U.S. patent application number 13/165184 was filed with the patent office on 2012-12-27 for catalyst composition and catalytic reduction system.
This patent application is currently assigned to GENERAL ELECTRIC COMPANY. Invention is credited to Xiaoying Bao, Robert Burch, Sarayute Chansai, Dan Hancu, Christopher Hardacre, Larry Neil Lewis, Daniel George Norton, Oltea Puica Siclovan.
Application Number | 20120329644 13/165184 |
Document ID | / |
Family ID | 47362391 |
Filed Date | 2012-12-27 |
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United States Patent
Application |
20120329644 |
Kind Code |
A1 |
Siclovan; Oltea Puica ; et
al. |
December 27, 2012 |
CATALYST COMPOSITION AND CATALYTIC REDUCTION SYSTEM
Abstract
A catalyst composition, a method of preparation of catalyst
composition, a catalytic reduction system including the catalyst
composition and a system using the catalytic reduction system are
provided. The catalyst composition includes a templated amorphous
metal oxide substrate, a catalyst material, and a sulfur scavenger
material. The catalyst material includes a catalyst metal disposed
on the templated metal oxide substrate and the sulfur scavenger
includes an alkali metal.
Inventors: |
Siclovan; Oltea Puica;
(Rexford, NY) ; Norton; Daniel George; (Niskayuna,
NY) ; Lewis; Larry Neil; (Scotia, NY) ; Hancu;
Dan; (Clifton Park, NY) ; Bao; Xiaoying;
(Schenectady, NY) ; Burch; Robert; (Northern
Ireland, GB) ; Hardacre; Christopher; (Northern
Ireland, GB) ; Chansai; Sarayute; (Northern Ireland,
GB) |
Assignee: |
GENERAL ELECTRIC COMPANY
SCHENECTADY
NY
|
Family ID: |
47362391 |
Appl. No.: |
13/165184 |
Filed: |
June 21, 2011 |
Current U.S.
Class: |
502/243 ;
423/244.02; 502/317; 502/330; 502/343; 502/344; 502/347;
60/299 |
Current CPC
Class: |
B01D 2255/2022 20130101;
B01D 2255/2027 20130101; B01D 53/8603 20130101; B01D 2257/302
20130101; B01D 2258/012 20130101; B01J 35/10 20130101; B01D
2255/2025 20130101; B01J 35/1061 20130101; B01D 2255/104 20130101;
B01J 37/0018 20130101; B01J 35/1066 20130101; B01D 2257/404
20130101; B01J 23/50 20130101; B01J 23/66 20130101; B01D 53/9418
20130101 |
Class at
Publication: |
502/243 ;
502/344; 502/347; 502/330; 502/317; 502/343; 423/244.02;
60/299 |
International
Class: |
B01J 23/04 20060101
B01J023/04; B01J 21/04 20060101 B01J021/04; B01J 21/08 20060101
B01J021/08; B01J 21/06 20060101 B01J021/06; B01J 23/78 20060101
B01J023/78; F01N 3/10 20060101 F01N003/10; B01J 23/30 20060101
B01J023/30; B01J 23/06 20060101 B01J023/06; B01J 23/58 20060101
B01J023/58; B01J 37/08 20060101 B01J037/08; B01D 53/48 20060101
B01D053/48; B01J 23/66 20060101 B01J023/66; B01J 23/08 20060101
B01J023/08 |
Claims
1. A catalyst composition, comprising: a templated amorphous metal
oxide substrate having a plurality of pores; a catalyst material
comprising a catalyst metal and disposed on the substrate; and a
sulfur scavenger comprising an alkali metal and disposed on the
substrate.
2. The composition of claim 1, wherein the alkali metal comprises
lithium, sodium, or potassium.
3. The composition of claim 2, wherein the alkali metal comprises
lithium.
4. The composition of claim 1, wherein the alkali metal is in an
amount from about 0.1 mole percent to about 15 mole percent of the
substrate.
5. The composition of claim 4, wherein the alkali metal is in an
amount from about 3 mole percent to about 10 mole percent of the
substrate.
6. The composition of claim 1, wherein the catalyst metal comprises
silver.
7. The composition of claim 1, wherein the templated amorphous
metal oxide substrate comprises alumina, silica, aluminosilicate,
or combination thereof.
8. The composition of claim 1, wherein the substrate further
comprises a dopant material selected from the group consisting of
zirconium, iron, gallium, indium, tungsten, zinc, platinum, and
rhodium.
9. The composition of claim 1, wherein the catalyst material and
sulfur scavenger are dispersed in an intermixed form in the
substrate.
10. A method of preparation of a catalyst composition, comprising:
combining a metal oxide precursor, a catalyst metal precursor and
an alkali metal precursor in the presence of a templating agent;
hydrolyzing and condensing to form an intermediate product that
comprises metal oxide, alkali metal oxide, and catalyst metal; and
calcining to form a templated amorphous metal oxide substrate
having a plurality of pores and comprising an alkali metal oxide
and catalyst metal.
11. A catalytic reduction system comprising: a catalyst support; a
catalyst composition disposed on the catalyst support, the catalyst
composition comprising: a templated amorphous metal oxide substrate
having a plurality of pores; a catalyst material comprising a
catalyst metal and disposed on the substrate; and a sulfur
scavenger comprising an alkali metal and disposed on the
substrate.
12. The catalytic reduction system of claim 11, wherein the alkali
metal comprises lithium.
13. The catalytic reduction system of claim 11, wherein the alkali
metal is in an amount from about 0.1 mole percent to about 15 mole
percent based on the substrate.
14. The catalytic reduction system of claim 13, wherein the alkali
metal is in an amount from about 3 mole percent to about 10 mole
percent based on the substrate.
15. The catalytic reduction system of claim 11, wherein the
catalyst metal comprises silver.
16. A system comprising: an internal combustion engine, and a
catalytic reduction system disposed to receive an exhaust stream
from the engine, wherein the catalytic reduction system comprises a
catalyst support; a catalyst composition disposed on the catalyst
support, the catalyst composition comprising: a templated amorphous
metal oxide substrate having a plurality of pores; a catalyst
material comprising a catalyst metal and disposed on the substrate;
and a sulfur scavenger comprising an alkali metal and disposed on
the substrate.
17. A method of removing sulfur from a catalytic reduction system,
comprising: passing an exhaust stream from an exhaust source over a
catalyst composition, wherein the catalyst composition comprises a
templated amorphous metal oxide substrate, a catalyst material
comprising a catalyst metal, and a sulfur scavenger; reacting the
exhaust stream with the catalyst composition to form sulfates;
decomposing the sulfates to produce sulfur oxides; and removing the
sulfur oxides from the catalytic reduction system.
18. The method of claim 17, wherein reacting the exhaust stream
comprises reacting the exhaust stream with the sulfur scavenger of
the catalyst composition to form the sulfates.
Description
BACKGROUND
[0001] The invention relates generally to a catalyst composition
and particularly to a catalyst composition and system for reducing
nitrogen oxides (NOx) through selective catalytic reduction
(SCR).
[0002] Exhaust streams generated by the combustion of fossil fuels
in, for example, furnaces, ovens, and engines, contain nitrogen
oxides (NOx) that are undesirable pollutants. There is a growing
need to have efficient and robust emission treatment systems to
treat the NOx emissions.
[0003] In selective catalytic reduction (SCR) using hydrocarbons
(HC), hydrocarbons serve as the reductants for NOx conversion.
Hydrocarbons employed for HC-SCR include relatively small molecules
like methane, ethane, ethylene, propane, and propylene, as well as
longer linear hydrocarbons like hexane, octane, etc., or branched
hydrocarbons like iso-octane. The injection of several types of
hydrocarbons has been explored in some heavy-duty diesel engines to
supplement the HC in the exhaust stream. From an infrastructure
point of view, it would be advantageous to employ an on-board
diesel fuel as the hydrocarbon source for HC-SCR.
[0004] Fuels, including gasoline or diesel fuels containing sulfur
lead to a number of disadvantages when trying to clean the exhaust
gases by some form of catalytic after-treatment. During the
combustion process, sulfur in the fuel gets converted to sulfur
dioxide (SO.sub.2), which poisons some catalysts. Further poisoning
happens from the formation of base metal sulfates from the
components of a catalyst composition, which sulfates can act as a
reservoir for poisoning sulfur species within the catalyst.
[0005] When the SCR catalysts absorb the NOx in the exhaust gas,
they also absorb sulfur oxides (SOx) in the exhaust gas. The sulfur
oxides poison the catalysts, and the NOx absorption performance
declines as the poisoning by SOx increases. Therefore, there is a
need to reduce sulfur absorption by the SCR catalysts and prevent
catalyst degradation.
BRIEF DESCRIPTION
[0006] In one embodiment, a catalyst composition is presented. The
catalyst composition includes a templated amorphous metal oxide
substrate having a plurality of pores, a catalyst material having a
catalyst metal and disposed on the substrate, and a sulfur
scavenger having an alkali metal and disposed on the substrate.
[0007] In one embodiment, a method of preparation of a catalyst
composition is presented. The method includes combining a metal
oxide precursor, a catalyst metal precursor and an alkali metal
precursor in the presence of a templating agent, hydrolyzing and
condensing to form an intermediate product that includes metal
oxide, alkali metal oxide, and catalyst metal, and then calcining
to form a templated amorphous metal oxide substrate having a
plurality of pores and includes an alkali metal oxide and catalyst
metal.
[0008] In one embodiment, a catalytic reduction system is
presented. The catalytic reduction system includes a catalyst
support and a catalyst composition disposed on a catalyst support.
The catalyst composition that includes a templated amorphous metal
oxide substrate having a plurality of pores, a catalyst material
having a catalyst metal and disposed on the substrate, and a sulfur
scavenger having an alkali metal and disposed on the substrate.
[0009] In one embodiment, a system is provided. The system includes
an internal combustion engine, and a catalytic reduction system
disposed to receive an exhaust stream from the engine. The
catalytic reduction system includes a catalyst support and a
catalyst composition disposed on a catalyst support. The catalyst
composition includes a templated amorphous metal oxide substrate
having a plurality of pores, a catalyst material having a catalyst
metal and disposed on the substrate, and a sulfur scavenger having
an alkali metal and disposed on the substrate.
[0010] In one embodiment, a method of removing sulfur from a
catalytic reduction system is presented. The method includes
passing an exhaust stream from an internal combustion engine over a
catalyst composition. The catalyst composition includes a templated
amorphous metal oxide substrate, a catalyst material comprising a
catalyst metal, and a sulfur scavenger. During operation, the
exhaust stream reacts with the catalyst composition to form
sulfates; the sulfates decompose to produce sulfur oxides that are
eventually removed from the catalytic reduction system.
BRIEF DESCRIPTION OF DRAWINGS
[0011] FIG. 1 is a graph depicting the NOx reduction activity of
undoped, fresh 4.5 mole percent silver on templated amorphous
alumina (Ag-TA) catalyst composition;
[0012] FIG. 2 is a graph depicting the NOx reduction activity of 1
mole percent Li doped, fresh 4.5 mole percent Ag-TA, in accordance
with one embodiment of the invention;
[0013] FIG. 3 is a graph depicting the NOx reduction activity of 5
mole percent Li doped, fresh 4.5 mole percent Ag-TA, in accordance
with one embodiment of the invention;
[0014] FIG. 4 is a graph depicting the NOx reduction activity of 14
mole percent Li doped, fresh 4.5 mole percent Ag-TA, in accordance
with one embodiment of the invention;
[0015] FIG. 5 is a graph depicting the NOx reduction activity of
undoped, 4.5 mole percent silver on templated amorphous alumina
(Ag-TA) catalyst composition after an hour of operation;
[0016] FIG. 6 is a graph depicting the NOx reduction activity of 1
mole percent Li doped, 4.5 mole percent Ag-TA after an hour of
operation, in accordance with one embodiment of the invention;
[0017] FIG. 7 is a graph depicting the NOx reduction activity of 5
mole percent Li doped, 4.5 mole percent Ag-TA after an hour of
operation, in accordance with one embodiment of the invention;
[0018] FIG. 8 is a graph depicting the NOx reduction activity of 14
mole percent Li doped, 4.5 mole percent Ag-TA after an hour of
operation, in accordance with one embodiment of the invention;
[0019] FIG. 9 is a graph depicting the after sulfation-NOx
reduction activity of undoped, fresh 4.5 mole percent silver on
templated amorphous alumina (Ag-TA) catalyst composition;
[0020] FIG. 10 is a graph depicting the after sulfation-NOx
reduction activity of 1 mole percent Li doped, fresh 4.5 mole
percent Ag-TA, in accordance with one embodiment of the
invention;
[0021] FIG. 11 is a graph depicting the after sulfation-NOx
reduction activity of 5 mole percent Li doped, fresh 4.5 mole
percent Ag-TA, in accordance with one embodiment of the
invention;
[0022] FIG. 12 is a graph depicting the after sulfation-NOx
reduction activity of 14 mole percent Li doped, fresh 4.5 mole
percent Ag-TA, in accordance with one embodiment of the
invention;
[0023] FIG. 13 is a graph depicting the after sulfation-NOx
reduction activity of undoped, 4.5 mole percent silver on templated
amorphous alumina (Ag-TA) catalyst composition after an hour of
operation, in accordance with one embodiment of the invention;
[0024] FIG. 14 is a graph depicting the after sulfation-NOx
reduction activity of 1 mole percent Li doped, 4.5 mole percent
Ag-TA after an hour of operation, in accordance with one embodiment
of the invention;
[0025] FIG. 15 is a graph depicting the after sulfation-NOx
reduction activity of 5 mole percent Li doped, 4.5 mole percent
Ag-TA after an hour of operation, in accordance with one embodiment
of the invention;
[0026] FIG. 16 is a graph depicting the after sulfation-NOx
reduction activity of 14 mole percent Li doped, 4.5 mole percent
Ag-TA after an hour of operation, in accordance with one embodiment
of the invention;
[0027] FIG. 17 is a comparative graph depicting amount of HCN
during operation of catalytic reduction system using undoped and 1
mole percent Li doped Ag-TA, in accordance with one embodiment of
the invention; and
[0028] FIG. 18 is a comparative graph depicting amounts of
CH.sub.3CHO and HCHO during operation of catalytic reduction system
using undoped and 1 mole percent Li doped Ag-TA, in accordance with
one embodiment of the invention.
DETAILED DESCRIPTION
[0029] The systems described herein include, without limitation,
embodiments that relate to a catalyst composition, and embodiments
that relate to a catalytic reduction system including the catalyst
composition and to a system using the catalytic reduction system
for reducing nitrogen oxides. Generally disclosed is a NOx
reduction catalyst and NOx reduction system for reducing NOx in
exhaust gas discharged from a combustion device. Suitable
combustion devices may include furnaces, ovens, or engines.
[0030] In the following specification and the claims that follow,
the singular forms "a", "an" and "the" include plural referents
unless the context clearly dictates otherwise.
[0031] As used herein, a catalyst is a substance that can cause a
change in the rate of a chemical reaction. The catalyst may
participate in the reaction and get regenerated at the end of the
reaction. "Templating" refers to a controlled patterning; and,
"templated" refers to determined control of an imposed pattern and
may include molecular self-assembly. The method of templating and
templated patterns are described in US publications 2010/0233053 A1
and 2010/0196263 A1, which are incorporated herein by reference.
"Amorphous" refers to material characterized by a lack of the
long-range order generally observed for crystalline substances.
[0032] A "monolith" as used herein includes a ceramic block having
a number of channels, and may be made by extrusion of clay, binders
and additives that are pushed through a dye to create a structure.
Approximating language, as used herein throughout the specification
and claims, may be applied to modify any quantitative
representation that could permissibly vary without resulting in a
change in the basic function to which it is related. Accordingly, a
value modified by a term such as "about" is not to be limited to
the precise value specified. In some instances, the approximating
language may correspond to the precision of an instrument for
measuring the value. All temperatures given herein are for the
atmospheric pressure. One skilled in the art would appreciate that
the boiling points can vary with respect to the ambience pressure
of the fuel.
[0033] In one embodiment, a composition is presented. The
composition includes a templated amorphous metal oxide substrate
having a plurality of pores, and a catalyst material and a sulfur
scavenger disposed on the substrate. The catalyst material includes
a catalyst metal and the sulfur scavenger includes an alkali metal.
As used herein, the amount of catalyst metal and alkali metal are
presented as percentages of the substrate. Unless otherwise
mentioned, the percentages presented herein are in mole percent.
The mole percentage is the fraction of moles of dopant element out
of the moles of the templated substrate. For example, in Ag-TA
(silver-templated alumina), silver is presented as a fraction of
moles of templated alumina (Al.sub.2O.sub.3).
[0034] The substrate may include an inorganic material. Suitable
inorganic materials may include, for example, oxides, carbides,
nitrides, hydroxides, carbonitrides, oxynitrides, borides, or
borocarbides. In one embodiment, the inorganic oxide may have
hydroxide coatings. In one embodiment, the inorganic oxide may be a
metal oxide. The metal oxide may have a hydroxide coating. Other
suitable metal inorganics may include one or more metal carbides,
metal nitrides, metal hydroxides, metal carbonitrides, metal
oxynitrides, metal borides, or metal borocarbides. Metallic cations
used in the foregoing inorganic materials can be transition metals,
alkali metals, alkaline earth metals, rare earth metals, or the
like.
[0035] In one embodiment, the catalyst substrate includes oxide
materials. In one embodiment, the catalyst substrate includes
alumina, zirconia, silica, zeolite, or any mixtures comprising
these elements. Suitable substrate materials may include, for
example, aluminosilicates, aluminophosphates, hexaaluminates,
zirconates, titanosilicates, titanates, or a combination of two or
more thereof. In one exemplary embodiment, the metal oxide is an
aluminum oxide. In other embodiments, other substrates may be
suitable and can be selected based on end-use parameters.
[0036] In one embodiment, the substrate is in the form of a powder.
The desired properties of the catalyst substrate include, for
example, a relatively small particle size and high surface area. In
one embodiment, the powder of the catalyst substrate has an average
diameter that is less than about 100 micrometers. In one
embodiment, the average diameter is less than about 50 micrometers.
In a further embodiment, the average diameter is from about 1
micrometer to about 10 micrometers. The catalyst substrate powder
may have a surface area greater than about 100 m.sup.2/gram. In one
embodiment, the surface area of the catalyst substrate powder is
greater than about 200 m.sup.2/gram. In one embodiment, the surface
area is in a range of from about 200 m.sup.2/gram to about 500
m.sup.2/gram, and, in another embodiment, from about 300
m.sup.2/gram to about 600 m.sup.2/gram.
[0037] One way of forming templated substrates is by employing
templating agents. Templating agents facilitate the production of
catalyst substrates containing directionally aligned forms. The
templating agent may be a surfactant, a cyclodextrin, a crown
ether, or mixtures thereof. An exemplary templating agent is
octylphenol ethoxylate, commercially available as TRITON
X-114.RTM..
[0038] The catalyst substrate may have periodically arranged pores
of determined dimensions. The median diameter of the pores, in some
embodiments, is greater than about 2 nm. The median diameter of the
pores, in one embodiment, is less than about 100 nm. In some
embodiments, the median diameter of the pores is in a range from
about 2 nm to about 20 nm. In another embodiment, the median
diameter is from about 20 nm to about 60 nm and in yet another
embodiment, the diameter is from about 60 nm to about 100 nm The
pores in some embodiments have a periodicity greater than about 50
.ANG.. The pores in some embodiments have a periodicity less than
about 150 .ANG.. In one embodiment, the pores have a periodicity in
the range of from about 50 .ANG. to about 100 .ANG.. In another
embodiment, the pores have a periodicity in the range from about
100 .ANG. to about 150 .ANG..
[0039] In certain embodiments, the pore size has a narrow monomodal
distribution. In one embodiment, the pores have a pore size
distribution polydispersity index that is less than 1.5. As used
herein, the polydispersity index is a measure of the distribution
of pore diameter in a given sample. In a further embodiment, the
polydispersity index is less than 1.3, and in a particular
embodiment, the polydispersity index is less than 1.1. In one
embodiment, the distribution of diameter sizes may be bimodal, or
multimodal.
[0040] In one embodiment, alumina, silica, or aluminum silicate is
the substrate or framework for a NOx catalyst. The role of a
substrate is to (1) provide robust support/framework at working
temperature with corrosive gas and steam and (2) provide gas
channels for NOx and reductant to get in touch with the catalytic
material.
[0041] Suitable catalyst metal may include one or more of gallium,
indium, rhodium, palladium, ruthenium, and iridium. Other suitable
catalyst metal includes transition metal elements and noble metals
including one or more of platinum, gold and silver. In one
embodiment, the catalyst metal comprises silver. In one particular
embodiment, the catalyst metal is substantially 100% silver.
[0042] The catalyst metal may be present in an amount of at least
about 0.5 mole percent of the substrate. In one embodiment, the
catalyst metal is present in an amount equal to or greater than 3
mole percent of the substrate. In one embodiment, the amount of
catalyst metal present is about 6 mole percent of the catalyst
substrate. In one embodiment, the catalytic metal may be present in
an amount in a range of from about 1 mole percent to about 9 mole
percent of the substrate.
[0043] In one embodiment, the catalyst composition includes one or
more sulfur scavenger. A "sulfur scavenger" as referred herein is a
sulfur-reactive material that preferentially reacts with sulfur,
compared to the reactivity of the catalyst metal with sulfur.
"Sulfur" as used herein includes the sulfur containing compounds
such as, for example, SO.sub.2.
[0044] Suitable sulfur scavengers of the catalyst composition
include alkali metals. In the catalyst composition, the alkali
metals may be in the compound form. The compound form of sulfur
scavenger may exist separately or along with the substrate or
catalyst metals. In one embodiment, one or more of lithium, sodium,
or potassium is used as a sulfur scavenger. In an exemplary
embodiment, the sulfur scavenger includes lithium. In one
embodiment, lithium exists as lithium oxide in the catalyst
composition. In one embodiment, lithium exists in the hydroxide
form. In one more embodiment, lithium exists as lithium aluminum
oxide.
[0045] The sulfur scavenger of the catalyst composition may exist
in different forms. In one embodiment, the sulfur scavenger is in a
compound form deposited on the substrate material. In another
embodiment, the sulfur scavenger cation is dissolved in the
substrate material. In one embodiment, the sulfur scavenger is
dispersed in the substrate material. In one particular embodiment,
the catalyst material and sulfur scavenger are dispersed in an
intermixed form in the substrate material. The "intermixed form"
herein refers to an arrangement wherein the catalyst material and
the sulfur scavenger are present throughout the body of substrate
material.
[0046] The sulfur scavenger may be present in an amount of at least
about 0.5 mole percent of the substrate. In one embodiment, the
sulfur scavenger is present in an amount up to about 15 mole
percent of the substrate. In one embodiment, the sulfur scavenger
may be present in an amount in a range of from about 3 mole percent
to about 10 mole percent of the substrate. In one embodiment, the
sulfur scavenger is present in amount equal to or greater than
about 5 mole percent of the substrate. In one embodiment, the
amount of sulfur scavenger present is about 9 mole percent of the
catalyst substrate.
[0047] In a method of preparing the catalyst composition, a metal
oxide precursor, a catalyst metal precursor and an alkali metal
precursor are reacted in the presence of a templating agent by
hydrolysis and condensation to form an intermediate that includes
the metal oxide, alkali metal oxide, and catalyst metal. This
intermediate is then calcined to form a catalyst composition
including a templated amorphous metal oxide substrate having a
plurality of pores, an alkali metal oxide, and catalyst metal. In
one embodiment, the method described results in a catalyst
composition, in which the alkali metal sulfur scavenger cation and
the catalyst metal are dispersed in an intermixed form in the
substrate metal oxide. The catalyst composition prepared by this
method provides results that are unexpectedly superior to more
conventionally prepared formulations.
[0048] In one embodiment, the metal-oxide precursors include
inorganic alkoxides. Suitable inorganic alkoxides may include one
or more of tetraethyl orthosilicate, tetramethyl orthosilicate,
aluminum isopropoxide, aluminum tributoxide, aluminum ethoxide,
aluminum-tri-sec-butoxide, aluminum tert-butoxide. In one
embodiment, the inorganic alkoxide is aluminum sec-butoxide.
[0049] In various embodiments, the solvents include one or more
solvents selected from aprotic polar solvents, polar protic
solvents, and non-polar solvents. Suitable aprotic polar solvents
may include propylene carbonate, ethylene carbonate, butyrolactone,
acetonitrile, benzonitrile, nitromethane, nitrobenzene, sulfolane,
dimethylformamide, N-methylpyrrolidone, or the like. Suitable polar
protic solvents may include water, nitromethane, acetonitrile, and
short chain alcohols. Suitable short chain alcohols may include one
or more of methanol, ethanol, propanol, isopropanol, butanol, or
the like. Suitable non polar solvents may include benzene, toluene,
methylene chloride, carbon tetrachloride, hexane, heptane, diethyl
ether, or tetrahydrofuran. In one embodiment, a combination of
solvents may also be used. Selection of the type and amount of
solvent may affect or control the amount of porosity generated in
the catalyst composition, as well as affect or control other pore
characteristics.
[0050] Modifiers may be used to control hydrolysis kinetics of the
inorganic alkoxides. Suitable modifiers may include one or more
ethyl acetoacetate (EA), ethylene glycol (EG), triethanolamine
(TA), or the like.
[0051] The templating agents serve as templates and may facilitate
the production of catalyst composition including templated
amorphous substrate materials, catalyst metal, and alkali metals.
The catalyst composition obtained by the calcination of an
intermediate product containing metal oxide-alkali metal oxide and
catalyst metal may contain directionally aligned pores. Control of
the pore characteristic may, in turn, provide control of the
particle size of catalytic metal by reducing the catalytic metal
lability or propensity to agglomerate. The particle size of
catalytic metal may be controlled, with respect to pore formation
of the porous template, by controlling or affecting one or more of
pore size, pore distribution, pore spacing, or pore dispersity.
[0052] In one embodiment, the calcination is conducted at
temperatures in a range from about 350 degrees Centigrade to about
800 degrees Centigrade. In another embodiment, the calcination is
conducted at temperatures in a range from about 400 degrees
Centigrade to about 700 degrees Centigrade. In yet another
embodiment, the calcination is conducted at temperatures in a range
from about 450 degrees Centigrade to about 750 degrees Centigrade.
In one embodiment, the calcination is conducted at a temperature of
about 550 degrees Centigrade. In various embodiments, the
calcination may be conducted for a time period in a range from
about 10 minutes to about 30 minutes, from about 30 minutes to
about 60 minutes, from about 60 minutes to about 1 hour, from about
1 hour to about 10 hours, from about 10 hours to about 24 hours, or
from about 24 hours to about 48 hours.
[0053] In a method of removing sulfur from a catalytic reduction
system, an exhaust stream is passed from an exhaust source, such as
an internal combustion engine, over the catalyst composition that
includes, as described previously, a templated amorphous metal
oxide substrate, a catalyst material, and a sulfur scavenger. The
exhaust stream reacts with the catalyst composition to form
sulfates. During a desulfation step, the sulfate formed decomposes
to produce sulfur oxides, which are removed from the system. In one
embodiment, desulfation comprises exposing the catalyst to a
reducing environment at an effective combination of time and
temperature to decompose sulfur-containing species on the catalyst
into gaseous sulfur-containing species, such as sulfur oxide
species, leaving behind sulfur scavenging solid species (such as
alkali metal oxide) on the catalyst.
[0054] Without being limited by theory, the inventors envisage a
preferential reactivity of sulfur scavenger to the sulfur, in
comparison with the catalyst metal reactivity with sulfur. In one
embodiment, the sulfur scavenger preferentially reacts with the
sulfur to form an alkali metal-sulfur compound. In one embodiment,
the alkali metal sulfur scavenger reacts with the SO.sub.2 gas and
forms alkali metal sulfates preferentially over forming catalyst
metal sulfate. In one example, the catalyst composition includes
templated amorphous alumina as a substrate, silver as a catalyst,
and lithium as a sulfur scavenger; the lithium cation reacts with
SO.sub.2 gas preferentially relative to silver or alumina, to form
lithium sulfate. In general, the lithium sulfate is more easily
decomposable compared to silver sulfate. Therefore, during
operation, the lithium sulfate formed will readily decompose to
release SO.sub.2 gas during desulfation. In one embodiment,
desulfation is carried out by flowing an excess amount of reductant
(Cl:N>10) through the catalytic system in the absence of either
O.sub.2 or NO at elevated temperatures, for example, from about
300.degree. C.-650.degree. C. In one embodiment, the catalyst was
subjected to 5 ppm of SO.sub.2 for 8 hours and subjected to
desulfation. The desulfation method was able to remove greater than
90% of SO.sub.2 at 650.degree. C. when O.sub.2 was absent and about
70%-80% of SO.sub.2 at 650.degree. C. when NO was absent. The
desulfation conditions are unfavorable to re-absorb SO.sub.2 gas by
lithium, silver or alumina, and therefore the SO.sub.2 gas exits
the reduction system.
[0055] While testing the performance of the catalyst system,
inventors surprisingly noticed that the alkali metal sulfur
scavengers further assist in reducing undesirable byproducts of
emission treatment released from the emission treatment system. By
using alkali metal sulfur scavengers, more than 50% reduction in
emission of HCN, CH.sub.3CHO, and HCHO are recorded in the emission
treatment system.
[0056] Along with substrate, catalyst metal, and sulfur scavenger,
the catalyst composition may also include a promoter for the
catalytic reaction of nitrogen oxide reduction. Non-limiting
examples of the promoter may include various metals or metal
oxides. The promoter may include one or more of indium, gallium,
tin, silver, manganese, molybdenum, chromium, germanium, cobalt,
nickel, gold, copper, iron, and their oxides. In one embodiment,
the sulfur scavenger alkali metal additionally acts as a
promoter.
[0057] Along with the metals and metal oxides mentioned above, the
catalyst composition may further have additional cations dispersed
or disposed on the catalyst substrate that enhance hydrothermal
stability of the composition and/or the catalytic activity of the
catalyst metal. In one embodiment, one or more additional cations
may be selected from the group consisting of zirconium, iron,
gallium, indium, tungsten, zinc, platinum, and rhodium. In one
embodiment, the additional dopant comprises zirconium.
[0058] In one embodiment, the catalyst composition can be included
in fabricating a catalytic surface. In one embodiment, the catalyst
composition can be shaped and formed as a catalyst surface. In
another embodiment, a slurry of the catalyst composition in a
liquid medium can be formed and contacted with a catalyst support
to form a catalytic reduction system with a washcoated monolith
catalyst. Therefore, in one embodiment, the catalytic reduction
system comprises the catalyst support and the catalytic composition
comprising the templated amorphous metal oxide substrate and the
catalyst material.
[0059] A catalyst support can be in any form including foams,
monoliths, and honeycombs. Suitable materials for the catalyst
support include ceramics and metals. Examples of ceramics include
oxides, such as alumina, silica, titanate compounds, as well as
refractory oxides, cordierite, mullite, and zeolite. Other examples
include metal carbides and metal nitrides. Carbon may be useful in
some embodiments. In specific embodiments, the catalyst support
includes silicon carbide, fused silica, activated carbon, or
aluminum titanate. Zeolite, as used herein, includes hydrated
aluminosilicates, such as analcime, chabazite, heulandite,
natrolite, phillipsite, and stilbite. Mullite, as used herein, is a
form of aluminum silicate. In another exemplary embodiment, the
suitable catalyst support includes metal corrugated forms.
[0060] In one embodiment, the slurry of the catalyst powder is
washcoated onto a catalyst support such as a monolith. In one
embodiment of the invention, the catalyst support is a monolith
including cordierite. The applied washcoat may be dried, sintered
and used to reduce emission content such as NOx.
[0061] In a method of using the catalytic reduction system, the
catalytic reduction system is disposed in the exhaust stream of an
exhaust gas source, such as an internal combustion engine. An
internal combustion engine may be part of any of a variety of
mobile or fixed/stationary assets, for example, an automobile,
locomotive, or power generator. Because different engines have
different combustion characteristics and because of the use of
different fuels, the exhaust stream components differ from one
system to another. Such differences may include variations in
NO.sub.x levels, presence of sulfur, oxygen level, steam content,
and the presence or quantity of other species of reaction product.
Changes in the operating parameters of the engine may also alter
the exhaust flow characteristics. Examples of differing operating
parameters may include temperature and flow rate. The catalytic
reduction system may be used to reduce NO.sub.x to nitrogen at a
desirable rate and at a desirable temperature appropriate for the
given system and operating parameters.
[0062] In one method of using the catalytic reduction system, the
catalytic reduction system is disposed in the exhaust stream of an
internal combustion engine. The catalyst composition of the
catalytic reduction system reduces nitrogen oxides to nitrogen. The
nitrogen oxide present in the gas stream may be reduced at a
temperature of about 250.degree. C. or greater. In one embodiment,
the reduction occurs at a temperature range of about 250.degree. C.
to about 350.degree. C. In another embodiment, the temperature is
in the range of about 350.degree. C. to about 500.degree. C. In
another specific embodiment the temperature is in the range of
about 500.degree. C. to about 600.degree. C. In one exemplary
embodiment, the nitrogen oxide present in the gas stream may be
reduced at a temperature of less than about 350.degree. C.
EXAMPLES
[0063] The following examples illustrate methods and embodiments in
accordance with exemplary embodiments, and as such should not be
construed as imposing limitations upon the claims. All components
are commercially available from common chemical suppliers.
Preparation of Materials
[0064] A 5000 mL 3-neck round bottom flask was set up with a
mechanical stirrer, reflux condenser, and addition funnel. About
6.51 g (38.5 mmol) of AgNO.sub.3 and about 0.6 g (8.7 mmol) of
LiNO.sub.3 were dissolved in about 240 mL water and added to the
flask for preparing 4.4 mole % of Ag and 1 mol % of Li doping.
Different lithium doping level may be achieved by varying the
addition of LiNO.sub.3. Following the addition to the flask, the
mechanical stirrer was turned on and contents of flask were
stirred. About 111.9 g of TRITON X-114 was mixed with heptane and
added to the flask. The mixture was stirred for 30 minutes at a
medium pace under ambient conditions to obtain a white suspension.
About 415 g (1.69 mol) of aluminum sec-butoxide
(Al(O.sup.secBu).sub.3) was added by charging a 1 L polyethylene
jar whose cap was equipped with a gas inlet and a dip-tube outlet.
Using 4-6 psi nitrogen, a feed of about 2.5 mL/min was achieved.
Addition was complete after 180 min. The contents were heated to
reflux for 22 h. The solid was recovered by filtration and washed
with ethanol. The obtained brown solid was then subjected to
pyrolysis at 550.degree. C. under nitrogen and then calcination in
air at 550.degree. C.
Catalyst Testing
[0065] After calcination, some powders were tested for fresh
performance, performance after one hour of operation, performance
after sulfation, and desulfation.
[0066] During the test, the catalyst composition was disposed in a
reactor to determine its nitrogen oxide conversion capabilities in
a simulated exhaust gas stream. An ultra-low sulfur diesel (ULSD)
fuel having a boiling point of less than 210.degree. C. was used as
a reductant. The reduction in NOx concentration relates to
catalytic activity of the catalyst compositions.
[0067] A simulated exhaust gas stream containing an exhaust gas
composition was used. The exhaust gas composition included 9
percent O.sub.2, 300 parts per million NO, 7 percent H.sub.2O, and
the balance N.sub.2. The gas hour space velocity (GHSV) was about
30,000 hr.sup.-1. For sulfation, about 5 ppm SO.sub.2 is added in
nominal conditions and passed for 8 hours at 350.degree. C. For
desulfation, the gas composition included an oxygen concentration
varying from zero to about 3 percent, about 300 parts per million
of NO, 7 percent H.sub.2O, and balance N.sub.2. The desulfation
step was normally carried out at a temperature varying from about
300.degree. C. to about 500.degree. C.
[0068] The temperature dependent NOx reduction activities of the
different compositions at different test conditions are plotted as
shown in FIG. 1-16. The comparison of amount of byproducts of the
emission treatment system in the absence and presence of lithium
sulfur scavenger is plotted in FIG. 17-18.
Test Results
[0069] FIG. 1 illustrates the NO.sub.x activities of the fresh 4.5
mol % Ag-TA catalyst composition without the addition of lithium,
while FIG. 2, FIG. 3, and FIG. 4 illustrate the NO.sub.x activities
of the fresh 4.5 mol % Ag-TA catalyst composition with 1%, 5%, and
14% respectively of Li addition as a sulfur scavenger. Similarly,
FIG. 5 illustrates the NOx acitivities of the 4.5 mol % Ag-TA
catalyst composition without the addition of lithium, after about
an hour of operation, while FIG. 6, FIG. 7, and FIG. 8 illustrate
the NO.sub.x activities after one hour of operation of the 4.5 mol
% Ag-TA catalyst composition with 1%, 5%, and 14% respectively of
Li addition as a sulfur scavenger.
[0070] FIG. 9 illustrates the NO.sub.x activities of the sulfated
fresh 4.5 mol % Ag-TA catalyst composition without the addition of
lithium, while FIG. 10, FIG. 11, and FIG. 12 illustrate the
NO.sub.x activities after sulfation of the fresh 4.5 mol % Ag-TA
catalyst composition with 1%, 5%, and 14% respectively of Li
addition as a sulfur scavenger. Similarly, FIG. 13 illustrates the
NOx acitivities of the 4.5 mol % Ag-TA catalyst composition without
the addition of lithium, after about an hour of sulfation, while
FIG. 14, FIG. 15, and FIG. 16 illustrate the NO.sub.x activities
after one hour of sulfation of the 4.5 mol % Ag-TA catalyst
composition with 1%, 5%, and 14% respectively of Li addition as a
sulfur scavenger.
[0071] By comparing these graphs, it can be seen that during
initial operation and during operation after sulfation, addition of
1% or 5% lithium improves NOx activity during initial stages and
after one hour of operation. 1% and 5% lithium addition seem to be
comparatively better than 14% Li addition. Between 1% and 5%
lithium addition, 5% Li addition comparatively improves the high
temperature NOx activity of Ag-TA catalyst.
[0072] FIG. 17 graphically illustrates the comparison of
temperature dependent HCN byproduct formation in the absence and
presence of 1% Li addition to the Ag-TA catalyst. The HCN by
product during NOx reduction over undoped 4.5 mol % Ag-TA catalyst
is about 30-70 ppm depending on the temperature of operation, while
for the Li doped 4.5 mol % Ag-TA catalyst only about 0-5 ppm of HCN
by products were determined
[0073] FIG. 18 compares the effect of Li addition in the formation
of CH.sub.3CHO and HCHO. It can be observed that the CH.sub.3CHO
formation reduces from about 40-130 ppm to a range of about 10-40
ppm after 1% Li addition. The HCHO formation reduces from about
10-30 ppm to a range of about 5-10 ppm after 1% Li addition.
[0074] The embodiments described herein are examples of
composition, system, and methods having elements corresponding to
the elements of the invention recited in the claims. This written
description may enable those of ordinary skill in the art to make
and use embodiments having alternative elements that likewise
correspond to the elements of the invention recited in the claims.
The scope of the invention thus includes composition, system and
methods that do not differ from the literal language of the claims,
and further includes other compositions and articles with
insubstantial differences from the literal language of the
claims.
[0075] While only certain features and embodiments have been
illustrated and described herein, many modifications and changes
may occur to one of ordinary skill in the relevant art. The
appended claims cover all such modifications and changes.
* * * * *