SO2-Tolerant TiO2-Supported DeNOx Catalysts via Dry Mixing
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Solution Overview
Problem
Conventional methods for producing supported catalysts are time-consuming, and commercially available DeNOx catalysts lack ideal particle size, morphology, and catalytic activity for effective use in filter bags, especially under conditions with high SO2 concentrations, leading to fast deactivation.
Innovation Solution
A method involving dry mixing of a catalyst precursor with a support material like TiO2, optionally with secondary materials like SiO2, followed by calcination, to create a SO2-tolerant catalyst with enhanced catalytic activity and reduced deactivation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional liquid impregnation and drying methods are used to produce supported catalysts, then the catalyst can be manufactured, but the production process becomes time-consuming (taking longer than five hours for impregnation and drying plus additional calcination time)
Solution Approach 1:
The catalyst precursor is dry-mixed with the support material before calcination, pre-positioning the active components on the support structure. This preliminary arrangement eliminates the need for time-consuming liquid impregnation and subsequent drying steps, while still achieving effective catalyst formation after calcination.
Solution Approach 2:
The patent extracts and eliminates the liquid impregnation and drying steps from the conventional production process. By using dry mixing followed directly by calcination, the method removes unnecessary intermediate steps that consume excessive time, thereby accelerating production without sacrificing catalyst performance.
2Reliability
If commercially available DeNOx catalysts are used, then catalyst functionality is provided, but the particle size, morphology, and catalytic activity are insufficient for optimal performance in filter bags, especially under high SO2 concentrations
Solution Approach 1:
The patent creates catalysts with optimized local properties by controlling the distribution and concentration of catalytic active components on the support material during dry mixing and calcination. This allows tailored particle size, morphology, and catalytic activity specifically suited for filter bag applications, rather than using generic commercially available catalysts.
Solution Approach 2:
The invention uses composite catalyst structures combining specific support materials (such as alumina, silica, or ceramic foams) with catalytically active components. This composite approach enables customization of particle characteristics and catalytic properties to match the specific requirements of filter bag applications and high SO2 environments.
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 method produces a catalyst with high NOx removal efficiency (30-90%) and reduced initial deactivation rate in the presence of SO2, maintaining activity over a wide temperature range (150-280°C).
Implementation Method 1
There is also a need for low-temperature selective catalytic reduction ('SCR') DeNOx catalyst with high SO2 tolerance
Implementation Method 2
mixing a dry catalyst precursor including a metal and a ligand with a dry support material to form a mixture, and calcining the mixture
Data Source
AI summary
Various aspects of the present disclosure are directed towards apparatuses, systems, and methods of preparing catalysts. In some embodiments, a catalyst includes a catalytically active component and a support material comprising TiO2 having a crystal structure comprising an anatase phase and a secondary material. In some embodiments, the support material includes a secondary material such as SiO2, MoO3, WO3, and Al2O3.