成果報告書詳細
管理番号20130000000713
タイトル*平成24年度中間年報 希少金属代替材料開発プロジェクト 排ガス浄化向け白金族使用量低減技術開発及び代替材料開発 ディーゼル排ガス浄化触媒の白金族使用量低減化技術の開発
公開日2013/10/1
報告書年度2012 - 2012
委託先名独立行政法人産業技術総合研究所 三井金属鉱業株式会社 水澤化学工業株式会社 国立大学法人名古屋工業大学 国立大学法人九州大学
プロジェクト番号P08023
部署名電子・材料・ナノテクノロジー部
和文要約
英文要約(1) Improvement of practical catalytic performance: (a) Advanced preparation of active species for DOC: The addition of acidic additives improved the oxidation activity of PtPd catalysts. Hydrogen reduction in the catalyst preparation procedure was also effective for the activity improvement, probably by efficient formation of catalytically active metallic PtPd species. (b) Advanced preparation of support materials for DOC: The highest activity for HC and NO oxidation was achieved over PtPd catalyst on Si-Al2O3 support with a Si content of 4 wt%. Furthermore, both activities increased with increasing mesopore diameter in the support, which was consistent with the CFD simulation results. (c) Advanced design of DPF: The effect of contamination in support materials, such as Cl and SiO2, on soot oxidation activity was investigated. Cl was found to react with Ag to form two-phase particles of Ag-AgCl by high temperature calcination. SiO2 interacted with Ag to form Ag/SiO2, which showed low oxidation activity. (d) Advanced catalyst design for improvement of catalytic performance: PtPd/Al2O3 with Pt/Pd weight ratio of 3/1 showed high catalytic activity for the total oxidation of hydrocarbons. Its high activity was attributed to Pt enrichment on the surface of alloyed Pt-Pd particles. (e) Development of catalyst preparation technologies: Surface improvement techniques using a small amount of organic compounds were applied to catalyst preparation of Pt-supported catalysts, which enabled an increase of Pt species interacting with Lewis acid sites on the acid supports. (f) Development of supported nanoparticle catalysts: A method was developed to prepare the Pt-Pd nanoparticle catalysts at extended scales up to 100 g per batch. The produced catalysts exhibited oxidation activity and durability comparable to those of the catalysts prepared with a conventional technique. (2) Development of practical catalyst manufacturing technologies: (a) Development of manufacturing technologies of support materials:
Si content and mesopore size of Si-doped Al2O3 were optimized and the preparation method of the support by sol-gel process was established. Furthermore, the production efficiency of the pilot plant was improved by optimization of the raw materials transport line as well as automation of the water washing and drying process. (b) Development of manufacturing technologies of honeycomb catalysts and their evaluation: The reduction of Pt group metals usage by 40% was achieved for diesel oxidation catalyst by applying our new shade coating methods with controlled macropores to the developed catalyst materials and supports. 50% reduction of Pt group metals usage was also anticipated by improvement of supporting methods. In the case of DPF, a problem of back pressure increase could be solved by optimizing coating method, while maintaining soot combustion performance equivalent to the current commercial products. (3) Development of catalyst commercialization technologies:
The performance of the DOC-DPF catalyst system with 43% less amount of platinum group metals usage was evaluated using an actual diesel engine of UD Trucks Corporation. Although the fresh catalysts showed almost equivalent activities to the current commercial products, catalyst deactivation was observed, which is a problem to be solved. On the other hand, DPF catalyst had a significant advantage in soot combustion over the current products.
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