Oxidation catalyst for exhaust gas purification, method for producing the same, and exhaust gas purification method using the same

Abstract

The purpose of the present invention is to provide an oxidation catalyst for exhaust gas purification having high durability and a method for producing the catalyst. The purpose is achieved by an oxidation catalyst for exhaust gas purification containing a refractory inorganic oxide, and a catalyst component and a metal component, which are supported on the refractory inorganic oxide, wherein the catalyst component is platinum, or platinum and palladium, and the metal component is one or more selected from the group consisting of magnesium, calcium, strontium and barium.

1 . An oxidation catalyst for exhaust gas purification comprising:
 a refractory inorganic oxide (A),   β-zeolite (B), and   a catalyst component (C-a) and a metal component (C-b), which are supported on the refractory inorganic oxide (A), said components (A), (B), (C-a) and (C-b) being supported on a three-dimensional structure (D),   wherein the catalyst component (C-a) is (i) platinum, or (ii) platinum and palladium,   wherein the metal component (C-b) is at least are metal selected from the group consisting of calcium, strontium and barium in an amount of 0.001 to 0.12 mol per 1 L of the catalyst calculated as Ca, or Sr, or 0.001 to 0.2 mol per 1 L of the catalyst calculated as Ba, and   wherein a total amount of the refractory inorganic oxide and the β-zeolite is in a range of 1-250 g per 1 L of the catalyst.   
     
     
         2 . The oxidation catalyst for exhaust gas purification according to  claim 1 , wherein when the catalyst component is platinum and palladium, platinum/palladium (metal mass ratio) is 40/1 to 1/1. 
     
     
         3 . The oxidation catalyst for exhaust gas purification according to  claim 1 , wherein the catalyst component and the metal component are supported on the refractory inorganic oxide simultaneously or one by one in turn. 
     
     
         4 . The oxidation catalyst for exhaust gas purification according to  claim 1 , wherein a silica/alumina molar ratio in the β-zeolite is 15-500. 
     
     
         5 . The oxidation catalyst for exhaust gas purification according to  claim 1 , wherein the amount of calcium or strontium is 0.005 to 0.1 mol per 1 L of the catalyst calculated as Ca or Sr, or the amount of barium is 0.005 to 0.15 mol per 1 L of the catalyst calculated as Ba. 
     
     
         6 . The oxidation catalyst for exhaust gas purification according to  claim 1 , wherein the amount of calcium or strontium is 0.01 to 0.09 mol per 1 L of the catalyst calculated as Ca or Sr, or the amount of barium is 0.01 to 0.12 mol per 1 L of the catalyst calculated as Ba. 
     
     
         7 . The oxidation catalyst for exhaust gas purification according to  claim 1 , wherein the amount of calcium or strontium is 0.015 to 0.08 mol per 1 L of the catalyst calculated as Ca or Sr, or the amount of barium is 0.015 to 0.1 mol per 1 L of the catalyst calculated as Ba. 
     
     
         8 . The oxidation catalyst for exhaust gas purification according to  claim 1 , wherein the amount of calcium or strontium is 0.02 to 0.055 mol per 1 L of the catalyst calculated as Ca or Sr, or the amount of barium is 0.015 to 0.1 mol per 1 L of the catalyst calculated as Ba. 
     
     
         9 . The oxidation catalyst for exhaust gas purification according to  claim 1 , wherein a supported amount of the catalyst component is 0.1-10% by mass to the refractory inorganic oxide calculated as the metal. 
     
     
         10 . The oxidation catalyst for exhaust gas purification according to  claim 2 , wherein the catalyst component is an alloy of platinum and palladium, when platinum and palladium are used. 
     
     
         11 . The oxidation catalyst for exhaust gas according to  claim 1 , wherein a total amount of the refractory inorganic oxide and β-zeolite is in the range of 10-150 g per 1 L of the catalyst. 
     
     
         12 . The oxidation catalyst for exhaust gas according to  claim 1 , wherein a total amount of the refractory inorganic oxide and β-zeolite is in the range of 15-100 g per 1 L of the catalyst. 
     
     
         13 . A method for purifying an exhaust gas, wherein an exhaust gas is processed using the catalyst set forth in  claim 1 . 
     
     
         14 . A method for producing an oxidation catalyst for exhaust gas, comprising:
 (i-1) adding a water-soluble precious metal salt of (a) platinum or (b) platinum and palladium being a material of a catalyst component (C-a) and a water-soluble metal salt (C-b) being calcium, strontium or barium to a refractory inorganic oxide (A) to be mixed, or   (i-2) adding a water-soluble precious metal salt being a material of the catalyst component (C-a) to the refractory inorganic oxide to obtain catalyst component-supported refractory inorganic oxide (A), and then adding a solution that contains a water-soluble metal salt and mixing each other to obtain the catalyst component, dried and/or calcined, and the metal component-supported refractory inorganic oxide (A),   (ii) mixing β-zeolite (B) with the catalyst component (C-a) and the metal component (C-b) supported refractory inorganic oxide (A) obtained in either (i-1) or (i-2) to obtain a mixture of the catalyst component and the metal component-supported refractory inorganic oxide (A), and   (iii) preparing a slurry which contains the catalyst component (C-a), metal component (C-b) supported refractory inorganic oxide (A) and β-zeolite (B) obtained in (ii), and the slurry is coated on a three-dimensional structure (D), wherein a supported amount of calcium or strontium is 0.001 to 0.12 mol per 1 L of the catalyst calculated as Ca or Sr, or a supported amount of barium is 0.001 to 0.2 mol per 1 L of the catalyst calculated as Ba, and wherein a total amount of refractory inorganic oxide and the β-zeolite is in a range of 1-250 g per 1 L of the catalyst.   
     
     
         15 . The method for producing the oxidation catalyst for exhaust gas according to  claim 14 , wherein the β-zeolite is mixed at (i-2). 
     
     
         16 . The method for producing the oxidation catalyst for exhaust gas according to  claim 14 , wherein the amount of calcium or strontium is 0.01 to 0.09 mol per 1 L of the catalyst calculated as Ca or the amount of barium is 0.01 to 0.12 mol per 1 L of the catalyst calculated as Ba. 
     
     
         17 . The method for producing the oxidation catalyst for exhaust gas according to  claim 14 , wherein the amount of calcium or strontium is 0.015 to 0.08 mol per 1 L of the catalyst calculated as Ca or Sr, or the amount of barium is 0.015 to 0.1 mol per 1 L of the catalyst calculated as Ba. 
     
     
         18 . The method for producing the oxidation catalyst for exhaust gas according to  claim 14 , wherein the amount of calcium or strontium is 0.02 to 0.055 mol per 1 L of the catalyst calculated as Ca or Sr. 
     
     
         19 . The method for producing the oxidation catalyst for exhaust gas purification according to  claim 14 , wherein a supported amount of the catalyst component is 0.1-10% by mass to the refractory inorganic oxide calculated as the metal. 
     
     
         20 . A method for purifying an exhaust gas, wherein an exhaust gas is processed using a catalyst obtained by the production method set forth in  claim 14 . 
     
     
         21 . The method for producing the oxidation catalyst for exhaust gas purification according to  claim 20 , wherein a supported amount of calcium or strontium is 0.005 to 0.1 mol per 1 L of the catalyst calculated as Ca or Sr, or a supported amount of barium is 0.005 to 0.15 mol per 1 L of the catalyst calculated as Ba.