Catalysts

The feature of the solution is the usage a catalyst with a carrier based on porous cellular materials. The catalyst consists of a catalyst carrier (foam catalyst), a secondary carrier (Al₂O₃) and a catalytic layer.

Application

For catalytic oxidation of organic substances, carbon monoxide, ammonia, ozone, nitric oxide reduction

Efficiency

Neutralization degree of CO, Ñ_õH_yO_z, NH₃, O₃: up to 99,9%

Product

TU 2178–001-72202761–2004

Capacity

• Permeability by GOST 25283–82: ~10–8 … 10–9 m^-2;
• Unit load 10⁴–10⁵hour^-1;
• Noise blanking: 5–10 dB (determined by primary carrier parameters and block arrangement);
• Tested operational life: 12 000 hours

Technical characteristics

Operating temperature	20 — 600 °Ñ*
Unit load	up to 80000 h-1
Permeability by GOST 25283–82	10-8-10-9 m-2
Porosity	85-98%
Compressive strength	20-100 MPa
Density	0,2-0,8 g/sm3
Specific surface	1-50 m2/g
Average cells’ size	0,5-4 mm
Neutralization degree ÑÎ, ÑõHyOz, NH3, O3 **	up to 99,9%
Operational life	up to 12000 hour
Blocks’ size	up to 800×400×20 mm
Catalytic layer composition	g-Al2O3 /LaxAg1-xMnO3±yg-Al2O3 /CsxLa1-xVO4±y Al2O3/TiO2 /V2O5

* — possible updating up to 1100 °Ñ;
** — gases not containing chlorine, sulphur, phosphorus, fluorine, arsenic

Key technology

This class of materials is 2–5 orders of magnitude greater than existing catalyst carriers (bulk, net) in permeability and specific surface.Besides, having little density (0,2–0,8 g/cm3) and properties’ isotropy, as well as sufficient mechanical strength, it gives engineers free play in designing on its basis. Size of layer pores Al2O3 fluctuates from 2 to 3000 nm. The principal part of pore volume of a layer is occupied by pores with controlled radius of 10–200 nm. the whole surface of the given composite material structure becomes available for interaction with gas molecules of the majority of two-nuclear and three-nuclear molecules, which size of free path is 30–60 nm, does not exceed the basic size of nanopores of the obtained material.

Coral-like structure of bridges’ covering in HPCM provide s high mechanical and thermalphysic characteristics of the obtained composite material. At thermal expansion, compression and mechanical bending of the primary carrier secondary carrier agglomerates attached to point defect of the surface do not interact with other agglomerates mechanically, unlike coverings put with the help of other methods. Employment of a metal carrier of far more considerable heat conductivity 3–5 W/m2 by comparison with traditional ceramic carriers (0,1–0,2 W/m2) allows to solve the problem of local catalyst overheating.

The main special feature of our technology is not development of original catalytic compounds, but the most efficient configuration and stabilization of catalytic a layer in space at nano-level (in defects of crystal structure of the secondary carrier) as well as at macro-level, using various features of primary carrier structure. Application of a catalyst based on foam materials allows to intensify energy — and mass — transfer at the surface, at the expense of efficient turbulization of the flow by carrier macrostructure that reduces thermal loading on the installation and surrounding materials, which in turn increases operational life and reduces installation cost. Possibility of direct energy transfer and heat generation right in the zone of endothermic reactions by means of electrical heating of the matrix of catalyst carrier will allow saving on energy, materials and installation complexity considerably. In aggregate, suggested nano-structural composite catalysts based on foam materials provide maximum activation of various catalytic processes.

For example, the proposed composite catalyst can replace traditionally used bulk catalysts on molded ceramic carriers in flame tubes of reforming furnaces. Lack of need for external flame heating and low hydraulic resistance will make it possible and rather easily to scale down devices for hydrocarbons reforming down to mini-units of hydrocarbon processing.

Application of catalysts on foam-metal carriers will allow simplifying waste-gate in internal-combustion engines (ICE) due to such foam-metal carriers’ characteristics as noise blanking, low hydraulic resistance, high unit load, low thermal capacity and stability against thermal shock. Highly advanced surface of the secondary carrier and possibility of electric heating of catalyst’s carrier in addition to the other technologies will allow solving the problem of the «cold start» and catalytic cleaning of diesel ICE exhaust fumes.

Design and delivery are possible on request:

• Catalytic blocks for processing of wide spread light hydrocarbons of oil gas into motor fuel;
• High-permeability catalysts of synthesis-gas production;
• Photo — and plasma — catalytic blocks of cleaning and sterilization of air indoors.
• Catalytic blocks of high-temperature catalytic neutralization of industrial gas emission, including gases containing dioxine and benzpyrene.