Zeolites grown on wire gauze: A new structured catalyst packing for dustproof, low pressure drop denox processes

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Abstract
To prove the applicability of zeolite crystals as a catalyst in dustproof low pressure drop reactors, a novel structured catalyst packing has been developed consisting of ZSM‐5 crystals in situ grown on metal wire gauze. Using this technique, mechanically strong catalyst packings of any required shape can be produced that give an extremely low pressure drop across the packing and that trap almost no dust particles. These features make the packing especially suitable for end‐of‐pipe processes, such as the catalytic removal of NOx from large flows of dust containing flue gas. To demonstrate the feasibility of the packing as a catalyst, it was tested — after incorporation copper into the zeolites by ion exchange — on its activity for Selective Catalytic Reduction of nitric oxide with ammonia at 350°C. Both the activity and selectivity of the catalyst packing proved to be superior to conventional vanadia/titania catalysts.