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Title: Final Technical Report: Low-Cost Manufacturing of High Performance deNO x Catalysts

Abstract

This Small Business Technology Transfer Phase I project has developed scalable, low light-off temperature, hydrothermally stable catalysts for removal of nitrogen oxide (NO x) contaminants from lean-diesel emissions (the process commonly known as “deNO x”), using hydrocarbons as the reductant. We developed the synthesis of a new form of deNOx catalyst originally developed at Argonne National Laboratory. This comprised a method to prepare more uniform catalytic materials by a proven scalable technology for the hydrocarbon catalyzed selective catalytic reduction (HC-SCR) of NO x. The program was able to minimize the use of expensive rare earth metal oxides in the catalysts for a deNOx strategy that already minimizes emissions, storage, transportation, and corrosion concerns associated with SCR using ammonia or urea. Forge Nano has already demonstrated a high-throughput, low-cost method of applying atomic layer deposition (ALD) coatings to particles, allowing this precision coating technique to be implemented at very low $/kg for Li-ion batteries. This program builds off that recently developed low-cost ALD technique to apply finely tuned coatings onto zeolite particles to prepare drop-in ready materials suitable for use as deNO x catalysts without sacrificing cost or performance. This research addresses the following barriers to support the commercial adoption ofmore » this deNO x catalyst strategy: Performance: We demonstrated the viability of scalable ALD oxide overcoats applied to metal exchanged zeolites for the catalytic reduction of NO x. These materials produce comparable light off temperature to the uncoated catalyst, and better activity and hydrothermal stability compared to the sol-gel route. Cost: An independent assessment of the total value proposition for ALD coated deNO x catalyst upgrading was performed to delineate cost saving opportunities with this ALD methodology.« less

Authors:
 [1];  [1];  [1]
  1. Forge Nano, Louisville, CO (United States)
Publication Date:
Research Org.:
Forge Nano, Louisville, CO (United States)
Sponsoring Org.:
USDOE Office of Science (SC)
OSTI Identifier:
1479665
Report Number(s):
DOE-FN-7676
7205311837
DOE Contract Number:  
SC0017676
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English

Citation Formats

Dameron, Arrelaine A., Marshall, Christopher, and Jackson, David. Final Technical Report: Low-Cost Manufacturing of High Performance deNOx Catalysts. United States: N. p., 2018. Web. doi:10.2172/1479665.
Dameron, Arrelaine A., Marshall, Christopher, & Jackson, David. Final Technical Report: Low-Cost Manufacturing of High Performance deNOx Catalysts. United States. doi:10.2172/1479665.
Dameron, Arrelaine A., Marshall, Christopher, and Jackson, David. Mon . "Final Technical Report: Low-Cost Manufacturing of High Performance deNOx Catalysts". United States. doi:10.2172/1479665. https://www.osti.gov/servlets/purl/1479665.
@article{osti_1479665,
title = {Final Technical Report: Low-Cost Manufacturing of High Performance deNOx Catalysts},
author = {Dameron, Arrelaine A. and Marshall, Christopher and Jackson, David},
abstractNote = {This Small Business Technology Transfer Phase I project has developed scalable, low light-off temperature, hydrothermally stable catalysts for removal of nitrogen oxide (NOx) contaminants from lean-diesel emissions (the process commonly known as “deNOx”), using hydrocarbons as the reductant. We developed the synthesis of a new form of deNOx catalyst originally developed at Argonne National Laboratory. This comprised a method to prepare more uniform catalytic materials by a proven scalable technology for the hydrocarbon catalyzed selective catalytic reduction (HC-SCR) of NOx. The program was able to minimize the use of expensive rare earth metal oxides in the catalysts for a deNOx strategy that already minimizes emissions, storage, transportation, and corrosion concerns associated with SCR using ammonia or urea. Forge Nano has already demonstrated a high-throughput, low-cost method of applying atomic layer deposition (ALD) coatings to particles, allowing this precision coating technique to be implemented at very low $/kg for Li-ion batteries. This program builds off that recently developed low-cost ALD technique to apply finely tuned coatings onto zeolite particles to prepare drop-in ready materials suitable for use as deNOx catalysts without sacrificing cost or performance. This research addresses the following barriers to support the commercial adoption of this deNOx catalyst strategy: Performance: We demonstrated the viability of scalable ALD oxide overcoats applied to metal exchanged zeolites for the catalytic reduction of NOx. These materials produce comparable light off temperature to the uncoated catalyst, and better activity and hydrothermal stability compared to the sol-gel route. Cost: An independent assessment of the total value proposition for ALD coated deNOx catalyst upgrading was performed to delineate cost saving opportunities with this ALD methodology.},
doi = {10.2172/1479665},
journal = {},
number = ,
volume = ,
place = {United States},
year = {2018},
month = {4}
}