GB2065629A - Catalytic oxidation of gas stream pollutants - Google Patents

Catalytic oxidation of gas stream pollutants Download PDF

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Publication number
GB2065629A
GB2065629A GB8040605A GB8040605A GB2065629A GB 2065629 A GB2065629 A GB 2065629A GB 8040605 A GB8040605 A GB 8040605A GB 8040605 A GB8040605 A GB 8040605A GB 2065629 A GB2065629 A GB 2065629A
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United Kingdom
Prior art keywords
gas stream
catalyst
waste gas
pollutants
layer
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GB8040605A
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USS Engineers and Consultants Inc
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USS Engineers and Consultants Inc
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Publication date
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Publication of GB2065629A publication Critical patent/GB2065629A/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
    • B01J23/00Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/70Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
    • B01J23/89Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with noble metals
    • B01J23/8933Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with noble metals also combined with metals, or metal oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
    • B01J23/8986Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with noble metals also combined with metals, or metal oxides or hydroxides provided for in groups B01J23/02 - B01J23/36 with manganese, technetium or rhenium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D53/00Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/34Chemical or biological purification of waste gases
    • B01D53/74General processes for purification of waste gases; Apparatus or devices specially adapted therefor
    • B01D53/86Catalytic processes
    • B01D53/864Removing carbon monoxide or hydrocarbons

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Environmental & Geological Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Biomedical Technology (AREA)
  • Analytical Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)
  • Catalysts (AREA)

Abstract

Pollutants in a waste gas stream are oxidized by passing the gas stream through a catalyst bed comprising a layer of oxides of manganese and copper and a separate downstream layer comprising at least one noble metal (e.g. Pd, Pt). An inert layer may be interposed between the two catalyst layers.

Description

SPECIFICATION Catalytic oxidation of gas stream pollutants This invention relates to catalytic oxidation of gas stream pollutants. Noble metals have been used as catalysts in the oxidation of pollutants in waste gas streams. However, these catalysts require high ignition temperatures and may, therefore, necessitate the use of large heat exchangers for preheating of the waste gas. Furthermore, because of the high temperatures, material costsforthe oxidation reactor are very high.
To overcome some of these problems, a catalytic oxidation system using the oxides of manganese and copper was developed. When the waste gas stream contains oxidizable pollutants in the form of carbon monoxide and hydrocarbons, it is possible to preheat to the relatively low ignition temperature needed to oxidize the CO. The heat released by oxidation of the CO heats the gas to the ignition temperature of the hydrocarbons.
The lower preheating temperature and the lower operating temperature of the catalyst bed result in savings in preheating costs and savings in material costs since the reactor can be made with, for example, cheaper carbon steel rather than stainless steel.
However, this oxide catalyst cannot withstand very high temperatures. This has created problems, especially when the level of pollutants is such that the gas temperature rises to 2500C or more upon combustion.
According to the present invention, there is provided a process for the catalytic oxidation of pollutants in a waste gas stream, comprising passing said waste gas stream through a gas permeable catalyst bed having a first catalyst layer of the oxides of manganese and copper, and a separate second catalyst layer comprising at least one noble metal.
The invention also provides an apparatus for the catalytic oxidation of pollutants in a waste gas stream, comprising a chamber containing a gas permeable catalyst bed having a first catalyst layer of the oxides of manganese and copper, and a separate second catalyst layer comprising at least one noble metal.
By using the catalyst bed of this invention, significant advantages have been found over a catalyst bed made up only of the oxides of manganese and copper. More complete removal of the oxidizable pollutants from the gas stream is possible. There is also better resistance to catalyst damage due to overheating since the first catalyst layer oxidizes only part of the combustibles in the gas stream, while the noble metal layer completes the combustion and can withstand much higher temperatures than the first catalyst layer.
Furthermore, this invention requires less heat transfer surface area in preheating the waste gas stream prior to contacting the catalyst as compared to a process using a noble metal catalyst alone. Also, it is possible to use cheaper materials for the apparatus of this invention as compared to an apparatus in which noble metals alone are used, due to the lower oxidation temperatures that are possi ble. For example, the same amount of pollutants can be removed from a waste gas using the catalyst bed of this invention with a temperature rise from 1000C entering the bed to 4000C leaving the bed as would be possible using a noble metal catalyst alone with a temperature rise across the bed of 4000 to 700 C.
This means that cheaper carbon steel could be used rather than more expensive stainless steel or other alloys. On the other hand, ifthe apparatus may have to handle high temperatures frequently, then the more expensive materials can be used to withstand such temperatures. This will avoid the need for emergency venting or the like.
The invention is further described, by way of example, with reference to the accompanying drawings, in which: Figure I is a schematic representation of a waste gas purification apparatus constructed in accordance with this invention, and Figure 2 is a schematic representation of a waste gas purification apparatus embodying the invention and including a plurality of catalyst beds.
Referring to Figure 1, a waste gas stream containing oxidizable pollutants enters a reactor 1 through an inlet 2 of a chamber 3. The gas stream then passes through a catalyst bed 4 composed of a first, top layer 5 comprising the oxides of manganese and copper and a second, noble metal layer 6. Preferably an intermediate inert layer 7 is present between layers 5 and 6. After the gas stream passes through the catalyst bed 4, it leaves through an outlet 8.
Figure 2 shows a preferred embodiment of the invention wherein a waste gas stream at 10 containing maleic anhydride vapors and other oxidizable pollutants enter a scrubber 11 where the waste gas stream is contacted with scrubbing liquid to remove the maleic anhydride leaving minor amounts of maleic acid dissolved in droplets of the scrubbing liquid suspended in the waste gas stream. The waste gas stream then passes through a line 12 to a heat exchanger 13 in which the waste gas stream contacts a plurality of closely spaced thin fin heating elements on which the scrubbing liquid evaporates from the droplets and deposits the dissolved solids on the heating elements.The heated waste gas stream free of entrained droplets and dissolved solids then passes through a line 14to a second heat exchanger 15 which preferably obtains its heat from a catalytic oxidation unit 17 after such unit has started up. The preheated gas stream from the heat exchanger 15 leaves through a line 16 and passes into the catalytic oxidation unit 17 which comprises a plurality of chambers 21 containing horizontal, parallel catalyst beds 23 with respective distributor plates 22. Each of the distributor plates 22 has openings which create in the plate a total open area of less than about 10 percent. The outer reactor wall 18 encloses manifolds 19 for conducting the waste gas stream into and from inlets 20 and outlets 24 of the chambers 21.The waste gas stream containing oxidizable pollutants enters through the inlets 20 and passes, by way of the distributor plates 22, through the gas permeable catalyst beds 23 and then leaves through the outlets 24.
The waste gas stream may be any of those containing impurities which may be removed by catalytic oxidation. However, the invention is particularly applicable to those waste gas streams containing oxidizable pollutants made up of hydrocarbons and carbon monoxide such as the waste gas streams produced in the manufacture of maleic anhydride. Typical hydrocarbon pollutants may be C1-C12 aliphatic and aromatic hydrocarbons. Exemplary hydrocarbons are benzene, maleic acid, formic acid, and formaldehyde. One exemplary waste gas stream contains the following amounts of impurities in parts by weight per 200,000 parts byweightof waste gas: benzene - 200, maleic acid - 21, formic acid - 17, formaldehyde - 75, and carbon monoxide 4000.The remainder will typically consist of nitrogen, oxygen, carbon dioxide, and water vapor with the nitrogen being present in an amount of about 76 to 80 percent by volume, the oxygen being present in an amount of about 10 to 15 percent by volume, the water vapor being present in an amount of about 5 to 15 percent by volume, and the carbon dioxide being present in an amount of about 2 to 8 percent by volume.
The first catalyst layer 5 which comprises the oxides of manganese and copper, and is preferably a Hopcalite catalyst, is preferably maintained at a temperature of 95 to 250 C, more preferably 110 to 180 C. The first catalyst layer preferably has a thickness of 0.25 to 8 inches (6 to 203 mm.) and more preferably 0.5 to 3 inches (13 to 76 mm.), and even more preferably 1 to 1-112 inches (25 to 38 mm.).
The layer 6 of the catalyst bed which comprises a noble metal catalyst such as palladium or platinum or both has the noble metal deposited on an inert carrier such as alumina. The layer 6 may be in the form of granules or a rigid structure in the form, for example, of a honeycomb. The preferred temperature across this layer is 200 to 7000C and more preferably 260 to 5009C.
The intermediate inert layer 7, if any, of the catalyst bed preferably has a thickness of up to 4 inches (102 mm.) and preferably 1 to 2 inches (25 to 51 mm.). The inert layer may be in the form of granules or a rigid structure. The preferred temperature across this inert layer is 190 to 4400C and more preferably 200 to 260 C.
When granules are used, they preferably have an average diameter of 1 to 4 millimeters.
The pressure drop from the inlet to the outlet of the catalyst bed 4 is preferably 1 to 10 inches of water (2 to 19 mm. of Hg); and when a distributor plate is used, the combined pressure drop over the distributor plate and the catalyst bed will generally be 2 to 11 inches of water (4 to 21 mm. of Hg).
When using a distributor plate, the preferred distance between the outlet side of the distributor plate and the inlet side of the catalyst bed is 18 inches to 5 feet (46 to 152 cm.).
The velocity of the waste gas stream at the inlet surface of the catalyst bed is preferably 0.5 to 4feet per second (15 to 122 cm/sec.), and more preferably 0.8 to 1.2 feet per second (24 to 37 cm./sec.).

Claims (10)

1. Process for the catalytic oxidation of pollutants in a waste gas stream, comprising passing said waste gas stream through a gas permeable catalyst bed having a first catalyst layer of the oxides of manganese and copper, and a separate second catalyst layer comprising at least one noble metal.
2. Process as claimed in claim 1, wherein said at least one noble metal is palladium or platinum or both supported on an inert carrier.
3. Process as claimed in claim 1 or claim 2, wherein said catalyst bed additionally has an inert layer between the two catalyst layers.
4. Process as claimed in any preceding claim, wherein the gas stream is passed to the catalyst bed through a distributor plate having openings creating in said plate a total open area of less than 10 percent.
5. Apparatus for the catalytic oxidation of pollutants in a waste gas stream, comprising a chamber containing a gas permeable catalyst bed having a first catalyst layer of the oxides of manganese and copper, and a separate second catalyst layer comprising at least one noble metal.
6. Apparatus as claimed in claim 5, wherein said at least one noble metal is palladium or platinum or both supported on an inert carrier.
7. Apparatus as claimed in claim 5 or claim 6, wherein said catalyst bed additionally has an inert layer between the two catalyst layers.
8. Apparatus as claimed in any one of claims 5 to 7, including upstream of the catalyst bed, a distributor plate having openings creating in said plate a total open area of less than 10 percent.
9. Process for the catalytic oxidation of pollutants in a waste gas stream, substantially as hereinbefore described with reference to Figure 1 or Figure 2 of the accompanying drawings.
10. Apparatus for the catalytic oxidation of pollutants in a waste gas stream, constructed and adapted to operate substantially as hereinbefore described with reference to and as illustrated in Figure 1 or Figure 2 of the accompanying drawings.
GB8040605A 1979-12-21 1980-12-18 Catalytic oxidation of gas stream pollutants Withdrawn GB2065629A (en)

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US10632879A 1979-12-21 1979-12-21

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GB2065629A true GB2065629A (en) 1981-07-01

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GB8040605A Withdrawn GB2065629A (en) 1979-12-21 1980-12-18 Catalytic oxidation of gas stream pollutants

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JP (1) JPS5697525A (en)
BE (1) BE886763A (en)
DE (1) DE3042843A1 (en)
FR (1) FR2471805A1 (en)
GB (1) GB2065629A (en)
IT (1) IT8068962A0 (en)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1990005577A1 (en) * 1988-11-23 1990-05-31 The Governors Of The University Of Alberta Method and apparatus for purifying air
US4983366A (en) * 1987-09-21 1991-01-08 Degussa Aktiengesellschaft Method for the catalytic conversion of waste gases containing hydrocarbon, halogenated hydrocarbon and carbon monoxide
US5008091A (en) * 1988-11-29 1991-04-16 Governors Of The University Of Alberta Method for purifying air
US5102634A (en) * 1990-01-17 1992-04-07 Nippon Shokubai Kagaky Kogyo Co., Ltd. Method for purifying exhaust gas and apparatus
US5192515A (en) * 1990-09-20 1993-03-09 Molecular Technology Corporation Reduction of nitrogen oxide and carbon monoxide in effluent gases
US5571491A (en) * 1991-12-19 1996-11-05 Modo-Chemetics Ab Purifying apparatus
WO2001037976A1 (en) * 1999-11-24 2001-05-31 General Electric Company Method of cleaning industrial waste gases
US6436360B1 (en) 1999-11-24 2002-08-20 General Electric Company Method of cleaning industrial waste gases
WO2012068191A1 (en) * 2010-11-18 2012-05-24 Sud-Chemie Inc. Method for removing co, h2 and ch4 from an anode waste gas of a fuel cell and catalyst system useful for removing these gases

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AT371372B (en) * 1981-07-01 1983-06-27 Kanzler Walter METHOD FOR PURIFYING EXHAUST GASES FROM FORMALDEHYD SYSTEMS
DE3325712C2 (en) * 1983-07-16 1987-03-12 Stettner & Co, 8560 Lauf Catalytic converter for the afterburning of flue gases
JPH0235915A (en) * 1988-07-26 1990-02-06 Nippon Sanso Kk Removing process and carbon monoxide
DE60321260D1 (en) 2002-03-29 2008-07-10 Tosoh Corp Catalytic combustion reactor with a heat exchanger and catalytic combustion process

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4983366A (en) * 1987-09-21 1991-01-08 Degussa Aktiengesellschaft Method for the catalytic conversion of waste gases containing hydrocarbon, halogenated hydrocarbon and carbon monoxide
WO1990005577A1 (en) * 1988-11-23 1990-05-31 The Governors Of The University Of Alberta Method and apparatus for purifying air
US5008091A (en) * 1988-11-29 1991-04-16 Governors Of The University Of Alberta Method for purifying air
US5102634A (en) * 1990-01-17 1992-04-07 Nippon Shokubai Kagaky Kogyo Co., Ltd. Method for purifying exhaust gas and apparatus
US5192515A (en) * 1990-09-20 1993-03-09 Molecular Technology Corporation Reduction of nitrogen oxide and carbon monoxide in effluent gases
US5571491A (en) * 1991-12-19 1996-11-05 Modo-Chemetics Ab Purifying apparatus
WO2001037976A1 (en) * 1999-11-24 2001-05-31 General Electric Company Method of cleaning industrial waste gases
US6436360B1 (en) 1999-11-24 2002-08-20 General Electric Company Method of cleaning industrial waste gases
WO2012068191A1 (en) * 2010-11-18 2012-05-24 Sud-Chemie Inc. Method for removing co, h2 and ch4 from an anode waste gas of a fuel cell and catalyst system useful for removing these gases
US9327238B2 (en) 2010-11-18 2016-05-03 Clariant Corporation Method for removing CO, H2 and CH4 from an anode waste gas of a fuel cell and catalyst system useful for removing these gases
KR101852645B1 (en) 2010-11-18 2018-04-26 클라리언트 코포레이션 Method for removing co, h2 and ch4 from an anode waste gas of a fuel cell and catalyst system useful for removing these gases

Also Published As

Publication number Publication date
FR2471805A1 (en) 1981-06-26
DE3042843A1 (en) 1981-07-02
IT8068962A0 (en) 1980-12-19
JPS5697525A (en) 1981-08-06
BE886763A (en) 1981-06-19

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