Development of Methane Oxidation Catalysts for Different Gas Turbine Combustor Concepts Sara Eriksson Licentiate Thesis 2005 KTH - The Royal Institute of Technology Department of Chemical Engineering and Technology Chemical Technology SE-100 44 Stockholm, Sweden TRITA-KET R211 ISSN 1104-3466 ISRN KTH/KET/R--211--SE ABSTRACT Due to continuously stricter regulations regarding emissions from power generation processes, development of existing gas turbine combustors is essential. A promising alternative to conventional flame combustion in gas turbines is catalytic combustion, which can result in ultra low emission levels of NOx, CO and unburned hydrocarbons. The work presented in this thesis concerns the development of methane oxidation catalysts for gas turbine combustors. The application of catalytic combustion to different combustor concepts is addressed in particular. The first part of the thesis (Paper I) reports on catalyst development for fuellean methane combustion. The effect on catalytic activity of diluting the reaction mixture with water and carbon dioxide was studied in order to simulate a combustion process with exhaust gas recirculation. Palladium-based catalysts were found to exhibit the highest activity for methane oxidation under fuel-lean conditions. However, the catalytic activity was significantly decreased by adding water and CO2, resulting in unacceptably high ignition temperatures of the fuel. In the second part of this thesis (Paper II), the development of rhodium catalysts for fuel-rich methane combustion is addressed. The effect of water addition on the methane conversion and the product gas composition was studied. A significant influence of the support material and Rh loading on the catalytic behavior was found. The addition of water influenced both the lowtemperature activity and the product gas composition. Keywords: catalytic combustion, methane oxidation, ceria, palladium, platinum, rhodium, TPO SAMMANFATTNING Eftersom utsläppskraven för energiproducerande anläggningar kontinuerligt skärps krävs utveckling av dagens förbränningsteknik. Katalytisk förbränning är ett attraktivt alternativ till konventionell flamförbränning då utsläppsnivåerna av NOx, CO och oförbrända kolväten kan minskas avsevärt. Arbetet som presenteras i denna avhandling behandlar utveckling av katalysatorer för förbränning av metan. Tillämpningen av katalytisk förbränning i olika förbränningskoncept för gasturbiner har särskilt undersökts. Första delen av avhandlingen (artikel I) behandlar katalysatorutveckling för förbränning av metan i luftöverskott. Inverkan på metanomsättningen av att späda ut reaktionsblandningen med vatten och koldioxid studerades i syfte att simulera en förbränningsprocess med recirkulation av förbränningsprodukter. Palladiumbaserade katalysatorer uppvisade den högsta aktiviteten vid luftöverskott. Emellertid minskade aktiviteten drastiskt då vatten och koldioxid tillsattes. Den andra delen av avhandlingen (artikel II) rapporterar om utvecklingen av rodiumkatalysatorer för metanförbränning i bränsleöverskott. Effekten av att tillsätta vatten till reaktionsblandningen undersöktes. Signifikanta skillnader för metanomsättning och sammansättning av produktgas upptäcktes för katalysatorer bestående av olika bärarmaterial och innehållandes olika halter av rodium. Tillsatsen av vatten påverkade metanomsättningen särskilt vid låga temperaturer liksom sammansättningen av produktgasen. Nyckelord: katalytisk förbränning, oxidation av metan, ceriumoxid, palladium, platina, rodium, TPO PUBLICATIONS REFERRRED TO IN THE THESIS The work presented in this thesis is based on the following publications, referred to in the text by their Roman numerals. The papers are appended at the end of the thesis. I. Catalytic combustion of methane in steam and carbon dioxide-diluted reaction mixtures S. Eriksson, M. Boutonnet and S. Järås, submitted to Appl. Catal. A. II. Partial oxidation of methane over rhodium catalysts for power generation applications S. Eriksson, M. Nilsson, M. Boutonnet and S. Järås, Catal. Today (2005), in press. OTHER PUBLICATIONS 1. Microemulsion: an alternative route to preparing supported catalysts S. Rojas, S. Eriksson, M. Boutonnet, Catal. Special. Period. Rep. R. Soc. Chem. 17 (2004) 258. 2. Preparation of catalysts from microemulsions and their applications in heterogeneous catalysis S. Eriksson, U. Nylen, S. Rojas, M. Boutonnet, Appl. Catal. A 265 (2004) 207. 3. Catalytic combustion of methane over bimetallic catalysts A. Ersson, H. Kusar, S. Eriksson, M. Boutonnet, S. Järås, presented at the 5th International Workshop on Catalytic Combustion, Seoul, Korea, 2002. 4. Stability tests of catalysts for methane combustion S. Eriksson, K. Persson, M. Boutonnet and S. Järås, presented at the 10th Nordic Symposium on Catalysis, Helsingør, Denmark, 2002. 5. Catalytic combustion of methane in humid gas turbine cycles K. Persson, S. Eriksson, P.O. Thevenin, S.G. Järås, presented at the 10th Nordic Symposium on Catalysis, Helsingør, Denmark, 2002. 6. Stability tests of catalysts for methane combustion S. Eriksson, K. Persson, M. Boutonnet and S. Järås, presented at the 2nd EFCATS School on Catalysis, Tihany, Hungary, 2002. 7. Combustion of methane over ceria based catalysts S. Eriksson, M. Boutonnet and S. Järås, presented at the 6th EuropaCat, Innsbruck, Austria, 2003. 8. Partial oxidation of methane over rhodium catalysts for power generation applications S. Eriksson, M. Nilsson, M. Boutonnet and S. Järås, presented at the 11th Nordic Symposium on Catalysis, Oulu, Finland, 2004. CONTENTS 1 2 3 4 INTRODUCTION 1 1.1 The Advanced Zero Emission Power (AZEP) concept 2 1.2 Scope of the work 2 GAS TURBINE COMBUSTION 5 2.1 Gas turbine configuration 5 2.2 Emissions from combustion 5 2.3 Zero emission combustion concepts 8 2.3.1 Post-combustion capture 9 2.3.2 Oxy-fuel combustion 10 2.3.3 Pre-combustion decarbonization 11 CATALYTIC COMBUSTION 13 3.1. Introduction 13 3.2. Catalytic combustor design 14 3.2.1 Fully catalytic design 14 3.2.2 Hybrid design 15 3.3 Commercial status of catalytic combustors 16 CATALYST DEVELOPMENT 17 4.1 Introduction 17 4.2 Fuel-lean catalytic combustion (Paper I) 17 4.2.1 Experimental set-up and testing conditions 17 4.2.2 Metal oxide catalysts 18 4.2.3 Noble metal catalysts 20 4.2.4 Temperature programmed oxidation (TPO) experiments 22 4.3 Fuel-rich catalytic combustion (Paper II) 22 4.3.1 Experimental set-up and testing conditions 23 4.3.2 Rhodium catalysts 24 4.4 The influence of combustion products on the catalyst performance (Papers I and II) 5 26 4.4.1 Palladium and platinum catalysts 26 4.4.2 Rhodium catalysts 27 CONCLUSIONS 29 ACKNOWLEDGEMENTS 31 CONTRIBUTIONS TO THE PAPERS 32 REFERENCES 33 APPENDICES: Papers I and II 1 INTRODUCTION Gas turbines that burn fuel to generate heat are widely used for the production of electricity. Natural gas is commonly used as fuel for stationary gas turbines due to low levels of impurities and long-term availability. However, the combustion process produces emissions that are harmful for the environment, i.e. oxides of nitrogen (NOx), unburned hydrocarbons (UHCs) and carbon monoxide (CO). The effect of these emissions was noticed in the 1950s when phenomena such as smog and acid rain appeared. This awareness resulted in strict regulations regarding emissions of pollutants being issued. Today, the control of emissions is one of the most important factors when designing a gas turbine. Catalytic combustion is an attractive alternative to conventional flame combustion from an environmental point of view. The main advantages of this technique are the opportunity to perform the combustion reaction over a wide range of fuel-to-air ratios and the ability to operate at lower temperatures than for conventional flame combustion. These features provide the possibility to reduce emission levels of pollutants such as NOx, CO, UHC and soot considerably. Since the concept of catalytically stabilized combustion was introduced in the 1970s, extensive research on finding suitable catalyst materials has been conducted. Furthermore, the environmental effect of carbon dioxide (CO2), which is one of the major combustion products, has been recognized. Carbon dioxide is a greenhouse gas and contributes to 50 % of the global warming. The production of CO2 cannot be avoided in combustion processes. However, a process can be modified in order to facilitate the separation of carbon dioxide from the exhaust. The separated CO2 could potentially be stored in geological reservoirs preventing air pollution. 1 1.1 The Advanced Zero Emission Power (AZEP) concept The Advanced Zero Emission Power (AZEP) concept has been a research project within the European Union with the aim of developing a zero emission, gas turbine-based power generation process. The AZEP concept enables NOx elimination as well as cost reduction of CO2 separation compared to conventional techniques (post-combustion capture). These targets can be achieved by i) combusting natural gas in pure oxygen produced by a mixedconductive membrane in which O2 is separated from air and, ii) dilution of the fuel/oxygen mixture with combustion products, i.e. water and carbon dioxide, instead of nitrogen. The division of Chemical Technology at KTH has been involved in the design of a combustor for the AZEP project together with ALSTOM Power and Paul Scherrer Institut. At an early stage, a catalytically stabilized combustion process was found to be an attractive option. Therefore, our work has been focused on the development of catalysts for AZEP mixtures, which contain large amounts of water and carbon dioxide. 1.2 Scope of the work The objective of the present thesis is to describe the development of catalysts for combustion of methane in gas turbine applications. Special attention was given to the influence of combustion products, i.e. water and carbon dioxide, on the catalytic performance. Furthermore, different combustion concepts were investigated. Fuel-lean catalytic combustion of methane was studied in Paper I. A variety of catalysts were prepared, with emphasis on palladium-based materials, and the activity in both air and exhaust gas-diluted mixtures was investigated. 2 In Paper II, a fuel-rich catalytic combustion concept was studied. The performance of rhodium-based catalysts was investigated with focus on the effect of support material, Rh loading and presence of water vapor on the methane conversion efficiency and the product gas composition. 3 4 2 GAS TURBINE COMBUSTION 2.1 Gas turbine configuration The main components of a gas turbine are a compressor, a combustion chamber and a turbine [1]. The configuration of a simple gas turbine system is presented in Figure 1. The compressed air is fed to the combustion chamber together with the fuel. The temperature increases during combustion resulting in an outlet temperature of approximately 1800 ºC. Before entering the turbine, the temperature of the exhaust must be reduced to avoid turbine material damage. Part of the compressed air is therefore bypassed the combustor and used for exhaust gas cooling. Power is then generated by expansion of the hot exhaust gas in the turbine. The main factors influencing the performance of gas turbines are the component efficiencies and the turbine working temperature. Combustor Fuel 1800 °C Air Exhaust 350 °C Bypass air Compressor 1400 °C Turbine Figure 1. Flow diagram of a conventional gas turbine combustor 2.2 Emissions from combustion The major compounds formed in combustion reactions, using air or oxygen as oxidant, are water and carbon dioxide. Furthermore, small amounts of nitrogen oxides (NOx), unburned hydrocarbons (UHCs), sulfurous oxides (SOx) and 5 carbon monoxide (CO) can be produced [2]. Even though the formation of these substances is limited, the high throughput rates in gas turbines will result in substantial emission levels. The emission levels of UHCs, CO and NOx depend on operating conditions, especially the air/fuel ratio as presented in Figure 2. Since the negative environmental effects of these compounds were noticed in the 1950s, continuously stricter regulations regarding emissions of pollutants have emerged. Figure 2. Dependence of emission levels of pollutants on air/fuel ratio. Adapted from Thevenin [3] When the combustion process is incomplete, only partial oxidation of the fuel occurs resulting in the formation of UHCs and CO. The formation of CO is favored by increasing the flame temperature (at constant air/fuel ratio), reducing the amount of H2 in the fuel and a rapid exhaust gas cooling rate. The main environmental concern regarding carbon monoxide is related to human health since it is highly toxic and can cause suffocation. The formation of UHC emissions is controlled by the same factors as CO and, therefore, they tend to follow the same trends. 6 Sulfurous oxides (SOx) may be formed when combusting a sulfur-containing fuel. This is generally the case for fuels such as heavy oils and coal. However, gaseous fuels such as natural gas contain very small amounts of sulfur. The main sulfurous oxide formed under combustion conditions is SO2. The primary environmental effects of SOx emissions include acid rain and human suffocation at high enough concentrations. The minimization of NOx emissions is at present one of the major concerns of gas turbine combustion. Environmental effects such as ozone depletion, acid rain and smog formation have been identified. Nitrogen oxides include nitric oxide (NO) and nitrogen dioxide (NO2) with NO being the predominant form in combustion emissions. Nitric oxide can be produced according to three different mechanisms: fuel, prompt and thermal. Fuel NOx is produced by oxidation of fuel-bound nitrogen whereas prompt NOx is formed by high-speed reactions of nitrogen, oxygen and hydrocarbon radicals. Prompt NOx is usually formed in combustion chambers operating with hydrocarbon fuel-rich flames. Thermal NOx is formed by oxidation of atmospheric nitrogen and is generally the main mechanism above 1100 Cº. The formation rate of thermal NOx has been found to increase exponentially with temperature making a reduction of the flame temperature the key factor for achieving low NOx emissions. For gas turbine systems, this means that a decrease of the adiabatic flame temperature is required. Emissions of nitrogen oxides can be drastically reduced by water injection, exhaust gas clean up by selective catalytic reduction (SCR) or dry low NOx technologies. The injection of water, or steam, results in a decrease of the flame temperature and, therefore, lower levels of NOx emissions. In dry low NOx technologies, combustor designs resulting in a lower flame temperature are used. A common approach is to use a lean premixed combustor. However, this can result in problems such as poor combustion efficiency and flame instability 7 and, therefore, higher emission levels of CO and UHC. An example of dry low NOx technologies is catalytic combustion, which allows a stable combustion reaction to take place at significantly lower temperatures than for conventional flame combustion. Therefore, ultra-low levels of NOx emissions (< 3 ppm) can be achieved without the formation of UHC and CO. 2.3 Zero emission combustion concepts More recently, the environmental effect of carbon dioxide has been noticed. Although some controversy exists, most agree that emissions of CO2 are connected to global warming. The high CO2 levels present today are related to both fossil-fuel combustion and forest depletion. The production of CO2 cannot be avoided for combustion processes since it is a natural by-product. However, the process can be modified in order to facilitate the separation of carbon dioxide from the exhaust. The captured CO2 can potentially be stored in oceans or geological reservoirs, i.e. depleted oil and gas reservoirs or deep saline aquifers. Another alternative is to use carbon dioxide for enhanced oil recovery, which is already occurring today. To facilitate the reduction of greenhouse gases, the Kyoto Protocol was adopted in 1997 [4]. The aim of the protocol is to prevent dangerous anthropogenic interference with the climate system and contains legally binding emission targets for developed countries for the post-2000 period. A total reduction of greenhouse gas emissions from 1990 levels by 5 % over the period 2008-2012 should be achieved. Within the European Community, an emission trade system for CO2, according to the Kyoto Protocol, started in February 2005. 8 Technologies for carbon dioxide capture from fossil fuel combustion processes can be divided into the following main groups [5]: • Post-combustion capture • Oxy-fuel combustion • Pre-combustion decarbonization 2.3.1 Post-combustion capture In the post-combustion capture concept, CO2 is separated from the exhaust gas without modifying the gas turbine system as presented in Figure 3. To atmosphere (N2, H2O, O2) CO2 capture CO2 for storage Fuel Air Steam Generator Gas Turbine Steam Turbine Figure 3. Post-combustion capture of CO2 Several different techniques can be employed to capture the carbon dioxide depending on gas composition and flow rates. Absorption into an alkaline solution, such as an amine, is the most suitable technique for fossil fuel power plants where the partial pressure of CO2 normally is in the range of 0.15-0.3 bar. Problems related to the use of this technology for gas turbines are high oxygen content in the flue gas, which could cause oxidation of amines to carboxylic 9 acids, and the presence of NO2 resulting in formation of amine salts. Both processes result in amine losses and corrosion problems. Another important parameter to consider is the cost of installation and operation of this type of system. 2.3.2 Oxy-fuel combustion In oxy-fuel combustion, the fuel is combusted in CO2-diluted reaction mixtures instead of nitrogen. A unit separating air into O2 and N2 is required prior to the combustion process as depicted in Figure 4. Recycling of CO2 is necessary in order to lower the flame temperature to values similar to conventional combustors. The steam produced in the combustion reaction can easily be separated from the exhaust gas by condensation. N2 Air Air separation CO2 for storage O2 Condenser H2O Fuel Combustor CO2 Gas Turbine Figure 4. Oxy-fuel combustion with CO2 capture The main advantage of this combustion technique is a reduced cost of CO2 separation due to the absence of nitrogen. Furthermore, the formation of NOx emissions is avoided. A challenge with this process is to separate oxygen from air in a cost-effective way. Pure oxygen could be produced by cryogenic air separation or membrane technology. 10 An alternative approach is to recycle both CO2 and water. This concept is applied in the Advanced Zero Emission Power (AZEP) process together with membrane technology for air separation [6, 7]. Here, the exhaust gas mixture is recycled to a unit consisting of an air separation membrane and a combustor. This unit is described in Figure 5 and is here referred to as MCM (mixed conductive membrane) reactor. A major advantage with the AZEP concept is that conventional gas turbine equipment can be utilized and the installation of a CO2 turbine can be avoided. A challenge with this concept is to achieve a stable combustion process with the high amounts of water present. Preliminary investigations have shown that catalytic combustion may be an attractive alternative. CO2 and H2O to separation unit Fuel CH4 + O2 CO2 + H2O --------------------------------- Air O2 Q O2 Q MCM reactor Air compressor Air turbine Figure 5. Description of the AZEP concept with the MCM reactor unit 2.3.3 Pre-combustion decarbonization The pre-combustion decarbonization process is described in Figure 6. The fuel is first converted to syngas, i.e. H2 and CO, by partial oxidation and/or steam reforming [8]. Partial oxidation is preferable when combusting coal, heavy oils and high molecular weight hydrocarbons, which are difficult to convert by steam reforming. The partial oxidation process uses air from the gas turbine compressor. 11 In the steam reforming route, approximately 25 % of the exhaust gas is recycled and used in order to form CO and H2. Thereafter, CO2 is formed by the water gas shift reaction, CO + H2O → CO2 + H2, and separated from the hydrogen. Separation of carbon dioxide by physical absorption is preferred under the prevailing conditions. Challenges with this combustion concept are related to the combustion of hydrogen mixtures. Modifications of existing burners might be necessary in order to obtain a reliable combustion process. CO2 for storage Partial oxidation and/or reforming CO shift CO2 separation H2 Fuel Compressed air (partial oxidation) Combustor Gas Turbine Air Gas turbine exhaust (steam reforming) Figure 6. Pre-combustion decarbonization 12 N 2, H 2O 3 CATALYTIC COMBUSTION 3.1. Introduction Catalytic combustion can be divided into primary and secondary combustion processes. In primary processes, the objective is to produce heat while limiting the amount of pollution formation. Secondary processes typically deal with abatement of volatile organic compounds (VOC). Secondary processes are also called low-temperature catalytic combustion since they occur at temperatures below 400 ºC. In primary processes, higher concentrations of hydrocarbons are present and, therefore, considerably higher temperatures (> 1000 ºC) can be achieved. Only catalytic combustion for gas turbine applications, which of course is a primary process, will be discussed here. Catalytic combustion for gas turbines is a promising alternative to conventional flame combustion that has been extensively investigated for more than 30 years [9, 10]. This technique utilizes a catalyst, which is placed in the combustion chamber as presented in Figure 7. The fuel is oxidized at the catalyst surface without requiring a flame. Since complete combustion can occur outside the flammability limits of the fuel/oxygen mixture, lower combustor outlet temperatures are achieved and the need for by pass air cooling can be avoided [11]. The main advantages of this technique are the opportunity to perform the combustion reaction over a wide range of fuel-to-air ratios and the ability to operate at lower temperatures than possible for conventional flame combustion. These qualities provide the possibility to reduce emission levels of pollutants such as NOx, CO, soot and unburned hydrocarbons significantly. 13 Catalytic combustor Fuel <1400 °C Air Exhaust 350 °C Compressor Turbine Figure 7. Flow diagram of catalytic gas turbine combustor The major challenge with this combustion method is to find a catalytic material that can withstand the harsh combustor environment, i.e. temperatures up to 1400 ºC, high gas velocities (10-40 m/s) and the possibility of thermal shocks, for longer periods of time. The activity of catalysts for gas turbine combustors should also be stable and last for at least one year of operation without problems. 3.2. Catalytic combustor design Ideally, a catalyst with both a high activity and long-term stability under all conditions relevant for gas turbine combustors, i.e. over a broad power load range, is preferred. In reality, it is a great challenge to obtain such a catalyst. Several combustor designs have been proposed in order to overcome this problem. Some of these configurations will be summarized here. More detailed information on this subject can be found elsewhere [12]. 3.2.1 Fully catalytic design In this design, all of the fuel and compressed air are mixed before entering the catalytic combustor. This configuration relies on a highly active ignition catalyst at the entrance and thermally stable catalysts further down stream. The 14 catalytic end segment should be active to some extent but, most importantly, stable at temperatures up to 1300 ºC, which is very difficult to obtain. 3.2.2 Hybrid design This two-stage combustion configuration consists of a catalytic segment followed by homogeneous gas phase combustion, i.e. flame combustion. Thus, a high temperature catalytic end segment can be avoided. The fuel is partly combusted over the catalyst, resulting in a moderate temperature increase, and complete conversion is obtained in the homogeneous zone. The catalyst outlet temperature is generally below 1000 ºC. Several different designs resulting in partial conversion of the fuel have been proposed. A catalyst of monolith structure with alternately coated channels can be utilized to control the catalyst temperature. The fuel/air mixture entering the inactive channels without catalyst coating will not be combusted before the high temperature homogeneous zone is reached. An advantage with this catalyst configuration is that the heat formed by the combustion reaction in the active channels is transported to the inactive channels. Thus, the formation of hot spots, which can damage the catalyst, can be avoided. If a fully coated catalyst structure is used, secondary fuel or secondary air configurations can be used to limit the catalyst temperature. In the secondary fuel configuration, part of the fuel is completely combusted over the catalyst and the remaining fuel is introduced directly to the subsequent homogeneous zone. In the secondary air concept, fuel-rich catalytic combustion occurs in the first stage producing hydrogen and carbon monoxide in addition to products of complete combustion. Additional air is added after the catalyst to fully oxidize the partial oxidation products, i.e. H2 and CO, in the homogeneous zone. 15 3.3 Commercial status of catalytic combustors The first commercial catalytic combustor for natural gas-fired gas turbines was recently introduced. In 2002, the XONON cool combustion system, which utilizes a two-stage lean premix preburner configuration, was commercialized by Catalytica Energy Systems [13, 14]. Since then, a 1.4 MW Kawasaki M1A13X gas turbine equipped with a XONON combustor has been operating in California. The combustor has a guaranteed life of 8000 h with emission levels of NOx < 3 ppm and CO and UHC < 6 ppm. Development of hybrid catalytic combustors has been carried out by Siemens Westinghouse Power Corp. for large industrial engines (> 200 MW) and by Solar Turbines for smaller engines (< 20 MW) [15]. However, further development of catalytic combustors is required to improve this technique and expand the field of application. The development of catalytic combustors has until now mainly been focused on fuel-lean methane combustion. This configuration usually requires a pre-burner in order to achieve low-temperature ignition, which result in higher levels of NOx emissions. Also, the flexibility of the combustor should be improved to meet variations in load, ambient conditions and gas turbine size. Moreover, other combustion concepts have emerged lately resulting in the need for different catalytic systems. The combustor concept utilizing secondary air resulting in fuel-rich catalytic combustion is one example. Benefits such as low-temperature ignition have been observed [16]. Therefore, pre-heaters could potentially be avoided. The development of catalytic materials for this concept together with testing under gas turbine conditions are of interest. Another example is the zero emission combustion concept utilizing exhaust gas recirculation as discussed previously. 16 4 CATALYST DEVELOPMENT 4.1 Introduction In general, combustion catalysts consist of a substrate, a washcoat (or support) and an active phase. The substrate, which can be metallic or ceramic, is usually of monolith structure. The washcoat is typically a metal oxide of relatively high surface area facilitating a high dispersion of the active phase. Several important factors should be considered when designing a catalyst. For example, the support material can play an important role. Common support materials for oxidation catalysts are Al2O3, ZrO2, SiO2 and mixed metal oxides. Properties such as surface area, acidity, crystal structure and support-noble metal interaction can influence the activity significantly. Aspects to consider related to the active phase include dispersion, particle size and oxidation state. In this chapter, results regarding catalysts for both fuel-lean (Paper I) and fuelrich (Paper II) combustion of methane are summarized. Issues related to combustion in AZEP mixtures, i.e. high amounts of water and CO2, were addressed in particular. 4.2 Fuel-lean catalytic combustion (Paper I) The catalytic activity of a variety of materials has been investigated for methane combustion under fuel-lean conditions [17]. Noble metal catalysts are generally found to be suitable ignition catalysts whereas metal oxide catalysts are active at higher temperatures. 4.2.1 Experimental set-up and testing conditions The activity tests were carried out in a laboratory-scale reactor consisting of a quartz tube placed in a cylindrical furnace as presented in Figure 8. 17 Thermocouples were inserted at the catalyst inlet and inside the furnace to monitor the temperature. Reactants and products were analyzed by paramagnetic and IR-spectroscopy techniques. Catalysts of monolith structure, each containing about 120 mg of catalyst material, were placed in the test rig. Furnace CH4 Quartz-glas reactor Catalyst H2O trap Exhaust Gas analyser Pump Evaporator H2O air/N2 CO2 Thermocouples Figure 8. Experimental set-up The experiments were carried out at atmospheric pressure under fuel-lean conditions (2.6 vol.% CH4 in air) at a gas hourly space velocity (GHSV) of 110 000 h-1. Repeated heating and cooling cycles in the temperature range 300-900 ˚C were performed for each catalyst whilst measuring the activity. 4.2.2 Metal oxide catalysts The catalytic properties of ceria-based materials have been widely investigated mainly due to the important role they play in the three-way catalysts (TWCs) used for pollution abatement but these materials are also of interest for gas turbine combustors. The properties that make ceria a promising material for use in catalysis are mainly (i) the ability to shift easily between reduced and oxidized state (i.e. Ce3+/Ce4+) and (ii) a high oxygen transport capacity [18]. 18 However, pure cerium oxide suffers from poor thermal resistance and inferior low-temperature activity for combustion applications. The catalytic performance of cerium oxide can be improved by addition of another metal oxide or a noble metal [19, 20]. In this section, the catalytic behavior of La or Zr doped cerium oxide is addressed. The methane conversion of doped cerium oxide materials is presented in Figure 9. A strong dependence of catalytic activity on catalyst inlet temperature can be observed. The mixed metal oxide containing lanthanum showed a higher activity in the entire temperature range investigated compared to the Zr-doped material. Ignition temperatures of 750 °C and 840 °C were obtained for Ce0.9La0.1O2 and Ce0.9Zr0.1O2, respectively. Here, the ignition temperature (or light-off temperature) is defined as the temperature required for 10 % conversion of methane. In contrast to the Zr-doped catalyst, complete conversion could be obtained for the La-doped catalyst at approximately 850 °C. 100 CH4 conversion (%) 80 60 40 20 0 600 650 700 750 800 850 900 Catalyst inlet temperature (°C) Figure 9. Methane conversion versus catalyst inlet temperature for Ce0.9La0.1O2 (■) and Ce0.9Zr0.1O2 (●) 19 Since the catalysts are active in the temperature range 750-900 °C, they are not suitable as light-off catalysts. For this application ignition should occur around 400 °C. However, materials of this type could be utilized as mid-temperature catalysts in a multiple-stage catalytic combustor. 4.2.3 Noble metal catalysts The high activity of palladium-based catalysts for methane oxidation has been well recognized for years [21]. In general, Pd is considered to be the most active ignition catalyst for fuel-lean combustion of methane. Platinum is also an efficient oxidation catalyst, especially for higher alkanes. In order to increase the activity of the La-doped ceria catalyst, 5 wt.% Pd or Pt was deposited on Ce0.9La0.1O2. The methane conversion was significantly improved in the entire temperature range as shown in Figure 10. A Pd/ZrO2 catalyst was also investigated to elucidate the influence of the support. The lowest ignition temperature was obtained for the supported Pd catalysts with light-off occurring at 400 °C. Significant differences in activity could be observed for different support materials. Both Pd catalysts showed similar activities in the low-temperature range; however, an improvement in conversion can be observed at higher temperatures when using Ce0.9La0.1O2. The active phase of palladium catalysts in fuel-lean methane oxidation is still an issue of debate. However, PdO is generally considered to be more active than metallic Pd [22-24]. The phase transformation PdO → Pd0 occurs during heating in the temperature range 680-800 °C depending on catalyst composition and reaction conditions [25, 26]. 20 100 CH4 conversion (%) 80 60 40 20 0 300 400 500 600 700 800 900 Catalyst inlet temperature (°C) Figure 10. Methane conversion versus catalyst inlet temperature during heating (closed symbols) and cooling (open symbols) for 5 % Pd/Ce0.9La0.1O2 (■ □), 5 % Pd/ZrO2 (▲ ∆) and 5 % Pt/Ce0.9La0.1O2 (● ○) in air A decrease in methane conversion of the palladium catalysts at higher temperatures related to this phase transformation can be observed in Figure 10. The activity is recovered upon cooling since re-oxidation of the metallic palladium occurs. The re-oxidation occurs at a lower temperature resulting in a PdO decomposition-reformation hysteresis. The activity of the supported platinum catalyst was considerably lower than for the Pd catalysts with light-off occurring at 660 °C. The activation of the C-H bond in methane is the first critical step in the combustion reaction. This activation occurs according to different mechanisms for Pd and Pt [27]. For Pd, a completely oxidized surface is generally preferred whereas a partially oxidized surface results in the highest activity for Pt. Since fuel-lean reaction conditions produce completely oxidized surfaces, this explains why the activity of the palladium catalysts is significantly higher than for the platinum catalyst in this study. 21 4.2.4 Temperature programmed oxidation (TPO) experiments In order to study the redox behavior of palladium deposited on different support materials more in detail, TPO experiments were performed. The results are presented in Figure 11. The decomposition of PdO occurs in approximately the same temperature range for both catalysts during heating. A temperature gap between reduction and re-oxidation of palladium can be observed. The reoxidation of palladium takes place at a higher temperature for the Ce0.9La0.1O2supported catalyst, which is probably related to the high oxygen mobility of the support, resulting in a stabilization of the PdO phase. These observations are in agreement with activity test results assuming that PdO is the active phase of the O2 concentration (a.u.) catalyst. 5 % Pd/Ce0.9La0.1O2 5 % Pd/ZrO2 300 400 500 600 700 800 900 Temperature (°C) Figure 11. TPO profiles for the palladium catalysts 4.3 Fuel-rich catalytic combustion (Paper II) In the hybrid combustor design utilizing secondary air as described previously, a catalytic fuel-rich stage where partial oxidation of the fuel occurs is followed by lean homogeneous combustion. Syngas, i.e. H2 and CO, is produced under fuel-rich conditions, resulting in a hydrogen-stabilized second stage 22 combustion process. Only limited studies of this combustion concept have been published in the past. Lyubovsky et al. investigated methane combustion under various fuel-to-air ratios for supported Pd, Pt and Rh catalysts demonstrating benefits such as low light-off temperature during fuel-rich operation [16]. Various metals, such as Rh, Pd, Pt, Ru, Ni, Co and Fe, have been investigated as catalysts for partial oxidation of methane to syngas [28]: CH4 + 1/2 O2 = CO + 2 H2 (1) Different reaction mechanisms for partial oxidation of methane have been proposed [29-34]. The reaction can either proceed according to i) complete combustion of some methane forming CO2 and H2O (reaction 2, below), followed by methane reforming by steam (reaction 3) and CO2 (reaction 4) yielding syngas or ii) direct partial oxidation forming CO and H2 as primary products (reaction 1). CH4 + 2 O2 = CO2 + 2 H2O (2) CH4 + H2O = CO + 3 H2 (3) CH4 + CO2 = 2 CO + 2 H2 (4) Several studies have reported that especially Rh-based catalysts are suitable for partial oxidation of methane due to their high activity, syngas selectivity and resistance to carbon deposition [35, 36]. Here, the behavior of supported rhodium catalysts for combustion applications is discussed. 4.3.1 Experimental set-up and testing conditions The experimental set up presented in Figure 8 was also used for investigating the fuel-rich combustion concept. The experiments were carried out at atmospheric pressure with nitrogen diluted fuel-rich gas mixtures (3.3 vol.% CH4, 1.7 vol.% O2, balance N2) at a gas hourly space velocity (GHSV) of 99 000 h-1. Repeated heating and cooling cycles in the temperature range 200-750 ˚C were performed for each catalyst whilst measuring the activity. 23 4.3.2 Rhodium catalysts The catalytic behavior of various supported rhodium catalysts is presented in Figure 12. It is evident that both the support material and Rh loading can influence the catalytic performance significantly. 100 Conversion (%) 80 60 40 20 0 200 300 400 500 600 700 800 Temperature catalyst inlet (°C) Figure 12. Conversion of methane (closed symbols) and oxygen (open symbols) in N2-diluted air versus catalyst inlet temperature for 0.5 % Rh/Ce-ZrO2 (■ □), 0.5 % Rh/Ce0.9La0.1O2 (0 1), 0.2 % Rh/ZrO2 (▲ ∆), 0.5 % Rh/ZrO2 (▼ &) and 1 % Rh/ZrO2 (● ○) The presence of ceria in the support improved the activity, especially at higher temperatures, and complete conversion could be obtained. This behavior is probably related to the high oxygen mobility of ceria. Previous studies have shown that the addition of Ce to ZrO2 increases the activity and stability of Pt and Ni catalysts for partial oxidation of methane due to an increased CH4 dissociation and enhanced carbon elimination from the surface [37, 38]. The activity can be significantly enhanced by increasing the Rh loading. Here, increasing the amount of rhodium from 0.2 to 1 wt% resulted in a decrease of the ignition temperature by 160 °C. The high-temperature activity was also considerably improved when increasing the Rh loading. These results show that the noble metal loading is an important factor to consider when preparing 24 combustion catalysts. If the amount of noble metal is too high, the dispersion can decrease resulting in fewer active sites. Therefore, an optimal metal loading should be found. For the fuel-rich combustion concept, the absolute values of the product concentrations after the catalyst are of importance in order to evaluate the stability of the subsequent homogeneous combustion stage. Simultaneous H2, CO and CO2 production can be observed as shown in Figure 13 (closed symbols). A reaction mechanism consisting of complete oxidation followed by steam and dry reforming is implied since formation of CO2 occurs mainly at lower temperatures whereas CO is produced at higher temperatures. 3,5 8 a 7 CO production (vol.%) H2 production (vol.%) b 3,0 6 5 4 3 2 2,5 2,0 1,5 1,0 0,5 1 0,0 0 200 300 400 500 600 700 200 800 300 CO2 production (vol.%) 2,0 400 500 600 700 800 Temperature catalyst inlet (°C) Temperature catalyst inlet (°C) c 1,5 1,0 0,5 0,0 200 300 400 500 600 700 800 Temperature catalyst inlet (°C) Figure 13. a) H2 production, b) CO production and c) CO2 production in N2-diluted air (closed symbols) and in 10 % H2O/N2-air (open symbols) versus catalyst inlet temperature for 0.5 % Rh/Ce-ZrO2 (■ □), 0.5 % Rh/Ce0.9La0.1O2 (0), 0.2 % Rh/ZrO2 (▲ ), 0.5 % Rh/ZrO2 (▼) and 1 % Rh/ZrO2 (● ○) 25 4.4 The influence of combustion products on the catalyst performance (Papers I and II) The combustion products, i.e. water and carbon dioxide, may influence the reaction significantly depending on catalyst composition and reaction conditions. The product gas composition can be altered, which can be an advantage in some cases. A major drawback of large amounts of water is that it may promote sintering of the catalyst at high temperatures resulting in a decreased dispersion of the active phase on the catalyst surface. In this section, results from Papers I and II regarding the influence of combustion products, i.e. water and CO2, on the catalytic activity are discussed. 4.4.1 Palladium and platinum catalysts The influence of water and carbon dioxide on palladium catalysts has been investigated in several studies [39-42]. Most authors agree that water has a negative effect on methane conversion whereas different opinions regarding the influence of CO2 can be found. A reaction order of approximately –1 has been identified for water. Both zero order and strong inhibition of order –2 have been reported for CO2. Furthermore, the effect of water was found to be dominant when both combustion products were present in the feed. Water may affect the activity according to the following reaction [43]: PdO + H2O = Pd(OH)2 Most studies have investigated the effect of relatively low amounts of water on the activity of palladium catalysts. However, the results presented in this work have been obtained in reaction mixtures consisting of 1.2 vol.% CH4, 2.4 vol.% O2, 11.3 vol.% CO2, 27.3 vol.% H2O, 57.8 vol.% N2 at a gas hourly space velocity (GHSV) of 110 000 h–1. The high concentration of combustion products has been investigated since these conditions are relevant in exhaust gas-diluted combustion processes such as the AZEP concept. 26 The results presented in Figure 14 show a drastic decrease in methane conversion for the Pd-based catalysts when water and CO2 are present in the feed, see Figure 10 for comparison. An influence of the support material on the activity can be observed with Ce0.9La0.1O2 exhibiting a significantly higher activity than ZrO2. Ciuparu et al. [44] propose that support materials with high oxygen mobility, such as ceria, will reduce the effect of water during methane combustion by oxygen transfer from the bulk to the PdO particles. This process will reduce the formation of surface hydroxyls, which probably prevent methane activation resulting in a decreased reaction rate. The activity of the supported platinum catalyst was only slightly decreased in the presence of water and CO2. 100 CH4 conversion (%) 80 60 40 20 0 300 400 500 600 700 800 900 Catalyst inlet temperature (°C) Figure 14. Methane conversion versus catalyst inlet temperature during heating (closed symbols) and cooling (open symbols) for 5 % Pd/Ce0.9La0.1O2 (■ □), 5 % Pd/ZrO2 (▲ ∆) and 5 % Pt/Ce0.9La0.1O2 (● ○) in exhaust gas-diluted mixtures 4.4.2 Rhodium catalysts The effect of water (10 vol.%) on supported rhodium catalysts for fuel-rich methane combustion was studied. The results presented in Figure 15 show that water has a negative effect on the catalytic performance in the low-temperature range with increased light-off temperatures, see Figure 12 for comparison. The 27 delay in ignition is presumably due to water adsorbed on the catalyst surface preventing methane C-H bond activation. However, advantages of adding water could be observed at higher temperatures. For example, the conversion of methane increased in this temperature range for all ZrO2-supported catalysts. 100 Conversion (%) 80 60 40 20 0 200 300 400 500 600 700 800 Temperature catalyst inlet (°C) Figure 15. Conversion of methane (closed symbols) and oxygen (open symbols) in 10 vol.% H2O/N2-air versus catalyst inlet temperature for 0.5 % Rh/Ce-ZrO2 (■ □), 0.5 % Rh/Ce0.9La0.1O2 (0 1), 0.2 % Rh/ZrO2 (▲ ∆), 0.5 % Rh/ZrO2 (▼ &) and 1 % Rh/ZrO2 (● ○) Furthermore, the product gas composition is altered when water vapor is added to the reaction mixture as observed in Figure 13. Higher amounts of CO2 are formed in the entire temperature range whereas less CO is formed. Also, at higher temperatures, the formation of H2 was enhanced by adding water resulting in H2/CO ratios higher than 2. The product gas composition is altered due to the water gas shift reaction taking place (reaction 5). The large amount of water vapor in the reaction mixture shifts the equilibrium favoring the products H2 and CO2. CO + H2O = CO2 + H2 (5) 28 5 CONCLUSIONS Two different catalytic combustion concepts have been investigated, i.e. fuellean and fuel-rich combustion of methane. In order to simulate a combustion process utilizing exhaust gas recirculation, the effect of water and CO2 on the catalyst performance was studied in particular. Significant differences in activity for methane oxidation and product gas composition could be detected for the different configurations. Palladium-based catalysts were found to exhibit the highest activity for methane oxidation under fuel-lean conditions. In fuel-air reaction mixtures, both supported Pd catalysts, i.e. Pd/Ce0.9La0.1O2 and Pd/ZrO2, exhibited similar light-off behaviour. The high temperature activity was however improved when using Ce0.9La0.1O2. The catalytic activity was significantly decreased by adding water and CO2 resulting in unacceptably high ignition temperatures of the fuel. Furthermore, the high-temperature activity was decreased due to the PdO → Pd0 phase transition. Even though the activity of the platinum catalyst was only slightly affected by the addition of combustion products, the initial activity was significantly lower than for Pd catalysts making this catalyst unsuitable for the first light-off stage. A variety of supported rhodium catalysts were prepared and tested for the fuelrich combustion concept. The results from the activity tests revealed a significant importance of the support material and Rh loading on the catalytic behavior. The catalysts containing ceria in the support material showed the highest activity and production of H2 and CO. The addition of water was found to have both positive and negative effects on the catalytic performance of rhodium under fuel-rich conditions. A negative effect on the activity in the low-temperature range with increased light-off 29 temperatures could be observed. However, the formation of hydrogen was increased in the presence of water at higher temperatures, which is favorable for a combustion configuration with a homogeneous final stage. The results presented here show that a hybrid combustor design consisting of a first fuel-rich catalytic stage followed by H2-stabilized homogeneous combustion is an attractive alternative to the more traditional fuel-lean catalytic combustion approach. The fuel-rich concept is particularly of interest for oxyfuel combustion processes utilizing exhaust gas recirculation. 30 ACKNOWLEDGEMENTS I would like to thank Prof. Sven Järås for giving me the opportunity to carry out my graduate studies at the Department of Chemical Engineering and Technology at KTH. I also thank Ass. Prof. Magali Boutonnet for her supervision. I want to thank my colleagues, former and present, at Chemical Technology and Chemical Reaction Engineering for providing a positive working environment and good friendship. Special thanks to Katarina, Ulf, Erik, Sergio, Anders and Stelios for stimulating collaboration. Also thanks to Marita and Bård for being good room-mates. I am grateful to Christina Hörnell for improving the linguistic quality of this thesis and Inga Groth for assistance with BET and XRD analysis. I would also like to thank the undergraduate students who I had the opportunity to work with, Marita Nilsson and Andrea Scarabello, for doing an excellent job. The financial support from the European Commission in FP5, contract number ENK5-CT-2001-00514, and the Swiss Government (BBW01.0054-1) is gratefully acknowledged. I want to thank the partners in the AZEP project with whom I had the pleasure to work with, especially Markus Wolf and Raffaella Villa at ALSTOM Power and Ioannis Mantzaras and Adrian Schneider at Paul Scherrer Institut. Last, but not least, I would like to thank my family and Jonas for support and encouragement during the years. 31 CONTRIBUTIONS TO THE PAPERS I. I am the main author of Paper I and the experimental work was performed by myself. II. I am the main author of Paper II. Marita Nilsson performed most of the experimental work under my guidance. 32 REFERENCES [1] H. Cohen, G.F.C. Rogers, H.I.H. 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