Denitration Catalyst Regeneration With High-Surface-Area Titanium Oxide
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Solution Overview
Problem
The denitration performance of spent denitration catalysts decreases due to wear, sintering, and adhesion of catalyst poison components, making it difficult to restore catalytic performance through existing methods like adjusting denitration catalyst components or mixing with new catalyst materials.
Innovation Solution
A regenerated denitration catalyst is produced by mixing a spent denitration catalyst with a second titanium oxide having a larger specific surface area than the first titanium oxide, along with other components like vanadium and phosphorus, to restore denitration performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a spent denitration catalyst is used after long period operation, then the disposal amount decreases and environmental loads are reduced, but the denitration performance decreases due to wear, sintering, and adhesion of catalyst poison components
Solution Approach 1:
The patent changes the particle size distribution parameter of the spent catalyst by selective classification, separating fine particles (which maintain high surface area) from coarse particles (which have lost surface area due to sintering). This parameter change allows the regenerated catalyst to achieve both reduced disposal amounts and maintained denitration performance.
Solution Approach 2:
The spent catalyst is segmented into different particle size fractions through classification. The fine particle fraction is retained and reused in the regenerated catalyst, while the coarse particle fraction is disposed of. This segmentation enables selective recovery of the most effective catalyst particles.
2Ease of manufacture
If the spent denitration catalyst is reused without regeneration, then the manufacturing cost decreases, but the denitration performance is insufficient due to surface area loss
Solution Approach 1:
The patent applies parameter changes by controlling the particle size distribution of the spent catalyst through classification and adjusting the mixing ratio with fresh catalyst. This enables cost-effective regeneration while restoring denitration performance to acceptable levels.
Solution Approach 2:
The regenerated catalyst is created as a composite material combining classified spent catalyst particles with fresh catalyst particles. This composite structure allows the spent portion to be reused economically while the fresh portion compensates for any remaining performance deficiencies.
3Stability of the object's composition
If the denitration catalyst particles are sintered at high temperature, then the thermal stability increases, but the specific surface area decreases leading to reduced catalytic activity
Solution Approach 1:
The patent segments the sintered catalyst particles by size, retaining the fine particles that still possess adequate surface area and discarding the heavily sintered coarse particles. This segmentation recovers the portion of the catalyst that remains effective.
Solution Approach 2:
The patent changes the particle size distribution parameter of the spent catalyst through classification, creating a regenerated catalyst with optimized particle size that balances thermal stability with sufficient surface area for catalytic activity.
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 regenerated catalyst achieves a denitration performance comparable to a new catalyst, with improved surface area and strength, reducing the need for disposal and extending the catalyst's lifespan.
Implementation Method 1
The mixed powder has a larger specific surface area than the spent denitration catalyst
Implementation Method 2
a denitration reaction in which NOx is decomposed into harmless nitrogen and water is performed in the presence of a denitration catalyst using ammonia (NH3) as a reducing agent
Data Source
AI summary
It is an object to provide a regenerated denitration catalyst whose denitration performance is restored compared with a denitration catalyst before use, utilizing a spent denitration catalyst, and a method for manufacturing the same. In a regenerated denitration catalyst according to the present disclosure, a spent denitration catalyst including a first titanium oxide as a main component, and a second titanium oxide are mixed. The spent denitration catalyst is already used in a denitration reaction in which nitrogen oxides in a gas are decomposed into nitrogen and water using a reducing agent. The second titanium oxide has a larger specific surface area per unit weight than the first titanium oxide. A content of the second titanium oxide based on a total weight of the first titanium oxide and the second titanium oxide is preferably 10% by weight or more and 90% by weight or less.