WO2014073995A1 - Supported oxide catalyst for low-temperature combustion of methane emitted from low-calorific sources and the process for preparation thereof - Google Patents

Supported oxide catalyst for low-temperature combustion of methane emitted from low-calorific sources and the process for preparation thereof Download PDF

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WO2014073995A1
WO2014073995A1 PCT/PL2013/000140 PL2013000140W WO2014073995A1 WO 2014073995 A1 WO2014073995 A1 WO 2014073995A1 PL 2013000140 W PL2013000140 W PL 2013000140W WO 2014073995 A1 WO2014073995 A1 WO 2014073995A1
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low
methane
sources
temperature combustion
catalyst
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French (fr)
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Zbigniew Sojka
Piotr ZAPAŁA
Andrzej Kotarba
Andrzej Adamski
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Uniwersytet Jagiellonski
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    • 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
    • B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
    • B01D53/86—Catalytic processes
    • B01D53/864—Removing carbon monoxide or hydrocarbons
    • 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
    • B01J23/24—Chromium, molybdenum or tungsten
    • B01J23/26—Chromium
    • 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
    • B01J35/30—Catalysts, in general, characterised by their form or physical properties characterised by their physical properties
    • 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
    • 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
    • B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J35/61—Surface area
    • B01J35/613—10-100 m2/g
    • 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
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/0201—Impregnation
    • 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
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/08—Heat treatment
    • B01J37/10—Heat treatment in the presence of water, e.g. steam
    • 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
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/34—Irradiation by, or application of, electric, magnetic or wave energy, e.g. ultrasonic waves ; Ionic sputtering; Flame or plasma spraying; Particle radiation
    • B01J37/341—Irradiation by, or application of, electric, magnetic or wave energy, e.g. ultrasonic waves ; Ionic sputtering; Flame or plasma spraying; Particle radiation making use of electric or magnetic fields, wave energy or particle radiation
    • B01J37/344—Irradiation by, or application of, electric, magnetic or wave energy, e.g. ultrasonic waves ; Ionic sputtering; Flame or plasma spraying; Particle radiation making use of electric or magnetic fields, wave energy or particle radiation of electromagnetic wave energy
    • B01J37/346—Irradiation by, or application of, electric, magnetic or wave energy, e.g. ultrasonic waves ; Ionic sputtering; Flame or plasma spraying; Particle radiation making use of electric or magnetic fields, wave energy or particle radiation of electromagnetic wave energy of microwave energy
    • 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
    • B01D2255/20784—Chromium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2255/00—Catalysts
    • B01D2255/20—Metals or compounds thereof
    • B01D2255/209—Other metals
    • B01D2255/2094—Tin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2257/00—Components to be removed
    • B01D2257/70—Organic compounds not provided for in groups B01D2257/00 - B01D2257/602
    • B01D2257/702—Hydrocarbons
    • B01D2257/7022—Aliphatic hydrocarbons
    • B01D2257/7025—Methane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2258/00—Sources of waste gases
    • B01D2258/06—Polluted air
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2259/00—Type of treatment
    • B01D2259/45—Gas separation or purification devices adapted for specific applications
    • B01D2259/4508—Gas separation or purification devices adapted for specific applications for cleaning air in buildings
    • 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
    • B01J2523/00—Constitutive chemical elements of heterogeneous catalysts
    • 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
    • B01J35/30—Catalysts, in general, characterised by their form or physical properties characterised by their physical properties
    • B01J35/391—Physical properties of the active metal ingredient
    • B01J35/393—Metal or metal oxide crystallite size
    • 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
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/03—Precipitation; Co-precipitation
    • B01J37/031—Precipitation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02C—CAPTURE, STORAGE, SEQUESTRATION OR DISPOSAL OF GREENHOUSE GASES [GHG]
    • Y02C20/00—Capture or disposal of greenhouse gases
    • Y02C20/20—Capture or disposal of greenhouse gases of methane

Definitions

  • the invention refers to a supported catalyst based on chromium and tin oxides for combustion of methane emitted from lean anthropogenic sources and the process for preparation thereof.
  • the catalytic systems obtained via functionalization of oxide supports with noble metals show the highest activity in methane combustion.
  • Patent application No. WO2004087311A1 described a catalyst for the low temperature catalytic oxidation of methane in the presence of hydrogen and water.
  • the catalyst comprises a high surface area alumina, tin oxide and at least one noble metal selected from the group consisting of palladium, platinum, rhodium or a combination thereof on a monolithic support.
  • Patent application No. JPl 1-067468 described a catalyst wherein palladium or palladium oxide is supported on a carrier containing tin oxide (IV) and/or palladium acetate.
  • Patent application No. EP578384A1 describes a process for the direct catalytic oxidation of methane to methanol in which a catalyst comprises chromium chemically bound to the oxygen of a metal oxide catalytic support surface.
  • the support may comprise silica, alumina, magnesia, titania, or zirconia.
  • a supported oxide catalyst for low-temperature oxidation of methane is featured by the fact that on the surface of crystalline Sn0 2 with the grain size ranging from 15 to 30 nm, and specific surface area between 20 and 80 m 2 /g, oxoclusters of chromium are dispersed.
  • Their concentration varies from 1 to 5 mol. % (calculated as Cr0 3 ), but preferably the content of 3 mol. % was found to be optimal.
  • preparation of the catalyst includes addition of ethanolamine to an aqueous solution of tin(IV) chloride.
  • the solution obtained in such a way is heated in hydrothermal conditions (temperature 160 °C, pressure 30 atm).
  • the obtained precipitate is centrifuged and chloride ions are elutriated.
  • the precipitate is then dried at 120° C for 12 hours.
  • the precipitate is calcined at 600 °C for 6 hours.
  • the obtained support undergoes functionalization with oxocomplexes of chromium. This process can be performed in two ways.
  • First method involves impregnation of the support with a solution of ammonium dichromate in such a way, that the volume of the used solution is lower than pore volume of the support.
  • Second method consists on impregnation of the support with a solution of ammonium dichromate in hydrothermal conditions in microwave autoclave. Once the reaction is accomplished, the precipitate is centrifuged. In both cases, after impregnation, the drying and calcination steps are applied in the conditions similar to those described previously for Sn0 2 .
  • tin(IV) chloride pentahydrate and 0.01 mole of CTAB hexadecylotrimethylammonium bromide
  • CTAB hexadecylotrimethylammonium bromide
  • Example II Functionalization of Sn0 2 by impregnation.
  • 1 g of Sn0 2 obtained according to the procedure described above was impregnated with 40 cm 3 of ammonium dichromate solution. Concentration of the solution was chosen in such a way, that the final concentration of CrO x (calculated as Cr0 3 ) was equal to 3 mol. %.
  • the preparation was dried at 120 °C for 12 hours and then calcined at 600 °C for 6 hours.
  • Sieve fraction 0.2-0.3 mm of a catalyst of the mass of 400 mg was placed in a quartz flow reactor with a sintered frit.
  • a gas reaction mixture containing oxygen and methane in a volume ration 5:1 passed through the reactor with a flow rate of 40 cm 3 /min.
  • the reaction was performed in the temperature programmed regime, increasing temperature with a rate of 10 °C/min up to 850 °C.
  • Analysis of the composition of the post- reaction gas mixture by using a mass spectrometer revealed, that at temperature of 500 °C 90 % of conversion was observed, at full selectivity to carbon dioxide.
  • a supported oxide catalyst of CrO x /Sn0 2 containing 3 mol. % of an active phase of the characteristic structure, where the crystalline support two- dimensional chromium oxoclusters predominate on the surface.
  • Characteristic features of the catalyst related to its structure and morphology are traced back to the preparation procedure.
  • the catalyst can be applied for combustion of lean methane at temperatures below 500 °C. Composition of the catalyst assures its high efficiency, and the applied preparation method permits to obtain the catalytic materials of reproducible parameters.

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Abstract

The invention solves the problem of the development of the supported oxide catalyst for total low-temperature combustion of methane from low-calorific sources type of oxoclusters of chromium deposited on the SnO2 with surface phase concentration of 3% mol. and the process for preparation thereof.

Description

Supported oxide catalyst for low-temperature combustion of methane emitted from low-calorific sources and the process for preparation thereof
The invention refers to a supported catalyst based on chromium and tin oxides for combustion of methane emitted from lean anthropogenic sources and the process for preparation thereof.
Even if methane concentration in the atmosphere is distinctly lower than that of C02, its contribution to the greenhouse effect is over twenty times higher. Reduction of the emission of the anthropogenic methane of low concentrations, produced in coal mines (VAM - ventilation air methane), landfills and agriculture is thus necessary. Classical method of thermal combustion of methane is a technology requiring high financial outlays related to construction of appropriate reactors working at temperatures 800-1200 °C. In such conditions various by-products of combustion process can be formed, exhibiting sometimes even higher toxicity than methane. In turn, the methods basing on enrichment of the low concentrated methane do not lead to total CH4 recovery and are economically expensive. Therefore, the most attractive solution proposed for elimination of methane from lean sources seems to be its catalytic combustion at low temperatures in the autothermal conditions. Using a catalyst for low-temperature combustion of methane encounters many barriers related to the highly inert chemical character of methane molecules. Regarding a high energy of the C-H bond, its activation is particularly difficult process. Moreover autothermal combustion of methane is difficult also due to its low concentration, which in the case of Polish coal mines does not exceed 1 %. Additional difficulties are related to high airflows of the order of 105 m3/min. More favorable conditions occur in the case of methane catch pits in landfills, where methane content can reach a level of few percents. This is the main reason why there is a strong need to elaborate a catalytic system, ensuring efficient oxidation of methane in economically reasonable temperature windows.
Until now, the studies on catalysts for methane combustion had rather fundamental character and were focused on two groups of catalysts (Supported catalysts based on noble metals, mainly Pt and Pd (Appl. Catal. B 39 (2002) 1 , J. Non-Cryst. Solids 345 (2004) 624, Appl. Catal. B 88 (2009) 430;Bare oxide systems of various composition and structure (Appl. Catal. B 15 (1998) 179, Catal. Lett. 75 (2001) 73, Appl. Catal. A 234 (2002) 1 , Catal. Today 158 (2010) 348, J. Mater. Chem. 20 (2010) 6968) Literature data indicate the fundamental importance of several parameters influencing activity of a suitable catalyst, such as composition of the active phase and oxidation states of individual elements, composition and nature of the support, morphology of the catalyst grains.
According to the literature, the catalytic systems obtained via functionalization of oxide supports with noble metals, mainly palladium and platinum, show the highest activity in methane combustion.
Patent application No. WO2004087311A1 described a catalyst for the low temperature catalytic oxidation of methane in the presence of hydrogen and water. The catalyst comprises a high surface area alumina, tin oxide and at least one noble metal selected from the group consisting of palladium, platinum, rhodium or a combination thereof on a monolithic support.
Patent application No. JPl 1-067468 described a catalyst wherein palladium or palladium oxide is supported on a carrier containing tin oxide (IV) and/or palladium acetate.
However, the low stability of noble metals in reaction conditions together with their relatively high costs discredit their potential application in industrial scale. Bare oxides, e.g. V205, M0O3, exhibit rather low activity in catalytic combustion of methane. Deposition of an active phase on oxide supports leads to the formation of various molecular structures with the properties distinctly different from those observed in the case of their bare states. This results in substantial increase of their activity. Such systems are also characterized by acceptable thermal stability and lower costs of production in comparison to those for catalysts based on noble metals.
Patent application No. EP578384A1 describes a process for the direct catalytic oxidation of methane to methanol in which a catalyst comprises chromium chemically bound to the oxygen of a metal oxide catalytic support surface. The support may comprise silica, alumina, magnesia, titania, or zirconia. Following the invention, a supported oxide catalyst for low-temperature oxidation of methane is featured by the fact that on the surface of crystalline Sn02 with the grain size ranging from 15 to 30 nm, and specific surface area between 20 and 80 m2/g, oxoclusters of chromium are dispersed. Their concentration varies from 1 to 5 mol. % (calculated as Cr03), but preferably the content of 3 mol. % was found to be optimal.
Following the invention, preparation of the catalyst includes addition of ethanolamine to an aqueous solution of tin(IV) chloride. The solution obtained in such a way is heated in hydrothermal conditions (temperature 160 °C, pressure 30 atm). The obtained precipitate is centrifuged and chloride ions are elutriated. The precipitate is then dried at 120° C for 12 hours. Subsequently the precipitate is calcined at 600 °C for 6 hours. The obtained support undergoes functionalization with oxocomplexes of chromium. This process can be performed in two ways. First method involves impregnation of the support with a solution of ammonium dichromate in such a way, that the volume of the used solution is lower than pore volume of the support. Second method consists on impregnation of the support with a solution of ammonium dichromate in hydrothermal conditions in microwave autoclave. Once the reaction is accomplished, the precipitate is centrifuged. In both cases, after impregnation, the drying and calcination steps are applied in the conditions similar to those described previously for Sn02.
The invention is illustrated by following examples.
Example I. Preparation of the catalyst.
0.6 g of tin(IV) chloride pentahydrate and 0.01 mole of CTAB (hexadecylotrimethylammonium bromide) were dissolved in distilled water in such a way to obtain 30 cm3 of a solution. To this solution 10 cm3 ethanolamine was added. The mixture was then placed in a Teflon vessel and underwent hydrothermal treatment in microwave autoclave. The reaction was run at 160 °C for 20 minutes under the pressure of 30 atmospheres. Obtained precipitate was centrifuged, rinsed with distilled water until the total removal of chloride ions. Subsequently the precipitate was dried at 120 °C for 12 hours, and calcined at 600 °C for 6 hours, with temperature increase of the rate of 4 T/min.
XRD analysis confirmed the presence of crystalline Sn02 only of mean crystallite size of 16 nm. Specific surface area of the obtained material was equal to 23 m /g.
Example II. Functionalization of Sn02 by impregnation. 1 g of Sn02 obtained according to the procedure described above was impregnated with 40 cm3 of ammonium dichromate solution. Concentration of the solution was chosen in such a way, that the final concentration of CrOx (calculated as Cr03) was equal to 3 mol. %. The preparation was dried at 120 °C for 12 hours and then calcined at 600 °C for 6 hours.
Spectroscopic and XRD studies confirmed beneficial two dimensional structure of the deposited oxoclusters, and a lack of undesired nanocrystalline forms of surface chromium oxides. Raman spectrum with deconvolution of the interesting range and UV- Vis/DR spectrum for the structure 3% mol CrOx/Sn02 is presented in the figures 1 i 2. Example III. Catalytic tests.
Sieve fraction 0.2-0.3 mm of a catalyst of the mass of 400 mg was placed in a quartz flow reactor with a sintered frit. A gas reaction mixture containing oxygen and methane in a volume ration 5:1 passed through the reactor with a flow rate of 40 cm3/min. The reaction was performed in the temperature programmed regime, increasing temperature with a rate of 10 °C/min up to 850 °C. Analysis of the composition of the post- reaction gas mixture by using a mass spectrometer revealed, that at temperature of 500 °C 90 % of conversion was observed, at full selectivity to carbon dioxide.
Following the invention, a supported oxide catalyst of CrOx/Sn02 containing 3 mol. % of an active phase of the characteristic structure, where the crystalline support two- dimensional chromium oxoclusters predominate on the surface. Characteristic features of the catalyst related to its structure and morphology are traced back to the preparation procedure. The catalyst can be applied for combustion of lean methane at temperatures below 500 °C. Composition of the catalyst assures its high efficiency, and the applied preparation method permits to obtain the catalytic materials of reproducible parameters.

Claims

Patent claims
1. Supported oxide catalyst for low-temperature combustion of methane emitted from low-calorific sources characterized in that on the surface of crystalline Sn02 oxoclusters of chromium, containing 2-5 mol. % (calculated as Cr03), are dispersed.
2. A catalyst according to the claim 1, characterized in that average grain size of its support ranges from 15 to 30 nm, and the specific surface is between 20 - 80 m /g.
3. The process for preparing the supported oxide catalyst for low temperature combustion of methane from calorie sources using an inert carrier in the form of tin oxide (IV), characterized in that the reaction is carried in a microwave hydrothermal autoclave using ethanolamine as the precipitating agent.
4. The process according to the claims 4, characterized in that the reaction is run at 150-200 °C, under the pressure of 30-60 arm for 20-30 min.
5. The process according to the claims 4, characterized in that the final preparation is calcined at 600 °C for 6 hours.
6. The process according to the claim 3, characterized in that Sn02 support is functionalized with oxocomplexes of chromium, containing 2-5 mol. % (calculated as Cr03).
7. The process according to the claim 8, characterized in that ammonium dichromate is used as a precursor of the active phase.
PCT/PL2013/000140 2012-11-07 2013-11-04 Supported oxide catalyst for low-temperature combustion of methane emitted from low-calorific sources and the process for preparation thereof WO2014073995A1 (en)

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Cited By (3)

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CN104888792A (en) * 2015-06-23 2015-09-09 北京联合大学 Low-temperature methane catalytic combustion catalyst preparation method
WO2018034050A1 (en) * 2016-08-17 2018-02-22 三井金属鉱業株式会社 Methane oxidation catalyst
US10486139B2 (en) 2017-03-30 2019-11-26 University Of Florida Research Foundation, Inc. IrO2 catalysts and methods of use thereof

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CN104888792A (en) * 2015-06-23 2015-09-09 北京联合大学 Low-temperature methane catalytic combustion catalyst preparation method
WO2018034050A1 (en) * 2016-08-17 2018-02-22 三井金属鉱業株式会社 Methane oxidation catalyst
US10486139B2 (en) 2017-03-30 2019-11-26 University Of Florida Research Foundation, Inc. IrO2 catalysts and methods of use thereof

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