Overcoming the Engineering Constraints for Scaling-Up the State-of-the-Art Catalyst for Tail-Gas N2O Decomposition

Ignacio Melián-Cabrera, Silvia Espinosa, Cristina Mentruit, Blaine Murray, Lorena Falco, Joseph Socci, Freek Kapteijn, Jacob A. Moulijn

Research output: Contribution to journalArticleScientificpeer-review

6 Citations (Scopus)
10 Downloads (Pure)

Abstract

An efficient process is reported for preparing a state-of-the-art Fe-ferrierite catalyst for N2O decomposition under industrial tail-gas conditions. In the synthesis procedure, we evaluate the very demanding constraints for scale-up; i.e. large reactor volumes are typically needed, and long processing times and considerable amounts of wastewater are generated. The proposed synthesis minimizes the amount of water used, and therefore, the amount of produced wastewater is minimal; in this approach there is no liquid residual water stream that would need intensive processing. This has remarkable benefits in terms of process design, since the volume of equipment is reduced and the energy-intensive filtration is eliminated. This route exemplifies the concept of process intensification, with the ambition to re-engineer an existing process to make the industrial catalyst manufacture more sustainable. The so-obtained catalyst is active, selective, and very stable under tail-gas conditions containing H2O, NO, and O2, together with N2O, keeping a high conversion during 70 h time on stream at 700 K, with a decay of 0.01%/h, while the standard reference catalyst decays at 0.06%/h; hence, it deactivates 6 times more slowly, with ∼5% absolute points of higher conversion. The excellent catalytic performance is preliminarily ascribed to the differential speciation.

Original languageEnglish
Pages (from-to)939-945
Number of pages7
JournalIndustrial and Engineering Chemistry Research
Volume57
Issue number3
DOIs
Publication statusPublished - 24 Jan 2018

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