Catalyst and process for nitric oxide reduction in a waste gas

• US 10,562,011 B2
• Filed: 09/10/2014
• Issued: 02/18/2020
• Est. Priority Date: 09/12/2013
• Status: Active Grant

• Current Assignee: Johnson Matthey PLC
• Original Assignee: Johnson Matthey PLC
• Inventors: Brandmair, Maria Theresia
• Primary Examiner(s): Davis, Sheng H
• Application Number:
  US14/482,090
• Publication Number:
  US 20150071841A1
• Time in Patent Office: 1,987 Days
• Field of Search: None
• CPC Class Codes: B01D 2253/106 Silica or silicates
• CPC Class Codes: B01D 2253/108 Zeolites
• CPC Class Codes: B01D 2255/20723 Vanadium
• CPC Class Codes: B01D 2255/20769 Molybdenum
• CPC Class Codes: B01D 2255/20776 Tungsten
• CPC Class Codes: B01D 2255/50 Zeolites
• CPC Class Codes: B01D 2255/9022 Two layers
• CPC Class Codes: B01D 2257/60 Heavy metals or heavy metal compounds
• CPC Class Codes: B01D 2257/602 Mercury or mercury compounds
• CPC Class Codes: B01D 2258/0283 Flue gases
• CPC Class Codes: B01D 53/8628 Processes characterised by a specific catalyst
• CPC Class Codes: B01J 21/063 Titanium; Oxides or hydroxides thereof
• CPC Class Codes: B01J 21/16 Clays or other mineral silicates
• CPC Class Codes: B01J 23/22 Vanadium
• CPC Class Codes: B01J 23/28 Molybdenum
• CPC Class Codes: B01J 23/30 Tungsten
• CPC Class Codes: B01J 23/6482 Vanadium
• CPC Class Codes: B01J 23/6525 Molybdenum
• CPC Class Codes: B01J 29/06 Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: B01J 37/04 : Mixing B01J37/0009, B01J37/0018 take precedence

Abstract

In order to improve the lifetime of an SCR catalyst in the waste gas purification by means of the SCR process of waste gas of a biomass combustion plant, the catalyst comprises a sacrificial component selected from a zeolite and/or a clay mineral, in particular halloysite. During operation, catalyst poisons contained in the waste gas, in particular alkali metals, are absorbed by the sacrificial component so that catalytically active centers of the catalyst are not blocked by the catalyst poisons.

Claims

1. A process for treating waste gas from a combustion plant,

the method comprising contacting the waste gas with a reducing agent in the presence of a catalyst for nitric oxide reduction in a waste gas from a combustion plant, wherein the waste gas comprises nitric oxides, alkali metals, phosphorus, chromium, or mercury,

the catalyst comprising:

a first layer comprising a sacrificial component comprising halloysite, wherein the sacrificial component absorbs catalyst poison in the waste gas, and

a second layer comprising a catalytically active component which comprises (1) a vanadium oxide and (2) tungsten oxide and/or molybdenum oxide,

thereby reducing at least some of the nitric oxides to nitrogen and water;

wherein the first and second layer are configured such that the first layer is positioned as an outer component; and

optionally, the second layer is located on or in a support substrate and the first layer is located at least partially over the second layer.

2. The process of claim 1, wherein the sacrificial component reacts with catalyst poisons selected from alkali metals, phosphorus, chromium and mercury.

3. The process of claim 1, wherein the sacrificial component absorbs catalyst poisons which are bonded in aerosol form and/or to ash or sulphur.

4. The process of claim 1, wherein the weight ratio of the sacrificial component to the catalytically active component is in the range of from 1/10 to 1/3.

5. The process of claim 1, wherein the catalytically active component comprises vanadium oxide and the catalytically active component is positioned on a support substrate.

6. The process of claim 1, wherein a combination of (1) the catalytically active components together with (2) a support mass is in the range of from 0.1% by weight to 10% by weight of the total weight of the catalyst.

7. The process of claim 1, where the catalyst comprises a support substrate comprising TiO2 and the support substrate is present in the catalyst in an amount in the range of from 60 to 85% by weight.

8. The process of claim 1, wherein the first and second layer are configured such that the waste gas is subjected to the first layer before the second layer.

9. The process of claim 1, wherein the second layer is located on or in a support substrate and the first layer is located at least partially over the second layer.

10. The process of claim 1, wherein the first layer comprising the sacrificial component is located upstream of the second layer comprising the catalytically active component, when the catalyst is positioned in the direction of flow of the waste gas.