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CHEMISTRY
Low-Temperature Oxidation
of Methane
Robert J. Farrauto
659
PERSPECTIVES
Engine exhaust:
Methane
Higher hydrocarbons
CO
Soot
NOx
Urea
Tailpipe emissions:
CO2
N2
H2O
all of which poison most catalysts, especially PdO and CeO2. The presence of 5%
steam in lean-burn engines can also inhibit
catalytic reactions and cause excessive sintering of the catalytic components and their
carriers. Furthermore, catalysts must be prepared cost-effectively in high volumes as a
washcoat on a monolith (6). It remains to be
shown whether Cargnello et al.s catalyst can
survive under these conditions.
The severity of the duty cycle for a typical
exhaust catalyst, together with an expected
lifetime of ~400,000 miles for diesel trucks
in the United States, is challenging for any
catalyst. Clearly this can only be achieved
with enhanced catalysts, an advanced engine
control strategy, and improved fuel quality.
In the diesel engine, the oxidation catalyst
must achieve simultaneous complete oxidation of not just methane but also carbon
monoxide (CO), higher hydrocarbons, and
nitric oxide (NO) to nitrogen dioxide (NO2).
In practice, the diesel oxidation catalyst will
likely be placed in a position near the engine
(see the gure) to elevate the inlet temperature to that required for methane oxidation.
As difcult as these criteria may sound,
the combination of improved catalysts,
engine control strategies, and improved fuel
quality has been successful for the gasoline three-way catalytic converter, which
has been in use in cars since 1981 to reduce
NOx emissions and to oxidize CO to CO2
and higher hydrocarbons to CO2 and H20
(4). The current U.S. standards require this
catalyst to meet stringent emission regulations for 150,000 miles of consumer driving;
matching this requirement is a major technological accomplishment.
660
nitric oxide. Cargnello et al. report a PdO catalyst that shows high activity and
stability, under thermal conditions that simulate an automobile exhaust system
but whether it can be successfully integrated into a catalyzed monolith while
avoiding sintering and poisoning remains unknown.
Natural gasred turbines for power generation would also benet from a catalyst
that can oxidize methane at low temperature. In the early 1970s, Engelhard Corporation (bought by BASF Corporation in 2006)
patented catalyst and process technology
with the promise of low CO, hydrocarbon,
and NO emissions without post-emission
treatment (7). This technology requires the
catalytic oxidation of a mixture of natural gas (mostly methane) and air below the
ammability limits. At a gas temperature
of ~650 to 700C, the mixture becomes
flammable, and complete homogeneous
combustion occurs at gas temperatures
approaching 1300C. The hot combustion
gas is then directed to a turbine for power
generation. The technology would make
mechanical burners obsolete and eliminate
the need for selective catalytic reduction of
NOx. However, no catalyst currently exists
that can convert methane at the required
temperature, and this technology has never
been commercialized.
A major requirement for the catalyst is
that it must light off methane at the air compressor discharge temperature of 340C at
13 atmospheres. The best candidate is PdO
on various carriers, but as discussed above,
it can become deactivated through conversion to Pd and sintering. The temperature
for decomposition of PdO to Pd (~800C at
atmospheric pressure) is much higher than
that at which it is reformed to PdO (550C)
(8, 9). This hysteresis creates a window
of little activity. Cargnello et al.s catalyst
shows very little hysteresis, meaning that
the catalyst reforms active PdO at higher
temperatures than previous catalysts. This
10.1126/science.1226310
CREDIT: P. HUEY/SCIENCE