Oxidation catalyst, method for preparing same, and filter for exhaust gas purification comprising same

Patent metadata

Field	Value
Publication number	US-10046312-B2
Application number	US-201415037598-A
Country	US
Kind code	B2
Filing date	Nov 18, 2014
Priority date	Nov 18, 2013
Publication date	Aug 14, 2018
Grant date	Aug 14, 2018

Abstract

The present invention relates to an oxidation catalyst, a method for preparing the same, and a filter for exhaust gas purification comprising the same and, more specifically, to an oxidation catalyst, a method for preparing the same, and a filter for exhaust gas purification comprising the same, the oxidation catalyst being formed by comprising an amorphous metal alloy powder, thereby being preparable at a low cost, being capable of enhancing purification efficiency for exhaust gas when applied to the filter for exhaust gas purification, and being capable of deriving reliability enhancement for operation of an exhaust gas purifier having the filter for exhaust gas purification mounted therein. To this end, the present invention provides an oxidation catalyst, a method for preparing the same, and a filter for exhaust gas purification comprising the same, the oxidation catalyst characterized by being coated onto the carrier surface of the filter for exhaust gas purification and being formed by comprising an amorphous metal alloy powder.

First claim

The invention claimed is:

1. A method of preparing an oxidation catalyst that coats a surface of a carrier of an exhaust gas purification filter, the method comprising:
a melting step of melting a metal and a master alloy, producing a molten metal alloy comprising the metal and the master alloy;
a rapid cooling step of producing an amorphous metal alloy by rapidly cooling the molten metal alloy; and
a powdering step of converting the amorphous metal alloy into powder, wherein the powdering comprises pulverization after vacuum atomization or melt spinning.

2. The method of claim 1 , wherein, in the melting step, at least one element selected from the group consisting of Fe, Ni, Mn, Co, Zr, and Pt and at least two elements selected from the group consisting of B, Y, Ti, P, Pd, Be, Si, C, Ag, Na, Mg, Ga, and Al are used as the metal and the master alloy.

3. The method of claim 2 , wherein, in the melting step, Fe, B, Y, Ti, and Pt are used as the metal and the master alloy.

4. The method of claim 3 , wherein, in the melting step, Fe, B, Y, Ti, and Pt are used as the metal and the master alloy at ratios of at least 50 atomic % of Fe, 10 to 30 atomic % of B, 5 to 20 atomic % of Y, and 0 to 10 atomic % of Ti+Pt.

5. The method of claim 1 , wherein, in the rapid cooling step, the molten metal alloy is cooled at a cooling rate ranging from 100° C./s to 1,000,000° C./s.

6. The method of claim 1 , further comprising a step of increasing a surface roughness value of the amorphous metal alloy after the powdering step.

7. The method of claim 1 , further comprising an oxidation step of oxidizing the amorphous metal alloy powder at a temperature ranging from 300° C. to 600° C. in an oxygen atmosphere.

8. The method of claim 7 , wherein, after the oxidation step, the oxidation catalyst comprising the amorphous metal alloy powder has a performance of converting CO into CO 2 of 95% or higher at 150° C. and does not react with NO.

9. The method of claim 7 , wherein, after the oxidation step, the oxidation catalyst comprising the amorphous metal alloy powder has an oxidation performance for NH 3 of 75% or higher at 300° C. and produces no NO 2 by-product during oxidation of NH 3 .

10. The method of claim 7 , wherein, in the oxidation step, a surface structure of the amorphous metal alloy changes from an FeO structure, in which a degree of oxidation of Fe in the amorphous metal alloy is +2, to an Fe 2 O 3 structure, in which a degree of oxidation of Fe in the amorphous metal alloy is +3, as a heat treatment temperature increases.

Assignees

• Corning Prec Materials Co Ltd

Inventors

• Kim Wun Gwi
• Kim Min Seok
• Kim Hyung Rae
• Lee Goo Soo
• Chang Jae Myung

Classifications

• B01D2255/915

  Catalyst supported on particulate filters · CPC title

• B01D2255/9202

  Linear dimensions · CPC title

• F01N2510/06

  for exhaust purification, e.g. catalytic reaction · CPC title

• B01J23/83

  with rare earths or actinides · CPC title

• B01D2257/406

  Ammonia · CPC title