Grantee Research Project Results

Final Report: Novel Nanoparticulate Catalysts for Improved VOC Treatment Devices

EPA Contract Number: 68D98152
Title: Novel Nanoparticulate Catalysts for Improved VOC Treatment Devices
Investigators: Higgins, Richard J.
Small Business: CeraMem Corporation
EPA Contact: Richards, April
Phase: I
Project Period: September 1, 1998 through March 1, 1999
Project Amount: $70,000
RFA: Small Business Innovation Research (SBIR) - Phase I (1998) RFA Text |  Recipients Lists
Research Category: SBIR - Air Pollution , Small Business Innovation Research (SBIR) , Air Quality and Air Toxics

Summary/Accomplishments (Outputs/Outcomes):

The purpose of this project was to develop nanoparticulate platinum-on-alumina oxidation catalysts that will provide significantly increased catalyst utilization in devices employed for elimination of volatile organic compounds (VOCs) from stationary emission sources. Catalysts were synthesized using a novel procedure that provided a combination of high metal dispersion and homogeneous metal distribution on the support particles. The catalysts were subsequently applied to small honeycomb monolith channel flow supports with 400 channels per square inch (cpsi) using typical washcoat methods. The amount of platinum incorporated within each monolith was controlled to be about one-quarter to one-half of the amount used in conventional honeycomb monolith devices utilizing platinum as the catalytic component.

The coupons were subsequently tested in a laboratory flow system for oxidation of an air stream containing toluene. For comparative purposes, monolith coupons of identical configuration were acquired from a major producer of these devices. These ?control? coupons contained supported platinum applied using conventional technology at a loading level typically employed for stationary abatement applications. Both experimental coupons and control coupons were tested for toluene oxidation at a range of temperatures and space velocities. Test results showed that the experimental coupons having one-quarter to one-half of the platinum content of the control coupons had equivalent oxidation performance to the control coupons. Characterization of the novel supported catalysts and analysis of the oxidation data indicated that the performance of the novel catalysts was derived from both higher metal dispersion and improved homogeneity of distribution within the monoliths. All specific performance objectives of the program were met or exceeded.

This project demonstrated the technical feasibility of a novel fabrication method for supported, non-selective oxidation catalysts with improved activity compared to those prepared by conventional methods. For platinum and other precious metals (e.g, palladium) used in stationary VOC abatement devices, use of the novel catalysts will translate to increased precious metal utilization and improved economics for such devices. Potential commercial applications for these devices include treatment of dilute VOC emissions generated from industrial applications such as adhesive coating, chemicals manufacturing, hydrocarbon processing, paint finishing, pharmaceutical manufacturing, printing, roasting operations, sheet and coil coating, soil remediation, wood furniture finishing, and vehicle loading/unloading.

The general chemical method used for preparation of the novel catalysts would also be applicable to other types of catalysts, including those used for other environmental applications and in chemical catalysis.

A major catalyst manufacturer is currently evaluating the prototype oxidation catalysts developed in the program. CeraMem Corporation?s preferred commercialization path for this technology would be via an exclusive royalty-bearing license of related patents to a catalyst manufacturer with an established presence in the stationary emissions control catalyst market.

Supplemental Keywords:

Sustainable Industry/Business, Air, Scientific Discipline, Toxics, Technology for Sustainable Environment, Engineering, Environmental Chemistry, Engineering, Chemistry, & Physics, Chemistry and Materials Science, VOCs, cleaner production/pollution prevention, air toxics, New/Innovative technologies, Environmental Engineering, novel catalyst systems, removal, catalysts, VOC treatment, innovative technologies, metal catalysts, emission control technologies, air pollutants, emissions contol engineering, pollution control technologies, Volatile Organic Compounds (VOCs), catalytic oxidation, innovative technology, nanoparticle catalysts