Abstract:
A catalyst for the selective reduction of nitrogen oxides to nitrogen in the presence of ammonia in the form of composite bodies formed from a mixture of zirconia (5 to 50% by weight), a zeolite (50 to 90%), a bond material (0 to 30%), and, optionally, a promoter selected from oxides of vanadium and copper in the amount of at least 0.1% by weight.

Description:
BACKGROUND OF THE INVENTION 
     All fossil fuel combustion processes generate nitrogen oxides (NOx). The probability that these NOx emisssions contribute to the &#34;acid rain&#34; problem, coupled with increased public awareness, prompted the search for catalytic materials which reduce NOx atmospheric emissions. 
     Pence U.S. Pat. No. 4,220,632 and Carter U.S. Pat. No. 3,895,094 disclose the use of zeolites in the selective catalytic reduction of ammonia or other reducing agent. U.S. Pat. No. 4,085,193 to Nakajima et al teaches the use of titania in the presence of vanadia and other metal oxides for the same purpose. Kittrell et al U.S. Pat. No. 4,473,535 teaches copper exchanged zeolite (mordenite) for the same purpose. Many other patents have issued in recent years teaching the reduction of NOx content of exhaust gases. Many NOx containing streams also contain sulfur oxides (SOx) which can adversely affect SCR catalyst performance. It is highly desirable that an SCR catalyst be resistant to poisoning by SOx. The present invention relates to an improved catalyst for the selective catalytic reduction (SCR) of oxides of nitrogen in the presence of a reducing gas such as ammonia in exhaust gas streams, especially those containing SOx. 
     DESCRIPTION OF THE INVENTION 
     We have discovered that an NOx selective catalytic reduction catalyst of improved efficiency and stability to poisoning by SOx can be produced by the combination of high surface area zirconia with a natural or synthetic zeolite. The materials are mixed, formed, dried, and fired into a desired shape such as rings or honeycombs, with or without the addition of a ceramic bonding material. The firing takes place at a temperature below the stability limit of the zeolite to form a monolithic body. The zirconia starting material should have a surface area (as measured by the B.E.T. method) of at least 10 square meters per gram, and preferably greater than 50 square meters per gram. A suitable source for the zirconia powder is the hydrolysis product of a zirconium salt. 
     The preferred amount of zirconia in the product is 10 to 30%, by weight. The operative range of zirconia is from 5 to 50% depending upon other factors. The zeolite should be present in the amount of 50 to 90%. Bond may be present, 0 to 30%. 
     The catalyst can be further enhanced by the addition of small amounts of promoter in the form of precursors of vanadium oxide and/or copper oxide and/or other base metal oxides. For best stability in the presence of SO 2  the vanadium addition is preferred. 
     A preferred zeolite is natural clinoptilolite which may be mixed with other zeolites such as chabazite. The zeolite must be primarily in the acid form or thermally convertible to the acid form in the catalytic product. This form may be produced directly by acid exchange or indirectly by ammonium exchange followed by heating to drive off ammonia and convert the material to the hydrogen form. 
     Zeolites which are useful in this invention are those which can be produced in the hydrogen form by either method and which are stable when in the hydrogen form. Certain zeolites such as zeolite A and sodalite are not stable in the acid form and are not effective in this invention. Examples of zeolites which can be prepared by ammonia and/or acid exchange are mordenite, clinoptilolite, erionite, heulandite, and ferrierite. Zeolites which can be prepared better or only by the ammonium exchange route are natural faujasite and its synthetic counterpart zeolite Y, chabazite and gmelinite. 
     Mixtures of zeolites may also be used. Other hydrogen form zeolites, such as those of the ZSM series, are prepared by the thermal decomposition of organic templates and are also suitable for use in the catalytic composites of this invention. 
     In use the exhaust gas, containing a suitable reducing gas such as ammonia, is passed over the catalyst. Depending upon the requirements of the particular application, the catalyst may be in the form of honeycombs, stacked and arranged, if plural, to provide a through flow path for the gases. Or it may be in the form of randomly dumped saddles, rings, stars, cross partition rings, spheres, pellets, or aggregates or the active catalyst composition can be coated onto a suitable substrate such as cordierite or other ceramic or metal honeycombs. The treated flue gas should be at least 200° C. to prevent deposition of ammonium salts, and may be as high as 650° C. The space velocity is not critical. Typically at 10,000 hourly space velocity (gas volume calculated to standard temperature and pressure) a 1600 ppm NOx content can be reduced by over 90% at 350° C. 
    
    
     DESCRIPTION OF SPECIFIC EMBODIMENTS 
     Example 
     Catalyst Preparation 
     A composition for making nominal 1/4 inch rings with 1/8 inch holes was prepared by mixing dry powders consisting of 4,000 grams of a powdered ammonium form of clinoptilolite with 1050 gms of chemically precipitated zirconium dioxide powder having a surface area of about 90 square meters per gram. Water was added in the amount of 1800 ml and mixing was continued for ten minutes. 
     Concentrated nitric acid, 106 ml, is added and the mixing continued for another ten minutes. Additional water may be added to adjust the consistency of the mix. When the mix is to be extruded 0.2% of an organic cationic polymer extrusion aid may be added after the mix is wet. 
     After extrusion the rings are dried in an air atmosphere for one to two hours at 200° F. The final firing takes place at 1,000° F. for five hours. 
     When it is desired to incorporate vanadium or copper into the composition the promoter precursor may be added during the mixing operation, or may be impregnated into the formed product after firing. The added promoter should be present in an amount of at least 0.1% by elemental weight, as the oxide (V 2  O 5  or CuO). 
     Various products were made according to the methods of the Example. 
     Table I shows the composition of a variety of catalysts made as described above, with varying amounts of zeolite, zirconia, binder and promoter. 
     The SO 2  concentrations were varied with time. The catalysts initial NOx reduction activity without SO 2  in the stream was measured over a 24 hour period and is listed in Table II, column 2. Then, 50 ppm SO 2  was added to the stream and the NOx reduction efficiency measured after an additional 24 hours with the results shown in column 3. Then, this SO 2  concentration was increased to 1600 ppm and the NOx reduction efficiency measured at 24, 48, and 330 hours, and shown in columns 4, 5 and 6, respectively. 
     Test conditions were: 
     
         ______________________________________Temperature, C.     350Oxygen Concentration, Vol %                5NOx Concentration, volume               500parts per millionNH3/NOx, Vol         1H.sub.2 O            15N.sub.2             BalanceSO.sub.2            As Indicated______________________________________ 
    
     The data of Table II clearly demonstrate that the zirconia containing catalyst of this invention, Sample No. 65411, out-performs the control catalyst, Sample No. 65233. The zirconia containing catalyst not only has a higher initial activity in the absence of SO2 but, more importantly, remains more active even in the presence of 1600 ppm SO2. 
     
                       TABLE I______________________________________SELECTIVE CATALYTIC REDUCTIONCATALYST COMPOSITIONSSample Number       Zeolite      ZrO.sub.2                            Binder______________________________________ 65233*     90            0      1065426        0           100     065411       80           20      0______________________________________ *Control 
    
     
                       TABLE II______________________________________NOx REMOVAL EFFICIENCIESOF SELECTIVE CATALYTIC REDUCTION CATALYSTSBEFORE AND AFTER EXPOSURE TO SO.sub.2           % NOx Removal  Intitial After 50 ppm % NOx removal AfterSample NOx      SO.sub.2 Exposure                        1600 ppm SO.sub.2 ExposureNumber Removed  24 hours     24 Hrs                              48 Hrs                                    330 Hrs______________________________________ 65233*  72.1     63.9         57.4  47.4  --65426  9.1      18.2         --    --    --65411  96.0     84.0         82.0  82.0  81.7______________________________________ Control