Deactivation of V2O5-WO3-TiO2 SCR catalyst at biomass fired power plants: Elucidation of mechanisms by lab- and pilot-scale experiments

In this work, deactivation of a commercial type V₂O₅-WO₃-TiO₂ catalyst by aerosols of potassium compounds was investigated in two ways: (1) by exposing the catalyst in a lab-scale reactor to a layer of KCl particles or fly ash from biomass combustion; (2) by exposing full-length monolith catalysts to pure KCl or K₂SO₄ aerosols in a bench-scale reactor. Exposed samples were characterized by activity measurements, SEM-EDX, BET/Hg-porosimetry, and NH₃ chemisorption. The work was carried out to support the interpretation of observations of a previous study in which catalysts were exposed on a full-scale biomass fired power plant and to reveal the mechanisms of catalyst deactivation.Slight deactivation (about 10%) was observed for catalyst plates exposed to a layer of KCl particles at 350 °C for 2397 h. No deactivation was found for catalyst plates exposed for 2970 h to fly ash (consisting mainly of KCl and K₂SO₄) collected from an SCR pilot plant installed on a straw-fired power plant. A fast deactivation was observed for catalysts exposed to pure KCl or K₂SO₄ aerosols at 350 °C in the bench-scale reactor. The deactivation rates for KCl aerosol and K₂SO₄ aerosol exposed catalysts were about 1% per day and 0.4% per day, respectively.SEM analysis of potassium-containing aerosol exposed catalysts revealed that the potassium salt partly deposited on the catalyst outer wall which may decrease the diffusion rate of NO and NH₃ into the catalyst. However, potassium also penetrated into the catalyst wall and the average K/V ratios (0.5–0.75) in the catalyst structure are high enough to explain the level of deactivation observed. The catalyst capacity for NH₃ chemisorption decreased as a function of exposure time, which reveals that Brønsted acid sites had reacted with potassium compounds and thereby rendered inactive in the catalytic cycle. The conclusion is that chemical poisoning of active sites is the dominating deactivation mechanism, but physical blocking of the surface area may also contribute to the loss of activity in a practical application. The results support the observation and mechanisms of deactivation of SCR catalysts in biomass fired systems proposed in a previous study [Y. Zheng, A.D. Jensen, J.E. Johnsson, Appl. Catal. B 60 (2005) 253].     

Preparation and electrochemical performance studies on Cr-doped Li3V2(PO4)3 as cathode materials for lithium-ion batteries

Cr-doped Li₃V_2−xCr_x(PO₄)₃/C (x = 0, 0.05, 0.1, 0.2, 0.5, 1) compounds have been prepared using sol–gel method. The Rietveld refinement results indicate that single-phase Li₃V_2−xCr_x(PO₄)₃/C with monoclinic structure can be obtained. Although the initial specific capacity decreased with Cr content at a lower current rate, both cycle performance and rate capability have excited improvement with moderate Cr-doping content in Li₃V_2−xCr_x(PO₄)₃/C. Li₃V_1.9Cr_0.1(PO₄)₃/C compound presents an initial capacity of 171.4 mAh g⁻¹ and 78.6% capacity retention after 100 cycles at 0.2C rate. At 4C rate, the Li₃V_1.9Cr_0.1(PO₄)₃/C can give an initial capacity of 130.2 mAh g⁻¹ and 10.8% capacity loss after 100 cycles where the Li₃V₂(PO₄)₃/C presents the initial capacity of 127.4 mAh g⁻¹ and capacity loss of 14.9%. Enhanced rate and cyclic capability may be attributed to the optimizing particle size, carbon coating quality, and structural stability during the proper amount of Cr-doping (x = 0.1) in V sites.     

NOx reduction performance of lean NOx catalyst and lean NOx adsorber using DME as reducing agent

The deactivation of a commercial Selective Catalytic Reduction (SCR) catalyst, of V₂O₅−WO₃/TiO₂ type, has been studied through comparisons with results from a full-scale biomass combustion plant to that with laboratory experiments. In the latter, the catalyst was exposed to KCl and K₂SO₄ by both wet impregnation with diluted salt solutions and deposition of generated submicrometer aerosol particles by means of an electrostatic field. The reactivity of fresh and deactivated samples was examined in the SCR reaction. Chemical and physical characterizations were focusing on internal structures and chemical composition. Deposition of submicrometer sized particles on the monolithic SCR catalyst was shown to induce deactivation with characteristics resembling those obtained in a commercial biomass combustion plant.     

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.     

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).     

NOx storage behavior and sulfur-resisting performance of the third-generation NSR catalysts Pt/K/TiO2–ZrO2

The NO_x storage and reduction (NSR) catalysts Pt/K/TiO₂–ZrO₂ were prepared by an impregnation method. The techniques of XRD, NH₃-TPD, CO₂-TPD, H₂-TPR and in situDRIFTS were employed to investigate their NO_x storage behavior and sulfur-resisting performance. It is revealed that the storage capacity and sulfur-resisting ability of these catalysts depend strongly on the calcination temperature of the support. The catalyst with theist support calcined at 500 °C, exhibits the largest specific surface area but the lowest storage capacity. With increasing calcination temperature, the NO_x storage capacity of the catalyst improves greatly, but the sulfur-resisting ability of the catalyst decreases. In situ DRIFTS results show that free nitrate species and bulk sulfates are the main storage and sulfation species, respectively, for all the catalysts studied. The CO₂-TPD results indicate that the decomposition performance of K₂CO₃ is largely determined by the surface property of the TiO₂–ZrO₂ support. The interaction between the surface hydroxyl of the support and K₂CO₃ promotes the decomposition of K₂CO₃ to form –OK groups bound to the support, leading to low NO_x storage capacity but high sulfur-resisting ability, while the interaction between the highly dispersed K₂CO₃ species and Lewis acid sites gives rise to high NO_x storage capacity but decreased sulfur-resisting ability. The optimal calcination temperature of TiO₂–ZrO₂ support is 650 °C.     

Electrochemical performance of Li3V2(PO4)3/C cathode material using a novel carbon source

Polyethylene glycol (PEG, mean molecular weight of 10,000) has been used to prepare a Li₃V₂(PO₄)₃/C cathode material by a simple solid-state reaction. The Raman spectra shows that the coating carbon has a good structure with a low I_D/I_G ratio. The images of SEM and TEM show that the carbon is dispersed between the Li₃V₂(PO₄)₃ particles, which improves the electrical contact between the corresponding particles. The electronic conductivity of Li₃V₂(PO₄)₃/C composite is 7.0 × 10⁻¹ S/cm, increased by seven orders of magnitude compared with the pristine Li₃V₂(PO₄)₃ (2.3 × 10⁻⁸ S/cm). At a low discharge rate of 0.28C, the sample presents a high discharge capacity of 131.2 mAh/g, almost achieving the theoretical capacity (132 mAh/g) for the reversible cycling of two lithium. After 500 cycles, the discharge capacity is 123.9 mAh/g with only 5.6% fading of the initial specific capacity. The Li₃V₂(PO₄)₃/C material also exhibits an excellent rate capability with high discharge capacities of 115.2 mAh/g at 1C and 106.4 mAh/g at 5C.     

The performances of higher alcohol synthesis over nickel modified K2CO3/MoS2 catalyst

Ni modified K₂CO₃/MoS₂ catalyst was prepared and the performance of higher alcohol synthesis catalyst was investigated under the conditions: T = 280–340 °C, H₂/CO (molar radio) = 2.0, GHSV = 3000 h^− 1, and P = 10.0 MPa. Compared with conventional K₂CO₃/MoS₂ catalyst, Ni/K₂CO₃/MoS₂ catalyst showed higher activity and higher selectivity to C₂⁺OH. The optimum temperature range was 320–340 °C and the maximum space-time yield (STY) of alcohol 0.30 g/ml h was obtained at 320 °C. The selectivity to hydrocarbons over Ni/K₂CO₃/MoS₂ was higher, however, it was close to that of K₂CO₃/MoS₂ catalyst as the temperature increased. The results indicated that nickel was an efficient promoter to improve the activity and selectivity of K₂CO₃/MoS₂ catalyst.     

Improvement of coke resistance of Ni/Al2O3 catalyst in CH4/CO2 reforming by ZrO2 addition

This work investigates the improvement of Ni/Al₂O₃ catalyst stability by ZrO₂ addition for H₂ gas production from CH₄/CO₂ reforming reactions. The initial effect of Ni addition was followed by the effect of increasing operating temperature to 500–700 °C as well as the effect of ZrO₂ loading and the promoted catalyst preparation methods by using a feed gas mixture at a CH₄:CO₂ ratio of 1:1.25. The experimental results showed that a high reaction temperature of 700 °C was favored by an endothermic dry reforming reaction. In this reaction the deactivation of Ni/Al₂O₃ was mainly due to coke deposition. This deactivation was evidently inhibited by ZrO₂, as it enhances dissociation of CO₂ forming oxygen intermediates near the contact between ZrO₂ and nickel where the deposited coke is gasified afterwards. The texture of the catalyst or BET surface area was affected by the catalyst preparation method. The change of the catalyst texture resulted from the formation of ZrO₂–Al₂O₃ composite and the plugging of Al₂O₃ pore by ZrO₂. The 15% Ni/10% ZrO₂/Al₂O₃ co-impregnated catalyst showed a higher BET surface area and catalytic activity than the sequentially impregnated catalyst whereas coke inhibition capability of the promoted catalysts prepared by either method was comparable. Further study on long-term catalyst stability should be made.     

Autothermal reforming of ethanol for hydrogen production over an Rh/CeO2 catalyst

Hydrogen production from ethanol by autothermal reforming over an Rh/CeO₂ catalyst was investigated with a stoichiometric feed composition. Ethanol as well as the reaction intermediates like acetaldehyde and acetone was entirely converted to hydrogen and C1 products at 673 K, and methane steam reforming and reverse water gas shift were the major reactions above 823 K. The Rh/CeO₂ catalyst exhibited stable activity and selectivity during 70 h on-stream operation at 823–923 K without obvious deactivation evidenced by the constant effluent gas composition. Structural analysis of the used catalyst revealed that CeO₂ prevented effectively the highly dispersed Rh particles with sizes of 1–3 nm from sintering and thus maintained sufficient Rh–CeO₂ interfacial areas, which facilitated coke gasification through the high oxygen storage-release capacity.     

Surface properties and catalytic performance of La1−xSrxCrO3 perovskite-type oxides for CO and C3H6 combustion

Catalytic CO oxidation and C₃H₆ combustion have been studied over La_1−xSr_xCrO₃ (x = 0.0–0.3) oxides prepared by solid-state reaction and characterised by X-ray diffraction (XRD), nitrogen adsorption (BET analysis) and X-ray photoelectron spectroscopy (XPS). The expected orthorhombic perovskite structure of the chromite is observed for all levels of substitution. However, surface segregation of strontium along with a chromium oxidation process, leading to formation of Cr⁶⁺-containing phases, is produced upon increasing x and shown to be detrimental to the catalytic activity. Maximum activity is achieved for the catalyst with x = 0.1 in which mixed oxide formation upon substitution of lanthanum by strontium in the chromite becomes maximised.     

Effect of CO2 in the feed stream on the deactivation of Co/γ-Al2O3 Fischer–Tropsch catalyst

The influence of CO₂ on the deactivation of Co/γ-Al₂O₃ Fischer–Tropsch (FT) catalyst in CO hydrogenation has been investigated. The presence of CO₂ in the feed stream reveals a negative effect on catalyst stability and in the formation of heavy hydrocarbons. The CO₂ acts as a mild oxidizing agent on cobalt metal during Fischer–Tropsch synthesis. During FT synthesis on Co/γ-Al₂O₃ of 70 h, the CO conversion and C₅₊ selectivity in the presence of CO₂ decreased more significantly than in the absence of CO₂. CO₂ is found to be responsible for the partial oxidation of surface cobalt metal at FT synthesis environment with the co-existence of generated water.     

Catalytic decomposition of alcohols over size-selected Pt nanoparticles supported on ZrO2: A study of activity, selectivity, and stability

This article discusses the performance of ZrO₂-supported size-selected Pt nanoparticles for the decomposition of methanol, ethanol, 2-propanol, and 2-butanol. The potential of each alcohol for the production of H₂ and other relevant products in the presence of a catalyst is studied in a packed-bed mass flow reactor operating at atmospheric pressure. All the alcohols studied show some decomposition activity below 200 °C which increased with increasing temperature. In all cases, high selectivity towards H₂ formation is observed. With the exception of methanol, all alcohol conversion reactions lead to catalyst deactivation at high temperatures (T > 250 °C for 2-propanol and 2-butanol, T > 325 °C for ethanol) due to carbon poisoning. However, long-term catalyst deactivation can be avoided by optimizing reaction conditions such as operating temperature.     

Liquid phase selective hydrogenation of phthalic anhydride to phthalide over titania supported gold catalysts

Au/TiO₂ catalysts with different gold loadings were prepared by deposition–precipitation method and used for the liquid phase hydrogenation of phthalic anhydride. All the studied Au/TiO₂ catalysts exhibited excellent activity with high selectivity (>92%) to phthalide under mild reaction conditions (180 °C and 3.0 MPa H₂). Specially, catalysts with 2–3 wt.% gold loading were highly active and selective for the formation of phthalide. When reused, the catalyst showed a certain deactivation, but still was highly selective to phthalide. The deactivation was attributed to the leaching of gold, collapse of the pore structure and accumulation of organic species on the surface.     

Highly efficient complete oxidation of dilute benzene over ultrafine Cu0.1Ce0.5Zr0.4O2−δ catalyst in a fluidized bed reactor

Ultrafine Cu_0.1Ce_0.5Zr_0.4O_2−δ catalyst operated in a fluidized bed reactor was found to be very effective for complete oxidation of dilute benzene in air. The complete conversion of benzene could be achieved at reaction temperature as low as 220 °C. The mechanism of benzene oxidation over the Cu_0.1Ce_0.5Zr_0.4O_2−δ catalyst was investigated by conducting pulse reaction of pure benzene in the absence of O₂ over the catalyst and the results indicated the involvement of lattice oxygen from the catalyst in benzene oxidation.     

Synthesis and Characterization of Nanostructure BPO4

Boron phosphate (BPO₄) is a well known catalyst for a range of organic chemical reactions. In this paper, we report the preparations and characterizations of nano-sized BPO₄ and nano-BPO₄-based core-shell spheres. The samples were synthesized hydrothermally using H₃BO₃, H₃PO₄ and short chain n-alkylamines (n = 3, 4) as starting materials. The resulting products were characterized by powder X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FT-IR), scan electron microscopy (SEM) and transmission electron microscopy (TEM), respectively. A possible mechanism for the formation of the materials is also discussed.     

Deterioration Mode of Barium-Containing NOx Storage Catalyst

Barium-containing NO _x storage catalyst showed serious deactivation under thermal exposure at high temperatures. To elucidate the thermal deterioration of the NO _x storage catalyst, four types of model catalyst, Pt/Al₂O₃, Ba/Al₂O₃, Pt–Ba/Al₂O₃, and a physical mixture of Pt/Al₂O₃ + Ba/Al₂O₃ were prepared and their physicochemical properties such as BET, NO TPD, TGA/DSC, XRD, and XPS were evaluated while the thermal aging temperature was increased from 550 to 1050°C. The fresh Pt–Ba/Al₂O₃ showed a sorption capacity of 3.35 wt%/g-cat. but the aged one revealed a reduced capacity of 2.28 wt%/g-cat. corresponding to 68% of the fresh one. It was found that this reduced sorption capacity was directly related to the deterioration of the NO _x storage catalyst by thermal aging. The Ba on Ba/Al₂O₃ and Pt–Ba/Al₂O₃ catalysts began to interact with alumina to form Ba–Al solid alloy above 600°C and then transformed into stable BaAl₂O₄ having a spinel structure. However, no phase transition was observed in the Pt/Al₂O₃ catalyst having no barium component, even after aging at 1050°C.     

Sintering of aluminum nitride by using alumina crucible and MoSi2 heating element at temperatures of 1650 °C and 1700 °C

Aluminum nitride (AlN) ceramics, prepared with Y₂O₃ and CaO sintering additives, have been densified in an Al₂O₃ crucible at temperatures of up to 1650 °C and 1700 °C using a conventional MoSi₂ heating element furnace. The results of this study show that relative densities in excess of 99% of theoretical and a relatively high-thermal conductivity of 147 W m⁻¹ K⁻¹ have been achieved for feedstock materials prepared with combined addition of 1 wt.% Y₂O₃ and 1 wt.% CaO. All of the phases in sintered samples have been shown to be crystalline AlN and minor amount of secondary phases, were detected such as enriched Y- and Ca-aluminates by the XRD patterns, back-scattered imagery and microprobe analysis. The advantage of using the particular experimental system and sintering condition is considered to be amenable to lower production cost and enhance the feasibility of mass production. Critical temperature for AlN densification to obtain the highest density is about 1650 °C.     

A VOx/meso-TiO2 catalyst for methanol oxidation to dimethoxymethane

Mesoporous TiO₂ was prepared by simply controlling the hydrolysis of Ti(OBu)₄ with the help of acetic acid. The mesoporous TiO₂ had a well-crystallized anatase phase and a high surface area of 290 m² g⁻¹ with a pore size of about 4 nm. The anatase phase and the mesoporous structure were maintained in the VO_x/TiO₂ catalyst with a monolayer dispersion of V₂O₅, however, the surface area decreased to 126 m² g⁻¹. The catalyst was highly active and selective for methanol oxidation, giving about 55% conversion of methanol and 85% selectivity to dimethoxymethane at 423 K.