Selective Catalytic Reduction Catalyst with Multimodal Pore Binder
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Solution Overview
Problem
Conventional SCR catalyst compositions with clay binders have limited catalytic activity, requiring larger volumes or more expensive catalytically active components to achieve desired NOx reduction, and existing methods for manufacturing pillared interlayered clays are inefficient and costly.
Innovation Solution
A selective catalytic reduction (SCR) catalyst composition using a binder with a disordered arrangement of delaminated layers and a multimodal pore size distribution, comprising macropores, mesopores, and micropores, which enhances access to catalytic sites and exhibits improved catalytic activity, allowing for lower catalyst usage and easier processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional clay binders are used in SCR catalyst compositions, then the catalyst composition can be held together with desired shape, but the catalytic activity per unit volume is low
Solution Approach 1:
The patent employs a porous inorganic material as binder instead of conventional dense clay binders. This porous structure provides both mechanical binding function and catalytic activity, allowing reactants to access active sites throughout the binder volume, thereby increasing catalytic activity per unit volume while maintaining structural integrity
Solution Approach 2:
The invention creates a composite binder system combining inorganic porous material with catalytic components. This composite approach allows the binder to simultaneously perform its traditional structural role and provide catalytic function, eliminating the need for separate catalyst and binder components and increasing overall catalytic efficiency
2Strength
If high levels of binder are required to hold the catalyst composition together, then the structural integrity is maintained, but the catalytic activity per unit volume decreases
Solution Approach 1:
The porous inorganic binder material performs multiple functions simultaneously: it provides structural binding to hold the catalyst composition together, maintains desired shape, and delivers catalytic activity through its porous structure and incorporated active sites. This multi-functionality allows high binder levels to maintain both structural integrity and high catalytic activity
3Reliability
If larger volumes of catalyst composition are used to compensate for low catalytic activity, then the desired catalytic effect is achieved, but the cost increases
Solution Approach 1:
The porous inorganic binder material provides high surface area and accessible pore structures that increase the number of active sites per unit volume. This allows the desired catalytic effect to be achieved with smaller catalyst volumes, reducing the quantity of expensive catalytic components required
Solution Approach 2:
By integrating catalytic components into the porous binder matrix, the invention creates a cost-effective composite material where the binder itself contributes to catalytic activity. This reduces the need for separate, expensive catalyst materials while maintaining or enhancing overall catalytic performance
4Reliability
If conventional SCR catalysts are used, then NOx reduction is achieved, but the manufacturing cost and complexity increase
Solution Approach 1:
The invention merges the functions of binder and catalyst into a single integrated porous inorganic material. This consolidation eliminates the need for separate manufacturing steps for applying catalyst coatings onto binder substrates, simplifying the manufacturing process and reducing costs while maintaining effective NOx reduction
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 SCR catalyst composition demonstrates increased catalytic activity and easier manufacturing compared to conventional and pillared interlayered clay systems, enabling effective NOx reduction with reduced catalyst quantities and lower production costs.
Implementation Method 1
The reductant can be absorbed onto the SCR catalyst and the NOx reduced as the gases pass through or over the catalysed substrate
Implementation Method 2
the porosity characteristics of the binder may affect the access of gaseous species to catalytic sites within the catalyst composition
Implementation Method 3
a gaseous reductant, typically anhydrous ammonia, aqueous ammonia, or urea, is added to an exhaust gas stream prior to the exhaust gas contacting the SCR catalyst. The reductant can be absorbed onto the SCR catalyst and the NOx reduced as the gases pass through or over the catalysed substrate
Data Source
AI summary
A SCR catalyst composition comprises a SCR catalyst; and a binder comprising a porous inorganic material, wherein the porous inorganic material comprises a disordered arrangement of delaminated layers, has a disordered porous structure, and has a multimodal pore size distribution comprising at least a first modal maximum having a macroporous or mesoporous pore size and a second modal maximum having a microporous pore size. The SCR catalyst composition can be manufactured using the method comprising the steps of: (i) providing an inorganic material having a layered structure; (ii) contacting the material with a cationic surfactant to form a swollen material; (iii) agitating the swollen material to form an agitated material; and (iv) calcining the agitated material to recover a delaminated inorganic material, wherein an SCR catalyst is mixed with the inorganic material prior to step (iv).