Development of highly active coated monolith SCR catalyst with strong abrasion resistance for low-temperature application

Monolith SCR catalysts coated with V₂O₅-WO₃/TiO₂ were prepared by varying binder and coating thickness. Comparing with a monolith extruded with 100% V₂O₅-WO₃/TiO₂ powder, a coated monolith with a catalyst-coating layer of 260 μm in thickness exhibited the similar initial NO_x reduction activity at 250°C. After 4 h abrasion (attrition) in an air stream containing 300 g·m⁻³ fine sands (50–100 μm) at a superficial gas velocity of 10 m·s⁻¹, the catalyst still has the activity as a 100% molded monolith does in a 24-h activity test and it retains about 92% of its initial activity at 250°C. Estimation of the equivalent durable hours at a fly ash concentration of 1.0 g·m⁻³ in flue gas and a gas velocity of 5 m·s⁻¹ demonstrated that this coated monolith catalyst is capable of resisting abrasion for 13 months without losing more than 8% of its initial activity. The result suggests the great potential of the coated monolith for application to de-NO_x of flue gases with low fly ash concentrations from, such as glass and ceramics manufacturing processes.