Catalyst device for treatment of formaldehyde and volatile organic compounds
Disclosed herein are catalyst compositions for removing formaldehyde, volatile organic compounds, and other pollutants from an air flow stream. In one embodiment, a catalyst composition comprises manganese oxide particles and rare earth metal catalyst particles.
1. A catalyst composition comprising:
cryptomelane potassium manganese oxide particles at a first mass percent; and
rare earth metal catalyst particles at a second mass percent, wherein the first and second mass percents are with respect to a total weight of the catalyst composition, and wherein the cryptomelane potassium manganese oxide particles and the rare earth metal catalyst particles are physically mixed within the catalyst composition.
2. The catalyst composition of claim 1 , wherein the rare earth metal catalyst particles comprise cerium oxide.
3. The catalyst composition of claim 1 , wherein the first mass percent is from about 30% to about 99%.
4. The catalyst composition of claim 1 , wherein the first mass percent is from about 30% to about 80%.
5. The catalyst composition of claim 1 , wherein the second mass percent is from about 1% to about 70%.
6. The catalyst composition of claim 1 , wherein the second mass percent is from about 20% to about 70%.
7. The catalyst composition of claim 1 , wherein the catalyst composition is in a form of one or more of pellets, beads, extrudates, rings, spheres, cylinders, trilobe, or quadralobe shaped pieces.
8. The catalyst composition of claim 1 , wherein the catalyst composition exhibits an XRD pattern characterized by the following °2θ peaks and intensities:
°2θ
Intensity (counts)
13
24
18
20
28.5
45
33
20
37.5
17
42
12
47.5
25
50
12
56
20
59
13
65
10
70
12
76.5
13
79
12
88
12.
9. A catalyst composition comprising:
cryptomelane potassium manganese oxide particles at a first mass percent from about 30% to about 80%; and
cerium oxide catalyst particles at a second mass percent from about 70% to about 20%, wherein the first and second mass percents are with respect to a total weight of the catalyst composition, wherein the cryptomelane potassium manganese oxide particles and the cerium oxide catalyst particles are physically mixed within the catalyst composition.
10. The catalyst composition of claim 9 , wherein the catalyst composition is in a form of one or more of pellets, beads, extrudates, rings, spheres, cylinders, trilobe, or quadralobe shaped pieces.
11. The catalyst composition of claim 9 , wherein the catalyst composition exhibits an XRD pattern characterized by the following °2θ peaks and intensities:
°2θ
Intensity (counts)
13
24
18
20
28.5
45
33
20
37.5
17
42
12
47.5
25
50
12
56
20
59
13
65
10
70
12
76.5
13
79
12
88
12.
12. A catalyst composition formed by:
physically mixing cryptomelane potassium manganese oxide particles, rare earth metal catalyst particles, and a binder material to form a slurry; and
calcining the slurry to produce the catalyst composition, wherein the cryptomelane potassium manganese oxide particles are present at a first mass percent, wherein the rare earth metal catalyst particles are present at a second mass percent, and wherein the first and second mass percents are with respect to a total weight of the catalyst composition.
13. The catalyst composition of claim 12 , wherein the rare earth metal catalyst particles comprise cerium oxide.
14. The catalyst composition of claim 12 , wherein the first mass percent is from about 30% to about 99%.
15. The catalyst composition of claim 12 , wherein the first mass percent is from about 30% to about 80%.
16. The catalyst composition of claim 12 , wherein the second mass percent is from about 1% to about 70%.
17. The catalyst composition of claim 12 , wherein the second mass percent is from about 20% to about 70%.
18. The catalyst composition of claim 12 , further comprising:
coating the slurry onto a solid substrate.
19. The catalyst composition of claim 12 , wherein the catalyst composition exhibits an XRD pattern characterized by the following °2θ peaks and intensities:
°2θ
Intensity (counts)
13
24
18
20
28.5
45
33
20
37.5
17
42
12
47.5
25
50
12
56
20
59
13
65
10
70
12
76.5
13
79
12
88
12.