The present invention relates to catalysts for purification of nitrogen oxides (hereinafter may also be abbreviated as NOx) and more particularly relates to a novel catalyst for purification of NOx, the catalyst comprising a solid in which Au and Fe atoms exist in a state of being close and which enables the purification of NOx at low temperatures and/or in an oxidative atmosphere.
In recent years, regulations on exhaust gases have been strengthened worldwide year by year from the viewpoint of global environmental protection. As a measure against them, an exhaust gas purification catalyst is used in an internal combustion engine. In the exhaust gas purification catalyst, a noble metal such as Pt, Pd, or Rh has been used as a catalyst component in order to efficiently remove HC, CO, and NOx from exhaust gases.
In an automobile using a catalyst for purification, such as a gasoline engine or a diesel engine, various systems have been used for improving catalytic activity and fuel efficiency. For example, combustion has been performed on the condition that an air-fuel ratio (A/F) is lean (excess oxygen) during a steady operation in order to improve the fuel efficiency while combustion has temporarily been performed on the condition that it is stoichiometric (theoretical air-fuel ratio, A/F=14.7) to rich (excess fuel) in order to improve the catalytic activity.
However, noble metal catalysts such as Pt, Pd, and Rh known in the art have low NOx purification performance on low-temperature and oxidization conditions and it is necessary to make the catalyst for purification have high temperature and to add HC (hydrocarbon), CO, or the like to make a reducing atmosphere in order to enhance the purification performance. An air-fuel ratio (A/F) cannot be increased even during a steady operation due to the influence on the catalytic activity, so that the noble metal catalysts provide limited improvement in fuel efficiency.
As described above, in the noble metal catalysts known in the art, energy for making the catalyst for purification have high temperature, fuel for temporarily making the catalyst for purification in a reducing atmosphere, and a reduced air-fuel ratio (A/F) in an engine are needed for obtaining purification performance, so that a new catalyst for purification that can exhibit NOx purification performance at low temperatures and/or in an oxidative atmosphere has been demanded for improving the fuel efficiency of internal combustion engines including automotive engines.
On the other hand, all the noble metal catalysts have the problem of exhaustion of resources, so that a catalyst using another metal, having purification performance equivalent to or better than those of the conventional noble metal catalysts, or a purification catalyst that can be prepared by a reduced amount of the noble metals used has been demanded.
Therefore, various attempts of improvement of catalysts for purification have been made.
For example, Japanese Unexamined Patent Application Publication No. 8-257403 describes an exhaust gas purification catalyst with high thermal resistance and excellent NOx purification performance, which is composed of a composite oxide comprising at least one of transition metal atoms and at least one element of Al and Si and has a part of a surface formed with the transition metal.
In addition, U.S. Pat. No. 3,760,717 describes a low-temperature harmful gas purification catalyst in which the ultrafine particles of at least one metal selected from the group consisting of Pt, Pd, Rh, Ru, Ir, Os, Au, Ag, Cu, Fe, and Ni are carried on the carrier of a metal oxide or a carbonaceous material using a high-temperature high-pressure fluid. In the above-described publication, the purification catalyst in which one of Pt, Pd, Rh, Ru, Fe, Ni, and Au is carried by a high-temperature high-pressure method or a supercritical method is described as a specific example.
Furthermore, Japanese Unexamined Patent Application Publication No. 2003-190787 describes a catalyst for purification of engine exhaust gases in which one or two or more selected from the group consisting of gold, silver, iron, zinc, manganese, cerium, and platinum group elements are carried on 12Cao.7Al2O3 which is a principal component. As a specific example, the catalyst for purification in which gold, silver, platinum, palladium, copper, iron, zinc, manganese, cerium, or rhodium alone or two of silver and rhodium, ruthenium, or copper are carried on 12Cao.7Al2O3 which is the principal component is exhibited to demonstrate the effect of reducing a combustion temperature by oxidation reaction of a particulate matter (PM) by oxygen radicals. However, the above-described publication does not specify the positional relationship between the two metals.
However, these known catalysts for purification do not demonstrate NOx purification performance at low temperatures and in an oxidative atmosphere.
Thus, an object of the present invention is to provide a catalyst that can demonstrate NOx purification performance at low temperatures and/or in an oxidative atmosphere.
As a result of extensive research for the purpose of achieving the object, the present inventors found that the reaction of decomposition of NOx is dissociative adsorption of NOx→desorption of N2 and O2 and a material having a low O2 desorption temperature has high NOx purification performance and, as a result of further examination, the present invention was accomplished.
The present invention relates to a catalyst for purification of nitrogen oxides, the catalyst comprising a solid in which Au and Fe atoms exist in a state of being close.
In accordance with the present invention, a catalyst that can demonstrate NOx purification performance at low temperatures and/or in an oxidative atmosphere can be obtained.
In the catalyst for purification of NOx according to the present invention, Au and Fe atoms preferably exist in a state of being close in a solid.
The state in which the Au and Fe atoms are close in the solid refers to the inclusion in which at least one of first atoms in contact with second atoms of the Au and Fe atoms is in the state of being close in the state of existing in nanoparticles which are primary particles or in a thin film.
Embodiments of the present invention will be explained in detail below with reference to the drawings.
The catalyst for purification of NOx according to the present invention may be in the state of being close in complete solid solution (alloying) in which Au and Fe atoms are homogeneously dispersed on a carrier such as an oxide carrier, for example, as illustrated in
Referring to
This indicates that the decomposition reaction of NO is dissociative adsorption of NO→desorption of N2 and O2 and a material that adsorbs NO and has a low O2 desorption temperature has high purification performance.
No or difficult desorption of O2 has been a factor of lowering the activity of a purification catalyst, NO has not been able to be purified in an oxidative atmosphere by a conventional Rh catalyst, and the metal has been reduced in a stoichiometric or reducing atmosphere to accelerate the desorption of O2 at lower temperatures than the O2 desorption temperature in the oxidative atmosphere. The purification of NO can be performed in an oxidative atmosphere even at a low temperature of around 450° C. since the O2 desorption temperature is decreased by using an FeAu alloy as an active spot. NO is considered to be able to be purified at further lower temperatures than that in the oxidative atmosphere by the presence of a reducing agent since a reduction temperature is lowered with FeAu similarly to the O2 desorption temperature.
In the catalyst for purification of NOx according to the present invention, Au and Fe atoms preferably exist in the state of being close in a solid such as nanoparticles or a thin film, as described above. Therefore, other metal atoms which can be alloyed with both atoms may be included in the part in which both atoms are close whereas an inactive substance such as a carrier material which cannot be alloyed with both atoms may be included only in the range in which it is ensured that both atoms can be in the state of being close. Thus, when it is necessary to use a carrier, the catalyst for purification NOx according to the present invention may be obtained, for example, by obtaining nanoparticles in which both metals are close with the nanoparticles of a material composing the carrier as nuclei or by layering and thinning Au and Fe atoms on a carrier substrate.
The above-described other metal atoms which can be alloyed with both atoms of Au and Fe atoms may include, for example, W (tungsten) which can improve the thermal resistance of Au by the alloying.
In addition, such carrier materials as described above may include Al2O3 (alumina), ZrO2 (zirconia), CeO2 (ceria), TiO2 (titania), and silicon carbide.
When the catalyst for purification of NOx according to the present invention is a thin film, the outermost layer may be any of
In the thin film, the composition of both elements in the outermost layer can be changed by changing the amount of deposited Fe, oxidative and reducing atmospheres, a heating temperature, and heating time. In the catalyst for purification of NOx, such as a thin-film-shaped catalyst, Au and Fe can preferably be alloyed by heating.
The heating can be performed by heating a deposit to a temperature of 450° C. or less, for example, to 350-450° C., for example, with an infrared laser.
The heating may also be a radiation heating method or electron beam heating. In addition, a sample support on which the deposit is put in the heating is preferably one that has a history of being thoroughly heated and, for example, desirably one that does not release a highly reactive gas by the heating.
The catalyst for purification of NOx according to the present invention includes a solid in which Fe or Au preferably has a concentration of 0.2-99.8 atm % based on the total of both elements and their atomic ratio is particularly preferably of 1/13 to 12/13.
In addition, the catalyst for purification of NOx according to the present invention preferably includes the solid which is primary particles or a thin film containing Au and Fe as main components as illustrated in
In accordance with the catalyst for purification of NOx according to the present invention, it is not necessary to increase a heating temperature for increasing NOx purification activity, for example, a heating temperature by a heater to such a high temperature as in the conventional case, and use of fuel for making an atmosphere in a reduced state becomes unnecessary or can considerably be decreased since it has NOx purification activity even in an oxidative atmosphere.
In addition, in accordance with the catalyst for purification of NOx according to the present invention, it is not necessary to lower an air-fuel ratio (A/F) in an engine and, for example, a high air-fuel ratio (A/F), e.g., A/F of more than 14.7, e.g., A/F≧20, in the case of a gasoline engine and A/F≧30 in the case of a diesel engine can theoretically be enabled during a steady operation.
Examples of the present invention will be described below.
In each Example below, the evaluations of an obtained catalyst were performed by measurement methods described below.
1. Measurement of O2 Desorption Temperature and N2 Desorption Temperature
Measurement Method Measurement of peak intensity by AES (Auger Electron Spectroscopy) at varied heating temperatures
Measuring Apparatus: KITANO SEIKI KCMA2002
2. Measurement of Temperature of Dissociative Adsorption of NO
Measurement Method Measurement of XPS (X-ray photoelectron spectroscopy) spectra at varied heating temperature
Measuring Apparatus: OSCA1600
3. Measurement of Surface Elemental Composition Ratio of Catalyst
Measurement Method Measurement of Au:Fe composition ratio by AES (Auger Electron Spectroscopy)
Measuring Apparatus: KITANO SEIKI KCMA2002
4. Measurement of Alloying of Catalyst
Measurement Method Measurement of Composition of Whole Bulk by XRD (X-Ray Diffraction)
Measuring Apparatus: PHILIPS X′Pert MRD
5. Measurement of Surface State of Catalyst
Measurement Method Measurement of secondary electron image by SEM
SEM Measuring Apparatus: ZEISS ULTRA55
Au and then Fe were deposited on an Al2O3 (sapphire) substrate to form a thin film and to prepare a catalyst for purification of NOx in each step as described below. Then, the thin film was heat-treated.
1) A Au-sputtered film was made on the Al2O3 (sapphire) substrate by ion sputtering (HITACH E101 Energy 100 eV, Ion Current 15 mA). The homogeneous Au film with a thickness of about 30 nm was deposited by performing the sputtering for 2 minutes×5 times (10 minutes in total). The secondary electron images of the surface after the deposition of Au by AES are illustrated in
2) The deposit is transported into the vacuum chamber of the PLD (Pulsed Laser Deposition) apparatus [including analyzing measures: Auger electron spectroscopy (AES) and X-ray photoelectron spectroscopy (XPS)] having a mechanism as illustrated in the schematic view in
Ideally, the PLD and the analyzing measures are in-situ. However, it is not necessary to be in-situ and it may be exposed temporarily to the atmosphere and transported if pretreatment as described below can be performed just before analysis.
3) Surface pretreatment is performed by Ar sputtering on the conditions of 0.5 eV, Cham. Pre., and 1.8×10−4 Torr for 30 minutes and twice repeating the conditions of 450° C. and 25 minutes as annealing.
4) As illustrated in
5) The deposit is heated to 350° C. and alloyed by an infrared laser. The surface after the heating is illustrated in
For the heating, the sample support on which the deposit was put and which had a history of being thoroughly heated and did not release a highly reactive gas by heating was used.
The surface composition after the heating by AES was about 40:60 (Fe:Au, atomic ratio).
Subsequently, the obtained catalyst was evaluated in the following steps.
6) A NO gas amount of about 1-10 Langmuir (5.0×10−6 Pa, 44s/1 Langmuir at room temperature) is introduced into the chamber to make the catalyst adsorb the NO gas.
7) The peaks of N1s, O1s, Fe2p, Au4f, and the like are observed with XPS (Φ ESCA1600, Monochlo Al—Ka (1486.7 eV), 350 W, 14.0 kV) to analyze dissociative adsorption characteristics by XPS. The results are indicated in
It was found from
8) The catalyst sample is heated by increasing its temperature by 50° C. with the infrared laser to observe variations in N and O peaks with AES (PHI, Energy 1.5 kV, Fil. Cur. 1.9 A, Emi. Cur. 0.9 mA). The measurement results are indicated in
Furthermore, the results of the XRD measurement of the deposit after the deposition of Fe and the deposit after the heat treatment at 350° C. are indicated in
Only Fe was deposited on an Al2O3 (sapphire) substrate using the PLD as illustrated in
For the obtained deposit sample, the catalyst sample was heated by increasing its temperature by 50° C. with the infrared laser in the same manner as in the step 8) in Example 1 to observe variations in N and O peaks with AES. The measurement results are indicated in
For Rh single crystals, a NO gas amount was introduced into the chamber to make Rh adsorb the NO gas and N1s XPS spectra and O1s XPS spectra were measured with XPS to analyze dissociative adsorption characteristics by XPS, in the same manner as in the steps 6) and 7) in Example 1. The measurement results are indicated in
For Au single crystals, a NO gas amount was introduced into the chamber to make Rh adsorb the NO gas and N1s XPS spectra and Au4f XPS spectra were measured with XPS to analyze dissociative adsorption characteristics by XPS, in the same manner as in the steps 6) and 7) in Example 1. The measurement results are indicated in
Au and Fe were deposited on an Al2O3 substrate so that they existed at a distance not to be close. When the concentrations of both elements in the surface of the obtained deposit in which Au and Fe separately existed were measured by AES, the surface Fe concentration was 40 atm. %.
The NO decomposition and desorption characteristics of the deposit after the heat treatment were evaluated. The measurement results are indicated in
A layered thin film with Fe of several nanometers/Au of 50 nm was formed on an Al2O3 substrate in the same manner as in Example 1.
The obtained deposit was heat-treated at varied temperatures.
The heating temperatures and the concentrations of both elements in a surface were measured by AES. The relationships between the heat treatment temperatures and the surface concentrations of Au/Fe are indicated in
It is understood from
The NO decomposition and desorption characteristics of the heat-treated catalyst in Example 2 (surface concentration of Fe: 40 atm. %), the catalyst after the deposition of Fe in Example 2 (surface concentration of Fe: 100 atm. %), and the catalysts prepared by heat-treating the deposits in which Fe exists in Comparative Example 1, Rh exists in Comparative Example 2, and Fe and Au separately exist in Comparative Example 4 were evaluated. The results are summarized in
It is clear from
In addition, when Fe and Au exist to be close in the solid composed of the layered thin film, the temperature of the dissociative adsorption of O2 is decreased to about 700° C. even if the surface contains Fe of 100%, so that the above-described advantage offered by the present invention is observed.
In accordance with the catalyst for purification of NOx according to the present invention, Au of which at least a part can be calculated in Japan and Fe which exists on the Earth in a large quantity can be used from the viewpoint of exhaustion of resources, it is not necessary to increase a heating temperature for increasing NOx purification activity to such a high temperature as in the conventional case, use of fuel for making an atmosphere in a reduced state become unnecessary or the purification of NOx is enabled from at least low temperatures since it has NOx purification activity even in an oxidative atmosphere, it is not necessary to make an air-fuel ratio (A/F) in an engine in a steady state approximately stoichiometric (A/F=14.7), and an operation at a high air-fuel ratio (A/F), e.g., A/F=20, in the case of a gasoline engine and A/F=30 in the case of a diesel engine can theoretically be enabled.
Number | Date | Country | Kind |
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2009-244704 | Oct 2009 | JP | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/JP2010/069232 | 10/22/2010 | WO | 00 | 7/2/2012 |