A low pressure drop reactor was prepared by washcoating Cu
ion-exchanged mordenite on a
honeycomb. The reactor configuration including reaction conditions
was experimentally
optimized both for low-pressure drop and for high catalytic activity of
the honeycomb reactor.
Over 90% of NO conversion was achieved by both Cu ion-exchanged
synthetic zeolite (CuHM)
and natural zeolite (CuNZA). The pressure drops due to honeycomb
reactors were low enough
to meet the constraint of the pressure drop (5 in. of H2O)
for its application to a utility boiler.
A mathematical model based on fluid flow, reaction kinetics, and
pressure drop was derived for
the design of the reactor, and then the reactor was simulated to
examine the effects of operating
conditions on NO conversion. Finally, the sulfur tolerance of the
honeycomb reactor developed
in this work has also been investigated.