Selective Catalytic Reduction Catalyst Composition

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This invention relates to a new composition and manufacturing method for selective catalytic reduction (SCR) catalysts used to remove nitrogen oxides (NOx) from exhaust gases. The catalyst composition features a binder made from a porous inorganic material with delaminated layers and a unique multimodal pore structure (with macropores/mesopores and micropores). The binder can be functionalized with metals like iron or copper to further boost catalytic performance. The method of preparation is simpler and more cost-effective than previous technologies, leading to improved SCR catalyst efficiency and potential cost savings.

Use CasesContent extracted from patent full text and abstract with AI.

• Automobile exhaust treatment systems, especially for diesel and lean-burn engines, to reduce NOx emissions.
• Stationary sources such as gas turbines and industrial plants to clean exhaust gas and comply with environmental regulations.
• Heavy machinery, trucks, and commercial vehicles requiring advanced emission control systems.
• Retrofit or upgrade of existing catalytic converters or SCR systems to enhance NOx removal efficiency.
• Development of novel emission treatment devices or honeycomb structures with improved catalyst performance.

BenefitsContent extracted from patent full text and abstract with AI.

• Improved catalytic activity due to enhanced porosity and access to catalytic sites, leading to greater NOx removal.
• Binder itself may contribute to catalytic activity, allowing for reduced reliance on expensive active catalytic components.
• The unique disordered, delaminated, and multimodal pore structure maximizes effectiveness and mass transfer.
• Simpler and more cost-effective manufacturing process compared to conventional pillared catalysts, reducing production costs.
• Material can be extruded into shaped forms (e.g., honeycomb), increasing versatility and compatibility with modern emission control hardware.
• Functionalization with transition metals enables performance tuning and further efficiency gains.
• Reduces the required catalyst volume for a given performance, enabling more compact designs.

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Patent Abstract

A SCR catalyst composition comprises a SCR catalyst; and a binder comprising a porous inorganic material, wherein the porous inorganic material comprises a disordered arrangement of delaminated layers, has a disordered porous structure, and has a multimodal pore size distribution comprising at least a first modal maximum having a macroporous or mesoporous pore size and a second modal maximum having a microporous pore size. The SCR catalyst composition can be manufactured using the method comprising the steps of: (i) providing an inorganic material having a layered structure; (ii) contacting the material with a cationic surfactant to form a swollen material; (iii) agitating the swollen material to form an agitated material; and (iv) calcining the agitated material to recover a delaminated inorganic material, wherein an SCR catalyst is mixed with the inorganic material prior to step (iv).