Catalyst – solid sorbent – or support therefor: product or process – Catalyst or precursor therefor – Metal – metal oxide or metal hydroxide
Patent
1991-02-11
1993-04-06
Shine, W. J.
Catalyst, solid sorbent, or support therefor: product or process
Catalyst or precursor therefor
Metal, metal oxide or metal hydroxide
4232135, B01J 2104, B01J 2310, B01J 2356, B01J 3703
Patent
active
052003841
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
This invention relates to purifying catalysts for exhaust gas emitted from internal combustion engines such as automobiles and a process for preparation thereof. More particularly, this invention relates to catalysts which exhibit excellent exhaust gas purification performance at lower temperature compared to usual catalysts and a process for preparation thereof.
BACKGROUND ART
Elements of the platinum group such as platinum and rhodium, and cerium oxide having an oxygen storage effect for enhancement of their activity at low temperature are mainly used now as catalytic converters to simultaneously remove hydrocarbons (HC), carbon monoxide (CO) and nitrogen oxides (NOx) in exhaust gas exhausted from internal combustion engines such as automobiles.
However, it is said that in catalysts containing an element of the platinum group and cerium oxide the oxygen storage function of cerium oxide strikingly lowers at a high temperature exposure above 800.degree. C. and thus the catalysts are liable to deteriorate at those temperatures. Thus, many methods have been disclosed comprising adding oxides of alkaline earth elements, or zirconium compounds for the purpose of inhibiting crystallization of cerium oxide and preeserving its oxygen storage effect (for example, Japanese Laid-Open Patent Publication Nos. 58347/1989 and 116741/1988).
Further, in the latest catalytic converter, catalysts having a two or more-layer structure and containing rhodium in the outer layer are becoming conventional and permit effective utilization of expensive rhodium. It is known in these catalysts that it is effective to add zirconium oxide for prevention of lowering of the catalytic performance due to interaction of rhodium with alumina. Further, in these catalysts, it is considered that the catalytic performance is enhanced by an interaction between rhodium and zirconium oxide (for example, Japanese Laid-Open Patent Publication Nos. 222,539/1986 and 88,040/1988).
However, when zirconium oxide is exposed to high temperatures, its crystalline structure changes from the metastable tetragonal system having a catalytic activity to the inactive monoclinic system, contribution of rhodium and zirconium oxide to catalytic performance due to their an interaction diminishes, and the catalytic performance is lowered. At present there is no known catalyst to stabilize zirconium oxide in the catalyst and preserve the an interaction between rhodium and zirconium oxide.
DISCLOSURE OF INVENTION
An object of this invention is to develop a catalyst which solves the above problems in the prior art and exhibits an excellent exhaust gas purification performance at lower temperature even after high temperature aging.
As a result of vigorous study for a solution to the above problems, the present inventors found that it is extremely effective for enhancement of the activity of exhaust gas-purifying catalysts at low temperature after high temperature aging, to combine a coprecipitated ceria-stabilized zirconia (cerium oxide-stabilized zirconium oxides prepared by the coprecipitation method) having a specific oxygen storage performance as well as heat resistance with a conventional catalyst containing at least one element of the platinum group, activated alumina, cerium oxide and optionally a zirconium compound.
This invention is described below in detail.
In the invention, addition of a coprecipitated ceria-stabilized zirconia gave a desirable result for enhancement of the activity at low temperature after high temperature aging.
As shown in FIG. 1, the structure of zirconium oxide changes from the metastable tetragonal system to the monoclinic system as the temperature becomes higher, whereas a coprecipitated ceria stabilized zirconia prepared by the coprecipitation method preserves the structure of the metastable tetragonal system having a catalytic activity even after high temperature exposure.
Further, as shown in FIG. 2, this ceria-stabilized zirconium coprecipitated oxide has a small decrease ratio of the specific surface area and
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Funabiki Masaki
Kayano Kunihide
Yamada Teiji
McGinty Douglas J.
N.E Chemcat Corporation
Shine W. J.
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