Catalytic converter

Abstract

Provided is a catalytic converter in which the entire catalyst constituting the catalytic converter can be efficiently utilized to purify exhaust gas, and the emission of hydrogen sulfide can be suppressed. A catalytic converter 10 includes catalyst layers 2A, 2B formed of a noble metal catalyst that are formed on cell wall surfaces of a substrate 1 having a cell structure in a longitudinal direction of the substrate 1 in which gas flows, in which the substrate 1 has a center region 1A having a relatively high cell density and a peripheral region 1B having a relatively low cell density, and lengths of the catalyst layers 2A, 2B of the center region 1A and the peripheral region 1B in the longitudinal direction are the same as each other, or the length of the catalyst layer 2B in the longitudinal direction is shorter than that of the catalyst layer 2A.

Claims

1. A catalytic converter comprising: a substrate that has a cell structure and is configured to allow gas to flow through the substrate; and a catalyst layer that is formed of a noble metal catalyst and is formed on a cell wall surface of the substrate, the catalyst layer extending in a longitudinal direction of the substrate, wherein the substrate has a center region and a peripheral region, the center region having a cell density higher than a cell density of the peripheral region, the cell wall surface includes a center cell wall surface provided in the center region and a peripheral cell wall surface provided in the peripheral region, the cell density of the center region is two times or lower than the cell density of the peripheral region, the catalyst layer includes a first catalyst layer provided in the center region and a second catalyst layer provided in the peripheral region, the first catalyst layer includes a first lower layer and a first upper layer, the first lower layer is provided on the center cell wall surface, the first upper layer is provided on the first lower layer and is in direct contact with a flow path for exhaust gas, the second catalyst layer includes a second lower layer and a second upper layer, the second lower layer is provided on the peripheral cell wall surface, the second upper layer is provided on the second lower layer and is in direct contact with a flow path for exhaust gas, a length of the substrate, a length of the first upper layer, and a length of the second upper layer are equal to each other in the longitudinal direction, a ratio of a length of the first lower layer to the length of the substrate is 80% in the longitudinal direction, and a ratio of a length of the second lower layer to the length of the substrate is 50% to 80% in the longitudinal direction.

2. A catalytic converter comprising: a substrate that has a cell structure and is configured to allow gas to flow through the substrate; and a catalyst layer that is formed of a noble metal catalyst and is formed on a cell wall surface of the substrate, the catalyst layer extending in a longitudinal direction of the substrate, wherein the substrate has a center region and a peripheral region, the center region having a cell density higher than a cell density of the peripheral region, the cell wall surface includes a center cell wall surface provided in the center region and a peripheral cell wall surface provided in the peripheral region, the cell density of the center region is two times or lower than the cell density of the peripheral region, the catalyst layer includes a first catalyst layer provided in the center region and a second catalyst layer provided in the peripheral region, the first catalyst layer includes a first lower layer and a first upper layer, the first lower layer is provided on the center cell wall surface, the first upper layer is provided on the first lower layer and is in direct contact with a flow path for exhaust gas, the second catalyst layer includes a second lower layer and a second upper layer, the second lower layer is provided on the peripheral cell wall surface, the second upper layer is provided on the second lower layer and is in direct contact with a flow path for exhaust gas, a length of the substrate, a length of the first upper layer, are a length of the second upper layer are equal to each other in the longitudinal direction, and a ratio of a length of the first lower layer to the length of the substrate is 70% to 90% in the longitudinal direction.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic diagram showing an embodiment of a catalytic converter according to the present invention.

(2) FIG. 2A is a schematic diagram showing, in a peripheral region of a substrate, the length of a cell wall surface in a longitudinal direction thereof and the lengths of upper and lower layers of a catalyst layer having a two-layer structure in the longitudinal direction, and

(3) FIG. 2B is a schematic diagram showing, in a center region of the substrate, the length of a cell wall surface in the longitudinal direction and the lengths of upper and lower layers of a catalyst layer having a two-layer structure in the longitudinal direction.

(4) FIG. 3 is a graph showing the exhaust gas flow rate distributions of a substrate having a uniform cell density and the substrate having different cell densities between the center region and the peripheral region.

(5) FIG. 4 is a graph showing the experiment results relating to the length of the catalyst layer of the peripheral region (the ratio thereof to the length of the substrate) and the emission amount of hydrogen sulfide, and the experiment results (Examples 1 to 4 and Comparative Examples 1 to 3) relating to the length of the catalyst layer of the peripheral region and the emission amount of NO.sub.x.

(6) FIG. 5 is a graph showing the experiment results relating to the length of the catalyst layer of the peripheral region (the ratio thereof to the length of the substrate) and the emission amount of hydrogen sulfide, and the experiment results (Example 5 and Comparative Examples 1 and 4) relating to the length of the catalyst layer of the peripheral region and the emission amount of NO.sub.x.

(7) FIG. 6 is a graph showing the experiment results relating to the length of the catalyst layer of the peripheral region (the ratio thereof to the length of the substrate) and the emission amount of hydrogen sulfide, and the experiment results (Example 6 and Comparative Examples 1 and 5) relating to the length of the catalyst layer of the peripheral region and the emission amount of NO.sub.x.

(8) FIG. 7 is a graph showing the experiment results relating to the length of the catalyst layer of the peripheral region (the ratio thereof to the length of the substrate) and the emission amount of hydrogen sulfide, and the experiment results (Comparative Examples 1, 6, and 7) relating to the length of the catalyst layer of the peripheral region and the emission amount of NO.sub.x.

MODES FOR CARRYING OUT THE INVENTION

(9) Hereinafter, an embodiment of a catalytic converter according to the present invention will be described with reference to the drawings.

(10) Exhaust System for Exhaust Gas

(11) First, an exhaust system for exhaust gas in which the catalytic converter according to the present invention is provided will be briefly described. In the exhaust system for exhaust gas to which the catalytic converter according to the present invention is applied, an engine, a three-way catalytic converter, a sub muffler, and a main muffler are disposed and connected to each other through a system pipe, and exhaust gas produced from the engine flows to each unit through the system pipe and is exhausted. Next, hereinafter, the embodiment of the catalytic converter will be described.

(12) Embodiment of Catalytic Converter

(13) FIG. 1 is a schematic diagram showing the embodiment of the catalytic converter according to the present invention. FIG. 2A is a schematic diagram showing, in a peripheral region of a substrate, the length of a cell wall surface in a longitudinal direction thereof and the lengths of upper and lower layers of a catalyst layer having a two-layer structure in the longitudinal direction, and FIG. 2B is a schematic diagram showing, in a center region of the substrate, the length of a cell wall surface in the longitudinal direction and the lengths of upper and lower layers of a catalyst layer having a two-layer structure in the longitudinal direction. In addition, FIG. 3 is a graph showing the exhaust gas flow rate distributions of a substrate having a uniform cell density and the substrate having different cell densities between the center region and the peripheral region.

(14) Briefly, a catalytic converter 10 shown in FIG. 1 includes: a cylindrical substrate 1 having plural cells; and catalyst layers having a two-layer structure that are formed on cell wall surfaces constituting the cells.

(15) Here, examples of a material of the substrate 1 include a ceramic material such as cordierite or silicon carbide which is formed of a composite oxide of magnesium oxide, aluminum oxide, and silicon dioxide; and a material other than a ceramic material such as a metal material. In addition, examples of a support constituting the catalyst layers that are formed on the cell wall surfaces of the substrate include oxides containing at least one porous oxide of CeO.sub.2, ZrO.sub.2, and Al.sub.2O.sub.3 as a major component; one oxide among ceria (CeO.sub.2), zirconia (ZrO.sub.2), and alumina (Al.sub.2O.sub.3); and a composite oxide formed of two or more oxides among ceria (CeO.sub.2), zirconia (ZrO.sub.2), and alumina (Al.sub.2O.sub.3) (for example, a CeO.sub.2—ZrO.sub.2 compound which is a CZ material, or an Al.sub.2O.sub.3—CeO.sub.2—ZrO.sub.2 tertiary composite oxide (ACZ material) into which Al.sub.2O.sub.3 is introduced as a diffusion barrier).

(16) The substrate 1 has a honeycomb structure including cells having plural lattice contours having, for example, rectangular, hexagonal, and octagonal shapes, and exhaust gas flows through the inside of each cell (X1 direction).

(17) The substrate 1 has two regions including: a center region 1A having a relatively high cell density; and a peripheral region 1B having a relatively low cell density.

(18) Here, the exhaust gas flow rate distributions will be described with reference to FIG. 3. In the exhaust gas flow rate distributions of FIG. 3, two end points of a diameter centering on the center 0 of a cross-sectional circle of the substrate are set as −1 and 1, and intermediate positions therebetween are shown as ratios with respect to a radius. The exhaust gas flow rate at each position is shown as a ratio with respect to the flow rate at the center of a substrate of a catalytic converter having a uniform cell density of the substrate.

(19) In the catalytic converter having a uniform cell density of the substrate, as indicated by a dashed line in FIG. 3, the exhaust gas flow rate of the center region of a cross-section of the substrate is significantly higher than that of the peripheral region thereof. Therefore, there is a problem in that it is difficult to sufficiently utilize the catalyst layers of the entire substrate. On the other hand, as in the catalytic converter 10 according to the present invention, by forming the substrate 1 using the two regions having different cell densities and setting the cell density of the peripheral region 1B to be relatively low, as indicated by a solid line in the same drawing, a difference in flow rate between the center region 1A and the peripheral region 1B of the substrate 1 can be significantly reduced, and all the catalyst layers included in the catalytic converter 10 can be efficiently utilized to purify exhaust gas.

(20) Further, in the catalytic converter 10 shown in the drawings, the length of the catalyst layer formed on the cell wall surface of each region varies between the peripheral region 1B and the center region 1A of the substrate 1.

(21) Here, a catalyst layer 2B formed on a surface of a cell wall surface 1Ba of the peripheral region 1B shown in FIG. 2(a) has a two-layer structure including a lower layer 2Ba, which is provided on the cell wall surface 1Ba side, and an upper layer 2Bb, which is provided above the lower layer 2Ba and come into direct contact with exhaust gas, and each layer is formed of one element or two or more elements among Pd, Pt, and Rh which are noble metal catalysts. Likewise, a catalyst layer 2A formed on a surface of a cell wall surface 1Aa of the center region 1A shown in FIG. 2(b) has a two-layer structure including a lower layer 2Aa, which is provided on the cell wall surface 1Aa side, and an upper layer 2Ab, which is provided above the lower layer 2Aa, and each layer is formed of one element or two or more elements among Pd, Pt, and Rh which are noble metal catalysts.

(22) When the length of the substrate 1 in the longitudinal direction (the length in the direction in which exhaust gas flows) is represented by t1, both the lengths of the cell wall surfaces 1Aa, 1Ba are t1, and both the lengths of the upper layers 2Ab, 2Bb of the catalyst layers 2A, 2B are t1. On the other hand, the lengths of the lower layers 2Aa, 2Ba of the catalyst layers 2A, 2B are t3 and t2, respectively. A relationship of t1>t3>t2 is established.

(23) In this way, by generating a difference in cell density between the center region 1A and the peripheral region 1B and setting the length of (the lower layer 2Ba of) the catalyst layer 2B of the peripheral region 1B in the longitudinal direction to be shorter than that of (the lower layer 2Aa of) the catalyst layer 2A of the center region 1A, both superior exhaust gas purification performance and a high effect of suppressing hydrogen sulfide can be expected from the catalytic converter 10.

(24) In addition, in regard to the cell density, it is preferable that the cell density of the center region 1A is set to be in a range of higher than one time and two times or lower than the cell density of the peripheral region 1B. The reasons for setting the upper and lower limits to be in the numerical value range are as follows: when the ratio of the cell density is one time or lower, the control of the amount of exhaust gas flowing to cells of each region is insufficient due to a difference in cell density between the center region 1A and the peripheral region 1B; and when the ratio of the cell density exceeds two times, the amount of exhaust gas flowing to the peripheral region 1B is excessively large, which may decrease purification performance.

(25) Instead of the two-layer structure shown in the example of the drawings, the catalyst layers may have, for example, a configuration of a one-layer structure or a configuration of a three-layer structure.

(26) Experiment Relating to Length of Catalyst Layer of Peripheral Region (Ratio Thereof to Length of Substrate) and Emission Amount of Hydrogen Sulfide, Experiment Relating to Length of Catalyst Layer of Peripheral Region and Emission Amount of NO.sub.x, and Results of Experiments

(27) The present inventors prepared honeycomb-structured substrates of Examples 1 to 6 and Comparative Examples 1 to 7, performed experiments of measuring the emission amount of hydrogen sulfide when varying the length of the catalyst layer of the peripheral region (the ratio thereof to the length of the substrate), and performed experiments of measuring the emission amount of No.sub.x when varying the length of the catalyst layer of the peripheral region.

Example 1

(28) A honeycomb-structured substrate formed of cordierite was prepared by extrusion, and a difference in cell density was generated between the center region and the peripheral region. Regarding the size of the honeycomb structure, the diameter of a circular cross-section perpendicular to a flowing direction of exhaust gas was φ103 mm, and the length t1 thereof in a longitudinal direction thereof was 105 mm. The cell density of a peripheral region having a relatively low cell density was 400 cpsi (62 cells/cm.sup.2), the cell density of a center region having a relatively high cell density was 600 cpsi (93 cells/cm.sup.2), a switch line between the center region and the peripheral region was at a position of φ70 mm, and the lattice shape of the cells was rectangular. Further, the catalyst layers had a two-layer structure, the support amounts of lower layers as Pt-supported layers were 0.7 g/L, and the support amounts of upper layers as Rh-supported layers were 0.2 g/L. In regard to the lengths of the catalyst layers, the lengths of the upper layers of the catalyst layers of the center region and the peripheral region were the same as the length of the substrate (the ratio thereof to the length t1 of the substrate was 100%), and the length of the lower layer of the peripheral region was 70% of the length of the substrate, and the length of the lower layer of the center region was 80% of the length of the substrate.

Example 2

(29) Example 2 was the same as Example 1, except that, in regard to the lengths of the catalyst layers, the length of the lower layer of the peripheral region was 60% of the length of the substrate.

Example 3

(30) Example 3 was the same as Example 1, except that, in regard to the lengths of the catalyst layers, the length of the lower layer of the peripheral region was 80% of the length of the substrate (accordingly, the lengths of the lower layers of the catalyst layers of the peripheral region and the center region were the same as each other).

Example 4

(31) Example 4 was the same as Example 1, except that, in regard to the lengths of the catalyst layers, the length of the lower layer of the peripheral region was 50% of the length of the substrate.

Comparative Example 1

(32) A honeycomb-structured substrate formed of cordierite was prepared by extrusion, and the cell density was uniform in a cross-section. Regarding the size of the honeycomb structure, the diameter of a circular cross-section perpendicular to a flowing direction of exhaust gas was φ103 mm, and the length t1 thereof in a longitudinal direction thereof was 105 mm. The cell density was 400 cpsi (62 cells/cm.sup.2), and the lattice shape of the cells was rectangular. Further, the catalyst layers had a two-layer structure, the support amounts of lower layers as Pt-supported layers were 0.7 g/L, and the support amounts of upper layers as Rh-supported layers were 0.2 g/L. In regard to the lengths of the catalyst layers, the lengths of the upper layers were the same (100%) as the length of the substrate, and the lengths of the lower layers were 80% of the length of the substrate.

Comparative Example 2

(33) Comparative Example 2 was the same as Example 1, except that, in regard to the lengths of the catalyst layers, the length of the lower layer of the peripheral region was 90% of the length of the substrate.

Comparative Example 3

(34) Comparative Example 3 was the same as Example 1, except that, in regard to the lengths of the catalyst layers, the length of the lower layer of the peripheral region was 100% of the length of the substrate.

(35) In addition, the details of other Examples 5 and 6 and Comparative Examples 4 to 7 will be shown in Table 2 below.

Experimental Method

(36) In a purification performance evaluation test, an actual engine was used, an A/F ratio was inverted from a lean side (15.1) to a rich side (14.1), and the engine was held in a rich atmosphere. At this time, the emission amount of NO.sub.x was measured. When the emission amount of Comparative Example 1 was represented by 100%, ratios of the emission amounts of the other specimens thereto were obtained.

(37) On the other hand, in a hydrogen sulfide emission amount measurement test, a vehicle was driven at a constant speed of 40 km/h to adsorb sulfur, and was accelerated to 100 km/h with a wide-open throttle. After the speed reached 100 km/h, the throttle was closed to stop the vehicle. When an engine idle state was left to stand for a certain period of time, the emission amount of hydrogen sulfide was measured. When the emission amount of Comparative Example 1 was represented by 100%, ratios of the emission amounts of the other specimens thereto were obtained.

(38) The measurement results are shown in Tables 1 and 2 and FIGS. 4 to 7.

(39) TABLE-US-00001 TABLE 1 Cell Length of Length of Specification Catalyst Catalyst (Whether or layer of layer of Not Cell Region Region Densities of Having Having Emission Center Region High Cell Low Cell Amount of Emission and Peripheral Density Density Hydrogen Amount of Region are (Ratio (%) (Ratio (%) Sulfide (Ratio NO.sub.x (Ratio Same as or to Length to Length (%) To (%) To Different from of of Comparative Comparative Sample Each Other) Substrate) Substrate) Example 1) Example 1) Example 1 Different 80 70 96.8 93.4 Example 2 Different 80 60 94.1 97.1 Example 3 Different 80 80 99.6 89.7 Example 4 Different 80 50 91.4 100.8 Comparative Same 80 80 100 100 Example 1 Comparative Different 80 90 102.3 86.0 Example 2 Comparative Different 80 100 105.0 82.3 Example 3

(40) TABLE-US-00002 TABLE 2 Cell Length of Length of Specification Catalyst Catalyst (Whether or layer of layer of Not Cell Region Region Densities of Having Having Emission Center Region High Cell Low Cell Amount of Emission and Peripheral Density Density Hydrogen Amount of Region are (Ratio (%) (Ratio (%) Sulfide (Ratio NO.sub.x (Ratio Same as or to Length to Length (%) To (%) To Different from of of Comparative Comparative Sample Each Other) Substrate) Substrate) Example 1) Example 1) Comparative Different 90 80 102.7 86.8 Example 4 Example 5 Different 90 60 96.6 92.2 Example 6 Different 70 70 93.4 97.3 Comparative Different 70 50 87.3 105.5 Example 5 Comparative Different 60 90 96.4 94.8 Example 6 Comparative Different 60 60 87.2 106.8 Example 7

(41) From Table 1 and FIG. 4, the following results were obtained: in Examples 1 to 4, the emission amount of hydrogen sulfide was reduced as compared to Comparative Example 1; and in Examples 1 to 3, the emission amount of NO.sub.x was also reduced, and both the hydrogen sulfide emission suppressing effect and the exhaust gas purifying effect were satisfied.

(42) In addition, it was found from FIGS. 5 and 6 that, in effective regions of the drawings, the emission amount of hydrogen sulfide and the emission amount of NO.sub.x of Examples 5 and 6 were able to be reduced as compared to Comparative Example 1.

(43) In addition, it was found from FIG. 7 that, when the length of the catalyst layer of the center region was 60%, there was no region in which both the emission amount of hydrogen sulfide and the emission amount of NO.sub.x were reduced as compared to Comparative Example 1.

(44) It was found from FIGS. 4 to 7 that the ratio range of the length of the catalyst layer of the center region to the substrate was able to be defined to be 70% to 90% in which each example was superior to Comparative Example 1.

(45) Hereinabove, the embodiments of the invention have been described with reference to the drawings. However, a specific configuration is not limited to the embodiments, and design changes and the like which are made within a range not departing from the scope of the invention are included in the invention.

REFERENCE SIGNS LIST

(46) 1 . . . SUBSTRATE, 1A . . . CENTER REGION, 1Aa . . . CELL WALL SURFACE, 1B . . . PERIPHERAL REGION, 1Ba . . . CELL WALL SURFACE, 2A . . . CATALYST LAYER (CATALYST LAYER OF CENTER REGION), 2Aa . . . LOWER LAYER, 2Ab . . . UPPER LAYER, 2B . . . CATALYST LAYER (CATALYST LAYER OF PERIPHERAL REGION), 2Ba . . . LOWER LAYER, 2Bb . . . UPPER LAYER, 10 . . . CATALYTIC CONVERTER