Method for preparing a catalyst composition suitable for removing sulfur from a catalytic reduction system

Patent metadata

Field	Value
Publication number	US-9545618-B2
Application number	US-201414305914-A
Country	US
Kind code	B2
Filing date	Jun 16, 2014
Priority date	Jun 21, 2011
Publication date	Jan 17, 2017
Grant date	Jan 17, 2017

Abstract

A method of preparing a catalyst composition suitable for removing sulfur from a catalytic reduction system and the catalyst composition prepared by the method are provided. The method of preparation of a catalyst composition, comprises: combining a metal oxide precursor, a catalyst metal precursor and an alkali metal precursor in the presence of a templating agent; hydrolyzing and condensing to form an intermediate product that comprises metal oxide, alkali metal oxide, and catalyst metal; and calcining to form a templated amorphous metal oxide substrate having a plurality of pores wherein the alkali metal oxide and catalyst metal are dispersed in an intermixed form in the metal oxide substrate.

First claim

The invention claimed is:

1. A method of preparation of a catalyst composition, comprising:
combining a metal oxide precursor, a catalyst metal precursor and a sulfur scavenger precursor in the presence of a templating agent to form a combination;
hydrolyzing and condensing the combination so that the sulfur scavenger precursor is converted to a sulfur scavenger compound and the catalyst metal precursor is converted to a catalyst metal to form an intermediate product that comprises metal oxide, a sulfur scavenger compound and catalyst metal wherein the sulfur scavenger compound is comprised of an alkali metal cation; and
calcining the intermediate product to form a templated amorphous metal oxide substrate having a plurality of pores wherein the sulfur scavenger compound and catalyst metal are dispersed in an intermixed form in the metal oxide substrate and wherein the sulfur scavenger compound comprises an alkali metal containing material wherein the sulfur scavenger compound is lithium hydroxide and/or lithium aluminum oxide.

2. The method of claim 1 wherein the catalyst metal is silver metal.

3. The method of claim 1 wherein the metal oxide substrate is comprised of alumina.

4. The method of claim 1 wherein the metal oxide substrate is free of silica.

5. The method of claim 1 wherein the sulfur scavenger precursor is LiNO 3 .

6. The method of claim 1 wherein the metal oxide substrate is amorphous alumina, and the catalyst metal is silver metal.

7. The method of claim 1 wherein the templating agent comprises a surfactant, a cyclodextrin, a crown ether, or mixtures thereof.

8. A method of removing sulfur from a catalytic reduction system, comprising: passing an exhaust stream from an exhaust source over a catalyst composition prepared by the method of claim 1 ;
reacting the exhaust stream with the catalyst composition to form sulfates; decomposing the sulfates to produce sulfur oxides; and removing the sulfur oxides from the catalytic reduction system.

9. The method of claim 8 , wherein reacting the exhaust stream comprises reacting the exhaust stream with the sulfur scavenger compound of the catalyst composition to form the sulfates.

10. A catalyst composition produced by the method of claim 1 .

Assignees

• Gen Electric

Inventors

• Siclovan Oltea Puica
• Norton Daniel George
• Lewis Larry Neil
• Hancu Dan
• Bao Xiaoying
• Burch Robert
• Hardacre Christopher
• Chansai Sarayute

Classifications

• B01D2257/302

  Sulfur oxides · CPC title

• B01D53/8603

  Removing sulfur compounds · CPC title

• B01J23/50

  Silver · CPC title

• B01D2257/404

  Nitrogen oxides other than dinitrogen oxide · CPC title

• B01J35/1066

  Operations & Transport · mapped topic