Washcoat

War gases Washcoats Washers Washing Washing fastness... 

Toners can be used in a variety of appHcations, depending on the substrate and the effect desired. They can be sprayed either directiy onto the wood or over other wood stains. The soHds of toners are usually low (5—15 wt %) and generally require the use of a washcoat or sealer prior to topcoating. 

The soHds content of a washcoat is usually 5—12 wt %. It is important that washcoats leave a very thin film of material to allow the proper amount of sealing and to prevent bridging the pore, which would result in blistering of subsequent build coats. 

Glazes and Wiping Stains. Some appHcations such as kitchen cabinet finishing utilize wiping stains direct-to-the-wood. In most fine furniture appHcations, wiping stains and glazes are appHed over the washcoat or sealer step. 

CAMET control catalyst was shown to obtain 80% NO reduction and 95% carbon monoxide reduction in this appHcation in the Santa Maria, California cogeneration project. The catalyst consists of a cormgated metal substrate onto which the active noble metal is evenly deposited with a washcoat. Unlike the typical 20 on titania turbine exhaust catalysts used eadier in these appHcations, the CAMET catalyst is recyclable (52). 

The most widely used exhaust control device consists of a ceramic monolith with a thin-waHed open honeycomb stmcture. The accessible surface of this monolith system is iacreased by applyiag a separate coatiag, a wash coat, of a high surface area material such as gamma-alumiaa with the catalyticaHy active species impregaated iato this washcoat. The catalyst aeeds to oxidize hydrocarboas, coavert CO to CO2, and reduce NO. The whole system forms a catalytic converter that, suitably encased, is placed between the engine and the muffler/silencer unit. 

In addition to platinum and related metals, the principal active component ia the multiflmctioaal systems is cerium oxide. Each catalytic coaverter coataias 50—100 g of finely divided ceria dispersed within the washcoat. Elucidatioa of the detailed behavior of cerium is difficult and compHcated by the presence of other additives, eg, lanthanum oxide, that perform related functions. Ceria acts as a stabilizer for the high surface area alumina, as a promoter of the water gas shift reaction, as an oxygen storage component, and as an enhancer of the NO reduction capability of rhodium. 

Carrier. The metal catalyst is generally dispersed on a high surface area carrier, ie, the carrier is given a washcoat of catalyst, such that very small (2—3 nm dia) precious metal crystaUites ate widely dispersed over the surface area, serving two basic functions. It maximizes the use of the cosdy precious metal, and provides a large surface area thereby increasing gas contact and associated catalytic reactions (18). 

Catalyst Deactivation. Catalyst deactivation (45) by halogen degradation is a very difficult problem particularly for platinum (PGM) catalysts, which make up about 75% of the catalysts used for VOC destmction (10). The problem may weU He with the catalyst carrier or washcoat. Alumina, for example, a common washcoat, can react with a chlorinated hydrocarbon in a gas stream to form aluminum chloride which can then interact with the metal. Fluid-bed reactors have been used to offset catalyst deactivation but these are large and cosdy (45). 

Diffusion effects can be expected in reactions that are very rapid. A great deal of effort has been made to shorten the diffusion path, which increases the efficiency of the catalysts. Pellets are made with all the active ingredients concentrated on a thin peripheral shell and monoliths are made with very thin washcoats containing the noble metals. In order to convert 90% of the CO from the inlet stream at a residence time of no more than 0.01 sec, one needs a first-order kinetic rate constant of about 230 sec-1. When the catalytic activity is distributed uniformly through a porous pellet of 0.15 cm radius with a diffusion coefficient of 0.01 cm2/sec, one obtains a Thiele modulus y> = 22.7. This would yield an effectiveness factor of 0.132 for a spherical geometry, and an apparent kinetic rate constant of 30.3 sec-1 (106). 

If the same quantity of active ingredient is concentrated in an outside shell of thickness 0.015 cm, one obtains y> = 2.27. This would yield an effectiveness factor of 0.431 in a slab geometry, and the apparent kinetic constant has risen to 99.2 sec-1. If the active ingredient is further concentrated in a shell of 0.0025 cm, one obtains y> = 0.38, an effectiveness factor of 0.957, and an apparent kinetic constant of 220 sec-1. These calculations are comparable to the data given in Fig. 15. This analysis applies just as well to the monolith, where the highly porous alumina washcoat should not be thicker than 0.001 in. 

Firstly, there are technical reasons concerning catalyst and reactor requirements. In the chemical industry, catalyst performance is critical. Compared to conventional catalysts, they are relatively expensive and catalyst production and standardization lag behind. In practice, a robust, proven catalyst is needed. For a specific application, an extended catalyst and washcoat development program is unavoidable, and in particular, for the fine chemistry in-house development is a burden. For coated systems, catalyst loading is low, making them unsuited for reactions occurring in the kinetic regime, which is particularly important for bulk chemistry and refineries. In that case, incorporated monolithic catalysts are the logical choice. Catalyst stability is crucial. It determines the amount of catalyst required for a batch process, the number of times the catalyst can be reused, and for a continuous process, the run time. 

A washcoat, which provides a high surface area onto which the active catalyst is impregnated. The washcoat typically consists of a mixture of zirconium, cerium and aluminium oxides. Apart from providing high surface area the washcoat also acts as an oxygen storage system (see below). 

At the heart of an automotive catalytic converter is a catalyzed monolith which consists of a large number of parallel channels in the flow direction whose walls are coated with a thin layer of catalyzed washcoat. The monolith catalyst brick is wrapped with mat, steel shell and insulation to minimize exhaust gas bypassing and heat loss to the surroundings. 

Figure 10.5. Monolith, washcoat and noble metal particles in an automotive exhaust catalyst.

Numerous permutations in composition exist, but usually the precise composition, particularly that of the washcoat, is a commercial secret. Detailed accounts of the three-way catalyst have been given by Heck and Farrauto [R.M. Heck and R.J. Farrauto, Catalytic Air Pollution Control, (2002, 2" Edition), WUey, New York.]. Here we briefly describe the functions of the catalyst ingredients. 

Alumina, present in the gamma modification, is the most suitable high surface area support for noble metals. The y-Al203 in washcoats typically has a surface area of 150-175 m g However, at high temperatures y-alumina transforms into the alpha phase, and stabilization to prevent this is essential. Another concern is the diffusion of rhodium into alumina, which calls for the application of diffusion barriers. 

Platinum serves as the catalyst for the oxidation of CO and hydrocarbons. It is relatively insensitive to contamination by lead or sulfur. At high temperatures it is not known to dissolve in the washcoat, but sintering into larger particles may lead to a substantial loss of platinum surface area with dramatic consequences for the overall oxidation activity. 

Also a simulation of the flow field in the methanol-reforming reactor of Figure 2.21 by means of the finite-volume method shows that recirculation zones are formed in the flow distribution chamber (see Figure 2.22). One of the goals of the work focused on the development of a micro reformer was to design the flow manifold in such a way that the volume flows in the different reaction channels are approximately the same [113]. In spite of the recirculation zones found, for the chosen design a flow variation of about 2% between different channels was predicted from the CFD simulations. In the application under study a washcoat cata-... 

Among the non-traditional routes for formation of catalyst and catalyst/carrier coatings, the most prominent way is the washcoat route followed by wet impregna-... 

Figure 3.1 Cross section of micro channels coated with alumina washcoat exhibiting U- or V-shapes [6 ...

Figure 3.3 Typical preparation steps needed for preparing a washcoat layer in a micro channel [23. ...

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