DK180289B1 - Monolithic honeycomb oxidation catalyst and process for its preparation - Google Patents

Monolithic honeycomb oxidation catalyst and process for its preparation Download PDF

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Publication number
DK180289B1
DK180289B1 DKPA201600583A DKPA201600583A DK180289B1 DK 180289 B1 DK180289 B1 DK 180289B1 DK PA201600583 A DKPA201600583 A DK PA201600583A DK PA201600583 A DKPA201600583 A DK PA201600583A DK 180289 B1 DK180289 B1 DK 180289B1
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DK
Denmark
Prior art keywords
monolithic honeycomb
group
inert
washcoat
vanadium pentoxide
Prior art date
Application number
DKPA201600583A
Other languages
Danish (da)
Inventor
Lucassen Hansen Viggo
Hougaard Pedersen Kim
Castellino Francesco
Original Assignee
Haldor Topsoe As
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Publication date
Application filed by Haldor Topsoe As filed Critical Haldor Topsoe As
Priority to DKPA201600583A priority Critical patent/DK180289B1/en
Priority to CN201680058965.3A priority patent/CN108136372B/en
Priority to PCT/EP2016/075723 priority patent/WO2017072138A1/en
Publication of DK201600583A1 publication Critical patent/DK201600583A1/en
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Publication of DK180289B1 publication Critical patent/DK180289B1/en

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02Impregnation, coating or precipitation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/16Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • B01J23/20Vanadium, niobium or tantalum
    • B01J23/22Vanadium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/16Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • B01J23/24Chromium, molybdenum or tungsten
    • B01J23/30Tungsten
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B01J35/56

Abstract

A method of preparation of a monolithic honeycomb oxidation catalyst, the honeycomb oxidation catalyst has a plurality of flow through channels confined by walls, the walls consisting of an inert material coated with a core layer comprising an inert clay material, the core layer is coated with a top layer comprising at least one metal selected from the group of platinum group metals and vanadium pentoxide.

Description

DK 180289 B1 1 Method of preparing a monolithic honeycomb oxidation cata- lyst The invention relates to a monolithic honeycomb catalyst for the oxidation of carbon monoxide and volatile organic compounds (VOCs) in exhaust gases and flue gases from sta- tionary flue gas sources including gas turbines and power plants.
The invention is in particular directed to a method of preparation of a monolithic honeycomb shaped oxidation cat- alyst with a core layer comprising inert clay material and a top layer comprising one or more platinum group metals (PGM) coated on a monolithic honeycomb shaped substrate for use in the removal of carbon monoxide and VOCs in flue gas formed in stationary sources in the combustion of fossil fuel like natural gas, coal or oil.
Methods for removing CO and VOCs by catalytic oxidation are well-known in the art.
The most typical oxidation catalyst compositions employed in flue gas cleaning from stationary sources are based on platinum supported on alumina for applications such as CO and VOC oxidation.
It is also known that palladium promoted vanadium oxide catalysts offer a very high CO and VOC oxidation activity in combination with a high sulfur resistance.
Those catalysts are in particular preferred where there is a risk of exposure to high sulfur containing flue gases and where high sulfate emissions and fouling of downstream
DK 180289 B1 2 equipment and/or risk of catalyst deactivation has to be minimized. The advantage of palladium based oxidation catalysts is that these catalysts have a relatively low sulfur oxidation activity, which is particularly important when employed in the cleaning of sulfur oxide containing flue gas. For use in gas cleaning from stationary sources, the cata- lyst is washcoated on a monolithic honeycomb substrate, typically consisting of stacked up corrugated sheets of ce- ramic material or non-woven glass fibers forming a mono- lithic honeycomb structure with a plurality of parallel flow through channels.
Monolithic honeycomb shaped catalysts of the above type are typically prepared by coating the monolithic honeycomb sub- strate with a washcoat containing a catalyst carrier mate- rial and impregnating the coated substrate with a solution of precursors of the catalytic active metal oxides. Alter- natively, the washcoat can also contain the precursors. Washcoating of a monolithic honeycomb substrate is usually performed by slurry pickup in the substrate by pouring the slurry into the channels of the substrate, by dipping the substrate at one side into the washcoat slurry and option- ally applying vacuum at the opposite side or by pumping the washcoat slurry into the channels and optionally applying vacuum.
DK 180289 B1 3 After having been coated with the washcoat, the substrate is dried and finally calcined for activation of the cata- lytic components in the coat.
EP 0599379 discloses a method for preparing an oxidation catalyst comprising a corrugated metal washcoated with a layer comprising a clay material such as bentonite onto which a top layer comprising a platinum group metal such as palladium. After the washcoating a calcination step is car- ried out.
It is well known that the oxidation reaction is much faster than diffusion of CO and some VOCs into the catalyst wall at typical oxidation reaction conditions and it would therefore be an advantage in terms of cost saving, when re- ducing or limiting distribution of the expensive PGM cata- lyst material only to the outer surface of the walls or the wall coat of the monolithic honeycomb substrate.
In the known oxidation catalysts as prepared by the above mentioned coating methods, the PGM catalyst is distributed throughout the whole wall cross section. Thus, the PGM cat- alyst distributed beneath surface of the walls does not participate in the catalytic CO and reactive VOC oxidation.
The problem is solved by the present invention, when providing the walls of the substrate with a core layer of inert clay materials and applying a washcoat comprising PGM on the surface of the core layer.
We have further found that diffusion of PGM can be elimi- nated or substantially diminished when decreasing the rate
DK 180289 B1 4of diffusion of PGM on the substrate.
Instead of having precursor compounds of PGM dissolved in an aqueous impreg- nation liquid, the precursor compounds are added to an aqueous slurry containing vanadium compounds, which act asa carrier for PGM and which is used for the coating of the inert clay core layer on the substrate.
In this aqueous slurry, the PCM compounds are adsorbed on the supported va- nadium compound particles and are thereby not dissolved in the aqueous phase of the aqueous slurry, which otherwisewould result in undesired diffusion into the walls of the substrate and/or clay core layer.
The catalyst prepared according to the invention has the advantage that it shows at least as good structure stabil-
ity as conventional monoliths since the overall thickness of the monolith wall is preserved due to the inert clay core layer.
The present invention reduces additionally the catalystload per unit volume of monolith leading to a reduced SO; oxidation.
The present invention is a method of preparing a monolithic honeycomb oxidation catalyst comprising the steps of
(a) providing an inert monolithic honeycomb substrate with a plurality of flow through channels confined by walls by stacking or rolling up one or more corrugated sheets of in- ert material, optionally provided with flat liners; (b) coating the monolithic honeycomb substrate with a corelayer comprising an inert clay material;
DK 180289 B1 (c) providing a washcoat comprising at least one metal se- lected from the group of platinum group metals and vanadium pentoxide; (d) coating the core layer with a top layer by applying 5 the washcoat prepared in step (c); and (e) calcining the coated monolithic honeycomb substrate, wherein the washcoat of step(c) is prepared by (1) pulverising a finished SCR catalyst product comprising vanadium pentoxide; (ii) dispersing the pulverized catalyst product in water and forming a slurry; (iii) adding a water soluble precursor of the at least one metal selected from the group of platinum group metals.
Specific features of the method according to the invention are alone or in combination thereof that the washcoat further comprises an oxide of tungsten and ti- tania; the finished SCR catalyst product comprises vanadium pent- oxide further comprises titania and an oxide of tungsten; the platinum group metal is palladium; the one or more corrugated sheets of inert material and the optional flat liners, comprise entangled non-woven fibers; the entangled non-woven fibers are glass fibers; the inert clay material is selected from the kaolin group, hydrous alumina silicates, the chlorite group, the py- rophillite group, bentonite or mixtures thereof; the top layer comprises 0.1 to 10 % by weight vanadium pentoxide; the top layer comprises 100 to 30000 ppm by weight palladi- um.
DK 180289 B1 6 By the terms “inert material” and “inert clay material” as used hereinbefore or in the following description and claims it should be understood that the material is not catalytically active.
Example An Pd-V;05-WO3-TiO, based oxidation catalyst on an inert clay core was prepared as follows.
A monolithic honeycomb substrate made of a number of corru- gated sheets made of glass fibers and provide each with a flat liner were coated with a core layer of kaolin by dip- ping the substrate into a slurry of kaolin and butanol un- til the wall thickness of the coated substrate was 0.4 mm. The thus prepared monolithic honeycomb substrate was then allowed to drain for 10 minutes, dried for three days and fired for two hours at 550°C in N, atmosphere.
The substrate with the kaolin core layer was coated with a wash coat prepared as follows: 200 grams of crushed and milled V>O05-WO3-Ti0» SCR catalyst in water (25 % by mass) was adjusted to a pH value of 8.5 by adding an aqueous ammonia solution. To the resulting slurry was added a Pd nitrate solution of 100 ppmw by metal until 1000 ppmw Pd by dry matter in the slurry was achieved. The resulting slurry was sufficiently mixed while adjusting pH to 8.5 using an aqueous ammonia solution fol- lowed by addition of polysaccharide to a concentration of
0.1 % by mass.
DK 180289 B1 7 The monolithic honeycomb substrate with an inert core layer of kaolin as prepared above was dipped into the slurry for
1.5 minutes and the slurry was afterwards allowed to drain from the substrate for 15 minutes. The resulting monolithic honeycomb catalyst was then calcined for two hours at 400°C.

Claims (9)

DK 180289 B1 1DK 180289 B1 1 1. Fremgangsmade til fremstilling af en monolitisk honeycomb- oxidationskatalysator omfattende trinnene at (a) tilvejebringe et inert, monolitisk honeycombsubstrat med et stort antal gennemstrømningskanaler, der er omgivet af vægge ved stabling eller oprulning af en eller flere korrugerede plader af inert materiale, der eventuelt er forsynet med flade foringer; (b) coate det monolitiske honeycombsubstrat med et kernelag omfattende et inert lermateriale; (c) tilvejebringe en washcoat omfattende mindst et metal valgt fra gruppen af platingruppemetaller og vanadiumpentoxid; (d) coate kernelaget med et toplag ved at påføre den i trin (c) fremstillede washcoat; og (e) calcinere det coatede, monolitiske honeycombsubstrat, hvori washcoaten i trin (c) fremstilles ved at (0) pulverisere et færdigt SCR katalysatorprodukt omfattende vanadiumpentoxid; (ii) dispergere det pulveriserede katalysatorprodukt i vand og danne en opslæmning; (iii) tilsætte en vandopløselig prækursor af det mindst ene metal valgt fra gruppen af platingruppemetaller.A method of making a monolithic honeycomb oxidation catalyst comprising the steps of (a) providing an inert, monolithic honeycomb substrate having a plurality of flow channels surrounded by walls by stacking or winding one or more corrugated sheets of inert material, optionally is provided with flat liners; (b) coating the monolithic honeycomb substrate with a core layer comprising an inert clay material; (c) providing a washcoat comprising at least one metal selected from the group consisting of platinum group metals and vanadium pentoxide; (d) coating the core layer with a top layer by applying the washcoat prepared in step (c); and (e) calcining the coated monolithic honeycomb substrate, wherein the washcoat in step (c) is prepared by (0) pulverizing a finished SCR catalyst product comprising vanadium pentoxide; (ii) dispersing the powdered catalyst product in water and forming a slurry; (iii) adding a water-soluble precursor of the at least one metal selected from the group of platinum group metals. 2. Fremgangsmåde ifølge krav 1, hvori washcoaten endvidere omfatter en oxid af wolfram og titania.The method of claim 1, wherein the washcoat further comprises an oxide of tungsten and titania. 3. Fremgangsmåde ifølge krav 1, hvori det færdige SCR katalysatorprodukt omfattende vanadiumpentoxid endvidere omfatter titania og et wolframoxid.The process of claim 1, wherein the finished SCR catalyst product comprising vanadium pentoxide further comprises titania and a tungsten oxide. 4. Fremgangsmåde ifølge ethvert af kravene 1 til 3, hvori platingruppemetallet er palladium.A method according to any one of claims 1 to 3, wherein the platinum group metal is palladium. DK 180289 B1 2DK 180289 B1 2 5. Fremgangsmåde ifølge ethvert af kravene 1 til 4, hvori den en eller flere korrugerede plader af inert materiale og de eventuelle flade foringer omfatter sammenfiltrede uvævede fibre.A method according to any one of claims 1 to 4, wherein the one or more corrugated sheets of inert material and the optional flat liners comprise entangled nonwoven fibers. 6. Fremgangsmåde ifølge krav 5, hvori de sammenfiltrede uvævede fibre er glasfiber.The method of claim 5, wherein the entangled nonwoven fibers are glass fiber. 7. Fremgangsmåde ifølge ethvert af kravene 1 til 6, hvori det inerte lermateriale vælges fra gruppen af kaolin, vandholdige aluminiumsilikater, chloritgruppen, pyrophillitgruppen, bentonit eller blandinger deraf.A process according to any one of claims 1 to 6, wherein the inert clay material is selected from the group of kaolin, aqueous aluminosilicates, the chlorite group, the pyrophillite group, bentonite or mixtures thereof. 8. Fremgangsmåde ifølge ethvert af krav 1 til 7, hvori toplaget omfatter 0,1 til 10 vægtprocent vanadiumpentoxid.A method according to any one of claims 1 to 7, wherein the top layer comprises 0.1 to 10% by weight of vanadium pentoxide. 9. Fremgangsmåde ifølge ethvert af kravene 1 til 8, hvori toplaget omfatter 100 til 30000 ppm vægtprocent palladium.A method according to any one of claims 1 to 8, wherein the top layer comprises 100 to 30,000 ppm by weight of palladium.
DKPA201600583A 2015-10-28 2016-10-03 Monolithic honeycomb oxidation catalyst and process for its preparation DK180289B1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
DKPA201600583A DK180289B1 (en) 2016-10-03 2016-10-03 Monolithic honeycomb oxidation catalyst and process for its preparation
CN201680058965.3A CN108136372B (en) 2015-10-28 2016-10-26 Monolithic honeycomb oxidation catalyst and preparation method thereof
PCT/EP2016/075723 WO2017072138A1 (en) 2015-10-28 2016-10-26 Monolithic honeycomb oxidation catalyst and method of preparation thereof

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Application Number Priority Date Filing Date Title
DKPA201600583A DK180289B1 (en) 2016-10-03 2016-10-03 Monolithic honeycomb oxidation catalyst and process for its preparation

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DK180289B1 true DK180289B1 (en) 2020-10-07

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP3386621B2 (en) * 1995-03-30 2003-03-17 トヨタ自動車株式会社 Exhaust gas purification catalyst for diesel engines
US7235507B2 (en) * 2004-08-14 2007-06-26 Sud-Chemie Inc. Catalyst for purifying diesel engine exhaust emissions
EP1832332B1 (en) * 2006-03-09 2016-05-04 Haldor Topsøe A/S Process and system for purification of sulphur-containing exhaust gas
US20150375207A1 (en) * 2013-02-14 2015-12-31 Haldor Topsoe A/S Method and catalyst for the simultaneous removal of carbon monoxide and nitrogen oxides from flue or exhaust gas
WO2017072138A1 (en) * 2015-10-28 2017-05-04 Haldor Topsøe A/S Monolithic honeycomb oxidation catalyst and method of preparation thereof

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