Multi-function Catalyst for Stationary Emissions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current catalyst systems for treating NOx and CO emissions in combustion exhaust gases from stationary sources require separate substrates and precious metals, leading to increased costs and environmental concerns due to the use of platinum group metals, which also promote undesirable reactions.
Innovation Solution
A multi-function catalyst article combining a vanadium-containing SCR catalyst with transition metals like copper, manganese, cobalt, molybdenum, or cerium, optionally with a crystalline molecular sieve, eliminating the need for precious metals and allowing for a single substrate to handle both NOx reduction and CO oxidation, thereby reducing costs and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate substrates and precious metals are used for treating NOx and CO emissions, then catalytic activity is improved, but system complexity and cost increase
Solution Approach 1:
The patent combines multiple catalytic functions (NOx reduction via SCR and CO oxidation) into a single catalyst article. The catalyst composition includes vanadium-containing SCR catalyst component for NOx reduction and transition metal compounds (copper, manganese, cobalt, molybdenum, or cerium) for CO oxidation, both integrated on one substrate structure.
Solution Approach 2:
The single catalyst article performs multiple functions: it reduces NOx through selective catalytic reduction using ammonia and simultaneously oxidizes CO to CO2. This multi-functional design eliminates the need for separate catalyst substrates for different emission components.
2Reliability
If separate substrates are used for NOx and CO treatment, then catalytic performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent integrates multiple catalytic functions (NOx reduction via SCR and CO oxidation) into a single catalyst article. The catalyst composition includes vanadium-containing SCR catalyst component for NOx reduction and transition metal compounds (copper, manganese, cobalt, molybdenum, or cerium) for CO oxidation, both integrated on one substrate structure.
Solution Approach 2:
The patent replaces expensive precious metals (platinum group metals) with cheaper transition metal compounds. Specifically, copper, manganese, cobalt, molybdenum, or cerium compounds are used instead of platinum group metals for CO oxidation, significantly reducing material costs while maintaining catalytic functionality.
3Reliability
If platinum group metals are used for CO oxidation, then catalytic activity is improved, but environmental harm increases
Solution Approach 1:
The patent replaces expensive precious metals (platinum group metals) with cheaper transition metal compounds. Specifically, copper, manganese, cobalt, molybdenum, or cerium compounds are used instead of platinum group metals for CO oxidation, significantly reducing material costs while maintaining catalytic functionality.
Solution Approach 2:
The patent eliminates the use of platinum group metals, which are associated with environmental concerns and ethical issues related to mining and disposal. By using abundant transition metals, the invention reduces environmental harm while maintaining or improving catalytic performance.
4Productivity
If multiple substrates are used for different catalytic functions, then treatment efficiency is improved, but device size increases
Solution Approach 1:
The patent combines multiple catalytic functions (NOx reduction via SCR and CO oxidation) into a single catalyst article. The catalyst composition includes vanadium-containing SCR catalyst component for NOx reduction and transition metal compounds (copper, manganese, cobalt, molybdenum, or cerium) for CO oxidation, both integrated on one substrate structure.
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 solution enables efficient NOx conversion and CO oxidation without precious metals, resulting in a more compact, cost-effective system with lower back-pressure and reduced environmental impact by eliminating the need for separate substrates and platinum group metals.
Implementation Method 1
The SCR reaction generally consists of the reduction of NOx by ammonia (NH3) to form water and nitrogen
Implementation Method 2
A multi-function catalyst article combining a vanadium-containing SCR catalyst with transition metals like copper, manganese, cobalt, molybdenum, or cerium, optionally with a crystalline molecular sieve, eliminating the need for precious metals and allowing for a single substrate to handle both NOx reduction and CO oxidation
Implementation Method 3
Catalytic activity of these catalytic components is promoted by transfer of the heat of the exhaust gas being treated to the catalytic components themselves
Data Source
AI summary
A multi-function catalyst article for treating both NO and carbon monoxide emissions in a flow of a combustion exhaust gas from a stationary emission source comprises a honeycomb monolith substrate comprising one or more channels which are open at both ends and extend along an axial length thereof and through which, in use, a combustion exhaust gas flows, which catalyst article comprising a catalyst composition comprising a combination of a first, vanadium-containing SCR catalyst component and a second component which is a compound of a transition metal comprising copper, manganese, cobalt, molybdenum, nickel or cerium or a mixture of any two or more thereof and optionally a third, crystalline molecular sieve component.