Catalyst systems
The present invention provides monolithic structural catalysts. The catalysts have a thin wall structure and are advantageous for catalyzing reactions of gaseous fluid or liquid fluid molecules, such as the denitration or selective catalytic reduction (SCR) of nitrogen oxides (NO x ) in combustion flue gases. In an embodiment, the honeycomb-like monolithic structural body includes catalytically active outer peripheral walls and a plurality of catalytically active thin-walled inner partition walls, the thin-walled inner partition walls adapted to enhance fluid flow through the monolithic catalytic body and to increase interaction of the fluid molecules with the catalyst body.
1. A monolithic structural catalyst body comprising:
an outer peripheral wall and a plurality of inner partition walls having an average thickness of less than 0.22 mm,
the outer peripheral wall and the plurality of inner partition walls having dispersed throughout a chemical composition comprising 50-99.9% by weight an inorganic oxide composition and at least 0.1% by weight a catalytically active metal functional group,
the monolithic structural catalyst body having at least two of the following characteristics:
a hydraulic diameter greater than or equal to 100 mm;
a transverse compressive strength of at least 1.5 kg/cm 2 ; or
a macroporosity greater than or equal to 0.05 cc/g in pores of diameter ranging from 600 to 5,000 Angstroms;
further comprising additional catalytic material deposited on at least one of the outer peripheral wall and the plurality of inner partition walls.
2. The monolithic structural catalyst body of claim 1 , wherein the average thickness of the inner partition walls ranges from 0.05 mm to 0.20 mm.
3. The monolithic structural catalyst body of claim 1 , wherein the average thickness of the inner partition walls ranges from 0.10 mm to 0.18 mm.
4. The monolithic structural catalyst body of claim 1 , wherein the hydraulic diameter is greater than or equal to 150 mm.
5. The monolithic structural catalyst body of claim 1 , wherein the transverse compressive strength is greater than 3 kg/cm 2 .
6. The monolithic structural catalyst body of claim 1 , wherein the transverse compressive strength is greater than 4 kg/cm 2 .
7. The monolithic structural catalyst body of claim 1 , wherein the monolithic structural catalyst body has a defect level of 2% or less.
8. The monolithic structural catalyst body of claim 1 , wherein the monolithic structural catalyst body has a defect level of 0.3% or less.
9. A monolithic structural catalyst body comprising:
an outer peripheral wall and
a plurality of inner partition walls having an average thickness of less than 0.22 mm,
the outer peripheral wall and the plurality of inner partition walls having dispersed throughout a chemical composition comprising 50-99.9% by weight an inorganic oxide composition and at least 0.1% by weight a catalytically active metal functional group,
wherein the monolithic structural catalyst body has a hydraulic diameter greater than or equal to 100 mm, a transverse compressive strength of at least 1.5 kg/cm 2 and a macroporosity greater than or equal to 0.05 cc/g in pores of diameter ranging from 600 to 5,000 Angstroms.
10. The monolithic structural catalyst body of claim 9 , wherein the average thickness of the inner partition walls ranges from 0.05 mm to 0.20 mm.
11. The monolithic structural catalyst body of claim 9 , wherein the average thickness of the inner partition walls ranges from 0.10 mm to 0.18 mm.
12. The monolithic structural catalyst body of claim 9 , wherein the hydraulic diameter is greater than or equal to 150 mm.
13. The monolithic structural catalyst body of claim 9 , wherein the transverse compressive strength is greater than 3 kg/cm 2 .
14. The monolithic structural catalyst body of claim 9 , wherein the transverse compressive strength in greater than 4 kg/cm 2 .
15. The monolithic structural catalyst body of claim 9 , wherein the monolithic structural catalyst body has a defect level of 2% or less.
16. The monolithic structural catalyst body of claim 9 , wherein the monolithic structural catalyst body has a defect level 0.3% or less.