Method suitable for improving abrasive resistance of flat plate type catalyst

Abstract

The invention discloses a method suitable for improving the abrasive resistance of a flat plate type catalyst, and belongs to the technical field of denitration catalysts. The method comprises the following steps: (a) optionally selecting 1-3 of a pre-hydrolyzed silane coupling agent solution, a silica sol solution and a titanium sol solution as binders, and mixing the binders with nano TiO2, montmorillonite, glass fibers, ammonium heptamolybdate, ammonium metavanadate and auxiliary materials to prepare pug; the main components are composed of nano TiO2, a binder added in the binder solution, montmorillonite, glass fibers, ammonium heptamolybdate, ammonium metavanadate and auxiliary materials; the pug consists of a main component and water, and the main component accounts for 65-75% of the total mass of the pug; and (b) coating, drying, curling, assembling and calcining the pug to obtain the flat plate type catalyst. The flat plate type catalyst has excellent wear resistance, meanwhile, introduction of the silane coupling agent, the silica sol or the titanium sol does not inhibit denitration performance of the catalyst, and the flat plate type catalyst can be widely applied to working conditions with high requirements for wear resistance.

Description

Technical Field

[0001] This invention relates to the field of denitrification catalyst technology, and more specifically, to a method suitable for improving the wear resistance of plate-type catalysts. Background Technology

[0002] Selective catalytic reduction (SCR) technology is used to treat nitrogen oxides (NOx) in industrial flue gas. x A common method is to use a catalytic reaction to remove harmful NO. x It is converted into harmless nitrogen (N2). In SCR technology, the catalyst plays a crucial role and, based on its structure, can be divided into three types: honeycomb, flat plate, and corrugated plate. Compared to the other two catalyst types, flat plate catalysts, due to their special structural design, exhibit superior performance in treating flue gas containing high ash and dust, making them particularly suitable for high-dust-load environments such as thermal power plants and waste incineration plants.

[0003] In practical applications, the wear resistance of a catalyst is one of the key factors determining the service life of a plate-type catalyst. Particulate matter in flue gas continuously impacts the catalyst surface, causing wear. Therefore, enhancing the wear resistance of plate-type catalysts is of great significance for improving their service life and reducing maintenance costs. The wear resistance of plate-type catalysts is not only related to their material composition and preparation process, but also closely related to the added additives. Given fixed material composition and process conditions, selecting appropriate additives and preparation methods to improve the wear resistance of the catalyst is particularly important. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a method suitable for improving the wear resistance of plate-type catalysts. The prepared plate-type denitration catalyst has excellent wear resistance, and the introduction of silane coupling agent, silica sol and titanium sol does not inhibit the denitration performance of the catalyst. It can be widely used in working conditions with high requirements for wear resistance.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A method for improving the wear resistance of flat-plate catalysts includes the following steps:

[0007] (a) Select 1-3 of the following from the pre-hydrolyzed silane coupling agent solution, silica sol solution, and titanium sol solution as binders, and mix them together with nano TiO2, montmorillonite, glass fiber, ammonium heptamolybdate, ammonium metavanadate, and auxiliary materials to obtain mud material;

[0008] The main components consist of nano-TiO2, binder added to the binder solution, montmorillonite, glass fiber, ammonium heptamolybdate, ammonium metavanadate, and excipients. Based on 100% of the total mass of the main components, the main components include the following substances in the following amounts: montmorillonite 4-5 wt%, binder 0.1-5.0 wt%, glass fiber 4-6 wt%, ammonium heptamolybdate 3-5 wt%, ammonium metavanadate 2-3 wt%, excipients 1.0 wt%, and the balance being nano-TiO2.

[0009] The resulting clay consists of a main component and water, with the main component accounting for 65-75% of the total mass of the clay.

[0010] (b) The mud is coated, dried, rolled, assembled into unit boxes, and calcined to obtain a flat-plate catalyst.

[0011] The present invention is further configured such that the silica sol solution is prepared by mixing water with either alkaline silica sol or acidic silica sol, and the titanium sol solution is prepared by mixing water with either alkaline titanium sol or acidic titanium sol.

[0012] The present invention is further configured such that the excipients consist of methylcellulose, lactic acid, polyethylene oxide, ammonia water with a concentration of 15wt%, and kapok.

[0013] The present invention is further configured such that the amount of methylcellulose added is 0.1-0.2 wt% of the total mass of the main components, the amount of lactic acid added is 0.1-0.3 wt% of the total mass of the main components, the amount of polyethylene oxide added is 0.1-0.4 wt% of the total mass of the main components, the amount of ammonia added is 0.1-0.2 wt% of the total mass of the main components, and the amount of lactic acid added is 0.05-0.2 wt% of the total mass of the main components.

[0014] The present invention is further configured such that the silane coupling agent is any one of aminosilane, vinylsilane, methacrylate silane, epoxysilane, thiol silane, and isocyanate silane;

[0015] The general formula for silane coupling agents is: ;

[0016] Where Y is one of vinyl, epoxy, amino, or mercapto groups, and X, X′, and X″ are any one of methoxy, ethoxy, or chlorino groups.

[0017] The present invention is further configured to prepare a silane coupling agent solution by mixing a silane coupling agent with water in a certain proportion.

[0018] The present invention is further configured such that the specific steps of mixing are as follows: glass fiber is added to the binder solution, stirred evenly and fully impregnated, then nano TiO2 is added for mixing, and then montmorillonite, ammonium heptamolybdate, ammonium metavanadate and auxiliary materials are added for further mixing to obtain mud.

[0019] The present invention is further configured such that the specific steps of mixing are as follows: first, glass fiber is dispersed in nano-TiO2, then a binder solution is added for mixing, and then montmorillonite, ammonium heptamolybdate, ammonium metavanadate and auxiliary materials are added to the initial mixture for further mixing to obtain mud.

[0020] The present invention is further configured such that the total mixing time is 30-120 min.

[0021] This invention builds upon traditional vanadium-titanium-based formulations by adding organic and inorganic binders such as silane coupling agents, silica sol, and titanium sol, which act as bridges between the glass fiber skeleton and TiO2 support in the traditional formulation. The surface of glass fibers typically contains hydroxyl (-OH) groups, which can react with the silane groups in the silane coupling agent. Simultaneously, the TiO2 support also has numerous hydroxyl groups, which participate in the reaction with the silane coupling agent, thus forming a bonding bridge through the silane coupling agent and improving the catalyst's wear resistance. Under normal circumstances, the reactivity between the silane coupling agent, glass fiber, and TiO2 support is very low. However, when the silane coupling agent comes into contact with moisture, it hydrolyzes to form a large number of silanol groups (-SiOH). These silanol groups are highly reactive and readily undergo condensation reactions with the hydroxyl groups on the surfaces of the glass fiber and TiO2 support to form stable silicon-oxygen bonds (-Si-O-Si-) and silicon-oxygen-titanium bonds (-Si-O-Ti-). The formation of these chemical bonds can significantly improve the wear resistance of the denitration catalyst. Meanwhile, the other end of the silane coupling agent typically contains organic functional groups, such as amino, vinyl, or epoxy groups. These functional groups can react with or be compatible with organic binders (such as polyethylene oxide) in the formulation, further improving the adhesion strength of the catalyst slurry and enhancing the overall molding performance during flat-plate catalyst coating. Furthermore, the addition of silica sol and titanium sol can further promote the reaction with the silane coupling agent and the glass fiber skeleton, thereby further strengthening the adhesion between the slurries and improving wear resistance. By carefully controlling the amount of silane coupling agent and silica sol added and the feeding steps during slurry mixing, the influence of silane coupling agent and silica sol on activity can be avoided. Titanium sol generally does not inhibit product activity and may even enhance it.

[0022] The beneficial effects of this invention are:

[0023] 1. Without changing the main components and active components of the plate-type catalyst, the wear resistance of the plate-type catalyst can be improved by at least 30wt% by adding some new additives.

[0024] 2. The amount of the added silane coupling agent is very low, generally controlled between 0.1-5 wt%, which has little impact on the production cost of the plate catalyst.

[0025] 3. No major adjustments are needed to the production process of flat-plate catalysts, therefore no modification to the existing production equipment is required.

[0026] 4. There are various types of silane coupling agents, silica sols, and titanium sols that can be used in this technology, which can be divided into two main categories: acidic and alkaline systems. Appropriate silane coupling agents, silica sols, and titanium sols can be selected and adapted to existing compounding formulations. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the process by which the silane coupling agent of the present invention reacts with glass fiber and TiO2 support to form a bridging bond. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] This invention relates to a method for improving the wear resistance of flat-plate catalysts, comprising the following steps:

[0030] Choose 1-3 of the following as binder solutions: pre-hydrolyzed silane coupling agent solution, silica sol solution, and titanium sol solution. Mix them with nano-TiO2, montmorillonite, glass fiber, ammonium heptamolybdate, ammonium metavanadate, and auxiliary materials for 30-120 minutes to obtain mud.

[0031] A pre-hydrolyzed silane coupling agent solution was prepared by mixing a silane coupling agent with water in a certain proportion. The silane coupling agent was any one of aminosilane, vinylsilane, methacrylate silane, epoxysilane, thiol silane, or isocyanate silane.

[0032] The general formula for silane coupling agents is: Where Y is one of vinyl, epoxy, amino, or mercapto groups, and X, X′, and X″ are any one of methoxy, ethoxy, or chlorino groups.

[0033] Silica sol solution is prepared by mixing water with either alkaline or acidic silica sol, and titanium sol solution is prepared by mixing water with either alkaline or acidic titanium sol.

[0034] When using 2-3 types of binder solutions during mixing, each binder solution can be mixed in a certain proportion first, and then mixed with other components (specifically: glass fiber is added to the binder solution, stirred evenly and fully impregnated, and then nano TiO2 is added for mixing to obtain a preliminary mixture, or glass fiber is first dispersed in nano TiO2, and then the binder solution is added for mixing to obtain a preliminary mixture; then montmorillonite, ammonium heptamolybdate, ammonium metavanadate, and auxiliary materials are added to the preliminary mixture for further mixing to obtain mud). Alternatively, the components can be added step by step to the mixing process.

[0035] Based on 100% of the total mass of the clay, the clay consists of a main component comprising 65-75% of the total mass, with the remainder being water. The main components are nano-TiO2, the binder added to the binder solution (i.e., composed of at least one of the following: silane coupling agent added to the pre-hydrolyzed silane coupling agent solution, silica sol added to the silica sol solution, and titanium sol added to the titanium sol solution), montmorillonite, glass fiber, ammonium heptamolybdate, ammonium metavanadate, and auxiliary materials. Based on 100% of the total mass of the main components, the main components include the following substances in the following amounts: montmorillonite 4-5 wt%, binder 0.1-5.0 wt%, glass fiber 4-6 wt%, ammonium heptamolybdate 3-5 wt%, ammonium metavanadate 2-3 wt%, auxiliary materials 1.0 wt%, and the balance being nano-TiO2; the auxiliary materials consist of methylcellulose, lactic acid, polyethylene oxide, ammonia water with a concentration of 15 wt%, and kapok. The amount of methylcellulose added is 0.1-0.2 wt% of the total mass of the main components, the amount of lactic acid added is 0.1-0.3 wt% of the total mass of the main components, the amount of polyethylene oxide added is 0.1-0.4 wt% of the total mass of the main components, the amount of ammonia water added is 0.1-0.2 wt% of the total mass of the main components, and the amount of lactic acid added is 0.05-0.2 wt% of the total mass of the main components.

[0036] (b) After the mud is uniformly coated, dried, rolled, assembled into unit boxes and calcined at 400-600℃ for 4-8 hours, a flat-plate denitrification catalyst is obtained.

[0037] Specific implementation examples are shown in Examples 1-6. In all comparative examples and examples, the wear resistance and denitrification activity of the plate catalyst were tested in accordance with the test methods specified in the People's Republic of China Electric Power Industry Standard DL / T 1286—2021 "Technical Specification for Testing Flue Gas Denitrification Catalysts in Thermal Power Plants". Each sample was tested 5 times, and the average value was recorded.

[0038] Example 1

[0039] In the experiment, the conventional production process for plate-type catalysts was followed, but the pre-hydrolysis of silane coupling agent KH-151 and the glass fiber impregnation steps were added to the mixing process. Specifically, vinyltriethoxysilane (KH-151) was first mixed with water to promote the pre-hydrolysis of the silane coupling agent, generating a large number of active silanol groups (-SiOH), resulting in a pre-hydrolyzed silane coupling agent solution. Next, glass fibers were immersed in the pre-hydrolyzed silane coupling agent solution, ensuring uniform stirring and thorough impregnation for 30 minutes, followed by the addition of nano-TiO2 for mixing. Afterward, other raw materials were added and the components were mixed evenly to form a slurry.

[0040] The resulting clay material consists of water and a main component, which accounts for 70% of the total mass of the clay. The main component of the clay contains 82.1 wt% nano-TiO2, 4.5 wt% montmorillonite, 5.0 wt% glass fiber, 4.0 wt% ammonium heptamolybdate, 2.4 wt% ammonium metavanadate, 1.0 wt% silane coupling agent (added to the pre-hydrolyzed silane coupling agent solution), and 1.0 wt% auxiliary materials (including 0.2 wt% methylcellulose (viscosity 300-560 cP, 2% in water (20℃)), 0.2 wt% lactic acid, 0.3 wt% polyethylene oxide (average molecular weight 4 million), 0.2 wt% 15 wt% ammonia water, and 0.1 wt% kapok). The clay material is uniformly coated onto a steel mesh substrate (mesh density 90 wt%, mesh diameter 1.0 mm) to a thickness of 0.75 mm. After drying, edge rolling, unit box assembly, and calcination at 500℃ for 4 hours, the production and preparation of the implementation sample is completed.

[0041] The wear resistance and denitrification activity tests of the sample in Example 1 (Table 1) showed that by adding 1.0 wt% of the pre-hydrolyzed silane coupling agent KH-151 as the main component, the wear resistance of the sample significantly decreased to 87 mg / 100 r, and the wear resistance performance improved by nearly 60 wt% (compared to Comparative Example 2), meeting the industry standard of less than 130 mg / 100 r. However, the denitrification activity decreased to 37.0 m / h, a reduction of 10% (compared to Comparative Example 2). This change was due to the excessive reaction between the silane coupling agent and the hydroxyl groups on the surface of nano-titanium dioxide, leading to a reduction in effective oxygen vacancies, thereby inhibiting the denitrification activity of the catalyst.

[0042] Example 2

[0043] This experiment was similar to Example 1, employing a conventional production process for a flat-plate catalyst. However, the mixing step incorporated pre-hydrolysis of the silane coupling agent KH-151 and pre-wetting of the glass fiber. Specifically, vinyltriethoxysilane (KH-151) was first mixed with water to promote the pre-hydrolysis of the silane coupling agent, generating abundant silanol groups (-SiOH), resulting in a pre-hydrolyzed silane coupling agent solution. Next, the glass fiber was immersed in the silane coupling agent solution, ensuring uniform stirring and thorough wetting for 30 minutes. Nano-TiO2 was then added for mixing. Subsequently, other raw materials were added and the components were mixed thoroughly to form a slurry. The resulting slurry consisted of water and a main component, which comprised 70% of the total slurry mass. The main components of the clay material include: 82.6 wt% nano-TiO2, 4.5 wt% montmorillonite, 5.0 wt% glass fiber, 4.0 wt% ammonium heptamolybdate, 2.4 wt% ammonium metavanadate, 0.5 wt% silane coupling agent, and 1.0 wt% auxiliary materials (including 0.2 wt% methylcellulose, 0.2 wt% lactic acid, 0.3 wt% polyethylene oxide, 0.2 wt% ammonia solution with a concentration of 15 wt%, and 0.1 wt% kapok). The clay material is uniformly coated onto a steel mesh substrate (mesh density of 90 wt%, mesh diameter of 1.0 mm) to a coating thickness of 0.75 mm. After drying, edge rolling, unit box assembly, and calcination at 500℃ for 4 hours, the production and preparation of the implementation sample is completed.

[0044] The wear resistance and denitrification activity tests of the sample in Example 2 (Table 1) showed that when the content of silane coupling agent KH-151 was reduced to 0.5 wt%, the wear resistance and denitrification activity of the sample did not change significantly compared with Example 1. However, the denitrification activity of the sample was still lower than that of comparative examples 1 and 2. Therefore, it is necessary to further reduce the amount of silane coupling agent.

[0045] Example 3

[0046] This experiment was similar to Examples 1 and 2, employing a conventional production process for a flat-plate catalyst. However, a pre-hydrolysis of the silane coupling agent KH-151 and a pre-wetting process for the glass fiber were introduced in the mixing step. Specifically, vinyltriethoxysilane (KH-151) was first mixed with water to promote the pre-hydrolysis of the silane coupling agent, generating abundant silanol groups (-SiOH), resulting in a pre-hydrolyzed silane coupling agent solution. Next, the glass fiber was immersed in the silane coupling agent solution, ensuring uniform stirring and thorough wetting for 30 minutes. Nano-TiO2 was then added for mixing. Subsequently, other raw materials were added and the components were mixed evenly to form a slurry. The resulting slurry consisted of water and a main component, which accounted for 70% of the total mass of the slurry. The main components of the clay material include 82.85 wt% nano-TiO2, 4.5 wt% montmorillonite, 5.0 wt% glass fiber, 4.0 wt% ammonium heptamolybdate, 2.4 wt% ammonium metavanadate, 0.25 wt% silane coupling agent, and 1.0 wt% auxiliary materials (including 0.2 wt% methylcellulose, 0.2 wt% lactic acid, 0.3 wt% polyethylene oxide, 0.2 wt% 15 wt% ammonia water, and 0.1 wt% kapok). The clay material is uniformly coated onto a steel mesh substrate (mesh density of 90 wt%, mesh diameter of 1.0 mm) to a thickness of 0.75 mm. After drying, edge rolling, unit box assembly, and calcination at 500℃ for 4 hours, the production and preparation of the implementation sample is completed.

[0047] The test results of Example 3 (Table 1) show that when the content of silane coupling agent KH-151 was reduced to 0.25 wt%, the wear resistance of the sample reached 85 mg / 100 r, maintaining a level basically consistent with the previous two examples; simultaneously, the denitrification activity reached 42.5 m / h, comparable to the control sample without added silane coupling agent. This result indicates that an appropriate amount of added silane coupling agent can effectively react with glass fiber and TiO2 support to form a stable bonding bridge to improve wear resistance, while avoiding excessive occupation of oxygen vacancies on the TiO2 surface, thus not affecting the denitrification activity of the catalyst. This finding provides important guidance for the optimization of planar denitrification catalysts, ensuring both improved wear resistance and maintained catalytic efficiency.

[0048] Example 4

[0049] This embodiment follows the preparation of a planar catalyst as in Example 3, except that the proportion of the main components of the mud is changed. The main components are: glass fiber 3.4 wt%, nano TiO2 84.45 wt%, montmorillonite 4.5 wt%, ammonium heptamolybdate 4.0 wt%, ammonium metavanadate 2.4 wt%, silane coupling agent 0.25 wt%, and total auxiliary materials 1.0 wt% (including methylcellulose 0.2 wt%, lactic acid 0.2 wt%, polyethylene oxide 0.3 wt%, 15 wt% ammonia water 0.2 wt%, and kapok 0.1 wt%).

[0050] The wear resistance test results of Example 4 (Table 1) show that, while maintaining the KH-151 silane coupling agent content at 0.25 wt%, reducing the glass fiber content increases the wear resistance from 85 mg / 100 r to 117 mg / 100 r, although the wear resistance decreases. This is consistent with the experimental trends of Comparative Examples 1 and 2, confirming the important role of glass fiber in improving the wear resistance of the catalyst. Furthermore, compared to Example 3, the wear resistance of Example 4 decreased by 27%, higher than the 15% observed in the comparative experiments (the decrease in Comparative Example 1 compared to Comparative Example 2), further confirming the positive impact of the reaction between the silane coupling agent and glass fiber on enhancing the wear resistance of the catalyst. The denitrification activity of Example 4 was 42.8 m / h, basically the same as that of Example 3, indicating that moderate adjustment of the glass fiber content has little effect on the denitrification activity of the catalyst.

[0051] Example 5

[0052] The preparation process in this embodiment is the same as in Example 3, but the silane coupling agent is changed from KH-151 to N-β-(aminoethyl)-γ-aminopropylmethyldimethoxysilane (KH-602). The proportions of the raw materials remain unchanged, specifically: nano-TiO2 82.85wt%, montmorillonite 4.5wt%, glass fiber 5.0wt%, ammonium heptamolybdate 4.0wt%, ammonium metavanadate 2.4wt%, silane coupling agent 0.25wt%, and auxiliary materials 1.0wt% (including methylcellulose 0.2wt%, lactic acid 0.2wt%, polyethylene oxide 0.3wt%, 15wt% ammonia water 0.2wt%, and kapok 0.1wt%). After these components are mixed evenly to form a slurry, it is uniformly coated on a steel mesh substrate (mesh density 90wt%, mesh diameter 1.0mm) to a coating thickness of 0.75mm. After drying, edge rolling, unit box assembly, and calcination at 500℃ for 4 hours, the production and preparation of the implementation sample is completed.

[0053] In Example 5 (Table 1), by replacing the acidic KH-151 in the previous experiments with the basic silane coupling agent KH-602, the results showed that the wear resistance and denitrification activity of the sample were similar to those in Example 3. This indicates that both acidic and basic silane coupling agents work effectively in this formulation system, significantly enhancing the wear resistance of the plate-mounted catalyst, without negatively impacting the denitrification activity when used in appropriate amounts. This finding provides greater flexibility in the selection of excipients for plate-mounted catalysts and also provides guidance on the balance between enhancing wear resistance and maintaining denitrification activity.

[0054] Example 6

[0055] This embodiment follows the preparation of a planar catalyst as in Example 3, except that glass fibers are immersed in a mixture of a pre-hydrolyzed silane coupling agent solution (vinyltriethoxysilane (KH-151) is mixed with water to promote the pre-hydrolysis of the silane coupling agent, generating abundant silanol groups (-SiOH), to obtain a pre-hydrolyzed silane coupling agent solution) and an alkaline silica sol solution (alkaline silica sol (purchased from Shandong Yinfeng Nanomaterials Co., Ltd., model JN-40) is mixed evenly with water) to ensure uniform stirring and full wetting for 30 minutes before continuing the preparation process; and the proportion of the main components of the mud is changed. The resulting clay consists of water and main components, with the main components accounting for 70% of the total mass of the clay. The main components of the clay include 82.6 wt% nano-TiO2, 4.5 wt% montmorillonite, 5.0 wt% glass fiber, 4.0 wt% ammonium heptamolybdate, 2.4 wt% ammonium metavanadate, 0.25 wt% silane coupling agent, 0.25 wt% alkaline silica sol, and 1.0 wt% auxiliary materials (including 0.2 wt% methylcellulose, 0.2 wt% lactic acid, 0.3 wt% polyethylene oxide, 0.2 wt% ammonia water with a concentration of 15 wt%, and 0.1 wt% kapok).

[0056] The wear resistance test results of Example 6 (Table 1) show that, while keeping the amount of KH-151 silane coupling agent constant at 0.25 wt%, the addition of silica sol will cause the wear resistance to continue to decrease slightly. At the same time, due to the increase in silicon content, the activity also shows a slight downward trend, but the overall change is not significant.

[0057] Example 7

[0058] This embodiment follows the preparation of a planar catalyst as in Example 6, except that the alkaline silica sol solution is replaced with an alkaline titanium sol solution (obtained by uniformly mixing alkaline titanium sol (purchased from Hangzhou Jikang New Materials Co., Ltd., model SS-TA05WJ) with water). The resulting mud consists of water and main components, with the main components accounting for 70% of the total mass of the mud. The main components of the mud include 82.6 wt% nano-TiO2, 4.5 wt% montmorillonite, 5.0 wt% glass fiber, 4.0 wt% ammonium heptamolybdate, 2.4 wt% ammonium metavanadate, 0.25 wt% silane coupling agent, 0.25 wt% alkaline titanium sol, and 1.0 wt% auxiliary materials (including 0.2 wt% methylcellulose, 0.2 wt% lactic acid, 0.3 wt% polyethylene oxide, 0.2 wt% 15 wt% ammonia water, and 0.1 wt% kapok).

[0059] The wear resistance test results of Example 7 (Table 1) show that, while maintaining the KH-151 silane coupling agent content at 0.25 wt%, the addition of titanium sol causes a slight decrease in wear resistance. However, the titanium sol does not inhibit the activity, which is the opposite of the trend in Example 6. This is because titanium dioxide is the carrier of the denitrification catalyst, and the core component of titanium sol is titanium dioxide nanoparticles. Therefore, the addition of titanium sol will not inhibit the denitrification activity.

[0060] Comparative Example 1

[0061] The control group sample was prepared using conventional production processes and formulations for plate-type catalysts. A stainless steel mesh (90 wt% mesh density, 1.0 mm diameter) was used as the substrate. The mass percentages of the components in the coating slurry were as follows: 84.7 wt% nano-TiO2, 4.5 wt% montmorillonite, 3.4 wt% glass fiber, 4.0 wt% ammonium heptamolybdate, 2.4 wt% ammonium metavanadate, and 1.0 wt% excipients (including 0.2 wt% methylcellulose, 0.2 wt% lactic acid, 0.3 wt% polyethylene oxide, 0.2 wt% 15 wt% ammonia, and 0.1 wt% kapok). These components were mixed uniformly to form a slurry-like mixture, which was then uniformly coated onto the steel mesh substrate to a thickness of 0.75 mm. After drying, edge rolling, unit box assembly, and calcination at 500℃ for 4 hours, the production of the control sample was completed.

[0062] The test results of wear resistance and denitrification activity of Comparative Example 1 are shown in Table 1: The wear resistance is 252 mg / 100 r, which is much greater than the industry-recognized 130 mg / 100 r, so the wear resistance is poor; the denitrification activity is 41.7 m / h, which meets the industry standard of above 40 m / h.

[0063] Comparative Example 2

[0064] Comparative Example 2 also employed the conventional production process for a flat-plate catalyst, using a stainless steel mesh as the substrate (mesh density of 90 wt%, mesh diameter of 1.0 mm). However, the mass ratio of the slurry was slightly adjusted, primarily by increasing the proportion of glass fiber. The specific formulation was as follows: nano-TiO2 83.1 wt%, montmorillonite 4.5 wt%, glass fiber increased to 5.0 wt%, ammonium heptamolybdate 4.0 wt%, ammonium metavanadate 2.4 wt%, and auxiliary materials 1.0 wt% (including 0.2 wt% methylcellulose, 0.2 wt% lactic acid, 0.3 wt% polyethylene oxide, 0.2 wt% ammonia water with a concentration of 15 wt%, and 0.1 wt% kapok). The mixed slurry was uniformly coated onto the stainless steel mesh substrate to a thickness of 0.75 mm. After drying, edge rolling, unit box assembly, and calcination at 500℃ for 4 hours, the production process of this comparative sample was completed.

[0065] The test results of Comparative Example 2 are shown in Table 1. By increasing the glass fiber content, the wear resistance of the sample was significantly improved, while the wear strength decreased by 15%; however, the denitrification activity remained almost unchanged at 40.9 m / h, indicating that adjusting the glass fiber ratio had little effect on the denitrification activity.

[0066] Table 1 Comparison of Abrasion Resistance and Denitrification Activity

[0067]

[0068] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A method for improving the attrition resistance of a flat plate catalyst characterized by, The method comprises the following steps: (a) mixing 1-3 kinds of pre-hydrolyzed silane coupling agent solution, silica sol solution, and titania sol solution as a binder with nano-TiO2, montmorillonite, glass fiber, ammonium heptamolybdate, ammonium metavanadate, and auxiliary materials to obtain a paste; The nano-TiO2, the binder in the binder solution, the montmorillonite, the glass fiber, the ammonium heptamolybdate, the ammonium metavanadate, and the auxiliary materials form main components; the main components comprise the following contents of substances: 4-5 wt% of montmorillonite, 0.1-5.0 wt% of the binder, 4-6 wt% of the glass fiber, 3-5 wt% of the ammonium heptamolybdate, 2-3 wt% of the ammonium metavanadate, 1.0 wt% of the auxiliary materials, and the balance of nano-TiO2, based on 100% of the total mass of the main components; The obtained paste is composed of the main components and water, and the main components account for 65-75% of the total mass of the paste; (b) coating, drying, edge rolling, unit box assembly, and calcination treatment of the paste to obtain a flat plate catalyst.

2. A method for improving the attrition resistance of a flat plate catalyst according to claim 1, wherein The silica sol solution is prepared by mixing one of alkaline silica sol or acidic silica sol with water, and the titania sol solution is prepared by mixing one of alkaline titania sol or acidic titania sol with water.

3. The method for improving the attrition strength of the flat plate catalyst according to claim 1, wherein, The auxiliary materials are composed of methyl cellulose, lactic acid, polyethylene oxide, 15 wt% ammonia water, and kapok.

4. The method for improving the attrition strength of the flat plate catalyst according to claim 3, characterized in that, The methyl cellulose is added in an amount of 0.1-0.2 wt% of the total mass of the main components, the lactic acid is added in an amount of 0.1-0.3 wt% of the total mass of the main components, the polyethylene oxide is added in an amount of 0.1-0.4 wt% of the total mass of the main components, the ammonia water is added in an amount of 0.1-0.2 wt% of the total mass of the main components, and the lactic acid is added in an amount of 0.05-0.2 wt% of the total mass of the main components.

5. The method for improving the attrition strength of the flat plate catalyst according to claim 1, wherein The silane coupling agent is any one of amino silane, vinyl silane, methacrylate silane, epoxy silane, thiol silane, and isocyanate silane; The silane coupling agent has a general formula of ; Y is any one of vinyl, epoxy, amino, and mercapto, and X, X', and X" are any one of methoxy, ethoxy, and chloro.

6. The method for improving the attrition strength of the flat plate catalyst according to claim 1, wherein The silane coupling agent is mixed with water in a certain proportion to obtain a silane coupling agent solution.

7. The method for improving the attrition strength of the flat plate catalyst according to claim 1, wherein The specific steps of the mixing are as follows: the glass fiber is added to the binder solution, stirred uniformly and fully immersed, then the nano-TiO2 is added for mixing, and then the montmorillonite, the ammonium heptamolybdate, the ammonium metavanadate, and the auxiliary materials are added for further mixing to obtain the paste.

8. The method for improving the attrition strength of the flat plate catalyst according to claim 1, wherein, The specific steps of the mixing are as follows: the glass fiber is first dispersed in the nano-TiO2, then the binder solution is added for mixing, and then the montmorillonite, the ammonium heptamolybdate, the ammonium metavanadate, and the auxiliary materials are added to the initial mixture for further mixing to obtain the paste.

9. The method for improving the attrition strength of the flat plate catalyst according to claim 1, wherein, The total mixing time is 30-120 min.

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