Vanadium-Free DeNOx Catalyst via Microcrystalline Anatase TiO2
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Solution Overview
Problem
Current SCR catalysts face challenges with vanadium content regulations, aging resistance, low-temperature activity, and high costs, particularly in large-scale industrial applications, and existing solutions are often based on specialized and expensive chemicals.
Innovation Solution
A composition comprising a titanium compound with a microcrystalline anatase structure, an iron compound, and a tungsten compound, obtained through the sulfate process, which is used to create a vanadium-free or reduced DeNOx catalyst with enhanced catalytic activity and stability, achieved by mixing with binders and calcination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vanadium-containing catalysts are used to achieve high catalytic activity, then the catalytic performance is improved, but the environmental safety and health risk worsen due to vanadium evaporation and toxicity
Solution Approach 1:
The patent removes vanadium from the catalyst composition entirely, extracting the harmful substance while maintaining catalytic function through alternative materials (tungsten and iron compounds). This directly resolves the contradiction by eliminating the source of toxicity and evaporation while preserving SCR catalyst performance.
Solution Approach 2:
The patent employs readily available, inexpensive raw materials (titanium sulfate, iron compounds, tungsten compounds) that can be processed into effective catalysts without requiring expensive specialized chemicals. This approach makes vanadium-free catalysts economically viable for large-scale industrial applications.
2Reliability
If specialized highly purified chemicals are used to create effective catalysts, then the catalytic performance is improved, but the manufacturing cost worsens
Solution Approach 1:
The patent utilizes common, inexpensive industrial chemicals (titanium sulfate, iron compounds, tungsten compounds) as starting materials instead of expensive specialized purified chemicals. These readily available materials are processed through standard industrial procedures to produce effective catalysts, significantly reducing manufacturing costs while maintaining performance.
Solution Approach 2:
The patent employs a self-service approach where the catalyst components are derived from standard industrial chemical processes (sulfate process for titanium dioxide production). The iron and tungsten compounds are incorporated during常规 processing steps, eliminating the need for separate expensive purification and specialization steps typically required for high-performance catalysts.
3Object-affected harmful factors
If existing vanadium-free catalyst systems are used to reduce toxicity, then the environmental safety is improved, but the low-temperature activity and aging resistance worsen
Solution Approach 1:
The patent creates a composite catalyst system combining titanium compound support with iron compound and tungsten compound active components. This composite structure synergistically provides both low-temperature activity and aging resistance without vanadium, resolving the contradiction between environmental safety and catalytic performance stability.
Solution Approach 2:
The patent optimizes specific parameters including the microcrystalline structure of titanium compound, the ratio of iron to tungsten compounds, and the particle size distribution to enhance low-temperature activity and aging resistance. By carefully controlling these parameters, the catalyst achieves reliable performance across a wide temperature range while remaining vanadium-free.
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 provides catalytically active and aging-resistant SCR catalysts with improved low-temperature activity and cost-effectiveness, suitable for large-scale industrial use, maintaining high NO conversion values even after thermal aging.
Implementation Method 1
a titanium compound obtained in the production of TiO2 via the sulfate process during the hydrolysis of a titanium sulfate-containing solution
Data Source
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AI summary
The invention relates to a composition that comprises a titanium compound, an iron compound, and a tungsten compound, characterised in that said titanium compound has a microcrystalline anatase structure and/or is obtained in the production of TiO2 according to the sulphate process, during hydrolysis of a solution which contains titanyl sulphate, and also in that said composition has a vanadium content, calculated as V, of less than 0.15 wt.%, preferably less than 0.05 wt.%, more preferred less than 0.03 wt.% and especially preferred less than 0.01 wt.% in relation to the solids content of the composition. In addition, the invention relates to a catalyst or catalyst raw material containing the claimed composition, as well as to a dimensionally stable and catalytically active solid body which can be obtained by mixing the composition defined above with binders, plasticisers and optionally, further additives, molding the obtained composition preferably by extrusion, and subsequently carrying out calcination, or by providing a dimensionally stable and catalytically active solid body that can be obtained by applying the above-defined composition, optionally together with binders, plasticisers and further additives, to a substrate, and subsequently carrying out calcination. The invention also relates to the use of the claimed composition and claimed dimensionally stable solid body as a catalyst or in the production of a catalyst, and to a method for producing said composition by mixing the titanium compound, which has a microcrystalline anatase structure and/or is obtained in the production of TiO2 according to the sulphate process, during hydrolysis of a solution containing titanyl sulphate, with an iron compound and a tungsten compound.