Honeycomb catalyst and manufacturing method thereof

A manufacturing method of a honeycomb catalyst, comprising:

• applying a first catalytic slurry containing a particulate catalytically active component whose maximum particle diameter is smaller than a maximum pore diameter of pores to a honeycomb structure comprising porous partition walls having a plurality of pores, which are arranged to form a plurality of cells allowing communication between two end faces;
• and plugging portions arranged to plug the cells in one of the end faces to load the catalytically active component on inner surfaces of pores;
• and
• subsequently applying a second catalytic slurry containing a particulate catalytically active component, whose minimum particle diameter is larger than the maximum pore diameter of the pores, to the honeycomb structure to load the catalytically active component on surfaces of partition walls;
• thereby
• obtaining the honeycomb catalyst in which the catalytically active component-loading pores, which allow a gas to pass therethrough, are formed in partition walls and a ratio of a mass (Mw) of the catalytically active component loaded on surfaces of the partition walls per unit volume of the partition walls to a mass (Mp) of the catalytically active component loaded on the inner surfaces of the pores is (Mw):(Mp)=1:3 to 3:1.

A manufacturing method of a honeycomb catalyst, comprising:

• applying a third catalytic slurry containing a particulate catalytically active component of a predetermined viscosity to a honeycomb structure comprising the porous partition walls having a plurality of pores, which are arranged to form the plurality of cells allowing communication between two end faces;
• and plugging portions arranged to plug the cells in one of the end faces to load the catalytically active component on inner surfaces of pores;
• and subsequently
• applying a fourth catalytic slurry which contains a particulate catalytically active component and has a higher viscosity than that of the third catalytic slurry to the honeycomb structure to load the catalytically active component on surfaces of partition walls, thereby
• obtaining the honeycomb catalyst in which the catalytically active component-loading pores, which allow a gas to pass therethrough, are formed in the partition walls and a ratio of a mass (Mw) of the catalytically active component loaded on surfaces of the partition walls per unit volume of the partition walls to a mass (Mp) of the catalytically active component loaded on the inner surfaces of the pores is (Mw):(Mp)=1:3 to 3:1.