Honeycomb structure and catalyst for cleaning exhaust gas using same, and method for producing catalyst for cleaning exhaust gas

Patent metadata

Field	Value
Publication number	US-10946366-B2
Application number	US-201816054146-A
Country	US
Kind code	B2
Filing date	Aug 3, 2018
Priority date	Mar 27, 2014
Publication date	Mar 16, 2021
Grant date	Mar 16, 2021

Abstract

The present invention addresses the problem and purpose of providing a honeycomb structure that has a sufficiently high strength and is excellent in endurance, and a catalyst for cleaning an exhaust gas using the same that is excellent in resistance to sulfur oxide (SOX). The honeycomb structure of the present invention is one consists of a flat inorganic fiber sheet comprising an inorganic fiber sheet having supported thereon an inorganic binder and zeolite, and a corrugated inorganic fiber sheet comprising an inorganic fiber sheet having supported thereon the same inorganic binder and zeolite, which are alternately combined with each other, wherein it is characterized in that the zeolite has a particle diameter (i.e., a median particle diameter, D50) of from 0.5 to 10.0 μm.

First claim

The invention claimed is:

1. A method for producing a catalyst for cleaning an exhaust gas using a honeycomb structure,
wherein the honeycomb structure consists of
a flat inorganic fiber sheet comprising an inorganic fiber sheet having supported thereon an inorganic binder and zeolite and
a corrugated inorganic fiber sheet comprising an inorganic fiber sheet having supported thereon the same inorganic binder and zeolite,
which are alternately combined with each other; and

the zeolite has a median particle diameter of from 0.5 to 10.0 μm;
wherein the catalyst comprises a denitration catalyst component that is supported on the zeolite of the honeycomb structure;
wherein the denitration catalyst component is bismuth; and
wherein the method comprises
a step of supporting bismuth (Bi) on the zeolite by an ion exchange method,
in the step, bismuth (Bi) being dissolved in a solvent, the solvent is a compound having one or more alkoxy group and one or more hydroxy group per molecule, a compound having two or more hydroxy groups per molecule, or an acid.

2. A method for producing the catalyst for cleaning an exhaust gas according to claim 1 ,
wherein the inorganic fiber sheet is a glass fiber sheet.

3. A method for producing the catalyst for cleaning an exhaust gas according to claim 1 ,
wherein an inorganic acid salt or an organic acid salt is used as a precursor compound of bismuth being supported on the zeolite.

4. A method for producing the catalyst for cleaning an exhaust gas according to claim 3 ,
wherein the inorganic salt is nitrate or chloride.

5. A method for producing the catalyst for cleaning an exhaust gas according to claim 3 ,
wherein an organic acid salt is acetate.

6. A method for producing the catalyst for cleaning an exhaust gas according to claim 1 ,
wherein the solvent is a compound having two or more hydroxy groups per molecule.

7. A method for producing the catalyst for cleaning an exhaust gas according to claim 6 ,
wherein the compound having two or more hydroxy groups per molecule is a diol compound.

8. A method for producing the catalyst for cleaning an exhaust gas according to claim 7 ,
wherein the diol compound is ethylene glycol.

9. A method for producing the catalyst for cleaning an exhaust gas according to claim 1 ,
wherein the method further comprises:
a step of providing a slurry of bismuth and zeolite,
agitating the slurry of bismuth and zeolite with heating followed by cooling to room temperature,
adding an inorganic binder to the slurry to form a catalyst slurry, and
coating an inorganic fiber sheet with the catalyst slurry.

10. The method for producing a catalyst for cleaning an exhaust gas using a honeycomb structure according to claim 9 , wherein the slurry is agitated at 60° C. for three hours.

11. The method for producing a catalyst for cleaning an exhaust gas using a honeycomb structure according to claim 9 , wherein the inorganic binder is zirconia.

Assignees

• Hitachi Zosen Corp

Inventors

• Hikazudani Susumu
• Shono Emi
• Shimizu Kana

Classifications

• F01N2370/04

  Zeolitic material · CPC title

• F01N2330/30

  Honeycomb supports characterised by their structural details · CPC title

• F01N2330/10

  Fibrous material, e.g. mineral or metallic wool · CPC title

• B01D2255/9202

  Linear dimensions · CPC title

• B01D2255/50

  Zeolites · CPC title