Supported multielement catalyst and use of the same for NH3 synthesis

Unmet Need

High-temperature oxidation of NH₃ to NO and NO₂ is an essential process for the large-scale production of nitric acid. A typical nitric acid plant running this commercial process uses >50 kg of catalysts in the form of alloy gauzes for which the annual replacement expenses can reach $5 million. Supply shortages and subsequent market price increase of Rh, a key component of these alloy gauzes, has caused significant concerns about the sustainability of nitric acid production and the corresponding chemical and fertilizer manufacturing industries. As such, there is a need for the development of a more sustainable HEA catalyst that can perform high-temperature NH₃ oxidation at a commercial scale.

Technology Description

Researchers at Johns Hopkins University have developed a new high-entropy alloy (HEA) catalyst for NH3 oxidation. Alumina extrudates are used as substrates for supporting the HEA catalysts in NH3 oxidation applications. The HEA nanoparticles can be grown on extruded alumina by adopting a semi-continuous manufacturing process.

Value Proposition

·        Catalyst generates 100% conversion of NH₃ at 750 ^oC

·        Method retains >93% yield of NO_x (NO + NO₂) with a N₂O selectivity of <0.1%.

·        Required reaction temperature is ~200 ^oC less compared to that of commercial Pt-Rh gauze catalysts

Stage of Development

·  Scaling manufacturing capabilities of the catalysts.

Data Availability

Data available upon request.

Publication

N/A