MULTI-FUNCTION CATALYST ARTICLE FOR TREATING BOTH CO AND NOx IN STATIONARY EMISSION SOURCE EXHAUST GAS

Patent metadata

Field	Value
Publication number	US-2021094022-A1
Application number	US-202016948587-A
Country	US
Kind code	A1
Filing date	Sep 24, 2020
Priority date	Sep 27, 2019
Publication date	Apr 1, 2021
Grant date	—

Abstract

A multi-function catalyst article for treating both NO and carbon monoxide emissions in a flow of a combustion exhaust gas from a stationary emission source comprises a honeycomb monolith substrate comprising one or more channels which are open at both ends and extend along an axial length thereof and through which, in use, a combustion exhaust gas flows, which catalyst article comprising a catalyst composition comprising a combination of a first, vanadium-containing SCR catalyst component and a second component which is a compound of a transition metal comprising copper, manganese, cobalt, molybdenum, nickel or cerium or a mixture of any two or more thereof and optionally a third, crystalline molecular sieve component.

First claim

1 . A multi-function catalyst article for treating both NO and carbon monoxide emissions in a flow of a combustion exhaust gas from a stationary emission source, the article comprising a honeycomb monolith substrate comprising one or more channels which are open at both ends and extend along an axial length thereof and through which, in use, a combustion exhaust gas flows, which catalyst article comprising a catalyst composition comprising a combination of a first, vanadium-containing SCR catalyst component and a second component which is a compound of a transition metal comprising copper, manganese, cobalt, molybdenum, nickel or cerium or a mixture of any two or more thereof and optionally a third, crystalline molecular sieve component.

2 . A multi-function catalyst article according to claim 1 , which does not comprise any precious metals.

3 . A multi-function catalyst article according to claim 1 , wherein the catalyst composition is impregnated with palladium as an only precious metal present in the multi-function catalyst article.

4 . A multi-function catalyst article according to claim 1 , wherein the catalyst composition comprises palladium as an only precious metal present in the multi-function catalyst article which has been pre-fixed onto a refractory metal oxide support material.

5 . A multi-function catalyst article according to claim 3 , wherein the palladium loading in the multi-function catalyst article as a whole is 0.5 to 350 gft −3 , optionally 3 to 20 gft −3 .

6 . A multi-function catalyst article according to claim 1 , wherein the second component comprises copper, manganese, cobalt, cerium or a mixture of any two or more thereof.

7 . A multi-function catalyst article according to claim 1 , wherein the second component is a mixed oxide comprising manganese, magnesium, aluminium and lanthanum (MnMgAlLaOx).

8 . A multi-function catalyst article according to claim 1 , wherein the catalyst composition comprises the third, crystalline molecular sieve component, which is optionally ion-exchanged with the transition metal iron, copper, nickel, cobalt or zinc or a combination of any two or more thereof.

9 . A multi-function catalyst article according to claim 8 , wherein either:
(i) all transition metals present in second component are different from the transition metal ion-exchanged in the third, crystalline molecular sieve component; or (ii) one or more transition metal in the second component is the same as the metal ion-exchanged in the third, crystalline molecular sieve component, wherein the quantity of the metal present in the catalyst composition is in excess of the ion-exchange capacity of the third, crystalline molecular sieve component.

10 . A multi-function catalyst article according to claim 1 , wherein the catalyst composition does not comprise a crystalline molecular sieve.

11 . A catalyst composition which is a catalytic washcoat or paste comprising a mixture of a first, vanadium-containing SCR catalyst component and a second component which is a compound of a transition metal comprising copper, manganese, cobalt, molybdenum, nickel or cerium or a mixture of any two or more thereof and one or more fillers, binders, processing aids, water and dopants and optionally a third, crystalline molecular sieve component.

12 . A method of making a honeycomb monolith substrate comprising a catalyst composition for use as a multi-function catalyst article for treating both NO x and carbon monoxide emissions in a flow of a combustion exhaust gas from a stationary emission source, which method comprising preparing a catalytic washcoat or paste according to claim 11 , coating the catalytic washcoat or paste onto an inert honeycomb monolith substrate and drying and calcining the resulting coated inert honeycomb monolith substrate.

13 . A method of making a honeycomb monolith substrate comprising a catalyst composition for use as a multi-function catalyst article for treating both NO x and carbon monoxide emissions in a flow of a combustion exhaust gas from a stationary emission source, which method comprising preparing a catalytic washcoat or paste comprising a catalyst composition comprising a mixture of a first, vanadium-containing SCR catalyst component and optionally a third, crystalline molecular sieve component and one or more fillers, binders, processing aids, water and dopants, coating the catalytic washcoat or paste onto an inert honeycomb monolith substrate and drying and calcining the resulting coated inert honeycomb monolith, impregnating channel walls of the calcined coated inert honeycomb monolith substrate with an aqueous salt of a compound of a transition metal selected from the group consisting of a transition metal comprising copper, manganese, cobalt, molybdenum, nickel or cerium or a mixture of any two or more thereof and drying and calcining the impregnated coated inert honeycomb monolith substrate.

14 . A catalyst composition which is an extrudable mass comprising a mixture of water, a first, vanadium-containing SCR catalyst component and a second component which is a compound of a transition metal comprising copper, manganese, cobalt, molybdenum, nickel or cerium or a mixture of any two or more thereof and optionally a third, crystalline molecular sieve component and one or more binder component, which is a clay, alumina and/or glass fibres.

15 . A method of making a honeycomb monolith substrate comprising an extruded catalyst composition for use as a multi-function catalyst article for treating both NO x and carbon monoxide emissions in a flow of a combustion exhaust gas from a stationary emission source, which method comprising preparing an extrudeable mass according to claim 14 , extruding the extrudeable mass through a suitable die to form a wet honeycomb shaped object comprising an array of longitudinally extending channels and drying and calcining the resulting extruded wet honeycomb shaped object.

16 . A method of making a honeycomb monolith substrate comprising an extruded catalyst composition for use as a multi-function catalyst article for treating both NO x and carbon monoxide emissions in a flow of a combustion exhaust gas from a stationary emission source, which method comprising preparing an extrudeable mass comprising a catalyst composition comprising a mixture of water, a first, vanadium-containing SCR catalyst component and optionally a third, crystalline molecular sieve component and one or more binder component, which is a clay, alumina and/or glass fibres, extruding the extrudeable mass through a suitable die to form a wet honeycomb shaped object comprising an array of longitudinally extending channels, drying and calcining the resulting extruded wet honeycomb shaped object, impregnating channel walls of the calcined honeycomb monolith substrate with an aqueous salt of a compound of a transition metal comprising copper, manganese, cobalt, molybdenum, nickel or cerium or a mixture of any two or more thereof and drying and calcining the impregnated extruded honeycomb monolith substrate.

17 . An exhaust system for selectively catalysing the reduction of oxides of nitrogen (NO x ) including nitrogen monoxide and carbon monoxide in an exhaust gas of a stationary source of combined NO x and CO emissions, which system comprising an injector for introducing a nitrogenous reductant into the exhaust gas located downstream from the oxidation catalyst; and a catalyst article according to claim 1 located downstream of the injector.

18 . An exhaust system according to claim 17 comprising a heat recovery steam generat

Assignees

• Johnson Matthey Plc
• Johnson Matthey Catalysts Germany Gmbh

Inventors

• Andersen Paul Joseph
• Baer Ferdinand
• Brandmair Maria Theresia
• Doura Kevin
• Kreuder Heike
• DURAN MARTIN Desiree

Classifications

• B01J35/57

  Honeycombs · CPC title

• B01J23/34

  Manganese · CPC title

• B01D2255/20761

  Copper · CPC title

• B01J23/02

  of the alkali- or alkaline earth metals or beryllium · CPC title

• B01J23/002

  Mixed oxides other than spinels, e.g. perovskite · CPC title