A catalyst reduces methane emissions from gas engines, works with sulfur in the exhaust, and can be recycled after use.
TANAKA Precious Metal Technologies Co., Ltd. has developed the MOC1-30 series, a methane oxidation catalyst designed to reduce methane emissions from gas engines running on natural gas and city gas. The catalyst is designed to maintain high methane conversion even in the presence of sulfur, a major cause of catalyst degradation.
Methane is a greenhouse gas with a much higher warming effect than carbon dioxide, making its reduction an important goal for industries using gas engines. Conventional methane oxidation catalysts gradually lose efficiency because sulfur compounds in the exhaust reduce catalytic activity, while high operating temperatures cause platinum particles in the catalyst to clump together, further lowering performance.
The MOC1-30 series addresses both problems. It uses a proprietary design that converts sulfur deposited on the catalyst surface into sulfur trioxide while keeping platinum particles firmly attached to the catalyst support. This reduces sulfur poisoning, prevents platinum particle growth, and helps maintain catalytic activity for a longer period.
Performance tests showed that the catalyst maintained more than 80% methane conversion after 1,000 hours of continuous operation at an inlet gas temperature of 350°C under sulfur-containing test conditions. In another test at 400°C, it maintained about 90% methane conversion after 100 hours. According to TANAKA, the catalyst performed significantly better than conventional platinum- and palladium-based methane oxidation catalysts.
The catalyst is intended for applications such as marine gas engines and stationary gas engines, where methane emissions are becoming increasingly regulated. It can also reduce maintenance costs by extending catalyst life and lowering the frequency of replacement. Because it performs well in sulfur-containing environments, it may also reduce the need for separate desulfurization systems, improving overall system efficiency.
The catalyst is compatible with precious metal recycling after use. TANAKA said it has an integrated system covering precious metal sourcing, catalyst development, manufacturing, sales, and recycling to support material recovery.
Demand for methane emission control technologies is expected to grow as gas engines are increasingly used in ships, emergency power systems, and distributed power generation for data centers. The company said the new catalyst is aimed at helping reduce greenhouse gas emissions while lowering operating costs in these applications.
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