Functionalized Metal Vanadate SCR Catalyst for Poison and Aging Resistance

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Solution Overview

Problem

Existing SCR catalysts face issues such as aggregation of catalytic sites, weak redox cycling, insufficient acid sites, interaction with exhaust gases leading to poisoning, and poor resistance to hydrothermal aging, which affect the efficiency and stability of nitrogen oxide reduction.

Innovation Solution

Functionalizing metal vanadates with H3-APO4A− and SOB2− groups to enhance the surface properties, incorporating Group 15 or 16 element oxides as promoters, and using a synthesis method that includes calcination and functionalization with specific gases to improve acid characteristics and resistance to poisons.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If vanadium oxide is used as a catalytic site, then the SCR reaction can be performed, but the catalytic sites aggregate due to low melting point

Engineering Contradiction:

Improvecatalyst stabilityVSAvoidcatalytic site dispersion

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent uses metal vanadates (composites of vanadium oxide with metal oxides) as catalytic sites instead of pure vanadium oxide. The metal vanadate structure prevents aggregation while maintaining catalytic activity, resolving the contradiction between catalyst stability and catalytic site dispersion.

Inventive Principle:

Principle #40Composite materials

2Productivity

If vanadium oxide is used as a catalytic site, then the SCR reaction can be performed, but the redox cycling trait is weak

Engineering Contradiction:

ImproveSCR reaction efficiencyVSAvoidredox cycling capability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent modifies the chemical composition parameters of the catalytic site by using metal vanadates with specific metal-to-vanadium ratios. This changes the electronic and structural properties to enhance redox cycling capability while maintaining high SCR reaction efficiency.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If vanadium oxide is used as a catalytic site, then the SCR reaction can be performed, but the resistance to catalyst surface poisoning by SO2 is poor

Engineering Contradiction:

Improvepoisoning resistanceVSAvoidSO2 interaction

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent incorporates promoters that can interact with SO2 to form beneficial surface species that actually enhance catalyst stability and prevent deactivation. The harmful SO2 interaction is converted into a protective mechanism through the promoter-catalyst-exhaust gas system.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Reliability

If vanadium oxide is used as a catalytic site, then the SCR reaction can be performed, but the resistance to hydrothermal aging is poor

Engineering Contradiction:

Improvehydrothermal stabilityVSAvoidcatalyst lifespan

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent uses promoters and support materials that provide structural and chemical stability before hydrothermal aging occurs. These components act as a cushion against the harsh hydrothermal conditions, protecting the catalytic sites from degradation and extending catalyst lifespan.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 modified catalysts exhibit improved SCR reaction performance, enhanced resistance to poisons, and increased stability against hydrothermal aging, leading to better nitrogen oxide reduction efficiency.

Implementation Method 1

a catalyst for nitrogen oxide reduction, including: a catalyst site including one or more of (Chemical Formula 1) (TM)XV2OX+5 (X is 1, 2, or 3; TM is one or more selected from the group consisting of Mn, Co, Ni, and Cu) (Chemical Formula 2) (RM)VO4 (RM is one or more selected from the group consisting of La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and Lu) (Chemical Formula 3) LaV3O9; and a support on which the catalyst site is supported

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

relatively weak redox cycling trait

Methodology Applied

Scientific EffectRedox reactions: Redox Reactions

Data Source

PatentUS20250367601A1Catalysts for selective nitrogen oxide reduction and its manufacturing method

Publication Date: 2025.12.04 UNIVERSITY INDUSTRY COOPERATION GROUP OF KYUNG HEE UNIVERSITY

AI summary

Embodiments relate to a metal vanadate catalyst for nitrogen oxide reduction functionalized with H3-APO4A− (A=1, 2, or 3) and SOB2− (B=3 or 4) and a synthesis method thereof, and more particularly, to a solid-state catalyst for nitrogen oxide reduction, including a transition metal vanadate or a rare-earth metal vanadate as a catalytic site in a support, some of the catalytic sites being modified with H3-APO4A− and SOB2− functional groups, and a synthesis method thereof.