Catalytic Air Pollution Control

Ronald M. Heck, PHD, is President of RMH Consulting, where he specializes in consultation on environmental catalysis for auto, diesel, and stationary sources; general catalysis; fuel cells; reaction engineering; combustion technology; and chemical engineering. Previously, Dr. Heck was a Research Manager responsible for developing new catalyst technology for Engelhard Corporation's worldwide customers in environmental catalysis.Robert J. Farrauto, PHD, is a Research Fellow at BASF Catalysts and Adjunct Professor in the Earth and Environmental Engineering Department of Columbia University in the City of New York, where he teaches courses in catalysis and supervises graduate student research. His responsibilities at BASF Catalysts include the development of advanced catalysts for the hydrogen economy. He has worked extensively in the development of catalysts for the environmental, petroleum, and chemical industries.Suresh T. Gulati, PHD, is a Consultant to the Science and Technology Division of Corning. He has also been a research fellow with Corning, specializing in the behavior of brittle materials. Dr. Gulati has many years of experience working with automotive substrates, with an emphasis on their design and durability for diesel and passenger car applications.

• Preface xiiiAcknowledgments xviiAcknowledgments, First Edition xixAcknowledgments, Second Edition xxiI Fundamentals 11. Catalyst Fundamentals 31.1 Introduction 31.2 Catalyzed Versus Noncatalyzed Reactions 31.3 Catalytic Components 131.4 Selectivity 141.5 Promoters and their Effect on Activity and Selectivity 151.6 Dispersed Model for Catalytic Component on Carrier: Pt on Al2O3 161.7 Chemical and Physical Steps in Heterogeneous Catalysis 181.8 Practical Significance of Knowing the Rate-Limiting Step 21References 22Questions 232. The Preparation of Catalytic Materials: Carriers, Active Components, and Monolithic Substrates 242.1 Introduction 242.2 Carriers 242.3 Making the Finished Catalyst 302.4 Nomenclature for Dispersed Catalysts 322.5 Monolithic Materials as Catalyst Substrates 322.6 Preparing Monolithic Catalysts 362.7 Catalytic Monoliths 372.8 Catalyzed Monolith Nomenclature 382.9 Precious Metal Recovery from Monolithic Catalysts 38References 38Questions 403. Catalyst Characterization 413.1 Introduction 413.2 Physical Properties of Catalysts 423.3 Chemical and Physical Morphology Structures of Catalytic Materials 483.4 Techniques for Fundamental Studies 60References 61Questions 624. Monolithic Reactors for Environmental Catalysis 634.1 Introduction 634.2 Chemical Kinetic Control 634.3 The Arrhenius Equation and Reaction Parameters 664.4 Bulk Mass Transfer 694.5 Reactor Bed Pressure Drop 744.6 Summary 76References 76Questions 775. Catalyst Deactivation 795.1 Introduction 795.2 Thermally Induced Deactivation 795.3 Poisoning 885.4 Washcoat Loss 945.5 General Comments on Deactivation Diagnostics in Monolithic Catalysts for Environmental Applications 95References 97Questions 98II Mobile Source 1016. Automotive Catalyst 1036.1 Emissions and Regulations 1036.2 The Catalytic Reactions for Pollution Abatement 1066.3 The Physical Structure of the Catalytic Converter 1076.4 First-Generation Converters: Oxidation Catalyst (1976–1979) 1146.5 NOx, Co and HC Reduction: the Second Generation: The Three-Way Catalyst (1979–1986) 1186.6 Vehicle Test Procedures (U.S., European, and Japanese) 1236.7 NOx, Co, and HC Reduction: the Third Generation (1986–1992) 1286.8 Palladium TWC Catalyst: The Fourth Generation (Mid-1990s) 1366.9 Low-Emission Catalyst Technologies 1386.10 Modern TWC Technologies for the 2000s 1466.11 Toward a Zero-Emission Stoichiometric Spark-Ignited Vehicle 1486.12 Engineered Catalyst Design 1536.13 Lean-Burn Spark-Ignited Gasoline Engine 157References 163Questions 1747. Automotive Substrates 1767.1 Introduction to Ceramic Substrates 1767.2 Requirements for Substrates 1787.3 Design/Sizing of Substrates 1807.4 Physical Properties of Substrates 1857.5 Physical Durability 1947.6 Advances in Substrates 2077.7 Commercial Applications 2227.8 Summary 229References 230Questions 2368. Diesel Engine Emissions 2388.1 Introduction 2388.2 Worldwide Diesel Emission Standards 2418.3 NOx-Particulate Trade-Off 2458.4 Analytical Procedures for Particulates 2458.5 Particulate Removal 2468.6 NOx Reduction Technologies 2638.7 2007 Commercial System Designs (PM Removal Only) 2728.8 2010 Commercial System Approaches under Development (PM and NOx Removal) 2758.9 Retrofit and Off-Highway 2818.10 Natural Gas Engines 282References 283Questions 2929. Diesel Catalyst Supports and Particulate Filters 2959.1 Introduction 2959.2 Health Effects of Diesel Particulate Emissions 2989.3 Diesel Oxidation Catalyst Supports 2989.4 Design/Sizing of a Diesel Particulate Filter 3029.5 Regeneration Techniques 3139.6 Physical Properties and Durability 3199.7 Advances in Diesel Filters 3249.8 Applications 3409.9 Summary 350References 352Questions 35510. Ozone Abatement within Jet Aircraft 35710.1 Introduction 35710.2 Ozone Abatement 35810.3 Deactivation 36310.4 Analysis of In-Flight Samples 36510.5 New Technology 371References 372Questions 373III Stationary Sources 37511. Volatile Organic Compounds 37711.1 Introduction 37711.2 Catalytic Incineration 37911.3 Halogenated Hydrocarbons 38311.4 Food Processing 39011.5 Wood Stoves 39211.6 Process Design 39411.7 Deactivation 39411.8 Regeneration of Deactivated Catalysts 395References 399Questions 40112. Reduction of No X 40312.1 Introduction 40312.2 Nonselective Catalytic Reduction of NOx 40412.3 Selective Catalytic Reduction of NOx 40712.4 Commercial Experience 41712.5 Nitrous Oxide (N2O) 42712.6 Catalytically Supported Thermal Combustion 429References 434Questions 43913. Carbon Monoxide and Hydrocarbon Abatement from Gas Turbines 44013.1 Introduction 44013.2 Catalyst for CO Abatement 44113.3 Non-Methane Hydrocarbon (NMHC) Removal 44313.4 Oxidation of Reactive Hydrocarbons 44413.5 Oxidation of Unreactive Light Paraffins 44513.6 Catalyst Deactivation 447References 448Questions 44914. Small Engines 45014.1 Introduction 45014.2 Emissions 45014.3 EPA Regulations 45114.4 Catalyst for Handheld and Nonhandheld Engines 45514.5 Catalyst Durability 463References 464Questions 466IV New and Emerging Technologies 46715. Ambient Air Cleanup 46915.1 Introduction 46915.2 Premair® Catalyst Systems 47015.3 Other Approaches 478References 479Questions 48116. Fuel Cells and Hydrogen Generation 48216.1 Introduction 48216.2 Low-Temperature PEM Fuel Cell Technology 48816.3 The Ideal Hydrogen Economy 49516.4 Conventional Hydrogen Generation 49616.5 Hydrogen Generation from Natural Gas for PEM Fuel Cells 49916.6 Other Fuel Cell Systems 505References 511Questions 517Index 518

"This book will be of benefit to those working in the immediate area of catalytic pollution control, as well as those concerned with broader aspects of environmental chemistry both at the professional and student levels. Librarians are encouraged to ensure this volume is on their shelves." (Platinum Metals Review, March 2010)