US2018318798A1PendingUtilityA1

Methane Oxidation Catalyst and Method of Using Same

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Assignee: HER MAJESTY THE QUEEN IN RIGHT OF CANADA AS REPRESENTED BY THE MINI OF NATURAL RESOURCESPriority: Nov 12, 2015Filed: Oct 19, 2016Published: Nov 8, 2018
Est. expiryNov 12, 2035(~9.2 yrs left)· nominal 20-yr term from priority
Inventors:Gianni CaravaggioLioudmila Nossova
B01D 2258/018B01J 23/44B01D 53/944B01D 2255/2063B01D 2255/1023B01D 2257/7025B01J 37/0244B01J 23/63B01D 2255/1021B01D 2255/2092B01J 37/0205B01D 53/94B01J 37/0201B01J 23/10B01D 2255/9207B01D 53/72B01J 21/04B01J 35/1019B01J 35/1028B01J 35/1023Y02C20/20B01J 35/615B01J 35/617B01J 35/618
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Claims

Abstract

Provided herein is a methane oxidation catalyst having a support comprising alumina doped with lanthanum and comprising platinum and palladium as active phases. The platinum and palladium are present in the catalyst at an amount effective for producing an exhaust stream from a natural gas vehicle having reduced levels of methane. The catalyst disclosed herein may exhibit improvements in sulfur and water resistance.

Claims

exact text as granted — not AI-modified
1 . A method for reducing unburned methane in a gas stream resulting from methane combustion in a natural gas vehicle (NGV), said gas stream comprising sulfur, said method comprising passing the gas stream through a methane oxidation catalyst having a support comprising alumina doped with lanthanum and comprising platinum and palladium as active phases, thereby producing an exhaust stream from said natural gas vehicle having reduced levels of methane relative to the gas stream resulting from methane combustion,
 wherein the platinum and palladium are present in the methane oxidation catalyst at a weight ratio of Pt:Pd that is greater than 0.75:1.0.   
     
     
         2 . The method of  claim 1 , wherein the gas stream resulting from the methane combustion has a temperature of between 350° C. and 600° C. 
     
     
         3 . The method of  claim 1 , wherein the gas stream resulting from methane combustion comprises between 10 and 20,000 ppm of methane. 
     
     
         4 . The method of  claim 1 , wherein the gas stream resulting from methane combustion comprises oxygen. 
     
     
         5 . The method of  claim 1 , wherein the gas stream resulting from methane combustion comprises water. 
     
     
         6 . The method of  claim 1 , wherein the platinum is present in the methane oxidation catalyst at between 0.5 and 10 wt %. 
     
     
         7 . The method of  claim 1 , wherein the palladium is present in the methane oxidation catalyst at between 0.5 and 10 wt %. 
     
     
         8 . The method of  claim 1 , wherein the platinum and palladium are present in the methane oxidation catalyst at a concentration effective to reduce the methane content in the gas stream resulting from methane combustion by at least 75% at 500° C. after 500 hours on stream. 
     
     
         9 . The method of  claim 1 , wherein the methane oxidation catalyst has a T 50  of below 460° C. after aging in a simulated natural gas vehicle exhaust for 500 h at 500° C. in the presence of 10 vol % water and 10 ppm sulfur dioxide. 
     
     
         10 . The method of  claim 1 , wherein the platinum is present in the methane oxidation catalyst at between 3 wt % and 10 wt % and the palladium is present in the methane oxidation catalyst at between 1 wt % and 10 wt %. 
     
     
         11 . The method of  claim 1 , wherein platinum and palladium are present in the methane oxidation catalyst at a weight ratio of greater than 1. 
     
     
         12 . The method of  claim 1 , wherein the palladium is present in the methane oxidation catalyst at greater than 2 wt %. 
     
     
         13 . The method of  claim 1 , wherein the methane oxidation catalyst is prepared by incipient wetness impregnation in which the platinum and palladium are added sequentially, or wherein the methane oxidation catalyst is prepared by wet impregnation in which the platinum and palladium are added simultaneously. 
     
     
         14 . The method of  claim 1 , wherein the alumina is gamma alumina. 
     
     
         15 . The method of  claim 1 , wherein the specific surface area (BET) of the support is at least 120 m 2 /g. 
     
     
         16 . Use of a methane oxidation catalyst for reducing unburned methane in a gas stream resulting from methane combustion in a natural gas vehicle (NGV), said gas stream comprising at least sulfur, said methane oxidation catalyst having a support comprising alumina doped with lanthanum and comprising platinum and palladium as active phases,
 wherein the platinum and palladium are present in the methane oxidation catalyst at a weight ratio of Pt:Pd that is greater than 0.75:1.0.   
     
     
         17 . Use of the methane oxidation catalyst of  claim 16 , wherein the exhaust gas stream has a temperature of between 350° C. and 600° C. 
     
     
         18 . Use of the methane oxidation catalyst of  claim 16 , wherein the gas stream resulting from methane combustion comprises between 10 and 20,000 ppm of methane. 
     
     
         19 . Use of the methane oxidation catalyst of  claim 16 , wherein the gas stream resulting from methane combustion comprises oxygen. 
     
     
         20 . Use of the methane oxidation catalyst of  claim 16 , wherein the gas stream resulting from methane combustion comprises water. 
     
     
         21 . Use of the methane oxidation catalyst of  claim 16 , wherein the platinum is present in the methane oxidation catalyst at between 0.5 and 10 wt %. 
     
     
         22 . Use of the methane oxidation catalyst of  claim 16 , wherein the palladium is present in the methane oxidation catalyst at between 0.5 and 10 wt %. 
     
     
         23 . Use of the methane oxidation catalyst of  claim 16 , wherein the platinum and palladium are present in the methane oxidation catalyst at a concentration effective to reduce the methane content in the gas stream resulting from methane combustion by at least 75% at 500° C. after 500 hours on stream. 
     
     
         24 . Use of the methane oxidation catalyst of  claim 16 , wherein the platinum is present in the methane oxidation catalyst at between 3 and 5 wt % and the palladium is present in the methane oxidation catalyst at between 1 and 3 wt %. 
     
     
         25 . Use of the methane oxidation catalyst of  claim 16 , wherein the methane oxidation catalyst has a T 50  of below 460° C. after aging in a simulated natural gas vehicle exhaust for 500 h at 500° C. in the presence of 10 vol % water and 10 ppm sulfur dioxide. 
     
     
         26 . Use of the methane oxidation catalyst of  claim 16 , wherein platinum and palladium are present in the methane oxidation catalyst at a weight ratio of greater than 1. 
     
     
         27 . Use of the methane oxidation catalyst of  claim 16 , wherein the palladium is present in the methane oxidation catalyst at greater than 2 wt %. 
     
     
         28 . Use of the methane oxidation catalyst of  claim 16 , wherein the methane oxidation catalyst is prepared by incipient wetness impregnation in which the platinum and palladium are added sequentially, or wherein the methane oxidation catalyst is prepared by wet impregnation in which the platinum and palladium are added simultaneously. 
     
     
         29 . Use of the methane oxidation catalyst of  claim 16 , wherein the alumina is gamma alumina. 
     
     
         30 . Use of the methane oxidation catalyst of  claim 16 , wherein the specific surface area (BET) of the support is at least 120 m 2 /g. 
     
     
         31 . A methane oxidation catalyst for use in a catalytic converter that is mountable on a natural gas vehicle (NGV), said methane oxidation catalyst having a support comprising alumina doped with lanthanum and comprising platinum and palladium as active phases, and are present at an amount effective for producing an exhaust stream from said vehicle having reduced levels of methane relative to a gas stream resulting from combustion in the presence of sulfur, wherein the platinum and palladium are present in the methane oxidation catalyst at a weight ratio of Pt:Pd that is greater than 0.75:1.0. 
     
     
         32 . The methane oxidation catalyst of  claim 31 , wherein the platinum is present in the methane oxidation catalyst at between 0.5 and 10 wt %. 
     
     
         33 . The methane oxidation catalyst of  claim 31 , wherein the palladium is present in the methane oxidation catalyst at between 0.5 and 10 wt %. 
     
     
         34 . The methane oxidation catalyst of  claim 31 , wherein the platinum is present in the methane oxidation catalyst at between 3 and 5 wt % and the palladium is present in the methane oxidation catalyst at between 1 and 3 wt %. 
     
     
         35 . The methane oxidation catalyst of  claim 31 , wherein the catalyst has a T 50  of below 460° C. after aging in a simulated natural gas vehicle (NGV) exhaust for 500 h at 500° C. in the presence of 10 vol % water and 10 ppm sulfur dioxide. 
     
     
         36 . The methane oxidation catalyst of  claim 31 , wherein the palladium is present in the methane oxidation catalyst at greater than 2 wt %. 
     
     
         37 . The methane oxidation catalyst of  claim 31 , wherein the methane oxidation catalyst is prepared by incipient wetness impregnation in which the platinum and palladium are added sequentially, or wherein the methane oxidation catalyst is prepared by wet impregnation in which the platinum and palladium are added simultaneously. 
     
     
         38 . The methane oxidation catalyst of  claim 31 , wherein the alumina is gamma alumina. 
     
     
         39 . The methane oxidation catalyst of  claim 31 , wherein the specific surface area (BET) of the support is at least 120 m 2 /g.

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