Process for the Reduction of nitrogen oxides

Abstract: A process for reducing nitrogen oxides comprising passing them in admixture with ammonia or hydrogen, or a mixture of the two, over a group VIII metal catalyst on a hydrophobic support. The process is carried out at 0 to 200°C when hydrogen is used, or 100 to 200°C when ammonia or an ammonia/hydrogen mixture is used as the reducing gas. It is useful in pollution control, for example, in reducing nitrogen oxide emissions in industrial waste gases.

Description: This invention relates to the reduction of oxides of nitrogen over a catalyst. Nitrogen oxides are common pollutants and are widely found in industrial waste gases. Such oxides form a very important environmental problem and are a contributor, along with sulfur oxides, to environmental degradation through the climatic process known as "acid rain". Therefore, for environmental reasons, control of nitrogen oxides is very important. Typically, nitrogen oxides are removed from industrial waste gases by catalytic reduction to nitrogen and water. However, for such processes to function properly, it is necessary to maintain the waste gas at a relatively high temperature, for example about 700-900°F (371-482°C). An example of one such process is shown in U.S.P. 3567367 of Kandell et al. The use of a high temperature process such as shown in the Kandell patent has many disadvantages. Usually, fuel must be expended to keep the gases to be treated in the operating temperatures range. Once the gases have been passed over the catalyst, it is then necessary either to vent hot gas (with the concomitant loss of heat) or else to supply expensive waste heat recovery apparatus. It is not possible to run conventional processes at ambient temperatures, because the catalyst rapidly becomes poisoned if there is any moisture in the gas stream being treated. The invention permits the reduction of nitrogen oxides at ambient or near ambient temperatures and pressures, although it can also operate at slightly elevated temperatures and pressures if desired. A particular advantage of the invention is that it permits the reduction of nitrogen oxides even when oxygen is present, provided that the operating conditions are chosen correctly as discussed below. The invention makes use of group VIII metal catalysts on a hydrophobic support. Hydrophobic catalyst supports are already known for other purposes. For example, U.S. Patent No. 4025560 of Rolston et al. shows a catalyst for the exchange of hydrogen isotopes between a gas stream and a water stream, where the catalyst support is an inherently hydrophobic material such as cubes of polytetrafluoroethylene (PTFE), polyethylene or the like. European Patent Application No. 0015585 of Hitachi Inc. shows catalysts similar to those of Rolston for other types of gas-liquid reactions. An activated carbon catalyst, which has been reacted with a monomer which forms hydrophobic polymers, is disclosed for carbon monoxide oxidation in U.S. Patent No. 4652537 of Tamura. European Patent Specification No. 0 286 967 A discloses a process for reducing the proportion of nitrogen oxides in exhaust gases from internal combustion engines. The exhaust gases, which contain unburnt hydrocarbons and carbon monoxide, are catalytically reduced using the hydrocarbons and carbon monoxide as reducing agents, the catalysts being hydrophobic zeolites optionally treated with a period 4 element, for example, copper. European Patent Specification No. 0 199 169 A discloses a process for reducing the nitrogen oxide content in the waste gases of combustion installations by catalytic reduction with ammonia, the catalysts comprising mixtures of one or more aluminosilicates of the faujasite group and a copper compound. An article "Control of NO x Emissions by Selective Catalytic Reduction with Hydrogen over Hydrophobic Catalysts" by L. Fu and K. T. Chuang, published in Journal of Energy and Fuels, 1989, 3, 740, after the priority date claimed in the present application, discloses the reduction of nitrogen oxides with hydrogen using noble metal catalyst on hydrophobic supports. The invention provides a process for reducing nitrogen oxides, by passing a gas stream containing nitrogen oxides and hydrogen and/or ammonia over a catalyst. The catalyst comprises at least one Group VIII metal on a hydrophobic support. The reaction is carried out at a temperature of from about 0° to about 200°C if the reducing agent is hydrogen and about 100°C to 200°C if the reducing agent is ammonia or an ammonia/hydrogen mixture. If the catalyst support is one which decomposes at under 200°C when exposed to the gas stream being reduced the temperature should be low enough so that the support is not decomposed. The temperature and catalyst are chosen, within the possibilities indicated above, such that the desired reduction takes place. The catalysts used in accordance with the invention have particular advantages in the reduction of nitrogen oxides, in that they will function at lower temperatures than previously proposed catalysts, thus avoiding the necessity of pre-heating the gas to be treated. Thus, the present process can be carried out at temperatures of from 0° to 200°C. At such temperatures these catalysts also function in the presence of oxygen, selectively to reduce nitrogen oxides instead of oxygen. If there is oxygen present, some oxygen will be reduced, and this effect increases with increasing oxygen concentration. However, oxygen concentrations of up to 100 times the concentration of hydrogen, on a volume % basis, and which do not exceed 20% by volume of the feed gas, do not cause severe loss of selectivity at the temperatures of this process. In its general aspect, the invention relates to the treatment of nitrogen oxides with hydrogen and/or ammonia, over a Group VIII metal deposited on a hydrophobic support. The invention can be used to catalyze the reduction of pure nitrogen oxides if desired. Thus, it is possible to carry out the invention to treat a stream of a pure nitrogen oxide (or a mixture of nitrogen oxides) admixed with hydrogen or ammonia. However, there is little commercial reason to reduce pure nitrogen oxides. The present process has the particular advantage that it can be used to remove nitrogen oxides, even when they are present in small concentrations such as 100 ppm., from a waste gas which also contains many other components. The invention also provides the use of a catalyst comprising at least one catalytically active group VIII metal disposed on a hydrophobic support to promote the selective reduction of at least one oxide of nitrogen in a waste gas containing the said oxide and oxygen, reduction being carried out at about O°C to 200° using hydrogen as a reducing gas or at about 100°C to 200°C using ammonia or an ammonia/hydrogen mixture as a reducing gas, and the temperature at which reduction is carried out being such that the support remains stable. In this disclosure, the term "nitrogen oxides", or the symbol NO x , is intended to include one or more of the species NO, NO₂, N₂O₅ and N₂O. Depending on the abundance of free oxygen and the temperature and pressure, these species interconvert, so that what is usually present is a mixture of various species. For simplicity, most of the Examples use a gas stream into which NO has been injected. However, other species form in situ , so what is being reduced is a mixture of oxides of nitrogen. In a particularly advantageous embodiment, the invention involves the treatment with hydrogen of waste gases or other gases containing nitrogen oxides. When used for pollution control, the nitrogen oxides are advantageously present in a concentration of less than 1.5% of the feed gas by volume, and particularly preferably in a concentration of less than 3000 ppm. If nitrogen oxides are present in larger concentrations, the reaction will still occur, but there will be a greater likelihood that the effluent gas will still contain some nitrogen oxides, which is undesirable in a pollution control process. The hydrogen is advantageously present in stoichiometric excess to the nitrogen oxide and preferably in considerable stoichiometric excess (for example 5 times or more) to ensure Complete reaction. Preferably, the hydrogen is present in amounts of above 0.5% of the feed gas. Other components of the feed gas stream can, for example, include one or more of N₂, CO₂, O₂, H₂O or CO (which will of course be oxidized to CO₂ if O₂ is present). Oxygen (if present) is advantageously present in a concentration less than 100 times the concentration of hydrogen present on a volume % basis and less than 20% of the overall feed stream. Preferably, at least 80% of the feed gas is a gas, for example, N₂ or CO₂, which is inert under the reaction conditions and H₂ and O₂ concentrations are adjusted, and water vapour added if necessary, so that the H₂ and O₂ do not form an explosive mixture. It is preferred that no more than about 200 ppm SO₂ be present in the feed gas, as SO₂ will reduce the catalyst activity while it is flowing over the catalyst. However, this inactivation is reversed when a feed gas which does not contain SO₂ is supplied to the catalyst. The pressure at which the process is carried out is not critical. Superatmospheric pressures can be used if desired. However, the process works satisfactorily at atmospheric pressure, and it is preferred to carry it out at atmospheric pressure as simple apparatus can be used. There is no particular advantage to using subatmospheric pressure, and care must be taken if such pressures are used to have a sufficient concentration of reactants so that the reaction proceeds at a reasonable rate. The present process can be used as part of an overall pollution control process, for the treatment of stack gases or other gaseous effluents containing SO₂, CO and nitrogen oxides which must be removed before the gas can be vented. In such a pollution control process, the SO₂ is first reduced to below 200 ppm, using a conventional SO₂ removal process. In a subsequent stage, the CO and any hydrocarbons present are oxidized. Conveniently such oxidation can take place using the process disclosed in European Patent Specification No. 246 031 published 19th November, 1987. Once the CO and hydrocarbons have been oxidized the effluent is treated using the present process to remove the nitrogen oxides. The catalyst is disposed on a hydrophobic support. The hydrophobic support preferably has a surface area of at least 50 m² per gram, and can have a surface area as high as 1,500 m² per gram. The support may be selected from the group of inherently hydrophobic plastic materials, for example styrene divinylbenzene ("SDB"), polytetrafluroroethylene ("PTFE"), polyethylene, polypropylene, or silicalite (a silica having a highly structured lattice which is described in U.S. Specification No. 4 061 724 dated December 6, 1977). Alternatively, the hydrophobic support may comprise an initially hydrophilic material which has been chemically treated so as to render it hydrophobic. For example, silica, carbon or fumed silica (such, for example, as that produced by Cabot Corp. under the name CAB-O-SIL EH-5) can be rendered hydrophobic by treatment with a silane, or fluorine. Treatment with tetrafluoroethylene monomer can be used to render the support hydrophobic, in the case of those supports which form sufficiently strong bonds with tetrafluoroethylene. The support is preferably porous. One convenient way of determining the hydrophobicity of a solid material, and hence its suitability as a support, is by measuring its "contact angle" according to Young's Theory. The support material advantageously has a contact angle of at least 30°, although materials with a contact angle of at least 50°, are preferred. For best results, a material with a contact angle of at least 90° is preferred. The support material can be present, for example, as discrete particles or granules, or it can be deposited on a second support, for example, a ceramic or a metal screen. For example, the support material can be deposited on conventional ceramic beads, saddles or rings. Preferably, the discrete particles of the hydrophobic support material are attached to the second support by means of a coating of an organic resin or polymer which is liquid-water-repellent and water vapour permeable, such, for example, as polytetrafluoroethylene or a silicone. Suitable silicones, for example, are poly-siloxanes such, for example, as polyalkyl-siloxanes. The silicone may include at least one substituent selected from ethyl, propyl, isopropyl and t-butyl groups. The catalyst comprises a group VIII metal, with Pt, Pd, Ru, Rh or Ir being preferred. Any group VIII metal, or any two or more of such metals, may be used in accordance with the invention. Any one or more of Fe, Co, Ni, Ru, Rh, Pd, Os, Ir and Pt may be used. If desired, the catalyst may comprise a mixture of Pt, Pd or Ru with each other or with another metal from Group VIII, for example, Rh or Ir. It is preferred that the other metal be present in a lesser amount by weight than the Pt, Pd or Ru. Depending on which catalyst is used and the temperature of the feed gas, the product of the reduction will be predominantly either nitrogen or ammonia. The Group VIII metal may be deposited on the hydrophobic support material in any suitable manner, for example, by slurrying the support material in a solution of a chloride of the desired Group VIII metal. When the reaction is carried out using NO and H₂ the product of the reduction can be nitrogen or ammonia or a mixture of the two. At the high end of the temperature range of the process (i.e. from about 75°C to 200°C) the product is substantially completely nitrogen, with only traces of ammonia. At lower temperatures, more ammonia is produced. The choice of catalyst also affects the product. Generally, at a given temperature, Pt tends to yield more NH₃ as a product, whereas other group VIII metals, such as Pd or Rh, yield nitrogen. If the feed gas contains a substantial excess of oxygen over NO x (for example molar ratios of over about 50 to 1) the product may also contain some N₂O. At temperatures of 100°-200°C, ammonia can be used instead of, or in addition to, H₂ as the reducing agent: ammonia does not act as a reducing agent at temperatures below about 100°C. The product is N₂, although some N₂O may be present if the feed gas contains a substantial molar excess of oxygen over NO x . The following Examples illustrate the invention. Example 1 A commercially available mixture of 50% by weight divinylbenzene and 50% by weight ethylvinylbenzene (available from Fluka Chemical Corp.) was combined with an equal weight of 2-methylpentanol (obtained from Alfa Products Division, Morton Thiokol Corp.). To the resulting solution was added 0.4% by weight of 2,2-azobis(2-methylpropronitrile). The solution was heated in a water bath at 85°C to prepare a block of solid porous styrene-divinylbenzene polymer (SDB) having a surface area of 465m²/g. The block was then crushed and heated to 250°C under helium to remove the 2-methylpentanol. The product was then sieved to provide a porous SDB powder with a size from 14 mesh to 8 mesh (U.S. Sieve Sizes). The powder was ethanol washed and was then slurried in ethanol containing dissolved H₂PtCl₆. The length of time of slurrying and the concentration of the solution were adjusted to give product having a platinum loading of 2% weight percent Pt. The resulting platinized material had a bulk density of 0.4 g/cm³. The platinized material was then rotary evaporated at 95°C under a slight vacuum to remove the alcohol, and was heated in air at 105°C for one hour. Subsequently, it was reduced in hydrogen at 200°C until the pH measured at the furnace outlet became neutral. 16 gm of the impregnated catalyst was placed in a reactor formed of 5/8 inch (15.9 mm) PYREX (T.M.) heat resistant tubing. A feed gas consisting of 1% hydrogen, 3.4% oxygen and 0.1% NO by volume with the balance being nitrogen, was passed through the reactor at atmospheric pressure. The flow rate was a standard volume of 3,000 litres per hour. The reactor was heated to various temperatures as shown below. T °C S.V. h⁻¹ [H₂]% [O₂]% Conversion % 25 3000 1 3.4 0 45 3000 1 3.4 91 70 3000 1 3.4 90 87 3000 1 3.4 89 120 3000 1 3.4 81 150 3000 1 3.4 70 Example 2 The procedure of example 1 was followed, except that the catalyst was formed by slurrying the SDB with a mixture of H₂PtCl₆, and H₂IrCl₆ in a ratio of 9:1 Pt to Ir content in ethanol. The oxygen volume percent of the mixture was 3.2% but the mixture was otherwise the same as in Example 1. The results of testing at different temperatures were as follows: T °C S.V. h⁻¹ [H₂]% [O₂]% Conversion % 25 3000 1 3.2 75 55 3000 1 3.2 56 68 3000 1 3.2 41 85 3000 1 3.2 20 Example 3 The same catalyst as was used in example 2 was used with a gas input having a standard volume of 5,000 litres per hour and a concentration of 1% hydrogen, 3.0% oxygen and 1,000 parts per million of NO. The conversion of NO was measured at start-up and after six hours. The conversion rate of NO remained constant at 88%. The product was nitrogen with traces of NH₃. After six hours, liquid water was introduced into the reactor, filling the reactor. The input gas continued to be supplied at 5,000 Standard Volume litres per hour. After 12 hours, conversion was again measured, and was found to be 90%, which is approximately the same as the conversion when no water was present. Therefore, this shows that conversion is essentially independent of the presence of water. Example 4 The procedure of example 2 was repeated, but at a standard volume of 3,000 litres per hour. The temperature at the feed to the reactor and the temperature of the effluent from the reactor were measured, as was the conversion. The product was N₂, and no NH₃ was observed. The results showed that there is a relatively small temperature increase as a result of the reaction, particularly at slightly elevated temperatures. T °C(Feed) T°C (Effluent) Conversion % dT°C 22 46 86 24 44 46 87 2 53 55 85 2 59 62 82 3 65 69 77 4 78 80 70 2 [H₂] = 1% [O₂] = 3.2% S.V. - 3000 h⁻¹ Example 5 Example 2 was repeated except that a catalyst was 0.5% Pt and 0.5% Ru. The catalyst was prepared by slurrying the SDB in ethanol with solutions of 5 gm/l. of RuCl₃ and H₂PtCl₆ respectively. Runs were carried out at standard volumes of 3,000 litres per hour and 10,000 litres per hour. The following results were obtained: T °C S.V. h⁻¹ [H₂]% [O₂]% Conversion % 30 3000 1 3.2 6 52 3000 1 3.2 7.5 65 3000 1 3.2 8 105 3000 1 3.2 23 130 3000 1 3.2 48 138 3000 1 3.2 76 145 3000 1 3.2 80 167 3000 1 3.2 83 30 10000 1 3.2 0 65 10000 1 3.2 8 100 10000 1 3.2 10 125 10000 1 3.2 18 160 10000 1 3.2 67 200 10000 1 3.2 57 Example 6 Example 5 was repeated, using a catalyst having a 5% Pt - 5% Ru loading. The results were as follows: T °C S.V. h⁻¹ [H₂]% [O₂]% Conversion % 25 3000 1 3.2 8.7 50 3000 1 3.2 78 65 3000 1 3.2 76 90 3000 1 3.2 77 113 3000 1 3.2 77 153 3000 1 3.2 71 167 3000 1 3.2 68 25 10000 1 3.2 10 38 10000 1 3.2 25 54 10000 1 3.2 46 77 10000 1 3.2 78 105 10000 1 3.2 78 130 10000 1 3.2 76 180 10000 1 3.2 66 Example 7 Example 5 was repeated using a catalyst with a 2% Pd - 2% Ru loading. The results were as follows: T °C S.V. h⁻¹ [H₂]% [O₂]% Conversion % 25 3000 1 3.2 4 37 3000 1 3.2 5 55 3000 1 3.2 60 60 3000 1 3.2 66 95 3000 1 3.2 66 105 3000 1 3.2 68 130 3000 1 3.2 68 130 3000 1 3.2 74 155 3000 1 3.2 70 25 10000 1 3.2 2 60 10000 1 3.2 6 82 10000 1 3.2 66 90 10000 1 3.2 70 110 10000 1 3.2 70 130 10000 1 3.2 71 165 10000 1 3.2 69 Example 8 The procedure of example 2 was repeated, except that the catalyst was 2% Ru (deposited from RuCl₃). All runs were carried out at a standard volume of 3,000 litres per hour. The results were as follows: T °C S.V. h⁻¹ [H₂]% [O₂]% Conversion % 45 3000 1 3.2 5 75 3000 1 3.2 10 120 3000 1 3.2 12.5 167 3000 1 3.2 40 187 3000 1 3.2 41 Example 9 The procedure of example 2 was repeated except that the catalyst was 2% Pd, deposited from PdCl₃. The results were as follows: T °C S.V. h⁻¹ [H₂]% [O₂]% Conversion % 22 3000 1 3.2 0 45 3000 1 3.2 21 70 3000 1 3.2 55 85 3000 1 3.2 47 100 3000 1 3.2 45 140 3000 1 3.2 29 156 3000 1 3.2 24 170 3000 1 3.2 22 Example 10 The procedure of example 5 was repeated, except that the catalyst was 6% Pd and 2% Ru. The results were as follows: T °C S.V. h⁻¹ [H₂]% [O₂]% Conversion % 25 3000 1 3.2 4 60 3000 1 3.2 17 70 3000 1 3.2 63 97 3000 1 3.2 77 125 3000 1 3.2 80 140 3000 1 3.2 82 177 3000 1 3.2 79 20 10000 1 3.2 40 46 10000 1 3.2 70 60 10000 1 3.2 72 75 10000 1 3.2 74 105 10000 1 3.2 78 145 10000 1 3.2 73 168 10000 1 3.2 70 185 10000 1 3.2 67 Example 11 Fluorinated carbon powder (Allied Chemical Type 2065) having a surface area of 340 m²/g, was slurried with H₂PtCl₆ in ethanol to give a Pt loading of 10%. The powder was then dried at 200°C under helium flow and reduced at 200°C under hydrogen flow. 4 g. of this powder was dispersed with 100 g. of water 16 g. of surfactant (20% Triton X-100 [T.M.] from J.T. Baker Chemical Co.). To this dispersion was added 6.7 g. of polytetrafluoroethylene (PTFE) suspension (du Pont Teflon 30 [T.M.]). The slurry was then added to 174 gm of commercial 1/4" (6.4 mm) ceramic rings (obtained from Norton co.) to coat the rings. The PTFE served as a bonding agent to bond the fluorocarbon powder to the rings. The rings were then dried, with the temperature being raised gradually from 60°C to 365°C, with a final period of 15 minutes at 365°C to cure the PTFE. Input gas of varying compositions as shown in the following table were passed through this catalyst at temperatures as shown in the table: (a) With feed gas containing 2050 ppm NO T °C S.V.h⁻¹ [H₂]% [O₂]% Conversion % 50 12000 1 0.6% 5 80 12000 1 0.6 76 100 12000 1 0.6 78 110 12000 1 0.6 78 55 12000 0.5 0.6 5 60 12000 0.5 0.6 22 70 12000 0.5 1.6 46 85 12000 0.5 1.6 66 100 12000 0.5 1.6 70 110 12000 0.5 1.6 66 (b) With feed gas containing 660 ppm NO T °C SV/H [H₂]% [O₂]% Conversion % 35 12000 1 2.5 10 45 12000 1 2.5 70 50 12000 1 2.5 75 60 12000 1 2.5 76 80 12000 1 2.5 68 100 12000 1 2.5 65 50 12000 0.5 2.5 15 60 12000 0.5 2.5 55 85 12000 0.5 2.5 65 90 12000 0.5 2.5 62 (c) With feed gas containing 2000 ppm NO T °C SV/H [H₂]% [O₂]% Conversion % 60 12000 1.0 10 22 62 12000 1.0 10 68 65 12000 1.0 10 66 75 12000 1.0 10 58 80 12000 1.0 10 50 85 12000 1.0 10 45 100 12000 1.0 10 32 70 12000 0.5 10 48 80 12000 0.5 10 60 90 12000 0.5 10 58 95 12000 0.5 10 55 Example 12 Fumed silica (CAB-O-SIL [T.M.] obtained from Cabot Corp. was rendered hydrophobic by treatment with silane. The hydrophobic silica was slurried with H₂PtCl₆ and PdCl₃ to give a Pt loading of 2% and a Pd loading of 4% by weight. It was then mixed with ceramic beads in a weight ratio of 1:9 so that the final Pt-Pd loading was 0.2% and the final Pd loading was 0.4%. Input gases of varying composition, shown in the following table, were passed over this catalyst, with the following results: Temperature: 25°C Pressure: Atmospheric Space velocity 8,400/h. H₂ concentration 1.0 vol. % O₂ concentration 2.5 vol. % ppm NO Conversion 100 88 150 87 200 82 275 75 300 68 It will be noted that, even at 25°C, very good conversion was obtained, although this conversion fell off as the concentration of NO was increased. Example 13 In the examples heretofore, the nitrogen oxide reduced was NO. This is the most widely-found species in industrial stack gases. However, to demonstrate that other nitrogen oxides are also decomposed, the following example was performed. A mixture of nitrogen oxides was obtained by mixing N₂ containing 5% NO with air. In this process about 25% of the NO is oxidized to NO₂. The mixture was then diluted with N₂ to obtain a feedstock having various different concentrations of NO and NO x (higher nitrogen oxides). The mixture was reduced using the catalyst of Example 10 and the following results were obtained. T °C [NO] Feed ppm [NO x ] Feed ppm Conv.(NO)% Conv.(NO x )% 50 650 860 74 72 60 700 860 71 68 70 880 1250 72 78 90 840 1150 73 77 110 840 1150 75 79 [H₂] = 1% [O₂ = 3.2 S.V. = h⁻¹ Example 14 A hydrophobic silica catalyst was formed by treating commercially available silica spheres of 1/4" (6.4 mm) diameter and having a surface area of 1450 m²/g, (obtained from United Catalyst, Inc.,) with silane to render them hydrophobic. A catalyst having 0.1% Pd and 0.15% Ru was obtained by suspending the silica spheres in an aqueous solution of PdCl₃ and RuCl₃ in a rotating beaker, while an infrared lamp evaporated water from the beaker. The catalyst was then dried in air at 95°C for 12 hours. It was then soaked in I N NaOH solution and washed with distilled water until no Cl⁻ ions were found in the water (when tested with Ag⁺). The catalyst was then dried and reduced in hydrogen at 250°C for 10 hours. Gas mixtures as shown in the following table were passed through this catalyst at atmospheric pressure in the reactor of Example 1, with the following results: T °C S.V. h⁻¹ [H₂]% [O₂]% Conversion % 25 3000 1 3.2 74 45 3000 1 3.2 63 70 3000 1 3.2 52 Example 15 Example 14 was repeated but the hydrophobic silica was slurried with PdCl₃ only to give a catalyst with a 2% by weight loading of Pd. Results with this catalyst were as follows: T °C S.V. h⁻¹ [H₂]% [O₂]% Conversion % 25 3000 1 3.2 14 45 3000 1 3.2 89 70 3000 1 3.2 76 95 3000 1 3.2 60 Example 16 To demonstrate the process of the invention using ammonia as the reducing agent, a catalyst was prepared using SDB particles (prepared as in Example 1) loaded with 0.2 weight percent Pt. The Pt loading was carried out as in Example 1. 16 grams of the impregnated catalyst was placed in a reactor formed of 5/8 inch (15.9 mm) Pyrex (trade mark) heat resistant tubing. A feed gas which included 2000 ppm NO and 2000 ppm NH₃, 4% O₂ and balance N₂ was passed through the reactor at a standard volume of 5,000 litres per hour. The reactor was heated to 170°C. The NO leaving the reactor was monitored. It was found that 38% of the NO has been reduced to nitrogen. No N₂O was detected.

Claims: A process for reducing at least one oxide of nitrogen which process comprises bringing said oxide of nitrogen, in admixture with a reducing gas selected from hydrogen, ammonia, and hydrogen/ammonia mixtures, into contact with a catalyst comprising at least one catalytically active group VIII metal disposed on a hydrophobic support, at a temperature at which the support remains stable, said temperature being from about O°C to 200°C when said reducing gas is hydrogen, and said temperature being from about 100°C to 200°C when said reducing gas is ammonia or an ammonia/hydrogen mixture. A process as claimed in claim 1, wherein the hydrophobic support is selected from (i) styrene divinylbenzene copolymers; (ii) polyethylene or polypropylene and copolymers thereof; (iii) silica which has been rendered hydrophobic by treatment with a silane, with fluorine or with tetrafluoroethylene monomer; (iv) polytetrafluoroethylene; (v) fluorinated carbon; and (vi) carbon which has been rendered hydrophobic by treatment with a silane or with a fluorine-containing compound, for example, tetrafluoroethylene. A process as claimed in claim 1 or claim 2, wherein the hydrophobic support has a surface area of from 50 to 1,500 m²/g. A process as claimed in any one of claims 1 to 3, wherein the feed gas for the process additionally comprises a gas, for example, N₂, CO₂ or a mixture thereof, which is inert under the conditions of the process. A process as claimed in claim 4, wherein the oxides of nitrogen are present in a concentration of less than 1.5% of the feed gas by volume, and the reducing gas is hydrogen, the hydrogen being present in stoichiometric excess to the nitrogen oxides. A process as claimed in any one of claims 1 to 5, wherein the catalyst comprises Pt, Pd, Ru, Rh, or Ir or at least two such metals in which at least one is selected from Pt, Pd or Ru. A process as claimed in any one of claims 1 to 6, wherein the catalyst comprises Pt, or Pt and Pd, or Pt and Ir with a lesser amount by weight of Ir than Pt. A process for reducing at least one oxide of nitrogen, which comprises bringing said oxide of nitrogen in admixture with hydrogen and at least one gas which is inert under the conditions of the process into contact with a catalyst comprising a hydrophobic support and a catalytically active metal selected from Pt, Pd, Ru, and mixtures of Pt or Pd with each other or with Ru, Ir or Rh, at a temperature at which the catalyst is stable of from O°C to 200°C. A process as claimed in claim 8, wherein the hydrogen is present in stoichiometric excess to the oxide of nitrogen. A process as claimed in claim 8 or claim 9, wherein the oxide of nitrogen is present in an amount of less than 1.5% of the feed gas by volume, at least 0.5% of the feed gas comprises hydrogen, at least 80% of the feed gas comprises said gas which is inert, and not more than 200 ppm SO₂ is present in the feed gas. A process as claimed in any one of claims 1 to 10, wherein the hydrophobic support comprises a styrene divinylbenzene copolymer. A process as claimed in any one of claims 1 to 11, wherein the hydrophobic support has a contact angle of at least 30°, preferably at least 50°, and advantageously at least 90°, at the temperature of the process. A process as claimed in any one of claims 1 to 12, wherein the said oxide of nitrogen is present in a waste gas which also contains oxygen, and the said catalyst promotes the selective reduction of the said oxide of nitrogen.

Inventors: CHUANG KARL T, FU LONG, CHUANG, KARL T., FU, LONG
Applicants: ATOMIC ENERGY OF CANADA LTD, ATOMIC ENERGY OF CANADA LIMITED L'ENERGIE ATOMIQUE DU CANADA LIMITEE
Application year: 1989
Main classification: B01J21
IPC codes: B01D53, B01J31, B01J23