阅读说明：本技术 功能性结构体以及功能性结构体的制造方法 (Functional structure and method for manufacturing functional structure ) 是由 增田隆夫 中坂佑太 吉川琢也 加藤祯宏 福岛将行 稻森康次郎 高桥寻子 马场祐一郎 于 2018-05-31 设计创作，主要内容包括：本发明提供一种功能性结构体,其能通过抑制功能性物质的功能降低来实现寿命延长,能谋求资源节约而无需繁杂的更换作业。功能性结构体(1)具备：多孔质结构的骨架体(10),其由沸石型化合物构成；以及至少一种功能性物质(20),其存在于骨架体(10)内,骨架体(10)具有相互连通的通路(11),功能性物质(20)存在于骨架体(10)的至少通路(11)中。(The invention provides a functional structure which can realize the prolonging of the service life by inhibiting the function reduction of functional materials and can save resources without complicated replacement operation. A functional structure (1) is provided with: a porous-structure skeleton (10) composed of a zeolite-type compound; and at least one functional substance (20) present within the skeleton body (10), the skeleton body (10) having mutually communicating passages (11), the functional substance (20) being present in at least the passages (11) of the skeleton body (10).)

1. A functional structure, comprising:

a porous-structure skeleton body composed of a zeolite-type compound; and

at least one functional substance present within the matrix,

the skeleton body has passages communicated with each other,

the functional substance is present in at least the passage of the scaffold.

2. The functional structure according to claim 1,

the passage has: any one of one-dimensional pores, two-dimensional pores, and three-dimensional pores defined by the framework structure of the zeolite-type compound; and a diameter expanding portion which is different from any one of the one-dimensional hole, the two-dimensional hole, and the three-dimensional hole, and which is provided with a hole having a diameter larger than that of the hole having the one-dimensional hole

The functional substance is present at least in the expanded diameter portion.

3. The functional structure according to claim 2, wherein,

the diameter expanding portion causes a plurality of holes constituting any one of the one-dimensional hole, the two-dimensional hole, and the three-dimensional hole to communicate with each other.

4. The functional structure according to any one of claims 1 to 3,

the functional material is a catalyst material and,

the skeleton body is a carrier supporting at least one of the catalyst substances.

5. The functional structure according to claim 4,

the catalyst material is a metal oxide particulate.

6. The functional structure according to claim 5,

the metal oxide fine particles have an average particle diameter larger than an average inner diameter of the passage and equal to or smaller than an inner diameter of the enlarged diameter portion.

7. The functional structure according to claim 5 or 6,

the metal element M of the metal oxide fine particles is contained in an amount of 0.5 to 2.5 mass% relative to the functional structure.

8. The functional structure according to any one of claims 5 to 7,

the metal oxide fine particles have an average particle diameter of 0.1 to 50 nm.

9. The functional structure according to any one of claims 5 to 8,

the metal oxide fine particles have an average particle diameter of 0.5 to 14.0 nm.

10. The functional structure according to any one of claims 5 to 8,

the ratio of the average particle diameter of the metal oxide fine particles to the average inner diameter of the passage is 0.06 to 500.

11. The functional structure according to claim 10,

the ratio of the average particle diameter of the metal oxide fine particles to the average inner diameter of the passage is 0.1 to 36.

12. The functional structure according to claim 11,

the ratio of the average particle diameter of the metal oxide fine particles to the average inner diameter of the passage is 1.7 to 4.5.

13. The functional structure according to any one of claims 2 to 12,

the average inner diameter of the passage is 0.1nm to 1.5nm,

the inner diameter of the diameter-expanded portion is 0.5nm to 50 nm.

14. The functional structure according to any one of claims 1 to 13,

also provided is at least one functional substance that is retained on the outer surface of the skeleton body.

15. The functional structure according to claim 14,

the content of the at least one functional substance present in the matrix is greater than the content of the at least one other functional substance remaining on the outer surface of the matrix.

16. The functional structure according to any one of claims 1 to 15,

the zeolite-type compound is a silicate compound.

17. A method for manufacturing a functional structure, comprising:

a firing step of firing a precursor material B obtained by impregnating a metal-containing solution into a precursor material a for obtaining a framework having a porous structure composed of a zeolite-type compound; and

a hydrothermal treatment step of subjecting a precursor material C obtained by firing the precursor material B to hydrothermal treatment.

18. The method of manufacturing a functional structure according to claim 17,

before the firing step, 50 to 500 mass% of a nonionic surfactant is added to the precursor material a.

19. The method of manufacturing a functional structure according to claim 17 or 18,

before the firing step, the precursor material a is impregnated with the metal-containing solution by adding the metal-containing solution to the precursor material a plurality of times.

20. The method for manufacturing a functional structure according to any one of claims 17 to 19,

when the precursor material A is immersed in the metal-containing solution before the firing step, the amount of the metal-containing solution added to the precursor material A is adjusted so that the atomic ratio Si/M, which is the ratio of silicon Si constituting the precursor material A to the metal element M contained in the metal-containing solution added to the precursor material A, is 10 to 1000.

21. The method of manufacturing a functional structure according to claim 17,

in the hydrothermal treatment step, the precursor material C is mixed with a structure-directing agent.

22. The method of manufacturing a functional structure according to claim 17,

the hydrothermal treatment step is performed in an alkaline environment.

Technical Field

The present invention relates to a functional structure including a skeleton having a porous structure and a functional material, and a method for manufacturing the functional structure.

Background

In refineries of petroleum complexes, various fuels such as petrochemical feedstocks called naphtha (naphtha), heavy oil, light oil, kerosene, gasoline, and LP gas are produced from crude oil. Crude oil is a mixture of various impurities in addition to the petrochemical raw materials and various fuels, and therefore, a step of distilling and separating each component contained in crude oil is required.

Therefore, in the petroleum refining process, crude oil is heated on a tray in a column of an atmospheric distillation apparatus to separate the crude oil into components by utilizing the difference in boiling point between the components, and the separated components are concentrated. Thus, low boiling point substances such as LP gas and naphtha are taken out from the upper tray of the atmospheric distillation apparatus, and high boiling point substances such as heavy oil are taken out from the bottom of the atmospheric distillation apparatus. Then, the separated and concentrated substances are subjected to secondary treatment such as desulfurization to produce various fuel products.

Generally, a petroleum-reforming catalyst is used for efficiently reforming naphtha having a low boiling point in the above-mentioned petroleum refining process to produce gasoline having a high octane number or the like. Since the naphtha fraction in the crude oil has a low octane number and is not suitable as gasoline for driving a vehicle, a modified gasoline having properties suitable for fuel of a vehicle is produced by modifying a paraffin component and a naphthene component having a low octane number in the naphtha fraction into aromatic components having a high octane number by using a petroleum-modifying catalyst.

Further, with the heavy crude oil, the following hydrocracking treatment was performed: the yield of desulfurized naphtha, desulfurized lamp oil, desulfurized light oil, and the like is improved by further cracking desulfurized heavy oil, desulfurized heavy light oil, and the like obtained by subjecting heavy oil to hydrodesulfurization treatment by a hydrodesulfurization device such as a direct desulfurization device or an indirect desulfurization device. For example, the yield of desulfurized light oil fraction and desulfurized naphtha fraction is increased by subjecting the atmospheric distillation residue oil to hydrocracking treatment, and desulfurized heavy oil is reduced, and the desulfurized heavy oil is subjected to catalytic cracking to produce LPG fraction, FCC gasoline fraction, and LCO fraction, thereby reducing the residue oil and increasing the light oil fraction. In this case, a catalyst containing a crystalline aluminosilicate carrier as a representative zeolite and a hydrocracking catalyst containing a zeolite and a porous inorganic oxide at a specific ratio have been proposed.

For example, as a hydrocracking catalyst, a catalyst in which a metal containing a material selected from Pd, Pt, Co, Fe, Cr, Mo, W, and a mixture thereof is deposited on the surface of a support containing Y-type zeolite is disclosed (patent document 1).

In the automotive field, as an exhaust gas catalyst structure for a vehicle equipped with a diesel engine, a ceramic catalyst body has been proposed in which a ceramic carrier is disposed on a surface of a base ceramic and both a main catalyst component and a co-catalyst component are supported on the ceramic carrier. In this ceramic catalyst body, a large number of pores including lattice defects in the crystal lattice and the like are formed on the surface of a ceramic support including γ -alumina, and a main catalyst component including Ce — Zr, Pt and the like is directly supported in the vicinity of the surface of the ceramic support (patent document 2).

Disclosure of Invention

Problems to be solved by the invention

However, in the catalyst structure described above, since the catalyst particles are supported on the surface or in the vicinity of the surface of the carrier, the catalyst particles move within the carrier due to the influence of force, heat, or the like from a fluid such as a substance to be modified during the modification treatment, and aggregation (sintering) is likely to occur between the catalyst particles. When the catalyst particles are aggregated, the effective surface area of the catalyst is reduced, and the catalytic activity is lowered, so that the life is shorter than usual, and therefore, the catalyst structure itself must be replaced and regenerated in a short period of time, which complicates the replacement operation and prevents the resource saving. Further, since the petroleum upgrading catalyst is generally connected to the downstream side of the atmospheric distillation unit and continuously used in the petroleum refining process, it is difficult to apply a catalyst reactivation technique, and if the reactivation technique can be applied, the operation is very complicated. Further, suppressing or preventing such a decrease over time in function is not only described as a problem in the field of catalysts but also in various technical fields, and a solution strategy for maintaining a function for a long period of time is desired.

An object of the present invention is to provide a functional structure and a method for manufacturing the functional structure, which can achieve a longer life by suppressing a decrease in the function of a functional material and can save resources without requiring a complicated replacement operation.

Technical scheme

As a result of intensive studies to achieve the above object, the present inventors have found the following facts, and have completed the present invention based on the findings, namely, a functional structure comprising: a porous-structure skeleton body composed of a zeolite-type compound; and at least one functional substance present in the matrix, the matrix having mutually communicating passages, the functional substance being retained at least in the passages of the matrix, whereby a life extension can be achieved by suppressing a functional decrease of the functional substance.

That is, the gist of the present invention is as follows.

[1] A functional structure, comprising:

a porous-structure skeleton body composed of a zeolite-type compound; and

at least one functional substance present within the matrix,

the skeleton body has passages communicated with each other,

the functional substance is present in at least the passage of the scaffold.

[2] The functional structure according to [1], wherein the passage includes: any one of one-dimensional pores, two-dimensional pores, and three-dimensional pores defined by the framework structure of the zeolite-type compound; and a diameter expanding portion which is different from any one of the one-dimensional hole, the two-dimensional hole, and the three-dimensional hole, and which is provided with a hole having a diameter larger than that of the hole having the one-dimensional hole

The functional substance is present at least in the expanded diameter portion.

[3] The functional structure according to item [2], wherein the diameter-expanded portion causes a plurality of holes constituting any one of the one-dimensional holes, the two-dimensional holes, and the three-dimensional holes to communicate with each other.

[4] The functional structure according to any one of the above [1] to [3], characterized in that the functional substance is a catalyst substance,

the skeleton body is a carrier supporting the at least one catalyst substance.

[5] The functional structure according to the above [4], wherein the catalyst substance is a metal oxide fine particle.

[6] The functional structure according to [5], wherein an average particle diameter of the metal oxide fine particles is larger than an average inner diameter of the passage and is equal to or smaller than an inner diameter of the enlarged diameter portion.

[7] The functional structure according to the above [5] or [6], characterized in that the metal element (M) of the metal oxide fine particles is contained in an amount of 0.5 to 2.5 mass% with respect to the functional structure.

[8] The functional structure according to any one of the above [5] to [7], wherein the metal oxide fine particles have an average particle diameter of 0.1nm to 50 nm.

[9] The functional structure according to any one of the above [5] to [8], wherein the metal oxide fine particles have an average particle diameter of 0.5nm to 14.0 nm.

[10] The functional structure according to any one of the above [5] to [8], wherein a ratio of an average particle diameter of the metal oxide fine particles to an average inner diameter of the passage is 0.06 to 500.

[11] The functional structure according to item [10], wherein a ratio of an average particle diameter of the metal oxide fine particles to an average inner diameter of the passage is 0.1 to 36.

[12] The functional structure according to item [11], wherein a ratio of an average particle diameter of the metal oxide fine particles to an average inner diameter of the passage is 1.7 to 4.5.

[13] The functional structure according to any one of the above [2] to [12], wherein the average inner diameter of the passage is 0.1nm to 1.5nm,

the inner diameter of the diameter-expanded portion is 0.5nm to 50 nm.

[14] The functional structure according to any one of the above [1] to [13], further comprising at least one functional substance held on an outer surface of the skeleton body.

[15] The functional structure according to the above [14], wherein a content of the at least one functional substance present in the skeleton body is larger than a content of the at least one other functional substance retained on the outer surface of the skeleton body.

[16] The functional structure according to any one of the above [1] to [15], wherein the zeolite-type compound is a silicate compound.

[17] A method for manufacturing a functional structure, comprising:

a firing step of firing a precursor material (B) obtained by impregnating a metal-containing solution into a precursor material (a) for obtaining a framework having a porous structure composed of a zeolite-type compound; and

a hydrothermal treatment step of subjecting a precursor material (C) obtained by firing the precursor material (B) to hydrothermal treatment.

[18] The method of producing a functional structure according to item [17], wherein 50 to 500 mass% of a nonionic surfactant is added to the precursor material (A) before the firing step.

[19] The method of producing a functional structure according to the above [17] or [18], wherein the metal-containing solution is impregnated into the precursor material (A) by adding the metal-containing solution to the precursor material (A) a plurality of times before the firing step.

[20] The method for producing a functional structure according to any one of [17] to [19], wherein, when the metal-containing solution is immersed in the precursor material (a) before the firing step, the amount of the metal-containing solution added to the precursor material (a) is adjusted so that the ratio (atomic ratio Si/M) of silicon (Si) constituting the precursor material (a) to a metal element (M) contained in the metal-containing solution added to the precursor material (a) is 10 to 1000 in terms of the ratio.

[21] The method of producing a functional Structure according to [17], wherein the precursor material (C) is mixed with a Structure-directing agent (Structure-directing agent) in the hydrothermal treatment step.

[22] The method of producing a functional structure according to item [17], wherein the hydrothermal treatment step is performed in an alkaline environment.

Advantageous effects

According to the present invention, it is possible to provide a functional structure that can achieve a longer life by suppressing a decrease in the function of a functional substance, and that can save resources without requiring a complicated replacement operation.

Drawings

Fig. 1 is a schematic view showing an internal structure of a functional structure according to an embodiment of the present invention, fig. 1(a) is a perspective view (partially shown in a cross section), and fig. 1(b) is a partially enlarged sectional view.

Fig. 2 is a partially enlarged cross-sectional view for explaining an example of the function of the functional structure of fig. 1, fig. 2(a) is a view for explaining the sieve function, and fig. 2(b) is a view for explaining the catalyst function.

Fig. 3 is a flowchart illustrating an example of a method for manufacturing the functional structure of fig. 1.

Fig. 4 is a schematic diagram showing a modification of the functional structure of fig. 1.

Detailed Description

Hereinafter, embodiments of the present invention will be described in more detail with reference to the drawings.

[ constitution of functional Structure ]

Fig. 1 is a view schematically showing the structure of a functional structure according to an embodiment of the present invention, fig. 1(a) is a perspective view (partially shown in cross section), and fig. 1(b) is a partially enlarged sectional view. The functional structure in fig. 1 is an example thereof, and the shape, size, and the like of each component of the present invention are not limited to fig. 1.

As shown in fig. 1(a), the functional structure 1 includes: a porous-structure skeleton 10 made of a zeolite-type compound; and at least one functional substance 20 present within the matrix 10.

The functional substance 20 is a substance that exerts one or more functions alone or by being combined with the skeleton body 10. Specific examples of the functions include: a catalyst function, a light (or fluorescence) function, a light absorption function, a recognition function, and the like. The functional substance 20 is preferably a catalyst substance having a catalyst function, for example. When the functional material 20 is a catalyst material, the skeleton body 10 is a carrier on which the catalyst material is supported.

In the functional structure 1, the plurality of functional substances 20, … are enclosed inside the porous structure of the skeleton body 10. The catalyst material as an example of the functional material 20 is preferably at least one of metal oxide fine particles and metal fine particles. The metal oxide fine particles and the metal fine particles are described in detail later. The functional substance 20 may be a metal oxide, an alloy of metals, or particles containing these composite materials.

The skeleton body 10 has a porous structure, and preferably has passages 11 communicating with each other by forming a plurality of holes 11a, and …, as shown in fig. 1 (b). Here, the functional substance 20 is present in at least the passage 11 of the skeleton 10, and preferably remains in at least the passage 11 of the skeleton 10.

With such a configuration, the movement of the functional substance 20 in the skeleton body 10 is restricted, and the aggregation of the functional substances 20 and 20 is effectively prevented. As a result, the decrease in the effective surface area of the functional substance 20 can be effectively suppressed, and the function of the functional substance 20 can be continued for a long period of time. That is, according to the functional structure 1, the decrease in the function due to the aggregation of the functional substance 20 can be suppressed, and the life of the functional structure 1 can be extended. Furthermore, by extending the life of the functional structure 1, the frequency of replacement of the functional structure 1 can be reduced, the amount of waste of the used functional structure 1 can be greatly reduced, and resources can be saved.

In general, when a functional structure is used in a fluid (for example, heavy oil, a reformed gas such as NOx), an external force may be applied from the fluid. In this case, if the functional substance is held only in an adhered state on the outer surface of the skeleton body 10, there is a problem that the functional substance is easily detached from the outer surface of the skeleton body 10 under the influence of an external force from a fluid. In contrast, in the functional structure 1, since the functional substance 20 is held in at least the passage 11 of the skeleton body 10, the functional substance 20 is less likely to be detached from the skeleton body 10 even if it is affected by an external force from a fluid. Namely, it is considered that: when the functional structure 1 is in a fluid, the fluid flows from the holes 11a of the skeleton body 10 into the passage 11, and therefore the velocity of the fluid flowing in the passage 11 is lower than the velocity of the fluid flowing on the outer surface of the skeleton body 10 due to flow path resistance (frictional force). Due to the influence of the flow path resistance, the pressure received by the functional material 20 held in the passage 11 from the fluid is smaller than the pressure received by the functional material from the fluid outside the skeleton body 10. Therefore, the functional substance 20 present in the skeleton 11 can be effectively inhibited from being detached, and the function of the functional substance 20 can be stably maintained for a long period of time. It should be noted that: the passages 11 of the skeleton body 10 have a plurality of bends and branches, and the more complicated the three-dimensional structure inside the skeleton body 10, the greater the flow path resistance as described above.

Further, the passage 11 preferably has: any one of one-dimensional pores, two-dimensional pores, and three-dimensional pores defined by the framework structure of the zeolite-type compound; and an expanded diameter portion 12 different from any of the one-dimensional hole, the two-dimensional hole, and the three-dimensional hole, in which case the functional substance 20 is preferably present at least in the expanded diameter portion 12, and more preferably is enclosed at least in the expanded diameter portion 12. The one-dimensional hole as used herein means a tunnel-type or cage-type hole in which one-dimensional channels are formed, or a plurality of tunnel-type or cage-type holes (a plurality of one-dimensional channels) in which a plurality of one-dimensional channels are formed. The two-dimensional hole is a two-dimensional channel formed by two-dimensionally connecting a plurality of one-dimensional channels, and the three-dimensional hole is a three-dimensional channel formed by three-dimensionally connecting a plurality of one-dimensional channels.

This can further restrict the movement of the functional substance 20 within the skeleton body 10, and can further effectively prevent the functional substance 20 from coming off and the functional substances 20 and 20 from aggregating with each other. The inclusion means a state in which the functional substance 20 is included in the skeleton body 10. In this case, the functional substance 20 and the matrix 10 do not necessarily have to be in direct contact with each other, and the functional substance 20 may be indirectly held in the matrix 10 with another substance (for example, a surfactant) interposed between the functional substance 20 and the matrix 10.

Fig. 1(b) shows a case where the functional substance 20 is wrapped around the enlarged diameter portion 12, but the present invention is not limited to this configuration, and the functional substance 20 may be present in the passage 11 in a state where a part thereof protrudes from the outside of the enlarged diameter portion 12. The functional substance 20 may be partially embedded in a part of the passage 11 other than the enlarged diameter portion 12 (for example, an inner wall portion of the passage 11), or may be held by fastening or the like.

Further, the enlarged diameter portion 12 preferably causes a plurality of holes 11a, 11a constituting any one of the one-dimensional hole, the two-dimensional hole, and the three-dimensional hole to communicate with each other. Thus, since a separate passage different from the one-dimensional hole, the two-dimensional hole, or the three-dimensional hole is provided in the skeleton body 10, the function of the functional substance 20 can be further exerted.

Preferably, the passage 11 is three-dimensionally formed so as to include a branching portion or a merging portion inside the skeleton body 10, and the diameter-enlarged portion 12 is provided at the branching portion or the merging portion of the passage 11.

The average inner diameter D of the passage 11 formed in the skeleton body 10 is calculated from the average of the minor diameter and the major diameter of the hole 11a constituting any one of the one-dimensional hole, the two-dimensional hole, and the three-dimensional hole_FFor example, it is 0.1nm to 1.5nm, preferably 0.5nm to 0.8 nm. Further, the inner diameter D of the enlarged diameter portion 12_EFor example, 0.5nm to 50nm, preferably 1.1nm to 40nm, and more preferably 1.1nm to 3.3 nm. Inner diameter D of enlarged diameter portion 12_EFor example, the pore diameter of the precursor (A) described later and the average particle diameter D of the functional substance 20 to be included_C. Inner diameter D of enlarged diameter portion 12_EIs of a size capable of entrapping the functional substance 20.

The framework 10 is made of a zeolite-type compound. Examples of the zeolite-type compound include: silicate compounds such as zeolite (aluminosilicate), cation-exchange zeolite, and silicalite (silicalite); zeolite-like compounds such as aluminoborate, aluminoarsenate, germanate and the like; and phosphate-based zeolite-like substances such as molybdenum phosphate. Among them, the zeolite-type compound is preferably a silicate compound.

The framework structure of the zeolite-type compound is selected from FAU-type (Y-type or X-type), MTW-type, MFI-type (ZSM-5), FER-type (ferrierite), LTA-type (A-type), MWW-type (MCM-22), MOR-type (mordenite), LTL-type (L-type), BEA-type (beta-type), etc., preferably MFI-type, more preferably ZSM-5. The zeolite-type compound has a plurality of pores formed therein and having pore diameters corresponding to respective framework structures, and for example, the MFI-type compound has a maximum pore diameter of 0.636nm

Average pore diameter of 0.560nm

Hereinafter, a case where the functional substance 20 is at least one of metal oxide fine particles and metal fine particles (hereinafter, sometimes collectively referred to as "fine particles") will be described in detail.

When the functional substance 20 is the fine particles, the fine particles 20 may be primary particles, secondary particles formed by aggregation of the primary particles, and the average particle diameter D of the fine particles 20_CPreferably greater than the average internal diameter D of the passage 11_FAnd is not more than the inner diameter D of the enlarged diameter part 12_E(D_F<D_C≤D_E). Such fine particles 20 are preferably wrapped around the diameter-enlarged portion 12 in the passage 11 to restrict the movement of the fine particles 20 in the skeleton body 10. Therefore, even when the fine particles 20 receive an external force from the fluid, the movement of the fine particles 20 in the skeleton body 10 can be suppressed, and the fine particles 20, … respectively wrapped around the diameter-enlarged portions 12, … dispersedly arranged in the passages 11 of the skeleton body 10 can be effectively prevented from contacting each other.

When the functional material 20 is a metal oxide fine particle, the average particle diameter D of the metal oxide fine particle 20 is_CIn the case of both the primary particles and the secondary particles, the particle size is preferably 0.1 to 50nm, more preferably 0.1 to less than 30nm, and still more preferably 05 to 14.0nm, and particularly preferably 1.0 to 3.3 nm. Further, the average particle diameter D of the metal oxide fine particles 20_CRelative to the average inner diameter D of the passage 11_FRatio (D)_C/D_F) Preferably 0.06 to 500, more preferably 0.1 to 36, further preferably 1.1 to 36, and particularly preferably 1.7 to 4.5.

When the functional material 20 is a metal oxide fine particle, the content of the metal element (M) in the metal oxide fine particle is preferably 0.5 to 2.5% by mass relative to the functional structure 1, and more preferably 0.5 to 1.5% by mass relative to the functional structure 1. For example, in the case where the metal element (M) is Co, the content (mass%) of the Co element is represented by { (mass of Co element)/(mass of all elements of the functional structure 1) } × 100.

The metal oxide fine particles may be composed of a metal oxide, and may be composed of a single metal oxide or a mixture of two or more metal oxides, for example. In the present specification, the term "metal oxide" (as a material) constituting the metal oxide fine particles means an oxide containing one metal element (M) and a composite oxide containing two or more metal elements (M), and is a generic term for an oxide containing one or more metal elements (M).

Examples of such metal oxides include: cobalt oxide (CoO)_x) Nickel oxide (NiO)_x) Iron oxide (FeO)_x) Copper oxide (CuO)_x) Zirconium oxide (ZrO)_x) Cerium oxide (CeO)_x) Aluminum oxide (AlO)_x) Niobium oxide (NbO)_x) Titanium oxide (TiO)_x) Bismuth oxide (BiO)_x) Molybdenum oxide (MoO)_x) Vanadium Oxide (VO)_x) Chromium oxide (CrO)_x) And the like, preferably any one or more of the above as a main component.

When the functional material 20 is a metal fine particle, the average particle diameter D of the metal fine particle 20 is_CIn the case of either the primary particles or the secondary particles, the particle size is preferably 0.08 to 30nm, more preferably 0.08 to less than 25nm, still more preferably 0.4 to 11.0nm, and particularly preferablyPreferably 0.8nm to 2.7 nm. Further, the average particle diameter D of the fine metal particles 20_CRelative to the average inner diameter D of the passage 11_FRatio (D)_C/D_F) Preferably 0.05 to 300, more preferably 0.1 to 30, further preferably 1.1 to 30, and particularly preferably 1.4 to 3.6.

When the functional material 20 is a metal fine particle, the content of the metal element (M) in the metal fine particle is preferably 0.5 to 2.5 mass% with respect to the functional structure 1, and more preferably 0.5 to 1.5 mass% with respect to the functional structure 1.

The fine metal particles may be composed of an unoxidized metal, and may be composed of a single metal or a mixture of two or more metals. In the present specification, "metal" constituting (as a material of) the metal fine particles means a single metal containing one metal element (M) and a metal alloy containing two or more metal elements (M), and is a generic term for metals containing one or more metal elements.

Examples of such metals include: platinum (Pt), palladium (Pd), ruthenium (Ru), nickel (Ni), cobalt (Co), molybdenum (Mo), tungsten (W), iron (Fe), chromium (Cr), cerium (Ce), copper (Cu), magnesium (Mg), aluminum (Al), and the like, and preferably any one or more of these as a main component.

In view of durability, the functional material 20 is preferably metal oxide fine particles.

The ratio (atomic ratio Si/M) of silicon (Si) constituting the skeleton body 10 to the metal element (M) constituting the fine particles 20 is preferably 10 to 1000, and more preferably 50 to 200. If the ratio is more than 1000, the activity may be low, and the like, so that the functional substance may not be sufficiently obtained. On the other hand, if the ratio is less than 10, the ratio of the fine particles 20 is too large, and the strength of the skeleton body 10 tends to decrease. The fine particles 20 referred to herein are fine particles present or carried in the interior of the skeleton body 10, and do not include fine particles adhering to the outer surface of the skeleton body 10.

[ function of functional Structure ]

As described above, the functional structure 1 includes: a skeleton body 10 having a porous structure; and at least one functional substance 20 present within the matrix 10. The functional structure 1 exerts a function corresponding to the functional substance 20 by bringing the functional substance 20 present in the skeleton body into contact with a fluid. Specifically, the fluid that contacts the outer surface 10a of the functional structure 1 flows into the skeleton body 10 from the hole 11a formed in the outer surface 10a, is guided into the passage 11, moves through the passage 11, and flows out of the functional structure 1 through the other holes 11 a. In the path of the fluid moving through the inside of the passage 11, by contacting the functional substance 20 held in the passage 11, a reaction (e.g., catalytic reaction) corresponding to the function of the functional substance 20 occurs. Since the skeleton has a porous structure, the functional structure 1 has a molecular sieve function.

First, the molecular sieve function of the functional structure 1 will be described by taking a case where the fluid is a liquid containing benzene, propylene, and mesitylene as an example, with reference to fig. 2 (a). As shown in fig. 2(a), a compound (e.g., benzene or propylene) composed of molecules having a pore diameter not larger than that of the pores 11a, in other words, not larger than the inner diameter of the passages 11 can be impregnated into the skeleton body 10. On the other hand, a compound (e.g., mesitylene) composed of molecules having a size larger than the pore diameter of the pores 11a cannot infiltrate into the skeleton body 10. In this way, when the fluid contains a plurality of compounds, the reaction of the compound that cannot enter the skeleton 10 is restricted, and the compound that can enter the skeleton 10 can be allowed to react.

Among the compounds produced in the skeleton 10 by the reaction, only a compound composed of molecules having a pore size equal to or smaller than that of the pores 11a can flow out of the skeleton 10 through the pores 11a, and is obtained as a reaction product. On the other hand, if the compound that cannot flow out of the pores 11a to the outside of the skeleton 10 is converted into a compound composed of molecules having a size that can flow out of the skeleton 10, it can flow out of the skeleton 10. In this manner, a specific reaction product can be selectively obtained by using the functional structure 1.

In the functional structure 1, as shown in FIG. 2(b),the functional substance 20 is preferably coated on the diameter-enlarged part 12 of the passage 11. When the functional material 20 is a metal oxide fine particle, the average particle diameter D of the metal oxide fine particle is_CLarger than the average inner diameter D of the passage 11_FAnd is smaller than the inner diameter D of the diameter-enlarged part 12_EIn the case of (D)_F<D_C<D_E) Small passages 13 are formed between the metal oxide fine particles and the diameter-enlarged portion 12. Therefore, as shown by the arrows in fig. 2(b), the fluid that has entered the small passages 13 comes into contact with the metal oxide fine particles. Since each metal oxide fine particle is wrapped around the diameter-enlarged portion 12, the movement of the metal oxide fine particle within the skeleton body 10 is restricted. This prevents aggregation of the metal oxide fine particles in the skeleton body 10. As a result, a large contact area between the metal oxide fine particles and the fluid can be stably maintained.

Next, a case where the functional substance 20 has a catalyst function will be described. Specifically, the functional substance 20 is iron oxide (FeO)_x) The fine particles are described by taking as an example a case where dodecylbenzene as a heavy oil is impregnated into the skeleton 10 of the functional structure 1. When dodecylbenzene is impregnated into the skeleton body 10, the dodecylbenzene is decomposed into various alcohols and ketones by an oxidative decomposition reaction, as described below. Further, benzene as a light oil is produced from a ketone (acetophenone in this case) which is one of the decomposition products. This means that the functional substance 20 functions as a catalyst in the oxidative decomposition reaction. In this way, the heavy oil is converted into the light oil by using the functional structure 1. Conventionally, hydrocracking treatment using hydrogen has been performed to convert heavy oil into light oil. On the other hand, if the functional structure 1 is used, hydrogen is not required. Therefore, the present invention can be used for converting heavy oil into light oil even in a region where hydrogen supply is difficult. Further, since hydrogen is not required, cost reduction can be achieved, and promotion of utilization of heavy oil which has not been sufficiently utilized so far can be expected.

[ chemical formula 1]

[ chemical formula 2]

[ method for producing functional Structure ]

Fig. 3 is a flowchart illustrating a method of manufacturing the functional structure of fig. 1. Hereinafter, an example of a method for producing a functional structure will be described with reference to a case where the functional substance present in the skeleton body is a metal oxide fine particle.

(step S1: preparation Process)

As shown in fig. 3, first, a precursor material (a) for obtaining a framework having a porous structure made of a zeolite-type compound is prepared. The precursor material (a) is preferably a regular mesoporous material, and may be appropriately selected depending on the kind (composition) of the zeolite-type compound constituting the framework of the functional structure.

Here, when the zeolite-type compound constituting the framework of the functional structure is a silicate compound, the regular mesoporous material is preferably a compound containing an Si — O framework in which pores having a pore diameter of 1nm to 50nm are uniformly and regularly developed in one-dimensional, two-dimensional, or three-dimensional size. Such a ordered mesoporous material is obtained as various compositions according to synthesis conditions, and specific examples of the compositions include: SBA-1, SBA-15, SBA-16, KIT-6, FSM-16, MCM-41 and the like, wherein MCM-41 is preferred. The pore diameter of SBA-1 is 10nm to 30nm, the pore diameter of SBA-15 is 6nm to 10nm, the pore diameter of SBA-16 is 6nm, the pore diameter of KIT-6 is 9nm, the pore diameter of FSM-16 is 3nm to 5nm, and the pore diameter of MCM-41 is 1nm to 10 nm. Examples of such a regular mesoporous material include: mesoporous silica, mesoporous aluminosilicates, mesoporous metallosilicates, and the like.

The precursor (a) may be any of commercially available products and synthetic products. In the case of synthesizing the precursor material (a), it can be carried out by a known method for synthesizing a regular mesoporous substance. For example, a mixed solution containing a raw material containing a constituent element of the precursor material (a) and a template agent for specifying the structure of the precursor material (a) is prepared, and hydrothermal treatment (hydrothermal synthesis) is performed by adjusting the pH as necessary. Then, the precipitate (product) obtained by the hydrothermal treatment is recovered (for example, filtered), washed and dried as necessary, and further fired, whereby the precursor material (a) as a regular mesoporous substance in a powder form can be obtained. Here, as the solvent of the mixed solution, for example, an organic solvent such as water or alcohol, or a mixed solvent thereof can be used. The raw material is selected depending on the type of the skeleton, and examples thereof include: silica agents such as Tetraethoxysilane (TEOS), fumed silica, quartz sand, and the like. Further, as the template agent, various surfactants, block copolymers and the like can be used, and it is preferably selected according to the kind of the composition of the ordered mesoporous material, and for example, in the case of preparing MCM-41, a surfactant such as cetyltrimethylammonium bromide is preferred. The hydrothermal treatment may be carried out, for example, in a closed vessel under the treatment conditions of 80 to 800 ℃ for 5 to 240 hours and 0 to 2000 kPa. The firing treatment may be carried out, for example, in air under the treatment conditions of 350 to 850 ℃ for 2 to 30 hours.

(step S2: impregnation step)

Next, the prepared precursor material (a) is immersed in a metal-containing solution to obtain a precursor material (B).

The metal-containing solution may be a solution containing a metal component (for example, metal ion) corresponding to the metal element (M) constituting the metal oxide fine particles of the functional structure, and may be prepared, for example, by dissolving a metal salt containing the metal element (M) in a solvent. Examples of such metal salts include: metal salts such as chlorides, hydroxides, oxides, sulfates, nitrates, etc., among which nitrates are preferable. As the solvent, for example, an organic solvent such as water or alcohol, or a mixed solvent thereof can be used.

The method for immersing the metal-containing solution in the precursor material (a) is not particularly limited, and for example, it is preferable to add the metal-containing solution in small amounts in a plurality of times while stirring the powdery precursor material (a) before the firing step described later. In addition, from the viewpoint that the metal-containing solution is more likely to infiltrate into the inside of the pores of the precursor material (a), it is preferable to add a surfactant as an additive in advance before adding the metal-containing solution to the precursor material (a). It is considered that such an additive has an effect of covering the outer surface of the precursor material (a), and it suppresses the metal-containing solution added later from adhering to the outer surface of the precursor material (a), and the metal-containing solution is more likely to infiltrate into the inside of the pores of the precursor material (a).

Examples of such additives include nonionic surfactants such as polyoxyethylene oleyl ether, polyoxyethylene alkyl ether, and polyoxyethylene alkylphenyl ether. Consider that: these surfactants have large molecular sizes and cannot enter the pores of the precursor material (a), and therefore do not adhere to the inside of the pores and do not inhibit the metal-containing solution from entering the inside of the pores. As a method for adding the nonionic surfactant, for example, it is preferable to add 50 to 500 mass% of the nonionic surfactant to the precursor material (a) before the firing step described later. If the amount of the nonionic surfactant added to the precursor material (a) is less than 50 mass%, the above-described inhibiting effect is difficult to be exhibited, and if the amount of the nonionic surfactant added to the precursor material (a) is more than 500 mass%, the viscosity is excessively increased, which is not preferable. Therefore, the amount of the nonionic surfactant added to the precursor material (a) is set to a value within the above range.

The amount of the metal-containing solution added to the precursor material (a) is preferably adjusted as appropriate in consideration of the amount of the metal element (M) contained in the metal-containing solution impregnated in the precursor material (a) (that is, the amount of the metal element (M) present in the precursor material (B)). For example, the amount of the metal-containing solution added to the precursor material (a) is preferably adjusted so that the ratio (atomic ratio Si/M) of silicon (Si) constituting the precursor material (a) to a metal element (M) contained in the metal-containing solution added to the precursor material (a) is 10 to 1000, more preferably 50 to 200, before the firing step described later. For example, when a surfactant is added as an additive to the precursor material (a) before the metal-containing solution is added to the precursor material (a), the content of the metal element (M) in the metal oxide fine particles can be set to 0.5 to 2.5 mass% relative to the functional structure by setting the amount of the metal-containing solution added to the precursor material (a) to 50 to 200 in terms of atomic ratio Si/M. In the state of the precursor material (B), if the metal concentration of the metal-containing solution, the presence or absence of the additive, and other conditions such as temperature and pressure are the same, the amount of the metal element (M) present in the pores thereof is substantially proportional to the amount of the metal-containing solution added to the precursor material (a). Further, the amount of the metal element (M) present in the precursor material (B) is in proportional relation to the amount of the metal element constituting the metal oxide fine particles present in the skeleton body of the functional structure. Therefore, by controlling the amount of the metal-containing solution added to the precursor material (a) within the above range, the metal-containing solution can be sufficiently impregnated into the pores of the precursor material (a), and the amount of the metal oxide fine particles present in the matrix of the functional structure can be adjusted.

After the precursor material (a) is immersed in the metal-containing solution, a cleaning treatment may be performed as needed. As the cleaning solution, water, an organic solvent such as alcohol, or a mixed solution thereof can be used. Further, it is preferable that the precursor material (a) is immersed in a metal-containing solution, and after a cleaning treatment is performed as necessary, a drying treatment is further performed. Examples of the drying treatment include natural drying at about evening-out and high-temperature drying at 150 ℃. When the firing treatment described later is performed in a state where a large amount of moisture contained in the metal-containing solution or moisture in the cleaning solution remains in the precursor (a), the skeleton structure of the regular mesoporous material as the precursor (a) may be broken, and therefore, it is preferable to sufficiently dry the precursor (a).

(step S3: firing Process)

Next, a precursor material (B) obtained by impregnating a precursor material (a) for obtaining a framework having a porous structure composed of a zeolite-type compound with a metal-containing solution is fired to obtain a precursor material (C).

The firing treatment is preferably carried out in air at a temperature of 350 to 850 ℃ for 2 to 30 hours, for example. By such firing treatment, the metal component crystals impregnated into the pores of the regular mesoporous material grow, and metal oxide fine particles are formed in the pores.

(step S4: hydrothermal treatment Process)

Next, a mixed solution in which the precursor material (C) and the structure directing agent are mixed is prepared, and the precursor material (C) obtained by firing the precursor material (B) is subjected to hydrothermal treatment to obtain the functional structure.

The structure-directing agent is a template agent for defining the skeleton structure of the skeleton of the functional structure, and a surfactant, for example, can be used. The structure-directing agent is preferably selected according to the skeleton structure of the skeleton of the functional structure, and is preferably a surfactant such as tetramethylammonium bromide (TMABr), tetraethylammonium bromide (TEABr), tetrapropylammonium bromide (TPABr), or the like.

The mixing of the precursor material (C) and the structure-directing agent may be performed in the present hydrothermal treatment step, or may be performed before the hydrothermal treatment step. The method for preparing the mixed solution is not particularly limited, and the precursor material (C), the structure-directing agent, and the solvent may be mixed at the same time, or the precursor material (C) and the structure-directing agent may be dispersed in the solvent in the respective solutions and then the respective dispersed solutions may be mixed. As the solvent, for example, an organic solvent such as water or alcohol, or a mixed solvent thereof can be used. It is preferable that the pH of the mixed solution is adjusted in advance with an acid or an alkali before the hydrothermal treatment.

The hydrothermal treatment can be carried out by a known method, and is preferably carried out in a closed vessel under treatment conditions of, for example, 80 to 800 ℃ for 5 to 240 hours and 0 to 2000 kPa. Further, it is preferable to perform hydrothermal treatment in an alkaline environment.

Although the reaction mechanism is not necessarily clear here, when the precursor material (C) is subjected to hydrothermal treatment as a raw material, the skeleton structure of the regular mesoporous material as the precursor material (C) is gradually destroyed, but the position of the metal oxide fine particles inside the pores of the precursor material (C) is substantially maintained, and a new skeleton structure (porous structure) as a skeleton of the functional structure is formed by the action of the structure-directing agent. The functional structure obtained in this way includes a skeleton body having a porous structure and metal oxide fine particles present in the skeleton body, the skeleton body further includes passages through which the plurality of pores communicate with each other via the porous structure, and at least a part of the metal oxide fine particles are present in the passages of the skeleton body.

In the present embodiment, in the hydrothermal treatment step, a mixed solution in which the precursor material (C) and the structure-directing agent are mixed is prepared, and the hydrothermal treatment is performed on the precursor material (C), but the present invention is not limited thereto, and the hydrothermal treatment may be performed on the precursor material (C) without mixing the precursor material (C) and the structure-directing agent.

It is preferable that the precipitate (functional structure) obtained after the hydrothermal treatment is recovered (e.g., filtered), and then washed, dried, and fired as necessary. As the cleaning solution, water, an organic solvent such as alcohol, or a mixed solution thereof can be used. Examples of the drying treatment include natural drying at about evening-out and high-temperature drying at 150 ℃. When the sintering treatment is performed in a state where a large amount of moisture remains in the precipitate, the skeleton structure of the skeleton body as the functional structure may be broken, and therefore, sufficient drying is preferable. The firing treatment may be performed, for example, in air under the treatment conditions of 350 to 850 ℃ for 2 to 30 hours. By such a firing treatment, the structure directing agent attached to the functional structure is burned off. In addition, depending on the purpose of use, the functional structure can be used as it is without firing the collected precipitate. For example, when the use environment of the functional structure is a high-temperature environment that is an oxidizing environment, the structure-directing agent is burned off by exposure to the use environment for a certain period of time, and the same functional structure as in the case of performing the firing treatment can be obtained, and therefore, the functional structure can be used as it is.

Although the method for producing a functional structure has been described above by way of example in the case where the functional material is fine metal oxide particles, the functional structure can be produced substantially in the same manner as described above even in the case where the functional material is fine metal particles. For example, after the functional structure having the metal oxide particles is obtained as described above, the functional structure in which the metal fine particles are present in the skeleton body can be obtained by performing a reduction treatment in a reducing gas atmosphere such as hydrogen gas. In this case, the metal oxide fine particles present in the matrix are reduced to form metal fine particles corresponding to the metal element (M) constituting the metal oxide fine particles. Alternatively, by using a metal element (M) contained in the metal-containing solution impregnated in the precursor material (a) as a metal species (for example, noble metal) that is difficult to be oxidized, the metal fine particles can be crystallized and grown in the firing step (step S3), and then subjected to hydrothermal treatment, a functional structure in which the metal fine particles are present in the skeleton body can be obtained.

[ modified example of functional Structure 1]

Fig. 4 is a schematic diagram showing a modification of the functional structure 1 of fig. 1.

The functional structure 1 in fig. 1 is shown to include the skeleton body 10 and the functional substance 20 present in the skeleton body 10, but the present invention is not limited to this configuration, and for example, as shown in fig. 4, the functional structure 2 may further include at least one functional substance 30 retained on the outer surface 10a of the skeleton body 10.

The functional substance 30 is a substance that performs one or more functions. The other functional substance 30 may have the same function as or a different function from the functional substance 20. Specific examples of the functions of the other functional substances 30 are the same as those described for the functional substance 20, and among them, the functional substance 30 preferably has a catalyst function, and in this case, the functional substance 30 is a catalyst substance. In the case where both of the functional substances 20 and 30 have the same function, the material of the other functional substance 30 may be the same as or different from the material of the functional substance 20. According to the present configuration, the content of the functional substance held in the functional structure 2 can be increased, and the function of the functional substance can be further promoted.

In this case, it is preferable that the content of the functional substance 20 present in the skeleton body 10 is larger than the content of the other functional substance 30 retained on the outer surface 10a of the skeleton body 10. Thus, the function of the functional substance 20 retained inside the skeleton body 10 becomes dominant, and the function of the functional substance is stably exhibited.

The functional structure according to the embodiment of the present invention has been described above, but the present invention is not limited to the above-described embodiment, and various modifications and changes can be made based on the technical idea of the present invention.