Conversion of nitrogen oxides in the presence of a catalyst supported on a mesh-like structure

[0001] This application is a divisional application of Ser. No. 09/687,976, now U.S. Pat. No. 6,534,022, filed Oct. 13, 2000, incorporated by reference in its entirety.

[0002] This application claims priority on provisional applications Ser. No. 60/159,800 filed Oct. 15, 1999 and Ser. No. 60/222,261 filed Jul. 31, 2000, both abandoned.

[0003] This invention relates to the conversion of nitrogen oxides, such as NO and NO₂, and more particularly, to the conversion of nitrogen oxides in the presence of a catalyst supported on a mesh-like structure.

[0004] Of interest are commonly owned U.S. applications Ser. No. 09/181,186 entitled Method and Apparatus for Making a Catalyst Carrier Device Element filed Oct. 28, 1998 in the name of Vogt et al., now U.S. Pat. No. 6,276,045 and corresponding to PCT/US99/24907 filed Oct. 21, 1999; Ser. No. 09/265,164 entitled Exhaust Gas Catalytic Converter filed Mar. 9, 1999 in the name of J. Lloyd et al. abandoned and corresponding to PCT/US00/06137 filed Mar. 8, 2000; Ser. No. 09/156,023 entitled Coated Products filed Sep. 17, 1998 in the name of L. Schuh et al., now U.S. Pat. No. 6,217,732 and corresponding to PCT/US98/19811 filed Sep. 23, 1998; Ser. No. 09/589,817 entitled Heat Exchanger/Reactor Apparatus filed Jun. 7, 2000 in the name of Timothy Griffin et al., abandoned, Ser. No. 09/322,524 entitled Structured Packing and Element Therefor filed May 28, 1999 in the name of Rudolf A. Overbeek et al., abandoned, and corresponding to PCT/US99/10784 filed May 14, 1999; Ser. No. 09/002,539 entitled Structured Packing and Element Therefor filed Jan. 2, 1998 in the name of Bettina Paikert et al., now U.S. Pat. No. 6,277,340, corresponding to PCT/US98/27699 filed Dec. 29, 1998 all of the above US patents incorporated by reference herein in their entirety.

[0005] Nitrogen oxides, such as NO and NO₂, are undesired by-products found in exhaust gases in various plants such as power plants, including natural gas-fired power plants, waste-to-energy plants, and fuel combustion plants. Nitrogen oxides also may be found in the combustion products of diesel engines.

[0006] U.S. Pat. No. 4,280,926 discloses a method for producing a catalytic material for reduction of nitrogen oxides utilizing ammonia as reducing agent. The support material has the shape of a fibrous sheet consisting of non-metallic inorganic fibers mixed with a catalytic active powder. The product can be further treated by impregnation in catalytically active agents. The sheets can be shaped to a honeycomb structure and fixated by a silica solution adhesive.

[0007] U.S. Pat. No. 4,416,800 discloses a method for producing a catalytic material. The support material has the shape of a fibrous sheet consisting of non-metallic inorganic fibers mixed with a catalyst carrier powder. The product can be further treated by impregnation in slurry or solution containing carrier materials and catalytically active agents. The catalytic material can be used for:

• [0008] a) reduction of nitrogen oxides in the presence of ammonia (catalyst: Cu, Fe, V, W and Mo on Al₂O₃ or TiO₂)
• [0009] b) oxidation of carbon monoxide and hydrocarbons (catalyst: Pt on Al₂O₃ or TiO₂)

[0010] In accordance with an aspect of the present invention, there is provided a process for removing at least one nitrogen oxide from a fluid, in particular a gas. The process comprises converting the at least one nitrogen oxide in the presence of a catalyst supported on a mesh-like structure. The mesh-like structure preferably has a porosity of greater than about 85%. Preferably the mesh-like structure is fibrous and made of a metal, metal and ceramic or a ceramic.

• • [0011] In a further aspect the mesh-like structure has a porosity of greater than 90%.

[0012] In a still further aspect, the at least one nitrogen oxide is selected from the group consisting of NO and NO₂ and N₂O.

[0013] In a further aspect, the at least one nitrogen oxide is selected from the group consisting of NO and NO₂ or mixtures thereof. In another aspect, the at least one nitrogen oxide is NO. In another aspect, the at least one nitrogen oxide is NO₂. In another embodiment, the at least one nitrogen oxide is N₂O. In yet another aspect, the at least one nitrogen oxide includes NO and NO₂. In yet another aspect, the at least one nitrogen oxide includes NO, NO₂ and N₂O.

[0014] In a further aspect, the catalyst is coated on the mesh-like structure and preferably the coating thickness is less than 30 microns.

[0015] In a still further aspect, a process for removing NO from a gas comprises oxidizing the contained NO to NO₂ and contacting the NO₂ with a metal carbonate, bicarbonate or hydroxide supported on a mesh-like structure, the mesh-like structure comprising a fibrous material of at least one of a metal, metal and ceramic or ceramic and having a porosity of at least 87%.

[0037] The term “removing at least one nitrogen oxide,” as used herein, means that the at least one nitrogen oxide is reacted with a molecule(s) to produce diatomic nitrogen. Such reactions include, but are not limited to, oxidation-reduction reactions. In another aspect, the at least one nitrogen oxide is first further oxidized and then reacted with a metal carbonate, bicarbonate or hydroxide to produce a metal nitrite and metal nitrate, with the nitrite and nitrate being reduced to produce diatomic nitrogen and regenerate the metal carbonate, bicarbonate or hydroxide.

[0038] The mesh-like material is comprised of fibers or wires, such as a wire or fiber mesh, a ceramic fiber mesh, a combination of metal and ceramic fibers, a metal felt or gauze, metal fiber filter or the like. The mesh-like structure may be comprised of a single layer, or may include more than one layer, it may be made of wires; e.g., a knitted wire structure or a woven wire structure and preferably is comprised of a plurality of layers of wires or fibers to form a three-dimensional network of materials. In a preferred embodiment, the support structure is comprised of a plurality of layers of fibers that are oriented randomly in the layers. One or more metals may be used in producing a metal mesh. Alternatively the mesh fibers may include ceramic fibers in place of or in combination with metal fibers. Ceramic fiber meshes are commercially available from Crane & Co. of Massachusetts, USA.

[0039] In a preferred embodiment wherein the mesh-like structure is comprised of a plurality of layers of fibers to form the three-dimensional network of materials, the thickness of such support is at least five microns, and generally does not exceed ten millimeters. In accordance with a preferred embodiment, the thickness of the network is, at least 50 microns and more preferably at least 100 microns and generally does not exceed 2 millimeters.

[0040] In general, the thickness or diameter of the fibers which form the plurality of layers of fibers is less than about 500 microns, preferably less than about 150 microns and more preferably less than about 30 microns. In a preferred embodiment, the thickness or diameter of the fibers is from about 8 to about 25 microns.

[0041] The three dimensional mesh-like structure may be produced as described in U.S. Pat. No. 5,304,330, 5,080,962; 5,102,745 or 5,096,663 incorporated by reference in their entirety. It is to be understood, however, that such mesh-like structure may be formed by procedures other than as described in the aforementioned patents.

[0042] The mesh-like structure that is employed in the present invention (without supported catalyst on the mesh) has a porosity or void volume which is greater than 85%, and preferably is greater than 87% and more preferably is greater than 90%. The term “void volume” as used herein is determined by dividing the volume of the structure which is open by the total volume of the structure (openings and mesh material) and multiplying by 100.

[0043] In one embodiment, the catalyst is supported on the mesh-like material without the use of a particulate support.

[0044] In another embodiment, the catalyst for converting nitrogen oxide(s) is supported on a particulate support that is supported on the mesh-like material. The term particulate as used herein includes and encompasses spherical particles, elongated particles, fibers, etc. In general, the average particle size of the particulate on which catalyst may be supported does not exceed 200 microns and is typically no greater than 50 microns with the average particle size in the majority of cases not exceeding 20 microns. In general, the average particle size of such particulates is at least 0.002 micron and more generally at least 0.5 microns. When the catalyst supported on the particulate support is coated on the mesh, the average particle size of the catalyst support generally does not exceed 10 microns and, when entrapped in the mesh, generally does not exceed 150 microns.

[0045] In an embodiment of the invention, the mesh-like structure, that functions as a support for the catalyst is in the form of a shaped structured packing. This packing can be configured as described below in embodiments given by example to provide for turbulence of the gas phase flowing over the catalyst in the reactor. The mesh-like catalyst support structure may be provided with suitable corrugations in order to provide for increased turbulence as described in more detail hereinafter. Alternatively, the mesh-like structure may include tabs or vortex generators to provide for turbulence, also as shown hereinafter. The presence of turbulence generators enhances mixing in the radial (and longitudinal) direction and also improves access to catalyst either coated on or entrapped in the mesh by providing local pressure differentials across the mesh, and thus creating a driving force for flow. The structured packing can also be in the form of a module such as a roll of one or more sheets that is placed into the tubes of a reactor such that the channels in the module follow the longitudinal direction of the tube. The roll can comprise sheets that are flat, corrugated or wavy or a combination thereof and the sheets can contain fins or holes to promote mixing. The sheets can also be shaped into corrugated strips that are separated from each other by a flat sheet that exactly fit the size of the tube and are held together by welds, wires, a cylindrical flat sheet or combinations thereof. Alternatively, the mesh, with metal, metal and ceramic or ceramic fibers, may be formed into a honeycomb structure with parallel channels. The channels of the honeycomb may include holes and/or turbulence generators to allow for increased mass transfer of the reactants to the catalyst.

[0046] It is to be understood that the mesh-like support that supports the catalyst may be employed in a form other than as a structured sheet. For example, the mesh-like support may be formed as rings, particles, ribbons, etc. and employed in a reactor as a packed bed.

[0047] The catalyst which is supported on the mesh-like structure may be present on the mesh-like support as a coating on the wires or fibers that form the mesh-like structure and/or may be present and retained in the interstices of the mesh-like structure.

[0048] The catalyst may be coated on the mesh-like structure by a variety of techniques, e.g., dipping or spraying. The catalyst particles may be applied to the mesh-like structure by contacting the mesh-like structure with a liquid coating composition (preferably in the form of a coating bath) that includes the particles dispersed in a liquid under conditions such that the coating composition enters or wicks into the mesh-like structure and forms a porous coating on both the interior and exterior portions of the mesh-like structure.

[0049] In a preferred embodiment, the liquid coating composition has a kinematic viscosity of no greater than 175 centistokes and a surface tension of no greater than 300 dynes/cm.

[0050] In one embodiment, the catalyst is coated onto the mesh by dip-coating. In a preferred embodiment, the three-dimensional metal mesh-like material is oxidized before coating; e.g., heating in air at a temperature of from 300° C. up to 700° C. In some cases, if the mesh-like material is contaminated with organic material, the mesh-like material is cleaned prior to oxidation; for example, by washing with an organic solvent such as acetone.

[0051] The coating bath is preferably a mixed solvent system of organic solvents and water in which the particles are dispersed. The polarity of the solvent system is preferably lower than that of water in order to prevent high solubility of the catalyst and to obtain a good quality slurry for coating. The solvent system may be a mixture of water, amides, esters, and alcohols. The kinematic viscosity of the coating bath is preferably less than 175 centistokes and the surface tension thereof is preferably less than 300 dynes/cm.

[0052] In a preferred embodiment of the invention, the mesh-like structure that is coated includes metal wires or fibers or ceramic fibers or metal and ceramic fibers and the metal wires or fibers that are coated are selected or treated in a manner such that the surface tension thereof is higher than 50 dynes/cm, as determined by the method described in “Advances in Chemistry, 43, Contact Angle, Wettability and Adhesion, American Chemical Society, 1964. ”

[0053] In coating a mesh-like structure that includes metal fibers, the liquid coating composition preferably has a surface tension from about 50 to 300 dynes/cm, and more preferably from about 50 to 150 dynes/cm, as measured by the capillary tube method, as described in T. C. Patton, “Paint Flow and Pigment Dispersion”, 2^nd Ed., Wiley-Interscience, 1979, p. 223. At the same time, the liquid coating composition has a kinematic viscosity of no greater than 175 centistokes, as measured by a capillary viscometer and described in P. C. Hiemenz, “Principles of colloid and Surface Chemistry”, 2^nd Ed., Marcel Dekker Inc., 1986, p. 182.

[0054] In such an embodiment, the viscosity and surface tension of the liquid-coating composition is coordinated with the surface tension of the metal being coated such that the liquid-coating composition is drawn into the interior of the structure to produce a particulate coating on the mesh-like structure upon drying. The metal to be coated preferably has a surface tension which is greater than 50 dynes/cm and preferably is higher than the surface tension of the liquid coating composition to obtain spontaneous wetting and penetration of the liquid into the interior of the mesh.

[0055] In the case where the metal of the structure that is to be coated does not have the desired surface tension, the structure may be heat-treated to produce the desired surface tension.

[0056] The liquid coating composition can be prepared without any binders or adhesives for causing adherence of the particulate coating to the structure.

[0057] The surface of the structure to be coated may also be chemically or physically modified to increase the attraction between the surface and the particles that form the coating; e.g., heat treatment or chemical modification of the surface.

[0058] The solids content of the coating bath generally is from about 2% to about 50%, preferably from about 5% to about 30%.

[0059] The bath may also contain additives such as surfactants, dispersants, water soluble polymers, etc. In general, the weight ratio of additives to particles in the coating bath is from 0.0001 to 0.4 and more preferably from 0.001 to 0.1.

[0060] The mesh-like material preferably is coated by dipping the mesh-like material into a coating bath one or more times while drying or calcining in between dippings. The temperature of the bath is preferably at room temperature, but has to be sufficiently below the boiling point of the liquid in the bath.

[0061] After coating, the mesh-like material that includes a porous coating comprised of a plurality of particles is dried, preferably with the material in a vertical position. The drying is preferably accomplished by contact with a flowing gas (such as air) at a temperature of from 20° C. to 150° C. more preferably from 100° C. to 150° C. After drying, the coated mesh-like material is preferably calcined, for example, at a temperature of from 250° C. to 800° C., preferably 300° C. to 500° C., most preferably at about 400° C. In a preferred embodiment, the temperature and air flow are coordinated in order to produce a drying rate that does not affect adversely the catalyst coating, e.g., cracking, blocking of pores, etc. In many cases, a slower rate of drying is preferred. This slower rate of drying can be accomplished by use of a humidified drying gas. It may also be advantageous to vary the humidity of the drying gas as a function of time.

[0062] The thickness of the formed coating may vary. In general, the thickness is at least 1 micron and in general no greater than 100 microns. Typically, the coating thickness is less than 50 microns and more typically does not exceed 30 microns. Applicant has found that coating thickness of less than 30 microns enhances catalyst effectiveness and, therefore, increases volumetric activity.

[0063] The interior portion of the mesh material that is coated has a porosity which is sufficient to allow the particles which comprise the coating to penetrate or migrate into the three-dimensional network. Thus, the pore size of the three-dimensional material and the particle size of the particles comprising the coating, in effect, determine the amount and uniformity of the coating that can be deposited in the interior of the network of material and/or the coating thickness in the network. The larger the pore sizes the greater the thickness of the coating which can be uniformly coated in accordance with the invention.

[0064] In the case where the particles are in the form of a catalyst precursor, the product, after the deposit of the particles, is treated to convert the catalyst precursor to an active catalyst. In the case where the particles which are deposited in the three-dimensional network of material is a catalyst support, active catalyst or catalyst precursor may then be applied to such support, e.g., by spraying, dipping, or impregnation.

[0065] In using a coating bath, the coating slurry in some cases may include additives. These additives change the physical characteristics of the coating slurry, in particular the viscosity and surface tension such that during dipping the slurry penetrates the mesh, and a coating can be obtained with a homogeneous distribution on the interior and exterior of the mesh. Sols not only change the physical properties of the coating slurry, but also act as binders. After the deposition, the article is dried and calcined.

[0066] As representative stabilizing agents there may be mentioned: a polymer like polyacrylic acid, acrylamines, organic quaternary ammonium compounds, or other special mixes which are selected based on the particles. Alternatively an organic solvent can be used for the same purpose. Examples of such solvents are alcohols or liquid paraffins. Control of the pH of the slurry, for example, by addition of HNO₃ is another method of changing the viscosity and surface tension of the coating slurry.

[0067] The catalyst may be coated onto the mesh-like catalyst support by an electrophoretic coating procedure, as described in U.S. application Ser. No. 09/156,023, filed on Sep. 17, 1998, now U.S. Pat. No. 6,217,732. In such a procedure, a wire mesh-like structure is employed as one of the electrodes, and the catalyst of the requisite particle size, is suspended in a coating slurry. A potential is applied across the electrodes, one of which is the mesh-like structure formed from a plurality of layers of fibers, and the mesh-like structure is electrophoretically coated with the catalyst.

[0068] As hereinabove indicated, the supported selective oxidation catalyst may be supported on the mesh material by entrapping or retaining the particulate in the interstices of the mesh. For example, in producing a mesh-like structure comprised of a plurality of layers of randomly oriented fibers, the catalyst or a catalyst support may be included in the mix that is used for producing the mesh-like structure whereby the mesh-like structure is produced with the catalyst or catalyst support retained in the interstices of the mesh. For example, such mesh-like structures may be produced as described in the aforementioned patents, and with an appropriate catalyst or catalyst support being added to the mesh that contains the fibers and a binder, such as cellulose. The produced mesh structure includes the catalyst retained in the mesh structure.

[0069] These and other embodiments should be apparent to those skilled in the art from the teachings herein.

[0070] Although in a preferred embodiment, essentially the entire thickness of the material is coated with the catalyst, it is within the spirit and scope of the invention to coat less than the entire thickness with such particles. It also is possible within the spirit and scope of the present invention to have various coating thicknesses within the three-dimensional structure at the internal interstices of the mesh material.

[0071] Catalyst for converting nitrogen oxides are known in the art. Representative examples of such include but are not limited to oxides of vanadium, aluminum, titanium, tungsten and molybdenum. Zeolites may also be used. Examples of the latter include ZSM-5 modified with protons or copper, cobalt, silver, zinc, or platinum cations or their combination. Other examples of catalysts used for converting nitrogen oxides are precious metals such as platinum, rhodium and palladium. It is to be understood, however, that the scope of the present invention is not to be limited to the specific catalysts hereinabove described.

[0072] The catalyst is supported on the mesh-like structure in an amount effective to convert nitrogen oxide(s). In general, the catalyst is present in an amount of at least 5%, and preferably at least 10%, with the amount of catalyst generally not exceeding 60% and more generally not exceeding 40%, all by weight, based on mesh and catalyst. In one embodiment where the porosity or void volume of the mesh-like structure prior to adding supported catalyst is greater than 87%, the weight percent of catalyst is from about 5% to about 40%, and when the porosity or void volume is greater than 90%, the weight percent of supported catalyst is from about 5% to about 80%.

[0073] In one embodiment, the catalyst which is supported on the mesh-like structure is employed in the reduction of nitrogen oxides with a reducing agent e.g. urea, ammonia, hydrocarbons, etc in the presence of oxygen to produce nitrogen and water. Reductants such as ammonia or urea are widely used for NOx abatement from stationary sources but not from, mobile sources such as gasoline, diesel or natural gas fired vehicles due to inconveniences in ammonia storage and delivery, concerns over safety issues, and ammonia slippage (unreacted ammonia in the effluent). If hydrocarbons are used as a reductant carbon oxides will also be produced. Hydrocarbons are more likely to be used as a reductant in mobile sources. However, the invention described herein includes any reductant used in any source, whether mobile or stationary.

[0074] In another embodiment, the catalyst which is supported on the mesh-like structure is employed in the decomposition of nitrogen oxides into diatomic oxygen and diatomic nitrogen. Typical catalysts used for this purpose are transition metal and noble metal cations exchanged into zeolites, or supported on metal oxides.

[0075] In another embodiment, the catalyst which is supported on the mesh-like structure is employed in the oxidation of ammonia to form nitrogen and water (selective catalytic oxidation). This reaction can be used to remove any unreacted ammonia after selective catalytic reduction.

[0076] In another embodiment where NOx levels are low in the feed, it is advantageous to enrich the concentration of NOx in order to enhance the rate of reaction. In this embodiment, NOx is first enriched by adsorption onto a catalyst and then reacted, or adsorbed onto a catalyst-or adsorbent and then desorbed and reacted on the same or different catalyst. Often the temperatures required for adsorption and reaction are different, with low temperatures preferred for adsorption and higher temperatures preferred for reaction. Given the fast temperature changes typical of mobile sources such as automotive engines, a quick change between adsorption and reaction are required to achieve optimum system efficiency. The use of the mesh-like structure described herein is ideal for such applications given its' superior heat transfer, low thermal mass and its' ability to be heated electrically. In addition, the use of the mesh-like structure improves catalyst effectiveness and, therefore, increases volumetric activity.

[0077] For example, ammonia or urea may be reacted with NO and NO₂ found in the exhaust gases of fossil fueled power plants, or in the combustion products of internal combustion engines to produce nitrogen and water in the presence of the catalyst supported on a mesh-like structure as hereinabove described. Such reactions are as follows:

 4NO+4NH₃+O₂→4N₂+6H₂O
NO+NO₂+2NH₃→2N₂+3H₂O

[0078] It is also possible to use a portion of the engine fuel to reduce the nitrogen oxide in those cases where it is less convenient to use ammonia or urea, such as in a mobile engine such as a typical automotive diesel engine.
C_xH_y+2NO+(x+y/4−1)O₂—N₂+y/2H₂O+xCO₂

[0079] The reduction of nitrogen oxide and catalyst therefor is shown, for example in U.S. Pat. Nos. 5,750,460, 5,707,509, 5,580,534 and 5,905,056. In the present invention, such a catalyst is supported on a mesh-like material, as hereinabove described.

[0080] When used for a diesel engine, the mesh-like material that includes the catalyst for converting the nitrogen oxide(s) may be shaped into a honeycomb structure. In general, such reactions take place at a temperature of from about 100° C. to about 500° C., preferably from about 200° C. to about 400° C.

[0081] In another embodiment it is possible to catalytically decompose N₂O according to the following reaction:
N₂O→N₂+½O₂

[0082] In another embodiment, an oxidation catalyst such as platinum, palladium, rhodium, cobalt, nickel, iron, copper, molybdenum, etc., and a potassium carbonate absorbent may be supported on the mesh-like structure hereinabove described. Such a combination of the catalyst, and the potassium carbonate, supported on a mesh-like structure, may be employed in oxidizing simultaneously, CO to CO₂ and NO to NO₂, according to the following reactions:
CO+½O₂→CO₂
NO+½O₂→NO₂

[0083] The CO and NO may be found in the exhaust gas of a natural gas-fired power plant. The NO₂ is absorbed by, and reacted with, a carbonate or bicarbonate or hydroxide, such as an alkali or alkaline earth metal carbonate, bicarbonate or hydroxide, in particular potassium carbonate, to form carbon dioxide and potassium nitrite and potassium nitrate according to the following reaction:
2NO₂+K₂CO₃→CO₂+KNO₂+KNO₃

[0084] The potassium nitrite and potassium nitrate which remain on the catalyst, then are reacted with a reducing agent such as hydrogen gas in the absence of oxygen in order to regenerate the catalyst, in accordance with the following reaction:
KNO₂+KNO₃+4H₂+CO₂→K₂CO₃+4H₂O(g)+N₂

[0085] Water, as steam, and elemental nitrogen are exhausted instead of NO or NO₂, and potassium carbonate once again is present as an absorbent on the mesh-like structure, thereby allowing the oxidation and absorption cycle to begin again. This process is described in U.S. Pat. Nos. 5,665,321, 5,762,885 and 5,650,127.

[0086] Various embodiments of structural packings will now be described. In FIG. 1, packing 2 is diagrammatically representative of a plurality of parallel corrugated sheets of porous mesh material (referred to herein as MEC material) in which the corrugations 4 are represented by diagonal lines which are at an angle α to the vertical direction of flow F. FIG. 1a, a representative cross section of a corrugation 6. Adjacent corrugated sheets 8 alternate 90° from each other. The MEC material is preferably metal fibers but may be ceramic or combinations thereof.

[0087] Vertical orientation of the packing relative to the flow direction F is desired to optimize the pressure drop vs. the NO removal and minimize the NH₃ slip (unreacted NH₃). This is best represented by a removal efficiency characterized by the term k/Δp where k is the first order reaction rate constant and Δp is the pressure drop. Table 1 shows the relationship between the angle of inclination Δ and the removal efficiency for different angles of inclination and also compared to a typical solid ceramic monolith honeycomb structure used for this purpose. Angle α may be in the range of about 45° to about 70°. However, a mesh honeycomb may be used in the alternative. Typical solid ceramic honeycombs, Table 1, exhibits a pressure drop at a superficial velocity of 5 m/s and 350C. of about 750 Pa/m. What is important is the degree of mixing achieved in a structure with a lower pressure drop (higher angle of inclination) which will tend to decrease ammonia slip while maintaining NO conversion. This lower pressure drop is important in power generation systems since any additional pressure loss will decrease power generating turbine efficiency.

[0088]

	TABLE 1
	Reaction Temperature =
	300° C.		Corrugated Porous structure
	Honeycomb		45 deg angle		60 deg angle
	GHSV	Conv	k/Δp	Conv	k/Δp	Conv	k/Δp
	10000	95.9	2366	91.8	3637	89.4	7377
	20000	84.3	1371	83.9	1980	84.2	4680
	Reaction Temperature =
	350° C.		Corrugated Porous structure
	Honeycomb		45 deg angle		60 deg angle
	GHSV	Conv	k/Δp	Conv	k/Δp	Conv	k/Δp
	10000	97.7	2794	93.9	4067	92.7	8603
	20000	88.7	1615	89.2	2414	87.9	5357

[0089] Table 1 shows that although there is a slight loss in conversion in going from a structure containing a 45° angle of inclination to a structure with a 60° angle, this is overshadowed by the increase in overall efficiency. The above Table also shows that the advantage of the catalyzed porous corrugated structure over the honeycomb increases with increasing GHSV. This is due to the additional benefit of better mixing at higher throughputs for the turbulence causing corrugated structure as opposed to the laminar flow regime typical of a honeycomb.

[0090] It is believed that to further increase the conversion, a combination of corrugated porous MEC mesh material and conventional ceramic honeycomb monolith in a vertical flow orientation should be used. This is shown in FIG. 3c. However, a mesh honeycomb constructed of metal fibers or ceramic fibers or both materials, may also be used in the alternative.

[0091] In FIG. 3a, a conventional ceramic honeycomb structure 10 has a length of L₁, whereas a corrugated structure 12 using MEC mesh material of the present invention for the structure packing elements has a height of L₂ and L₂<L₁ for a given conversion value. In FIG. 3c, the corrugated structure 14 is combined with a honeycomb structure 16 of generally the same construction as structures 10 and 12 except the combined lengths L₃ are now shorter to provide a given conversion provided by either the honeycomb alone of FIG. 3a or the corrugated structure of FIG. 3b. Thus improved conversion is provided while using less corrugated structure material. The use of less of the novel DeNOx structure is a compromise solution to those existing facilities which prefer a quicker revamp/turnaround at the expense of somewhat higher removal. The increase in conversion will be caused by the improved mixing of the structure creating an improved efficiency of the downstream honeycomb.

[0092] In FIG. 2, a preferred converter structure 18 comprises a housing 20 preferably square or rectangular in cross section having a chamber in which packing 22 is located. The packing 22 comprises MEC porous mesh fibrous material elements, preferably metal fibers, as described herein above.

[0093] The porous MEC material comprises a plurality of corrugated elements 24 as shown in FIG. 1 and referred to in Table 1 preferably at an inclination angle α of 45° or at any other suitable angle according to a given implementation. The elements 24 are in this embodiment identical, but may differ according to the particular implementation. In FIG. 19, the angle of adjacent elements is defined by 2α wherein each diagonal line in the figure represent the corrugations of an element, the two crossing diagonals representing adjacent elements wherein the flow direction is as shown in FIG. 1. As seen in FIG. 4, the angle of inclination α of adjacent elements differs by 2α and alternate. No vortex generators are on the elements 24. The number of elements used depends upon the dimensions of the housing 20 and the dimensions of the corrugations and of course the sheet thickness.

[0094] In FIG. 5, in the alternative, a corrugated mesh material element 26 may be used in place of the corrugated elements 24 of FIG. 4. The element 26 has optional vortex generators 28. The element 26 of FIG. 6 is fabricated in apparatuses shown and described in the aforementioned applications PCT/US00/06137; PCT/US98/27699, the former corresponding to application U.S. Ser. No. 09/181,186 Pat. No. 6,276,045 and the latter corresponding to U.S. Ser. No. 09/002,539 Pat. No. 6,277,340 mentioned in the introductory portion herein. The latter applications provide a description of an apparatus fully incorporated by reference herein for making the elements 26 forming corrugations 32 and the vortex generators in the sheet material. The corrugations are formed by adjacent side walls 34, 36, 38, 40 and so on. The corrugations define roots 42 and crests 44. The side walls are inclined preferably at an angle β (FIG. 8) of about 90°. The roots and crests extend in a linear direction.

[0095] The elements 24, FIG. 4, are oriented with their corrugation channel axes at alternating angles to the flow direction F, FIG. 1. The corrugations form gas channels there through. These channels are in fluid communication with each other at the edges of the elements at the housing 20 peripheral surface. The flow pattern angle may be at any desired value according to a given implementation as set forth in Table 1 above at the desired minimum pressure drop. The gas entering the housing 20 in direction 21, FIG. 2, enters into the channels of the elements and then is diverted at angle a initially then at 2α thereto in the adjacent elements and so on alternating in the direction of flow. This creates a turbulence in the flow. This turbulence creates a pressure differential across the elements resulting in fluid flow through the pores of the MEC porous sheet material.

[0096] In FIGS. 6, 7 and 8, optional vortex generators 46 and 48 are triangular and bent from the plane of the element 26 sheet material. The generators 46 and 48 alternate in the direction in which they project from the plane of the sheet material as best seen in FIG. 8. The corrugations have a width w. The vortex generators provide additional turbulence and thus further promote fluid flow through the pores of the MEC material due to the pressure differential thereacross.

[0097] In FIG. 9, structured packing 102 in a further embodiment is formed of porous mesh MEC material, metal fibers or ceramic fibers or both, and comprises an array of identical packing elements 104, 106, 108 and 110 which are part of a larger array 103, FIG. 11. This packing structure shows optional vortex generators of a novel configuration. While nine elements are shown in FIG. 11, this is by way of illustration, as in practice more or fewer elements may be used according to a given implementation. Also, the elements are shown in a square array. This configuration is also by way of illustration as a preferred embodiment. In practice, the array may also be rectangular, circular or any other desired shape in plan view, comparable to the view of FIG. 11, as desired for a given implementation.

[0098] The elements are housed in an outer tower housing 112 which in this case is square in transverse section. Other housings (not shown) may be rectangular or circular in transverse section, as shown for example in embodiments described hereinafter. Each element 104, 106, 108 and 110 is formed from an identical substrate blank 114, FIG. 13, of preferably composite porous fibers as described hereinabove. The material is preferably formed from the material as described above herein or as described in the US patents noted in the introductory portion and which are incorporated by reference herein.

[0099] The blank 114 is a fragment of and represents a portion of a larger complete blank forming each of the elements of FIG. 11. The complete blank (not shown) appears as shown for the partial blank 114 with an identical repetition of the illustrated pattern extending to the right in the Figure (and according to a given implementation, may extend further vertically from the top to bottom of the figure).

[0100] In FIG. 13, the substrate blank 114 includes a plurality of optional through cuts represented by solid lines. Fold lines are illustrated by broken lines 116, 118, 120, 160 and so on. A first row 122 of identical tabs 124 and identical through holes 126 are formed with a tab 124 and hole 126 disposed between each of alternating pairs of adjacent fold lines, such as lines 116 and 118, 120 and 121 and so on. Tabs 124 eventually form vortex generators as will be described below herein. The holes 126 are adjacent the tip region of the tabs 124 and are located on a channel forming fold line at which the inclined edge 130 emanates. The same reference numerals with or without primes and multiple primes in the figures represent identical parts.

[0101] Each tab 124 has a first edge 128 coextensive with a channel forming fold line, such as line 118. The tab 124 has a second edge 130 which emanates at a second channel fold line such as fold line 116 inclined to the fold lines 116 and 118 terminating at a distal end segment tip 132. The edges 128 and 130 terminate at one end at tab fold line 160 along plane 133. The tip 132 has an edge that is coextensive with edge 128 both of which edges are straight and lie on a channel fold line, such as line 118. The edges 128 and 130 both emanate from a common transverse plane 133 as do all of the edges of the tabs 124 of row 122. The tip 132, which is optional, preferably is square or rectangular for the purpose to be described, but may be other shapes as well according to a given implementation. Holes 126 are slightly larger than the tip 132 so as to permit a tip 132 of a tab 124 to pass therethrough in a manner to be explained. All of the tabs 124 and holes of row 122 are aligned parallel to plane 133.

[0102] Additional rows 127 and 129 of tabs 124 and holes 126 are aligned parallel to row 122 and are aligned in the same column such as column 134 between a given set of fold lines such as lines 116 and 118. The tabs 124 and holes 126 between fold lines 116 and 118 are aligned in column 134. The blank 114 as shown has alternating columns 136, 138 and so on corresponding to column 134 of tabs 124 and holes 126 which are aligned in the respective rows 127 and 129. More or fewer such rows and columns may be provided according to a given implementation.

[0103] The rows 122, 127 and 129 alternate with rows 140, 142 and 144 of tabs 124 and holes 126. The tabs 124 and holes 126 of rows 140, 142 and 144 are in the alternate columns 146, 148, 150, 139, 143, and 147. Consequently, the blank 114 has a plurality of rows and columns of the tabs 124 and holes 126 with the tabs of a given set of columns and rows alternating in vertical and horizontal position with the tabs and holes of the remaining columns and rows as shown.

[0104] In FIGS. 10 and 10a, the element 104, as are all of the elements, is formed by bending the blank substrate material along the fold lines 116, 118, 120, 121 and so on (FIG. 13) in alternating opposite directions. This forms the blank 114 into a channelized quasi-corrugated structure. The structure has identical preferably square in plan view channels 154, 156,158 and so on. These channels face in alternating opposite directions 159 (FIG. 12). Thus channels 154, 158 and so on face toward the bottom of the figure, directions 159 and channels 156, 161, 163 and so on face in the opposite direction toward the top of the figure.

[0105] In FIG. 12, representative element 162 has channels 164, 166, 168, 170 each having a respective intermediate connecting wall 172, 174, [1 ]76 and 178 and so on lying in planes extending from left to right in the figure spaced in a normal direction. Channel 166 has lateral side walls 180 and 182 and channel 168 has lateral side walls 182 and 184 with wall 182 being in common for channels 166 and 168. The element 162 has further identical channels as seen in FIG. 11. All of the elements of packing 102 are constructed similarly with identical channels.

[0106] Prior to forming the channels or at the same time, the tabs 124, FIG. 13, are bent to extend from the plane of the blank 114 to form vortex generators at collinear fold lines 160 lying on plane 133.

[0107] The tabs 124 in row 122 are bent out of the plane of the figure in opposite directions in alternate columns 134, 136, 138 and so on. Thus the tabs of columns 134, 138, and 145 are bent in the same direction, e.g., out of the drawing plane toward the viewer. The tabs in columns 136 and 141 are bent in the opposite direction out of the plane of the figure away from the viewer. The same bending sequence is provided the tabs of rows 127 and 129 which are in the same columns as the tabs of row 122 so that the tabs of a given column are all bent in parallel directions.

[0108] The tabs 124′ of the next row 140 in the adjacent alternate columns 146, 148, 150 and so on are all bent parallel in the same direction at corresponding collinear fold lines 186 parallel to plane 133 toward the viewer. They are also parallel to the tabs of columns 134, 138 and so on.

[0109] The tabs 124″ of the next row 127 are bent at their respective fold lines in the same direction as the tabs 124′ in row 127, e.g., toward the viewer out of the plane of the drawing. These tabs are parallel to the tabs of row 140.

[0110] The tabs 124′″ of the row 142 are bent at their fold lines in a direction opposite to the bend of the tabs of rows 127 and 140, e.g., in a direction out of the plane of the drawing away from the viewer. These tabs are parallel and bent in the same direction as the tabs in columns 136 and 141. The tabs of row 129 are bent in the same direction as the tabs of rows 122 and 127 in the same columns, repeating such bends. The tabs of row 144 are bent the same as the tabs of rows 142 and 140 toward the viewer.

[0111] In FIGS. 9 and 10, element 104 has a set of tabs 124₁, 124₁′, 124₁″, 124₁′″, 121 and 123 in channel 154. The tabs 124₁, 124₁″, and 121 all extend in the same direction, for example, from channel 154 connecting wall 190 into the channel 154. The tabs 124₁′, and 123 extend from the same lateral side wall, e.g., side wall 192. The tab 124₁′″, however, extends into channel 154 from the opposite lateral side wall 194. The tabs in plan view along the channel 154 length, from the top of the figure to the bottom, in FIGS. 9 and 10, interrupt the vertical channels and thus form a solely tortuous generally vertical path for fluids. No open continuous vertical linear fluid path is available along the channel lengths for any of the channels.

[0112] The tabs in the next opposite facing channel 156 are in mirror image orientation to the tabs of channel 154 as best seen in FIG. 10.

[0113] The tortuous blocking interruption of the vertical linear path by the tabs is best seen in FIG. 12. Representative element 162 channel 166 has an uppermost tab 124₂, a next lower tab 124₂′ and then still lower tabs 124₂″ and 121₂, and so on. Tabs in adjacent columns in certain rows, such as row 144, FIG. 13, have the same orientation as the tabs in the representative channel 166 such as tabs 123, 123₂, FIG. 10. As shown in FIG. 12, a portion of each of the tabs overlies a portion of the other tabs in the channel. In the plan view the channel 166 is totally blocked by the tabs, as are all of the channels, in the vertical direction normal to the plane of the figure. Thus no linear vertical fluid path is present along the length of the channel 166 (or channels 154, 156, 158 and so on in FIG. 10). Also, each tab in a given channel has one edge thereof adjacent to and abutting either a lateral side wall or a connecting wall.

[0114] The tabs extending from an intermediate connecting wall, such as tab 124₂, FIG. 12, attached to wall 174 of element 162, extend toward and pass through the hole 126 of the connecting wall of the adjacent packing element, such as wall 197 of element 1102. However, none of the tabs of element 1102 extend into or toward the channels of the element 162. Thus, the tabs of each element are employed for substantially cooperating with only the channels of that element to provide the desired tortuous fluid paths. The tabs of each element are substantially independent of the channels of the adjacent elements, notwithstanding that the tips 132 of the connecting wall tabs cooperate as described with the connecting walls and channels of the adjacent elements.

[0115] The tabs 124 and tips 132 are not bent away from the plane of the blank 114, FIG. 13 for those walls of the channels next adjacent to the housing, which walls abut the housing 112. Thus the tabs at the edges of the structure array 103, FIG. 11, do not extend beyond the structure so as to not interfere with the housing 112 interior walls. In the same manner, the tabs at the edge surfaces of the structure 103 are not bent beyond the plane of these surfaces as shown in FIG. 11. Holes 126 in these edge surfaces are also not necessary.

[0116] The tips 132 and holes 126 are optionally employed to provide drip flow of liquid to opposite sides of the respective channel walls to enhance fluid contact throughout the packing structure. Also, the use of vortex generators, cross communicating holes and the like are optional for the present invention.

[0117] The holes 126 also provide fluid communication among the channels in directions transverse the vertical axis of the structure array 103. Of course, the openings in the structured elements sheet material formed by bending the tabs out of the plane of the sheet material provide major fluid communication between the channels in a transverse direction. These openings and openings 126 may be formed in all four walls of each interior channel.

[0118] The elements of structure array 103, FIG. 11, such as elements 104, 106, 108, 110 and so on, are preferably secured together by spot welding the corners of the channels at their upper and bottom ends. The welding is optional as the elements may be dimensioned to fit closely into the tower housing 112 (FIG. 11) and held in place to the housing by friction or by other means (not shown) such as fasteners or the like. The elements may also be secured together first by any convenient fastening devices or bonding medium.

[0119] It should be understood that the number of tabs in a channel and their relative orientation is given by way of example. For example, only one tab, such as tab 124₁′″ in channel 154 extends from the lateral side wall 194 into channel 154. In practice, more than one tab would extend from each side wall into each channel. Also, the sequence of tab orientation, e.g., which tabs extend from a given wall in a vertical sequence, is also by way of example, as other orientations may be used according to a given need.

[0120] Further, the vertical length of the elements and the packing array channels of the array 103 in practice may vary from that shown. The channel lengths are determined by the factors involved for a given implementation as determined by the type of fluids, volumes thereof, flow rates, viscosities and other related parameters required to perform the desired process as discussed hereinabove in more detail. The structure of FIGS. 9-13 is described further in the aforementioned PCT application PCT/US98/27699 incorporated in its entirety by reference herein.

[0121] In FIGS. 14, 15 and 16, a catalyst support structure or heat transfer modular packing 2028, according to a given implementation, is placed axially in a tube 2020 for the length of the tube 2020. The packings 2028 each comprise a single one piece sheet of porous mesh or screen material made of metal or other fibers. The fiber material may also be ceramic, glass, carbon or any combination thereof. The modular packings 2028 are place in preferably abutting (or closely spaced relation) in the tube 2020 ore.

[0122] Representative modular packing 2028 comprises a single sheet of the porous mesh material. The mesh material, FIG. 16, is folded at fold lines 2030, 2031, 2032 and so on at one side 2034 of the packing 2028, and at fold lines 2030′, 2031′ and 2032′ and so on at the opposite side of the 2036 tube 2020. Fold lines 2030, 2030′ define a planar section 2038 therebetween of the flat planar sheet mesh material. Fold lines 2031, 2031′ form an adjacent planar section 2040 of mesh material. Sections 2038 and 2040 form a fluid flow channel 2042 therebetween for fluid flowing nominally in direction 2044, FIG. 14. The actual direction of fluid flow in the tube is complex due to turbulence as will be described and also flows inclined transverse to the tube longitudinal axis defined by direction 2044.

[0123] The region between sections 2038 and 2040, by way of example, between fold lines 2030′ and 2031′ forms a generally rectangular intermediate tube interface 2046 which abuts the tube 2020 inner surface. The sections 2038 and 2048 which are representative of the orientation of the other sections in the packing 2028 are parallel and parallel to the other sections in the packing. As a result there is an array 2048 of parallel sections, each section terminating at a foldline forming an interface with the fold line of the adjacent section. The intermediate interfaces such as interface 2046 all abut an inner surface of the tube 202020 in preferable thermal conductive relation. The sections such as sections 2038 and 2040 and so on are all interconnected as a one piece structure separated by fold lines and an intermediate interface, such as interface 2046.

[0124] The array of sections such as sections 2038, 2040 and 2060 form a corresponding array of fluid channels such as channel 2042 which are all parallel of generally the same transverse width in directions 2050, FIG. 16. Located in each channel are turbulence generator vanes 2052, 2054 and 2056, for example in channel 2058. The vanes are all inclined at about 45° with respect to the fluid flow direction 2044 through the tube 2020, but may be inclined at other angles. The vanes redirect fluid impinging on the vanes transversely against the tube 2020 inner side wall surface to optimize heat transfer to the tube. The vanes 2052, 2054 and 2056 are just a few of the vanes attached to section. Other like vanes are in spaced alignment with the vanes 2052, 2054 and 2056 in the axial fluid flow direction 2044 of the tube 2020 in a vertical array. Either an interface or vane (at the edge of the packing such as vanes 2057 and 2059, FIG. 16) is in thermal conductive contact with the inner surface of tube 2020. The modular packing 2028 is thus a zig-zag structure folded in accordion fashion with somewhat rectangular channels formed by planar sections and intermediate interfaces. The intermediate interfaces are at angles to the plane of some of the sections so as to mate with corresponding curvature of the tube 2020 inner surface as shown in FIG. 14.

[0125] The configuration and layout of the vanes 2052, 2054, 2056 and so on is best illustrated in connection with FIGS. 17 and 18. In FIGS. 17 and 18, the orientation of the vanes are different, but the dimensioning of the vanes is the same for a given tube internal diameter as the relative orientation of the vanes is not critical for a given tube, the orientation of all of the modules preferably being the same in a corresponding tube. However, the orientation of the vanes, which may be about 45° to the longitudinal axis of the tube may also be different for a given set of modules in a tube according to a given implementation.

[0126] In FIG. 17, three identical rectangular blank sheets 2062, 2062′ are formed of wire mesh from a blank 2063, the mesh material to be described below. Representative sheet 2062′ is an elongated rectangular sheet of fiber mesh material having two parallel identical longitudinal edges 64 and parallel identical end edges 2066. Solid lines in the blank 2063 sheet represent through cuts. The blank sheet 2062′ has a plurality of aligned sections 2068, 2070 and 2072 and so on in a linear array. The sections have different lengths L that corresponds to the transverse dimension across the tube 2020 internal diameter for that section (see FIG. 16). The interfaces are between each such section such as interfaces 2074, 2076 and 2078. The interfaces alternate on opposite sides of the tube 2020 as shown in FIG. 16. The vanes are formed by cuts 2088, FIG. 18, in blank 20104 at 45° to the length dimension of the blank and sections from left to right in the figure.

[0127] As best seen in FIG. 18, in blank 20104 the vanes such as vanes 2080, 2082 and 2084 in representative section 2086 are identical and formed by through cuts 2088. Vanes 2090 and 2092 are shorter than vanes 2080, 2082 and 2084 as they are located in the corner of the section. The mirror image vanes 2094 and 2096 in the diagonal opposite corner of section 86 are the same as vanes 2090 and 2092, but in the alternative may differ from each other according to a given implementation.

[0128] Cut 2088 has a straight portion 2088′ and an angled cut at one end of the cut and a U-shaped cut 2098 in conjunction with cut 2088′. Representative vane 2084 has a fold line 20100 shown by the dashed line. The fold lines for the vanes in the other sections are not shown by dashed lines, but are intended to be included. The fold lines for all of the central sections in blank 20104 excluding the two opposite end sections such as section 20102 are parallel to fold line 20100.

[0129] The sections are each separated by two fold lines such as fold lines 20106 and 20108 between sections 2086 and 20102. Sections 20106 and 20108 form intermediate interface 20110 therebetween. A further intermediate interface 20112 is between fold lines 20114 and 20116 of respective sections 20118 and 2086 and so on.

[0130] The vanes of end section 20102 are different then the vanes intermediate the end sections. The vanes 20120, 20122, 20124 and so on of the end section 20102 are thinner in transverse width, and have curved external edges 20128. These vanes directly abut the inner surface of the tube and therefore have curvatures that match the curvature of the curved inner surface of the tube 2020. These end section vanes correspond in location to vanes 2054, 2057, for example, in FIG. 16, modular packing 2028. It should be understood that the drawings are not to scale and are generally schematic in nature to explain the principles rather than provide exact dimensional relation of the different elements of the packing and tube 2020.

[0131] Because the vanes of the different modular packings 2028, FIGS. 14-16, are inclined generally at 45° to the longitudinal axis of the tube 2020, these vanes all direct fluid against the inner surface of the tube wall to maximize heat transfer from the interior of the sections to the tube. The vanes also create local pressure differentials, i.e., turbulence, which may maximize fluid flow through the mesh of the substrate material forming the modular packing 2028 as will be described in more detail herein. The mesh material because of the small pore size normally does not exhibit fluid flow therethrough when the pressure differential thereacross on opposite surfaces is about the same or a small value.

[0132] The size and spacing of the openings in the mesh material of the sections, preferably in combination with the vane turbulence generators, are optionally selected to obtain a desired bulk mixing and pressure drop through the mesh of the structured packing, although such openings and generators are not necessary for the present embodiment.

[0133] The invention now will be described with respect to the following examples; however, the scope of the present invention is not intended to be limited thereby.

[0134] A NO_x conversion catalyst comprised of a mixture of transition metal oxides is ground in an Eiger ball mill for five minutes at 4000 rpm to make a slurry of 19.6 weight percent solids to produce a mean particle size of 2.4 micron. To this slurry mixture 2 weight % of Nyacol alumina sol was added on the basis of the solids weight in the slurry. A Hastelloy X microfiber sheet of 0.4 millimeter thickness and 90% porosity was formed into a honeycomb structure that was then coated with this slurry mixture by dip coating of the structure. The excess slurry in the channels was removed by air knife treatment at 5 bar pressure. The structure weighed 6.14 grams prior to coating and 7.25 grams after coating and drying at 120° C. for 1 hour, thus giving a weight percent pickup of 15.4 weight percent. This coated honeycomb was then coated a second time with the same air knife removal of slurry from the honeycomb channels. The second coating resulted in a honeycomb with a weight of 8.40 grams which yields a sample of 26.9 weight percent. Two more honeycomb structures of 6.32 and 8.43 grams weight were coated as described in this example and the final weight percent of these two sample were 27.9 and 28.6%. These samples were used for catalytic evaluation of NOx removal in a simulated exhaust gas and were shown to be effective catalysts for removal of NOx.

[0135] To sixty grams of the slurry mixture in Example 1, sixty grams of water was added to dilute the solid content in the slurry to 9.8 weight percent. A honeycomb of 5.87 grams was coated with the 19.6 weight percent slurry of Example 1, and dried as described in Example 1. This honeycomb structure was then coated a second time with the 9.8 weight percent slurry, and air knifed as described in Example 1. This second coating resulted in a final loading level of 21.2 weight percent. This sample was used for catalytic evaluation of NOx removal in a simulated exhaust gas, and was shown to be an effective catalyst for removal of NOx.

[0136] A second batch of the catalyst was ball milled as described in Example 1 for 5 minutes. To this slurry was added 1 weight percent Povidone (PVP) (a water soluble polymer product by BASF) based on the total slurry concentration. To this slurry was added 5 weight percent Nyacol alumina sol based on the solids content in the slurry. The solids content was found to be 23.1 weight percent. For two honeycomb structures made from the microfiber material used in Example 1, dip coating of this 23.1% slurry produced a coated product containing 20.5 and 19.8 weight percent solids after drying at 120° C. for 0.5 hour, and calcination at 500° C. for 1 hour. To a third honeycomb structure this 23.1 weight percent slurry was diluted to 17.8 weight percent, and the coated product had a loading level of 16.3 weight percent. These samples were used for catalytic evaluation of NOx removal in a simulated exhaust gas, and were shown to be effective catalysts for removal of NOx.

[0137] A packing of the following specifications was made:

[0138]

	Reactor size
	Reactor width	0.05 m
	Reactor depth	0.05 m
	Bundle height	0.09 m
	Bundle volume	2.25E− m3
		04
	No. of bundles	2
	Sheets/bundle	10
	Reactor total height	0.18 m
	Reactor total volume	4.50E− 04m3
	Packing specific	500 m2/m3
	surface area
	Packing material
	Fiber diameter	12 μm
	Sheet thickness	0.8 mm
	Porosity	90%
	Material	316 Stainless Steel

and the catalyst coated in the following way:

[0139] The DeNOx catalyst was ground with a ball-mill to an average particle size smaller than 5 μm. The catalyst was mixed with water in a weight ratio of 15:85, and homogenized in a ball mill with zirconia balls. The pH of the slurry was adjusted to 8.5 by addition of ammonia. The slurry was transferred to a coating bath which contained two electrodes connected to the positive poles of a power supply. Each sheet of the bundle was coated separately. The sheet was placed vertically parallel to and at equal distance from each of the electrodes and connected to the negative pole of the power supply. The coating was deposited at 9V for 30 seconds. The sheet was taken from the bath, and dried in air at 100° C. for 30 minutes, after which it was calcined in air at 500° C. for 30 minutes at a heating rate of 10° C./min.

[0140] The performance of a novel Selective Catalytic Reduction (SCR) DeNOx catalyst structure of the configuration described in Example 4 was used in a standard DeNOx activity test using the following conditions: an inlet NOx concentration of 500 ppm, NH3 feed of 1.1 x stoichiometric, temperature of 350° C., space velocity of 10000 l/h and a pressure drop of 1.5 mbar/m (0.06 psi/ft). Under these conditions a NOx reduction efficiency of 92% was measured for this catalyst structure containing 0.16 g vanadium. This can be compared to the same catalyst configured as a honeycomb (35 cpsi, 2.3 g vanadium) giving a NOx removal efficiency of 96% under the same reaction conditions.

[0141] The DeNOx reaction is generally believed to first order with respect to NOx Therefore the catalyst structure of this example reaches a comparable NOx removal at a first order removal rate/unit catalyst that is 11 times faster than that of a conventional structure.

[0142] In this example the performance of the same catalyst structure as in Example 2 has been used to study NOx removal efficiency for low NOx applications. A gas stream containing 27 ppm NOx has been treated over the catalyst structure after ammonia injection at two different points upstream of the reactor. In the first case the resulting inlet gas stream is well mixed, in the second case NOx and NH₃ are poorly mixed before entering the catalyst structure. The results of these experiments (run under the same conditions as in Example 5 except for NOx and NH₃ concentrations) are summarized in the table below:

[0143]

	Perfect		Poor
	Mixing		Mixing
	Honeycomb	MEC	Honeycomb	MEC
NOx, IN (ppm)	26.5	27	27	27
Removal	84	86	18	87
Efficiency
(%)
NOx, OUT	4	4	22	4
(ppm)
NH3, OUT	3	3	22	3
(ppm)

[0144] The mesh-like SCR DeNOx structure can guarantee very low amounts of NOx and NH₃ in the outlet of streams that are not perfectly premixed. This is not true of the conventional system, where performance falls off drastically if perfect premixing is not achieved.

[0145] A mesh type SCR-DeNOx corrugated structure was compared to a standard straight channel solid ceramic honeycomb at conditions simulating the exit of a Gas Turbine. Both structures utilized the same catalyst (3% V₂0₅ on WO₃/TiO₂. Pressure drop in all cases is 740-840 Pa/m.

• [0146] Temperature—350C.
• [0147] NO in—20-30 ppm
• [0148] NH₃/NO in—0.92-1.0
• [0149] Test Reactor Cross Section—86×90 mm
• [0150] Test Reactor Length—740-750 mm
• [0151] Superficial Velocity—6.4 m/s
  Mesh Type Structure
• [0152] 500 m2/m3 sheet surface
• [0153] Catalyst loading=0.19 (wt catalyst/wt catalyst+wt mesh)
• [0154] Corrugation angle=60 deg relative to horizontal
  Honeycomb Catalyst
• [0155] 882 m2/m3
• [0156] 45.9 cpsi
  The specific rate constant in the results below takes into account differences in NH₃/NO inlet.
• [0157] k/SV=−ln (1−x/r)
• [0158] where k=specific rate constant (1/h)
• [0159] SV=space velocity (vol feed/vol structure)
• [0160] x=NO conversion
• [0161] r=NH₃/NO inlet
  Results

[0162]

	Reactor			NO
	Length	NO in		Con-	NH3slip
Catalyst	(mm)	(ppm)	NH3/NO	version	(ppm)	k (1/h)
Honeycomb	740	26	0.92	80.4%	0.7	27800
Mesh Like	750	21	0.95	86.90	0.7	33153

This example clearly shows that a mesh type corrugated structure is able to remove more NO than a solid ceramic honeycomb structure of the same volume.

[0163] In the following, example the top 250 mm of the ceramic solid honeycomb structure was removed and replaced, in one case by a catalyzed mesh like corrugated structure and in another by an uncatalyzed metal foil of the same corrugated configuration. This was done in order to assess the impact of improved mixing prior to the honeycomb on ammonia slip (unreacted ammonia).

[0164]

Results
	Reactor
Catalyst	Length	NO in		NH3slip
(1/h)	(mm)	NH3/NO (ppm)	NO	Conversion	k (ppm)
60 deg mesh +	750	25	0.99	87.7%	0.3
29270
Honeycomb
60 deg Foil +	750	28	0.95	83.40	1.25
29201
Honeycomb

The results of this example show that a catalyzed mixer corrugated element in combination with a straight channel honeycomb is much more effective in converting ammonia than an uncatalyzed corrugated mixer followed by a straight chain solid ceramic honeycomb. In addition, comparison of examples 7 and 8 shows that the use of mixer (catalyzed or uncatalyzed) corrugated structure plus honeycomb is more efficient in removing NOx than the same length of honeycomb alone.

[0165] A 25% (by wt. of solids) slurry of a V₂O₅—WO₃/TiO₂ catalytic material was prepared by ball milling to <1 micron size. The solids content of the slurried material was reduced to 10% by addition of deionized water. To this slurry, 2% (by wt. based on the solids content of the slurry) of nitric acid stabilized zirconia sol was added. Additionally, 1% (by wt. based on the weight of the slurry) of ammonium sulfate was also added to this slurry.

[0166] Sheets, 2.5 cm by 3.5 cm 0.8 mm thick, 95% void volume, made of high purity silica fibers were coated using this slurry. The sheets were then dried at 120° C. for 1 h. A second coating of catalyst from the slurry was performed and the sheets dried again at 120° C. for 1 h. The dried sheets were calcined at 350° C. for 4 h. The uptake of catalytic material on the silica fiber sheets was found to be 70% (based on the final wt. of the coated sheet). The catalyst thus prepared was tested for its NO reduction capability.

The conditions of the testing were:

• [0167] NO Concentration: 410 ppm
• [0168] NH₃ Concentration: 390 ppm
• [0169] Oxygen Concentration: 5%
• [0170] CO₂ Concentration: 13%
• [0171] H₂O Concentration: 8%

[0172] NO conversion of 86% was observed at a temperature of 300° C. and a space velocity of 25000 h⁻¹.

[0173] The disclosures of all publications, including patents and published patent applications, are herein incorporated by reference to the same extent as if each publication were specifically and individually incorporated herein by reference.

[0174] It is to be understood, however, that the scope of the present invention is not to be limited to the specific embodiments described above. The invention may be practiced other than as particularly described and still be within the scope of the accompanying claims.