A new denitrification strategy based on high-temperature catalytic coatings Y₂O₃-BaO-ZrO₂ without using ammonia in a lab-scale natural gas combustion furnace

Catalytic decomposition of NO at high temperatures without the use of ammonia, offers an eco-friendly and sustainable solution for denitrification in industrial combustion or heating processes. To simulate a complex combustion flue gas, we designed a lab-scale natural gas industrial combustion furnace specifically for assessing the impacts of Y₂O₃-BaO-ZrO₂ catalyst coated on SiC plates on NO emissions. Various factors including the plate number, excess air ratio, combustion power, and coating position were considered. Results demonstrated that arranging the Y₂O₃-BaO-ZrO₂ coated plates shifted the high-temperature zone of the furnace downstream. When the excess air ratio was below 1.05, the catalytic coating significantly reduced NO emission concentration at the furnace outlet by over 40 %. However, this reduction coincided with a substantial presence of unburned CO in flue gases. Placing the coated SiC plates in the constant temperature zone of 1100–1200 °C within the middle of furnace offered significant advantages in NO removal, particularly as the combustion power increased. Based on a 60-h durability evaluation of Y₂O₃-BaO-ZrO₂ coating, the observed good high-temperature thermal and chemical stabilities further enhanced the coating's potential for industrial application. The possible mechanism of the reduction NO by CO over coating surfaces were analyzed by in situ optical measurements. After calculation, using 12 kg Y₂O₃-BaO-ZrO₂ catalysts might decrease at least 642 kg of ammonia consumption under ideal conditions, and significantly reduce the investment cost on existing flue gas denitrification equipment. Therefore, the investigated technology is a green and sustainable denitrification strategy, which would potentially provide a novel approach towards attaining ultra-low NO emissions.