Systems, methods and materials for NOx decomposition with metal oxide materials

• US 10,549,236 B2
• Filed: 01/29/2019
• Issued: 02/04/2020
• Est. Priority Date: 01/29/2018
• Status: Active Grant

• Current Assignee: Ohio State Innovation Foundation (Ohio State University)
• Original Assignee: Ohio State Innovation Foundation (Ohio State University)
• Inventors: Fan, Liang-Shih, Baser, Deven Swapneshu, Sandvik, Peter, Kathe, Mandar, Fryer, Charles
• Primary Examiner(s): Vanoy, Timothy C
• Application Number:
  US16/260,447
• Publication Number:
  US 20190232220A1
• Time in Patent Office: 371 Days
• CPC Class Codes: B01D 2251/102 Oxygen
• CPC Class Codes: B01D 2251/40 Alkaline earth metal or magnesium compounds
• CPC Class Codes: B01D 2251/602 Oxides
• CPC Class Codes: B01D 2255/2047 Magnesium
• CPC Class Codes: B01D 2255/2073 Manganese
• CPC Class Codes: B01D 2255/20746 Cobalt
• CPC Class Codes: B01D 2255/20761 Copper
• CPC Class Codes: B01D 2255/40 Mixed oxides
• CPC Class Codes: B01D 2257/404 Nitrogen oxides other than dinitrogen oxide
• CPC Class Codes: B01D 2258/0283 Flue gases
• CPC Class Codes: B01D 2258/0291 from waste incineration plants
• CPC Class Codes: B01D 53/565 by treating the gases with solids
• CPC Class Codes: B01D 53/8628 Processes characterised by a specific catalyst
• CPC Class Codes: B01D 53/869 Multiple step processes
• CPC Class Codes: B01D 53/8696 Controlling the catalytic process
• CPC Class Codes: B01D 53/90 Injecting reactants
• CPC Class Codes: B01J 23/04 Alkali metals
• CPC Class Codes: B01J 23/34 Manganese
• CPC Class Codes: B01J 23/72 Copper
• CPC Class Codes: B01J 23/75 Cobalt
• CPC Class Codes: B01J 2523/00 : Constitutive chemical elements of heterogeneous catalysts
• CPC Class Codes: B01J 2523/17 : Copper
• CPC Class Codes: B01J 2523/22 : Magnesium
• CPC Class Codes: B01J 2523/3712 : Cerium
• CPC Class Codes: B01J 2523/69 : Tungsten
• CPC Class Codes: B01J 2523/72 : Manganese
• CPC Class Codes: B01J 2523/845 : Cobalt
• CPC Class Codes: B01J 35/00 : Catalysts, in general, characterised by their form or physical properties
• CPC Class Codes: B01J 35/30 : characterised by their physical properties
• CPC Class Codes: B01J 37/14 : with gases containing free oxygen

Abstract

Systems and methods use oxygen uncoupling metal oxide material for decomposition of NO_x. A gaseous input stream comprising NO_x is contacted with a metal oxide particle, generating nitrogen (N₂) gas and an oxidized metal oxide particle. After contacting the first gaseous input stream with the metal oxide particle, a first gaseous product stream is collected. The first gaseous product stream includes substantially no NO_x. A second gaseous input stream comprising at least one sweeping gas is also contacted with the oxidized metal oxide particle. After contacting the oxidized metal oxide particle, the sweeping gas includes oxygen (O₂) and a reduced metal oxide particle is generated. Then a second gaseous product stream is collected, where the second gaseous product stream includes oxygen (O₂) gas.

Claims

1. A method comprising:

contacting a first gaseous input stream comprising NO_x with a metal oxide particle, whereupon the NO_x in the first gaseous input stream reacts with the metal oxide particle to generate nitrogen (N₂) gas and an oxidized metal oxide particle,

wherein contacting the first gaseous input stream with the metal oxide particle occurs at a first temperature of from 400°

C. to 700°

C.;

collecting a first gaseous product stream comprising substantially no NO_x;

contacting a second gaseous input stream comprising at least one sweeping gas with the oxidized metal oxide particle, whereupon the sweeping gas comprises oxygen (O₂) gas after contacting the oxidized metal oxide particle and a reduced metal oxide particle is generated,

wherein the at least one sweeping gas is oxygen (O₂) gas free;

wherein contacting the second gaseous input stream with the oxidized metal oxide particle occurs at a second temperature of from 600°

C. to 1000°

C.; and

collecting a second gaseous product stream comprising the oxygen (O₂) gas.

2. The method according to claim 1, wherein contacting the first gaseous input stream with the metal oxide particle occurs in a first reactor operating at the first temperature;

and

wherein contacting the second gaseous input stream with the oxidized metal oxide particle occurs in the first reactor operating at the second temperature.

3. The method according to claim 2, further comprising:

monitoring NO_x content in the first gaseous input stream;

upon the NO_x content exceeding a predetermined threshold, stopping contacting the first gaseous input stream with the metal oxide particle;

after stopping contacting the first gaseous input stream with the metal oxide particle, heating the first reactor to the second temperature;

after heating the first reactor to the second temperature, contacting the second gaseous input stream with the oxidized metal oxide particle;

after a predetermined time, stopping contacting the second gaseous input stream with the oxidized metal oxide particle; and

lowering a first reactor temperature to the first temperature.

4. The method according to claim 3, further comprising using the reduced metal oxide particle as the metal oxide particle during contacting the first gaseous input stream with the metal oxide particle.

5. The method according to claim 1, further comprising:

providing the metal oxide particle to the first reactor,

wherein contacting the first gaseous input stream with the metal oxide particle occurs in the first reactor operating at the first temperature; and

wherein collecting the first gaseous product stream includes providing a first reactor outlet stream substantially free of NO_x gas; and

providing the oxidized metal oxide particle to the second reactor,

wherein contacting the second gaseous input stream with the oxidized metal oxide particle occurs in a second reactor operating at the second temperature; and

wherein collecting the second gaseous product stream includes providing a second reactor outlet stream comprising the oxygen (O₂) gas.

6. The method according to claim 5, further comprising using the reduced metal oxide particle as the metal oxide particle provided to the first reactor.

7. The method according to claim 1, wherein the first gaseous product stream includes less than 0.001% by volume NO_x.