Abstract This thesis describes efforts made on the development of an existing catalytic incinerator. The development work, called process characterization, consists of four general parts. These are the development of measurement methodology, the studying of construction materials, the selection of suitable catalysts and the testing of the effects of process operation conditions. The two application areas for catalytic incineration considered in this thesis are solvent emission abatement (VOC, volatile organic compounds) and chip bin emission abatement (SVOC, sulphur-containing volatile organic compounds). As a baseline, the process characterization is started with the development of measurement methodology. In general, the methodology will decrease costs and simplify the carrying out of the actual measurements and thereby make the measurement time more effective. In the methodology it is proposed that continuous total concentration measurement should be used in connection with qualitative sampling to obtain reliable measurement data. The selection of suitable construction materials for the application is very important. As shown in this thesis, the end conversions in solvent emission abatement may even be improved through the selection of the proper construction materials. In chip bin emission abatement, the problem arises from corrosive oxidation products that set limits on the construction materials used as well as on oxidation conditions. Catalyst selection is based on the following catalytic properties: activity, selectivity and durability. These catalytic properties are studied either at the laboratory or on an industrial scale. The catalytic materials tested are Pt, Pd, Pt-Pd, Cu-Mn oxides, MnO2-MgO, CuxMg(1-x)Cr2O4 and CuxCr2O4. The most important selection criteria in solvent emission abatement are proposed to be activity and selectivity. In the case of chip bin-SVOC-abatement, these are selectivity and durability. Based on these criteria, catalysts containing Cu-Mn oxides and Pt were demonstrated to be the best catalysts in VOC oxidation, and catalyst containing MnO2-MgO was shown to be best catalyst in SVOC oxidation. A study on the effect of process operation parameters (temperature, concentration and gas hourly space velocity (GHSV)) and moisture was carried out with the aid of factorial design. In VOC (n-butyl acetate) oxidation, the most influential process parameter was GHSV, which decreased the end conversion when it was increased. In SVOC (DMDS) oxidation, the effect of temperature was most significant. The end conversions increased as the temperature increased. Moisture slightly decreased the formation of by-products in n-butyl acetate oxidation. In DMDS oxidation, moisture slightly increased the end conversions at a lower temperature level (300°C). At the end of the thesis, these process parameters are also discussed from the standpoint of the catalysts' activity, selectivity and durability. Finally, proposals for process improvements are suggested.

Hydrothermal synthesis is a widely used technique for the preparation of fine particles. It can be carried out in batch or flow systems, although most studies have used batch reactors below 200 C. More recently, however, continuous hydrothermal synthesis has been employed in near- and supercritical water to obtain metal oxide particles. This technique offers tremendous promise for control of particle characteristics due to the rapidly changing properties of water with temperature and pressure in the critical region. However, the role of temperature in this process is not completely understood. Moreover, agglomeration of particles remains a problem in both batch and continuous hydrothermal techniques. This work is concerned with the use of continuous hydrothermal synthesis at near-critical and supercritical conditions to obtain iron oxide and lithium iron phosphate nanoparticles. Factors that affect size, size-distribution, and morphology of nanoparticles were investigated and the results have been used to resolve differences in the literature concerning the effect of temperature on particle size. It was shown that agglomeration can be minimized by using a protective polymer coating and this appears to be an effective method to control particle size. The continuous hydrothermal technique was also extended to materials other than metal oxides by synthesizing lithium iron phosphate. Differences in the particle sizes obtained using the batch and continuous methods were shown to be due to the different mechanisms of particle formation in the two techniques. Better particle characteristics (size, size distribution and morphology) were obtained using the continuous hydrothermal technique than using the batch hydrothermal method. Iron oxide nanoparticles were also deposited on the surface and in the pores of activated carbon pellets in a batch reactor in order to minimize agglomeration of particles. The resulting iron oxide activated carbon nanocomposites exhibited significant catalytic performance in the oxidation of propanal. Therefore, the use of supercritical water to deposit metal oxide particles on hydrophobic surfaces offers promise for carbon-supported catalyst preparation without the use of toxic or noxious solvents.

Abstract The harmful emissions of chlorinated volatile organic compounds (CVOCs) originate only from man-made sources. CVOCs are used in a variety of applications from pharmaceuticals production to decaffeination of coffee. Currently, CVOC emissions are limited by strict legislation. For these reasons, efficient CVOC abatement technologies are required. Catalytic oxidation is very promising option for this purpose, since catalysts can be tailored to each case to maximize the efficiency and minimize the formation of unwanted products, such as dioxins or Cl2. The goal of this thesis was to study the role of the physico-chemical properties of catalysts in dichloromethane (DCM) oxidation. To reach the aim, several catalytic materials were prepared and characterized, and their performance was tested in total oxidation of DCM. The catalytic materials used were powders of four single metal oxides (γ-Al2O3, TiO2, CeO2, MgO), three mixed oxides (Al2O3-xSiO2) washcoated on a cordierite monolith and four active phases (Pt, Cu, V, Mn). At first, support properties were studied. It was found that the DCM conversion and HCl production are dependent on support acidity when the studied single oxides are considered. The best DCM conversions and HCl yields were observed with the support having the highest total acidity (γ-Al2O3). Further, the quality of the by-products formed was dependent on the type of the acid sites present on the support surface. Secondly, the impregnation of the active compound was observed to improve the selectivity of the material. From the tested active phases, Pt presented the best performance, but also V2O5 and CuO showed almost equal performances. Especially CuO supported on γ-Al2O3, that had less formation of by-products and is less toxic than V-containing oxides, seems to be a promising alternative to Pt. Concerning stability, no deactivation was observed after 55h of testing of Pt/Al2O3. Furthermore, in the used reaction conditions, the formation of CuCl2 is not thermodynamically favoured. Finally, the good characteristics of the powder form catalysts were successfully transferred to the monolith. The performance of the Pt/90Al2O3-10SiO2 catalyst in DCM oxidation was improved when the channel density was increased due to an increase in geometric surface area and mechanical integrity factor, and a decrease in open fraction area and thermal integrity factor. / Tiivistelmä Haitallisten kloorattujen orgaanisten yhdisteiden (CVOC) päästöt ovat ihmisten aiheuttamia. CVOC-yhdisteitä käytetään mm. liuottimina lääkeaineiden valmistuksessa ja kofeiinin poistossa. Nykyisin CVOC-päästöjä rajoitetaan tiukalla lainsäädännöllä. Näistä syistä tehokas CVOC-yhdisteiden käsittelymenetelmä on tarpeen. Katalyyttinen hapetus on hyvä vaihtoehto tähän tarkoitukseen, koska katalyytit voidaan räätälöidä niin, että puhdistuksen tehokkuus saadaan maksimoitua samalla kun ei-haluttujen tuotteiden, kuten dioksiinit ja kloorikaasu, muodostuminen voidaan minimoida. Tämän väitöskirjatyön tavoitteena oli selvittää katalyyttien fysikaalis-kemiallisten ominaisuuksien yhteyksiä dikloorimetaanin (DCM) hapetukseen. Tavoitteen saavuttamiseksi valmistettiin useita katalyyttejä, jotka karakterisoitiin ja testattiin DCM:n kokonaishapetuksessa. Työssä tutkittiin neljää jauhemaista metallioksidia (γ-Al2O3, TiO2, CeO2 ja MgO), kolmea metallioksidiseosta (Al2O3-xSiO2), jotka pinnoitettiin kordieriittimonoliitille, sekä neljää aktiivista ainetta: Pt, Cu, V and Mn. Aluksi työssä keskityttiin tukiaineiden ominaisuuksiin. Työn tulokset osoittivat, että DCM:n konversio ja HCl:n tuotanto ovat riippuvaisia tukiaineen happamuudesta. Paras tulos saavutettiin alumiinioksidilla, jolla oli korkein kokonaishappamuus. Lisäksi havaittiin, että sivutuotteiden laatu riippuu tukiaineen pinnalla olevien happopaikkojen tyypistä. Aktiivisen aineen impregnointi tukiaineeseen paransi materiaalin selektiivisyyttä. Tutkituista aineista Pt osoittautui parhaimmaksi, mutta myös V2O5 ja CuO olivat lähes yhtä hyviä. Erityisesti CuO-katalyytti, joka tuotti vähemmän sivutuotteita ja joka on materiaalina vähemmän haitallinen kuin V2O5, osoittautui lupaavaksi jalometallikatalyyttien korvaajaksi. Materiaalien stabiilisuuteen liittyen Pt/Al2O3-katalyytin toiminnassa ei havaittu muutoksia 55 tunnin testauksen jälkeen. Lisäksi CuCl2:n muodostuminen ei mallinnuksen mukaan ole termodynaamisesti todennäköistä tutkituissa reaktio-olosuhteissa. Jauhemaisen katalyytin hyvät ominaisuudet pystyttiin pinnoituksessa siirtämään monoliittirakenteiseen katalyyttiin. Pt/90Al2O3-10SiO2 -katalyytin aktiivisuus DCM:n hapetuksessa tehostui, kun monoliitin aukkoluku kasvoi aiheutuen suuremmasta geometrisestä pinta-alasta ja mekaanisesta eheystekijästä sekä pienemmästä avoimen pinnan osuudesta ja termisestä eheystekijästä.