阅读说明：本技术 催化材料 (Catalytic material ) 是由 藤田直人 M·H·陈 成田庆一 青野纪彦 萨摩笃 于 2020-03-27 设计创作，主要内容包括：本发明提供一种化学稳定的甲烷的净化性能优异的排气净化用催化剂。该催化材料(30)包含：由氧化铝构成的载体(32)；和直接载持于载体(32)的由钯和钯氧化物中的至少一种构成的催化剂(34)。载体(32)的比表面积优选为20m～(2)/g以上90m～(2)/g以下。在优选的一个方式中,在催化剂(34)与载体(32)的接合面上的催化剂(34)的结晶面中,Pd(100)和PdO(101)所占的比例为20个数％以上。(The invention provides a chemically stable catalyst for purifying exhaust gas, which has excellent methane purification performance. The catalytic material (30) comprises: a support (32) composed of alumina; and a catalyst (34) composed of at least one of palladium and a palladium oxide directly supported on the carrier (32). The specific surface area of the carrier (32) is preferably 20m 2 More than 90 m/g 2 The ratio of the carbon atoms to the carbon atoms is less than g. In a preferred embodiment, Pd (100) and PdO (101) are present in the crystal plane of the catalyst (34) on the junction surface between the catalyst (34) and the carrier (32)The proportion of the components is more than 20 percent.)

1. A catalytic material for the purification of methane, the catalytic material characterized by comprising:

a support composed of alumina; and

a catalyst composed of at least one of palladium and a palladium oxide directly supported on the carrier,

the specific surface area of the carrier is 20m²More than 90 m/g²The ratio of the carbon atoms to the carbon atoms is less than g.

2. The catalytic material of claim 1, wherein:

the ratio of Pd (100) and PdO (101) in the crystal plane of the catalyst on the interface between the catalyst and the carrier is 20% or more by number.

3. The catalytic material of claim 1 or 2, wherein:

the ratio of theta (001), theta (111) and alpha (104) in the crystal plane of the carrier on the bonding surface between the catalyst and the carrier is 30% by number or more.

4. The catalytic material of any of claims 1 to 3, wherein:

the catalyst has an average particle diameter of 20nm or less.

5. The catalytic material of any of claims 1 to 4, wherein:

the catalyst has a supporting ratio of 10 mass% or less in the total amount of the carrier and the catalyst.

6. The catalytic material of any of claims 1 to 5, wherein:

which is used to purify exhaust gas discharged from an internal combustion engine fueled by natural gas.

Technical Field

The present invention relates to a catalytic material for purifying exhaust gas containing methane. The present invention is based on the priority claim of japanese patent application No. 2019-067927, filed 3/29/2019, the entire contents of which are incorporated herein by reference.

Background

Exhaust gas discharged from an internal combustion engine (engine) of a vehicle such as an automobile contains harmful gas components such as Hydrocarbons (HC), carbon monoxide (CO), and nitrogen oxides (NOx), and Particulate Matter (PM) containing carbon as a main component. The regulations for exhaust gas that limit the amount of these harmful gases and PM discharged are being strengthened year by year. Therefore, in internal combustion engines and their peripheral technologies, studies are being made to reduce the emission of harmful gases and PM from vehicles and the like.

Thus, due to CO per unit distance₂In recent years, vehicles (e.g., CNG vehicles) using natural gas internal combustion engines fueled by natural gas have been attracting attention. Among them, HC discharged from a gasoline internal combustion engine using gasoline as a fuel is a component that is easily burned at a relatively low temperature, such as aromatic hydrocarbon, olefin, and alkane, while HC discharged from a natural gas internal combustion engine is mostly methane (CH) that is chemically stable and is not easily decomposed at a low temperature₄). As aboutAs a conventional technique for a catalyst for purifying methane contained in the exhaust gas of such a natural gas internal combustion engine, for example, patent documents 1 to 5 are cited.

Documents of the prior art

Patent document

Patent document 1: japanese patent application laid-open No. 2002-336655

Patent document 2: japanese patent application laid-open No. 2002-263491

Patent document 3: japanese patent application laid-open No. 2001-190931

Patent document 4: japanese patent application laid-open No. 2008-246473

Patent document 5: japanese patent application laid-open No. 2014-091119

Disclosure of Invention

However, the exhaust gas purifying catalyst functions because the temperature is raised by the exhaust gas to a temperature at which the catalyst is activated. Therefore, at the time of cold start of the internal combustion engine, purification of methane in the exhaust gas is difficult, and there is a possibility that unpurified methane is discharged to the atmosphere. Natural gas fueled internal combustion engines₂The emission amount is low, but more than 80 mass% of HC in the exhaust gas is methane, and the global warming potential of methane is as high as CO₂25 times higher, which becomes a serious problem.

The present invention has been made in view of the above circumstances, and an object thereof is to provide an exhaust gas purifying catalyst which is chemically stable and has excellent methane purifying performance.

According to the present invention, a catalytic material for purifying methane is provided. The catalytic material comprises a carrier made of alumina and a catalyst made of at least one of palladium and palladium oxide directly supported on the carrier. And the specific surface area of the carrier is 20m²More than 90 m/g²The ratio of the carbon atoms to the carbon atoms is less than g.

According to the above configuration, the specific surface area of the alumina as the catalyst support is limited to a specific range. With respect to the alumina having such a specific surface area, the crystal structure of palladium and palladium oxide directly crystal-grown and supported on the surface thereof can be a structure having a high specific crystal orientation. As a result, the purification temperature of, for example, methane 50% of palladium and palladium oxide as the catalyst can be lowered, so that the purification performance of methane of the catalytic material can be improved.

In a preferred embodiment of the catalytic material provided by the present technology, the ratio of Pd (100) and PdO (101) in the crystal plane of the catalyst on the interface between the catalyst and the carrier is 20% by number or more. Such a configuration is preferable because methane purification performance can be more reliably improved.

In a preferred embodiment of the catalytic material provided by the present technology, the ratio of θ (001), θ (111), and α (104) in the crystal plane of the carrier on the interface between the catalyst and the carrier is 30% by number or more. Such a configuration is preferable because the ratio of Pd (100) to PdO (101) in the catalyst on the joint surface can be increased, and a catalytic material having excellent methane purification performance can be obtained.

In a preferred embodiment of the catalytic material provided by the present technology, the catalyst has an average particle diameter of 20nm or less. Such a configuration is preferable because the contact efficiency between the catalyst per unit mass and the methane gas can be improved. In addition, when the average particle diameter of the catalyst is 10nm or less, the catalyst activity can be further improved due to the size effect, which is preferable.

In a preferred embodiment of the catalytic material provided by the present technology, a supporting ratio of the catalyst in a total amount of the carrier and the catalyst is 10 mass% or less. The catalytic material disclosed herein is capable of exerting high methane purification performance with a smaller amount of catalyst. Therefore, it is preferable to set the catalyst supporting rate to 10 mass% or less because the effect is particularly remarkably exhibited.

In a preferred embodiment of the catalytic material provided by the present technology, the catalytic material is used for purifying exhaust gas discharged from the internal combustion engine using natural gas as fuel. When the internal combustion engine is fueled by natural gas, 80 mass% or more of HC contained in the exhaust gas is methane. The exhaust gas purifying catalyst of the present technology is preferably used for purifying exhaust gas having a high methane content because the above-described effects are more appropriately exhibited.

As described above, the catalytic material disclosed herein is excellent in methane purification performance, and can achieve a methane purification rate in a gas of 50% or more, for example, in a lower temperature range. Such a feature is preferable because it can be used advantageously even when applied to the purification of methane contained in exhaust gas having a relatively low temperature, for example, at the time of cold start of an internal combustion engine or at the time of idle stop control. Therefore, the catalyst material is suitably used as a catalyst material for an exhaust gas purifying catalyst for, for example, a natural gas (CNG) engine, a gasoline engine, a diesel engine, or the like. The present invention is also applicable to an internal combustion engine of a vehicle (including a hybrid vehicle having a driving power supply, a plug-in hybrid vehicle, and the like, in addition to an engine vehicle) in which the rotation speed variation is relatively large. Among them, the catalyst is particularly preferably used as a catalyst for an exhaust gas purifying catalyst of a CNG engine in which the HC contained in the exhaust gas has a high methane content.

Drawings

Fig. 1 is a partial sectional view schematically showing the structure of a catalyst according to an embodiment.

Fig. 2 is a schematic diagram showing a configuration of an exhaust gas purification system according to an embodiment.

Fig. 3A is a perspective view schematically showing an exhaust gas purifying catalyst according to an embodiment.

Fig. 3B is a partial sectional view schematically showing the structure of the catalyst layer of the exhaust gas purifying catalyst according to the embodiment.

Fig. 4 is a graph showing the relationship between the specific crystal plane ratio of palladium at the catalyst/support interface and the methane purification temperature of 50% in the catalyst bodies of the respective examples.

Fig. 5 is a graph showing the relationship between the average particle diameter of palladium and the methane 50% purification temperature of the catalyst bodies of the respective examples.

Fig. 6 is a graph showing the relationship between the ratio of the specific crystal plane of palladium and the ratio of the specific crystal plane of alumina at the catalyst/support interface in the catalyst bodies of the respective examples.

FIG. 7 is a graph showing the relationship between the average particle diameter of palladium and the ratio of specific crystal planes of alumina in the catalyst bodies of the respective examples and the specific surface area of alumina.

Fig. 8 is a graph showing the relationship between the palladium supporting rate and the methane 50% purification temperature of the catalyst of each example.

Detailed Description

Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. Matters necessary for carrying out the present invention other than those specifically mentioned in the present specification can be understood as matters of design by those skilled in the art based on the prior art in the field. The present invention can be implemented based on the disclosure of the present specification and the common general knowledge in the art. In the drawings, the same reference numerals are used for members and portions that achieve the same functions, and redundant descriptions may be omitted or simplified. The dimensional relationships (length, width, thickness, etc.) in the drawings do not necessarily reflect actual dimensional relationships. In the present specification, the expression "a to B" indicating a numerical range means "a to B inclusive".

Fig. 1 is a schematic cross-sectional view showing a structure of a catalyst material 30 according to an embodiment. The catalytic material 30 disclosed herein is a catalytic material for purifying methane. The catalytic material 30 comprises a carrier 32 and a catalyst 34 directly supported on the carrier 32. The constituent elements of the catalyst material 30 will be described below.

In the catalytic material 30 disclosed herein, the carrier 32 on which the catalyst 34 is supported is made of alumina. The crystal structure of alumina is not particularly limited. Various crystal forms of alumina are known, such as γ -alumina, δ -alumina, θ -alumina, and α -alumina, and the crystal structure of the alumina as the support 32 may include any 1 or 2 or more of these. Alumina other than the high-temperature stable phase α -alumina is called transition alumina (also called mesomorphic alumina), and generally, primary particles are ultrafine particles and have a large specific surface area. As an alumina carrier of a conventional automobile catalyst, generally, an intermediate alumina, particularly γ -alumina having a high specific surface area is widely used. To this end, according to the inventionAs a result of the investigation by the inventors, the alumina as the carrier 32 preferably has a small specific surface area, preferably a specific surface area of 90m²Lower than g (e.g. 20 m)²More than 90 m/g²(less than/g).

Although there is no necessary relationship between the specific surface area of the crystal and the crystal plane appearing on the surface of the crystal, it is known from the studies of the inventors that there is a certain degree of correlation between the specific surface area of alumina and the crystal plane appearing on the surface thereof. Further, it has been found that alumina having such a specific surface area has a high ratio of exposed special crystal planes on the surface thereof, which are likely to cause the catalyst 34 to grow in an appropriate shape. Such particular crystal planes of alumina (hereinafter sometimes simply referred to as "particular planes of alumina") are θ (001), θ (111), and α (104) of alumina. The use of such alumina as a carrier is preferable because, for example, in a method for producing the catalyst material 30 described later, the formation of the catalyst 34 having a specific crystal orientation on the surface thereof can be promoted.

The specific surface area of the alumina as the carrier 32 is 90m from the viewpoint of increasing the exposure ratio of the crystal planes on the surface of the catalyst 34, which is easy to grow in an appropriate shape²Suitable are less than/g, preferably 85m²A ratio of 80m or less per gram²Less than or equal to 75 m/g²Less than g, e.g. 60m²The ratio of the carbon atoms to the carbon atoms is less than g. However, when the specific surface area of the alumina as the carrier 32 is too small, the proportion of flat surfaces, in other words, specific crystal surfaces becomes too large in the outer shape of the alumina, and coarse growth is likely to occur when the supported catalyst 34 is produced or when the catalyst material is used, which is not preferable. From such a viewpoint, the specific surface area is, for example, 15m²Suitably at least 20 m/g, preferably²More than g, can be 25m²More than g or 30m²More than g (e.g. more than 30 m)²/g)、35m²A number of grams per gram, e.g. 40m²More than g.

The shape of the support 32 is not particularly limited as long as it has the above specific surface area. As a preferable example, the support 32 may be made of powdered alumina and/or porous alumina. When the carrier 32 is a powdery alumina, the average particle diameter thereof is, for example, preferably 20 μm or less, typically 10 μm or less or 7 μm or less, for example 5 μm or less. From the viewpoint of improving the heat resistance of the catalyst material 30, the average particle diameter of the carrier 32 may be typically 0.1 μm or more, for example, 0.5 μm or more, 1 μm or more, or 3 μm or more.

In the present specification, the average particle diameter of the powdery material such as the catalyst material 30 or the carrier 32 is a cumulative 50% particle diameter (D) in a volume-based particle size distribution measured by a laser diffraction/scattering method₅₀)。

The specific surface area of the carrier 32 is a value calculated by a BET method (for example, a BET one point method) based on the gas adsorption amount measured by a gas adsorption method (constant volume adsorption method). The adsorbent medium for the gas adsorption method is not particularly limited, and nitrogen (N) is suitably used, for example₂) And (4) qi.

In the catalytic material 30 disclosed herein, the catalyst 34 is composed of at least one of palladium and palladium oxide. The catalyst 34 is directly and integrally supported on the surface of alumina as the carrier 32. In other words, the catalyst 34 is bonded to the surface of the support 32 without using a binder such as a binder. Specifically, for example, the catalyst 34 is supported by directly growing crystals on the surface of alumina as a support. At this time, the catalyst 34 is crystal-grown on the surface of the alumina, but when the crystal plane of the alumina as the carrier 32 is the above-mentioned specific plane, the catalyst 34 is easily induced to crystal-grow with a certain crystal orientation relation with the specific plane of the alumina. The crystal planes of palladium (Pd) and palladium oxide (PdO) which are easily induced to grow by the above specific planes of aluminum oxide are Pd (100) and PdO (101) (hereinafter, sometimes referred to simply as "specific planes of palladium"). In other words, Pd tends to grow in a (100) plane orientation on a specific plane of alumina as the support 32. Or PdO is prone to (101) plane orientation growth. Regarding Pd and PdO, since the electronic state of Pd reversibly changes due to, for example, atmospheric fluctuations in exhaust gas, Pd is easily oxidized into PdO, and PdO is easily reduced into Pd. In the oxidation-reduction reaction of Pd and PdO, Pd (100) and PdO (101) are equivalent planes, and in the catalyst 34 disclosed herein, Pd and PdO may be treated equally. In the catalyst 34 disclosed herein, the valence of Pd in the palladium oxide may be a value greater than +2 (e.g., a value of about +2 to + 3).

In this way, on the above specific surface of the alumina as the carrier 32, palladium (Pd) and palladium oxide (PdO) as the catalyst 34 are easily epitaxially grown. Thus, the catalytic material disclosed herein has a high proportion of support 32 and catalyst 34 plane orientations as shown in FIG. 1. For example, the ratio of the specific surface of the palladium in the crystal plane of the catalyst 34 on the bonding surface between the catalyst 34 and the carrier 32 may be 20% by number or more. According to the studies of the inventors, it was confirmed that the methane purification performance of the catalyst material 30 can be improved by making the ratio of the specific surface of palladium high. The detailed mechanism is not clear, but it is considered that the crystal morphology of Pd and PdO as the catalyst 34 forms a specific crystal plane, a growth step, or the like due to the oriented growth thereof, which provides an active site for the methane purification reaction.

The larger the proportion of the specific surface of the palladium on the catalyst/support interface of the catalytic material 30, the lower the methane purification temperature, for example, 50%, and the like, the higher the methane purification performance can be. The ratio of the specific surface of palladium is preferably 20% by number or more, more preferably 25% by number or more, and may be, for example, 30% by number or more, 35% by number or more, 40% by number or more, or the like. The upper limit of the proportion of the specific surface of palladium at the interface between the catalyst and the carrier is not particularly limited, and may be substantially 100% by number or less (for example, 100% by number), and may be, for example, 95% by number or less, 90% by number or less, 85% by number or less, 80% by number or less, 70% by number or less, or the like.

Wherein, as described above, the specific surface of the palladium at this catalyst/support interface is capable of inducing growth due to the specific surface of the alumina. From such a viewpoint, it can be said that the ratio of the specific surface of alumina is preferably large on the crystal surface of alumina constituting the catalyst/support interface. Therefore, the ratio of the specific surface of alumina at the interface is preferably 30% by number or more, more preferably 32% by number or more, and may be 35% by number or more, for example. The upper limit of the ratio of the specific surface of palladium at the interface between the catalyst and the carrier is not particularly limited, and may be 100% by number or less (for example, 100% by number), and may be substantially 50% by number or less, 45% by number or less, for example, about 40% by number or less.

In the technique disclosed herein, the crystal plane constituting the interface between the catalyst 34 and the support 32 can be specified by a known method of observation using a Transmission Electron Microscope (TEM). In one example, a crystal structure image or a crystal photon image at the interface between the catalyst 34 and the support 32 may be acquired, and the crystal planes constituting the interface may be identified for the catalyst 34 and the support 32, respectively. The identification of the crystal plane may be performed based on a known crystal plane spacing (lattice spacing), or may be performed using an electron diffraction observation model of TEM. In the present specification, as described in examples to be described later, crystal planes are identified based on the crystal plane spacing.

Further, the sizes of palladium (Pd) and palladium oxide (PdO) as the catalyst 34 are not strictly limited. From the viewpoint of cost reduction or the like, the catalyst 34 may be a granular catalyst having a large specific surface area (hereinafter referred to as catalyst particles or the like), and for example, it is preferable that the particle diameter of 90% or more of the catalyst particles is about 20nm or less, which can exhibit a size effect. The catalyst particles have an average particle diameter of, for example, 15nm or less, more preferably 10nm or less, and typically may be 8nm or less or 7nm or less. The lower limit of the average particle diameter of the catalyst particles is not particularly limited, and is typically about 0.1nm or more, and may be, for example, 1nm or more.

The average particle diameter of the catalyst particles is a value (volume equivalent spherical diameter) calculated by a pulse adsorption method using carbon monoxide (CO) as an adsorption gas. The pulse adsorption method was carried out according to "a method for measuring a metal surface area by a CO pulse method" of the reference catalyst part of the Japan catalyst society.

In the catalyst material 30 disclosed herein, the amount of the catalyst 34 supported is not particularly limited, but when the amount of the catalyst 34 supported is too small, the catalytic activity obtained by the catalyst 34 is insufficient, which is not preferable. As an example, as the supported amount of the catalyst 34 suitable as the exhaust gas purifying catalyst, for example, the proportion (supported amount) of the catalyst 34 in the total mass of the catalyst material 30 is preferably 0.001 mass% or more, more preferably 0.01 mass% or more, and for example, may be 0.1 mass% or more. On the other hand, when the supported amount of the catalyst 34 is too large, the catalyst 34 is liable to cause particle growth, and is disadvantageous in terms of cost. Therefore, the proportion of the catalyst 34 in the total mass of the catalyst material 30 may be, for example, 10 mass% or less, preferably 8 mass% or less, and typically 5 mass% or less.

The above-mentioned catalytic material 30 can be obtained by integrally supporting palladium or a palladium oxide on the surface of alumina as the carrier 32 so that the ratio of Pd (100) or PdO (101) on the bonding surface (crystal interface) is increased. The method for producing the catalyst material 30 is not limited to this, and for example, the catalyst material can be produced by impregnating the carrier 32 with a salt (for example, a nitrate) containing a palladium component as the catalyst 34 or an aqueous solution containing a complex (for example, a tetraammine complex), drying the aqueous solution, and firing the dried aqueous solution. In this case, the catalyst material 30 having a large ratio of the specific surface area of palladium on the interface can be obtained by using the alumina having the above specific surface area as the carrier 32.

The catalytic material 30 described above is provided as a product excellent in methane purification performance. Therefore, the catalyst material 30 is suitably used as, for example, a purification catalyst for purifying exhaust gas of an internal combustion engine using natural gas as a fuel. Hereinafter, a system for purifying exhaust gas using the catalyst material 30 will be briefly described.

Fig. 2 is a schematic diagram showing an exhaust gas purification system 1 according to an embodiment. The exhaust gas purification system 1 purifies harmful components, such as HC, CO, NO, contained in exhaust gas discharged from the internal combustion engine 2_xAnd traps PM contained in the exhaust gas. The exhaust gas purification system 1 has an internal combustion engine 2 and an exhaust path thereof. The exhaust gas purification system 1 according to the present embodiment includes an internal combustion Engine 2, an exhaust path, an Engine Control Unit (ECU) 7, and a sensor 8. The exhaust gas purifying catalyst according to the present technology is provided in an exhaust path of the internal combustion engine 2 as one component of the exhaust gas purifying system 1. And the exhaust gas flows through the inside of the exhaust path. The arrows in the figure indicate the flow direction of the exhaust gas.In the present specification, a side close to the internal combustion engine 2 in the flow direction of the exhaust gas is referred to as an upstream side, and a side far from the internal combustion engine 2 is referred to as a downstream side.

A mixed gas containing oxygen and fuel gas is supplied to the internal combustion engine 2. The internal combustion engine 2 converts thermal energy generated by combustion of the air-fuel mixture into kinetic energy. The ratio of oxygen to fuel gas supplied to the internal combustion engine 2 is controlled by the ECU 7. The burned gas mixture is discharged as an exhaust gas to the exhaust passage. The internal combustion engine 2 having the configuration shown in fig. 1 is mainly configured as an internal combustion engine using natural gas as fuel.

The internal combustion engine 2 is connected to an exhaust path at an exhaust port not shown. The exhaust path of the present embodiment is constituted by an exhaust manifold 3 and an exhaust pipe 4. The internal combustion engine 2 is connected to an exhaust pipe 4 via an exhaust manifold 3. The exhaust path typically has a catalyst body 5 and a filter body 6. For example, the catalyst body 5 has the catalyst body of the present technology. The catalyst body 5 may have, for example, a two-way catalyst, or another catalyst such as an HC selective reduction type NOx catalyst, an NOx storage reduction catalyst, or a urea selective reduction type NOx catalyst. The filter 6 is not necessarily required to be formed, and may be provided as needed. The filter 6 may be provided in the same manner as in the conventional art, and is not particularly limited. The Filter 6 may be, for example, a Particulate Filter (PF) that traps minute PM and reduces the number of PM discharged, a catalytic Particulate Filter that supports a two-way or three-way catalyst and provides a catalytic purification function, or the like. Among them, as the catalyst in the catalyst particle filter, the catalytic material 30 disclosed herein may also be used. The configuration of the catalyst body 5 and the filter body 6 is arbitrarily variable, and the catalyst body 5 and the filter body 6 may be provided singly or in plurality independently.

The ECU 7 is electrically connected to the internal combustion engine 2 and the sensor 8. The ECU 7 receives signals from various sensors (for example, an oxygen sensor, a temperature sensor, and a pressure sensor) 8 that detect the operating state of the internal combustion engine 2, and controls the driving of the internal combustion engine 2. The structure of the ECU 7 is not particularly limited, as long as it is the same as the conventional one. The ECU 7 is, for example, a processor or an integrated circuit. The ECU 26 receives information such as the operating state of the vehicle and the like, and the amount, temperature, pressure, and the like of the exhaust gas discharged from the internal combustion engine 2, for example. The ECU 7 performs operation control such as fuel injection control, ignition control, intake air amount adjustment control, and the like on the internal combustion engine 2, for example, based on the received information.

Fig. 3A is a perspective view of the catalyst body 5 according to the embodiment. X in the figure is the first direction of the catalyst body 5. The catalyst 5 is provided in the exhaust pipe 4 so that the first direction is along the flow direction of the exhaust gas. For convenience of explanation, when attention is paid to the flow of the exhaust gas, one direction X1 in the first direction X is referred to as an exhaust gas inflow side (upstream side), and the other direction X2 is referred to as an exhaust gas outflow side (downstream side). In the catalyst body 5, one direction X1 may be referred to as a front side, and the other direction X2 may be referred to as a rear side. Fig. 3B is an enlarged schematic view of a part of a cross section of the catalyst body 5 according to the embodiment cut along the first direction X. The catalyst body 5 disclosed herein has, for example, a substrate 10 and a catalyst layer 20 having a straight flow structure. The following description will be made in order of the substrate 10 and the catalyst layer 20.

As the substrate 10, various conventional materials and forms of substrates used for such applications can be used. The substrate 10 typically has a so-called honeycomb structure. The substrate 10 is preferably made of a material having high heat resistance and high resistance to rapid temperature change, such as ceramics including cordierite, aluminum titanate, and silicon carbide (SiC), or alloys including stainless steel. The outer shape of the substrate 10 is not particularly limited, and a cylindrical substrate (in the present embodiment) may be used as an example. However, as for the external shape of the entire substrate, in addition to the cylindrical shape, an elliptic cylindrical shape, a prismatic shape, an amorphous shape, a granular shape, or the like can be adopted. In the present embodiment, the columnar axis direction of the columnar substrate 10 coincides with the first direction X. The end of the base material 10 in one direction X1 is a first end 10a, and the end in the other direction X2 is a second end 10 b. In the present specification, the dimension of the constituent elements such as the base material 10 along the first direction X is referred to as a length.

In the substrate 10, cells (voids) 12 in the honeycomb structure extend in the first direction X. The cell 12 is a through hole penetrating the substrate 10 in the first direction X and serves as a flow path for exhaust gas. The substrate 10 comprises partition walls 14 that divide the cells 12. The shape of a cross section (hereinafter simply referred to as "cross section") of the cell 12 perpendicular to the first direction X, in other words, the structure of the partition wall 14 that partitions the cell, is not particularly limited. The cross-sectional shape of the cell 12 may be any of various geometric shapes such as a square, a parallelogram, a rectangle, a trapezoid, etc., a triangle, other polygons (e.g., a hexagon, an octagon), a circle, etc. The shape, size, number, and the like of the cells 12 can be appropriately designed in consideration of the flow rate and composition of the exhaust gas supplied to the catalyst body 5.

The partition walls 14 separate adjacent cells 12 facing the cells 12. When the thickness Tw of the partition wall 14 (the dimension in the direction perpendicular to the surface, hereinafter the same) is small, the specific surface area of the substrate 10 can be increased, and weight reduction and low heat capacity can be facilitated. The thickness Tw of the partition wall 14 may be, for example, 1mm or less, 0.75mm or less, 0.5mm or less, 0.1mm or less, or the like. On the other hand, by providing the partition wall 14 with an appropriate thickness, the strength and durability of the catalyst body 5 can be improved. From such a viewpoint, the thickness Tw of the partition wall 14 may be, for example, 0.01mm or more and 0.025mm or more. The length Lw (total length) of the partition wall 14 in the X direction is not particularly limited, and may be approximately 50 to 500mm, for example, approximately 100 to 200 mm. In the present specification, the volume of the substrate 10 refers to the apparent volume of the substrate. Therefore, the volume of the substrate 10 includes the volume of the cells 12 in addition to the substantial volume of the honeycomb structure (including the partition walls 14) as a skeleton.

As shown in fig. 3B, the catalyst layer 20 is disposed on the surface of the partition wall 14. The catalyst layer 20 includes a catalytic material 30 disclosed herein as a palladium catalyst of a noble metal catalyst. By constituting the Pd layer of the catalyst body 5 with the catalytic material 30 provided by the present technology, it is possible to start purifying methane from a lower temperature and reduce the amount of methane emission. In other words, the catalyst 5 having excellent methane purification performance can be provided.

The catalyst layer 20 may contain another noble metal catalyst together with the palladium catalyst. Alternatively, the catalyst body 5 may have a catalyst layer containing another noble metal catalyst (not shown) separately from the catalyst layer containing the palladium catalyst (hereinafter, referred to as a palladium (Pd) layer) 20. As such another catalyst layer, a platinum (Pt) layer or a rhodium (Rh) layer may be considered. The Pt layer contains platinum (Pt) as a noble metal catalyst and an alloy mainly containing Pt. The Rh layer contains rhodium (Rh) as a noble metal catalyst and an alloy mainly containing Rh. These catalyst layers 20 and the other catalyst layers may contain other metal catalysts, respectively, in addition to the noble metal catalyst described above. Examples of such metal catalysts include Rh, Pd, Pt, ruthenium (Ru), osmium (Os), iridium (Ir), and platinum group catalysts which are alloys thereof, and metals containing metal elements such as iron (Fe), cobalt (Co), nickel (Ni), copper (Cu), silver (Ag), and gold (Au), or alloys thereof in addition to or instead of the platinum group elements. However, the metal catalysts contained in the Pd layer, the Pt layer, and the Rh layer may be each Pd, Pt, and Rh in an amount of 80 mass% or more, and each Pd, Pt, and Rh is preferably 90 mass% or more, more preferably 95 mass% or more, and particularly preferably substantially 100 mass% of Pd, Pt, and Rh. It is, of course, permissible to contain other metal catalysts which are inevitably mixed in.

Of the Pd layer, the Pt layer, and the Rh layer, the Pd layer and the Pt layer are particularly high in activity as oxidation catalysts, and in the catalyst body 5, a high oxidation action is exhibited with respect to CO and HC, in particular, among harmful components in exhaust gas. The Rh layer is particularly high in activity as a reduction catalyst, and in the catalyst body 5, exhibits a high reducing action on NOx, in particular, among harmful components in the exhaust gas. By having these Pd layer, Pt layer, and Rh layer, the catalyst body 5 can function as a three-way catalyst. The arrangement of the Pd layer, Pt layer, and Rh layer is not particularly limited, and the Pd layer is more preferably arranged on the front side (for example, a region from the first end 10a on the upstream side toward the downstream side) with respect to the Pd layer because the Pd layer can further lower the methane 50% purge temperature, for example. The Pt layer is more preferably disposed on the opposite rear side (e.g., in a region from the second end 10b on the downstream side toward the upstream side). The Rh layer is preferably disposed in a longer region along the first direction (for example, disposed in a Pd layer and a Pt laminated layer) from the viewpoint of improving the NOx purification ability.

The Pt layer and the Rh layer may contain a noble metal catalyst contained therein, and a carrierA carrier for supporting these catalysts. As such a carrier, a carrier (typically, a powder) that is known to be usable for such a purpose can be suitably used. For example, alumina (Al) is a preferred example of the carrier₂O₃) Rare earth metal oxide, alkali metal oxide, alkaline earth metal oxide, cerium oxide (CeO)₂) Zirconium oxide (ZrO)₂) Silicon dioxide (SiO)₂) Magnesium oxide (MgO), titanium dioxide (TiO)₂) Etc., or a solid solution thereof, for example, a ceria-zirconia composite oxide (CZ composite oxide: CeO (CeO)₂－ZrO₂). These can be used alone in 1, also can be used in 2 or more combinations. Among them, at least one of alumina and a CZ composite oxide is preferably used. The carrier may be polycrystalline or monocrystalline.

Each of the Pd layer, the Pt layer, and the Rh layer may suitably contain an optional component in addition to the noble metal catalyst and the support for the noble metal catalyst. Examples of such optional components include a cocatalyst not carrying a metal catalyst, an oxygen storage material (OSC material) having an oxygen storage capacity, and an oxygen storage material having an NO storage capacity_xCompetent NO_xAdsorbents, stabilizers, and the like. Examples of the cocatalyst include alumina and silica. Examples of the OSC material include ceria or a ceria-containing composite oxide, for example, a CZ composite oxide.

Examples of the stabilizer include rare earth elements such as lanthanum (La) and yttrium (Y), alkaline earth elements such as calcium (Ca) and barium (Ba), and other transition metal elements. These elements are typically present in the catalyst layer in the form of oxides. Among them, rare earth elements such as lanthanum and yttrium can increase the specific surface area at high temperatures without impairing the catalytic function, and thus are suitable for use as stabilizers. Such a carrier may be polycrystalline or monocrystalline. In the catalyst layer 20, the Pd layer containing the oxidation catalyst preferably contains a stabilizer, for example, barium element. This can appropriately suppress the poisoning of the oxidation catalyst and improve the catalytic activity. In addition, the dispersibility of the oxidation catalyst can be improved, and the particle growth of the oxidation catalyst can be suppressed at a higher level.

The coating amounts of the Pd layer, Pt layer, and Rh layer are not particularly limited. From the viewpoint of increasing the exhaust gas flow-through property of the partition wall 14 and reducing the pressure loss, the volume per 1L of the substrate may be approximately 120g/L or less and 100g/L or less, preferably 80g/L or less, for example 70g/L or less. In some embodiments, the amount of coating may be, for example, 50g/L or less, and typically 30g/L or less. On the other hand, from the viewpoint of improving the purification performance of methane and other exhaust gases, the amount of the catalyst is about 5g/L or more, preferably 10g/L or more, for example, 20g/L or more per 1L volume of the substrate. By satisfying the above range, the reduction of the pressure loss and the improvement of the exhaust gas purification performance can be achieved at a higher level. The coating amount of the catalyst layer 20 is the mass of the catalyst layer 20 per unit volume of the base material. However, the volume of the substrate is not considered for the substrate in the portion where the catalyst layer 20 is not formed, but is considered for the substrate in the portion where the catalyst layer 20 is formed.

The thicknesses of the Pd layer, Pt layer, and Rh layer are not particularly limited, and may be appropriately designed according to the size of the cells 12 of the substrate 10, and the like. For example, the thicknesses of the Pd layer, the Pt layer, and the Rh layer are preferably about 20 μm to 500 μm, and for example, about 50 μm to 200 μm.

The catalyst body 5 having the above-described structure can be manufactured, for example, by the following method. First, the substrate 10 and a slurry for forming the catalyst layer 20 are prepared. As for the slurry, a Pd layer forming slurry, a Pt layer forming slurry, and an Rh layer forming slurry may be prepared, respectively. These catalyst layer forming slurries contain, as essential components, metal catalyst components (typically solutions containing metal catalysts in ionic form) that are different from each other, and may contain other optional components such as a support, a co-catalyst, an OSC material, a binder, various additives, and the like. Among them, alumina sol, silica sol, and the like can be used as the binder. The properties of the slurry (viscosity, solid fraction, etc.) may be appropriately adjusted depending on the size of the substrate 10 used, the form of the cells 12 (partition walls 14), the desired properties of the catalyst layer 20, and the like.

For example, the average particle diameter of the particles in the slurry may be about 0.3 μm or more, preferably 0.4 μm or more, more preferably 0.5 μm or more, and may be about 3 μm or less, preferably 1 μm or less, more preferably 0.7 μm or less. For example, as for the slurry for forming the catalyst layer, the temperature of 25 ℃, the shear rate: 400s^-1The viscosity η 400 at that time may be 50 to 150 mPas, preferably 60 to 110 mPas. The viscosity of the slurry is measured in a temperature environment of 25 ℃ by using a commercially available shear viscometer.

Next, the prepared slurry for forming the catalyst layer was flowed into the cell 12 from the end of the substrate 10 and supplied to a predetermined length along the X direction. When the Pd layer is formed, the slurry may be flowed from the first end 10a and supplied to the length L1 in the X2 direction. When the Pt layer is formed, the slurry may be flowed from the second end 10b and supplied to a predetermined length in the X1 direction. When forming the Rh layer, the slurry may be flowed from either the first end portion 10a or the second end portion 10b and supplied to a desired length. At this time, the slurry may be sucked from the opposite end. Further, air may be blown from the end portion on the opposite side to discharge the surplus slurry. The suction speed and/or the blowing speed in this case are different depending on the viscosity of the slurry, and may be about 10 to 100m/s, preferably 10 to 80m/s, for example, 50m/s or less. Thereafter, the substrate 10 after the slurry supply is dried and fired at a predetermined temperature and for a predetermined time for each slurry supply. Thereby, the granular raw material is sintered to form the porous catalyst layer 20. The drying and firing method may be the same as the conventional method for forming the catalyst layer. This enables the catalyst layer 20 to be formed on the surface of the partition wall 14 of the substrate 10.

According to the catalyst body 5 configured as described above, the exhaust gas discharged from the internal combustion engine 2 flows into the cell 12 from the first end 10a of the substrate 10. The exhaust gas flowing into the cell 12 passes through the catalyst layer 20 formed on the surface of the partition wall 14, and is discharged from the second end 10 b. Here, a Pd layer, for example, is disposed on the upstream side of the catalyst layer 20. The Pd layer contains a catalytic material 30 as disclosed herein. The catalyst material 30 can, for example, bring the 50% purification temperature of methane to a temperature lower than 360 ℃, and is excellent in low-temperature purification performance. Therefore, when the exhaust gas contains methane as HC, for example, even if the temperature of the exhaust gas is likely to decrease by the F/C control or the like, the catalyst body 5 can purify more methane at a lower temperature than in the related art. In addition, the exhaust gas is heated to a higher temperature by the catalytic reaction on the upstream side. Further, the exhaust gas having passed through the Pd layer in which the Rh layer is laminated passes through the Pt layer in which the Rh layer is laminated. The temperature of the exhaust gas reaching the Pt layer and the Rh layer is heated to a higher temperature, and therefore harmful components including methane can be purified from the exhaust gas at a high purification rate in the process of passing through the Pt layer laminated with the Rh layer. In addition, the presence of the Rh layer also purifies the NOx component in the exhaust gas. Thereby, the exhaust gas can be discharged from the exhaust gas outflow side end portion 10b to the outside of the catalyst 5 in a state where the harmful component is removed.

The present invention is not limited to the following test examples.

[ test example 1]

(example 1)

As the carrier, a carrier having a specific surface area of 6m was prepared²9.8 g/g of alumina powder was dispersed in an aqueous palladium nitrate solution adjusted to have a Pd support amount of 0.2g, and the mixture was stirred and mixed for 30 minutes, and then heated at 120 ℃ for 12 hours to dry the mixture. The resultant dried powder was heat-treated at 500 ℃ for 1 hour to obtain a powdery catalytic material of example 1. Wherein the heat treatment temperature is 500 ℃ which is a temperature at which the alumina does not undergo phase change, sintering, or the like. The catalyst material was pressed at a pressure of 300kN using a press apparatus, and the resulting molded article was sieved to adjust the particle size to 0.5 to 1.0mm, thereby preparing a catalyst sample of example 1.

(example 2)

The carrier of example 1 was changed to a specific surface area of 20m²The same procedures as in example 1 were carried out except for the alumina powder/g, thereby preparing the catalyst material and the catalyst sample of example 2.

(example 3)

The carrier of example 1 was changed to 44m in specific surface area²The same procedures as in example 1 were carried out except for the alumina powder/g, thereby preparing the catalyst material and the catalyst sample of example 3.

(example 4)

The carrier of example 1 was changed to a specific surface area of 79m²The same procedures as in example 1 were carried out except for the alumina powder/g, thereby preparing the catalyst material and the catalyst sample of example 4.

(example 5)

The carrier of example 1 was changed to a specific surface area of 90m²The same procedures as in example 1 were carried out except for the alumina powder/g, thereby preparing the catalyst material and the catalyst sample of example 5.

(example 6)

The carrier of example 1 was changed to a specific surface area of 109m²The same procedures as in example 1 were carried out except for the alumina powder/g, thereby preparing the catalyst material and the catalyst sample of example 6.

(example 7)

The carrier of example 1 was changed to 125m in specific surface area²The same procedures as in example 1 were carried out except for the alumina powder/g, thereby preparing the catalyst material and the catalyst sample of example 7.

[ TEM observation of catalytic Material ]

The prepared catalytic materials of examples 1 to 7 were analyzed by X-ray diffraction, and palladium (Pd) and palladium oxide (PdO) were detected in addition to alumina as a carrier. Therefore, it was confirmed that, when TEM was used for the catalytic materials of the respective examples, a substance with a darker contrast was carried on the surface of the powdery alumina in the form of nanoparticles. From this, it is understood that Pd and/or PdO are precipitated on the surface of the alumina carrier in the catalytic materials of the respective examples. Regarding Pd and PdO, it is known that Pd is easily oxidized to PdO and PdO is easily reduced to Pd due to, for example, a change in the atmosphere of exhaust gas, and the electronic state of Pd reversibly changes. Hereinafter, for the sake of convenience, Pd and/or PdO deposited on the surface of the alumina support may be simply referred to as "palladium particles".

(ratio of specific crystal planes on interface)

Next, atomic structure images were obtained for the catalytic materials of examples 1 to 7, and crystal structure analysis of the interface between the alumina support and the palladium particle was performed. Specifically, for the catalytic materials of the respective examples, 11 points or more (N: 11 or more) of the atomic structure pattern of the crystal interface between the alumina support and the palladium particle was prepared. The inclination of the TEM observation sample was adjusted so that the incident direction of the electron beam was along the band axis of the alumina support and the palladium particles, thereby obtaining an atomic structure image. In addition, crystal interfaces between the alumina carrier and the palladium particles were observed for a plurality of different palladium particles supported on the alumina particles.

From the atomic structure image of the interface obtained, the crystal planes of alumina and palladium at the interface where Pd precipitates were investigated. In this example, the surface intervals of the surfaces parallel to the interfaces of alumina and palladium were measured and identified as the surface intervals of the respective crystal surfaces of alumina and palladium, respectively, to examine the crystal surfaces of the precipitation interfaces. According to the results, for alumina and palladium, respectively, the following formulas were based: the ratio (% by number) of the specific crystal plane was calculated as (the number of samples in which the crystal plane of the interface was the specific crystal plane) ÷ (the number of samples for identifying the crystal plane of the interface) × 100, and the ratio of the specific crystal plane among the total number of crystal planes for identifying the interface (N ═ 11 or more) was calculated for each of alumina and palladium. The specific crystal planes of alumina are 3 planes of θ (001), θ (111), and α (104). The specific crystal plane of palladium is 2 planes of Pd (100) and PdO (101). The results are shown in table 1 below. The joint surface may be identified not only by the method using the surface interval but also by the method using electron beam diffraction.

(particle diameter of Palladium particles)

In addition, the particle size of the palladium particles precipitated on the surface of the alumina support was measured while examining the ratio of the specific crystal planes. The particle diameter of the palladium particles was calculated from the metal surface area and the palladium amount obtained by using a chemisorption analyzer using a CO pulse method (volume equivalent spherical diameter). The results are shown in table 1 below.

[ evaluation of methane purifying Performance ]

The catalyst test bodies of examples 1 to 7 were evaluated for methane purification performance of simulated exhaust gas of natural gas (CNG) vehicles using a catalyst evaluation device.The catalyst evaluation device includes a mass flow controller, a heating furnace, and an engine exhaust gas analyzer, and is capable of generating a gas having a predetermined composition, supplying the gas to a catalyst sample, and analyzing components of a gas flowing into the catalyst sample and a gas flowing out of the catalyst sample. Specifically, 1.0g of the catalyst sample of each example was set in the catalyst evaluation device, and the temperature of the portion where the catalyst sample was set was increased from room temperature (25 ℃) to 500 ℃ at a temperature increase rate of 20 ℃/min while supplying the simulated exhaust gas of the CNG vehicle. Based on the measured methane (CH) in the gas flowing into the catalyst specimen and the measured methane (CH) in the exhaust gas₄) The methane purification rate was continuously measured, and the temperature of the catalyst sample when the methane purification rate reached 50% (methane 50% purification temperature: t is_50％). The results are shown in table 1 below.

As the simulated exhaust gas of the CNG vehicle, a gas having the following composition was used.

CH₄：4000ppm；

O₂: 10 mass%;

H₂o: 10 mass%;

CO：500ppm；

NO：500ppm；

N₂: the remainder.

[ Table 1]

TABLE 1

[ evaluation ]

(specific crystal plane of Palladium and 50% purification temperature of methane)

FIG. 4 shows the relationship between the specific crystal plane ratio of the palladium particles at the interface of the catalyst materials of examples 1 to 7 and the methane purification temperature of the catalyst material at 50%. Fig. 5 shows the relationship between the average particle diameter of the palladium particles and the methane 50% purification temperature of the catalyst material. The lower the value of the methane 50% purification temperature, the more the high methane purification performance can be obtained at the lower temperature. As shown in fig. 4, it is basically observed that the larger the proportion of the specific crystal plane of palladium at the interface of the catalytic material is, the lower the methane 50% purification temperature tends to be. In particular, the catalyst material of example 3 in which the specific crystal plane ratio was 54% by number at most had a 50% methane purification temperature of 348.3 ℃ which was the lowest temperature among examples 1 to 7. However, as shown in fig. 5, it was confirmed that no clear relationship was seen between the particle diameter of the palladium particles and the methane 50% purification temperature. However, it is considered that the catalytic material of example 1 in which the average particle diameter of the palladium particles is increased more than 30nm is too large, and thus the catalyst activity efficiency is lowered and the methane 50% purification temperature is raised.

As is clear from the above description, the methane purification performance is improved by using Pd (100) or PdO (101) equivalent thereto as crystal growth planes and supporting the palladium particles so that these planes are parallel to the surface of the carrier. In other words, it is found that the methane purifying performance is improved when the ratio of palladium particles growing in Pd [100] or PdO [101] equivalent orientation to the carrier is large. Further, it can be said that the methane purifying performance is improved when the palladium particles are not excessively coarse (for example, about 30nm or less, preferably about 20nm or less). In the present test example, for example, when the average particle diameter of the palladium particles is 20nm or less and the ratio of the specific crystal planes on the interface is about 20% by number or more, the methane purification 50% temperature is less than 360 ℃, and the methane purification performance is preferably improved.

Next, fig. 6 shows the relationship between the ratio of the specific crystal plane of the palladium particles at the interface of the catalyst materials of examples 1 to 7 and the ratio of the specific crystal plane of the alumina support at the interface of the catalyst materials. As shown in fig. 6, it is understood that the ratio of the specific crystal plane of the palladium particles on the interface of the catalytic material shows an excellent correlation with the ratio of the specific crystal plane of the alumina support. It is also understood that, although the palladium particles having a specific crystal plane as an interface which contributes to a reduction in the methane purification temperature of 50%, in the present test example, the palladium particles in the catalyst material have various ratios of 7% by number (example 7) to 54% by number (example 3), the larger the ratio of the specific crystal plane of the alumina as the carrier, the higher the ratio of the growth plane of the palladium particles formed therein to the specific crystal plane. In other words, it is found that palladium particles contributing to a reduction in the methane purification temperature by 50% are easily formed on a specific crystal plane of the alumina support. From these descriptions, it can be said that the palladium particles grown on the crystalline alumina support are epitaxially grown, and the more any one of θ (001), θ (111) and α (104) as a specific crystal plane is exposed on the surface of the alumina support, the more the crystal growth plane of palladium crystal grown on the surface thereof becomes Pd (100) or PdO (101), and the growth direction thereof is oriented in a specific direction, that is, Pd [100] or PdO [101] equivalent thereto, thereby enabling the realization of a catalytic material having a higher methane purification performance. In the present test example, it can be said that, for example, in order to make the ratio of the palladium particles grown on the specific surface about 20% by number or more, the ratio of the specific crystal surface on the interface of the alumina as the support is preferably 30% by number or more.

Here, in order to confirm the properties of the alumina carrier in more detail, fig. 7 shows the relationship between the average particle diameter of the palladium particles, the ratio of the specific crystal plane at the interface of the alumina carrier, and the specific surface area of alumina in the catalytic materials of examples 1 to 7. As shown in fig. 7, the average particle diameter of the palladium particles substantially has a certain correlation with the specific surface area of the alumina. That is, it is found that the larger the specific surface area of the alumina is, the smaller the average particle diameter of the palladium particles formed on the surface thereof tends to be. For example, it is known that the catalytic materials of examples 1 to 7 can be obtained by adjusting the specific surface area of alumina to about 10m so that the average particle diameter of the palladium particles is less than 30nm²(ii)/g or more, and it is also known that the specific surface area may be about 15m or less for the purpose of making the average particle diameter about 20nm or less²(ii)/g or more, and the specific surface area may be about 20m or more for stabilizing the average particle diameter to about 15nm or less²More than g.

As shown in fig. 7, it is found that the ratio of the specific crystal planes at the interface of the alumina support and the specific surface area of alumina show substantially a certain correlation. That is, it is found that the smaller the specific surface area of alumina is, the higher the ratio of the specific interface of alumina to be exposed on the surface and the palladium particles to be oriented and precipitated on the surface tends to be. The specific surface area of alumina can be observedAbout 80m²In the range of more than g, the proportion of the specific interface of alumina on the deposition surface of the palladium particles increases linearly as the specific surface area decreases, and the specific surface area of alumina is about 80m²In the region of/g or less, the ratio of the specific alumina interface on the deposition surface of the palladium particles is concentrated at a constant ratio. For example, with respect to the catalytic materials of examples 1 to 7, it can be said that the specific surface area of alumina is about 90m so that the palladium particles grown at a specific interface are about 20% by number or more and the proportion of specific crystal planes at the interface of the alumina support is about 30% by number or more²About/g or less.

As described above, the specific surface area of the alumina as a monomer was 20m²More than 90 m/g²When the amount is less than or equal to/g, a catalytic material having a large proportion of palladium particles contributing to a reduction in the methane purification temperature by 50% is obtained, and therefore, such a catalytic material is preferable.

[ test example 2]

(example 1)

The same procedure as in example 3 of test example 1 was repeated to prepare the catalyst material and the catalyst sample of example 3.

(example 8)

The Pd content of the aqueous palladium nitrate solution of example 3 of test example 1 was changed to 1.0g, and alumina powder (specific surface area: 44 m)²The same procedures as in example 3 were repeated except that the amount of addition of/g) was changed to 9.0g, thereby preparing the catalyst material and the catalyst sample of example 8. The supporting ratio of the palladium particles (catalyst) in the catalyst material of example 8 was 10 mass%.

(example 9)

The Pd content of the aqueous palladium nitrate solution of example 3 of test example 1 was increased to 1.5g, and alumina powder (specific surface area: 44 m)²The same procedures as in example 3 were repeated except that the amount of addition was decreased to 8.5g, thereby preparing the catalyst material and the catalyst sample of example 9. The supporting ratio of the palladium particles (catalyst) in the catalyst material of example 9 was 15 mass%.

(example 6)

The same procedure as in example 6 of test example 1 was repeated to prepare the catalyst material and the catalyst sample of example 6.

(example 10)

The Pd content of the aqueous palladium nitrate solution of example 6 of test example 1 was changed to 1.0g, and alumina powder (specific surface area: 109 m)²The same procedures as in example 6 were repeated except that the amount of addition of/g) was changed to 9.0g, thereby preparing the catalyst material and the catalyst sample of example 10. The supporting ratio of the palladium particles (catalyst) in the catalyst material of example 10 was 10 mass%.

(example 11)

The Pd content of the aqueous palladium nitrate solution of example 6 of test example 1 was changed to 1.5g, and alumina powder (specific surface area: 109 m)²The same procedures as in example 6 were repeated except that the amount of addition of/g) was changed to 8.5g, thereby preparing the catalyst material and the catalyst sample of example 11. The supporting ratio of the palladium particles (catalyst) in the catalyst material of example 11 was 15 mass%.

[ TEM observation of catalytic Material ]

(ratio of specific crystal planes on interface)

The prepared catalytic materials of examples 3, 6, 8 to 11 were analyzed by X-ray diffraction, and palladium (Pd) and palladium oxide (PdO) were detected in addition to alumina as a carrier. Therefore, when TEM observation was performed on the catalyst materials of the respective examples, it was confirmed that palladium particles were deposited and supported on the surfaces of alumina particles as a carrier. Here, with respect to the catalytic materials of examples 3, 6, and 8 to 11, an atomic structure image of an alumina/palladium interface was obtained by TEM observation, and the ratio of a specific crystal plane in the total number of alumina/palladium interfaces (N: 11 or more) in which a crystal plane was identified on the interface was calculated for each of alumina and palladium in the same manner as in the above-described test example 1, and the results thereof are shown in table 2 below. The specific crystal planes of alumina are 3 planes of θ (001), θ (111), and α (104). The specific crystal plane of palladium is 2 planes of Pd (100) and PdO (101).

(particle diameter of Palladium particles)

The prepared catalytic materials of examples 3, 6, 8 to 11 were examined for the specific crystal plane ratio, and the particle diameter of the palladium particles deposited on the surface of the alumina carrier was measured in the same manner as in test example 1. The results obtained are shown in table 2 below.

[ evaluation of methane purifying Performance ]

The prepared catalytic materials of examples 3, 6, 8 to 11 were investigated for methane purification performance of simulated exhaust gas of CNG vehicle under the same conditions as in test example 1. Then, the temperature of the catalyst sample (50% methane purification temperature: T) at which the methane purification rate reached 50% was examined_50％) The results are shown in table 2 below.

[ Table 2]

TABLE 2

[ evaluation ]

Fig. 8 shows the relationship between the palladium supporting amount of the catalytic material and the methane 50% purification temperature. It is understood that in any of examples 3, 8 and 9 using alumina having a relatively small specific surface area and examples 6, 10 and 11 using alumina having a relatively large specific surface area as the carrier, the catalyst material having a high methane purification performance can be obtained by decreasing the methane purification temperature by 50% by increasing the palladium supporting rate of the catalyst material. As shown in fig. 8, when examples 9 and 11 in which the supporting rate of palladium particles was 15 mass% were compared, example 11 in which the specific surface area of the supported alumina was large had a low methane 50% purification temperature. However, in examples 3, 8, 6, and 10 in which the supporting rate of the palladium particles was small, a reverse phenomenon of a 50% reduction in the purification temperature of methane in example 3 or 8 in which the specific surface area of alumina was small was observed. It is also found that the smaller the palladium particle supporting ratio, the larger the difference in methane 50% purification temperature between the catalytic materials having the same palladium particle supporting ratio, and that, for example, in the catalytic materials of examples 3 and 6 having a supporting ratio of 2 mass%, the specific surface area is 44m²The catalytic material of example 3 in a ratio of/g to a specific surface area of 109m²The 50% methane purification temperature was reduced by 13 ℃ compared to the catalytic material of example 6 per gram.

From these, it can be said that in order to achieve the same methane 50% purification temperature (about 42 to 43 ℃) as that of the catalyst material having a palladium supporting rate of 15% in example 9 or example 11, for example, the catalyst material having a palladium supporting rate of 2% in example 3 disclosed herein may be used in an amount of about 3 times. That is, it was found that the amount of palladium required to achieve a predetermined methane 50% purification temperature can be greatly reduced to, for example, 4/10.

Specific examples of the present invention have been described above in detail, but these are merely examples and do not limit the scope of the claims. The techniques described in the claims include various modifications and changes to the specific examples described above.

For example, in the above-described embodiment, the catalyst material containing only palladium is used as the methane purification catalyst, but the form of the methane purification catalyst is not limited thereto. For example, a catalyst containing rhodium, a catalyst containing platinum, a catalyst containing rhodium and platinum, or the like may be prepared in addition to the catalyst containing only palladium. Alternatively, a catalyst material containing only palladium and a catalyst material containing a catalyst other than palladium may be used in combination.

For example, in the above-described embodiment, the internal combustion engine is a CNG engine, but the internal combustion engine provided in combination with the catalyst may be a gasoline engine, a diesel engine, or the like as long as it is used for purifying methane. These internal combustion engines may be engines mounted on hybrid vehicles having a vehicle-driving power supply.