 357.6 336.1 347.3
Comp. Ex. 2 (5 wt.% La2O3 + 5 wt.% CaO)/10A2B 365.2 344.3 357.3
Comp. Ex. 3 (5 wt.% La2O3 + 5 wt.% BaO)/10A2B 371.3 353.8 365.9


[0061] Table 2 shows Pd dispersion degrees of the tested catalyst after aging. As is clear from Table 2, Pd dispersion degree of the catalyst of Example 1 was higher than that of the Comparative Examples.
[Table 2]
 Carrier compositionPd dispersion degree
Comp. Ex. 4 γ-Al2O3 2.79%
Comp. Ex. 5 5 wt.% La2O3/10A2B 3.24%
Comp. Ex. 6 (1 wt.% La2O3 + 2 wt.% BaO)/10A2B 3.44%
Comp. Ex. 1 (5 wt.% La2O3 + 5 wt.% SrO)/10A2B 3.68%
Ex. 1 (5 wt.% La2O3 + 5 wt.% Pr6O11)/10A2B 4.77%
Comp. Ex. 2 (5 wt.% La2O3 + 5 wt.% CaO)/10A2B 4.56%
Comp.Ex. 3 (5 wt.% La2O3 + 5 wt.% BaO)/10A2B 3.80%


[0062] Table 3 shows electronegativity values of the carriers. The electronegativity was a weighted average of the electronegativity (Pauling's electronegativity) of a metal or metals forming the corresponding metal oxide and that of oxygen, based on the compositional proportions of the elements contained in the metal oxide. As shown in Table 3, aluminum borate serves as an acidic carrier having an electronegativity higher than that of Al2O3. In the case where aluminum borate is modified with an electron-accepting element such as an alkaline earth metal element or a rare earth metal element, conceivably, electrons are supplied from noble metal elements to the carrier, whereby the noble metal elements are immobilized on the carrier even in a rich region. Also, presumably, the electronegativity of the carrier decreases to be almost a neutral electronegativity, which is equivalent to that of Al2O3, to thereby attain excellent reactivity (e.g., inhibition of adsorption of exhaust gas components). Thus, as is clear from Tables 1 and 2, Pd dispersion degree and component (in particular, CO) removal reactivity at low temperature are conceivably enhanced, by virtue of the above effects. The electronegativity of the carrier was found to be preferably 2.732 or lower. Also, when the amount of an oxide modifying aluminum borate is adjusted to 7 mass% or more, purification performance and Pd dispersibility can be enhanced.

[0063] Notably, electronegativity can be derived through the following calculation.

[0064] In the case of Comparative Example 5, the ratio by mass of La2O3 : 10Al2O3·2B2O3 in 10Al2O3·2B2O3 modified with 5 mass% La2O3 is 5 : 95. When 5 mass% La2O3 is reduced to the corresponding mol% value, the value is 18.72 mol% with respect to that of 10Al2O3·2B2O3 taken as 100 mol%. Pauling's electronegativity values of the elements forming the oxide are as follows: La = 1.1, O = 3.44, B = 2.04, and Al = 1.61. Thus, the weighted average is as follows: 118.72%×(2×1.1 + 3×3.44) + (20×1.61 + 4×2.04 + 36×3.44)}/(18.72%×5 + 60) = 2.733.
[Table 3]
 MaterialElectronegativity of carrier
Comp. Ex. 4 Al2O3 2.708
- 10A2B 2.737
Comp. Ex. 5 5 wt.% La2O3/10A2B 2.733
Comp. Ex. 6 (1 wt.% La2O3 + 2 wt.% BaO)/10A2B 2.733
Comp. Ex. 1 (5 wt.% La2O3 + 5 wt.% SrO)/10A2B 2.722
Ex. 1 (5 wt.% La2O3 + 5 wt.% Pr6O11)/10A2B 2.731
Comp.Ex. 2 (5 wt.% La2O3 + 5 wt.% CaO)/10A2B 2.714
Comp.Ex. 3 (5 wt.% La2O3 + 5 wt.% BaO)/10A2B 2.725



Claims

1. An exhaust gas purification catalyst carrier, characterized by comprising a modified aluminum borate which contains aluminum borate represented by formula 10Al2O3.2B2O3 or formula 9Al2O3.2B2O3 and one addition element containing two elements which are La and Pr, the addition element being supported on the outer surface of aluminum borate entities as an addition element oxide, and the ratio (amount of addition element oxide)/( amount of aluminum borate + amount of addition element oxide) being 6 to 13 mass %.
 
2. An exhaust gas purification catalyst, characterized by comprising an exhaust gas purification catalyst carrier as recited in claim 1, and Pd supported on the carrier.
 
3. An exhaust gas purification catalyst product, characterized by comprising a catalyst support formed of a ceramic or metallic material, and a layer of an exhaust gas purification catalyst as recited in claim 2, the layer being supported on the catalyst support.
 


Ansprüche

1. Träger für einen Abgasreinigungskatalysator, dadurch gekennzeichnet, dass er ein modifiziertes Aluminiumborat umfasst, das Aluminiumborat enthält, welches durch die Formel 10Al2O3·2B2O3 oder die Formel 9Al2O3·2B2O3 repräsentiert wird, sowie ein Anlagerungselement, das zwei Elemente, nämlich La und Pr, enthält, wobei das Anlagerungselement als Anlagerungselementoxid auf der Außenseite von Aluminiumborateinheiten getragen wird, und wobei das Verhältnis (Menge Anlagerungselementoxid)/(Menge Aluminiumborat + Menge Anlagerungselementoxid) 6 bis 13 Masse-% beträgt.
 
2. Abgasreinigungskatalysator, dadurch gekennzeichnet, dass er einen Träger für einen Abgasreinigungskatalysator nach Anspruch 1 sowie auf dem Träger getragenes Pd umfasst.
 
3. Abgasreinigungskatalysatorprodukt, dadurch gekennzeichnet, dass es einen aus einem keramischen oder metallischen Material gebildeten Katalysatorträger sowie eine Schicht aus einem Abgasreinigungskatalysator nach Anspruch 2 umfasst, wobei die Schicht auf dem Katalysatorträger getragen wird.
 


Revendications

1. Porteur pour catalyseur de purification de gaz d'échappement, caractérisé en ce qu'il comprend un borate d'aluminium modifié qui contient du borate d'aluminium répondant à la formule 10Al2O3·2B2O3 ou à la formule 9Al2O3·2B2O3, et un élément d'addition contenant deux éléments qui sont le lanthane (La) et le praséodyme (Pr), l'élément d'addition étant porté par la surface extérieure des entités du type borate d'aluminium sous la forme d'un oxyde d'élément d'addition, et le rapport (quantité d'oxyde d'élément d'addition)/(quantité de borate d'aluminium + quantité d'oxyde d'élément d'addition) représentant 6 % à 13 % en masse.
 
2. Catalyseur de purification de gaz d'échappement, caractérisé en ce qu'il comprend un porteur pour catalyseur de purification de gaz d'échappement tel que défini dans la revendication 1, et du palladium (Pd) porté par le porteur.
 
3. Produit catalytique de purification de gaz d'échappement, caractérisé en ce qu'il comprend un support de catalyseur constitué d'un matériau céramique ou métallique, et une couche d'un catalyseur de purification de gaz d'échappement tel que défini dans la revendication 2, la couche étant portée par le support de catalyseur.
 




Drawing








Cited references

REFERENCES CITED IN THE DESCRIPTION



This list of references cited by the applicant is for the reader's convenience only. It does not form part of the European patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be excluded and the EPO disclaims all liability in this regard.

Patent documents cited in the description




Non-patent literature cited in the description