Carbon-bearing material combustion catalyst, method of preparing said catalyst, catalyst support and preparation method thereof

FIELD: chemistry.

SUBSTANCE: invention relates to a catalyst for combustion of carbon-bearing material contained in exhaust gas of an internal combustion engine, to a method of preparing said catalyst, as well as a support for said catalyst and method of preparing said support. The invention describes a method of preparing a carbon-bearing material combustion catalyst which is attached to a ceramic substrate, involving mixing aluminium silicate having atomic equivalent ratio Si/Al≥1 and an alkali and/or alkali-earth metal source in a polar solvent such as water or another, drying the liquid mixture to obtain a solid substance and burning it at temperature of 600°C or higher. The aluminium silicate is sodalite. Alternatively, the carbon-bearing material combustion catalyst is prepared through a sequence of steps for mixing, drying and burning, whereby the method involves burning sodalite at temperature of 600°C or higher. A catalyst prepared using the method given above is described. Described also is a method of preparing a catalyst support involving a step for attaching the combustion catalyst to a ceramic substrate, and a catalyst support made using said method.

EFFECT: stable combustion and removal of carbon-bearing material at low temperature for a long period of time.

26 cl, 3 ex, 1 av ex, 27 dwg

 

The technical field to which the invention relates.

The present invention relates to a catalyst for the combustion of carbon-containing material, which is used for burning and removal of carbonaceous material such as carbon fines (for example, particulate matter (PM) (PM)contained in exhaust gas, and to a method thereof. In addition, the present invention also relates to a catalyst carrier for fixing the catalyst for the combustion of carbon-containing material on a ceramic substrate and method of its production.

Background of invention

Carbon fines (for example, particulate matter (PM) (PM)contained in exhaust gas of an internal combustion engine such as a diesel engine, is burned and removed a diesel particulate filter ((DFTC)(DPF)) or similar. In order to remove as much of the PM at a low cost, it is desirable to carry out the burning and removing PM at a relatively low temperature. Thus, to burn and remove PM from the exhaust gas using DFTC carrying a catalyst for promotion of the combustion of carbon-containing material, such as PM.

As such a catalyst for the combustion of carbon-containing material is usually used, for example, a noble metal such as Pt, Pd, Rh, or its oxide. Use the catalysis of the Torah, made of expensive noble metal, however, leads to high costs and adversely leads to the problem of resource depletion. Furthermore, the activity of burning PM is insufficient, and, thus, in normal operating conditions the raw PM can gradually accumulate. In order to remove the accumulated PM, it is necessary to increase the temperature of the exhaust gas using fuel or electric heating catalyst to 600°C or higher. In the sulfur dioxide contained in the exhaust gas is converted to sulfur trioxide or sulfuric acid mist, and therefore, the exhaust gas can not be fully realized, even when the PM can be removed.

For the above reason were developed catalysts having catalytic particles made of oxides of alkali metals such as potassium, and fixed on the oxide ceramic particles (see patent documents 1-4). When such an alkali metal particulate matter (PM)suspended in the exhaust gas can be burned and removed at a low temperature of about 400°C.

The catalyst, made of alkali metal, however, the alkali metal which is catalytic component, can be washed in the presence of water. When the catalyst is used under conditions vkljuchajuwih is a lot of water vapor, for example, in the exhaust gas of the engine, the exhaust gas cannot be carried out stably for a long time. When using an excessive amount of an alkali metal, taking into account the leaching of alkaline metal, to prevent the loss of catalytic activity may be a danger to the foundations, made of ceramics or the like, for fixing alkali metal.

Patent document 1: JP-A-2001-170483

Patent document 2: JP-A-2005-230724

Patent document 3: JP-A-2005-296871

Patent document 4: JP-A-2005-342604

Disclosure of the invention

The problem addressed by the invention

The present invention is made in view of the above problems occurring in the prototype, and the aim of the present invention is to provide a catalyst for the combustion of carbon-containing material, which can ensure stable combustion and the removal of carbon-containing material at a low temperature for a long time, creating a method of producing catalyst combustion, creating a catalyst carrier and method of producing catalyst carrier.

The way to solve problems

According to the first example of the present invention provides a method of producing catalyst for the combustion of carbon-containing material. The catalyst combustion is intended for the jihane carbon-containing material, contained in the exhaust gas of the internal combustion engine, when mounted on ceramic substrate. The method of obtaining includes a step of mixing aluminosilicate having an atomic equivalent ratio of Si/Al≥1, and a source of alkali metal and/or source of alkaline earth metal in water, the stage of drying the liquid mixture by heating the mixture after the stage of mixing and evaporation of water results in solids and stage firing solids at a temperature of 600°C or higher with getting in the catalyst combustion of carbon-containing material. Aluminum silicate is sodalite.

According to the second example of the present invention a catalyst for the combustion of carbon-containing material is produced by way of the first example.

In the production method of the first example of the present invention provide phase blending stage stage drying and firing to obtain a catalyst for the combustion of carbon-containing material.

Thus, at the stage of mixing of the aluminosilicate (i.e. sodalite), with the atomic equivalent ratio of Si/Al≥1, and a source of alkali metal and/or a source of alkaline earth metal is mixed in the water. Then at the stage of drying the liquid mixture after stage mixture is heated for evaporation of water results in solids. Solid state is t of a mixture of an element of the alkali metal and/or alkaline earth element metal and silicate. Then at the stage of firing the solid is calcined at a temperature of 600°C or higher. Thus can be obtained a catalyst for the combustion of carbon-containing material of the second example of the invention.

The catalyst for the combustion of carbon-containing material contains an element of the alkali metal and/or alkaline earth element metal. Element of the alkali metal and/or alkaline earth element metal has and/or have the effect of promotion combustion of carbon-containing material, such as suspended particulate matter (PM)in the exhaust gas. Thus, the catalyst for the combustion of carbon-containing material can provide the combustion of carbon-containing material at a low temperature.

In addition, the catalyst for the combustion of carbon-containing material can keep the element of the alkali metal and/or alkaline earth element metal. Thus, the element of the alkali metal and/or alkaline earth element metal can be prevented from leaching in the presence of water.

Thus, the catalyst for the combustion of carbon-containing material is difficult washed in the presence of water. When using the catalyst attached to the substrate, made for example of ceramic or the like, it is necessary to fix the catalyst on the substrate in an excessive amount, in order to prevent razrusheny the substrate. Thus, the catalyst for the combustion of carbon-containing material can consistently promote the combustion of carbon-containing material in a long time.

The catalyst for the combustion of carbon-containing material according to the second example of the present invention obtained by the method of the first example of the present invention, has the characteristics of promotion combustion of carbon-containing material, such as suspended particulate matter (PM)contained in exhaust gas of an internal combustion engine, as described above. The above catalyst for the combustion of carbon-containing material can provide the combustion of carbon-containing material at a temperature equal to or lower than the temperature of conventional noble metal catalyst.

The above catalyst for the combustion of carbon-containing material almost does not reduce the catalytic activity in the presence of water as described above.

The catalyst for the combustion of carbon-containing material, mounted on a ceramic substrate, using almost no decomposition of the ceramic substrate in the presence of water in contrast to conventional catalyst of an alkali metal and, thus, can prevent the decomposition of the ceramic substrate.

Thus, the catalyst for the combustion of carbon-containing material can be the t consistently to promote the combustion of carbon-containing material even in the presence of water for a long time.

The reason why the catalyst for the combustion of carbon-containing material has excellent catalytic activity, as described above, is not clear, but it is believed that Na aluminosilicate, such as sodalite, the element of the alkali metal source is an alkali metal and an element of the alkaline earth metal source, alkaline earth metal, which are the source material, contribute to the catalytic activity.

Thus, in the above-mentioned catalyst for the combustion of carbon-containing material Na sodalite and the element of the alkali metal source is an alkali metal, and alkaline earth element metal source, alkaline earth metal show features promotion combustion of carbon-containing material.

In addition, the structure of the catalyst for combustion of carbon-containing material holds in it the element of the alkali metal and/or alkaline earth element metal of relatively high torque connection and makes it difficult to wash out element of the alkali metal and/or alkaline earth element metal, even in the presence of water. Thus, the catalyst combustion can prevent the loss of catalytic activity, as described above, and also to prevent corrosion of the ceramic substrate.

In the first example of the present invention a catalyst for the combustion of carbonaceous material is material obtained by the stage of firing, which includes the firing of a solid mixture consisting of aluminosilicate (e.g., sodalite) and the source element of the alkali metal and/or source element of the alkali earth metal at a temperature of 600°C or higher. The catalyst for the combustion of carbon-containing material obtained in the above stage of firing, is used by being mounted on the ceramic substrate. Thus, the stage firing is carried out without fixing the mixture on the ceramic substrate, and the consolidation of the catalyst on the ceramic substrate is carried out after the stage of firing.

When the mixture of sodalite and source of alkali metal and/or source of alkaline earth metal is fired at a temperature of 600°C or higher after fixing on the ceramic substrate, Na contained in the sodalite, alkali metal in the source of alkali metal and alkaline earth metal in the source of alkaline earth metal can be washed. Washed alkali metal and/or alkaline earth metal can partially change the structure of the ceramic substrate consisting, for example, cordierite, which gives a lower coefficient of thermal expansion and strength, causing cracks or the like in the ceramic substrate.

In the present invention, as described above, the catalyst for the combustion of carbon-containing material is subjected to a stage of firing, is used, will the and fixed on the ceramic substrate. This catalyst combustion firmly holds the element of the alkali metal and/or alkaline earth element metal. Thus, when the catalyst combustion is fixed on the ceramic substrate heating during or after fixing can prevent the leaching of alkali metal and/or alkaline earth metal from the catalyst combustion. The result can be prevented occurrence of cracks in the ceramic substrate.

In the first example of the invention the catalyst for the combustion of carbon-containing material can be easily obtained at the stage of mixing, the stage of stage of drying and firing, Thereby aluminosilicate (e.g., sodalite) and a source of alkali metal and/or a source of alkaline earth metal is mixed in water and dried to obtain a mixture (solid), which is then fired at a temperature of 600°C or higher. Thus, the catalyst for the combustion of carbon-containing material can be easily obtained.

In accordance with the first and second examples of the present invention a catalyst for the combustion of carbon-containing material and the method thereof can be provided so as to stably burn and remove the carbonaceous material at a low temperature for a long time.

In the third example of the present invention provides a method of obtaining a catalyst carrier, it is which is designed to carry the catalyst for the combustion of carbon-containing material on a ceramic substrate. The catalyst combustion is used for combustion of carbonaceous material contained in the exhaust gas of the internal combustion engine. The method of obtaining includes a step of fixing the catalyst for the combustion of carbon-containing material obtained by the method of the first example of the invention, the ceramic substrate is obtained catalyst carrier.

In the fourth example of the present invention, the catalyst carrier obtained by the method of receiving according to a third example of the invention.

The catalyst carrier according to a fourth example of the invention obtained by the method of obtaining a third example of the invention, is a catalyst for the combustion of carbon-containing material obtained by the method of the first example of the invention, the ceramic substrate.

Thus, the catalyst carrier can show excellent action and effect of the catalyst for combustion of carbon-containing material, as described above. Thus, the catalyst carrier can provide stable combustion and the removal of carbon-containing material at a low temperature for a long time.

The above catalyst for the combustion of carbon-containing material can prevent the leaching of alkali metal and/or alkaline earth metal, which can decompose to remixes.cue substrate in the presence of water. Thus, the catalyst carrier can consistently burn carbonaceous material for a long time almost without decomposition of the ceramic substrate even in the presence of water.

In the third example of the present invention a method of obtaining a catalyst carrier uses the catalyst for the combustion of carbon-containing material obtained by the step of firing the first example of the invention. At the stage of firing the mixture (solid) aluminum silicate (for example, sodalite) and a source of alkali metal and/or source of alkaline earth metal is fired at a temperature of 600°C or higher. A method of obtaining a catalyst carrier includes a step of fixing the catalyst for the combustion of carbon-containing material on a ceramic substrate, which results in catalyst carrier. As indicated above, the catalyst combustion, obtained above stage firing, firmly holds the element of the alkali metal and/or alkaline earth element metal. Thus, at the stage of fixing can be prevented leaching of the alkali metal and/or alkaline earth metal from the catalyst combustion of carbon-containing material. As a result, can be prevented occurrence of cracks or the like in the ceramic substrate due to the leaching of the alkali metal and/or alkaline earth metal. Even support is of catalyst carrier, obtained after curing catalyst, makes it difficult leaching of the alkali metal and/or alkaline earth metal from the catalyst combustion of carbon-containing material. Thus, the catalyst carrier can be used stably for a long time.

Thus, according to the third and fourth examples of the present invention, the catalyst carrier and method thereof can be provided so as to stably burn and remove the carbonaceous material at a low temperature for a long time.

In the fifth example of the present invention a method of producing catalyst for the combustion of carbonaceous material used for the combustion of carbonaceous material contained in the exhaust gas of the internal combustion engine when the catalyst is fixed on the ceramic substrate, includes a step of firing to firing of sodalite at a temperature of 600°C or above for the preparation of the catalyst combustion of carbon-containing material.

In the sixth example of the present invention a catalyst for the combustion of carbon-containing material is produced by method of receiving according to the fifth example of the invention.

The catalyst for the combustion of carbon-containing material according to the sixth example of the present invention obtained by the method of obtaining a fifth example of the present invention, has the effect of promotion combustion of carbon-containing material, such as suspended particulate matter (PM)contained in exhaust gas of the internal combustion engine. Thus, the catalyst for the combustion of carbon-containing material can provide the combustion of carbon-containing material at a temperature equal to or lower than the temperature of conventional noble metal catalyst.

The above catalyst for the combustion of carbon-containing material almost does not reduce the catalytic activity in the presence of water as described above.

The catalyst for the combustion of carbon-containing material, mounted on a ceramic substrate, using almost no decomposition of the ceramic substrate in the presence of water in contrast to conventional catalyst of an alkali metal and, thus, can prevent the decomposition of the ceramic substrate.

Thus, the catalyst for the combustion of carbon-containing material can continuously contribute to the combustion of carbon-containing material even in the presence of water for a long time.

The reason why the catalyst for the combustion of carbon-containing material has excellent catalytic activity, as described above, is not clear, but it is believed that Na sodalite, which is the starting material, contributing Catalytica the kind of activity.

Thus, it is considered that the above catalyst for the combustion of carbonaceous material obtained by firing sodalite at a temperature of 600°C or above, Na is the element contained in the sodalite shows the characteristics of the promotion combustion of carbon-containing material.

In addition, it is believed that the structure of the catalyst for combustion of carbon-containing material retains Na-element relatively high torque connections and, thus, makes it difficult leaching Na even in the presence of water. Thus, the catalyst combustion can prevent the loss of catalytic activity and corrosion of the ceramic substrate.

In the fifth example of the present invention a catalyst for the combustion of carbon-containing material gain stage firing, which includes the firing of sodalite at a temperature of 600°C or higher. The catalyst for the combustion of carbonaceous material obtained by the above stage of firing, is used by being mounted on the ceramic substrate. Thus, the stage firing is carried out without fixing sodalite ceramic substrate, and the consolidation of the catalyst on the ceramic substrate is carried out after the stage of firing.

When sodalite is fired at a temperature of 600°C or higher after fixing on the ceramic substrate, Na-element contained in the sodalite, can the t to be washed, and washed Na may partially change the structure of the ceramic substrate consisting, for example, cordierite, which may provide a lower coefficient of thermal expansion and strength, causing cracks or the like in the ceramic substrate.

In the present invention, as described above, the catalyst for the combustion of carbon-containing material, the last stage of firing, is used by being mounted on the ceramic substrate. So the catalyst combustion firmly holds the element of the alkali metal (Na)contained in the sodalite. Thus, when the catalyst combustion is mounted on the ceramic substrate during heating or after fixing, the catalyst can prevent alkali metal from leaching from the catalyst combustion. The result can be prevented occurrence of cracks or the like in the ceramic substrate.

In the fifth example of the present invention stage firing may easily be the catalyst for the combustion of carbon-containing material. Thus, sodalite is fired at a temperature of 600°C or higher, which may easily be the catalyst for the combustion of carbon-containing material.

According to the fifth and sixth examples of the present invention a catalyst for the combustion of carbon-containing material and the method thereof can be provided so as to stably burn and remove the coal is odatabase material at a low temperature for a long time.

In the seventh example of the present invention provides a method of obtaining a catalyst carrier, which is designed to carry the catalyst for the combustion of carbon-containing material on a ceramic substrate. The catalyst combustion is used for combustion of carbonaceous material contained in the exhaust gas of the internal combustion engine. The method of obtaining includes a step of fixing the catalyst for the combustion of carbon-containing material obtained by the method of obtaining a fifth example of the present invention, a ceramic substrate, which results in catalyst carrier.

In the eighth example of the present invention, the catalyst carrier obtained by the method of receiving according to the seventh example of the invention.

The catalyst carrier according to the eighth example of the present invention obtained by a method of obtaining a seventh example of the invention, is a catalyst for the combustion of carbon-containing material obtained by the method of obtaining a fifth example of the invention. Thus, the catalyst carrier can show excellent action and effect of the catalyst for combustion of carbon-containing material, as described above. Thus, the catalyst carrier can provide stable combustion and the removal of carbon-containing material at a low temperature over the length of the additional time.

The above catalyst for the combustion of carbon-containing material can prevent the leaching of alkali metal and/or alkaline earth metal, which can reduce the ceramic substrate in the presence of water as described above. Thus, the catalyst carrier can provide stable combustion and removal of carbonaceous material for a long time almost without decomposition of the ceramic substrate even in the presence of water.

In the seventh example of the present invention a method of obtaining a catalyst carrier uses the catalyst for the combustion of carbon-containing material obtained by the step of firing the fifth example of the invention, which includes the firing of sodalite at a temperature of 600°C or higher. A method of obtaining a catalyst carrier includes a step of fixing the catalyst for the combustion of carbon-containing material on a ceramic substrate obtained catalyst carrier. As indicated above, the catalyst combustion, collect the above stage firing, firmly holds the element of the alkali metal (Na)contained in the sodalite. Thus, at the stage of fixing can be prevented leaching of the alkali metal from the catalyst combustion of carbon-containing material. The result can be prevented occurrence of cracks or the like in the ceramic vile who eke thanks washed alkali metal.

According to the seventh and eighth examples of the present invention a catalyst for the combustion of carbon-containing material and the method thereof can be provided so as to stably burn and remove the carbonaceous material at a low temperature for a long time.

The best way of carrying out the invention

Now will be described the preferred variants of the invention.

First will be described below first variant of the invention.

The above catalyst for the combustion of carbon-containing material is used for burning and removal of carbonaceous material or the like. The above-described carbon-containing material includes, for example, carbon fines (particulate matter, PM) or the like contained in the exhaust gas of a diesel engine.

The above method of receiving according to the first embodiment of the invention includes a step of mixing, stage stage drying and calcining as described above.

At the stage of mixing according to the first variant of the invention, the silicate having an atomic equivalent ratio of Si/Al≥1, and a source of alkali metal and/or a source of alkaline earth metal is mixed in the water. In this case, the aluminosilicate and a source of alkali metal and/or a source of alkaline earth metal is preferably mixed to be homogeneous is about dispergirovannykh.

In the case when the atomic equivalent ratio of Si/Al<1, we obtain a catalyst for the combustion of carbon-containing material may allow element of the alkali metal and/or alkaline earth element metal to be easily washed in the presence of water. In the above-mentioned catalyst for the combustion of carbon-containing material may have difficulty in maintaining stable catalytic activity for a long time.

In particular, in the first embodiment of the present invention as above-mentioned aluminosilicate is used sodalite. Sodalite represented by General formula 3(Na2O·Al2O3·2SiO2)·2NaX, in which X represents an atom or atomic group monatomic anion, for example, HE or halogen, such as F, Cl, Br, I, or similar.

At the stage of mixing of the aluminosilicate (sodalite) and a source of alkali metal and/or a source of alkaline earth metal is mixed in water to form a liquid mixture.

The source of the alkali metal includes, for example, a compound of alkali metal or similar. The source of alkaline earth metal includes, for example, the connection alkaline earth metal or the like.

The source element of the alkali metal contains one or more kinds of elements selected from the group consisting of Na, K, Rb and Cs. Element of the alkali earth metal preference is sustained fashion contains one or more kinds of elements selected from the group consisting of Ca, Sr and Ba. As a result, the catalyst for the combustion of carbon-containing material can provide the combustion of carbon-containing material at low temperatures.

Thus, at the stage of mixing is preferably mixed at least aluminosilicate (sodalite) and a source of alkali metal and/or a source of alkaline earth metal, with the exception of the Mg source. The source of Mg can be used in conjunction with another source of alkali metal and/or source of the other alkaline earth metal without the use of source Mg with sodalite.

The source of alkali metal and/or a source of alkaline earth metal is preferably, for example, carbonate, sulfate, phosphate, nitrate, salt of organic acid, a halide, oxide or hydroxide.

In this case, the source of alkali metal and/or a source of alkaline earth metal can be easily mixed in a polar solvent such as water. Thus, the source of alkali metal and/or a source of alkaline earth metal can be uniformly mixed at the stage of mixing.

More preferably as a source of alkali metal can be used salt of an alkali metal, and as the source of alkaline earth metal may be used the alkali earth metal salt. In the data the m case, the reported source of the alkali metal and/or a source of alkaline earth metal have high solubility in a polar solvent, such as water, and thus can be dissolved in the polar solvent. When the stage of mixing is carried out in a polar solvent such as water, an aluminosilicate and a source of alkali metal and/or a source of alkaline earth metal can be mixed uniformly and easily.

At the stage of mixing instead of water is a polar solvent other than water. The aluminosilicate and a source of alkali metal and/or a source of alkaline earth metal are mixed in a polar solvent, and at a stage of drying the polar solvent can be evaporated to obtain a solid substance. In particular, the polar solvent for use may be an alcohol, such as methanol, ethanol or the like.

As the polar solvent is preferably used a solvent which is more volatile than water.

At the stage of drying the polar solvent can be more easily evaporated.

At the stage of mixing the source of the alkali metal and/or a source of alkaline earth metal aluminosilicate may be preferably mixed so that the total number of element of the alkali metal and alkaline earth element metal contained in the source of an alkali metal and/or the source of alkaline earth metal is equal to or less than 2.25 mol per 1 mol of the element Si of the aluminosilicate.

When the General to icesto element of the alkali metal and alkaline earth element metal exceeds 2.25 mol per 1 mol of the element Si aluminosilicate (sodalite), the solid material can easily melt at the stage of firing. Thus, the catalyst for the combustion of carbon-containing material obtained after the stage of firing, may want to jump in the molten state, which can give increased hardness of the catalyst. In the result, it is difficult to adjust the size of the catalyst for combustion of carbon-containing material to the desired size of the grains in the implementation stage grinding stage after firing, described next. In this case, even when the catalyst combustion of carbon-containing material has excellent catalytic activity, the catalyst can be easily degraded by water. Thus, the degree of decrease in catalytic activity can be large because of the water. As a result, it is difficult to maintain a given catalytic activity for a long time.

More preferably, at the stage of mixing the source of the alkali metal and/or a source of alkaline earth metal aluminosilicate may be preferably mixed so that the total number of element of the alkali metal and alkaline earth element metal contained in the source of an alkali metal and/or the source of alkaline earth metal is equal to or less than 1 mol per 1 mol of the element Si of the aluminosilicate.

Even more preferably, at the stage of mixing the source school is full metal and/or a source of alkaline earth metal aluminosilicate may be preferably mixed so that what is the total number of element of the alkali metal and alkaline earth element metal contained in the source of an alkali metal and/or the source of alkaline earth metal is equal to or less than 0.5 mol per 1 mol of the element Si of the aluminosilicate.

The above total number of element of the alkali metal and alkaline earth element of metal represents the total number of element of the alkali metal and alkaline earth element metal contained in the aluminosilicate (sodalite). When using any one of the source of the alkali metal and the source of alkaline earth metal number of other source can be calculated to be equal to 0 mol. When using multiple sources of an alkali metal and sources of alkaline earth metal total number of these sources can be calculated as above the total amount.

Then at the stage of drying the liquid mixture obtained after the stage of mixing, heat for evaporation of water results in solids. In the first embodiment of the present invention, the solid consists of a mixture of a source of alkali metal and/or source of alkaline earth metal aluminosilicate (sodalite).

Then at the stage of firing the solid is fired at a temperature of 600°C or higher. So can be obtained vishey the above catalyst for the combustion of carbon-containing material.

When the firing temperature (i.e. the maximum temperature during heating) is below 600°C at the stage of firing, the element of the alkali metal and/or alkaline earth element metal, everyone has a tendency to be easily washed in the presence of water. Thus, the above catalyst for the combustion of carbon-containing material may have difficulty in stable fashion show catalytic activity towards carbon-containing material in a long time. At the stage of firing firing is preferably performed at a firing temperature of 700°C or higher and more preferably 800°C or higher.

When the firing temperature exceeds 1200°C, the catalyst for the combustion of carbon-containing material goes directly into the molten state at the stage of firing and, thus, can be a solid form, having a high hardness. As a result it may be difficult to adjust the size of the catalyst for combustion of carbon-containing material to the desired size of the grains in the implementation stage grinding stage after firing, described below.

Accordingly, at the stage of burning solid substance may preferably be calcined at a temperature of from 700°C to 1200°C.

The term "firing temperature at the stage of firing", as used here, means the temperature of the solids, and not the ambient temperature. Still the way at the stage of firing, the firing is carried out so that the temperature of the solids becomes 600°C or higher. At the stage of firing fired at a firing temperature is preferably within one hour or longer, preferably for five hours or more, and more preferably within ten hours or more.

Then after stage firing is carried out stage of grinding for grinding the catalyst for the combustion of carbon-containing material. In this case, can be obtained powdery catalyst for the combustion of carbon-containing material. This powdered catalyst combustion of carbon-containing material can be readily fixed, for example, on a ceramic substrate having a honeycomb structure. Because the surface area of the catalyst becomes large, the catalyst combustion can have more excellent catalytic activity.

At the stage of grinding in the regulation of the conditions of reduction can be obtained a catalyst for the combustion of carbon-containing material having a desired grain size.

Preferably at the stage of grinding the catalyst for the combustion of carbon-containing material can have an average diameter is adjusted to be equal to or less than 50 μm. In that case, when the average diameter exceeds 50 μm, when a ceramic substrate is covered with cat what lyst combustion of carbon-containing material, the ceramic substrate may be clogged, or the number of the fixed catalyst can be easily changed. The average diameter of the catalyst may be preferably equal to or less than 10 microns.

The average diameter of the catalyst for combustion of carbon-containing material can be measured, for example, diffraction/diffusion device to measure the distribution of grain size or scanning electron microscope.

The above catalyst for the combustion of carbon-containing material is used by being mounted on the ceramic substrate.

The above catalyst for the combustion of carbon-containing material obtained by the stage of firing, which comprises firing a mixture (solid) aluminosilicate (sodalite) and a source of alkali metal and/or source of alkaline earth metal at a temperature of 600°C or higher. Thus obtained, the structure of the catalyst combustion retains an element of the alkali metal and/or alkaline earth element metal of relatively high torque connections. Thus, the catalyst for the combustion of carbon-containing material may make it difficult leaching of the alkali metal and/or alkaline earth metal, when the catalyst is fixed on the ceramic substrate. In addition, the catalyst combustion can prevent the destruction of the ceramic substrate you item alkali metal and alkaline earth metal.

On the contrary, when the unfired mixture is fixed on the ceramic substrate, Na from sodalite, the element of the alkali metal from a source of alkali metal and alkaline earth element metal from a source of alkaline earth metal can destroy the ceramic substrate.

Thus, in the first embodiment of the present invention stage firing is carried to the fixing of the catalyst on the ceramic substrate without fixing the mixture on the ceramic substrate.

In the second embodiment of the present invention a catalyst for the combustion of carbon-containing material obtained by the method of obtaining the first variant of the invention, is used for burning and removal of carbonaceous material carbon stuff (PM) or the like contained in the exhaust gas of the internal combustion engine such as a gasoline engine or a diesel engine.

Next, the following will be described a fifth variant of the present invention.

At the stage of firing fifth variant of the invention sodalite is fired at a temperature of 600°C or higher.

Sodalite represented by General formula 3(Na2O·Al2O3·2SiO2).2NaX, in which X represents an atom or atomic group monatomic anion, for example, HE or halogen, such as F, Cl, Br, I, or similar.

When the firing temperature at the stage of burning is below 600°C, it is difficult in order to teach the catalyst for the combustion of carbon-containing material, have the desired effect. Thus, in this case, the catalytic activity of the catalyst for combustion of carbonaceous material obtained for the combustion of carbon-containing material, can be reduced. Preferably, the firing temperature may be equal to or higher than 700°C.

When the firing temperature is 1200°C or higher, sodalite can be easily washed at the stage of firing. Thus, the catalyst for the combustion of carbon-containing material obtained after the stage of burning, immediately goes into a molten state, and therefore it can give increased hardness of the catalyst. As a result, it can be difficult to adjust the size of the catalyst for combustion of carbon-containing material to the desired size of the grains in the implementation stage grinding stage after firing, described below.

Thus, at the stage of firing sodalite preferably fired at a temperature of 700-1200°C.

The firing temperature at the stage of firing represents the temperature of the sodalite and not the ambient temperature. Thus, at the stage of firing, the firing is carried out so that the temperature of the actual solid material is 600°C or higher. At the stage of firing fired at a firing temperature is preferably within one hour or longer, preferably for five hours or more, and more PR is doctitle for ten hours or more.

The method of producing catalyst combustion preferably includes a step of pulverizing the catalyst for the combustion of carbon-containing material obtained after the stage of firing.

Can be obtained powdery catalyst for the combustion of carbon-containing material. This powdered catalyst combustion of carbon-containing material can be easily secured, for example, on a ceramic substrate having a honeycomb structure. Because the surface area of the catalyst becomes large, the catalyst combustion can have more excellent catalytic activity.

Under grinding conditions grinding can be suitably adjusted to obtain a catalyst combustion of carbon-containing material having a desired grain size. In particular, similarly to the first embodiment of the present invention a catalyst for the combustion of carbon-containing material can have an average diameter, adjusted to be equal to or less than 50 μm and more preferably 10 μm or less.

The above catalyst for the combustion of carbon-containing material is used by being mounted on the ceramic substrate.

The catalyst combustion, obtained a stage of firing, firmly holds the element of the alkali metal (Na) a relatively large force connection and, thus, makes it difficult vimean the e element of the alkali metal, when the catalyst is fixed on the ceramic substrate, therefore preventing the destruction of the ceramic substrate is washed element of the alkali metal.

On the contrary, when the unfired sodalite is fixed on the ceramic substrate, the element of the alkali metal (Na) sodalite washed away during heating or after fixing sodalite on the substrate, and therefore washed sodalite can destroy a ceramic substrate.

In other words, in the fifth embodiment of the present invention stage firing is carried out to consolidate the sodalite ceramic substrate, thus, without fastening the sodalite ceramic substrate.

In the sixth embodiment of the present invention a catalyst for the combustion of carbon-containing material obtained by the method of obtaining a fifth variant of the invention, is used for burning and removal of carbonaceous material carbon stuff (PM) or the like contained in the exhaust gas of the internal combustion engine such as a gasoline engine or a diesel engine.

Next, with reference to the accompanying drawings will be described methods of obtaining the catalyst carrier according to the third and seventh preferred variants of the present invention and a carrier catalyst according to the fourth and eighth preferred variants of the present invention.

SPO is about getting the third variant of the present invention has the same form, as the seventh variant of the invention, except the catalyst for the combustion of carbon-containing material. The catalyst carrier of the fourth variant of the invention has the same form as the eighth variant of the invention, except for the catalyst combustion.

Thus, the method of obtaining the third variant of the present invention uses a catalyst for the combustion of carbon-containing material obtained by the method of obtaining the first variant of the invention. The method includes a step of fixing the catalyst for the combustion of carbon-containing material on a ceramic substrate obtained catalyst carrier according to the fourth variant of the invention. A method of obtaining a seventh variant of the present invention uses a catalyst for the combustion of carbon-containing material obtained by the method of obtaining a fifth variant of the invention. The method includes a step of fixing the catalyst for the combustion of carbon-containing material on a ceramic substrate obtained catalyst carrier according to the eighth version of the invention.

At the stage of fixing preferably, at least the catalyst for the combustion of carbon-containing material and the Sol or suspension of oxide ceramic particles are mixed with the formation of the composite material, and a ceramic substrate preferably is covered with a composite material to heat.

In particular, the first catalyst combustion of carbon-containing material and the Sol or suspension of oxide ceramic particles are mixed with the formation of the composite material. Solvent, such as water, optionally injected into the composite material, if necessary, by regulation in the viscosity of the composite material to the proper values. The ceramic substrate is covered with the thus obtained suspension of the composite material to heat.

In this case, as shown in Fig, the above catalyst for the combustion of carbon-containing material 1 and the oxide ceramic particles 15 are fired on the ceramic substrate 22, so that it is possible to easily obtain the catalyst carrier 2 carrying the catalyst combustion 1 on the ceramic substrate 22. On the ceramic substrate 22 is formed connective layer 155 including an oxide ceramic particles 15, connected together. Thus, it can be obtained catalyst carrier 2 containing a catalyst for the combustion of 1 or catalytic particles dispersed in the connective layer 155.

The catalyst carrier 2 with such a structure holds the catalyst for the combustion of carbon-containing material 1 connecting layer 155. Thus, the catalyst combustion 1 or catalytic particles, it is difficult to fall out during use, to support the content in the catalytic activity.

Preferably the above-mentioned oxide ceramic particles include one or more elements selected from the group consisting of aluminum oxide, silicon dioxide, titanium oxide and zirconium oxide.

In this case, as can be easily formed interconnect layer having a large specific surface area, the surface area of the catalyst carrier can be increased. As a result, the catalyst for the combustion of carbon-containing material has a tendency to contact with carbonaceous material, so that the catalyst carrier can provide a more efficient combustion of carbon-containing material.

Ceramic substrate for use may be a substrate consisting, for example, cordierite, alumina, aluminum titanate, SiC or titanium oxide.

Ceramic substrate for use may be a substrate having, for example, granulomatous form filldropdown form panopoulou form a monolithic form of an inflated type or similar.

Preferably, the ceramic substrate may be composed of cordierite, SiC or aluminum titanate. More preferably, the ceramic substrate may have a honeycomb structure. In this case, the catalyst carrier may be more suitable for purification of exhaust gas.

The honeycomb structure includes an outer PE everynow wall, a partition provided in the form of a honeycomb inside the outer peripheral wall, and the cells separated by partitions and with the penetration of both ends of the structure. The honeycomb structure for use may be a structure in which all the cells are open at both ends. Alternative cell structure for use may be another structure, in which some portion of the cells is open at both ends of the honeycomb structure, and the remaining cells are closed by stoppers formed at both ends.

The catalyst carrier can carry not only the above-mentioned catalyst for the combustion of carbon-containing material, but also one or more kinds of rare earth elements on the ceramic substrate. Rare earth elements for use may be, for example, Ce, La, Nd and the like. As the above-mentioned rare earth element can be used an oxide particles of rare earth elements.

In this case, the status of rare-earth element causes the absorption and desorption of oxygen, therefore additionally promotora combustion of carbon-containing material.

On Fig shows an example of the catalyst carrier 2 for bearing rare earth element 16 together with a catalyst for the combustion of carbon-containing material 1 on the substrate 22. This media was pushing the jam 2 can be obtained by mixing the catalyst for the combustion of carbon-containing material 1, rare earth element 16 and, for example, Zola oxide ceramic particles 15 or similar, with the additional introduction of water into the mixture, if necessary, to adjust the mixture to the proper viscosity and firing the thus obtained suspension of the composite material on the ceramic substrate 22. In this case the catalyst carrier 2, which includes the connecting layer 155 containing oxide ceramic particles 15, United together, and formed on the ceramic substrate 22. The catalyst for the combustion of carbon-containing material 1 and rare earth element 16, dispersed in the connective layer 155 are mounted on the catalyst carrier 2.

The catalyst carrier can carry a noble metal, if required, in addition to the catalyst combustion of carbon-containing material. In this case, can be further improved catalytic activity of the catalyst for combustion to the combustion of carbon-containing material. Also, since the catalyst for the combustion of carbon-containing material has excellent catalytic activity, the amount of deposited noble metal, which is relatively expensive, can be significantly reduced compared with the conventional case. The noble metal includes, for example, Pt, Pd, Rh, etc.

On Fig poisonpill catalyst carrier 2, in which the catalyst for the combustion of carbon-containing material 1, the rare earth element 16 and a noble metal 17 dispersed in the connective layer 155 containing oxide ceramic particles 15, connected together. Such catalyst carrier 2 can be obtained by mixing the catalyst for the combustion of carbon-containing material 1, the rare earth element 16, for example, Zola oxide ceramic particles 15 or the like, and complex precious metal additional introduction of water into the mixture, if necessary, to adjust the mixture to the proper viscosity and firing the thus obtained suspension of the composite material on the ceramic substrate 22.

As shown in Fig, noble metal 17 is preferably attached to the oxide ceramic particles 15. When the rare earth element oxide contains particles of a rare earth element, as shown in Fig, noble metal 17 is preferably attached to the oxide particles 16 rare earth element.

The above catalyst carrier can form a layer of noble metal 17, made of a noble metal, as shown in Fig and 24.

As shown in Fig, a layer of noble metal 17 may be formed on the coupling layer 155 containing a catalyst for the combustion of carbon-containing material 1, attached is the ceramic substrate 22. Thus, the connecting layer 155 containing a catalyst for the combustion of carbon-containing material 1, is formed on the ceramic substrate 22, and a layer of noble metal 17 may be formed on the coupling layer 155.

In this case, the catalyst carrier can be prevented poisoning alkali metal and/or alkaline earth metal catalyst for the combustion of carbon-containing material 1.

As shown in Fig, a layer of noble metal 17 may be formed between the ceramic substrate 22 and the connecting layer 155 containing a catalyst for the combustion of carbon-containing material 1. Thus, the layer of noble metal 17 may be formed on the ceramic substrate 22, and the connecting layer 155 containing a catalyst for the combustion of carbon-containing material 1 may be formed on the layer of the noble metal 17.

In this case, the alkali metal and/or alkaline earth metal catalyst combustion of carbon-containing material 1 can be prevented from moving to the ceramic substrate 22 made of ceramic, in order to prevent further corrosion of the ceramic substrate 22.

EXAMPLES

Example 1

Hereinafter the present invention will be described using the following examples.

In this example, the catalyst for the combustion of carbon-containing material used is La burning and removal of carbonaceous material, contained in the exhaust gas from the internal combustion engine, get to studying the characteristics of the promotion combustion of carbon-containing material (e.g., carbon).

In this example, the catalyst for the combustion of carbon-containing material was obtained in the implementation stage of the firing, which includes the firing of sodalite at a temperature of 600°C or higher.

In particular, first get the powder sodalite (3(Na2O·Al2O3·2SiO2)·2NaX).

Then sodalite calcined at a temperature of 1000°C or higher. In particular, sodalite is heated at a rate of temperature increase of 100°C/h After the temperature of the sodalite reaches the firing temperature of 1000°C, sodalite kept at it for 10 hours with the implementation in the stage of firing. Then, the thus obtained sintered material is pulverized to have an average diameter of 10 μm or less, and a maximum grain size of 100 μm or less is obtained powdery catalyst for the combustion of carbon-containing material. Powdery catalyst for the combustion of carbon-containing material is called as "sample E1".

Then examine the characteristics of the promotion combustion of carbon-containing material of the catalyst for combustion of carbon-containing material (sample E1)obtained in this example. As compare inogo example, examine the characteristics of the promotion of combustion (noble metal)containing the catalyst (Pt powder and powder of potassium carbonate.

In particular, first, 200 mg of catalyst particles (for example, sample E1 (noble metal containing catalyst or powder potassium carbonate) and 20 mg of carbon black (CA)(CB)), respectively, measure the exact electronic scales. These catalytic particles mixed in for some time using an agate mortar, so that the ratio of catalytic particles (mass) to CONDITION (weight) is 10:1, and the result is three types of test samples containing catalytic particles and carbon soot. As a comparative sample get sample for testing from one CONDITION without the use of catalytic particles. The sample for testing from one CONDITION then stirred for some time using an agate mortar similar to the other samples. In other words, the samples for testing are four types of samples, namely the sample one CONDITION, a mixture of noble metal containing catalyst and services, the mixture of sample E1 and MOUSTACHE and a mixture of potassium carbonate and MOUSTACHE.

Then 6 mg of each sample for testing is heated to a maximum temperature of 900°C at a rate of temperature increase of 10°C/min with burning in the US. In this case, determine the DTA exothermic peak temperature of each sample for testing using the device due to the military conduct thermal analysis-differential thermogravimetric analysis(TG-DTA) (TG-DTA)) (device “TG8120”, produced by Rigaku Industrial Co., Ltd.). Determine the DTA exothermic peak temperature of 0.5 mg of sample for testing from the same CONDITION. The heating is carried out, allowing air to pass through the sample for testing with flow rate 50 ml/min figure 1 shows the measurement results of the DTA exothermic peak temperatures when using the appropriate catalytic particles.

Next, 1 g of each sample for testing (sample E1 (noble metal)containing the catalyst or powder potassium carbonate) is introduced into 500 cm3water and mix night and day, in order to wash out. Then after washing with water the catalytic particle filter. The filtered catalyst particles sufficiently washed by passing through them 1500 cm3water and then dried. Then after washing with water, 200 mg of each type of catalytic particles (sample E1 and (noble metal)containing the catalyst) and 20 mg of carbon black (US) accurately measure the electronic scales. Each type of catalytic particles and carbon black are mixed in for some time using an agate mortar, so that the ratio of catalytic particles (mass) to CONDITION (weight) is 10:1, and the result is two types of test samples containing catalytic particles and carbon soot. The test pieces made of one who, washed, dried, and then mixed using an agate mortar similar to the other samples. The sample for testing, using potassium carbonate as catalyst particles, water-soluble operation of washing with water, and thus, the subsequent processes cannot be performed. In other words, samples for testing after washing with water include three types of samples, namely the sample one CONDITION, a mixture of noble metal containing catalyst and the MUSTACHE and the mixture of sample E1 and services. Again determine the DTA exothermic peak temperature of each sample for testing using device simultaneous thermal analysis-differential thermogravimetric analysis (TG-DTA). Figure 1 shows the measurement results of the DTA exothermic peak temperatures of the respective test specimens after washing with water.

As you can see in figure 1, the sample using the sample E1, and the sample using potassium carbonate, everyone has low DTA exothermic peak temperature before washing with water and can cause burning of carbon-containing material (AMT) at a relatively low temperature. As you can see in figure 1, the sample E1 has an exothermic peak around 450°C, but actually starts the combustion of carbon at a lower temperature (for example, about 400°C).

p> Also, as you can see in figure 1, a sample of one CONDITION (noble metal)containing the catalyst and the sample E1 is almost not change the characteristics of the promotion of burning for US before and after washing with water. On the other hand, in the sample, using potassium carbonate as potassium carbonate dissolved in water after washing with water, it is impossible to determine the characteristics of the promotion of combustion of the sample.

Thus, the sample E1 has excellent characteristics promotion for burning carbonaceous material and can ensure stable combustion and the removal of carbon-containing material at a low temperature. In addition, the sample E1 can maintain excellent performance even in the presence of water and, thus, can provide stable combustion of carbon-containing material in a long time.

In this example, the sodalite calcined at a firing temperature that is different from sample E1, so getting the three types of catalysts.

Thus, in the sample E1 sodalite calcined at a firing temperature of 1000°C for holding time of 10 hours, but three types of catalysts obtained by way of firing at a firing temperature of 700°C for holding time of 10 hours at a firing temperature of 600°C for holding time of 10 hours, and when the firing temperature of 500°C for exposure times of 10 h with the responsibility. Specifications promotion burning of the three catalysts for the combustion of carbonaceous material examined in the same manner as the characteristics of the sample E1. In this case, examine the characteristics of the promotion burning powder sodalite carbonaceous material (powder) is used for catalyst combustion of carbon-containing material as a comparative example. Use powder sodalite, remaining for about 10 h at room temperature, approximately 25°C instead of firing. Characterization promotion burning exercise when determining the DTA exothermic peak temperature of each catalyst in the same manner as for sample E1. Figure 2 also shows the result for sample E1, and the catalyst for the combustion of carbon-containing material was fired at a firing temperature of 1000°C.

As you can see in figure 2, the DTA exothermic peak temperatures of the catalysts for the combustion of carbon-containing material obtained by firing sodalite at a temperature of 600°C or above, have very low values of 500°C or below. DTA exothermic peak temperatures of the catalyst noble metal (Pt), usually used as catalyst for the combustion of carbon-containing material, is approximately 520°C (see figure 1). It is clear that these rolled atory combustion of carbon-containing material each has a fairly excellent catalytic activity towards carbon-containing material.

The catalyst for the combustion of carbonaceous material obtained by firing at a temperature of 600°C or above, also has the DTA exothermic peak temperature, which is equal to or below the DTA exothermic peak temperature of the catalyst noble metal (Pt) after washing with water, and can maintain excellent catalytic activity after washing with water.

On the contrary, the catalyst obtained by calcining at 500°C shows the DTA exothermic peak temperature of about 520°C at the same level as the temperature of the catalyst noble metal (Pt) before washing with water. However, after washing with water DTA exothermic peak temperatures of the catalyst is increased to about 540°C, and the catalytic activity is reduced compared to the catalyst of a noble metal. Unfired sodalite has insufficient catalytic activity for the combustion of carbon-containing material whether before or after washing with water.

In the present example, various types of zeolites, other than sodalite (SOD), burn for comparison with the sample E1 and then, using these catalysts, exploring the characteristics of the promotion of burning.

In particular, first as zeolite, other than sodalite, get twelve types of zeolites with different zeolite structures (for example, BEA,FAU-type FER-type LTA-type, LTL-type MFI-type and MOR-type) and/or different ratios of SiO2/Al2O3zeolite compositions (see Fig).

These zeolites are manufactured by the company Tosoh Corporation. On Fig shows the product name of each zeolite type zeolite structure and the ratio of SiO2/Al2O3. Names of zeolites shown in Fig and 3, described later, correspond to the names of zeolites produced by the company Tosoh Corporation. On Fig also shown sodalite (SOD)used to obtain the sample E1.

Then various zeolites shown in Fig, calcined in the same manner as the sample E1. In particular, each type of zeolite is heated at a rate of temperature increase of 100°C/h After the temperature of the solids reaches the firing temperature of 1000°C, the solid is kept at it for 10 hours, exposing stage firing. After this, the thus obtained sintered material is pulverized to have an average diameter of 10 μm or less, and a maximum grain size of 100 μm or less, which results in a powdery catalyst. Specifications promotion combustion of carbon-containing material of these catalysts are examined in the same manner as for sample E1. It should be noted that the characteristics of the promotion of combustion catalysts after s is mevki water is not carried out. Figure 3 shows the results. Figure 3 also shows the result for sample E1, obtained by calcination of sodalite as “SOD”.

As can be seen in figure 3, when in use as a catalyst material obtained by calcining the zeolite other than sodalite, the DTA exothermic peak temperatures of the catalyst is very high, and the characteristics of the promotion combustion catalyst for carbon-containing material are insufficient. On the contrary, the catalyst obtained by calcining SOD (sample 1)shows very low DTA exothermic peak temperature of about 450°C. Thus, the catalyst can provide the combustion of carbon-containing material at a low temperature. Thus, it is necessary to choose the sodalite among zeolites at the stage of firing.

As described above, in the present example, the firing of sodalite at a temperature of 600°C or higher may provide the catalyst for the combustion of carbon-containing material, which can ensure stable combustion and the removal of carbon-containing material at a low temperature for a long time.

Example 2

In this example, the catalyst for the combustion of carbon-containing material is produced by phase mixing, stage drying and stage firing.

Thus, at the stage of mixing an aluminosilicate having an atomic equivalent ratio of Si/Al≥1, and istocnikach metal and/or a source of alkaline earth metal is mixed in the water. Then at the stage of drying the liquid mixture after stage mixture is heated for evaporation of water results in solids. After that, at the stage of firing the solid is calcined at a temperature of 600°C or higher with getting in the catalyst combustion of carbon-containing material.

In particular, in the beginning a powder sodalite 3(Na2O·Al2O3·2SiO2)·2Na), as aluminosilicate having an atomic equivalent ratio of Si/Al≥1. Then, 100 parts by weight of sodalite and 5 parts by weight of calcium carbonate is injected into the water and mix in the water.

Then at the stage of drying the liquid mixture is heated at a temperature of 120°C for evaporation of water. So, get a solid substance, which is a mixture of sodalite and potassium carbonate.

Then the solid is calcined at a temperature of 800°C. In particular, sodalite is heated at a rate of temperature increase of 100°C/h After the temperature of the sodalite reaches the firing temperature of 800°C, sodalite kept at it for 10 hours with the implementation in the stage of firing.

Then, the thus obtained sintered material is pulverized to have an average diameter of 10 μm or less, and a maximum grain size of 100 μm or less is obtained powdery catalyst for the combustion of carbon-containing material. Powdered cat is the lyst combustion of carbon-containing material is called as "sample E2".

Then examine the characteristics of the promotion combustion of carbon-containing material of the catalyst for combustion of carbon-containing material (sample E2)obtained in this example. As a comparative example, examine the characteristics of the promotion of combustion (noble metal)containing the catalyst (Pt powder and powder of potassium carbonate.

First, in the same manner as in example 1, receive four types of samples for testing, namely the sample one CONDITION, a mixture of noble metal containing catalyst and services, the mixture of sample E2 and MOUSTACHE and a mixture of potassium carbonate and MOUSTACHE.

Then 6 mg of each sample for testing is heated to a maximum temperature of 900°C at a rate of temperature increase of 10°C/min with burning in the US. In this case, determine the DTA exothermic peak temperature of each sample for testing using device simultaneous thermal analysis-differential thermogravimetric analysis(TG-DTA) (TG-DTA)) (device “TG8120”, produced by Rigaku Industrial Co., Ltd.). Determine the DTA exothermic peak temperature of 0.5 mg of sample for testing from the same CONDITION. The heating is carried out, allowing air to pass through the sample for testing with flow rate 50 ml/min figure 4 shows the measurement results of the DTA exothermic peak temp the temperature when using the appropriate catalytic particles. Figure 5 shows the results of determining the relationship between temperature and TG using one CONDITION. Figure 6 shows the results when using the noble metal containing catalyst as the catalytic particles. 7 shows the results when using2CO3. On Fig shows the results when using the sample E2. On each of 5-8 the longitudinal axis shows the DTA exothermic peak temperature showing the maximum rate of combustion of carbon soot.

Next, 1 g of each type of catalytic particles (sample E2 (noble metal)containing the catalyst or powder potassium carbonate) is introduced into 500 cm3water and mix night and day, in order to wash out. Then after washing with water the catalytic particle filter. The filtered catalyst particles sufficiently washed by passing through them 1500 cm3water and then dried at a temperature of 120°C. Then, after washing with water, 200 mg of each type of catalytic particles (sample E2 and (noble metal)containing the catalyst) and 20 mg of carbon black (US) accurately measure the electronic scales. Each type of catalytic particles and carbon black are mixed in for some time using an agate mortar, so that the ratio of catalytic particles (mass) to CONDITION (weight) is 10:1, and is the result of two kinds of samples for testing, containing catalytic particles and carbon soot. The test pieces made from the same CONDITION, washed, dried, and then mixed using an agate mortar similar to the other samples. The sample for testing, using potassium carbonate as catalyst particles, water-soluble operation of washing with water, and thus, the subsequent process could not be carried out. In other words, samples for testing after washing with water include three types of samples, namely the sample one CONDITION, a mixture of noble metal containing catalyst and the MUSTACHE and the mixture of sample E2 and services. Again determine the DTA exothermic peak temperature of each sample for testing using device simultaneous thermal analysis-differential thermogravimetric analysis (TG-DTA). Figure 4 shows the measurement results of the DTA exothermic peak temperatures of the respective test specimens after washing with water.

As can be seen in figure 4-8, sample, using the sample E2, and the sample using potassium carbonate, everyone has low DTA exothermic peak temperature before washing with water and, thus, can cause burning of carbon-containing material (AMT) at a relatively low temperature. As can be seen in figure 4, and 8, the sample E2 is esotericism the th peak of about 400°C, but the burning of carbon actually begins even at a lower temperature (for example, about 350°C)than the DTA exothermic peak temperatures.

As can be seen in figure 4, a sample of one CONDITION (noble metal)containing the catalyst and the sample E2 is almost not change the characteristics of the promotion of burning for US before and after washing with water. On the contrary, in the sample, using potassium carbonate, potassium carbonate dissolved in water after washing with water, and therefore it is impossible to determine the characteristics of the promotion of burning.

Accordingly, the sample E2 has excellent characteristics promotion for burning carbonaceous material and, thus, can provide stable combustion and the removal of carbon-containing material at a low temperature. Because the sample E2 can maintain excellent performance even in the presence of water, the sample E2 can ensure stable combustion of carbon-containing material in a long time.

The above sample E2 is a catalyst obtained by calcining a mixture of 100 parts by weight of sodalite and 5 parts by weight of potassium carbonate at a temperature of 800°C for 10 h In the present example, then, in order to investigate the influence of firing temperature on the catalytic activity of the mixture (solid) sodalite and potassium carbonate calcined at p is slichnih temperatures by obtaining a variety of catalysts.

In particular, first, 100 parts by weight of sodalite and 10 parts by weight of potassium carbonate are mixed in water to form a liquid mixture. Then the liquid mixture is heated at a temperature of 120°C for evaporation of water results in a solid substance (mixture). The mixture is then fired at different firing temperature, for example, 500°C, 600°C, 700°C, 800°C, 900°C, 1000°C, 1100°C, 1200°C and 1300°C, which results in nine types of catalysts. These catalysts have the same way, except for changing the firing temperature, and in the same manner as sample 2, except for changing the mixing ratio of potassium carbonate and sodalite and firing temperature. In addition, in order to investigate the influence of the time of firing, the firing at a temperature of 600°C, to get not only a catalyst obtained by calcining for 10 hours like the sample E2, but also a catalyst obtained by firing during the time of firing 5 o'clock the Firing of other catalysts, obtained by firing at other temperatures firing is carried out for 10 hours like the sample E2.

Specifications promotion combustion of carbon-containing material of these catalysts are examined in the same manner as sample characteristics E2. In this case also examine the characteristics of the promotion combustion of a mixture of sodalite and potassium carbonate for carbon-containing material as a comparative PR is a measure. Instead fired a mixture of sodalite and potassium carbonate, left for 10 hours at room temperature of about 25°C.

Characterization promotion burning exercise when determining the DTA exothermic peak temperature in the same manner as for sample E2. The results are shown in Fig.9.

As can be seen in Fig.9, the DTA exothermic peak temperatures of the catalyst for combustion of carbonaceous material obtained by firing at a temperature of 600°C or higher is equal to or below 460°C before and after washing with water, which is very low. DTA exothermic peak temperatures of the catalyst noble metal (Pt), usually used as catalyst for the combustion of carbon-containing material, is approximately 520°C (see figure 4). Thus, it is possible to see that such a catalyst for the combustion of carbon-containing material has a sufficiently excellent catalytic activity towards carbon-containing material.

On the contrary, the catalyst calcined at temperatures below 600°C, shows a fairly low DTA exothermic peak temperature compared with the catalyst of noble metal (Pt) before washing with water and shows excellent catalytic activity. However, after washing with water DTA exothermic peak temperature is utilizator increases significantly and its catalytic activity is reduced compared to a catalyst of a noble metal. The unburnt mixture sodalite and potassium carbonate has sufficient catalytic activity to leaching by water, but has a catalytic activity, significantly reduced after washing.

The reason that the catalyst obtained by the step of calcining at a temperature below 600°C, and the catalyst obtained without the stage of firing, have catalytic activity, significantly reduced after washing with water, as described above, consists in leaching of potassium after washing with water.

Thus, it is necessary to carry out the stage of firing at a firing temperature of 600°C or higher. As can be seen in Fig.9, the firing at a temperature of 700-1200°C can provide the catalyst for the combustion of carbonaceous material having a lower DTA exothermic peak temperature, thus, excellent catalytic activity. In addition, as can also be seen in the same figure, the loss of catalytic activity after washing with water, catalyst, annealed for 10 h, is suppressed compared with the case of the catalyst, calcined for 5 hours

In the examples, as described above, at the stage of mixing the potassium carbonate is mixed as a source To sodalite with obtaining the catalyst for the combustion of carbon-containing material. In the present example, the sodalite mix different types of potassium salts with many catalysts for the combustion of carbon-containing material and then determine the DTA exothermic peak temperature of the catalyst.

In particular, each of potassium salts (e.g. potassium carbonate, potassium nitrate, potassium chloride, potassium sulfate, potassium acetate, potassium phosphate and potassium hydrate) is mixed with sodalite with the mixture. Each potassium salt is mixed with sodalite so that the number of the element potassium salt potassium is 0,225 mol or 0,00225 mol relative to 1 mol of the element Si of sodalite. The mixing is carried out in water as the sample E2, and the liquid mixture is dried from water getting in the mixture, as described above.

The mixture is then heated at a rate of temperature increase of 100°C/h After the temperature of the solid material reaches the firing temperature of 1000°C, the mixture was kept at it for 10 hours, thus exposing stage firing. After this, the thus obtained sintered material is pulverized to have an average diameter of 10 μm or less, and a maximum grain size of 100 μm or less, which results in powdered catalyst.

DTA exothermic peak temperature of each of the thus obtained catalysts burning before and after washing with water determined in the same manner as for sample E2. The results are shown in figure 10. Figure 10 reference figure X1 shows the state before washing with water, in which the number of element of the alkali metal (quantity) of each salt of an alkali metal or STA is in the element of the alkali earth metal (quantity) salts of alkaline earth metal is 0,225 mol relative to 1 mol of the element Si of sodalite. Reference numeral X2 shows the state after washing with water, in which the number of element of the alkali metal (quantity) of each salt of the alkali metal or the number of element of the alkali earth metal (quantity) salts of alkaline earth metal is 0,225 mol relative to 1 mol of the element Si of sodalite. Reference numeral X3 represents before washing with water, in which the number of element of the alkali metal (quantity) of each salt of the alkali metal or the number of element of the alkali earth metal (quantity) salts of alkaline earth metal is 0,00225 mol relative to 1 mol of the element Si of sodalite. Reference numeral X4 shows the state after washing with water, in which the number of element of the alkali metal (quantity) of each salt of the alkali metal or the number of element of the alkali earth metal (quantity) salts of alkaline earth metal is 0,00225 mol relative to 1 mol of the element Si of sodalite.

As can be seen in figure 10, any catalyst for the combustion of carbon-containing material obtained using any of the salts of potassium, shows excellent catalytic activity before and after washing with water. Reducing the amount of salt potassium slightly reduces the catalytic activity. Even in this case, the catalyst supports DTA exothermic pickova the temperature below 450°C before and after washing with water, showing excellent catalytic activity.

In the above example, at the stage of mixing the potassium salt mix as a source of alkali metal (for example, salt is an alkali metal) with sodalite with obtaining the catalyst for the combustion of carbon-containing material. Then, in the present example, at the stage of mixing in addition to the potassium salt with sodalite mix different sources of alkali metal or alkaline earth metal with many catalysts for the combustion of carbon-containing material. Determine the DTA exothermic peak temperatures of these catalysts.

In particular, first, each of the various salts of alkali metal (e.g. sodium carbonate, potassium carbonate, rubidium carbonate and cesium carbonate), or any of the various salts of the alkali earth metal (for example, a hydrate of magnesium, calcium carbonate, strontium carbonate and barium carbonate) is mixed with sodalite with the mixture. Every salt of an alkali metal or alkali earth metal salt is mixed with sodalite so that the number of element of the alkali metal of each alkali metal salt or the number of element of the alkali earth metal salt, alkaline earth metal is 0,225 mol or 0,00225 mol relative to 1 mol of the element Si of sodalite. In addition, the mixing is carried out in water in the same way as for education is CA E2, and liquid mixture is dried by evaporation of water, as indicated above, results in a mixture.

The mixture is then heated at a rate of temperature increase of 100°C/h After the temperature of the solid material reaches the firing temperature of 1000°C, the mixture was kept at it for 10 hours with the implementation in the stage of firing. After this, the thus obtained sintered material is pulverized to have an average diameter of 10 μm or less, and a maximum grain size of 100 μm or less, which results in powdered catalyst.

DTA exothermic peak temperature of the thus obtained catalysts combustion determined in the same manner as for sample E2. The results are shown figure 11. Figure 11 cross-axis shows the particles of the alkali metal source is an alkali metal and particles of alkaline earth metal source, alkaline earth metal, introduced at the stage of mixing, and the longitudinal axis shows the DTA exothermic peak temperature. Figure 11 reference numeral Y1 represents before washing with water, in which the number of element of the alkali metal source is an alkali metal or the number of element of the alkali earth metal source, alkaline-earth metal is 0,225 mol relative to 1 mol of the element Si of sodalite. Figure 11 reference numeral Y2 p which shows the condition after washing with water, in which the number of element of the alkali metal source is an alkali metal or the number of element of the alkali earth metal source, alkaline-earth metal is 0,225 mol relative to 1 mol of the element Si of sodalite. Figure 11 reference numeral Y3 represents before washing with water, in which the number of element of the alkali metal source is an alkali metal or the number of element of the alkali earth metal source, alkaline-earth metal is 0,00225 mol relative to 1 mol of the element Si of sodalite. Figure 11 reference Y4 figure shows the state after washing with water, in which the number of element of the alkali metal source is an alkali metal or the number of element of the alkali earth metal source, alkaline-earth metal is 0,00225 mol relative to 1 mol of the element Si of sodalite.

As you can see in figure 11, the catalyst for the combustion of carbonaceous material obtained by mixing each of the different elements of an alkali metal (for example, Na, K, Rb, Cs) c sodalite at the stage of mixing, shows excellent catalytic activity before and after washing with water, even when using any of the elements of the alkali metal.

In contrast, the catalysts of combustion produced by mixing various elements of the alkaline earth metals (for example, Mg, Ca, Sr, Ba) with sodalite at a hundred the AI mixing. Although only a catalyst obtained by adopting Mg as an element of the alkali earth metal, shows slightly insufficient catalytic activity, any of the catalysts shows the catalytic activity of an acceptable level for practical use in any case.

Thus, the mixture of other elements, alkali metal elements or alkaline earth metal, other than, with sodalite can also provide a catalyst for the combustion of carbonaceous material having excellent catalytic activity.

Use case source of Mg as the source of alkaline earth metal will be described below in detail. As seen in figure 11, the catalyst obtained by adding 0,00225 mol Mg to sodalite with respect to 1 mol of the element Si sodalite, shows excellent catalytic activity. On the contrary, the catalyst obtained by adding 0,225 mol Mg, can in fact be used, but gives a reduction of catalytic activity. On the other hand, the catalysts obtained using other elements, alkaline earth metal (e.g., Ca, Sr, Ba), show excellent catalytic activity in any case.

Accordingly, when the alkaline earth metal is preferably used source of alkaline earth metal other than g. When using source Mg sodalite and source of Mg mixed so that the amount of Mg from the Mg source is preferably less than 0,225 mol and more preferably 0,00225 mol or less relative to 1 mol of the element Si of sodalite.

In the above example, at the stage of mixing one kind of alkali metal or alkaline earth metal is mixed with sodalite to obtain catalyst for the combustion of carbon-containing material. Then, in the present example, at the stage of mixing many elements of the alkali metal and/or alkaline earth elements, metal is mixed with sodalite to obtain catalysts for the combustion of carbon-containing material. Determine the DTA exothermic peak temperature of the catalyst.

In particular, the first source of alkali metal (e.g. sodium carbonate, rubidium carbonate or cesium carbonate) or a source of alkaline earth metal (for example, a hydrate of magnesium, calcium carbonate, strontium carbonate or barium carbonate) in addition to the potassium carbonate is mixed with sodalite with obtaining mixtures. Each of the thus obtained mixtures contains sodalite, potassium carbonate and the source of an alkali metal other than potassium carbonate, or the source of alkaline earth metal.

Each mixture was prepared as follows. Thus, the potassium carbonate as the source of potassium is added to when the Dalit so, the amount of potassium from the source of potassium is 0,1125 mol relative to 1 mol of the element Si of sodalite. Then each of the different sources of an alkali metal or sources of the alkali earth metal is added to the sodalite so that the number of element of the alkali metal from a source of alkaline earth metal or the number of element of the alkali earth metal from a source of alkaline earth metal is 0,1125 mol relative to 1 mol of the element Si of sodalite.

Thus, the total amount of potassium from potassium carbonate and quantity of another element of the alkali metal element or an alkaline earth metal is 0,225 mol relative to 1 mol of the element Si of sodalite in each mixture.

The mixing is carried out in water in the same manner as for sample E2, and the mixture is dried by evaporation of water, as indicated above, results in a mixture.

The mixture is then heated at a rate of temperature increase of 100°C/h After the temperature of the solid material reaches the firing temperature of 1000°C, the mixture was kept at it for 10 hours with the implementation in the stage of firing the mixture. After this, the thus obtained sintered material is pulverized to have an average diameter of 10 μm or less, and a maximum grain size of 100 μm or less, which results in catalyst combustion uglerodnom rasego material.

DTA exothermic peak temperature of the thus obtained catalysts burning before and after washing with water determined in the same manner as for sample E2. The results are shown in Fig. On Fig the longitudinal axis shows the DTA exothermic peak temperature, and the transverse axis shows the particles of the alkali metal from a source of alkali metal or particles of alkaline earth metal from a source of alkaline earth metal other than potassium carbonate, introduced at the stage of mixing. Fig also shows the DTA exothermic peak temperatures of the catalyst for combustion of carbon-containing material (i.e. the sample indicated by the reference number To the transverse axis Fig) before and after washing with water (catalyst) was obtained by mixing only potassium carbonate with sodalite and firing the mixture.

As you can see in Fig, at the stage of mixing, when each element of the alkali metal (e.g., Na, Rb, Cs) or alkaline earth elements, metal (such as Mg, Ca, Sr, Ba) in addition to potassium (K) is mixed with sodalite, the catalyst for the combustion of carbonaceous material having excellent catalytic activity, is also obtained as in the case of mixing one with sodalite.

Thus, when using multiple sources of an alkali metal and/or sources of alkaline earth metaluna stage of mixing can be obtained by catalytic combustion of carbon-containing material, having excellent catalytic activity.

Further, in the present example, in order to investigate the influence of the input source of an alkali metal or source of alkaline earth metal on the catalytic activity of the catalyst combustion, sodalite is mixed with a source of alkali metal or alkaline earth metal at different ratios introduction to the many catalysts for the combustion of carbon-containing material. Then determine the DTA exothermic peak temperatures of these catalysts.

First, potassium carbonate or barium carbonate is mixed in an amount of from 0 to 100 parts by weight with 100 parts by weight of sodalite with obtaining mixtures.

In particular, as shown in Fig and 26, described next, 100 parts by weight of sodalite (SOD) is mixed with potassium carbonate in an appropriate amount of 0 parts by weight, of 0.1 parts by weight and 0.5 parts by weight, 1 parts by weight, 3 parts by weight, 5 parts by weight, 10 parts by weight, 15 parts by weight, 20 parts by weight, 40 parts by weight and 100 parts by weight with results in mixtures.

As shown in Fig and 27, described next, 100 parts by weight of sodalite (SOD) is mixed with barium carbonate in an appropriate amount of 0 parts by weight, 5 parts by weight, 10 parts by weight, 15 parts by weight, 20 parts by weight, 40 parts by weight, 70 parts by weight, 100 parts by weight, 150 parts by weight, 200 parts by weight and 300 parts by weight with results in mixtures.

Such mixing is carried out in water in the same manner as for sample E2, and the liquid mixture is dried by evaporation of the odes, as described above, results in a variety of mixtures.

Then the above mixture is heated at a rate of temperature increase of 100°C/h After the temperature of the mixture reaches the firing temperature of 1000°C, the mixture was kept at it for 10 hours with the implementation in the stage of firing. After this, the thus obtained sintered material is pulverized to have an average diameter of 10 μm or less, and a maximum grain size of 100 μm or less, which results in catalyst combustion of carbon-containing material.

DTA exothermic peak temperature of the thus obtained catalysts burning before and after washing with water determined in the same manner as for sample E2.

On Fig and 26 shows the results of the DTA exothermic peak temperatures before and after washing with water, catalysts, combustion of carbonaceous material obtained by using potassium carbonate. On Fig and 27 shows the results of the DTA exothermic peak temperatures before and after washing with water, catalysts, combustion of carbon-containing material obtained with the use of barium carbonate.

On Fig shows the values obtained by converting the amount (parts by weight) mixing element To 100 parts by weight of sodalite in the number of the mixing element (mol) relative to the number of the TSS Si (mol) sodalite (see Fig). Similarly, on Fig shows the values obtained by converting the amount (parts by weight) mixing element VA on 100 parts by weight of sodalite in the number of mixing element BA (mol) relative to the number of Si (mol) sodalite (see Fig).

As you can see in Fig, 27, 13 and 14, even when the number of element of the alkali metal and/or the amount of alkaline earth metal is changed at the stage of mixing, the obtained catalysts for the combustion of carbon-containing material show excellent catalytic activity.

On the contrary, increasing the number of element of the alkali metal element or an alkaline earth metal increases the difference in the DTA exothermic peak temperature before and after washing with water. As you can see in Fig and 27, sodalite is mixed with a source of alkali metal or alkaline earth metal at the stage of mixing so that the number of element of the alkali metal (K)contained in the source of alkali metal (K2CO3), or the number of element of the alkali earth metal (BA)contained in the source of alkaline earth metal (VASO3), is equal to or less than 2.25 mol relative to 1 mol of the element Si of sodalite. Thus, it is possible to obtain a catalyst for the combustion of carbonaceous material having a relatively small difference in the DTA exothermic peak of the new temperature before and after washing with water, i.e. the catalyst for the combustion of carbonaceous material having excellent resistance to water. When the above number of element of the alkali metal or the number of element of the alkali earth metal exceeds 2.25 mol, mixture immediately easily melted during firing, and thus it is difficult to grind the catalyst for the combustion of carbon-containing material obtained after firing.

From this point of view, the number of element of the alkali metal (mol) or the number of element of the alkali earth metal (mol) is more preferably equal to or less than 1 mol, and more preferably equal to or less than 0.5 mol, relative to 1 mol of the element Si of sodalite at the stage of mixing.

As described above, according to the present example, the phase mixing stage and firing are carried out with obtaining the catalyst for the combustion of carbon-containing material, so that the carbonaceous material can stably be burned and removed at a low temperature for a long time.

Example 3

In this example, get the catalyst carrier 2 carrying the catalyst for the combustion of carbon-containing material (sample E2)obtained in example 2, the ceramic substrate having a ceramic honeycomb structure 22.

As shown in Fig-17, the ceramic substrate 22 of the present example includes an outer peripheral wall is ku 21, walls 25 formed in the shape of a honeycomb inside the outer peripheral wall 21, and the cells 3, separated by partitions 25. Cell 3 is partially open with the two ends 23 and 24 of the ceramic substrate 22. Thus, part of the cells 3 are open at both ends 23 and 24 of the ceramic substrate 22, while the remaining cells 3 are closed by plugs 32 formed at the two ends 23 and 24. As shown in Fig and 16 in this example, the holes 31 for opening ends of the cells 3 and the tube 32 for closing the ends of the cells 3 are arranged alternately to form a so-called checkerboard model. The catalyst for the combustion of carbon-containing material 1 (sample E2)obtained in example 2, is attached to the walls 25 of the ceramic substrate 22. As shown in Fig, the connecting layer 155, obtained by firing Sol of aluminum oxide, is formed on the partition walls 25, so that the catalyst for the combustion of carbon-containing material 1 is fixed in the connecting layer 155. The connecting layer 155 includes an oxide ceramic particles 15 are made of aluminum oxide and United together, and the catalyst for the combustion of 1 or catalytic particles are dispersed in the connective layer 155.

As shown in Fig, the part where the tube 32, and the other part where the tubes 32 are not located in the catalyst carrier 2 of the present example, R is sporogony, alternately, both ends of the cells located on the end 23 on the upper side, which is the inlet of the exhaust gas 10, and at the end of the 24 on the lower side, which is the release of the exhaust gas 10. In the partition 25 is formed a series of holes, allowing you to pass the exhaust gas 10.

The catalyst carrier 2 of the present example has a full size 160 mm in diameter and 100 mm in length. The cell has a size of 3 mm in thickness and pitch of 1.47 mm

The ceramic substrate 22 is made of cordierite. Cell 3 has a rectangular cross-section. Cell 3 can have other cross-sectional shape including a triangular shape, a hexagonal shape, etc.

In this example, the holes 31 for opening ends of the cells 3 and the tube 32 for closing the ends of the cells 3 are arranged alternately to form a so-called checkerboard model.

Next, described below is a method of obtaining a ceramic honeycomb structure of the present example.

First, talc, fused silica and aluminum hydroxide measure so as to form the desired composition of cordierite, and to the specified measured materials add a blowing agent, a binder, water, etc. that are mixed and stirred mixing machine. Thus obtained clay ceramic material is pressed and molded molding machine received the eat-molded element, having a cell shape. After drying, the molded element is cut into desired pieces, in order to obtain a molded element includes an outer peripheral wall, partition walls provided inside the walls in the honeycomb shape, and the cells separated by partitions and penetrating both ends. Then, the molded element is heated at a temperature of 1400-1450°C for 2-10 h for firing in time, in order to get burnt in the time element with a honeycomb structure.

Then on cell structure put sticky tape to fully cover both ends of the honeycomb structure. The laser beam down alternately to the parts of the adhesive tape in accordance with the provisions covered by plugs at the two ends of the ceramic honeycomb structure, and the adhesive tape is melted or burned out and removed with the formation of through holes. Thus, the through-hole are formed on parts of the ends of the cells is blocked by traffic jams. Parts other than the ends of the cells are covered with tape. In this example, through holes are formed in the sticky tape so that the through holes and the parts covered with masking tape, are located alternately on both ends of the cell. In this example, we used sticky tape is a polymer film having a thickness of 0.1 mm

Then talc, fused dioxide kremnyi aluminum hydroxide, representing the main source material for the tube material, measure so as to form a desired composition, and to the specified measured materials add a binder, water, etc. that are mixed and stirred mixing machine to obtain a suspension of the tube material. At the moment enter the pore-forming, if necessary. After receiving corps, including the suspension of the material tube, the end surface of the honeycomb structure partially having formed therein through holes, is dipped in a suspension material. Thus, the tube material is introduced into an appropriate number of through holes masking tape to the ends of the cells. The other end of the honeycomb structure is subjected to the same operations. The above provides a cell structure in which the tube material is located in the overlapped holes cells.

Then a honeycomb structure and the material of the tube, located in the overlapped areas, simultaneously calcined at a temperature of about 1400-1450°C. Thus, the adhesive tape is burned out and is removed from the obtained ceramic honeycomb structure (ceramic substrate) 22, having a number of holes 31 for opening ends of the cells 3 and many of the tubes 32 for closing the ends of the cells 3 are formed on both ends of the cells 3, as shown in Fig.

Then the catalyst combustion in leadstream material (sample E2), obtained in example 2, is mixed with a suspension of alumina containing 3% wt. Zola aluminum oxide. Next, add water to the mixture to adjust the mixture to the desired viscosity with the results in the suspension of the composite material. Then the partition 25 of the ceramic substrate 22 is covered with composite material. Then, the ceramic substrate is fired by heating at a temperature of 500°C. the Amount of coating suspension of the composite material 60 g/l substrate having a honeycomb structure. Thus, as shown in Fig, 16 and 18 receive the catalyst carrier 2 carrying the catalyst for the combustion of carbon-containing material 1 on the ceramic substrate 22.

The catalyst carrier 2 of the present example is catalyst for the combustion of carbon-containing material 1 "sample E2" of example 2 on the wall of the cell 22. Thus, the honeycomb structure 2 can provide the combustion of carbon-containing material at a low temperature without decomposition of the substrate using the excellent catalyst for the combustion of carbon-containing material 1. In addition, the water almost does not reduce the catalytic activity for carbon-containing material.

The catalyst for the combustion of carbon-containing material (sample E2) is obtained by firing a mixture of sodalite and source of alkali metal (potassium carbonate). Thecontainer combustion of carbonaceous material on the firm retains an element of the alkali metal (K), that almost does not cause leaching of the alkali metal. Thus, when the catalyst for the combustion of carbon-containing material attached to the cell structure, prevents the leaching of the alkali metal and further corrosion of the ceramic substrate.

Although in the present example, the catalyst carrier obtained using the ceramic substrate (for example, a ceramic honeycomb structure made of cordierite, porous ceramics with high temperature resistance, made for example of SiC, aluminum titanate or the like, can also be used as the ceramic substrate to obtain the same catalyst carrier. Although in the present example, as the above-mentioned ceramic substrate is a ceramic honeycomb structure with the end of the cell, closed tube, for example, a ceramic honeycomb structure without tubes can be used to reduce the pressure loss.

When receiving the catalyst carrier, designed to consolidate the catalyst for the combustion of carbon-containing material and containing not only the composite oxide particles, but also rare earth element, when the catalyst for the combustion of carbon-containing material (sample E2) is mixed with a suspension of alumina containing 3% Sol of aluminum oxide, for the floor is possible catalyst carrier can be optionally entered oxide particles, consisting, for example, from the CeO2, ZrO2, solid solution CeO2-ZrO2or similar.

When receiving the catalyst carrier, designed to secure the precious metal in addition to the catalyst combustion of carbonaceous material, the catalyst for the combustion of carbon-containing material (sample E2) is mixed with a suspension of alumina containing 3% Sol of aluminum oxide, to obtain a catalyst carrier, for example, platinum nitrate solution may optionally be dispersed in a number.

In this example, the catalyst carrier is produced by fixing the catalyst for the combustion of carbon-containing material (sample E2)obtained in example 2, on the ceramic substrate. Alternative the same way as the method in the present example, can be carried out using the catalyst for the combustion of carbon-containing material (e.g., sample E1)obtained in example 1 instead of the sample E2, which results in catalyst carrier for carrying a catalyst combustion obtained in example 1, the ceramic substrate.

Comparative example

In comparative example produces a catalyst carrier for fixing the unfired mixture of sodalite and source of alkali metal (potassium carbonate) on the ceramic substrate as a relatively what about the example with respect to the carrier of the catalyst of example 3.

The carrier of the catalyst obtained in comparative example is the same as the carrier of the catalyst in example 3, except the type of the fixed catalyst.

Upon receipt of the carrier of the catalyst of comparative example first get a ceramic substrate with a ceramic honeycomb structure, made of the same type cordierite, as in example 3.

Then, 100 parts by weight of sodalite and 5 parts by weight of potassium carbonate is mixed with water. The liquid mixture is heated to evaporate water from getting in the solid mixture. So, get a mixture of sodalite and potassium carbonate.

The mixture is then mixed with a suspension of alumina containing 3% wt. Zola aluminum oxide, and water is added to adjust the mixture to the desired viscosity with the results in the suspension of the composite material. Then analogously to example 3 of the partition walls of the ceramic substrate covered with a suspension of composite material and is heated at a temperature of 500°C, so that the mixture is fired on a ceramic substrate. Thus, get the catalyst carrier serving as a comparative example.

On visual inspection of the catalyst carrier obtained in the comparative example, there is a crack in the side of the ceramic substrate. Thus, when the unfired mixture of sodalite and source of alkali metal (n is an example, potassium carbonate) is fixed on the ceramic substrate, alkali metal (potassium) are easily washed out from the mixture by heating, for example, when roasting, etc. Washed alkali metal influences cordiality component of the ceramic substrate with the destruction of the crystal system. Thus, thermal expansion coefficient and the strength of the ceramic substrate is partially changed, easily causing cracks or the like on the ceramic substrate, as described above.

Brief description of drawings

Figure 1 shows an explanatory graph showing the DTA exothermic peak temperature when the carbonaceous material is combusted with appropriate catalytic particles or without the use of any catalyst in example 1.

Figure 2 presents an explanatory diagram showing the relation between the firing temperature and the DTA exothermic peak temperatures of the catalyst for combustion of carbon-containing material before and after washing with water in example 1.

Figure 3 presents explanatory diagram showing the relationship between zeolite particles and the DTA exothermic peak temperatures of the catalyst in example 1.

4 shows an explanatory graph showing the DTA exothermic peak temperature when uhlandstras the second material is burned with the use of appropriate catalytic particles or without the use of any catalyst in example 2.

Figure 5 presents a graph showing the relation between temperature, TG, DTA, when carbon black is burned separately without the use of the catalyst in example 2.

Figure 6 presents a graph showing the relation between temperature, TG, DTA, when carbon black is burned using a noble metal containing catalyst as the catalytic particles in example 2.

Figure 7 presents a graph showing the relation between temperature, TG, DTA, when carbon black is burned with the use of potassium carbonate as catalyst particles in example 2.

On Fig presents a graph showing the relation between temperature, TG, DTA, when carbon black is burned with the use of the catalyst for combustion of carbon-containing material (sample E1) as the catalytic particles in example 2.

Figure 9 presents an explanatory diagram showing the relation between the firing temperature and the DTA exothermic peak temperatures of the catalyst for combustion of carbon-containing material before and after washing with water in example 2.

Figure 10 presents an explanatory diagram showing the relation between the particles of potassium salts and DTA exothermic peak temperatures of the catalyst for combustion of carbonaceous material on the and after washing with water in example 2.

Figure 11 presents an explanatory diagram showing the relation between the particles of the alkali metal, the particles of the alkaline earth metal and DTA exothermic peak temperatures of the catalyst for combustion of carbon-containing material before and after washing with water in example 2.

On Fig an explanatory diagram showing the relation between the particles of the alkali metal other than potassium, the particles of the alkaline earth metal and DTA exothermic peak temperatures of the catalyst for combustion of carbon-containing material before and after washing with water in example 2.

On Fig an explanatory diagram showing the ratio between the amount of potassium, mixed at the stage of mixing, and the DTA exothermic peak temperatures of the catalyst for combustion of carbon-containing material before and after washing with water in example 2.

On Fig an explanatory diagram showing the relationship between the amount of barium mixed at the stage of mixing, and the DTA exothermic peak temperatures of the catalyst for combustion of carbon-containing material before and after washing with water in example 2.

On Fig presents a perspective view of a catalyst carrier with a ceramic honeycomb structure in example 3.

On Fig presents cross-section of the catalyst carrier with KERS who achieved a honeycomb structure in the longitudinal direction in example 3.

On Fig presents a cross section showing a catalyst carrier with a ceramic honeycomb structure in a state where the exhaust gas passes through the catalyst carrier in example 3.

On Fig presents a cross section showing the structure of the catalyst carrier, comprising a catalyst for the combustion of carbonaceous material dispersed in the connective layer comprising an oxide ceramic particles together.

On Fig presents a cross section showing the structure of the catalyst carrier, comprising a catalyst for the combustion of carbon-containing material and a rare earth element is dispersed in the connective layer comprising an oxide ceramic particles together.

On Fig presents a cross section showing the structure of the catalyst carrier for fixing the catalyst for the combustion of carbon-containing material, rare earth element and a noble metal dispersed in the connective layer comprising an oxide ceramic particles together.

On Fig an explanatory diagram showing the state of the noble metal fixed on the oxide particle.

On Fig an explanatory diagram showing the state of the noble metal, sakralen the th on rare earth element, such as oxide particle of the rare earth element.

On Fig presents a cross section showing the structure of the catalyst carrier having a layer of a noble metal formed on the coupling layer containing a catalyst for the combustion of carbon-containing material is formed over the substrate.

On Fig presents a cross section showing the structure of the catalyst carrier having a layer of a noble metal formed between the substrate and the connecting layer containing a catalyst for the combustion of carbon-containing material.

On Fig presents a diagram showing types of zeolites and the ratio of SiO2/Al2O3each zeolite composition.

On Fig presents a graph showing the results of the DTA exothermic peak temperatures before and after washing with water, catalysts, combustion of carbonaceous material obtained by using potassium carbonate.

On Fig presents a graph showing the results of the DTA exothermic peak temperatures before and after washing with water, catalysts, combustion of carbon-containing material obtained with the use of barium carbonate.

1. The method of producing catalyst for the combustion of carbon-containing material intended for the combustion of carbonaceous material contained within the exhaust gas of the internal combustion engine, moreover, the catalyst is fixed on the ceramic substrate, which includes:
a mixture of aluminosilicate having an atomic equivalent ratio of Si/Al≥1, and a source of alkali metal and/or source of alkaline earth metal in a polar solvent such as water or other than water;
drying the liquid mixture by heating the mixture after the stage of mixing and evaporation of water results in solids; and
firing solids at a temperature of 600°C. or higher is obtained catalyst combustion of carbon-containing material,
in which the aluminosilicate is sodalite.

2. The method of producing catalyst for the combustion of carbon-containing material according to claim 1, in which the source of the alkali metal includes one or more elements selected from the group consisting of Na, K, Rb and Cs, and the source of the alkaline earth metal includes one or more elements selected from the group consisting of CA, Sr and BA.

3. The method of producing catalyst for the combustion of carbon-containing material according to claim 1, in which each source of alkali metal and/or source of alkaline earth metal is a carbonate, sulfate, phosphate, nitrate, salt of organic acid, a halide, oxide or hydroxide.

4. The method of producing catalyst for the combustion of carbon-containing material according to claim 1, additionally containing study the crushing of the catalyst for combustion of carbon-containing material after the stage of firing.

5. The method of producing catalyst for the combustion of carbon-containing material according to claim 1, in which at the stage of mixing instead of water, use a polar solvent other than water, and the aluminosilicate and a source of alkali metal and/or a source of alkaline earth metal are mixed in a polar solvent, and
in which at the stage of drying the polar solvent is evaporated to obtain a solid substance.

6. The method of producing catalyst for the combustion of carbon-containing material according to claim 1 in which the aluminosilicate and a source of alkali metal and/or a source of alkaline earth metal is mixed so that the total number of element of the alkali metal and alkaline earth element metal contained in the source of an alkali metal and/or the source of alkaline earth metal is equal to or less than 2.25 mol relative to 1 mol of the element Si of the aluminosilicate.

7. The method of producing catalyst for the combustion of carbon-containing material according to claim 6, in which at the stage of mixing the silicate and the source of the alkali metal and/or a source of alkaline earth metal is mixed so that the total number of element of the alkali metal and alkaline earth element metal contained in the source of an alkali metal and/or the source of alkaline earth metal is equal to or less than 1 mol relative to 1 mol of the element Si of the aluminosilicate.

. The method of producing catalyst for the combustion of carbon-containing material according to claim 7, in which at the stage of mixing the silicate and the source of the alkali metal and/or a source of alkaline earth metal is mixed so that the total number of element of the alkali metal and alkaline earth element metal contained in the source of an alkali metal and/or the source of alkaline earth metal is equal to or less than 0.5 mol relative to 1 mol of the element Si of the aluminosilicate.

9. The method of producing catalyst for the combustion of carbon-containing material according to claim 1, in which at the stage of firing the solid is calcined at a temperature in the range from 700 to 1200°C.

10. The catalyst for the combustion of carbon-containing material obtained by the method of receiving according to any one of claims 1 to 9.

11. A method of obtaining a catalyst carrier for fixing the catalyst for the combustion of carbonaceous material on the ceramic substrate, and the catalyst carrier is intended for combustion of carbonaceous material contained in the exhaust gas of the internal combustion engine, which includes
consolidation of the catalyst combustion, obtained by the method of receiving according to any one of claims 1 to 9, the ceramic substrate is obtained catalyst carrier.

12. A method of obtaining a catalyst carrier according to claim 11, in which at the stage of fixing, on ENISA least the catalyst for the combustion of carbon-containing material and the Sol or suspension of oxide ceramic particles are mixed with the formation of the composite material, and a ceramic substrate covered with composite material and then heated.

13. A method of obtaining a catalyst carrier according to item 12, in which the oxide ceramic particles mainly contain one or more elements selected from the group consisting of aluminum oxide, silicon dioxide, titanium oxide and zirconium oxide.

14. A method of obtaining a catalyst carrier according to claim 11, in which the ceramic substrate comprises cordierite, SiC or aluminum titanate.

15. A method of obtaining a catalyst carrier according to claim 11, in which the ceramic substrate has a honeycomb structure.

16. The catalyst carrier obtained by the method of receiving according to claim 11.

17. The method of producing catalyst for the combustion of carbon-containing material intended for the combustion of carbonaceous material contained in the exhaust gas of the internal combustion engine being mounted on the ceramic substrate, and the method includes
the firing of sodalite at a temperature of 600°C. or higher to obtain a catalyst for the combustion of carbon-containing material.

18. The method of producing catalyst for the combustion of carbonaceous material 17, in which at the stage of firing sodalite is fired when the is the temperature value in the range from 700 to 1200°C.

19. The method of producing catalyst for the combustion of carbon-containing material according to 17, further comprising
grinding the catalyst for the combustion of carbon-containing material obtained after the stage of firing.

20. The catalyst for the combustion of carbon-containing material obtained by the method of obtaining on any of PP-19.

21. A method of obtaining a catalyst carrier for fixing the catalyst for the combustion of carbon-containing material on a ceramic substrate, intended for combustion of carbonaceous material contained in the exhaust gas of the internal combustion engine, and the method includes a step of fixing the catalyst combustion, obtained by the method of obtaining on any of PP-19, the ceramic substrate is obtained catalyst carrier.

22. A method of obtaining a catalyst carrier according to item 21, in which at the stage of fixing at least the catalyst for the combustion of carbon-containing material and the Sol or suspension of oxide ceramic particles are mixed with the formation of the composite material, and a ceramic substrate covered with composite material and then heated.

23. A method of obtaining a catalyst carrier according to article 22, in which the oxide ceramic particles mainly contain one or more elements selected from the group consisting of aluminum oxide on the silicon oxide, titanium oxide and zirconium oxide.

24. A method of obtaining a catalyst carrier according to item 21, in which the ceramic substrate comprises cordierite, SiC or aluminum titanate.

25. A method of obtaining a catalyst carrier according to item 21, in which the ceramic substrate has a honeycomb structure.

26. The catalyst carrier obtained by the method for item 21.



 

Same patents:

FIELD: process engineering.

SUBSTANCE: proposed invention relates to catalyst composition and can be used for treatment of, for example ICE exhaust gases. Composition based on zirconium oxide with concentration equal at least 25% comprises, in % by wt: 15 to 60 of cerium oxide, 10 to 25 yttrium oxide, 2 to 10 of lanthanum oxide and 2 to 15 of oxide of the other rare-earth metal Besides said composition, after incineration for 10 h at 1150°C, features specific surface equal to at least 15 m2/g, and crystalline phase with cubic lattice. Composition results from formation of the mix containing compounds of zirconium, cerium, yttrium, lanthanum and additional rare-earth element, extraction of sediment from said mix with the help of base, heating said sediment in water, adding surfactant to sediment and its incineration. This composition can be used as a catalyst.

EFFECT: high reducing capacity and stable specific surface.

23 cl, 5 tbl, 3 dwg, 13 ex

FIELD: chemistry.

SUBSTANCE: present invention relates to catalysts supports which are used as supports for metal and metal oxide components of catalysts used in different chemical reactions. The invention describes a catalyst support precursor which contains a mixture of alpha aluminium oxide and/or transition aluminium oxide; binder; and a solid sponging agent which expands or releases gas when sufficient heat is supplied. A method of making a catalyst support is described, which involves preparation of the catalyst support precursor described above and water, moulding the obtained precursor into a structure, heating the said structure for a sufficient time and at temperature sufficient for formation of a porous structure as a result of the effect of the sponging agent, and then heating the porous structure for a sufficient time and at temperature sufficient for melting of the porous structure, thereby forming a porous catalyst support. A catalyst preparation method is described, which involves the above described steps for making a porous catalyst support and depositing a catalytically effective amount of silver onto the surface of the support. Described also is a catalyst made using the method described above and a method for oxidising ethylene in the presence of the said catalyst. Described also are catalyst support precursors which contain alpha aluminium oxide and/or transition aluminium oxide, binder, a sponging agent and/or talc or a water-soluble titanium compound, and methods of making the said precursors.

EFFECT: increased bearing strength of the carrier, optimum surface area and porosity, which eliminates diffusion resistance for reagents and gaseous products under reaction conditions.

33 cl, 1 tbl, 14 ex

FIELD: chemistry.

SUBSTANCE: present invention relates to removal of sulphur from hydrocarbon streams, to a composition which is suitable for use in desulphuration of streams of cracked petrol and diesel fuel, and a method of preparing the said composition. A method of preparing a composition for removing sulphur from hydrocarbon streams involving the following is described: (a) mixing: 1) a liquid, 2) first metal formate, 3) material containing silicon dioxide, 4) aluminium oxide and 5) second metal formate, to form a mixture of the said components; (b) drying the said mixture to form a dried mixture; (c) calcination of the dried mixture; and (d) reduction of the calcined mixture with a reducing agent under reduction conditions to form a composition which contains a low valency activator, (e) separation of the obtained composition, where the said calcined reduced mixture facilitates removal of sulphur from a stream of hydrocarbons under desulphuration conditions, and where the said liquid is ammonia, and the composition obtained using the method described above. A method of removing sulphur from a stream of hydrocarbons involving the following is described: (a) bringing the stream of hydrocarbons into contact with the composition obtained using the method described above in a desulphuration zone under conditions which facilitate formation of a desulphurated stream of hydrocarbons from the said sulphonated composition and formation of a separate desulphurated stream of hydrocarbons and a separate sulphonated composition; (c) regeneration of at least a portion of the said separate sulphonated composition in the regeneration zone to remove at least a portion of sulphur contained in it and/or on it and formation of a regenerated composition as a result, (d) reduction of the said regenerated composition in an activation zone to form a composition containing a low valency activator which facilitates removal of sulphur from the stream of hydrocarbons when it touches such a composition, and e) subsequent return of at least a portion of the said reduced composition to the said desulphuration zone. Cracked petrol and diesel fuel obtained using the method described above are described.

EFFECT: more stable removal of sulphur from streams of hydrocarbons during desulphuration.

26 cl, 8 tbl, 17 ex

FIELD: chemistry.

SUBSTANCE: invention relates to a crust catalyst specifically designed for oxidising methanol to formaldehyde, a method of preparing the said catalyst and use of a catalyst for oxidising methanol to formaldehyde. A catalyst is described, which contains at least one coating layer on an inert, preferably essentially non-porous carrier, where the said coating layer, before removal of organic components b) and c), contains (a) oxides or precursor molybdenum and iron compounds transformed to corresponding oxides, where molar ratio Mo:Fe ranges from 1:1 to 5:1, and, if necessary, other metal or metal oxide compounds or precursor compounds transformed to corresponding oxides, (b) at least one organic binder material, preferably an aqueous dispersion of copolymers selected from vinylacetate/vinylaurate, vinylacetate/ethylene, vinylacetate/acrylate, vinylacetate/maleate, styrene/acrylate or mixtures thereof, and (c) at least one other component selected from a group consisting of SiO2 sol or its precursor, Al2O3 sol or its precursor, ZrO2 sol or its precursor, TiO2 sol or its precursor, liquid glass, MgO, cement, monomers, oligomers or polymers of silanes, alkoxysilanes, aryloxysilanes, acryloxysilanes, aminosilanes, siloxanes or silanols. Described also is a method of preparing the catalyst and its preferred use in the method with a fixed bed catalyst.

EFFECT: obtaining an active, selective and wear-resistant catalyst.

35 cl, 4 ex,1 dwg

FIELD: mechanics.

SUBSTANCE: present invention relates to method for manufacturing of catalyst on metal substrate. Method includes the following actions: binding compound that contains coordinated functional group with catalyst substrate; impregnation of catalyst substrate, with which compound is connected, by solution, which contains polynuclear metal complex, where ligand is coordinated by one atom of catalyst metal or multiple atoms of catalyst metal of the same type, and substitution, at least partially, of ligand coordinated by polynuclear metal complex, with coordinated functional group of compound; and drying and annealing of catalyst substrate impregnated with solution. At the same time metal complex is multinuclear complex. Coordinated functional group of compound and functional group of ligand, which is coordinated by metal of catalyst, are each independently selected from the group, that consists of the following: -COO-, -CR1R2O-, -NR1-, -NR-1R2, -CR1=N-R2, -CO-R1, -PR1R2, -P(=O)R1R2, -P(OR1)(OR2), -S(=O)2R1, -S+(-O-)R1, -SR1 and -CR1R2-S-, where R1 and R2 each independently is hydrogen or univalent organic group.

EFFECT: invention makes it possible to produce catalyst on substrate, in which metal of catalyst is applied on substrate with high extent of dispersity.

3 cl, 4 ex, 6 dwg

FIELD: chemistry.

SUBSTANCE: invention relates to the process of obtaining olefin or diolefin hydrocarbons C3-C4 through catalytic dehydrogenation of corresponding paraffin hydrocarbons, and specifically to preparation of a dehydrogenation catalyst, and can be used in chemical and petrochemical industry. The method of preparing a catalyst for dehydrogenating paraffin hydrocarbons C3-C4 by impregnating the γ-Al2O3 catalyst support with a solution of Cr and K salts with subsequent drying and tempering at high temperature is distinguished by that, before impregnation with salt solutions, the γ-Al2O3 catalyst support undergoes high temperature treatment with hydrogen at 300-500°C and impregnation of the support with the metal salts is carried out in 24-65 hours.

EFFECT: obtained catalyst surpasses known catalysts on activity and selectivity.

9 ex

FIELD: chemistry.

SUBSTANCE: present invention relates to dehydrogenation catalysts, their preparation and use. Described is a dehydrogenation catalyst composition based on iron oxide which includes an iron oxide component with low concentration of titanium, where the said iron oxide component is obtained through thermal treatment of a residue of yellow iron oxide prepared via precipitation from a solution of an iron salt, and where the said dehydrogenation catalyst composition based on iron oxide has first titanium concentration which is less than approximately 300 parts per million. Also described is a method of preparing a dehydrogenation catalyst based on iron oxide, with a first titanium oxide concentration less than approximately 300 parts per million, with the said method involving: obtaining a component in form of red iron oxide with low content of titanium, through thermal treatment of a residue of yellow iron oxide prepared by via precipitation of from a solution of an iron salt, where the said yellow iron oxide has a second titanium concentration; mixing the said component in form of red iron oxide with an additional component of the dehydrogenation catalyst and water with formation of a mixture; moulding particles from said mixture; and thermal treatment of said particles thereby obtaining said dehydrogenation catalyst based on iron oxide. Also described is a dehydrogenation method involving: bringing a hydrocarbon which can be dehydrogenated, under hydrogenation reaction conditions, into contact with a dehydrogenation catalyst composition based on iron oxide, which contains an iron oxide component with low content of titanium, where the said iron oxide component is obtained through thermal treatment of a residue of yellow iron oxide prepared via precipitation from a solution of an iron salt, and an additional component of the dehydrogenation catalyst, where the said dehydrogenation catalyst composition based on iron oxide has a first titanium concentration which is less than approximately 300 parts per million; and separation of the dehydrogenation product. Also described is a method of improving operation of a dehydrogenation reactor installation which includes a dehydrogenation reactor containing a first dehydrogenation catalyst volume which can reduce titanium concentration, with the said method involving: removal of the dehydrogenation catalyst from the said dehydrogenation reactor and its replacement with a dehydrogenation catalyst composition based on iron oxide containing an iron oxide component with low content of titanium, where the said iron oxide component is obtained through thermal treatment of a residue of yellow iron oxide prepared via precipitation from a solution of an iron salt, and an additional component of dehydrogenation catalyst, where the said dehydrogenation catalyst composition based on iron oxide has a first titanium concentration which is less than approximately 300 parts per million, and thereby obtaining a second dehydrogenation reactor installation; and carrying out processes in the said second dehydrogenation reactor installation in dehydrogenation reaction conditions.

EFFECT: more efficient method of preparing dehydrogenation catalyst.

19 cl, 1 tbl, 1 dwg, 2 ex

FIELD: oil-and-gas production.

SUBSTANCE: invention related to oil-and-gas production, particularly to crude oil refinery with low temperature initiated cracking, and can be use for distilled motor fuel production increase. The method includes of oil residue processing into distillate fraction by adding catalyst followed by thermal-cracking, as a catalyst use ashes micro sphere magnetic fractions d from heat and power plants in a quantity 2.0-20.0% wt, containing 40.0-95.0% wt, iron oxide (III), with micro sphere diametres 0.01-0.60 mm, tempered at 600-800°C, process itself to be executed at temperature 400-500°C.

EFFECT: increase in distilled fractions total outcome up to 58,0% wt with the temperature up to 350°C, outcome of gasoline fractions up to 18,0% wt (with the temperature up to 200°C).

1 cl, 1 tbl, 7 ex

FIELD: chemistry.

SUBSTANCE: invention relates to the technology of making carbon carriers for different types of catalysts and sorbents. Description is given of a method of making large spherical carbon carrier for catalysts, which involves heating a moving bed of palletised black to 800-900°C, feeding a stream of gaseous or vaporous hydrocarbons in the moving bed, packing the carbon black by thermal decomposition of hydrocarbons on the surface of its particles with formation of pyrocarbon until attaining 0.5-0.7 g/cm3 packed density of carbon black, cooling the mass of the material and its screening with separation of the fraction of granules, which are subjected to repeated pyrolytic packing with subsequent activation of the obtained product. This method is distinguished by that, gaseous or vaporous hydrocarbons are fed into the layer of carbon black at the first and second stages with different bulk speed: at the first stage with speed of 65-72 hour-1, and at the second stage at temperature 650-750°C and speed 52-58 hour-1. Granules with size 3.5-6.0 mm undergo packing at the second stage. Material is activated until attaining void space of 0.3-0.7 cm3/g. At the second stage packing using pyrocarbon is done until attaining weight of granules of 0.88-0.95 g/cm3.

EFFECT: obtaining a carrier with strong and composition homogenous granules.

2 cl, 2 ex

FIELD: chemistry.

SUBSTANCE: object of the present invention is to develop method for making catalyst to produce methacrylic acid by gaseous catalytic oxidation of metacrolein, isobutyl aldehyde or isobutyric acid. There is disclosed method for making catalyst to produce methacrylic acid by gaseous catalytic oxidation of metacrolein, isobutyl aldehyde or isobutyric acid, involving as follows: (a) the stage of mixing water and compounds, each containing any Mo, V, P, Cu, Cs or NH4, to prepare aqueous solution or dispersed compounds (further, both mentioned as a suspension); (b) the stage of drying suspension produced at the stage (a), to make dry suspension; (c) the stage of burning dry suspension produced at the stage (b), to make burnt substance; (d) the stage of filtrating mixed burnt substance produced at the stage (c) and water to separate aqueous solution and water-insoluble substance; and (e) the stage of drying water-insoluble substance produced at the stage (d) to make dry water-insoluble substance; and (f) the stage of coating the carrier with dry water-insoluble substance produced at the stage (e), with using a binding agent to make coated mould product, and (g) the stage of burning coated mould product produced at the stage (f) in inert gas atmosphere, in the air or with reducing agent added.

EFFECT: making catalyst with long life, high activity and selectivity.

8 cl, 9 tbl, 9 ex

FIELD: oil and gas industry.

SUBSTANCE: invention refers to technology of active alumina stabilised nickel-containing catalysts for redox processes. There is described a method for manufacturing impregnation nickel catalysts for redox processes, e.g. for hydrocarbon conversion, involving carrier impregnation with nickel and aluminium nitrates, drying and ignition; before impregnation, the carrier is heated to temperature exceeding a steam condensation point of the impregnation solution, and the impregnating solution has temperature below a boiling point.

EFFECT: reduced number of impregnation cycles and improving catalyst activity.

2 cl, 2 ex, 1 tbl

FIELD: chemistry.

SUBSTANCE: present invention relates to removal of sulphur from hydrocarbon streams, to a composition which is suitable for use in desulphuration of streams of cracked petrol and diesel fuel, and a method of preparing the said composition. A method of preparing a composition for removing sulphur from hydrocarbon streams involving the following is described: (a) mixing: 1) a liquid, 2) first metal formate, 3) material containing silicon dioxide, 4) aluminium oxide and 5) second metal formate, to form a mixture of the said components; (b) drying the said mixture to form a dried mixture; (c) calcination of the dried mixture; and (d) reduction of the calcined mixture with a reducing agent under reduction conditions to form a composition which contains a low valency activator, (e) separation of the obtained composition, where the said calcined reduced mixture facilitates removal of sulphur from a stream of hydrocarbons under desulphuration conditions, and where the said liquid is ammonia, and the composition obtained using the method described above. A method of removing sulphur from a stream of hydrocarbons involving the following is described: (a) bringing the stream of hydrocarbons into contact with the composition obtained using the method described above in a desulphuration zone under conditions which facilitate formation of a desulphurated stream of hydrocarbons from the said sulphonated composition and formation of a separate desulphurated stream of hydrocarbons and a separate sulphonated composition; (c) regeneration of at least a portion of the said separate sulphonated composition in the regeneration zone to remove at least a portion of sulphur contained in it and/or on it and formation of a regenerated composition as a result, (d) reduction of the said regenerated composition in an activation zone to form a composition containing a low valency activator which facilitates removal of sulphur from the stream of hydrocarbons when it touches such a composition, and e) subsequent return of at least a portion of the said reduced composition to the said desulphuration zone. Cracked petrol and diesel fuel obtained using the method described above are described.

EFFECT: more stable removal of sulphur from streams of hydrocarbons during desulphuration.

26 cl, 8 tbl, 17 ex

FIELD: chemistry.

SUBSTANCE: invention relates to production of alternating copolymers of olefins with carbon monoxide through catalytic copolymerisation in suspended copolymerisation conditions. Described is a method of preparing a supported catalyst for copolymerisation of olefins with carbon monoxide, involving synthesis of a palladium complex by reacting palladium (II) salts, a bidentate ligand Y^Y of general formula R1R2YRYR3R4, where Y=N or P; R=CnH2n, where n=2-4; R1-R4=-C6H5 or -C6H4OCH3 groups, and hydrogen acid HX with pKa≤2, selected from acids CH3COOH, CF3COOH, HBF4, CH3C6H4SO3H, with subsequent addition to catalytic solution of the carrier, where the mixture of the catalytic solution and polymer or inorganic carrier is stirred for 0.5-2 hours in an inert atmosphere of a medium containing methanol and toluene, with subsequent removal of the liquid phase until obtaining a solid desired product. Also described is a method for copolymerisation of olefins with carbon monoxide at temperature 20-95° and pressure of comonomers of 0.1-5 MPa. The copolymerisation process is carried out in the presence of a supported catalyst prepared using the above described method in suspended copolymerisation conditions in a medium of hydrocarbons with addition of 5-7 wt %, methanol or alcohol medium.

EFFECT: increased output of product per gram of carrier; possibility of using different media in suspended copolymerisation conditions; the catalyst is used as a solid end product and does not lose its activity for a long period of time.

8 cl, 19 ex, 1 tbl

FIELD: chemistry.

SUBSTANCE: described is a catalyst for oxidising methanol to formaldehyde which contains catalyst Fe2(MoO4)3/MoO3 mixtures in which the atomic ratio Mo/Fe ranges from 1.5 to 5, and a compound of cerium, molybdenum and oxygen in amount ranging from 0.1 to 10 wt % with respect to pure cerium. Described is a multilayer catalyst layer formed using the above described catalyst. Described is a method of preparing a catalyst, involving a) mixing a suspension obtained through precipitation of a Fe2(MoO4)3/MoO3 mixture in which the ratio Mo/Fe ranges from 1.5 to 5, from a solution of a soluble iron (III) salt mixed with a solution of a molybdate of an alkali metal or ammonia with an aqueous suspension obtained from reacting hot molybdenum trioxide and cerium (III) carbonate in atomic ratio Mo/Ce ranging from 1.5 to 2.1 until generation of CO2 stops, b) dilution, precipitation, filtration an washing the residue converted to a suspension after that by stirring before mixing with a suspension of the product of reacting molybdenum trioxide with cerium carbonate, c) formation of a dry mixture or paste thereof in form of granules and d) calcination thereof at temperature ranging from 450 to 600°C. A method is described for oxidising methanol using the above described catalyst.

EFFECT: increased stability of the catalyst layer.

15 cl, 2 tbl, 5 ex

FIELD: chemistry.

SUBSTANCE: invention relates to a method of producing engine fuel, more specifically to a catalyst process of producing diesel fuel with improved temperature characteristics from crude oil. A method is described for preparing a catalyst for producing diesel fuel from natural raw material based on crystalline silico aluminophosphates with zeolite-like structure of the SAPO-31 type by preparing an aqeous reaction mixture which contains an aluminium source, phosphoric acid and a silicon source, as well as an organic structure forming compound, and with total composition expressed in molar ratios: R/Al2O3=0.5-2.0, P2O5/Al2O3=0.8-1.2, SiO2/Al2O3=0.05-1.5, H2O/Al2O3=15-200, where: R is an organic structure forming compound, which is a separate di-n-butylamine or a mixture of di-n-butylamine with di-n-propylamine, taken in molar ratio of 1:2, with subsequent crystallisation of the prepared mixture in hydrothermal conditions, necessary for formation of zeolite-like crystals with SAPO-31 structure, filtration, washing, drying, calcination and further introduction of a modifying group VIII metal. Also described is a method of producing diesel fuel from natural raw material at high temperature and hydrogen pressure in the presence of a catalyst, where the process is carried out in a single step and the catalyst used is crystalline silico aluminiumphosphate with a zeolite-like SAPO-31 structure, modified by a group VIII metal, obtained using the above described method.

EFFECT: high catalyst activity during hydrogenation of unsaturated hydrocarbons and ether bonds, as well as in decarbonation reactions and isomerisation formed paraffins with normal structure with high selectivity towards isomer products and with reduced formation of heavy compounds and cracking starting material; process of producing diesel fuel is carried out in a single step.

5 cl, 9 ex

FIELD: chemistry.

SUBSTANCE: invention relates to a catalyst for converting hydrocarbons, which contains zeolite, method of making said catalyst and method of converting hydrocarbon petroleum products on the catalyst. The zeolite-containing catalyst for converting hydrocarbons, which contains zeolite, heat resistant inorganic oxide and optionally clay, is distinguished by that, the said zeolite has MFI structure, which contains phosphorous and transition metals, or a mixture of said zeolite with MFI structure, containing phosphorous and transition metals, with macroporous zeolite, which contains 75 to 100 wt % of the said zeolite with MFI structure in terms of mass of the mixture, containing phosphorous and transition metals, and 0 to 25 wt % macroporous zeolite; wherein the said zeolite with MFI structure, containing phosphorous and transition metals, in terms of mass of oxide, has the following chemical formula without taking water into account: (0 to 0.3)Na2O·(0.03 to 5.5)Al2O3·(1.0 to 10)P2O5·(0.7 to 15)M1xOy·(0.01 to 5)M2mOn·(0.5 to 10)RE2O3·(70 to 97)SiO2 I or (0 to 0.3)Na2O·(0.3 to 5)Al2O3·(1.0 to 10)P2O5·(0.7 to 15)MpOq·(0.5 to 10)RE2O2·(70 to 98)SiO2 II in which M1 is a transition metal, which is chosen from Fe, Co and Ni, M2 is a transition metal, which is chosen from Zn, Mn, Ga and Sn, M is a transition metal, which is chosen from Fe, Co, Ni, Cu, Zn, Mo or Mn, and RE is a rare-earth metal; x is equal to 1 or 2, where if x equals 1, y equals half the valency of transition metal M1, and when x equals 2, y equals valency of transition metal M1; m equals 1 or 2, when m equals 1, n equals half the valency of transition metal M2, and when m equals 2, n equals valency of transition metal M2; p equals 1 or 2, when p equals 1, q equals half the valency of transition metal M, and when p equals 2, q equals valency of transition metal M; the catalyst also contains an auxiliary component, one or more of which are chosen from a group consisting of IVB group metals, group VIII base metals and rare-earth metals of the period table of elements; in terms of catalyst mass, the said catalyst contains 1 to 60 wt % zeolite, 0.1 to 10 wt % auxiliary component of the catalyst, 5 to 98 wt % heat resistant inorganic oxide and 0 to 70 wt % clay in form of oxides. The method of preparing the catalyst involves mixture and suspension of all or part of the heat resistant inorganic oxide and/or its precursor, water and optionally clay, addition of zeolite and drying the obtained suspension, addition of auxiliary compound before addition of zeolite and before or after addition of clay, addition of acid to establish pH of the suspension equal to 1 to 5, ageing at 30 to 90°C for 0.1 to 10 hours and addition of the remaining heat resistant inorganic oxide and/or its precursor after ageing.

EFFECT: obtained catalyst has high activity and stability and is highly capable of converting petroleum hydrocarbons with high output of propylene, ethylene and lower aromatic hydrocarbons.

20 cl, 24 ex, 5 tbl

FIELD: chemistry.

SUBSTANCE: cracking catalysts contains aluminium oxide, phosphorus and molecular sieves with clay or without clay whereat said aluminium oxide is η-aluminium oxide or mixture of η-aluminium oxide and χ-aluminium oxide and/or γ-aluminium oxide with general composition per all catalyst, wt: % η-aluminium oxide 0.5-50; χ-aluminium oxide and/or γ-aluminium oxide 0-50; molecular sieves 10-70; clay 0-75; and phosphorus in the form of P2O5 0.1-8. The method for catalysts preparation includes: drying of the suspension containing aluminium compound, molecular sieves and water with clay or without clay and calcination of the said suspension with following adding of phosphorus compound. The said aluminium compound is aluminium compound able to form η-aluminium oxide or mixture of the aluminium compound able to form η-aluminium oxide with compound able to form χ-aluminium oxide and/or γ-aluminium oxide with every component using in such amount that resulting catalyst agrees aforementioned composition. The methods for catalysts preparation are described also providing additional inlet of rare earth metal or usage in the quality of molecular sieves of the zeolites mixture containing zeolite Y and zeolite with structure MFI whereat content of zeolite Y is 30-90% wt and content of zeolite with structure MFI is 10-70% wt per total amount of zeolites mixture.

EFFECT: increase of catalyst activity and quality enhancing of the petrol containing in the cracking products.

23 cl, 26 tbl, 52 ex

FIELD: chemistry.

SUBSTANCE: mould catalyst for hydrocracking contains at least zeolite Y and inorganic high-melting oxide with monomodal pores distribution (by mercury porosimetre) whereat at least 50% of total volume is represented with pores having diametre in the range from 4 to 50 nm and the volume at least 0.4 ml/g. The method for carrier preparation and the carrier obtained with this method are described; the said method includes moulding of the mixture containing at least zeolite Y and high-melting oxide with calcinations losses in the range (LIR) from 55 to 75%. The catalytical composition for hydrocracking includes said carrier, at least one component of hydrogenating metal selected from the metal of groups V1B and group V111 and optionally at least one promoting element selected from silicon boron in the case when carrier virtually does not contain the alumosilicate zeolite. The method for catalytical composition preparation and composition obtained with this method are described; the said method includes optional calcinations of the said carrier, precipitation of the at least one hydrogenating metal selected from described above ones in the corresponding amount; the said precipitation is carried out by impregnation with solution containing organic compound having at least two functional groups selected from carboxyl, carbonyl and hydroxyl groups. The hydrocracking method with application of the aforementioned catalytical composition is described.

EFFECT: enhancing of the catalytical composition activity, selectivity and hydrogenation ability.

18 cl, 5 tbl

FIELD: chemistry.

SUBSTANCE: invention relates to field of oil processing, in particular CO oxidation catalysts, used as additive to cracking catalyst for oxidising oxygen into carbon dioxide in process of cracking catalyst regeneration. Claimed catalyst for CO oxidation in process of cracking catalyst regeneration contains manganese compounds, aluminium oxide and natural bentonite clay, with the following component content, wt %: manganese in terms of MnO2 6-20, bentonite clay - 24-44, Al2O3 - the remaining part, and has microspherical form of particles with average size 70 mc, wear resistance 92-97%, bulk density 0.7-0.8 g/cm3. Described is method of preparing catalyst for CO oxidation in process of cracking catalyst regeneration, which includes mixing manganese (IV) hydroxide, obtained by precipitation of manganese nitrate from water solution with ammonium, with composition, which consists of aluminium hydroxide and bentonite clay, preliminarily processed with concentrated nitric acid (12.78 mole/l), composition drying and burning, which is carried out step by step: at temperature 500°C during 4-6 hours, and then at temperature 950-970°C during 4 hours.

EFFECT: increase of catalyst activity and wear-resistance.

2 cl, 1 tbl, 12 ex

FIELD: chemistry.

SUBSTANCE: invention relates to field of chemical industry, in particular, to creation of highly active homogenous catalysts. Described is catalyst based on binary bridge bis(phenoximine) complex of titanium, in which as bridge between phenyl substituents of imine nitrogen it contains n - phenylene group, and corresponds to the following formula: . Described is method of preparing described above catalyst by interaction of tetradentate diimine ligand with compound of transitive metal, in which as components for ligand preparation used is 4,4"-diamino-l-terphenyl and 3,5-dicumylsalicilic aldehyde, and as compound of transitive metal used is titanium diisopropoxydichloride TiCl2(OPr)2. Described is process of ethylene polymerisation in medium of hydrocarbon solvent in presence of catalyst obtained by claimed method with co-catalyst.

EFFECT: increase of polymerisation process economy due to lower catalyst consumption; obtaining of linear polyethylene with high and extra-high molecular mass, with temperature of melting 140-142°C, improved morphology of polymer powder and absence of its adhering on reactors wall.

4 cl, 2 tbl, 17 ex

FIELD: chemistry.

SUBSTANCE: invention relates to a special perovskite type compound, a catalyst which contains such a compound, a method of decomposing dinitrogen monoxide (N2O), a device for producing nitric acid and a method of producing nitric acid. The invention also relates to use of the said perovskite type compound in decomposing N2O. The invention describes the device used in the method of producing nitric acid at the ammonia oxidation step, which includes a perovskite type compound for decomposing dinitrogen monoxide having general formula (1). There is an ammonia oxidation catalyst, one or more separating gauzes and a perovskite type compound along the gas stream containing the product. The invention describes a method of producing nitric acid using the said device. Described also is a catalyst for use in the said device, which has a cellular support and a perovskite type compound of general formula (1). The invention also describes a method of decomposing dinitrogen monoxide for use in the device described above, which involves bringing dinitrogen monoxide into contact with the perovskite type compound of general formula (1) and using the said perovskite compound to decompose dinitrogen monoxide for use in the device described above.

EFFECT: decomposition of N2O in the gas containing the product formed during oxidation of ammonia when producing nitric acid.

14 cl, 5 ex, 16 tbl, 1 dwg

Up!