Oxidation of Sulfur Dioxide Over Supported Vanadia Catalysts: Molecular Structure ± Reactivity Relationships and Reaction Kinetics

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Oxidation of Sulfur Dioxide Over Supported Vanadia Catalysts: Molecular Structure ± Reactivity Relationships and Reaction Kinetics Catalysis Today 51 (1999) 301±318 Oxidation of sulfur dioxide over supported vanadia catalysts: molecular structure ± reactivity relationships and reaction kinetics Joseph P. Dunna, Harvey G. Stenger Jr.b, Israel E. Wachs*,b aBOC Gases Technology, 100 Mountain Avenue, Murray Hill, NJ 07974, USA bZettlemoyer Center for Surface Studies, Department of Chemical Engineering, Lehigh University, Bethlehem, PA 18015, USA Abstract The oxidation of sulfur dioxide to sulfur trioxide over supported vanadium oxide catalysts occurs as both a primary and secondary reaction in many industrial processes, e.g., the manufacture of sulfuric acid, the selective catalytic reduction of NOx with ammonia and the regeneration of petroleum re®nery cracking catalysts. This paper discusses the fundamental information currently available concerning the molecular structure and sulfur dioxide oxidation reactivity of surface vanadia species on oxide supports. Comparison of the molecular structure and reactivity information provides new fundamental insights on the following topics related to the catalytic properties of surface vanadia species during the sulfur dioxide oxidation reaction: 1. role of terminal V=O, bridging V±O±V and bridging V±O-support bonds, 2. number of surface vanadia sites required to perform SO2 oxidation, 3. influence of metal oxide additives, 4. generation and influence of the surface sulfate overlayer, 5. effect of surface acidity on the reaction turnover frequency, 6. competitive adsorption between SO2 and SO3 and 7. reaction kinetics. # 1999 Elsevier Science B.V. All rights reserved. Keywords: Oxidation; Sulfur dioxide; Vanadia catalyst; Sulfur trioxide 1. Introduction ciated sulfur oxide, SOx, emissions. Approximately two-thirds of the 50 billion pounds of sulfur oxides Sulfur dioxide, SO2, is formed from both the oxida- released annually in the United States are emitted from tion of sulfur contained in fossil fuels and industrial coal ®red power plants [1]. Industrial fuel combustion processes that treat and produce sulfur-containing and industrial processes (primarily sulfuric acid man- compounds. The catalytic oxidation of sulfur dioxide ufacture, petroleum re®ning and smelting of non- appears in numerous industrial processes and has a ferrous metals) account for the remainder of the signi®cant environmental impact because of the asso- emissions. Sulfuric acid is the largest volume chemical cur- *Corresponding author. Tel.: +1-610-758-4274; fax: +1-610- rently produced in the world, approximately 95 billion 758-6555; e-mail: [email protected] pounds per year [2], and is manufactured by the 0920-5861/99/$ ± see front matter # 1999 Elsevier Science B.V. All rights reserved. PII: S 0920-5861(99)00052-8 302 J.P. Dunn et al. / Catalysis Today 51 (1999) 301±318 contact process, which involves the high temperature 2. savings in operating costs generated by lowering catalytic oxidation of sulfur dioxide to sulfur trioxide SCR temperatures, without the worry of ammo- over a unique supported liquid phase catalyst (silica nium sulfate production and deposition. supported vanadium pyrosulfate with alkali promo- Two new NO /SO removal techniques, SNO (Hal- ters). Under reaction conditions, 450±6108C, the x x x dor Topsoe) and DeSONO (Degussa), combine SCR active vanadia component of the catalyst exists as a x technology with sulfuric acid production [12,13]. Flue molten salt forming a very thin liquid layer on the gas is heated to 3808C and nitrogen oxides are surface of the silica support (only 100±1000 AÊ thick). removed via conventional SCR technology. The pro- Sulfur dioxide oxidation to sulfur trioxide proceeds on ducts are further heated to 4208C and the SO is both the active sites located in the interior of the liquid 2 oxidized to SO over a sulfuric acid contact catalyst. ®lm and on the boundary between the ®lm and the 3 The sulfur trioxide is then contacted with water pro- surface of the silica support [3±5]. Thermodynami- ducing concentrated sulfuric acid. Any unreacted cally controlled equilibrium limitations exist at the ammonia from the SCR reactor is oxidized to NO temperatures necessary for the catalyst to activate, x over the second catalyst bed, consequently, avoiding T>4208C, and the conversion of the sulfur dioxide feed the formation of ammonium sulfates. is incomplete with the very small unreacted portion Sulfur oxide emissions from ¯uid catalytic cracking typically being directly emitted into the environment. (FCC) units account for a sizable fraction of annual In contrast to the sulfuric acid contact process, the SO emissions and are increasingly being targeted by oxidation of SO to SO is undesirable during the x 2 3 the Environmental Protection Agency (EPA). The selective catalytic reduction (SCR) of nitrogen oxides amount of SO emitted from a FCC unit regenerator (NO ) found in the ¯ue gas of power plants. SCR x x is a function of the quantity of sulfur in the feed, coke removes NO in the ¯ue gas by reacting the nitrogen x yield and conversion [14]. Typically, 45±55% of feed oxides with ammonia and oxygen to form nitrogen and sulfur is converted to hydrogen sul®de in the FCC water at approximately 3708C over titania supported reactor, 35±45% remains in the liquid products, and vanadia catalysts (e.g., V O /WO ±MoO /TiO ). 2 5 3 3 2 about 5±10% is deposited on the catalyst in the coke Under typical SCR design and operating conditions, [14,15]. The sulfur in the coke is oxidized to SO NO reduction ef®ciency is directly proportional to the 2 x (90%) and SO (10%) in the FCC regenerator. Tradi- NH :NO ratio up to NO reduction levels of about 3 3 x x tional techniques of SO control such as ¯ue gas 80%. Operating with too high of a NH :NO ratio can x 3 x scrubbing and feedstock hydrodesulfurization are lead to unreacted ammonia bypassing the reactor, effective, but are labor and cost intensive. The least ammonia slip, where it readily combines with SO 3 costly alternative is the use of a SO -reduction catalyst at temperatures below 2508C to form ammonium x as an additive to the FCC catalyst inventory. The sulfates, which can block the catalyst's pores and foul catalyst must be able to: downstream heat exchangers [6]. This problem is so serious that industrial speci®cations for SCR pro- 1. oxidize SO2 to SO3 in the FCC regenerator, cesses include upper limits for the outlet concentration 2. chemisorb the SO3 in the FCC regenerator, and of sulfur trioxide corresponding to approximately 1± then 2% sulfur dioxide conversion. Several studies have 3. release it as hydrogen sulfide in the reducing FCC investigated the development of catalysts capable of reactor. simultaneously suppressing the oxidation of sulfur dioxide to sulfur trioxide while ef®ciently promoting Supported vanadia catalysts, such as Amoco's DeSOx the selective catalytic reduction of nitric oxide [7±11]. catalyst (V2O5/CeO2/Mg2Al2O5), have demonstrated The advantages of such catalysts would be: high activity towards these reactions. In addition, petroleum re®ning operations such as 1. the ability to install more intrinsically active SCR FCC and hydrodesulfurization (HDS) yield hydrogen catalysts (e.g., higher vanadia loadings) without sul®de as an undesired product. The hydrogen sul®de the fear of simultaneously increasing SO3 produc- is typically concentrated and fed to a Claus plant to tion and produce elemental sulfur. However, due to equilibrium J.P. Dunn et al. / Catalysis Today 51 (1999) 301±318 303 limitations only 97% of the sulfur is recovered in the this report due to the limited information available in Claus plant and the tail gas, therefore, needs to be the literature concerning the surface arrangement of treated before being released to the atmosphere. The these catalysts. mobil oil SOx treatment (MOST) process involves combusting the Claus tailgas with air, converting all of the sulfur species to SO2 and SO3.TheSOx is 2. Synthesis of supported vanadia catalysts sorbed onto a V2O5/CeO2/Mg2Al2O5 spinel where it is later regenerated to produce concentrated H2S and Many different synthesis methods have been used in SO2, which is recycled to the Claus plant for further the preparation of supported vanadia catalysts: vapor processing [16]. phase grafting with VOCl3 [19±21], non-aqueous In spite of the industrial importance and environ- impregnation with vanadium alkoxides [22,23] and mental consequences of the above catalytic oxidation vanadium acetate [24], aqueous impregnation of vana- processes involving sulfur dioxide, few fundamental dium oxalate [25], as well as dry impregnation with studies have been performed on the kinetics and crystalline V2O5 [26±29]. However, all the catalysts mechanism of sulfur dioxide oxidation with the excep- were found to contain the same surface vanadia spe- tion of the unique sulfuric acid contact catalyst [3±5]. cies independent of the initial synthesis method after However, the studies on commercial sulfuric acid prolonged calcination [30]. The absence of a ``pre- catalysts are not applicable to the environmental paration memory effect'' is due to the high mobility of oxidation reactions over conventional solid metal V2O5 (Tamman temperature of 3708C) and the strong oxide catalysts since the contact catalyst contains driving force of the mixed oxide system to lower its the active vanadia/alkali/sulfate component as a mol- surface free energy by forming a monolayer of surface ten salt on the silica support. Current research into the vanadia species on the high surface free energy oxide oxidation of SO2 to SO3 over conventional supported support [26±29]. The formation of a monolayer is even vanadia catalysts has focused on establishing the observed during hydrocarbon oxidation reactions over fundamental kinetics and molecular structure-reactiv- physical mixtures of V2O5 and TiO2 [31]. Thus, the ity relationships of the oxidation reaction [17,18]. It is same thermodynamically stable surface metal oxide hoped that the insights generated from these studies species are formed independent of the speci®c synth- will assist in: esis method.
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