Abstract:
This invention is a catalyst and method of oxidizing ammonia by contacting the ammonia and air with catalyst of cobalt oxide, wherein the improvement comprises using activated alumina in conjunction with the cobalt oxide catalyst.

Description:
This application is a division of application Ser. No. 456,127, filed Jan. 6, 1983, abandoned, which in turn is a continuation-in-part of Ser. No. 270,164, filed June 3, 1981, abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates to the catalytic oxidation of ammonia to oxides of nitrogen, particularly oxidation of ammonia over a mixed catalyst bed of cobalt and aluminum oxide. 
     The process and catalyst of cobalt oxide mixed with other metal oxides for the oxidation ammonia are known in U.S. Pat. No. 1,919,005 hereby incorporated by reference. Also, mixturs of cobalt oxide with other metals as catalyst in the oxidation of ammonia are known in U.S. Pat. No. 3,985,681, hereby incorporated by reference. The above patents set forth clearly the prior art process and catalysts. However, those operating such processes are continually looking for improved catalysts and yields. The process produces NO and NO 2 , hereinafter NO x . 
     Admixtures of metal oxides within individual pellets or co-catalyst is known art, and is believed to utilize complex chemistry that involves interactive or sequential reactions. However, alumina alone is regarded as an inert material under ammonia oxidation conditions. This can be demonstrated by its use either as a catalyst support bed or as a feed-gas preheater layer on top of the colbalt oxide catalyst bed; neither of which give improved yields of NO x . 
     SUMMARY OF THE INVENTION 
     The catalyst and process of this invention has substantially increased yields of NO x . The method of the invention is the improvement in oxidizing ammonia by contacting ammonia and air with the catalyst of particles of cobalt oxide, wherein the improvement comprises using particles of activated alumina in conjunction with the cobalt oxide particles. Preferably, about 10 to 50 percent by weight of alumina is used. Both the alumina and the cobalt oxide particles preferably have a particle size of 6 to 14 mesh. Ammonia and air mixtures having an ammonia concentration by volume of 7.5-12 percent are introduced at a space velocity of 15,000 to 100,000 liters of gas per liter of catalyst in a bed of at least 3.75 cm (1.5 inches) deep. The inert gas temperature can be between 25° and 250° C. Upon ignition the bed temperature ranges from 500° C. to 900° C., preferably 600° C. to 850° C. The preferred pressure of the reaction is slightly above atospheric. The catalyst of this invention for oxidizing ammonia by contact with air and ammonia consists essentially of from about 90 to 50 percent by weight of cobalt oxide particles and from about 10 to about 50 percent by weight of alumina particles. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Example 
     Solid particles of 6-14 mesh of alumina, Al 2  O 3 , and particles of cobalt dioxide, Co 3  O 4 , of the same particle size or larger were placed in a two-inch tubular insulated reactor. Twenty-five ml of alumina particles and 75 ml of cobalt oxide particles were added. Ammonia and air, with the amount of ammonia shown as percent by volume in Table I, were preheated to 80° C. and passed through the reactor at volumetric velocity (VVH) shown. Oxidation proceeded at the upper and lower bed temperature (s) shown for the time shown. The yield in percent by weight of conversion of ammonia to NO x  was measured in the reacted gases at the outlet. Results are shown in Table I. 
     CONTROL 
     A control example was run omitting the alumina, but otherwise operating in the same manner. Results are shown in Table II. 
     DISCUSSION 
     The tables show by comparing yields of control runs against the runs of the example of the invention that yields are improved substantially at otherwise comparable operating conditions. 
     Surprisingly, we have found that a uniform physical mixture of catalyst (Co 3  O 4 ) and inert (Al 2  O 3 ) pellets, as separate particles, lowers the operating temperature of the catalyst bed and provides a substantial improvement in NO x  yield. This is especially important at ammonia in air concentrations above 7.5 percent, where the increase in adiabatic catalyst bed exit temperatures normally results in decreasing NO x  yields as an economic trade-off with higher throughput capacity. 
     It is postulated that the temperature at the actual pore surface of each Co 3  O 4  catalyst particle, where reaction is actually taking place, is much higher than that of the gas stream with which it is in contact. There are then simultaneous transfers occuring through the gas/solid interface film: mass transfer of ammonia and oxygen to the catalyst surface and NO x  back into the gas stream, accompanied by heat transfer of the heat of reaction from the catalyst pellet to the gas stream. Intimate physical contact of the Co 3  O 4  catalyst pellets with inert A1 2  O 3  pellets, allows another path for heat transfer via conduction into the alumina and thence into the gas stream, thus lowering the equilibrium temperature of each catalyst particle, providing improved yield to NO x . A synergistic benefit is evident, in that higher yields reduce the by-product losses to nitrogen--a very high heat release reaction, which reduces the total quantity of heat generated and further reduces the temperature differential created between the catalyst pore surface and the gas stream. The large difference in bed temperatures between Table II and Table I is due to use of the inert alumina as a heat-sink. Table III shows the temperture differences. 
     
                       TABLE I______________________________________EXAMPLE (25 ml Activated Alumina - 75 ml Co.sub.3 O.sub.4)*Volume                Upper Bed                              Lower BedRun  Velocity %      Time, Tempera-                              Tempera-                                      Yield,No.  Per Hour NH.sub.3                Hours ture, °C.                              ture, °C.                                      %______________________________________1    40,000   11.5   4     831     810     90.140,000   11.5   8     828     808     89.940,000   11.5   12    832     811     89.32    20,000   11.5   4     717     643     101.120,000   11.5   8     714     642     96.420,000   11.5   12    708     639     94.03    20,000   7.5    4     550     494     68.120,000   7.5    8     550     498     66.020,000   7.5    12    550     499     63.54    20,000   9.5    4     634     570     86.220,000   9.5    8     637     570     89.320,000   9.5    12    645     579     89.55    40,000   9.5    4     719     700     95.440,000   9.5    8     717     699     93.440,000   9.5    12    730     711     97.46    40,000   7.5    4     620     608     77.540,000   7.5    8     620     609     73.140,000   7.5    12    629     616     79.0______________________________________ *Volume velocity assuming 75 ml bed volume = ratio of flow rate of gas feed mixture to volume of catalyst in liters. 
    
     
                       TABLE II______________________________________CONTROL (WITHOUT ALUMINA)Volume                Upper Bed                              Lower BedRun  Velocity %      Time, Tempera-                              Tempera-                                      Yield,No.  Per Hour NH.sub.3                Hours ture, °C.                              ture, °C.                                      %______________________________________1    40,000   11.5   4     816     842     79.340,000   11.5   8     822     857     75.540,000   11.5   12    834     865     74.22    20,000   11.5   4     740     705     79.820,000   11.5   8     736     708     74.820,000   11.5   12    789     749     79.13    20,000   7.5    4     567     540     44.520,000   7.5    8     568     548     43.720,000   7.5    12    581     560     48.14    20,000   9.5    4     660     633     70.520,000   9.5    8     649     629     64.120,000   9.5    12    674     653     66.45    40,000   9.5    4     558     770     78.240,000   9.5    8     722     769     74.840,000   9.5    12    722     760     73.16    40,000   7.5    4     208     635     64.140,000   7.5    8     260     638     65.540,000   7.5    12    214     633     62.1______________________________________ 
    
     
                                           TABLE III__________________________________________________________________________Lower Bed Temperatures, ° C.                         Upper Bed Temperatures, °C.Run No.Table II     - Table I           = ΔT                  Average ΔT                         Table II                              - Table I                                    = ΔT                                           Average__________________________________________________________________________                                           ΔT1    842    810   32   45     816    831   -15  -6857    808   49          822    828   -6865    811   54          834    832    22    705    643   62   79     740    717   23   42708    642   66          736    714   22749    639   110         789    708   813    540    494   46   65     567    550   17   22548    498   59          568    550   18560    499   74          581    550   314    633    570   63   65     650    634   26   22629    570   59          649    637   12653    579   74          674    645   295    770    700   70   63     558    719   -161 -54769    699   70          722    717    5760    711   49          722    730   -86    635    608   27   24     208    620   -412 -395638    609   29          260    620   -360633    616   17          214    629   -415__________________________________________________________________________ Note the upper bed temperatures at 40,000 (VVH) velocity in Table II, run 1, 5 and 6, appear to have inordinately low temperatures due to movement of the reaction zone into the bed and away from the normal surface location where the thermocouple had been placed.