A new method for monolithic carbon catalyst manufacture for selective catalytic d-NOxing removal of combustion gases at low temperature (180-230C) with ammonia has been developed. The procedure constitutes a very interesting step in the field sorption and catalytic methods using carbonaceous materials. A series of experiments was carried out to test the formation of carbonaceous slip pastes into monolithic thin-wall blocks of "honeycomb" structure, and several factors affecting the formation process were tested at lab and semi-commercial scales. These research studies included drying and carbonization parameters, which influenced the quality (geometric shape and mechanical properties) of the finished carbon monoliths. After the shaping process, the prototypes were dried, carbonized, activated, and impregnated with metal oxides (V and Cu) in order to increase the d-NOxing activity. Very high NOx to N2 conversions at process temperature 190-200C have been obtained at lab and pilot scales.
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