Experimental study of mass transfer limitations in Fe- and Cu-zeolite-based NH3-SCR monolithic catalysts

An experimental study of steady-state selective catalytic reduction (SCR) of NO_x with NH₃ on both Fe-ZSM-5 and Cu-ZSM-5 monolithic catalysts was carried out to investigate the extent of mass transfer limitations in various SCR reactions. Catalysts with different washcoat loadings, washcoat thicknesses and lengths were synthesized for this purpose. SCR system reactions examined included NO oxidation, NH₃ oxidation, standard SCR, fast SCR and NO₂ SCR. Comparisons of conversions obtained on catalysts with the same washcoat volumes but different washcoat thicknesses indicated the presence of washcoat diffusion limitations. NH₃ oxidation, an important side reaction in SCR system, showed the presence of washcoat diffusion limitations starting at 350 °C on Fe-zeolite and 300 °C on Cu-zeolite catalysts. Washcoat diffusion limitations were observed for the standard SCR reaction (NH₃+NO+O₂) on both Fe-zeolite (≥350 °C) and Cu-zeolite (≥250 °C). For the fast (NH₃+NO+NO₂) and NO₂ SCR (NH₃+NO₂) reactions, diffusion limitations were observed throughout the temperature range explored (200–550 °C). The experimental findings are corroborated by theoretical analyses. Even though the experimentally observed differences in conversions clearly indicate the presence of washcoat diffusion limitations, the contribution of external mass transfer was also found to be important under certain conditions. The transition temperatures for shifts in controlling regimes from kinetic to washcoat diffusion to external mass transfer are determined using simplified kinetics. The findings indicate the necessity of inclusion of mass transfer limitations in SCR modeling, catalyst design and optimization.     

Redox features in the catalytic mechanism of the “standard” and “fast” NH3-SCR of NOx over a V-based catalyst investigated by dynamic methods

The redox mechanism governing the selective catalytic reduction (SCR) of NO/NO₂ by ammonia at low temperature was investigated by transient reactive experiments over a commercial V₂O₅/WO₃/TiO₂ catalyst for diesel exhaust aftertreatment. NO + NH₃ temperature-programmed reaction runs over reduced catalyst samples pretreated with various oxidizing species showed that both NO₂ and HNO₃ were able to reoxidize the V catalyst at much lower temperature than gaseous O₂: furthermore, they significantly enhanced the NO + NH₃ reactivity below 250 °C via the buildup of adsorbed nitrates, which act as a surface pool of oxidizing agents but are decomposed above that temperature. Both such features, which were not observed in comparative experiments over a V-free WO₃/TiO₂ catalyst, point out a key catalytic role of the vanadium redox properties and can explain the greater deNO_x efficiency of the “fast” SCR (NO + NH₃ + NO₂) compared with the “standard” SCR (NO + NH₃ + O₂) reaction. A unifying redox approach is proposed to interpret the overall NO/NO₂–NH₃ SCR chemistry over V-based catalysts, in which vanadium sites are reduced by the reaction between NO and NH₃ and are reoxidized either by oxygen (standard SCR) or by nitrates (fast SCR), with the latter formed via NO₂ disproportion over other nonreducible oxide catalyst components.     

Catalytic reduction of NH4NO3 by NO: Effects of solid acids and implications for low temperature DeNOx processes

Ammonium nitrate is thermally stable below 250 °C and could potentially deactivate low temperature NO_x reduction catalysts by blocking active sites. It is shown that NO reduces neat NH₄NO₃ above its 170 °C melting point, while acidic solids catalyze this reaction even at temperatures below 100 °C. NO₂, a product of the reduction, can dimerize and then dissociate in molten NH₄NO₃ to NO⁺ + NO₃⁻, and may be stabilized within the melt as either an adduct or as HNO₂ formed from the hydrolysis of NO⁺ or N₂O₄. The other product of reduction, NH₄NO₂, readily decomposes at ≤100 °C to N₂ and H₂O, the desired end products of DeNO_x catalysis. A mechanism for the acid catalyzed reduction of NH₄NO₃ by NO is proposed, with HNO₃ as an intermediate. These findings indicate that the use of acidic catalysts or promoters in DeNO_x systems could help mitigate catalyst deactivation at low operating temperatures (<150 °C).     

Novel promoting effect of SO2 on the selective catalytic reduction of NOx by ammonia over Co3O4 catalyst

Spinel nano-Co₃O₄ was prepared by solid-state reaction at room temperature and investigated for selective catalytic reduction of NO_x by NH₃ (NH₃-SCR). Although suffering from pore filling and plugging, treatment of this catalyst by SO₂ showed novel promoting effect on NH₃-SCR above 250 °C. Bulk cobalt sulfate was observed over the sulfated Co₃O₄ with XRD, which would be an active component for NH₃-SCR. The sulphated Co₃O₄ catalyst exhibited good resistance to SO₂ (500 ppm, 100 ppm) and 10% H₂O at a space velocity of about 25 000 h⁻¹ at 300 °C, as tested for 12 h.     

Selective Catalytic Reduction of NOx over H-ZSM-5 Under Lean Conditions Using Transient NH3 Supply

The selective catalytic reduction (SCR) of NO _x over zeolite H-ZSM-5 with ammonia was investigated using in situ FTIR spectroscopy and flow reactor measurements. The adsorption of ammonia and the reaction between NO _x , O₂ and either pre-adsorbed ammonia or transiently supplied ammonia were investigated for either NO or equimolar amounts of NO and NO₂. With transient ammonia supply the total NO reduction increased and the selectivity to N₂O formation decreased compared to continuous supply. The FTIR experiments revealed that NO _x reacts with ammonia adsorbed on Brønsted acid sites as NH₄ ⁺ ions. These experiments further indicated that adsorbed -NO₂ ^– is formed during the SCR reaction over H-ZSM-5.     

Electrical properties of V2O5–WO3/TiO2 EUROCAT catalysts evidence for redox process in selective catalytic reduction (SCR) deNOx reaction

Electrical conductivity measurements on EUROCAT V₂O₅–WO₃/TiO₂ catalyst and on its precursor without vanadia were performed at 300°C under pure oxygen to characterize the samples, under NO and under NH₃ to determine the mode of reactivity of these reactants and under two reaction mixtures ((i) 2000 ppm NO + 2000 ppm NH₃ without O₂, and (ii) 2000 ppm NO + 2000 ppm NH₃ + 500 ppm O₂) to put in evidence redox processes in SCR deNO_x reaction.It was first demonstrated that titania support contains certain amounts of dissolved W⁶⁺ and V⁵⁺ ions, whose dissolution in the lattice of titania creates an n-type doping effect. Electrical conductivity revealed that the so-called reference pure titania monolith was highly doped by heterovalent cations whose valency was higher than +4. Subsequent chemical analyses revealed that so-called pure titania reference catalyst was actually the WO₃/TiO₂ precursor of V₂O₅–WO₃/TiO₂ EUROCAT catalyst. It contained an average amount of 0.37 at.% W⁶⁺dissolved in titania, i.e. 1.07 × 10²⁰ W⁶⁺ cations dissolved/cm³ of titania. For the fresh catalyst, the mean amounts of W⁶⁺ and V⁵⁺ ions dissolved in titania were found to be equal to 1.07 × 10²⁰ and 4.47 × 10²⁰ cm⁻³, respectively. For the used catalyst, the mean amounts of W⁶⁺ and V⁵⁺ ions dissolved were found to be equal to 1.07 × 10²⁰ and 7.42 × 10²⁰ cm⁻³, respectively. Since fresh and used catalysts have similar compositions and similar catalytic behaviours, the only manifestation of ageing was a supplementary progressive dissolution of 2.9 × 10²⁰ additional V⁵⁺ cations in titania.After a prompt removal of oxygen, it appeared that NO alone has an electron acceptor character, linked to its possible ionosorption as NO⁻ and to the filling of anionic vacancies, mostly present on vanadia. Ammonia had a strong reducing behaviour with the formation of singly ionized vacancies. A subsequent introduction of NO indicated a donor character of this molecule, in opposition to its first adsorption. This was ascribed to its reaction with previously adsorbed ammonia strongly bound to acidic sites. Under NO + NH₃ reaction mixture in the absence of oxygen, the increase of electrical conductivity was ascribed to the formation of anionic vacancies, mainly on vanadia, created by dehydroxylation and dehydration of the surface. These anionic vacancies were initially subsequently filled by the oxygen atom of NO. N^o atoms, resulting from the dissociation of NO and from ammonia dehydrogenation, recombined into dinitrogen molecules. The reaction corresponded to

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. In the presence of oxygen, NO did not exhibit anymore its electron acceptor character, since the filling of anionic vacancies was performed by oxygen from the gas phase. NO reacted directly with ammonia strongly bound on acidic sites. A tentative redox mechanism was proposed for both cases.     

Transient TPSR, DRIFTS-MS and TGA studies of a Pd/ceria-zirconia catalyst in CH4 and NO2 atmospheres

In this study, the parameters governing the activity of Pd/ceria-zirconia catalysts in the selective catalytic reduction (SCR) of NO_x assisted by methane are investigated using a combination of temperature-programmed spectroscopic and thermogravimetric techniques and transient SCR conditions. By DRIFTS of adsorbed CO, it is established that Pd species on Ce_0.2Zr_0.8O₂ are mainly present in cationic form but exhibit high reducibility. As found by temperature-programmed surface reaction (TPSR) in CH₄ + NO₂ atmosphere, the CH₄-SCR reaction is initiated at 280 °C on Pd/Ce_0.2Zr_0.8O₂ and yields almost 100% N₂ above 500 °C. DRIFTS-MS and TGA experiments performed under transient SCR conditions show that DeNO_x activity is due to a surface reaction between some methane oxidation products on reduced Pd sites with ad-N_xO_y species presumably located on the support. The detrimental effect of O₂ on DeNO_x is explained by the promotion of the total combustion of methane assisted by the ceria-zirconia component at the expense of the SCR reaction above 320 °C.     

Exceptional Activity for NOx Reduction at Low Temperatures Using Combinations of Hydrogen and Higher Hydrocarbons on Ag/Al2O3 Catalysts

The effect of the addition of hydrogen on the SCR of NO _x with a hydrocarbon reaction was investigated. It was found that hydrogen had a remarkable effect on the temperature range over which NO _x could be reduced during the SCR reaction with octane. Reduction of NO _x was initiated at as low a temperature as 100 °C and >95% NO _x conversion was achieved over a temperature range of 200–450 °C. Hydrogen has the effect of activating octane at lower temperatures and also promotes the oxidation of NO to NO₂ in the absence of hydrocarbon. Transient kinetic and in situ DRIFTS measurements indicated that hydrogen has a direct role in the reaction mechanism by either promoting the formation and storage of an organic C = N species which can then readily reduce NO _x and/or removing a species which acts as a poison to the SCR reaction at low temperatures.     

Effect of composition and promoters in Au/TS-1 catalysts for direct propylene epoxidation using H2 and O2

A series of Au/titanium silicalite-1 (TS-1) catalysts with different Si/Ti ratios and promoted with alkali and alkaline earth cations were prepared by deposition–precipitation (DP) and tested for direct propylene epoxidation. It was found that the gold loading and catalytic activity was highly dependent on the pH of the DP synthesis solution and the final composition of the catalyst. Addition of Group 1 metals such as K or Cs had little effect on the gold content, but increased activity, while Group 2 metals such as Mg, Ca, Sr, and Ba increased both the gold content and the catalytic activity. The highest improvement was provided by a Mg promoted catalyst, which at 443 K and 0.1 MPa with a H₂/O₂/C₃H₆/Ar = 1/1/1/7 feed mixture gave a propylene oxide (PO) formation rate of 88 gPO h⁻¹ kg_cat⁻¹, compared to 57 gPO h⁻¹ kg_cat⁻¹ for an unpromoted catalyst, corresponding to a 50% enhancement of activity. Ammonia temperature-programmed desorption (NH₃-TPD) measurements indicated little change in adsorption amount with promotion indicating that the yield increase was not due to the elimination of acidic sites on the catalyst. Instead, the improved catalytic performance was ascribed to increased Au capture efficiency and dispersion by the catalyst. The effect of Si/Ti ratio, pH of synthesis, and the promoter ions on the gold content could be understood from their effect on the surface charge of the support.     

Influence of reaction products of K-getter fuel additives on commercial vanadia-based SCR catalysts: Part II. Simultaneous addition of KCl, Ca(OH)2, H3PO4 and H2SO4 in a hot flue gas at a SCR pilot-scale setup

A commercial V₂O₅–WO₃–TiO₂ corrugated-type SCR monolith has been exposed for 1000 h in a pilot-scale setup to a flue gas doped with KCl, Ca(OH)₂, H₃PO₄ and H₂SO₄ by spraying a water solution of the components into the hot flue gas. The mixture composition has been adjusted in order to have P/K and P/Ca ratios equal to 2 and 0.8, respectively. At these conditions, it is suggested that all the K released during biomass combustion gets captured in P–K–Ca particles and the Cl is released in the gas phase as HCl, thus limiting deposition and corrosion problems at the superheater exchangers during biomass combustion. Aerosol measurements carried out by using a SMPS and a low pressure cascade impactor have shown two distinct particle populations with volume-based mean diameters equal to 12 and 300 nm, respectively. The small particles have been associated to polyphosphoric acids formed by condensation of H₃PO₄, whereas the larger particles are due to P–K–Ca salts formed during evaporation of the water solution. No Cl has been found in the collected particles. During the initial 240 h of exposure, the catalyst element lost about 20% of its original activity. The deactivation then proceeded at slower rates, and after 1000 h the relative activity loss had increased to 25%. Different samples of the spent catalyst have been characterized after 453 h and at the end of the experiment by bulk chemical analysis, Hg-porosimetry and SEM-EDX. NH₃-chemisorption tests on the spent elements and activity tests on catalyst powders obtained by crushing the monolith have also been carried out. From the characterization, it was found that neither K nor Ca were able to penetrate the catalyst walls, but only accumulated on the outer surface. Poisoning by K has then been limited to the most outer catalyst surface and did not proceed at the fast rates known for KCl. This fact indicates that binding K in P–K–Ca compounds is an effective way to reduce the negative influence of alkali metals on the lifetime of the vanadia-based SCR catalysts. On the other hand, P-deposition was favoured by the formation of the polyphosphoric acids, and up to 1.8 wt% P was accumulated in the catalyst walls. Deactivation by polyphosphoric acids proceeded at about 0.2% day⁻¹. About 6–7% of the initial activity was lost due to the accumulation of these species. However, the measured relative activity reached a steady-state level during the last 240 h of exposure indicating that the P-concentration in the bulk reached a steady-state level due to the simultaneous hydrolysis of the polyphosphoric acids.     

Adsorption and oxidation of NH3 over V2O5/AC surface

V₂O₅/AC has been reported to be active for selective catalytic reduction (SCR) of NO with NH₃ at around 200 °C and resistant to SO₂ deactivation. To elucidate its SCR mechanism, adsorption and oxidation of NH₃ over V₂O₅/AC are studied in this paper using TG, MS and DRIFTS techniques. It is found that the adsorption and oxidation of NH₃ take place mainly at VO bond of V₂O₅. A higher V₂O₅ loading results in more NH₃ adsorption on the catalyst. V₂O₅ contains both Brnsted and Lewis acid sites; NH₄⁺ on Brnsted acid sites is less stable and easier to be oxidized than NH₃ on Lewis acid sites. Gaseous O₂ promotes interaction of NH₃ with AC and oxidation of NH₃ over V₂O₅/AC. NH₃ is oxidized into NH₂ and acylamide structures and then to isocyanate species, which is an intermediate for N₂ formation.     

Ceria modified MnOx/TiO2 as a superior catalyst for NO reduction with NH3 at low-temperature

A series of cerium modified MnOx/TiO₂ catalysts were prepared by sol–gel method and used for low-temperature selective catalytic reduction (SCR) of NOx with ammonia. The experimental results showed that NO conversion could be improved by doping Ce from 39% to 84% at 80 °C with a gas hourly space velocity (GHSV) of 40,000 h⁻¹. This activity improvement may be contributed to the increase of chemisorbed oxygen and acidity after Ce doping. TPR results also verified that the redox property of Ce modified MnOx/TiO₂ was enhanced at low-temperature.     

Low-temperature synthesis of La0.6Sr0.4Co0.2Fe0.8O3−δ perovskite powder via asymmetric sol–gel process and catalytic auto-combustion

La_0.6Sr_0.4Co_0.2Fe_0.8O_3−δ powder was synthesized by a combined EDTA-citrate complexing process via low-temperature auto-combustion synthesis with NH₄NO₃ as an oxidizer and a combustion trigger. Two novel methods were explored to improve this auto-combustion technology with reduced NH₄NO₃ addition: the use of La_0.6Sr_0.4Co_0.2Fe_0.8O_3−δ as the combustion catalyst and the application of asymmetric sol–gel process to provide the precursor with different NH₄NO₃ concentrations. The prepared perovskite powder was characterized by BET, SEM, XRD and iodometric titration techniques. The catalytic performance of the powder was also examined in the decomposition of peroxide hydrogen. Experimental results indicate that powders from catalytic combustion and asymmetric precursor routes have more advantages in terms of better crystallites, higher specific surface area, higher B-site valence state, improved sintering capability and better catalytic performance in peroxide hydrogen decomposition than that from the synthesis with uniform NH₄NO₃ distribution.     

A kinetic model for ammonia selective catalytic reduction over Cu-ZSM-5

Kinetic modeling, in combination with flow reactor experiments, was used in this study for simulating NH₃ selective catalytic reduction (SCR) of NO_x over Cu-ZSM-5. First the mass-transfer in the wash-coat was examined experimentally, by using two monoliths: one with 11 wt.% wash-coat and the other sample with 23 wt.% wash-coat. When the ratio between the total flow rate and the wash-coat amount was kept constant similar results for NO_x conversion and NH₃ slip were obtained, indicating no significant mass-transfer limitations in the wash-coat layer. A broad range of experimental conditions was used when developing the model: ammonia temperature programmed desorption (TPD), NH₃ oxidation, NO oxidation, and NH₃ SCR experiments with different NO-to-NO₂ ratios. 5% water was used in all experiments, since water affects the amount of ammonia stored and also the activity of the catalyst. The kinetic model contains seven reaction steps including these for: ammonia adsorption and desorption, NH₃ oxidation, NO oxidation, standard SCR (NO + O₂ + NH₃), rapid SCR (NO + NO₂ + NH₃), NO₂ SCR (NO₂ + NH₃) and N₂O formation. The model describes all experiments well. The kinetic parameters and 95% linearized confidence regions are given in the paper. The model was validated with six experiments not included in the kinetic parameter estimation. The ammonia concentration was varied from 200 up to 800 ppm using NO only as a NO_x source in the first experiment and 50% NO and 50% NO₂ in the second experiment. The model was also validated with transient experiments at 175 and 350 °C where the NO and NH₃ concentrations were varied stepwise with a duration of 2 min for each step. In addition, two short transient experiments were simulated where the NO₂ and NO levels as well as NO₂-to-NO_x ratio were varied. The model could describe all validation experiments very well.     

NO reduction with H2 in the presence of excess O2 over Pd/MFI catalyst

The NO SCR (selective catalytic reduction) activity with H₂ in the presence of excess O₂ was investigated over Pd/MFI catalyst prepared by sublimation method. With GHSV=90?000 h⁻¹, a very high steady-state conversion of NO to N₂ (70%) is achieved at 100 °C. Significant reorganizations take place inside the catalyst upon its first contact with all reactants and products at the reaction temperature. Pd⁰, which has a significant role in the NO-H₂-O₂ reaction, is possibly the active site for NO reduction. The formation of Pd-β hydride deactivates the catalyst for NO reduction. Throughout the entire NO-H₂-O₂ reaction, no N₂O or NO₂ is formed; N₂ is the only N-containing product. The presence of O₂ inhibits the formation of undesirable NH₃. The rate of the NO+H₂ reaction is fast or comparable to that of the H₂+O₂ reaction. The oxidation of Pd⁰ and subsequent agglomeration of PdO are responsible for the decreased NO reduction activity at high temperature.     

Electrochemical promotion of a platinum catalyst supported on the high-temperature proton conductor La0.99Sr0.01NbO4−δ

The recently discovered, high-temperature proton conductor, La_0.99Sr_0.01NbO_4−δ, was used as a support for the electrochemical promotion of a platinum catalyst. Ethylene oxidation was used as a probe reaction in the temperature range 350–450 °C. Moderate non-Faradaic rate modification, attributable to a protonic promoting species, occurred under negative polarisation; some permanent promotion was also observed. In oxidative atmospheres, both the p_O2 of the reaction mixture and the temperature influenced the type and magnitude of the observed rate modification. Rate-enhancement values of up to ρ = 1.4 and Faradaic-efficiency values approaching Λ = −100 were obtained. Promotion was observed under positive polarisation and relatively dry, oxygen-rich atmospheres suggesting that some oxygen ion conductivity may occur under these conditions. Impedance spectroscopy performed in atmospheres of 4 kPa O₂/N₂ and of 5 kPa H₂/N₂ under dry and slightly humidified (0.3 kPa H₂O) conditions indicated that the electrical resistivity is heavily dominated by the grain-boundary response in the temperature range of the EPOC studies; much lower grain-boundary impedances in the wetter conditions are likely to be attributable to proton transport.     

Influence of composition of MgAl2O4 supported NiCeO2ZrO2 catalysts on coke formation and catalyst stability for dry reforming of methane

Dry reforming of methane was studied over Ni catalysts supported on γAl₂O₃, CeO₂, ZrO₂ and MgAl₂O₄ (670 °C, 1.5 bar, 16–20 l CH₄ ml_catalyst⁻¹ h⁻¹). It is shown that MgAl₂O₄ supported Ni catalysts promoted with both CeO₂ and ZrO₂ are promising catalysts for dry reforming of methane with carbon dioxide. Within a certain composition range, the simultaneous promotion with CeO₂ and ZrO₂ has great influence on the amount of coke and the catalyst service time. XRD analyses indicate that formation of crystalline Ce_xZr_1−xO₂ mixed oxide phases occurs on double promotion. In particular, incorporation of low amounts of Zr in the CeO₂ fluorite structure provides stable dry reforming catalysis. As shown with TPR, promotion leads to a higher reduced state of Ni. SEM, XRD and TPR analyses demonstrate that highly dispersed, doubly promoted Ni catalysts with a strong metal-support interaction are essential for stable dry reforming and suppression of the formation of carbon filaments.     

Computational study of B- or N-doped single-walled carbon nanotubes as NH3 and NO2 sensors

The adsorption of NH₃ and NO₂ in B- or N-doped (10, 0) single-walled carbon nanotubes (SWCNTs) was investigated by using density functional computations to exploit their potential applications as gas sensors. NH₃ can be chemisorbed only in B-doped SWCNTs with apparent charge transfer, so B-doped SWCNTs can be used as NH₃ sensors. Both B- and N-doping make NO₂ chemisorption feasible in SWCNTs, but the binding of NO₂ with B is too strong, indicating an impractical recovery time as gas sensors. Due to the medium (optimal) adsorption energy and the conductance reduction accompanied with the charge transfer between SWCNTs and gas molecules, N-doped SWCNTs are potentially good NO₂ sensors.     

Effect of Co and Rh promoter on NOx storage and reduction over Pt/BaO/Al2O3 catalyst

Effect of cobalt and rhodium promoter on NO_x storage and reduction (NSR) kinetics was investigated over Pt/BaO/Al₂O₃. Kinetics of 2% cobalt loading over Pt/BaO/Al₂O₃ demonstrated highest NO_x uptake during lean cycle, while reduction efficiency during rich cycle appeared most poor. In contrast to this, rhodium showed suppressing effect of NO_x uptake during lean cycle and demonstrated an enhanced effect for the higher efficiency of NO_x reduction during rich cycle. DRIFT study for NO_x uptake and regeneration confirmed formation of surface BaNO_x from the band at 1300 cm⁻¹ and formation of bulk BaNO_x from the band at 1330 cm⁻¹.