US20150375207A1 - Method and catalyst for the simultaneous removal of carbon monoxide and nitrogen oxides from flue or exhaust gas - Google Patents

Method and catalyst for the simultaneous removal of carbon monoxide and nitrogen oxides from flue or exhaust gas Download PDF

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Publication number
US20150375207A1
US20150375207A1 US14/767,003 US201414767003A US2015375207A1 US 20150375207 A1 US20150375207 A1 US 20150375207A1 US 201414767003 A US201414767003 A US 201414767003A US 2015375207 A1 US2015375207 A1 US 2015375207A1
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catalyst
layer
oxidation
scr
ammonia
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Francesco Castellino
Viggo Lucassen Hansen
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Topsoe AS
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Haldor Topsoe AS
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Assigned to HALDOR TOPSOE A/S reassignment HALDOR TOPSOE A/S ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: Castellino, Francesco, LUCASSEN HANSEN, VIGGO
Publication of US20150375207A1 publication Critical patent/US20150375207A1/en
Priority to US15/968,889 priority Critical patent/US10493436B2/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/54—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
    • B01J23/56—Platinum group metals
    • B01J23/64—Platinum group metals with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • B01J23/648—Vanadium, niobium or tantalum or polonium
    • B01J23/6482—Vanadium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation 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
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation 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
    • B01D53/34—Chemical or biological purification of waste gases
    • B01D53/92—Chemical or biological purification of waste gases of engine exhaust gases
    • B01D53/94—Chemical or biological purification of waste gases of engine exhaust gases by catalytic processes
    • B01D53/9459—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts
    • B01D53/9463—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts with catalysts positioned on one brick
    • B01D53/9468—Removing one or more of nitrogen oxides, carbon monoxide, or hydrocarbons by multiple successive catalytic functions; systems with more than one different function, e.g. zone coated catalysts with catalysts positioned on one brick in different layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
    • B01J21/063—Titanium; Oxides or hydroxides thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/16—Catalysts 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/16—Catalysts 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
    • B01J23/20—Vanadium, niobium or tantalum
    • B01J23/22—Vanadium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B01J23/44—Palladium
    • B01J35/0006—
    • B01J35/023—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/19—Catalysts containing parts with different compositions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/40—Catalysts, in general, characterised by their form or physical properties characterised by dimensions, e.g. grain size
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/10—Noble metals or compounds thereof
    • B01D2255/102—Platinum group metals
    • B01D2255/1023—Palladium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/207—Transition metals
    • B01D2255/20707—Titanium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/207—Transition metals
    • B01D2255/20723—Vanadium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/90—Physical characteristics of catalysts
    • B01D2255/902—Multilayered catalyst
    • B01D2255/9022—Two layers

Definitions

  • the present invention relates to a method and catalyst for the simultaneous removal of carbon monoxide and nitrogen oxides (NOx) contained in flue or exhaust gas.
  • the invention provides a method, where flue gas or exhaust gas containing harmful carbon monoxide, organic compounds (VOC) and NOx is contacted with a layered catalyst in which a first layer comprises an oxidation catalyst and in an underlying layer a NH3-SCR catalyst for the simultaneous removal of the carbon monoxide and NOx.
  • VOC organic compounds
  • Removal of NOx, VOC and CO from flue or exhaust gas is conventionally exercised by use of two different catalyst compositions, wherein an oxidation catalyst is arranged upstream of an SCR catalyst with injection of a reductant between the catalysts.
  • NOx removal is typically performed by selective catalytic reduction (SCR) with NH3 on vanadium oxide or zeolite-based catalysts in monolithic form. Ammonia is injected upstream the SCR catalyst and reacts with the NOx on the catalyst surface.
  • An optimal temperature window for the vanadium oxide-based catalysts is 200-400° C., while zeolite based catalysts are more active at temperatures >400° C.
  • a flue gas containing both CO, VOCs and NOx is the flue gas from a turbine operating on natural gas.
  • the CO oxidation catalyst often based on Pt, is located upstream the SCR catalyst and the ammonia injection grid (“AIG”). This location has been chosen mainly due to the fact that the oxidation catalyst is very active in the oxidation of NH3 to NOx, which is highly undesired. Having the CO oxidation catalyst located upstream the AIG makes sure that no NH3 is wasted, but all amounts of injected ammonia reach the SCR catalyst limiting the operation costs of the utility.
  • the oxidation catalyst is arranged downstream the SCR catalyst. When positioned this way the oxidation catalyst is operated at lower temperatures than the conventional layout.
  • the problem with this configuration is that if not designed correctly, the oxidation catalyst may oxidize the NH3 slip to NOx, thus reducing the overall NOx removal of the plant.
  • the oxidation catalyst may be designed in a way that NH3 is converted to N2 instead, but such a catalyst is typically more expensive than a conventional oxidation catalyst due to both the kind and quantity of the noble metals used for its production.
  • the resulting reactor consists of two separate catalyst units, i.e. one SCR catalyst unit and one oxidation catalyst unit. More precisely, the total volume of catalyst installed will be determined by the size of the SCR catalyst unit, plus the size of the oxidation catalyst unit.
  • U.S. Pat. No. 7,390,471 discloses an exhaust gas treatment apparatus for reducing the concentration of NO x , HC and CO in an exhaust gas stream.
  • the treatment apparatus includes a multifunction catalytic element having an upstream reducing-only portion and a downstream reducing-plus-oxidizing portion that is located downstream of an ammonia injection apparatus.
  • SCR selective catalytic reduction
  • the selective catalytic reduction (SCR) of NO x is promoted in the upstream portion of the catalytic element by the injection of ammonia in excess of the stoichiometric concentration with the resulting ammonia slip being oxidized in the downstream portion of the catalytic element. Any additional NO x generated by the oxidation of the ammonia is further reduced in the downstream portion before being passed to the atmosphere.
  • the reduction-only catalyst may be vanadium/TiO 2 and the reduction-plus-oxidizing catalyst includes a reduction catalyst having 1.7 wt percent of vanadium/TiO2 impregnated with 2.8 g/ft 3 each of platinum and palladium.
  • the SCR activity of the oxidation catalyst is considerably lower than the SCR activity of an SCR-only catalyst meaning that the total volume of catalyst installed will be equal to the volume of the oxidation catalyst plus the volume of the SCR catalyst needed to compensate for the low SCR activity of the oxidation catalyst.
  • number one priority from a utility point of view is to reduce the total catalyst volume as much as possible.
  • Large volumes in fact mean high pressure drop across the catalyst bed and overall lower efficiency of the HRSG.
  • the pressure drop has a direct impact on the net power achievable from the turbine and an indirect effect on the heat flux, i.e. the calories that can be extracted from the flue gas by the HRSG.
  • the SCR activity of the oxidation catalyst has to be increased to the same high levels of an SCR-only catalyst.
  • One essential condition for obtaining this is the use of an oxidation catalyst very active in the oxidation of CO and VOC, but not reacting with NH3.
  • Another important condition is that the oxidation catalyst must still have the same oxidation activity as an oxidation-only catalyst.
  • the total volume of the resulting catalyst for the combined removal of both CO, VOC and NOx is equal to the volume of the largest catalyst between a dedicated oxidation and a dedicated SCR catalyst, which dependents on the required removal of CO, VOCs and NOx for a particular installation.
  • this invention provides a method for the reduction of amounts of carbon monoxide, volatile organic compounds and nitrogen oxides in flue or exhaust gas, said method comprising the steps of
  • the oxidation catalyst in the first layer consists of palladium, vanadium oxide and titanium oxide.
  • the resulting catalyst consists of a first catalyst layer oxidizing CO and VOC but not ammonia and a second layer of NH3-SCR-only catalyst.
  • both NOx and NH3 will easily access the underlying SCR catalyst and very limited SCR activity will be lost due to the diffusion rate of reagents across the oxidation catalyst layer.
  • the first catalyst layer has a layer thickness of between 10 and 200 micron, preferably of between 10 and 50 micron.
  • the flue or exhaust gas can additionally be treated with a conventional not layered SCR catalyst either up or downstream the layered catalyst.
  • the invention provides additionally a catalyst for simultaneous oxidation of carbon monoxide and volatile organic compounds and selective reduction of nitrogen oxides by reaction with ammonia, the catalyst comprises a first layer of an oxidation catalyst and a second layer of an NH3-SCR catalyst supporting completely the first layer.
  • the oxidation catalyst consists of palladium, oxides of vanadium and oxides of titanium.
  • the preferred oxidation catalyst according to en embodiment of the invention also has some SCR activity due to the presence of both TiO2 and vanadium oxides. Full SCR activity is thus preserved without the need of increasing the addition of ammonia. In this way, the desired removal of both CO and NOx can be accomplished with a significantly reduced catalyst volume.
  • the first catalyst layer has a layer thickness of between 10 and 200 micron, preferably of between 10 and 50 micron.
  • the resulting monolith catalyst When structuring the layered catalyst in monolithic form, the resulting monolith catalyst will have a uniform catalyst composition across the monolith length. CO, VOC and NOx removal proceeds simultaneously along the whole length of the monolith.
  • a V/Ti based commercial SCR catalyst has been coated with a catalyst consisting of 0.45 wt % Pd, 4.5 wt % V2O5 on TiI2.
  • the NOx removal efficiency has been measured and compared to the NOx removal efficiency of the same SCR catalyst not coated with the oxidation catalyst.
  • the results and conditions of the test are shown in Table 1 below:

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
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  • Oil, Petroleum & Natural Gas (AREA)
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  • General Engineering & Computer Science (AREA)
  • Catalysts (AREA)
  • Exhaust Gas Treatment By Means Of Catalyst (AREA)
  • Exhaust Gas After Treatment (AREA)
  • Crystallography & Structural Chemistry (AREA)
US14/767,003 2013-02-14 2014-02-03 Method and catalyst for the simultaneous removal of carbon monoxide and nitrogen oxides from flue or exhaust gas Abandoned US20150375207A1 (en)

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EP (1) EP2956232B1 (zh)
JP (1) JP6215361B2 (zh)
KR (1) KR102186734B1 (zh)
CN (1) CN104936679B (zh)
BR (1) BR112015019557B1 (zh)
CA (1) CA2899149C (zh)
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DK201600583A1 (en) * 2016-10-03 2018-04-23 Haldor Topsoe As Monolithic honeycomb oxidation catalyst and method of preparation thereof
US10857504B2 (en) * 2017-03-31 2020-12-08 Toyota Motor Engineering & Manufacturing North America, Inc. Two-stage catalyst for removal of NOx from exhaust gas stream
WO2021058484A1 (en) 2019-09-27 2021-04-01 Johnson Matthey Catalysts (Germany) Gmbh MULTI-FUNCTION CATALYST ARTICLE FOR TREATING BOTH CO AND NOx IN STATIONARY EMISSION SOURCE EXHAUST GAS
WO2021063939A1 (en) 2019-09-30 2021-04-08 Basf Corporation A multifunctional catalyst for hydrocarbon oxidation and selective catalytic reduction of nox
CN113856693A (zh) * 2021-09-29 2021-12-31 北京工业大学 一种用于催化氧化CO的MoSnCo催化剂及其制备方法
CN114828986A (zh) * 2019-12-11 2022-07-29 优美科股份公司及两合公司 用于在高NO2与NOx比率下进行高效SCR的系统和方法

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KR102479638B1 (ko) * 2015-03-20 2022-12-21 토프쉐 에이/에스 촉매화된 세라믹 캔들 필터 및 공정 오프가스 또는 배기가스의 정화 방법
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US10835854B2 (en) 2016-10-07 2020-11-17 Haldor Topsoe A/S Process for low temperature gas cleaning with ozone and a catalytic bag filter for use in the process
BR112019022419B1 (pt) * 2017-04-26 2024-01-16 Haldor Topsøe A/S Método e sistema para a remoção de matéria particulada e compostos nocivos dos gases de combustão
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CN108993544B (zh) * 2018-08-03 2020-12-25 生态环境部华南环境科学研究所 一种去除低温高硫尾气中NOx和VOCs的催化剂及其制备和应用
EP3730210A1 (en) * 2019-04-26 2020-10-28 Umicore Ag & Co. Kg Catalyst ceramic candle filter for combined particulate removal and the selective catalytic reduction (scr) of nitrogen-oxides
KR102155628B1 (ko) * 2019-05-14 2020-09-14 이덕기 반도체 제조공정의 질소산화물 및 입자성 물질 제거장치
CN111482071B (zh) * 2020-04-14 2022-09-27 中钢集团天澄环保科技股份有限公司 一种烧结烟气多污染物协同净化及余热利用系统及工艺
WO2021250161A1 (en) 2020-06-11 2021-12-16 Haldor Topsøe A/S Catalytic oxidation of carbon black exhaust gas
KR102457079B1 (ko) * 2020-11-30 2022-10-21 한국에너지기술연구원 복합유해물질 동시 제거 시스템
KR102527339B1 (ko) 2021-01-06 2023-04-28 울산과학기술원 일산화탄소 탈수소효소 및 포름산 탈수소효소를 이용한 개미산의 제조 방법
KR20220117529A (ko) 2021-02-17 2022-08-24 주식회사 엔바이온 질소화합물이 함유된 휘발성유기화합물 폐가스 처리 장치
CN113713608A (zh) * 2021-08-26 2021-11-30 复旦大学 一种用于CO和NOx同时去除的催化剂联用方法
US11635010B1 (en) 2021-10-05 2023-04-25 Umicore Ag & Co. Kg Combustion turbine and heat recovery system combination with SCR reactor assembly, and methods of assembling and using the same
WO2024052387A1 (en) 2022-09-06 2024-03-14 Umicore Ag & Co. Kg Catalytic system and method for the removal of hcn from off-gases of a fluid cracking unit using same, and fcc unit assembly including the catalytic system

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