Zeolite-mediated removal of NOx by NH3 from exhaust streams at low temperatures

NH₃ stored on zeolites in the form of NH₄⁺ ions easily reacts with NO to N₂ in the presence of O₂ at temperatures <373 K under dry conditions. Wet conditions require a modification of the catalyst system. It is shown that MnO₂ deposited on the external surface of zeolite Y by precipitation considerably enhances the NO_x conversion by zeolite fixed NH₄⁺ ions in the presence of water at 400–430 K. Particle-size analysis, temperature-programmed reduction, textural characterization, chemical analysis, ESR and XRD gave a subtle picture of the MnO₂ phase structure. The MnO₂ is a non-stoichiometric, amorphous phase that contains minor amounts of Mn²⁺ ions. It loses O₂ upon inert heating up to 873 K, but does not crystallize or sinter. The phase is reducible by H₂ in two stages via intermediate formation of Mn₃O₄. The manufacture of extrudates preserving stored NH₄⁺ ions for NO_x reduction is described. It was found that MnO₂ can oxidize NO by bulk oxygen. This enables the reduction of NO to N₂ by the zeolitic NH₄⁺ ions without gas-phase oxygen for limited time periods. The composite catalyst retains storage capacity for both, oxygen and NH₄⁺ ions despite the presence of moisture and allows short-term reduction of NO without gaseous O₂ or additional reductants. The catalyst is likewise suitable for steady-state DeNO_x operation at higher space velocities if gaseous NH₃ is permanently supplied.