DETAILED DESCRIPTION OF THE INVENTION

[0039] Hereinafter, detailed explanations are made about the catalyst and process for purification of exhaust gases according to the present invention, but the scope of the present invention is not bound to these explanations, and modes other than the below-mentioned examples can also be carried out fittingly within the range not damaging the spirit of the present invention.

[0040] (CO-Containing Exhaust Gases):

[0041] The catalyst for purification of exhaust gases and the process for purification of exhaust gases, according to the present invention, are applicable to carbon monoxide (CO)-containing exhaust gases as discharged from conventional various industrial apparatuses and facilities (hereinafter referred to as supplying sources), specifically, combustion exhaust gases from such as boilers, gas turbines, diesel engines, gas engines, heating furnaces, and various industrial processes.

[0042] Components, which are contained in the combustion exhaust gases, differ according to the aforementioned supplying sources and also to environmental conditions such as emission regulation. Specific examples of gas components which can have bad effects on environment, besides CO, include nitrogen oxides (NO _x ) and sulfur oxides (SO _x ).

[0043] In cases of the combustion exhaust gases, they may contain volatile organic compounds which are components derived from fuel but has not been burned, and their bad effects on environment are made problems of.

[0044] The catalyst for purification of exhaust gases, according to the present invention, is effective also for purification of the exhaust gases containing the above nitrogen oxides (NO _x ) and/or volatile organic compounds in addition to CO, and further can suppress the SO ₂ -oxidizing ratio to low.

[0045] There are cases where the exhaust gases are subjected to various purification of exhaust gases before the purification step is carried out with the catalyst for purification of exhaust gases according to the present invention. Accordingly, there are cases where components of the exhaust gases in the stage of having been discharged from the aforementioned supplying sources are different from those in the stage of being subjected to purification of exhaust gases with the catalyst for purification of exhaust gases according to the present invention.

[0046] The catalyst for purification of exhaust gases and the process for purification of exhaust gases, according to the present invention, are effective also for low-concentration-CO-containing exhaust gases which are difficult to efficiently purify with conventional catalysts for purification of exhaust gases and conventional processes for purification of exhaust gases. Specifically, the catalyst for purification of exhaust gases and the process for purification of exhaust gases, according to the present invention, are effective even for exhaust gases having a CO concentration of not higher than 100 ppm.

[0047] As to the exhaust gases, the temperature conditions or the velocity varies with conditions of discharge from the aforementioned supplying sources or with hysteresis of till before the implementation of the purification of exhaust gases.

[0048] (Catalyst):

[0049] The catalyst according to the present invention comprises a support and a catalytic component wherein the catalytic component is supported on the support. Hereinafter, detailed explanations are made about them.

[0050] <Support>:

[0051] The support, used for the catalyst for purification of exhaust gases according to the present invention, needs to include a titanium-containing oxide. The titanium-containing oxide referred to herein may be an oxide of Ti (titanium) alone (titanium oxide), or a composite oxide including a combination of Ti and at least one element selected from the group consisting of Si (silicon), Al (aluminum), W (tungsten), and Zr (zirconium). The titanium-containing oxide may be a mixture of this composite oxide (titanium-containing composite oxide) and the titanium oxide. Incidentally, the support may be a mixture of the above titanium-containing oxide with a non-titanium oxide usable for conventional supports, and examples of this non-titanium oxide include silica, alumina, silica-alumina, zirconia, and zeolite. Hereinafter, the “titanium-containing oxide” is referred to, inclusive also of such a mixed form.

[0052] In the above titanium-containing oxide, the Ti content is favorably in the range of 5 to 95 mol %, more favorably 20 to 95 mol %, relative to the total molar number of Ti and the other elements in the whole of the above titanium-containing oxide.

[0053] The support including the titanium-containing oxide not merely has the function of supporting the catalytic component, but also contributes to a function of keeping the supported state of the catalytic component, as supported on the titanium-containing oxide support, suitable for removal of CO, thereby enhancing the exhaust gas purification function of the catalytic component. As a result, high CO-removal efficiency is obtained without increasing the supported quantity of the catalytic component.

[0054] Particularly, the use of the Ti—Si-composite oxide has the advantage of giving what has a low SO ₂ -oxidizing ratio and is excellent in the exhaust gas purifiability.

[0055] The support, used for the catalyst for purification of exhaust gases according to the present invention, is a monolithically molded type porous honeycomb support obtained by a process including the steps of extrusion-molding and then calcining materials of the support.

[0056] In preparation for the titanium-containing oxide used as a material of the support, there can be adopted the same means as of conventional titanium-containing oxides, and examples thereof include techniques as disclosed in such as JP-A-146991/1978. Particularly, a technique as disclosed in the specification of Japanese Patent Application No. 2000-099593 (JP-A-062292/2001) as previously filed by the present applicant can be cited as a favorable technique.

[0057] As to raw materials for supplying the titanium-containing oxide used as a material of the support, a beforehand prepared titanium-containing oxide can be used as it is, and besides, compound materials which can produce the titanium-containing oxide by calcination can also be used. Specifically, both inorganic and organic compounds can be used, and usable examples thereof include hydroxides, ammonium salts, ammine complexes, oxalates, halides, sulfates, nitrates, carbonates, and alkoxides, all of which contain predetermined metals including Ti as an essential component.

[0058] The support, as used for the catalyst for purification of exhaust gases according to the present invention, is a honeycomb support and is therefore produced by a process including the steps of: molding the materials of the support containing the above titanium-containing oxide into a honeycomb form by extrusion molding; and then calcining the resultant molded structure; thereby forming a monolithically molded type porous honeycomb support.

[0059] Basically applicable to the above production process are the same production conditions as those for conventional porous honeycomb supports.

[0060] The materials of the support are extrusion-molded either in a state left as they are powdery, or in the form of such as a powder-dispersed slurry, with such as conventional extrusion molding apparatuses. Setting of the die shape of the extrusion molding apparatuses can adjust the shape and measurements and the′ inner wall thickness of the aimed gas passageways.

[0061] The molded product from the extrusion-molding is cut every predetermined length, thus obtaining the extrusion-molded structure. A change of the cutting interval can adjust the length of the porous honeycomb support.

[0062] The extrusion-molded structure is dried and/or aged, if necessary, and then calcined with such as calcination furnaces, thus obtaining the honeycomb support. The treatment conditions such as calcination temperature and calcination time can be set in the same range as that for production of conventional supports.

[0063] The honeycomb support obtained in this way is a porous support.

[0064] The porous support is a support of the porous structure having fine pore spaces. The porous support can support the catalytic component not only on its outer surfaces but also inside the fine pore spaces. The contact area between the exhaust gases and the catalytic component is so large that the purification reaction is efficiently carried out.

[0065] If the titanium-containing oxide is contained in materials of the support, the function of adsorbing and retaining the exhaust gas components in the porous structure is well displayed. Not only on outer surfaces of the support but also inside the porous structure of the support, the supported catalytic component and the titanium-containing oxide synergistically function to efficiently achieve the purification of exhaust gases.

[0066] The honeycomb support is such that a plurality of gas passageways through which the exhaust gases pass are arranged lengthwise and crosswise. The gas passageways are partitioned off by comparatively thin inner walls. The honeycomb support is what is called a honeycombed support. Specifically, it has such a structure as illustrated by FIG. 1 .

[0067] As to the sectional shape of the gas passageways, not only hexagons similar to honeycombs but also squares, rectangles, and other polygons are adoptable. There is also a case where curved shapes such as circles and ovals are included.

[0068] The measurements of the gas passageways differ also according to conditions such as the quantity of the exhaust gases being passed and the purifiability. Fittingly for the purpose, there can be set such as the one-edge length W (which may be referred to as “(mesh) opening size”) of the gas passageways, the inner wall thickness T, the opening ratio, the length of the gas passageways (i.e. the length L of the porous honeycomb support in a direction parallel to an exhaust gas flow direction during the use), and the number of the gas passageways.

[0069] The gas passageways may be arranged lengthwise and crosswise in the form of a straight lattice, or can also be arranged in the form of hound's tooth or spirally.

[0070] As to the sectional shape of the whole porous honeycomb support, squares, rectangles, and other polygons are adopted. Curved shapes such as circles are also adoptable.

[0071] The porous honeycomb support is more excellent in respect to the catalyst-supporting function and the catalytic activity than a sintered honeycomb support (including such as cordierite) conventionally known as a catalyst support. The sintered honeycomb support is a sintered structure as sintered usually in the range of about 1,200 to about 1,450° C., and is in the form of so well-sintered-and-set porcelain as to have an extremely small specific surface area. However, the porous honeycomb support, according to the present invention, is a product obtained by calcination at a comparatively low calcination temperature, specifically, in the range of 200 to 600° C., and has a porous structure of the large specific surface area throughout the entirety of from surface to inside of the support. As a result, the porous honeycomb support can support the catalytic component much inside the porous structure, so it becomes possible to obtain a honeycomb-shaped catalyst having high catalytic activity. As to the conventional sintered honeycomb support, the porous structure is absent, or slightly present even if any, inside the support, so the catalytic component cannot be supported much inside the support, and the catalytic activity cannot be displayed enough.

[0072] The porous honeycomb support, as referred to in the present invention, is a monolithically molded type honeycomb support and is therefore very excellent in the exhaust gas purification efficiency. Specifically, the porous honeycomb support, as referred to in the present invention, is not a honeycomb support obtained by such as a process in which: a framework structure made of metals and/or cordierite for forming a honeycomb structure is separately used besides materials of the support, and surfaces of the above framework structure are coated with the above materials of the support; but a honeycomb support obtained by a process involving molding the materials themselves of the support into a honeycomb form basically without using the above framework structure, so the exhaust gases being purified can pass not only through the finely partitioned gas passageways from the gas inlet side to the gas outlet side but also through the inner wall portions which partition the gas passageways off. As to the honeycomb support having the above framework structure, the exhaust gases do not pass through the inner wall portions in this way, whereas, as to the monolithically molded type honeycomb support, the purification efficiency can be more enhanced correspondingly to the passage of the exhaust gases through the inner wall portions.

[0073] <Catalytic Components and Supporting Thereof>:

[0074] (Catalytic Component A):

[0075] As to the catalyst for purification of exhaust gases according to the present invention, as the catalytic component A there is used a catalytic component including a noble metal element. As the noble metal element, for specific example, there is used at least one member selected from the group consisting of Pt, Pd, Rh, Ru, Ir, and Au. The catalytic component A may be a metal including the above noble metal element, or such as a compound (e.g. oxide) thereof.

[0076] Usable as raw materials for supplying the catalytic component A are materials utilized for such as production of conventional catalysts. Specific examples thereof include nitrates, halides, ammonium salts, ammine complexes, and hydroxides.

[0077] As to means for supporting the catalytic component A on the support, basically, there can be adopted those which are common to conventional metal-oxide-supported noble metal catalysts. In the treatment step of supporting the catalytic component A on the support, arrangements are made to support the catalytic component A in the form distributed with a quantitatively great inclination toward the neighborhood of outer surfaces (specifically, the outer surfaces and/or the inside near the outer surfaces) of the support in a high concentration.

[0078] In the case where the catalyst and the exhaust gases are brought into contact with each other at a high space velocity (SV) to remove the CO from the exhaust gases, most of the purification action by the catalyst can be considered to occur in surface layer portions of the catalyst. In such a case, the efficiency of the purification of the exhaust gases with the catalyst can be enhanced by supporting the catalytic component A in the form distributed with a quantitatively great inclination toward the catalyst surface layer portions with which the exhaust gases come into contact.

[0079] The quantity of the supported catalytic component A differs according to such as combinations of materials or treatment conditions of supporting treatment, but usually the catalytic component A is used in the range of 0.005 to 2.0 weight %, favorably 0.01 to 1.0 weight %, of the entirety of the catalyst. The reason therefor is as follows. In the case where the quantity of the supported catalytic component A is too small, the catalytic activity is low. Also in the case where the quantity of the supported catalytic component A is too large, the effect is hopeless of enhancement of the activity, and the economical performance is merely damaged, and further, there occur unfavorable effects such that the conversion of SO ₂ →SO ₃ is high.

[0080] The catalytic component A is usually supported in the form of particles on the support. As to particle diameters of the catalytic component A, those which have an average particle diameter of not larger than 30 nm are favorable. More favorably, the average particle diameter is not larger than 20 nm. The smaller the particle diameters of the catalytic component A are and the higher the degree of the dispersed state of the catalytic component A is, the higher the activity becomes.

[0081] (Catalytic Component B):

[0082] As to the catalyst for purification of exhaust gases according to the present invention, as the catalytic component B there can further be used a catalytic component including at least one element as included in groups I to III in a periodic table. Specific examples of the element as included in groups I to III in a periodic table include Na, Li, Mg, Ca, Y, Ce, and La. The catalytic component B may be a metal including the above element as included in groups I to III in a periodic table, or such as a compound (e.g. oxide) thereof.

[0083] If the catalyst further comprising the catalytic component B as another catalytic component is used, then the purifiability becomes better than in the case of supporting the catalytic component A alone, so the quantity of the catalytic component A as used can effectively be decreased. In addition, at the same time, the coexistence of the catalytic component B in the catalyst suppresses the oxidation of SO ₂ , and also enhances the resistance to the SOX and the heat resistance, so that it is possible to maintain the purification efficiency stably for a long term even if the quantity of the supported catalytic component A is small.

[0084] Raw materials for supplying the catalytic component B are not especially limited, and at least one materials as utilized for such as production of conventional catalysts are usable, but favorable examples thereof include those which contain organic components (e.g. organic acids) in their molecules, such as organic acid salts, alkoxides, and organometallic complexes.

[0085] The process for supporting the catalytic component B is not especially limited, either, and the catalytic component B can be supported by processes as utilized for production of conventional catalysts.

[0086] The quantity of the supported catalytic component B is favorably in the range of not larger than 20 weight %, more favorably 0.01 to 20 weight %, still more favorably 0.1 to 10 weight %, of the entirety of the catalyst. In the case where the quantity of the supported catalytic component B is too small, the above effect peculiar to the catalytic component B is not obtained. Even if the quantity of the supported catalytic component B is increased to larger than the above ranges, the effect is hopeless of enhancement of the activity, and the activity may inversely be deteriorated.

[0087] There is no especial limitation with regard to the supporting order, either. The catalytic component B may be supported any time of following, preceding, and simultaneously with the catalytic component A. Above all, it is favorable to support the catalytic component B following or simultaneously with the catalytic component A.

[0088] (Supporting of Catalytic Components A and B):

[0089] The catalyst for purification of exhaust gases, according to the present invention, comprises supporting of the above catalytic component A and, if necessary, the above catalytic component B, thereby having the aforementioned functions and effects. In each of cases where the supported state of the catalytic component A and the supported state of the catalytic component B are further combined in the following ways, there are peculiar functions and effects. Specific examples of the above cases include the following: 1) a case where the catalytic components A and B are both distributed with a quantitatively great inclination toward surfaces of the catalyst; and 2) a case where the catalytic component A is distributed with a quantitatively great inclination toward surfaces of the catalyst, whereas the catalytic component B is present quantitatively substantially evenly throughout the whole catalyst. Incidentally, explanations are hereinafter made about the supported state of being distributed with a quantitatively great inclination toward surfaces and the quantitatively substantially evenly supported state, but the explanations of such as supporting quantity are made independently of each other as to the catalytic components A and B.

[0090] That is to say, for the catalytic component to be distributed with a quantitatively great inclination toward surfaces of the catalyst (distribution inclined quantitatively greatly toward surfaces), it is enough that, in the catalyst resultant from supporting of the catalytic component in surfaces of the support and/or in the neighborhood of those surfaces, the catalytic component is present in surface layers of this catalyst or present in the neighborhood of surfaces of this catalyst with the distribution range being wide to some degree in a direction deeper than the above surface layers, so there is no especial limitation. For specific example, in a drawing figure (graph) showing the relation between the sectional thickness direction of the inner wall portions of the honeycomb-shaped catalyst and the X-ray intensity I characteristic of the catalytic component A or B as obtained by continuously measuring (carrying out linear analysis measurement of) an inner wall portion of the honeycomb-shaped catalyst as to the designated catalytic component in a direction from an outer surface of the inner wall portion toward its opposite outer surface with an electron probe microanalyzer (EPMA), when the integrated value of the X-ray intensity I throughout the whole of the sectional thickness T of the aforementioned inner wall portions is represented by No and when the integrated value of the X-ray intensity I of from outer surfaces of the inner wall portions to portions of the depth of T/4 in a direction toward the inside of the inner wall portions is represented by N, then 70≦(N/N ₀ ×100) is favorable, and 80≦(N/N ₀ ×100) is more favorable, and 90≦(N/N ₀ ×100) is still more favorable, and 95≦(N/N ₀ ×100) is particularly favorable.

[0091] More specifically, for example, favorably not less than 70 weight % (more favorably not less than 80 weight %, still more favorably not less than 90 weight %, particularly favorably not less than 95 weight %) of the total quantity of the catalytic component, as supported on the honeycomb support, is distributed with a quantitatively great inclination toward the range of from outer surfaces to a depth of 100 μm in the catalyst. Defining the quantity of the existence in the range of from outer surfaces to a depth of 100 μm in the catalyst in this way is favorable for the case where the inner wall thickness of the honeycomb-shaped catalyst is not less than 0.3 mm, more favorably in the range of 0.3 to 1.0 mm, still more favorably in the range of 0.3 to 0.6 mm.

[0092] On the other hand, that the catalytic component is present quantitatively substantially evenly throughout the whole catalyst is not limited to that the catalytic component is present in a quantitatively completely evenly distributed state throughout the whole catalyst, but, for example, the catalytic component may be distributed in the range of the neighborhood of surfaces more than average, or otherwise the catalytic component may be distributed inside the catalyst more than in its surfaces. In short, a form of the presence other than the above distribution inclined quantitatively greatly toward surfaces is enough. Specifically making mention with the above definition for No and N, this other form of the presence is shown by (N/N ₀ ×100)<70 and, favorably for being said to be quantitatively evener, (N/N ₀ ×100)<65, more favorably (N/N ₀ ×100)<60. Specifically making mention in the same way as of the case of the distribution inclined quantitatively greatly toward surfaces, the ratio of the catalytic component existing in the range of from outer surfaces to a depth of 100 μm in the catalyst relative to the total quantity of the catalytic component, as supported on the honeycomb support, is less than 70 weight % and, favorably for being said to be quantitatively evener, less than 65 weight %, more favorably less than 60 weight %.

[0093] As to the case where the catalytic components A and B are both distributed with a quantitatively great inclination toward surfaces of the catalyst, there are the following functions and effects. The CO-removing reaction mainly occurs in surfaces of the catalyst. Therefore, if arrangements are made in such a manner that the catalytic component A (which is a noble metal) and the catalytic component B (which is an element as included in groups I to III in a periodic table) can be both distributed with a quantitatively great inclination toward surfaces, even if the supporting quantity is the same, then the reaction efficiency can greatly be enhanced, and the economical performance is also excellent. In addition, the catalytic component B can enhance the CO-removing activity of the catalytic component A by what is called promoter effect.

[0094] As to the case where the catalytic component A is distributed with a quantitatively great inclination toward surfaces of the catalyst, whereas the catalytic component B is present quantitatively substantially evenly throughout the whole catalyst, then there are the following functions and effects. That is to say, the achievement of high CO-removing activity usually requires the catalyst to have high oxidizability, but demanded is selectivity such that the SO ₂ -oxidizing (SO ₂ →SO ₃ ) activity is desired to be suppressed to as low as possible. In addition, the element as included in groups I to III in a periodic table can effectively scavenge SO _x , and is therefore considered to consequently be also able to suppress the SO ₂ -oxidizing activity. The CO-removing reaction mainly occurs in surfaces of the catalyst, and the oxidation reaction of SO ₂ can occur also inside the catalyst. Therefore, if the catalytic component A (which is a noble metal) is caused to be distributed with a quantitatively great inclination toward surfaces, whereas the catalytic component B (which is an element as included in groups I to III in a periodic table) is caused to exist quantitatively substantially evenly throughout the whole catalyst, then the above selectivity as demanded to the catalyst can efficiently be enhanced.

[0095] In the present invention, the catalytic component A may be supported in the form distributed with a quantitatively great inclination toward surfaces of the catalyst, whereas the catalytic component B may be supported in the form either distributed with a quantitatively great inclination toward surfaces of the catalyst or existing quantitatively substantially evenly throughout the whole catalyst. However, hereinafter, explanations are made about both of these supported states of the distribution inclined quantitatively greatly toward surfaces and the quantitatively substantially even existence.

[0096] As to treatment processes for supporting the catalytic components A and/or B on the support, although there is no especial limitation, for example, a supporting technique by impregnation (impregnation of a solution or mixed solution (impregnation solution) containing the raw materials for supplying the catalytic components (hereinafter such raw materials are also referred to simply as catalytic components)) is favorably applicable thereto. In the case where the catalytic component is supported by the impregnation, the catalytic component is, for example, supported by chemical or physical adsorption. However, whether the supporting of the catalytic component is carried out by chemical adsorption or by physical adsorption is determined by how the kinds of the support and of the catalytic component being adsorbed are selected and combined, for specific example, as follows: in the case where the support is a titanium-containing oxide including such as oxides of silicon, aluminum, tungsten, and zirconium and where the catalytic component is hexaammineplatinum hydroxide, the treatment is mainly carried out by chemical adsorption; and in the case where the support is a titanium-containing oxide including such as oxides of silicon, aluminum, tungsten, and zirconium and where the catalytic component is an acetate of an element as included in groups I to III in a periodic table, the treatment is mainly carried out by physical adsorption.

[0097] Generally, in the case of the chemical adsorption, the support and the catalytic component are strongly bonded to each other, so, once the adsorption is achieved, the migration of the catalytic component from the support is difficult to occur. Accordingly, in the case where the support is impregnated with the impregnation solution containing the catalytic component (for example, in the case where the support is impregnated with such as an aqueous solution in which the catalytic component is dissolved), the adsorption usually runs precedently from surfaces of the catalyst either with the progress of the absorption of the impregnation solution or by attainment of the catalytic component (as diffused in the impregnation solution (also including that before being adsorbed by the support)) to absorption sites of the support, so that the migration of the catalytic component is difficult to cause by subsequent drying. Thus, in the case where the catalytic component is caused to be distributed with a quantitatively great inclination toward surfaces, it is, for example, enough to shorten the impregnation time, whereas, in the case where the catalytic component is caused to exist quantitatively substantially evenly throughout the whole catalyst, it is, for example, enough to lengthen the impregnation time. That is to say, as to the supporting of the catalytic component by the chemical adsorption, it can be considered that the supported state of such as whether the catalytic component is caused to be distributed with a quantitatively great inclination toward surfaces or to exist quantitatively substantially evenly is influenced to some degree also by drying conditions, but much by impregnation conditions such as the impregnation time.

[0098] Generally, in the case of the physical adsorption, the bonding between the support and the catalytic component is weaker than in the case of the chemical adsorption. Accordingly, in the case where the support is impregnated with the impregnation solution containing the catalytic component (for example, in the case where the support is impregnated with such as an aqueous solution in which the catalytic component is dissolved), the catalytic component can be caused to exist throughout the whole catalyst with the progress of the absorption of the impregnation solution, but the catalytic component also easily migrates along with migration of such as water by drying in the subsequent drying step. Thus, in the case where the catalytic component is caused to be distributed with a quantitatively great inclination toward surfaces, it is favorable to moderately shorten the impregnation time and further, if possible, to cause the catalytic component to migrate toward surfaces of the catalyst along with water by quick drying after the impregnation. On the other hand, in the case where the catalytic component is caused to exist quantitatively substantially evenly throughout the whole catalyst, it is favorable to moderately lengthen the impregnation time and further to inhibit the migration of the catalytic component by moderating the migration of water by slow drying after the impregnation. That is to say, as to the supporting of the catalytic component by the physical adsorption, it can be considered that the supported state of such as whether the catalytic component is caused to be distributed with a quantitatively great inclination toward surfaces or to exist quantitatively substantially evenly is usually more influenced by drying conditions, though depending on the balance between impregnation conditions, such as the impregnation time, and drying conditions.

[0099] Hereinafter, detailed explanations are made about conditions in the case of supporting the catalytic component by the chemical adsorption.

[0100] In the treatment of supporting the catalytic components A and/or B by the chemical adsorption, first, the support is impregnated with an impregnation solution containing the catalytic components A and/or B in a heated state. By this impregnation, the chemical adsorption is efficiently done to facilitate the supporting. Specifically, it is favorable to heat the temperature of the impregnation solution containing the catalytic components A and/or B to not lower than 40° C., more favorably not lower than 50° C., or not lower than 60° C., or not lower than 70° C., or not lower than 80° C., or not lower than 90° C. In the case where the temperature of the impregnation solution is too low, it may be impossible to support a desired quantity of catalytic component.

[0101] Examples of conditions in carrying out the impregnation include: impregnation time; pH of the impregnation solution; concentrations of the catalytic components in the impregnation solution; and impregnation temperature (temperature of the impregnation solution). Above all, the impregnation time is important. The impregnation time is defined as a time of from the initiation of the impregnation of the support with the impregnation solution, containing the catalytic component, till the end of the impregnation (separation of the support from the impregnation solution) (hereinafter the same).

[0102] Although there is no especial limitation with regard to the impregnation time, in the case where the catalytic component is caused to be distributed with a quantitatively great inclination toward surfaces of the catalyst, the impregnation time is favorably not longer than 10 minutes, more favorably not longer than 5 minutes, still more favorably not longer than 3 minutes. In the case where the impregnation time is longer than 10 minutes, it may be impossible to successfully cause the catalytic component to be distributed with a quantitatively great inclination toward surfaces of the catalyst. On the other hand, in the case where the catalytic component is caused to exist quantitatively substantially evenly throughout the whole catalyst, the impregnation time is favorably not shorter than 15 minutes, more favorably not shorter than 20 minutes, still more favorably not shorter than 30 minutes. In the case where the impregnation time is shorter than 15 minutes, it may be impossible to successfully cause the catalytic component to exist quantitatively substantially evenly throughout the whole catalyst.

[0103] In a period of from after the above impregnation step till before the below-mentioned drying step, a leaving-alone time may fittingly be provided, if necessary. Particularly, in the case where the catalytic component is desired to exist quantitatively substantially evenly throughout the whole catalyst, it may become effective to not only carry out the impregnation under the above favorable impregnation conditions but also provide a time to leave the impregnated product alone thereafter.

[0104] After being impregnated with the impregnation solution containing the catalytic component in the above way (or after the above leaving-alone time if this time is provided in the period of from after the impregnation step till before the drying step), such as the support is dried. Hereupon, in the case where the catalytic component is caused to be distributed with a quantitatively great inclination toward surfaces of the catalyst, it is favorable, for facilitation of the distribution of the catalytic component with a quantitatively great inclination toward surfaces of the support, that the drying of the support following the impregnation is quickly carried out, if necessary. However, there is no especial limitation. Specifically, the drying time (time of from the initiation of the drying till the substantial end of the drying) is favorably not longer than 1 hour, more favorably not longer than 30 minutes, still more favorably not longer than 20 minutes. Under conditions where the drying time is longer than 1 hour, it may be impossible to successfully cause the catalytic component to be distributed with a quantitatively great inclination toward surfaces of the catalyst. In addition, the drying temperature is favorably in the range of 60 to 300° C., more favorably 100 to 200° C. In the case where the drying temperature is lower than 60° C., there is a possibility that the drying may not sufficiently be done within the above favorable range of the drying time. In the case where the drying temperature is higher than 300° C., there may occur unfavorable effects such that the catalytic activity is deteriorated. On the other hand, in the case where the catalytic component is caused to exist quantitatively substantially evenly throughout the whole catalyst, it is favorable, for facilitating the quantitatively substantially even existence of the catalytic component throughout the whole catalyst by sufficiently impregnating the catalytic component up to inside the support, that the support is slowly dried spending time, if necessary. However, there is no especial limitation. Specifically, the drying time (time of from the initiation of the drying till the substantial end of the drying) is favorably not shorter than 2 hours, more favorably not shorter than 3 hours, still more favorably not shorter than 5 hours. In the case where the drying time is shorter than 2 hours, there may occur the above migration of the catalytic component to surfaces of the catalyst, resulting in being distributed with a quantitatively great inclination toward surfaces of the catalyst. In addition, the drying temperature is favorably in the range of 10 to 200° C., more favorably 20 to 150° C. In the case where the drying temperature is lower than 10° C., the drying may result in spending time more than necessary. In the case where the drying temperature is higher than 200° C., the drying may result in being done outside the above favorable range of the drying time, and there may occur the above migration of the catalytic component to surfaces of the catalyst, resulting in being distributed with a quantitatively great inclination toward surfaces of the catalyst.

[0105] In the chemical adsorption, the drying may be carried out either by air-blow drying or windless drying in any of the above cases, and is therefore not especially limited. However, it is usually favorable that the drying is carried out by the air-blow drying in the case where the catalytic component is caused to be distributed with a quantitatively great inclination toward surfaces of the catalyst, and by the windless drying in the case where the catalytic component is desired to exist quantitatively substantially evenly throughout the whole catalyst. Thus, in the case where the air-blow drying is carried out for the purpose of causing the catalytic component to be distributed with a quantitatively great inclination toward surfaces of the catalyst, it is enough that the linear velocity of the blowing is set fittingly for satisfying such as the desired drying time, so there is no especial limitation. However, specifically, the linear velocity is favorably in the range of 0.5 to 50 m/s, more favorably 1 to 30 m/s, still more favorably 2 to 20 m/s. In the case where the linear velocity is less than 0.5 m/s, it may be impossible to successfully cause the catalytic component to be distributed with a quantitatively great inclination toward surfaces of the catalyst. In the case where the linear velocity is more than 50 m/s, large apparatuses uneconomically becomes necessary, and further the catalyst may be destroyed. Incidentally, the value of the linear velocity on the occasion of the air-blow drying is defined as a value obtained by dividing the blowing gas flow rate (m ³ /s) by the sectional area (m ² ) of a portion, packed with the catalyst, of a drying apparatus (wherein the sectional area is defined as that in a state as not packed with the catalyst, that is, what is called blank sectional area).

[0106] Hereinafter, detailed explanations are made about conditions in the case of supporting the catalytic component by the physical adsorption.

[0107] Examples of conditions in carrying out the impregnation include: impregnation time; and concentrations of the catalytic components in the impregnation solution. Above all, the impregnation time is particularly important.

[0108] Although there is no especial limitation with regard to the impregnation time, in the case where the catalytic component is caused to be distributed with a quantitatively great inclination toward surfaces of the catalyst, the impregnation time is favorably not longer than 2 minutes, more favorably not longer than 1 minute, still more favorably not longer than 30 seconds. If the impregnation time is within the above range, it is possible to more successfully cause the catalytic component to be distributed with a quantitatively great inclination toward surfaces of the catalyst. On the other hand, in the case where the catalytic component is caused to exist quantitatively substantially evenly throughout the whole catalyst, the impregnation time is favorably not shorter than 1 minute, more favorably not shorter than 2 minutes, still more favorably not shorter than 5 minutes. In the case where the impregnation time is shorter than 1 minute, it may be impossible to successfully cause the catalytic component to exist quantitatively substantially evenly throughout the whole catalyst.

[0109] In a period of from after the above impregnation step till before the below-mentioned drying step, a leaving-alone time may fittingly be provided, if necessary. Particularly, in the case where the catalytic component is desired to exist quantitatively substantially evenly throughout the whole catalyst, it may become effective to not only carry out the impregnation under the above favorable impregnation conditions but also provide a time to leave the impregnated product alone thereafter.

[0110] After being impregnated with the impregnation solution containing the catalytic component in the above way (or after the above leaving-alone time if this time is provided in the period of from after the impregnation step till before the drying step), such as the support is dried. Hereupon, in the case where the catalytic component is caused to be distributed with a quantitatively great inclination toward surfaces of the catalyst, it is favorable, for facilitation of the distribution of the catalytic component with a quantitatively great inclination toward surfaces of the support by migration of the catalytic component to surfaces of the support along with migration of such as water toward surfaces of the catalyst in this drying step, that the drying of the support following the impregnation is quickly carried out. Specifically, the drying time (time of from the initiation of the drying till the substantial end of the drying) is favorably not longer than 30 minutes, more favorably not longer than 20 minutes, still more favorably not longer than 10 minutes. In the case where the drying time is longer than 30 minutes, there is a possibility that: the catalytic component cannot be caused to be distributed with a sufficiently great inclination toward surfaces of the catalyst, because the catalytic component cannot successfully be caused to migrate toward surfaces of the catalyst, or because the catalytic component is more impregnated into the catalyst. In addition, the drying temperature is favorably in the range of 80 to 300° C., more favorably 100 to 200° C. In the case where the drying temperature is lower than 80° C., there is a possibility that the drying may not sufficiently be done within the above favorable range of the drying time. In the case where the drying temperature is higher than 300° C., there may occur unfavorable effects such that the catalytic activity is deteriorated. On the other hand, in the case where the catalytic component is caused to exist quantitatively substantially evenly throughout the whole catalyst, it is favorable, for easily maintaining the state of the sufficient impregnation of the catalytic component up to inside the support and, as a result, facilitating the quantitatively substantially even existence of the catalytic component throughout the whole catalyst, that the support is slowly dried spending time. Specifically, the drying time (time of from the initiation of the drying till the substantial end of the drying) is favorably not shorter than 3 hours, more favorably not shorter than 5 hours, still more favorably not shorter than 10 hours. In the case where the drying time is shorter than 3 hours, it may be impossible to cause the catalytic component to exist quantitatively substantially evenly throughout the whole catalyst, for the reason such that there may occur the above migration of the catalytic component to surfaces of the catalyst, resulting in being distributed with a quantitatively great inclination toward surfaces of the catalyst. In addition, the drying temperature is favorably in the range of 10 to 150° C., more favorably 20 to 120° C. In the case where the drying temperature is lower than 10° C., the drying may result in spending time more than necessary. In the case where the drying temperature is higher than 150° C., there may occur the above migration of the catalytic component to surfaces of the catalyst, resulting in being distributed with a quantitatively great inclination toward surfaces of the catalyst.

[0111] In the physical adsorption, the drying may be carried out either by air-blow drying or windless drying in any of the above cases, and is therefore not especially limited. However, it is usually favorable that the drying is carried out by the air-blow drying in the case where the catalytic component is caused to be distributed with a quantitatively great inclination toward surfaces of the catalyst, and by the windless drying in the case where the catalytic component is desired to exist quantitatively substantially evenly throughout the whole catalyst. Thus, in the case where the air-blow drying is carried out for the purpose of causing the catalytic component to be distributed with a quantitatively great inclination toward surfaces of the catalyst, it is enough that the linear velocity of the blowing is set fittingly for satisfying such as the desired drying time, so there is no especial limitation. However, specifically, the linear velocity is favorably in the range of 1 to 50 m/s, more favorably 2 to 30 m/s, still more favorably 5 to 20 m/s. In the case where the linear velocity is less than 1 m/s, it may be impossible to successfully cause the catalytic component to be distributed with a quantitatively great inclination toward surfaces of the catalyst. In the case where the linear velocity is more than 50 m/s, large apparatuses uneconomically becomes necessary, and further the catalyst may be destroyed. Incidentally, the definition of the value of the linear velocity on the occasion of the air-blow drying is the same as that in the case of the above chemical adsorption.

[0112] With regard to treatment processes for supporting the catalytic component on the support, particularly in the case where the catalytic component is desired to exist quantitatively substantially evenly throughout the whole catalyst, besides the above treatment processes for supporting by impregnation there can be cited the following processes: {circle over (1)} a process including the step of mixing a powder or slurry of a component of the support (or a compound to form the component of the support by calcination) with a powder of the catalytic component, a solution containing the catalytic component, or a mixed solution containing the catalytic components; and {circle over (2)} a process including the steps of mixing together a solution of a component of the support (or a compound to form the component of the support by calcination) and a solution containing the catalytic component, and then forming a coprecipitate. By these processes, the catalytic component can be caused to quantitatively almost substantially evenly be supported even if such as drying conditions which are considerable conditions as to the above treatment processes for supporting by impregnation are not controlled or regulated. Specifically, in the case where the catalytic component B is caused to quantitatively substantially evenly be supported and where the catalytic component A is caused to be distributed with a quantitatively great inclination toward surfaces, it is enough that: a powder or slurry containing a component of the support (or a compound to form the component of the support by calcination) and the catalytic component B is prepared and molded, and then dried and calcined, and then on surfaces of the calcined product there is supported the catalytic component A by such as the above treatment processes for supporting by impregnation.

[0113] (Catalytic Component C):

[0114] The catalyst for purification of exhaust gases, according to the present invention, can be caused to further contain a catalytic component including at least one element selected from the group consisting of V, W, Mo, Cu, Mn, Ni, Co, Cr, and Fe as the catalytic component C. The catalytic component C may be a metal including the above various elements, or such as a compound (e.g. oxide) thereof. It is favorable to make the catalytic component C contained in the range of not more than 10 weight %, more favorably 0.01 to 10 weight %, in terms of atom of the above various elements (V, W, Mo, Cu, Mn, Ni, Co, Cr, and Fe) relative to the entity of the catalyst. The addition of the catalytic component C can more enhance the efficiency of the purification of the low-concentration-CO-containing exhaust gases, or give the nitrogen oxides (NO _x ) removal function.

[0115] Raw materials for supplying the catalytic component C are not especially limited, and at least one materials as utilized for production of conventional catalysts are usable. There is no especial limitation with regard to the supporting process, either, and the catalytic component C can be supported on the support by processes as utilized for production of conventional catalysts, for example, processes as aforementioned about the catalytic components A and B. There is no especial limitation with regard to the supporting order, either. Specifically, it is permissible that, on the support, there are simultaneously supported the catalytic components A and C, or there is supported the catalytic component C following the catalytic component A, or there is supported the catalytic component A following the catalytic component C. Also in the case of a catalyst containing the catalytic component B besides the catalytic component A, it is permissible that, on the support, there is supported the catalytic component C simultaneously with the catalytic components A and B, or there is supported the catalytic component C following the catalytic components A and B, or there are supported the catalytic components A and B following the catalytic component C. Incidentally, similarly to the catalytic component B, the catalytic component C may be caused to be distributed with a quantitatively great inclination toward surfaces of the catalyst or may be caused to exist quantitatively substantially evenly throughout the whole catalyst without such a quantitatively great inclination.

[0116] <Other Components and Their Being Contained>:

[0117] The catalyst for purification of exhaust gases, according to the present invention, can be caused to further contain a compound of at least one element selected from the group consisting of B, P, Sb, Pb, Sn, Zn, and In (hereinafter referred to as compound D′) and/or a sulfur compound as another component D. (Compound D′):

[0118] The addition of the compound D′ as another component D to the catalyst according to the present invention enables this catalyst to remove CO from exhaust gases with high efficiency for a long term while keeping the oxidation of SO ₂ low.

[0119] Raw materials for supplying the compound D′ are not especially limited, and at least one materials as utilized for production of conventional catalysts are usable. There is no especial limitation with regard to processes for making the compound D′ contained, either, and examples thereof include: a process involving making the compound D′ contained by supporting it on the support by processes as utilized for production of conventional catalysts; and a process involving making the compound D′ contained either by adding and mixing it in preparing the support or by using the compound D′ as one of materials of the support. Above all, in the case of making the compound D′ contained by the supporting, although there is no especial limitation with regard to the supporting order, either, specifically, it is favorable that, on the support, there are simultaneously supported the catalytic component A and the compound D′, or there is supported the compound D′ preceding the catalytic component A. Also in the case of a catalyst containing the catalytic component B besides the catalytic component A, it is favorable that, on the support, there is supported the compound D′ simultaneously with the catalytic components A and B, or there is supported the compound D′ preceding the catalytic components A and B. Incidentally, similarly to the catalytic component B, the compound D′ may be caused to be distributed with a quantitatively great inclination toward surfaces of the catalyst or may be caused to exist quantitatively substantially evenly throughout the whole catalyst without such a quantitatively great inclination. In addition, in the case of supporting both the above catalytic component C and the compound D′, the supporting order therebetween is not especially limited, and they may simultaneously be supported, or either one may be supported preceding the other.

[0120] It is favorable to make the compound D′ contained in the range of not more than 10 weight %, more favorably 0.005 to 10 weight %, still more favorably 0.02 to 5 weight %, in terms of atom of the above various elements (B, P, Sb, Pb, Sn, Zn, and In) relative to the entity of the catalyst. In the case where the compound D′ content is higher than 10 weight %, there is a possibility that the compound D′ may act as a poisonous component to the active component and thereby inversely deteriorate the activity.

[0121] As the compound D′, for example, phosphorus compounds are favorably usable, and explanations are hereinafter made about their cases in detail. However, compounds of the above various elements (B, Sb, Pb, Sn, Zn, and In) other than P are also usable in the same way as of the phosphorus compounds below.

[0122] There is no especial limitation with regard to raw materials for supplying the phosphorus compound, and, for example, there can favorably be used those which are cited as inorganic phosphorus compounds and organic phosphorus compounds, but it is particularly favorable to use water-soluble phosphorus compounds such as phosphoric acid, ammonium phosphate, and ammonium dihydrogenphosphate.

[0123] There are many unclear parts still at present with regard to the reason why making the phosphorus compound contained in the range of not more than 10 weight % in terms of phosphorus atom relative to the entity of the catalyst in the above way enables this catalyst to remove CO from exhaust gases with high efficiency for a long term, but this reason can be inferred as follows. That is to say, it can be considered that: if the catalyst is made to contain the phosphorus compound in the specific ratio as in the present invention, then deteriorations in physical properties (e.g. specific surface area, pore structure, crystal structure) of the catalyst itself, which easily occur in the case of long-term exposure of about 300 to about 500° C. high-temperature exhaust gases containing high-concentrated oxygen and water vapor, are inhibited and, as a result, deteriorations in performances of the catalyst can be inhibited. Therefore, a catalyst having the resistance to thermal load is obtained without increasing the quantity of the supported noble metal, and the resultant catalyst can maintain high activity even if exposed for a long term under a flow of the high-temperature exhaust gases containing high-concentrated oxygen and water vapor.

[0124] Although there is no especial limitation with regard to methods for making the catalyst contain the phosphorus compound, for example, the catalyst may be made to contain the phosphorus compound by adding the above phosphorus compound in the step of molding the support, or it is also possible to make the catalyst contain the phosphorus compound by using a starting material containing phosphorus when producing the support. In addition, it is also possible to make the catalyst contain the phosphorus compound by immersing the support into an aqueous solution containing the raw materials for supplying the phosphorus compound similarly to means as used for production of conventional catalysts.

[0125] There is no especial limitation with regard to the order of making the catalyst contain the phosphorus compound, either, and the catalyst may be made to contain the phosphorus compound either simultaneously with supporting the catalytic components A and/or B or after supporting the catalytic components A and B, so the catalyst can be made to contain the phosphorus compound in various orders, but it is favorable to make the catalyst contain the phosphorus compound before supporting the catalytic components A and/or B.

[0126] There is no especial limitation with regard to the form in which the phosphorus compound is contained in the support, and the phosphorus compound may be contained quantitatively substantially evenly in the support, or the contained form may be such that the concentration of the phosphorus compound as contained has a concentration gradient (concentration distribution), for example, the content is high near outer surfaces of the support, but becomes lower toward inside the support. However, above all, it is favorable that the phosphorus compound is contained quantitatively substantially evenly in the support.

[0127] (Sulfur Compound):

[0128] The catalyst according to the present invention can further comprise a sulfur compound as another component D in the range of not more than 1 weight % in terms of sulfur atom relative to the entity of the catalyst.

[0129] If the catalyst according to the present invention further comprises the sulfur compound, this catalyst can suppress the rise of the SO ₂ -oxidizing ratio (which is problematic during the operation) to keep it low and further has sufficient durability to SOX, so it becomes possible for this catalyst to maintain its performances with high efficiency stably for a long term. Furthermore, it also becomes possible for the catalyst to enhance its ability to remove the CO (particularly, low-concentration CO) and the unburned volatile organic compounds (e.g. acetaldehyde) from the exhaust gases.

[0130] Because sulfur-containing compounds, such as hydrogen sulfide and mercaptans, usually acts as poisonous components to the catalyst, it has generally been taken for granted that the sulfur component is a cause of deteriorating the catalyst activity. However, as a result of the present inventors' study, it has been found out that, if a specific sulfur compound such as sulfate ion (SO ₄ ²⁻ ) is made to be contained, then such as the above removability may be enhanced. Thus, the present inventors studied in more detail and, as a result, have found out that, although it cannot sweepingly be said to be enough to make the content large, if the content is controlled to a moderate one, the resultant catalyst is very excellent in such as the above removability.

[0131] There are many unclear parts still at present with regard to the reason why making the sulfur compound contained in the range of not more than 1 weight % in terms of sulfur atom relative to the entity of the catalyst in the above way enhances such as the ability to remove the CO (particularly, low-concentration CO) and the unburned volatile organic compounds (e.g. acetaldehyde) from the exhaust gases, but this reason can be inferred as follows. That is to say, a product obtained by making the titanium-containing oxide contain the sulfate ion has so far been known to display strong acidity as not seen in the case of the titanium-containing oxide alone, and is called solid super-strong acid. Being inferred from such a fact, if the sulfur compound is made to be contained in the range of not more than 1 weight % in terms of sulfur atom relative to the entity of the catalyst as in the present invention, then the sulfur compound (sulfate ion) results in coexisting with the titanium-containing oxide, and properties (e.g. acidity) of the titanium-containing oxide (which is the support) are thereby changed, and such a change in properties of the support exerts an influence on such as the supported state and electronic state of the catalytic component as supported on the support, and thereby provides better effects, so that it becomes possible for the catalyst to more efficiently purify the CO (particularly, low-concentration CO) and the unburned volatile organic compounds (e.g. acetaldehyde) in the exhaust gases, and further to maintain its performances stably for a long term.

[0132] Examples of the sulfur compound include sulfate ion and sulfite ion. The sulfur compound may be used either alone respectively or in combinations with each other. If the above sulfur compound is contained as a catalytic component, then the CO and the unburned volatile organic compounds (such as aldehydes) in the exhaust gases can more efficiently be purified.

[0133] Although there is no especial limitation with regard to methods for making the catalyst contain the sulfur compound, for example, the catalyst may be made to contain the sulfur compound by adding the above sulfur compound in the step of molding the support, or it is also possible to make the catalyst contain the sulfur compound by using a starting material including a sulfate salt when producing the support. In addition, it is also possible to make the catalyst contain the sulfur compound by immersing the support into an aqueous solution containing the raw materials for supplying the sulfur compound similarly to means as used for production of conventional catalysts.

[0134] As raw materials for supplying the sulfur compound, for example, there can be used the following: sulfuric acid, sulfurous acid, ammonium sulfate, ammonium sulfite, ammonium hydrogensulfate, and ammonium hydrogensulfite.

[0135] Although there is no especial limitation with regard to the order of making the catalyst contain the sulfur compound, either, it is favorable to make the catalyst contain the sulfur compound before supporting the catalytic components A and/or B.

[0136] Although there is no especial limitation with regard to the form in which the sulfur compound is contained in the support, the sulfur compound may be contained quantitatively substantially evenly in the support, or the contained form may be such that the contained concentration has a concentration gradient, for example, the content is high near outer surfaces of the support, but becomes lower toward inside the support.

[0137] The sulfur compound content is, as aforementioned, favorably in the range of not more than 1 weight %, but more favorably 0.01 to 1 weight %, still more favorably 0.05 to 0.75 weight %, particularly favorably 0.1 to 0.5 weight %, in terms of sulfur atom relative to the entity of the catalyst. In the case where the sulfur compound content is higher than 1 weight %, there are disadvantages in that the sulfur compound acts as a poisonous component to the active component and thereby inversely deteriorates the activity.

[0138] <Preparation of Catalyst and its Properties>:

[0139] The catalyst for purification of exhaust gases, according to the present invention, is obtained by a process including the steps of: supporting the catalytic component (from the above various supplying raw materials) in a predetermined supporting quantity on the porous honeycomb support including the titanium-containing oxide, and then subjecting the resultant product to drying and calcining treatments. The drying can usually be carried out by treatment under air atmosphere, nitrogen atmosphere, or flows of these gases in the temperature range of 50 to 200° C. for 1 to 24 hours.

[0140] The calcination can be carried out by heat-treatment in the temperature range of 200 to 900° C. for 1 to 10 hours. The calcination is usually carried out under air atmosphere or air flow, but it is also possible to replace air with nitrogen or gases including reducible gases such as hydrogen.

[0141] The catalyst, comprising the support and the catalytic component supported thereon, is of the porous structure having fine pores. The quantity of the pores has influence on diffusion of gases inside the catalyst. In addition, the specific surface area of the catalyst also has influence on the exhaust gas purifiability.

[0142] Usually, it is proper that the total pore volume is in the range of 0.2 to 0.8 cm ³ /g (mercury penetration method). In the case where the pore volume is too small, the catalytic activity may be low. In the case where the pore volume is too large, the mechanical strength of the catalyst may be low.

[0143] The specific surface area of the catalyst also has influence on performance. Usually adopted is a catalyst having a specific surface area in the range of 30 to 250 m ² /g, favorably 40 to 200 m ² /g (BET method). In the case where the specific surface area is too small, the catalytic activity may be insufficient. In the case where the specific surface area is too large, there may occur unfavorable effects such that: the catalytic activity is not so much enhanced, whereas the accumulation of catalytically poisonous components increases, or the life time of the catalyst becomes short.

[0144] <Mode for Using the Catalyst>:

[0145] The catalyst for purification of exhaust gases, according to the present invention, is a honeycomb-shaped catalytic structure, and is a monolithically molded structure of such a catalyst composition alone as obtained by a process including the steps of: molding such as a powder of the titanium-containing oxide into a desired shape with such as extrusion molding machines; and then calcining the resultant molded product; and then supporting the catalytic component on the resultant calcined product.

[0146] The catalyst is usually used in a state placed in a catalytic reactor made of such as metal. The catalytic reactor is provided with an exhaust-gas-introducing inlet and an exhaust-gas-discharging outlet, and with a structure such that the exhaust gases can efficiently come into contact with the catalyst as placed inside.

[0147] (Process for Purification of Exhaust Gases):

[0148] The process for purification of exhaust gases, according to the present invention, is a process for purification of exhaust gases to remove CO therefrom, and is characterized by comprising the step of bringing the exhaust gases into contact with the catalyst for purification of exhaust gases according to the present invention.

[0149] Basically applied to the case of carrying out the process for purification of exhaust gases according to the present invention are arts for purification of exhaust gases with conventional metal-oxide-supported noble metal catalysts. Usually, the catalytic reactor in which the catalyst is placed is set along the discharging way of such as exhaust gases. The exhaust gases undergo predetermined catalysis by coming into contact with surfaces of the catalyst when passing through the catalytic reactor.

[0150] The process for purification of exhaust gases, according to the present invention, can simultaneously purify not only the CO but also the unburned volatile organic compounds that are contained in the exhaust gases.

[0151] In the case of purifying the exhaust gases with the catalyst for purification of exhaust gases according to the present invention, the efficiency of the purification of exhaust gases with the catalyst is enhanced by properly setting conditions such as temperature and space velocity of the exhaust gases. For example, it is favorable to purify the combustion exhaust gases of 250 to 600° C. in gas temperature and 30,000 to 1,000,000H ⁻¹ in space velocity. More favorably, a gas temperature of 300 to 550° C. can be adopted, and a space velocity of 50,000 to 500,000H−1 can be adopted. Furthermore favorable are purification conditions of Linear Velocity (LV)=not less than 0.1 m/s (Normal) or dust concentration=not more than 10 mg/m ³ (Normal).

[0152] In the process for purification of exhaust gases according to the present invention, before and/or after the step for purification of exhaust gases with the catalyst for purification of exhaust gases according to the present invention, another step for purification of exhaust gases with another kind of catalyst for purification of exhaust gases may be combined. Favorable as this other step is a step which can efficiently purify components difficult to purify with the catalyst for purification of exhaust gases according to the present invention.

[0153] For example, in the case of purifying the exhaust gases containing the nitrogen oxides (NO _x ) besides such as CO, this purification can be carried out by combining a step for purification of exhaust gases with a DeNO _x catalyst and the step for purification of exhaust gases with the catalyst for purification of exhaust gases according to the present invention. If the purification is carried out in this way, in the case where the exhaust gases containing the CO and the nitrogen oxides (NO _x ) are purified, then the nitrogen oxides (NO _x ) can also efficiently be removed along with the CO. In addition, when the above exhaust gases containing the CO and the nitrogen oxides (NO _x ) are purified, this purification is favorably carried out under an atmosphere excessively containing molecular oxygen.

[0154] Incidentally, in the above step for purification of exhaust gases with a DeNO _x catalyst, the exhaust gases are brought into contact with a DeNO _x catalyst in the presence of a reducing agent. Examples of the reducing agent include ammonia, urea, and hydrazine. These may be used either alone respectively or in combinations with each other. Although the quantity of the reducing agent as used may be set fittingly for the demanded nitrogen oxides (NO _x ) removal ratio and is not especially limited, specifically, the molar ratio of the reducing agent to the nitrogen oxides (NO _x ) in the exhaust gases (reducing agent/NO _x ) is favorably less than 2, more favorably less than 1.5, still more favorably less than 1.2. In the case where the above molar ratio is not less than 2, there are disadvantages in that a large quantity of reducing agent will remain in gases after the nitrogen oxides (NO _x ) removal step.

[0155] As examples of the above case where there are combined the step for purification of exhaust gases with the catalyst for purification of exhaust gases according to the present invention and the step for purification of exhaust gases with a DeNO _x catalyst in the presence of a reducing agent on the occasion when the exhaust gases containing the CO and the NO _x are purified, there can be cited: 1) a process comprising the steps of: bringing the exhaust gases into contact with the catalyst for purification of exhaust gases according to the present invention, thereby removing the CO from the exhaust gases; and then bringing the exhaust gases into contact with a DeNO _x catalyst in the presence of a reducing agent, thereby removing the NO _x from the exhaust gases; and 2) a process comprising the steps of: bringing the exhaust gases into contact with a DeNO _x catalyst in the presence of a reducing agent, thereby removing the NO _x from the exhaust gases; and then bringing the exhaust gases into contact with the catalyst for purification of exhaust gases according to the present invention, thereby removing the CO from the exhaust gases.

[0156] The former process 1) has the advantage of being able to more inhibit the activity of the catalyst for purification of exhaust gases according to the present invention from being deteriorated by SO _x . Specifically, the oxidation reaction of SO ₂ →SO ₃ usually occurs also in the purification with a DeNO _x catalyst. The deterioration by SO ₃ in the activity of the catalyst for purification of exhaust gases according to the present invention is even more than by SO ₂ . If the catalyst for purification of exhaust gases according to the present invention is put upstream of the DeNO _x catalyst, then it is expected that the above deterioration in the activity can be inhibited.

[0157] The latter process 2) has the advantage of being able to more decrease a surplus of the reducing agent (e.g. NH ₃ ). Specifically, usually, the reducing agent (e.g. NH ₃ ), as used for the purification with a DeNO _x catalyst, gets concerned in the removal reaction of such as NO _x and thereby decreases in quantity, but, depending on purification conditions, results in remaining unreacted to mingle into exhaust gases after the purification and is therefore problematic. However, the catalyst for purification of exhaust gases according to the present invention further has the ability to oxidize the reducing agent (e.g. NH ₃ ). Thus, if the catalyst for purification of exhaust gases according to the present invention is put downstream of the above DeNO _x catalyst, it is expected that the catalyst for purification of exhaust gases according to the present invention can oxidize the unreacted reducing agent to more decrease it. In addition, particularly, in the case where a high NO _x -removal ratio is demanded such as case where a strict emission regulation value is imposed, the use of this process 2) is very effective in that: the reducing agent (e.g. NH ₃ ) can be excessively supplied to make the NO _x -removal efficiency with the DeNO _x catalyst in the prior step as high as possible, and further a large quantity of reducing agent remaining unreacted can be removed with the catalyst for purification of exhaust gases according to the present invention in the posterior step.

[0158] Applicable to the above technique for purification of exhaust gases with the DeNO _x catalyst is a technique as previously applied for a patent by the present applicant in Japan and disclosed in JP-A-235206/1998. The DeNO _x catalyst as used in this technique comprises a combination of a catalytic component a (titanium oxide) and a catalytic component b (oxide of metal including vanadium or tungsten) and has a structure such that the catalytic component b is supported on the catalytic component a.

[0159] The process for purification of exhaust gases, according to the present invention, can be intended also for the exhaust gases containing the nitrogen oxides (NO _x ) besides such as CO, as exhaust gases being purified, and can efficiently remove the CO even from such exhaust gases.

[0160] The process for purification of exhaust gases according to the present invention, which involves the use of the above catalyst for purification of exhaust gases according to the present invention, can also remove the NO _x simultaneously with such as CO. In this case, favorably for enhancing the efficiency of the removal of the NO _x , this removal is carried out in the presence of the reducing agent such as ammonia, urea, and hydrazine. Furthermore, in these cases, for example, it is favorable to purify exhaust gases of 250 to 500° C. in gas temperature and 2,000 to 500,000H ⁻¹ in space velocity.

[0161] The process for purification of exhaust gases according to the present invention may be combined with publicly known processes for purification of exhaust gases as disclosed in such as JP-A-146991/1978, JP-A-065721/1987, and JP-B-004126/1994.

[0162] In the present invention, very high catalytic activity is obtained, and further, high purification efficiency can be achieved without increasing the quantity of the supported noble metal as a catalytic component, because used as the catalyst for purification of the CO as contained in the exhaust gases is the honeycomb-shaped catalyst comprising: a monolithically molded type porous honeycomb structure including a titanium-containing oxide as a support; and a catalytic component A including at least one noble metal element, wherein the catalytic component A is supported on the support in the form distributed with a quantitatively great inclination toward surfaces of the catalyst. As a result, the process for purification of exhaust gases according to the present invention becomes a very effective process as a process for purification of CO-containing exhaust gases having a great space velocity as discharged from such as gas turbines.

[0163] (Effects and Advantages of the Invention):

[0164] The present invention can more enhance the efficiency of the purification of the CO-containing exhaust gases with the aforementioned catalyst for purification of exhaust gases comprising the metal-oxide-supported noble metal, particularly, can enable achievement of high purification efficiency without increasing the quantity of the supported noble metal as a catalytic component.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0165] Hereinafter, the present invention is more specifically illustrated by the following examples of some preferred embodiments in comparison with comparative examples not according to the invention. However the present invention is not limited to these examples. Incidentally, hereinafter, for convenience, the unit “weight part(s)” may be referred to simply as “part(s)”. In addition, the unit “weight %” may be referred to simply as “wt %”.

[0166] The following are conditions for compositional analysis and EPMA sectional linear analysis of catalysts produced in the below-mentioned Examples and Comparative Examples.

[0167] <Compositional Analysis of Catalysts>:

[0168] The compositional analysis of the catalysts was carried out by fluorescent X-ray analysis under the following conditions:

[0169] Analyzer: product name: RIX2000, produced by Rigaku Corporation

[0170] Atmosphere around samples during the analysis: vacuum

[0171] Spin rate of samples: 60 rpm

[0172] X-ray source: Rh tubular globe

[0173] <EPMA Sectional Linear Analysis>:

[0174] Analyzer: product name: EPMA-1610, produced by Shimadzu Corporation

[0175] X-ray beam diameter: 1 μm

[0176] Acceleration voltage: 15 kV

[0177] Sample current: 0.1 μA

[0178] Measurement interval: 1 μm

[0179] Measurement time: 1 second/point

[0180] —Catalysts for purification of exhaust gases—

EXAMPLE 1-1

[0181] Preparation of Ti—Si-Composite Oxide:

[0182] An amount of 100 kg of titanium tetrachloride was gradually added dropwise to 700 liters of water under cooled and stirred conditions. Next, 40 kg of colloidal silica with an SiO ₂ content of 20 weight % (Snowtex-20 (trade name), produced by Nissan Chemical Industries, Ltd.) was added thereto. After the end of the addition, the temperature was kept at about 30° C., and then ammonia water was gradually added dropwise thereinto under cooled and well-stirred conditions until the pH value became 7.5. The resultant gel was aged for 2 hours as it was. Thereafter, the aged gel was filtered off, and then washed with water, and then dried at 150° C. for 10 hours. The resultant product was calcined at 500° C., and then ground with a hammer mill to obtain a powder. In an X-ray diffraction chart of this powder, neither clear characteristic peak of TiO ₂ nor SiO ₂ was seen, but a broad diffraction peak was seen, from which it was verified that the resultant powder was a titanium-silicon-composite oxide (Ti—Si-composite oxide) having an amorphous fine structure.

[0183] Production of Honeycomb Support:

[0184] To 20 kg of the above Ti—Si-composite oxide, there were added 1 kg of phenol resin (Bellpearl (trade name), produced by Kanebo Co.) and 0.5 kg of starch (as a molding assistant) to mix them together. The resulting mixture was well kneaded with a kneader while a proper quantity of water was added thereto. The kneaded product was molded into a honeycomb form having an external form size of 80 mm square, an opening size of 2.1 mm, a wall thickness of 0.4 mm and a length of 500 mm with an extrusion molding machine. Thereafter, the resultant form was dried at 80° C. and then calcined at 450° C. for 5 hours under air atmosphere to obtain the honeycomb support.

[0185] The resultant honeycomb support has a latticed structure, as shown in FIG. 2 ( a ), such that the opening size of each exhaust gas passageway is 2.1 mm, and that the wall thickness of the lattice wall is 0.4 mm.

[0186] Production of Catalyst by Supporting Catalytic Component:

[0187] The above honeycomb support was impregnated with a boiled dinitrodiammineplatinum solution and thereby caused to chemically adsorb Pt, and then dried. Next, the resultant product was calcined at 450° C. for 2 hours under air atmosphere to obtain a catalyst A comprising the honeycomb support as the support and Pt as noble metal particles supported thereon.

[0188] Analysis of Catalyst:

[0189] The composition of the resultant catalyst A was analyzed. As a result, it was (Ti—Si-composite oxide):Pt=99.9:0.1 (weight ratio).

[0190] The catalyst A was analyzed by EPMA sectional linear analysis into Pt. Its result is shown in FIG. 3 . From this result, it was verified that not less than 90 weight % of the total quantity of the supported Pt was distributed in the range of from surfaces to a depth of 100 μm in the catalyst A. The average particle diameter of Pt, as measured with a transmission electron microscope, was smaller than 5 nm.

EXAMPLE 1-2

[0191] A catalyst B was obtained by the same process as of Example 1-1 except that the dinitrodiammineplatinum solution was replaced with a hexaammineplatinum hydroxide solution.

[0192] The composition of the catalyst B was (Ti—Si-composite oxide):Pt=99.9:0.1 (weight ratio). From the result of EPMA sectional linear analysis into Pt, it was verified that not less than 90 weight % of the total quantity of the supported Pt was distributed in the range of from surfaces to a depth of 100 μm. From the result of measurement with a transmission electron microscope, the average particle diameter of Pt was smaller than 5 nm.

EXAMPLE 1-3

[0193] A catalyst C was obtained by the same process as of Example 1-1 except that a titanium oxide honeycomb support was obtained by changing the metal oxide from the Ti—Si-composite oxide to a commercially available titanium oxide powder (DT-51 (trade name), produced by Millennium Inorganic Chemicals Limited).

[0194] The composition of the catalyst C was TiO ₂ :Pt=99.9:0.1 (weight ratio). From the result of EPMA sectional linear analysis into Pt, it was verified that not less than 90 weight % of the total quantity of the supported Pt was distributed in the range of from surfaces to a depth of 100 μm. From the result of measurement with a transmission electron microscope, the average particle diameter of Pt was smaller than 5 nm.

EXAMPLE 1-4

[0195] Preparation of Titanium Oxide:

[0196] An amount of 100 kg of titanium tetrachloride was gradually added dropwise to 700 liters of water under cooled and stirred conditions. After the end of the dropwise addition, the temperature was kept at about 30° C., and then ammonia water was gradually added dropwise thereinto under cooled and well-stirred conditions until the pH value became 7.5. The resultant gel was aged by leaving it as it was for 2 hours. Thereafter, the aged gel was filtered off, and then washed with water, and then dried at 150° C. for 10 hours. The resultant product was calcined at 500° C., and then ground with a hammer mill to obtain a titanium oxide powder.

[0197] Production of Honeycomb Support:

[0198] To 20 kg of the above titanium oxide powder, there were added 1 kg of phenol resin (Belipearl (trade name), produced by Kanebo Co.) and 0.5 kg of starch (as a molding assistant) to mix them together. The resulting mixture was well kneaded with a kneader while a proper quantity of water was added thereto. The kneaded product was molded into a honeycomb form having an external form size of 80 mm square, an opening size of 2.1 mm, a wall thickness (wall thickness of lattice wall) of 0.4 mm and a length of 500 mm with an extrusion molding machine. Thereafter, the resultant form was dried at 80° C. and then calcined at 450° C. for 5 hours under air atmosphere to obtain the honeycomb support of the titanium oxide.

[0199] Production of Catalyst by Supporting Catalytic Component:

[0200] The above honeycomb support was impregnated with a boiled dinitrodiammineplatinum solution and thereby caused to chemically adsorb Pt, and then dried. Next, the resultant product was calcined at 450° C. for 2 hours under air atmosphere to obtain a catalyst D comprising the honeycomb support as the support and Pt as noble metal particles supported thereon.

[0201] Analysis of Catalyst:

[0202] The composition of the resultant catalyst D was analyzed. As a result, it was TiO ₂ :Pt=99.9:0.1 (weight ratio).

[0203] The catalyst D was analyzed by EPMA sectional linear analysis into Pt. From its result, it was verified that not less than 90 weight % of the total quantity of the supported Pt was distributed in the range of from surfaces to a depth of 100 μm in the catalyst D.

[0204] The average particle diameter of Pt, as measured with a transmission electron microscope, was smaller than 5 nm.

EXAMPLE 1-5

[0205] A catalyst E was obtained by the same process as of Example 1-4 except that the honeycomb support was impregnated with the dinitrodiammineplatinum solution at room temperature.

[0206] The composition of the catalyst E was TiO ₂ :Pt=99.9:0.1 (weight ratio). From the result of EPMA sectional linear analysis into Pt, it was verified that 80 weight % of the total quantity of the supported Pt was distributed in the range of from surfaces to a depth of 100 μm.

[0207] The average particle diameter of Pt, as measured with a transmission electron microscope, was smaller than 5 nm.

COMPARATIVE EXAMPLE 1-1

[0208] A catalyst F was obtained by the same process as of Example 1-4 except that the honeycomb support was impregnated with a hydrogen hexachloroplatinate solution at room temperature.

[0209] The composition of the catalyst F was TiO ₂ :Pt=99.9:0.1 (weight ratio). From the result of EPMA sectional linear analysis into Pt, it was verified that only less than 70 weight % of the total quantity of the supported Pt was distributed in the range of from surfaces to a depth of 100 μm in the catalyst F

[0210] The average particle diameter of Pt, as measured with a transmission electron microscope, was smaller than 5 nm.

EXAMPLE 1-6

[0211] A catalyst G was obtained by supporting Pt on the honeycomb support by the same process as of Example 1-1 except that the honeycomb support was impregnated with the dinitrodiammineplatinum solution at room temperature.

[0212] The composition of the catalyst G was (Ti—Si-composite oxide):Pt=99.9:0.1 (weight ratio). From the result of EPMA sectional linear analysis into Pt, it was verified that 80 weight % of the total quantity of the supported Pt was distributed in the range of from surfaces to a depth of 100 μm.

[0213] The average particle diameter of Pt, as measured with a transmission electron microscope, was smaller than 5 nm.

COMPARATIVE EXAMPLE 1-2

[0214] A catalyst H was obtained by supporting Pt on the honeycomb support by the same process as of Example 1-4 except that the titanium oxide powder was replaced with an Al ₂ O ₃ powder, and that the honeycomb support was impregnated with a hydrogen hexachloroplatinate solution at room temperature.

[0215] The composition of the catalyst H was Al ₂ O ₃ :Pt=99.9:0.1 (weight ratio). From the result of EPMA sectional linear analysis into Pt, it was verified that only less than 70 weight % of the total quantity of the supported Pt was distributed in the range of from surfaces to a depth of 100 μm in the catalyst H

[0216] The average particle diameter of Pt, as measured with a transmission electron microscope, was smaller than 5 nm.

EXAMPLE 1-7

[0217] A catalyst I was obtained by supporting Pt and Pd on the honeycomb support by the same process as of Example 1-1 except that the dinitrodiammineplatinum solution was replaced with a mixed solution of hexaammineplatinum hydroxide and tetraamminepalladium hydroxide.

[0218] The composition of the catalyst I was (Ti—Si-composite oxide):Pt:Pd=99.9:0.05:0.05 (weight ratio). From the result of EPMA sectional linear analysis into Pt and Pd, it was verified that, as to both Pt and Pd, not less than 90 weight % of the total supporting quantity was distributed in the range of from surfaces to a depth of 100 μm.

EXAMPLE 1-8

[0219] The honeycomb support of the Ti—Si-composite oxide, as prepared in Example 1-1, was impregnated with a tungstic acid solution, and then dried. Next, the resultant product was calcined at 450° C. for 2 hours under air atmosphere. Furthermore, the resultant honeycomb support on which tungsten was supported was impregnated with a boiled hexaammineplatinum hydroxide solution, and then dried. Next, the resultant product was calcined at 450° C. for 2 hours under air atmosphere to support Pt and W on the honeycomb support, thus obtaining a catalyst J.

[0220] The composition of the catalyst J was (Ti—Si-composite oxide):W:Pt=97.4:2.5:0.1 (weight ratio). From the result of EPMA sectional linear analysis into Pt, it was verified that not less than 90 weight % of the total quantity of the supported Pt was distributed in the range of from surfaces to a depth of 100 μm.

EXAMPLE 2-1

[0221] A catalyst K was obtained by the same process as of Example 1-1 except that the dinitrodiammineplatinum solution was replaced with a mixed solution of hexaammineplatinum hydroxide and magnesium acetate.

[0222] The composition of the catalyst K was (Ti—Si-composite oxide):Mg:Pt=98.9:1:0.1 (weight ratio). From the result of EPMA sectional linear analysis into Pt, it was verified that not less than 90 weight % of the total quantity of the supported Pt was distributed in the range of from surfaces to a depth of 100 μm in the catalyst K. The average particle diameter of Pt, as measured with a transmission electron microscope, was smaller than 5 nm.

EXAMPLE 2-2

[0223] The honeycomb support of the Ti—Si-composite oxide, as prepared in Example 1-1, was impregnated with a cerium nitrate solution, and then dried. Next, the resultant product was calcined at 450° C. for 2 hours under air atmosphere. Furthermore, the resultant honeycomb support on which cerium was supported was impregnated with a boiled ruthenium nitrate solution, and then dried. Next, the resultant product was calcined at 450° C. for 2 hours under air atmosphere to support Ru and Ce on the honeycomb support, thus obtaining a catalyst L.

[0224] The composition of the catalyst L was (Ti—Si-composite oxide):Ce:Ru=94.7:5:0.3 (weight ratio). From the result of EPMA sectional linear analysis into Ru, it was verified that not less than 90 weight % of the total quantity of the supported Ru was distributed in the range of from surfaces to a depth of 100 μm.

EXAMPLE 2-3

[0225] A catalyst M was obtained by the same process as of Example 2-1 except that the mixed solution of hexaammineplatinum hydroxide and magnesium acetate was replaced with a mixed solution of hexaammineplatinum hydroxide and calcium acetate.

[0226] The composition of the catalyst M was (Ti—Si-composite oxide):Ca:Pt=98.9:1:0.1 (weight ratio). From the result of EPMA sectional linear analysis into Pt, it was verified that not less than 90 weight % of the total quantity of the supported Pt was distributed in the range of from surfaces to a depth of 100 μm. From the result of measurement with a transmission electron microscope, the average particle diameter of Pt was smaller than 5 nm.

EXAMPLE 2-4

[0227] A catalyst N was obtained by the same process as of Example 2-1 except that the mixed solution of hexaammineplatinum hydroxide and magnesium acetate was replaced with a mixed solution of hexaammineplatinum hydroxide and sodium acetate.

[0228] The composition of the catalyst N was (Ti—Si-composite oxide):Na:Pt=98.9:1:0.1 (weight ratio). From the result of EPMA sectional linear analysis into Pt, it was verified that not less than 90 weight % of the total quantity of the supported Pt was distributed in the range of from surfaces to a depth of 100 μm. From the result of measurement with a transmission electron microscope, the average particle diameter of Pt was smaller than 5 nm.

EXAMPLE 2-5

[0229] A catalyst O was obtained by the same process as of Example 2-1 except that the mixed solution of hexaammineplatinum hydroxide and magnesium acetate was replaced with a mixed solution of hexaammineplatinum hydroxide and lithium acetate.

[0230] The composition of the catalyst 0 was (Ti—Si-composite oxide):Li:Pt=98.9:1:0.1 (weight ratio). From the result of EPMA sectional linear analysis into Pt, it was verified that not less than 90 weight % of the total quantity of the supported Pt was distributed in the range of from surfaces to a depth of 100 μm. From the result of measurement with a transmission electron microscope, the average particle diameter of Pt was smaller than 5 nm.

EXAMPLE 2-6

[0231] A catalyst P was obtained by the same process as of Example 2-1 except that the mixe