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Abstract: Remarkable progress towards implementation of catalytic technology for N2O mitigation in nitric acid plants has been experienced in recent years. EnviNOx®, one of the commercial processes developed by Uhde, accomplishes the tail-gas abatement of N2O and NO x over a single reactor using iron-containing zeolite catalysts. Two variants of the process are available depending on the tail-gas temperature. This manuscript evaluates the low-temperature abatement process (<700K), where NO x and N2O are selectively reduced by NH3 and CH4, respectively. To this end, activity tests in mixtures with N2O, O2, NO, NH3, and CH4 at different temperatures and partial pressures of reactants were carried out over steam-activated FeZSM-5. Ammonia and nitric oxide strongly inhibit the selective catalytic reduction (SCR) of N2O by CH4, shifting the temperature for N2O conversion over 700K. Controlled ammonia dosing is required for the efficient operation of the low-temperature EnviNOx® variant over the particular iron zeolite used in this study. The optimal inlet NH3 concentration is determined by the NO concentration in the tail-gas and its temperature. In the absence of NO and NH3, the CH4-SCR of N2O over FeZSM-5 is effective above 623K. Still, this process cannot retrofit a number of existing plants with lower tail-gas temperatures. [Copyright &y& Elsevier]

Abstract: Various commercially available zeolite frameworks (MFI, FER, BEA, MOR, FAU) with iron impurities ranging from 85 to 780ppm and nominal Si/Al ratios of 10–15 have been tested in direct N2O decomposition after calcination and steam treatment. Our results show a significant impact of the framework type on the catalytic activity at these high degrees of iron dilution (Fe/Al<0.01). H-beta was the most effective material in the reaction, followed by the other pentasyl-type H-ferrierite and H-ZSM-5 zeolites. [Copyright &y& Elsevier]

Selective catalytic reduction (SCR) of N2O with C3H8 over Fe-zeolites (MFI, BEA, USY) under excess oxygen is strongly inhibited by NO. The assistance of the hydrocarbon in N2O reduction vanishes at high partial NO pressures, approaching the activity of the N2O+NO system at molar NO/C3H8 ratios of 1.5–2, with N2O/C3H8=1. This effect is opposite to the NO promotion in direct N2O decomposition over these catalysts at temperatures >625 K. At lower temperatures and in the absence of NO, propane is oxydehydrogenated to propene by N2O over the catalysts. Extraframework iron sites are essential for N2O and C3H8 conversions, in particular iron in isolated positions is most effective. Propane activates on N2O-oxidized iron sites, while acidic sites play a minor role in the overall process. In the absence of NO, N2O and C3H8 conversions are coupled in temperature. Addition of NO uncouples the N2O and C3H8 conversion profiles and shifts them to higher temperature. NO inhibits N2O decomposition over iron sites by competitive adsorption at temperatures where N2O reduction with C3H8 typically starts (>525 K). At these temperatures, adsorbed NO blocks the isolated Fe-sites for N2O activation. The relatively low activity for NOx reduction to N2 (<20%) and the lower optimal operation temperature for this process (550 K) compared to N2O reduction (725 K) makes the simultaneous removal of NO and N2O with hydrocarbons unfeasible over Fe-zeolites. [Copyright &y& Elsevier]

Abstract: Several catalysts, including FeZSM-5, Co2AlO4, LaCoO3, and BaFeAl11O19, were evaluated for N2O decomposition under representative flue-gas conditions in fluidized-bed combustion (FBC). Closely related formulations proved active and stable catalysts for process-gas or tail-gas de-N2O in nitric acid plants. With this as starting point, their potential suitability for N2O abatement in stationary combustion was assessed. Tests were carried out in a fixed-bed reactor at ambient pressure and in the temperature range of 473–1123K using mixtures of N2O, O2, NO, CO, SO2, and H2O. The mixed oxide catalysts were strongly inhibited by water and sulfur dioxide and experienced fast deactivation in the simulated mixture containing all the gases. Bulk sulfate phases were detected by X-ray diffraction in the used perovskite and hexaaluminate, revealing insufficient chemical stability in the presence of sulfur and discouraging installation in the freeboard of the combustor. In great contrast, the activity of steam-activated FeZSM-5 in the model and simulated mixtures was comparable, rendering very stable performance during 30h on stream. The unique tolerance of this iron zeolite to the complex combination of feed components makes it prone to implementation after the cyclone of FBCs, where temperatures are typically 800–1100K. [Copyright &y& Elsevier]