Molecular Sieve Catalyst for Low-Temperature Methane Oxidation
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Solution Overview
Problem
Existing methane oxidation catalysts face challenges in achieving high conversion efficiency at low temperatures, are sensitive to sulfur poisoning, and have poor thermal stability, especially in exhaust gases from natural gas engines containing excess oxygen.
Innovation Solution
A catalytic material comprising a molecular sieve with a framework of silicon, oxygen, and heteroatom T-atoms, with a heteroatom content of ≤ 0.20 mol%, combined with a platinum group metal, which exhibits high methane/ethane conversion efficiency at low temperatures and maintains stability under hydrothermal conditions, including sulfur tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional oxidation catalysts (Pd or Pt on alumina) are used to oxidize methane and ethane, then methane conversion efficiency can be achieved, but high operating temperatures (>500°C) are required
Solution Approach 1:
The patent changes the chemical composition parameters of the catalyst by incorporating specific metal combinations (Fe, Co, Ni, Cu, Mn) with controlled ratios and supporting materials (alumina, silica, gamma-alumina), enabling methane oxidation at lower temperatures while maintaining high conversion efficiency
Solution Approach 2:
The patent creates a composite catalytic material combining multiple metal components with specific support materials, where the synergistic interaction between different metals and supports enables low-temperature high-efficiency oxidation of methane and ethane
2Productivity
If conventional oxidation catalysts are used, then methane oxidation can proceed, but the catalysts are sensitive to poisoning by sulfur
Solution Approach 1:
The patent employs iron-based catalysts that can be easily replaced or regenerated compared to precious metal catalysts, and the specific composite formulation provides inherent sulfur tolerance that prevents permanent deactivation
Solution Approach 2:
The patent formulates catalysts where sulfur tolerance is an inherent property of the metal-support combination, converting what would normally be a harmful effect (sulfur poisoning) into a non-issue by designing the catalyst structure to resist sulfur adsorption and deactivation
3Productivity
If conventional oxidation catalysts operate at high temperatures, then methane conversion efficiency improves, but thermal stability deteriorates
Solution Approach 1:
The patent optimizes the chemical composition parameters of the catalyst by selecting specific metal combinations and their ratios, along with controlling the surface area and pore structure of the support materials, enabling the catalyst to maintain both high activity and thermal stability across a wide temperature range
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 catalytic material achieves high methane/ethane conversion efficiency at relatively low temperatures, maintains stability under hydrothermal conditions, and shows good tolerance to sulfur, enabling effective treatment of exhaust gases from natural gas engines without the need for high-temperature operation.
Implementation Method 1
A catalytic material comprises a molecular sieve and a platinum group metal (PGM) supported on the molecular sieve
Implementation Method 2
Method for oxidizing methane and ethane in exhaust gas of natural gas engines
Implementation Method 3
a molecular sieve with a framework of silicon, oxygen, and heteroatom T-atoms, with a heteroatom content of ≤ 0.20 mol%
Data Source
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AI summary
The invention relates to a method for treating an exhaust gas containing methane comprising contacting the exhaust gas with a catalytic material, which catalytic material comprises a molecular sieve and a platinum group metal (PGM) supported on the molecular sieve, wherein the molecular sieve has a framework consisting of silicon and oxygen and has a content of heteroatom T-atoms of ≤ about 0.20 mol%. The invention also relates to an apparatus.