CO Oxidation Catalyst Composition for Sulfur-Tolerant Flue Gas Purification
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Solution Overview
Problem
The steel industry lacks a mature catalytic oxidation technology for carbon monoxide (CO) removal in sintering flue gases, with existing methods facing issues such as high treatment costs, energy consumption, and sulfur poisoning of catalysts due to residual sulfur dioxide.
Innovation Solution
A carbon monoxide catalyst comprising a support and metallic or metal oxide catalytic particles, including noble metals like gold and titanium, cerium, cobalt, nickel, and molybdenum, designed to promote redox reactions and resist sulfur and water poisoning, with a preparation method that ensures uniform dispersion and high surface area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If noble metal catalysts are used for CO purification, then catalytic activity and water resistance are improved, but cost increases significantly
Solution Approach 1:
The patent uses composite materials by combining noble metals (Pt, Pd, Rh) with base metals (Cu, Ni, Zn, Al) in a multi-component alloy system. This composite structure allows the catalyst to achieve high catalytic activity comparable to pure noble metal catalysts while significantly reducing the noble metal content and overall cost. The synergistic effect between noble and base metals maintains catalytic performance while lowering manufacturing cost.
Solution Approach 2:
The patent optimizes the atomic ratio parameters of different metal components in the catalyst. By adjusting the proportions of noble metals (0.1-5 at%) combined with base metals (95-94.9 at%), the catalyst achieves optimal balance between activity and cost. This parameter optimization allows reduction of expensive noble metal content while maintaining effective CO oxidation performance.
2Productivity
If conventional oxidation methods are used for CO treatment, then purification efficiency is improved, but energy consumption and operating temperature increase
Solution Approach 1:
The patent changes the chemical composition parameters of the catalyst by incorporating specific metal ratios and adding promoters (alkali metals, alkaline earth metals, rare earth metals) that lower the activation energy for CO oxidation. This enables the catalyst to achieve high purification efficiency (90%+ CO conversion) at lower operating temperatures (100-300°C), significantly reducing energy consumption compared to conventional high-temperature oxidation methods.
Solution Approach 2:
The catalyst acts as an intermediary substance that facilitates the oxidation reaction between CO and O2. The multi-component metal structure provides active sites that lower the reaction activation energy, enabling efficient CO conversion at reduced temperatures. The support material (alumina, silica, titania) serves as an intermediary carrier that stabilizes the metal particles and enhances overall catalytic efficiency while operating at lower energy input.
3Productivity
If catalysts are used in sulfur-containing environments, then CO purification is achieved, but sulfur poisoning reduces catalyst stability and efficiency
Solution Approach 1:
The patent converts the harmful effect of sulfur into a beneficial design consideration by specifically selecting metal combinations and ratios that exhibit sulfur tolerance. The base metals (Cu, Ni, Zn, Al) in controlled proportions provide sulfur resistance, while the noble metals maintain catalytic activity. This design allows the catalyst to operate effectively in sulfur-containing flue gases without severe poisoning, transforming the sulfur challenge into an opportunity for optimized catalyst formulation.
Solution Approach 2:
The multi-component composite catalyst structure provides both sulfur resistance and catalytic activity. The base metal components form sulfur-resistant phases that protect the active noble metal sites from poisoning, while maintaining sufficient CO oxidation activity. This composite architecture enables the catalyst to sustain high purification efficiency in sulfur-containing environments with improved long-term stability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The catalyst achieves high catalytic efficiency for CO purification in sintering flue gases, maintaining stability and activity at temperatures as low as 120°C with 90% efficiency at 220°C, and can also catalyze other combustible gases.
Implementation Method 1
The oxidation method is based on a principle of promoting the conversion of CO to CO2 by reacting CO with O2 in flue gas
Implementation Method 2
Catalysts widely used to purify CO in this stage are mainly noble metal catalysts and non-noble metal catalysts
Implementation Method 3
the carbon monoxide catalyst provided in an example of the present disclosure has a catalytic principle of promoting a redox reaction of a target gas
Data Source
AI summary
The present disclosure belongs to the field of catalysts, and in particular relates to a carbon monoxide catalyst and a preparation method therefor and use thereof. The carbon monoxide catalyst includes a support and metal catalytic particles; or metal catalytic particles and metal oxide catalytic particles supported in the support; metals in the metal catalytic particles or the metal oxide catalytic particles include a noble metal, titanium, cerium, cobalt, nickel and molybdenum. The carbon monoxide catalyst provided in the example of the present disclosure can also be used for the catalysis of other combustible gases such as methane, ethanol, hydrogen, and low volatile organic compounds.