Disclosed herein are a catalyst composition, catalyst devices, and methods for removing formaldehyde, volatile organic compounds, and other pollutants from an air flow stream. The catalyst composition including manganese oxide, optionally one or more of alkali metals, alkaline earth metals, zinc, iron, binder, an inorganic oxide, or carbon.

Disclosed herein are a catalyst composition, catalyst devices, and methods for removing formaldehyde, volatile organic compounds, and other pollutants from an air flow stream. The catalyst composition including manganese oxide, optionally one or more of alkali metals, alkaline earth metals, zinc, iron, binder, an inorganic oxide, or carbon.

An automotive catalytic converter includes a three-way catalyst having Rh as the only precious metal configured as a front zone and a three-way catalyst having a mixture of Rh and Pd, Pt, or both configured as a rear zone, such that an exhaust gas from an internal combustion engine passes through the front zone before passing through the rear zone to minimize sulfur poisoning of the catalytic converter.

A method of manufacturing a methane oxidation catalyst and methane oxidation catalysts formed by the method are provided. The method includes providing a palladium (Pd)-based catalyst including Pd dispersed onto a support. A magnesium (Mg) precursor is introduced to the Pd-based catalyst by one of ion exchange or incipient wetness impregnation. After introducing the magnesium precursor to the Pd-based catalyst, the catalyst is dried and subjected to a final heat treatment that includes hydrothermal calcination. A method of methane oxidation in a lean exhaust environment via the methane oxidation catalyst is also provided.

A method of manufacturing a methane oxidation catalyst and methane oxidation catalysts formed by the method are provided. The method includes providing a palladium (Pd)-based catalyst including Pd dispersed onto a support. A magnesium (Mg) precursor is introduced to the Pd-based catalyst by one of ion exchange or incipient wetness impregnation. After introducing the magnesium precursor to the Pd-based catalyst, the catalyst is dried and subjected to a final heat treatment that includes hydrothermal calcination. A method of methane oxidation in a lean exhaust environment via the methane oxidation catalyst is also provided.

According to certain aspects, a wrapped green body carrier for a green body includes side supports and moveable supports mounted to the side supports. Each of the moveable supports includes an inner end configured to move relative to the side supports. The green body carrier includes a flexible sheet attached to and suspended from each inner end of the moveable supports. The inner ends of the moveable supports are configured to move inward to wrap the flexible sheet around at least a portion of the green body (e.g., more than 180°). Accordingly, the wrapped green body carrier supports a large circumference of the green body and accommodates large deviations in shape and/or diameter. In certain embodiments, the flexible sheet includes radiation coupling material or radiation blocking material so that wrapping the flexible sheet around the green body improves uniformity during microwave drying.

According to certain aspects, a wrapped green body carrier for a green body includes side supports and moveable supports mounted to the side supports. Each of the moveable supports includes an inner end configured to move relative to the side supports. The green body carrier includes a flexible sheet attached to and suspended from each inner end of the moveable supports. The inner ends of the moveable supports are configured to move inward to wrap the flexible sheet around at least a portion of the green body (e.g., more than 180°). Accordingly, the wrapped green body carrier supports a large circumference of the green body and accommodates large deviations in shape and/or diameter. In certain embodiments, the flexible sheet includes radiation coupling material or radiation blocking material so that wrapping the flexible sheet around the green body improves uniformity during microwave drying.

A reactor that may contact a gas stream with a catalyst composition includes a catalyst bed module having a first grouping including a first plurality of foam catalyst blocks each bounded by a first front face having a first surface area with an opposing first back face, a first top side with an opposing first bottom side, and a first side face with an opposing first alternate side face and a second grouping adjacent to the first grouping and having a second plurality of foam catalyst blocks each bounded by a second front face having a second surface area with an opposing second back face, a second top side with an opposing second bottom side, and a second side face with an opposing second alternate side face. The first back face of the first plurality of foam catalyst blocks and the second back face of the second plurality of foam catalyst face each face the other in a spaced relationship. The reactor also includes a sealing frame disposed between the first and second groupings and that may maintain the spaced relationship and form a sealed volume between the first plurality of foam catalyst blocks and the second plurality of foam catalyst blocks and a support frame having a support surface and an opening and that may support the first grouping and the second grouping. The first grouping and the second grouping are secured to the support surface such that the opening is positioned between the first grouping and the second grouping and adjacent to the sealed volume, and the sealed volume and the opening provide a passage for gas flow.

A reactor that may contact a gas stream with a catalyst composition includes a catalyst bed module having a first grouping including a first plurality of foam catalyst blocks each bounded by a first front face having a first surface area with an opposing first back face, a first top side with an opposing first bottom side, and a first side face with an opposing first alternate side face and a second grouping adjacent to the first grouping and having a second plurality of foam catalyst blocks each bounded by a second front face having a second surface area with an opposing second back face, a second top side with an opposing second bottom side, and a second side face with an opposing second alternate side face. The first back face of the first plurality of foam catalyst blocks and the second back face of the second plurality of foam catalyst face each face the other in a spaced relationship. The reactor also includes a sealing frame disposed between the first and second groupings and that may maintain the spaced relationship and form a sealed volume between the first plurality of foam catalyst blocks and the second plurality of foam catalyst blocks and a support frame having a support surface and an opening and that may support the first grouping and the second grouping. The first grouping and the second grouping are secured to the support surface such that the opening is positioned between the first grouping and the second grouping and adjacent to the sealed volume, and the sealed volume and the opening provide a passage for gas flow.

The present invention provides a regeneration method and a regeneration device of a poisoning honeycomb catalyst, and belongs to the field of catalyst regeneration. The regeneration method of the poisoning honeycomb catalyst provided by the present invention includes the following steps: carrying out microwave heating treatment on the poisoning honeycomb catalyst, and then spraying liquid nitrogen into cells of the poisoning honeycomb catalyst so that the poisoning honeycomb catalyst is regenerated. The regeneration method provided by the present invention is simple, and the efficiency of the regenerated catalyst can be increased by 90% more than the original efficiency. According to the regeneration device of a poisoning honeycomb catalyst provided by the present invention, the catalyst regeneration is carried out by using the regeneration device provided by the present invention, the regeneration operation is simple, and the catalytic efficiency of the regenerated catalyst is improved.