Engineering HC-SCR: Improved Low Temperature Performance through a Cascade Concept

A catalytic after treatment system for lean HC-SCR was constructed of two different catalyst beds, e.g. of a Ag/alumina and Cu-ZSM-5 catalyst (cascade concept). The improved activity especially at low temperature range was found to be due to the synergetic effect of the two catalysts, which combines the transformation of the feed gas over Ag/alumina to such compounds that are highly reactive towards N₂ over Cu-ZSM-5. The effluent coming from the Ag/alumina bed was analysed by GC–MS along with the NO to N₂ conversion over the whole system by GC. The results obtained from the GC–MS measurements revealed that hydrocarbon used as a reducing agent is oxidised and that besides oxygenates also various N-containing hydrocarbons are formed over the Ag/Al₂O₃.     

Characterization of highly active silver catalyst for NOx reduction in lean-burning engine exhaust

A new Ag/Al₂O₃ catalyst for removing NOx in lean exhaust gas was developed. Oxidized Ag/Al₂O₃ catalyst is highly active for reduction of NOx with ethanol and propene, whereas reduced Ag/Al₂O₃ catalyst is less active for these reactions. Selectivity to N₂ is also high on the oxidized Ag/Al₂O₃ compared to that on the reduced Ag/Al₂O₃. XRD and SEM studies of these two types of Ag catalysts suggest that oxidation induces an interaction between Ag and the support, where the particles are grown in large size. In contrast, the metallic Ag particles are finely dispersed by the reduction process. Although dispersion of Ag particles is decreased by the oxidation process, the catalytic activity is increased. This suggests that the Ag-alumina sites created in the high temperature oxidizing environment are active in catalytic reduction of NOx. This revised version was published online in July 2006 with corrections to the Cover Date.     

Catalytic activity of ethylene oxidation over Au,Ag and Au–Ag catalysts: Support effect

Au, Ag and Au–Ag catalysts on different supports of alumina, titania and ceria were studied for their catalytic activity of ethylene oxidation reactions. An addition of an appropriate amount of Au on Ag/Al₂O₃ catalyst was found to enhance the catalytic activity of the ethylene epoxidation reaction because Au acts as a diluting agent on the Ag surface creating new single silver sites which favor molecular oxygen adsorption. The Ag catalysts on both titania and ceria supports exhibited very poor catalytic activity toward the epoxidation reaction of ethylene, so pure Au catalysts on these two supports were investigated. The Au/TiO₂ catalysts provided the highest selectivity of ethylene oxide with relatively low ethylene conversion whereas, the Au/CeO₂ catalysts was shown to favor the total oxidation reaction over the epoxidation reaction at very low temperatures. In comparisons among the studied catalysts, the bimetallic Au–Ag/Al₂O₃ catalyst is the best candidate for the ethylene epoxidation. The catalytic activity of the gold catalysts was found to depend on the support material and catalyst preparation method which govern the Au particle size and the interaction between the Au particles and the support.     

Preparation of sulfated alumina supported on mesoporous MCM-41 silica and its application in esterification

New types of mesoporous SA/MCM-41 solid acid catalysts were prepared by loading sulfated alumina (SA) on MCM-41. The prepared catalysts were characterized by XRD, IR, N₂ physisorption, elemental analysis, FT-IR of adsorbed pyridine and NH₃-TPD. The esterification of acetic acid with n-butanol and citric acid with n-butanol were used as model reactions to test the catalytic activities and reusability of the SA/MCM-41 solid acid catalysts. Compared with SA catalyst, SA/MCM-41 catalysts exhibited higher catalytic performances, which were attributed to their high BET surface area and large pore volume. Moreover, 20SA/MCM-41 solid acid catalyst showed excellent reusability in both esterifications.     

A Highly Active Ag/Alumina Catalytic Converter for Continuous HC-SCR During Lean-Burn Conditions: From Laboratory to Full-Scale Vehicle Tests

A common-rail diesel vehicle was equipped with a full-scale Ag/alumina catalytic converter. The converter consisted of several Ag/alumina bricks, with free space in between each brick to fulfil important gas phase reactions. An oxidation catalyst was placed at the end of the converter to remove formed CO and unburned HC. High conversion levels of NO _x , around 60%, were recorded at several speeds and loads using additional HC (diesel) injection corresponding to 2–5% fuel penalty.     

Role of organic nitro compounds in selective reduction of NOx with ethanol over different supported silver catalysts

The adsorption of organic nitro compounds such as nitromethane and nitroethane on different supported silver catalysts (Ag/Al₂O₃, Ag/TiO₂, Ag/SiO₂) has been studied using infrared spectroscopy. The adsorbed NCO species formation was strongly influenced by the catalyst support and therefore clearly detected on Ag/Al₂O₃ and Ag/TiO₂ catalysts by thermal decomposition of nitromethane and nitroethane at temperatures higher than 150°C. With the Ag/SiO₂ catalyst, very little NCO formation was observed at 350°C. On the other hand, the catalyst support was found to affect the N₂ formation in the selective reduction of NO_x on supported silver catalysts. On the basis of these findings, the role of adsorbed nitromethane, nitroethane and isocyanate species in the selective reduction of NO_x is discussed with respect to the catalyst support effect and the catalytic activity. This revised version was published online in July 2006 with corrections to the Cover Date.     

Chemical and physical changes related to the deactivation of alumina used in catalytic epoxidation with hydrogen peroxide

This report addresses several questions regarding the deactivation of alumina in catalytic epoxidation using aqueous 70% H₂O₂. The structural, textural, morphological, and chemical changes of a polycrystalline alumina (γ-Al₂O₃ and boehmite) were studied in five consecutives reactions of 24 h. The chemical and physical processes involved in the transformations during alumina recycling are attributed mainly to the presence of water in the reaction mixture. Water plays a dual role in the catalytic system. On the one hand, water may cause deleterious changes of the structure of γ-Al₂O₃ and its textural properties. On the other hand, the presence of water shifts the adsorption equilibria of the organic molecules (acetic acid, diols, and oligomers), preserving the type Ia AlOH sites, which are active for catalytic epoxidation. In this way, the water in the alumina/H₂O₂ catalytic system seems to be significant in prolonging the lifetime of the catalyst.     

The role of silver species on Ag/Al2O3 catalysts for the selective catalytic oxidation of ammonia to nitrogen

The role of Ag species on Ag/Al₂O₃ catalyst for the selective catalytic oxidation (SCO) of NH₃ to N₂ was studied using 10 wt% Ag/Al₂O₃ catalysts prepared with impregnation, incipient wetness impregnation and sol–gel methods. The catalyst characterization was preformed using N₂ adsorption–desorption, UV/Vis, TEM and XRD. O₂-chemisorption and H₂–O₂ titration were measured to confirm the metal dispersion on the catalyst. The Ag species state and Ag particle size have significant influence on the Ag/Al₂O₃ activity and N₂ selectivity of the SCO of NH₃ at low temperature. Ag⁰ is proposed to be an active species on the H₂ pretreated catalyst at low temperature (<140 °C). It is evident that well-dispersed and small particle Ag⁰ enhances catalytic activity at low temperature, whereas large particle Ag⁰ is relate to a high N₂ selectivity. In contrast, Ag⁺ could also be the active species at temperatures above 140 °C.     

Controlling the Sulfur Poisoning of Ag/Al2O3 Catalysts for the Hydrocarbon SCR Reaction by Using a Regenerable SOx Trap

The deactivation of a silver-based hydrocarbon selective catalytic reduction catalyst by SO_x and the subsequent regeneration under various operating conditions has been investigated. Using a sulfur trap based on a silica-supported catalyst it was found that, for a Ag/SiO₂ + Ag/Al₂O₃ combination, the negative effect of SO₂ on the n-octane-SCR reaction can be eliminated under normal operating conditions. The trap can be regenerated by hydrogen at low temperatures or at higher temperatures using a hydrocarbon reductant.     

A Study of the NOx Selective Catalytic Reduction with Ethanol and Its By-products

The NOx selective catalytic reduction (SCR) with ethanol has been investigated over alumina supported silver catalyst with a special attention to the main involved reactions depending on the temperature test. With this aim, the possible reducers from ethanol transformations were also evaluated (C₂H₅OH, CH₃CHO, C₂H₄, CO). In addition, the contributions of the gas phase reactions and the alumina support were also pointed out. Based on the C-products and N-compounds distributions, it is assumed that at low temperature (T < 300 °C), ethanol reacts firstly with NO + O₂ to produce acetaldehyde and N₂. For higher temperatures, two reaction pathways have been proposed, supported by the CH₃CHO-SCR results: a direct reaction between NO₂ and CH₃CHO, or via –NCO species.     

Steam reforming of methanol using Cu-ZnO catalysts supported on nanoparticle alumina

Methanol steam reforming was studied over several catalysts made by deposition of copper and zinc precursors onto nanoparticle alumina. The results were compared to those of a commercially available copper, zinc oxide and alumina catalyst. Temperature programmed reduction, BET surface area measurements, and N₂O decomposition were used to characterize the catalyst surfaces. XRD was used to study the bulk structure of the catalysts, and XPS was used to determine the chemical states of the surface species. The nanoparticle-supported catalysts achieved similar conversions as the commercial reference catalyst but at slightly higher temperatures. However, the nanoparticle-supported catalysts also exhibited a significantly lower CO selectivity at a given temperature and space time than the reference catalyst. Furthermore, the turnover frequencies of the nanoparticle-supported catalysts were higher than that of the commercial catalyst, which means that the activity of the surface copper is higher. It was determined that high alumina concentrations ultimately decrease catalytic activity as well as promote undesirable CH₂O formation. The lower catalytic activity may be due to strong Cu-Al₂O₃ interactions, which result in Cu species which are not easily reduced. Furthermore, the acidity of the alumina support appears to promote CH₂O formation, which at low Cu concentrations is not reformed to CO₂ and H₂. The CO levels present in this study are above what can be explained by the reverse water-gas-shift (WGS) reaction. While coking is not a significant deactivation pathway, migration of ZnO to the surface of the catalyst (or of Cu to the bulk of the catalyst) does explain the permanent loss of catalytic activity. Cu₂O is present on the spent nanoparticle catalysts and it is likely that the Cu⁺/Cu⁰ ratio is of importance both for the catalytic activity and the CO selectivity.     

Steam reforming of methanol using Cu-ZnO catalysts supported on nanoparticle alumina

Methanol steam reforming was studied over several catalysts made by deposition of copper and zinc precursors onto nanoparticle alumina. The results were compared to those of a commercially available copper, zinc oxide and alumina catalyst. Temperature programmed reduction, BET surface area measurements, and N₂O decomposition were used to characterize the catalyst surfaces. XRD was used to study the bulk structure of the catalysts, and XPS was used to determine the chemical states of the surface species. The nanoparticle-supported catalysts achieved similar conversions as the commercial reference catalyst but at slightly higher temperatures. However, the nanoparticle-supported catalysts also exhibited a significantly lower CO selectivity at a given temperature and space time than the reference catalyst. Furthermore, the turnover frequencies of the nanoparticle-supported catalysts were higher than that of the commercial catalyst, which means that the activity of the surface copper is higher. It was determined that high alumina concentrations ultimately decrease catalytic activity as well as promote undesirable CH₂O formation. The lower catalytic activity may be due to strong Cu-Al₂O₃ interactions, which result in Cu species which are not easily reduced. Furthermore, the acidity of the alumina support appears to promote CH₂O formation, which at low Cu concentrations is not reformed to CO₂ and H₂. The CO levels present in this study are above what can be explained by the reverse water-gas-shift (WGS) reaction. While coking is not a significant deactivation pathway, migration of ZnO to the surface of the catalyst (or of Cu to the bulk of the catalyst) does explain the permanent loss of catalytic activity. Cu₂O is present on the spent nanoparticle catalysts and it is likely that the Cu⁺/Cu⁰ ratio is of importance both for the catalytic activity and the CO selectivity.     

Effect of SO2 on NOx reduction by ethanol over Ag/Al2O3 catalyst

A new Ag/Al₂O₃ catalyst for removing NO_x in diesel engine exhaust gas was developed. The influence of SO₂ on the reduction of lean NO_x by ethanol over the Ag/Al₂O₃ catalyst was evaluated in simulated diesel exhaust and characterized using TPD, XRD, XPS, SEM and BET measurements. The Ag/Al₂O₃ catalyst was highly active for the reduction of NO_x with ethanol in the presence of SO₂ although the reduction of NO_x is suppressed at lower temperatures. The activity for NO_x reduction is high even on the Ag/Al₂O₃ catalyst exposed to a SO₂ (200 ppm)/O₂ (10%)/H₂O (10%) flow for 20 h at 723 K and comparable to that on the fresh Ag/Al₂O₃ catalyst. No crystallized Ag metal and Ag compounds were formed by the SO₂/O₂/H₂O exposure. On the other hand, crystallized Ag₂SO₄ was easily formed when the Ag/Al₂O₃ catalyst was exposed to a SO₂ (200 ppm)/O₂ (10%)/NO (800 ppm)/H₂O (10%) flow for 10 h at 723 K. XRD, SEM and XPS studies showed that the formation of crystallized Ag₂SO₄ results in growing of Ag particles in larger size and lowering the surface content of Ag particles. In addition, the specific surface area of the Ag/Al₂O₃ catalyst decreases from 221 to 193 m²/g. Although the dispersion of Ag particles was decreased by the formation of Ag₂SO₄, the activity for the reduction of lean NO_x was, remarkably, not affected. This suggests that the Ag–alumina sites created by the Ag₂SO₄ formation are still active for the lean catalytic reduction of NO_x. This revised version was published online in July 2006 with corrections to the Cover Date.     

CO<Subscript>2</Subscript> hydrogenation to methanol over Cu/ZnO catalysts synthesized via a facile solid-phase grinding process using oxalic acid

Reduced Cu/ZnO catalyst was synthesized through solid phase grinding of the mixture of oxalic acid, copper nitrate and zinc nitrate, followed by subsequent calcination in N₂ atmosphere without further H₂ reduction. The catalysts were characterized by various techniques, such as XRD, TG-DTA, TPR and N₂O chemisorption. Characterization results suggested that during the calcination in N₂, as-ground precursor (oxalate complexes) decomposed to CuO and ZnO, releasing considerable amount of CO, which could be used for in situ reduction of CuO to Cu^o. The in situ reduced O/I-Cu/ZnO catalyst was evaluated in CO₂ hydrogenation to methanol, which exhibited superior catalytic performance to its counterpart O/H-Cu/ZnO catalyst obtained through conventional H₂ reduction. The decomposition of precursor and reduction of CuO happened simultaneously during the calcination in N₂, preventing the growth of active Cu⁰ species and aggregation of catalyst particles, which was inevitable during conventional H₂ reduction process. This method is simple and solvent-free, opening a new route to prepare metallic catalysts without further reduction.     

Influence of binder on catalytic performance of Ni/HZSM-5 for hydrodeoxygenation of cyclohexanone

The influences of binders (alumina, silica sol, kaolin) on the performance of Ni/H-ZSM-5 for hydrodeoxygenation of cyclohexanone were investigated in a fixed-bed reactor. N₂ sorption, X-ray diffractions, H₂-temperature-programmed reduction, transmission electron microscopy, ²⁷Al MAS NMR, and temperature-programmed desorption of ammonia were used to characterize the catalysts. The obtained results exhibited that porosity and acidity of the catalysts were strongly influenced by the binders. The most outstanding catalytic performance was observed on catalyst with alumina binder, which bears a well-developed pore structure and more acid sites than the others. Thus, alumina was chosen as the optimum binder to Ni/HZSM-5.     

Structural Analysis of Potential Active Sites in Metallo-Zeolites for Selective Catalytic Reduction of NO x . An Attempt for the Structure Versus Activity Relationship

The paper reviews the state of the art of the activity of metallo-zeolites and Ag/alumina in catalytic abatement of nitric oxides from exhaust gases from lean-burn combustion processes. The review is centered on the selective catalytic reduction of NO _x by hydrocarbons to molecular nitrogen (HC-SCR-NO _x ) over Co-, Fe- and Ag-zeolites, and Ag/alumina, i.e. those providing high and stable deNO _x activity in streams containing a high excess of water vapor existing under lean-burn combustion conditions. Analysis of the structure of these catalysts is described by employing a combination of spectral, diffraction, adsorption and redox techniques. An attempt is made to correlate the analyzed structure with the HC-SCR-NO _x activity.     

Selective Catalytic Reduction of NO x Over Nano-Sized Gold Catalysts Supported on Alumina and Titania and Over Bimetallic Gold–Silver Catalysts Supported on Alumina

The reduction of NO with octane under lean conditions was examined over gold supported on alumina and titania and over alumina supported bimetallic gold–silver catalysts. The silver loading was either 1.2 or 1.9 wt% whereas 0.3, 1 or 5 wt% gold was used. The catalysts were characterized by means of EDXS, N₂-adsortion, UV–Vis and TEM to correlate recorded results with different preparation methods. UV–Vis measurements indicated that gold was present in the form of fine Au particles, single Au ions and small (Au)_n ^δ+ clusters on the catalysts and silver was mainly present in the form of single Ag ions. The highest NO to N₂ reduction activity was recorded over the 0.3Au–Al₂O₃ catalyst. The Au–TiO₂ catalysts did not result in significant NO to N₂ reduction.     

NOx removal efficiency and N2 selectivity during selective catalytic reduction processes over Al2O3 supported highly cross-linked polyethylene catalysts

The performance of a highly cross-linked polyethylene catalyst supported on alumina for low temperature selective catalytic reduction of NO_x by unburned hydrocarbons (HCs) existing in an exhaust gas was examined at different engine conditions with the addition of exhaust-gas recirculation. The HXPE catalyst was shown to exhibit good NO_x reduction activity at low temperatures (100–250 °C) where the only reductant was the unburned HC, which was already present in the exhaust flow. The maximum NO_x reduction of approximately 52% was achieved at a temperature of 150 °C. HXPE demonstrated very good selectivity toward N₂ in the majority of tested conditions (∼80%).     

Enhanced NOx Conversion with Decane Over Ag/Al2O3 and Metal Supported ZSM-5 Composite SCR Catalysts

A combination of Ag/Al₂O₃ and a partial oxidation catalyst M/ZSM-5, M being different metal cations, were evaluated for selective catalytic reduction of NO with decane. Physical mixture of Ag/Al₂O₃ and M/ZSM-5 catalysts showed significant increase in NOx conversion compared to single component Ag/Al₂O₃ catalyst. M/ZSM-5 as a second catalyst component was found to generate more reactive hydrocarbons, such as unsaturated small chain hydrocarbons and oxygenates in situ, and enhance the NOx conversion over Ag/Al₂O₃ HC-SCR catalyst.     

The role of AgOAl species in silver–alumina catalysts for the selective catalytic reduction of NOx with methane

We examined the role of silver and alumina in Ag–alumina catalysts for the selective catalytic reduction (SCR) of NO_x by methane in gas streams containing excess oxygen. A cogelation technique was used to prepare Ag–alumina materials with high dispersion of silver even at high metal loadings (>10 wt%) and after air calcination at 650 °C. Typically, a part of silver is present as fine nanoparticles on the alumina, whereas another part is ionic, bound with the alumina as [AgOAl] species. Dilute nitric acid leaching was used to remove the silver particles and all weakly bound silver from the surface of these materials. Complementary structural characterization was performed by HRTEM, XPS, XRD, and UV–vis DRS. We found that the higher the initial silver content, the higher the amount of the residual [AgOAl] species after leaching. NO–O₂-TPD tests identified that silver does not modify the surface properties of the alumina. The SCR reaction-relevant NO_x adsorption takes place on alumina. Temperature-programmed surface reaction (TPSR) and kinetic measurements at steady state were used to check the reactivity of the adsorbed NO_x species with methane and oxygen to form dinitrogen. Only the alumina-adsorbed nitrates react with CH₄ to produce N₂ in the presence of oxygen, beginning at ∼300 °C as found by TPSR. Moreover, the SCR reaction rates and apparent activation energies are the same for the leached and parent Ag–alumina catalysts. Thus, metallic silver nanoparticles are spectator species in CH₄-SCR of NO_x. These catalyze the direct oxidation of methane at temperatures as low as 300 °C, which explains the lower methane selectivity for the SCR reaction measured over the parent samples.