A low-cost aerosol preparation process for catalyst powder

Abstract

The present invention discloses a low-cost aerosol preparation process for catalyst powder, which specifically comprises the following steps: step 1: providing a solid catalyst material with catalytic activity; step 2: placing the solid catalyst material in a pretreatment device for surface activation treatment; step 3: performing secondary surface activation treatment; step 4: placing the solid catalyst material that has undergone surface activation treatment in an aerosolization device, and converting the solid catalyst material into tiny particles with a particle size of 8 to 20 μm through the aerosolization device: low-cost catalyst powder preparation is achieved by introducing an adjustable inert gas and a soluble polymer, and adopting a combination of an ultrasonic atomizer and a rotary spray dryer; thereby reducing raw material and energy consumption and reducing production costs; efficient preparation: introducing an adjustable inert gas and a circulating gas recovery device, and adopting a combination of an ultrasonic atomizer and a rotary spray dryer can improve the preparation efficiency of the catalyst powder.

Description

Technical Field

[0001] The invention belongs to the technical field of catalyst powder preparation, and particularly relates to a low-cost aerosol preparation process of catalyst powder. Background Art

[0002] Catalyst powder is pre-alloyed powder, which is a metal-based composite powder composed of Fe-based, Ni-based, Mn, Cr and other metals. The alloy particles are made of two or more different materials. The role of catalyst powder aerosol preparation is to convert solid catalyst materials into tiny particles that can be suspended in the gas so that they can play a role in gas phase reactions or catalytic reactions. At the same time, through aerosol preparation, solid catalyst materials can be subdivided into tiny particles, increasing their surface area, thereby improving reaction efficiency. This is because catalytic reactions usually occur on the solid surface. By increasing the surface area, more active sites can be provided and the reaction rate can be enhanced. In addition, aerosol preparation can also achieve uniform dispersion of catalyst materials and ensure the uniformity of catalyst particles in the reaction system. In short, the role of aerosol preparation of catalyst powder is to increase the surface area of ​​​​catalytic materials, improve reaction efficiency, and ensure uniform dispersion of catalyst particles to achieve higher reaction performance and catalytic effect.

[0003] The low-cost FeMnNi powder catalyst and preparation method disclosed in Publication No. CN103170347B uses Fe and Mn as the main components, adds small amounts of Ni, Cr, C, and Si elements, and uses an atomization method to prepare the catalyst powder, achieving low-cost manufacturing. However, this patent still has the following deficiencies in the entire preparation process:

[0004] 1. Currently, the aerosolization preparation of catalyst powder usually requires the use of special chemicals and raw materials, such as catalyst precursors and solvents. The cost of these raw materials is relatively high, especially for high-performance and high-purity catalyst materials.

[0005] 2. The preparation process of catalyst powder is affected by the characteristics of raw materials. Some catalyst materials may have high viscosity or surface tension, making the droplet formation and drying process more difficult, thereby reducing the preparation speed and output;

[0006] 3. During the aerosolization process, the structure of the catalyst powder may be affected, such as changes in the crystal structure and increases in grain size. These structural defects may lead to a decrease in catalyst performance, such as reduced activity and poor selectivity. At the same time, during the aerosolization process, the active substances in the catalyst powder may be lost due to volatilization, dissolution or reaction;

[0007] 4. During the aerosol preparation process, gas flow plays an important role in the formation and distribution of particles. If the gas flow is uneven, such as the presence of dead corners, eddies, etc., it may lead to uneven distribution of particles in the gas, resulting in uneven particle size distribution;

[0008] 5. During the aerosol preparation process, uneven decomposition of droplets may also lead to poor stability and dispersibility of particles. If there is an uneven rate or method during the decomposition of droplets, it may lead to uneven formation of particles, thereby affecting the stability and dispersibility of particles. Summary of the Invention

[0009] The purpose of the present invention is to provide a low-cost aerosol preparation process for catalyst powder to solve the problems of high cost preparation, low efficiency preparation, reduced catalyst performance, uneven particle size distribution, and poor particle stability and dispersibility raised in the above background technology.

[0010] To achieve the above objectives, the present invention provides the following technical solution: a low-cost aerosol preparation process for catalyst powder, specifically comprising the following steps:

[0011] Step 1: providing a solid catalyst material with catalytic activity;

[0012] Step 2: placing the solid catalyst material in a pretreatment device for surface activation treatment;

[0013] Step 3: Perform secondary surface activity treatment;

[0014] Step 4: Place the solid catalyst material that has been treated with surface activity in an aerosolization device, and use the aerosolization device to convert the solid catalyst material into tiny particles with a particle size of 8 to 20 μm;

[0015] Step 5: During the aerosolization process, an adjustable gas mixture is introduced to control the particle size and shape. Then, an electric or magnetic field is used to directional control the particles to obtain a more uniform particle size distribution. A soluble polymer is then introduced to enhance the stability and dispersibility of the particles.

[0016] Step 6: Collect and separate the obtained catalyst powder.

[0017] As a preferred technical solution of the present invention, the solid catalyst material in step 1 is composed of the following composition: Fe is 40-60%, Co is 15-25%, Ni is 0.1-0.8%, and the remaining component is Si, so as to achieve low-cost preparation.

[0018] As a preferred technical solution of the present invention, the particle size of the solid catalyst material in step 1 is in the range of 40 to 100 μm.

[0019] As a preferred technical solution of the present invention, the surface activation treatment in step 2 and step 3 is achieved by at least two methods of plasma treatment, ion implantation or chemical modification to improve the surface activity and catalytic performance of the catalyst material.

[0020] As a preferred technical solution in the present invention, the aerosolization equipment in step 4 includes an ultrasonic atomizer and a rotary spray dryer, wherein the ultrasonic atomizer has a multi-stage nozzle system and a circulating gas recovery device, and the rotary spray dryer has adjustable gas flow and temperature control functions.

[0021] As a preferred technical solution of the present invention, the surface active treatment method in step three is the same as the surface active treatment method in step two, and the treatment time is 8 to 18 minutes.

[0022] As a preferred technical solution of the present invention, in step five, the gas mixture specifically includes nitrogen or argon; wherein the injection content of the gas mixture is 5 to 13 L / min.

[0023] As a preferred technical solution of the present invention, in step 5, the method for controlling the orientation of the particles by the action of an electric field or a magnetic field is as follows:

[0024] S1. Create an electric or magnetic field by using electrodes, electromagnetic coils, or magnets, ensuring that the strength and direction of the electric or magnetic field are sufficient to exert the desired directional force on the particles;

[0025] S2. Applying an electric field or a magnetic field: placing the particle suspension in an electric field or a magnetic field and applying a voltage of 5 to 13 V or a current of 3 to 6 mA, or adjusting the strength and direction of the magnetic field, so that the particles move in a directed manner under the action of the electric field or the magnetic field;

[0026] S3. Control the orientation time: Control the orientation time of the particles in the electric field or magnetic field as needed, specifically 20 to 60 seconds;

[0027] S4. Stop the electric field or magnetic field: After the orientation process is completed, stop applying the electric field or magnetic field to stop the particles from moving in an orientation direction and keep them in the orientation state;

[0028] S5. Separating and collecting particles: Separate and collect the oriented particles as needed.

[0029] As a preferred technical solution of the present invention, in step 5, the soluble polymer includes polyvinyl alcohol (PVA): PVA is a water-soluble polymer with good dispersibility and stability; it can form hydrogen bonds or physical adsorption with the surface of the particles, effectively preventing the aggregation and deposition of the particles;

[0030] Sodium polyacrylate (sodium polyacrylate, PAA): PAA is a negatively charged polymer that can interact with the positive charges on the particle surface to form electrostatic repulsion, thereby enhancing the dispersion and stability of the particles;

[0031] Polyvinylpyrrolidone (PVP): PVP is a polymer with good solubility that can form physical adsorption or chemical bonds with the surface of particles to improve the dispersibility and stability of particles.

[0032] Compared with the prior art, the present invention has the following beneficial effects:

[0033] 1. Low-cost preparation: By introducing adjustable inert gas and soluble polymer, and using a combination of ultrasonic atomizer and rotary spray dryer, low-cost catalyst powder preparation can be achieved; thereby reducing raw material and energy consumption and reducing production costs;

[0034] 2. Efficient preparation: By introducing adjustable inert gas and circulating gas recovery devices, and adopting a combination of ultrasonic atomizer and rotary spray dryer, the preparation efficiency of catalyst powder can be improved, the preparation speed can be accelerated, the output can be increased, and the production time can be reduced;

[0035] 3. Improve catalyst performance: Through surface active treatment and directional control of particles, the surface activity and catalytic performance of catalyst materials can be enhanced, thereby improving the catalytic activity, selectivity and stability of the catalyst;

[0036] 4. Uniform particle size distribution: By controlling the orientation of particles through electric or magnetic fields, a more uniform particle size distribution can be obtained, reducing the size differences of particles and improving the consistency and stability of the product;

[0037] 5. Improve particle stability and dispersibility: By introducing soluble polymers, the stability and dispersibility of particles can be enhanced, the aggregation and sedimentation of particles can be reduced, and the quality and operability of the product can be improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 It is a structural schematic diagram of the present invention. DETAILED DESCRIPTION

[0039] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention. Example

[0040] See also Figure 1 The present invention provides a technical solution: a low-cost aerosol preparation process for catalyst powder, which specifically includes the following steps:

[0041] Step 1: providing a solid catalyst material with catalytic activity;

[0042] Step 2: placing the solid catalyst material in a pretreatment device for surface activation treatment;

[0043] Step 3: Perform secondary surface activity treatment;

[0044] Step 4: Place the solid catalyst material that has been treated with surface activity in an aerosolization device, and use the aerosolization device to convert the solid catalyst material into tiny particles with a particle size of 8 μm;

[0045] Step 5: During the aerosolization process, an adjustable gas mixture is introduced to control the particle size and shape. Then, an electric or magnetic field is used to directional control the particles to obtain a more uniform particle size distribution. A soluble polymer is then introduced to enhance the stability and dispersibility of the particles.

[0046] Step 6: Collect and separate the obtained catalyst powder.

[0047] In this embodiment, the solid catalyst material in step 1 is composed of the following composition: 40% Fe, 15% Co, 0.1% Ni, and the remaining component is Si, so as to achieve low-cost preparation.

[0048] In this embodiment, the particle size of the solid catalyst material in step 1 is in the range of 40 μm.

[0049] In this embodiment, the surface activation treatment in step 2 and step 3 is achieved by plasma treatment and ion implantation to improve the surface activity and catalytic performance of the catalyst material.

[0050] In this embodiment, the gas atomization equipment in step 4 includes an ultrasonic atomizer and a rotary spray dryer, wherein the ultrasonic atomizer has a multi-stage nozzle system and a circulating gas recovery device, and the rotary spray dryer has adjustable gas flow and temperature control functions.

[0051] In this embodiment, the surface active treatment method in step three is the same as the surface active treatment method in step two, and the treatment time is 8 minutes.

[0052] In this embodiment, in step five, the gas mixture specifically includes nitrogen or argon; wherein the injection content of the gas mixture is 5 L / min.

[0053] In this embodiment, in step 5, the method for controlling the orientation of the particles by the action of an electric field or a magnetic field is as follows:

[0054] S1. Create an electric or magnetic field by using electrodes, electromagnetic coils, or magnets, ensuring that the strength and direction of the electric or magnetic field are sufficient to exert the desired directional force on the particles;

[0055] S2. Applying an electric field or a magnetic field: placing the particle suspension in an electric field or a magnetic field and applying a voltage of 5 to 13 V or a current of 3 mA, or adjusting the strength and direction of the magnetic field, so that the particles move in a directed manner under the action of the electric field or the magnetic field;

[0056] S3. Control the orientation time: Control the orientation time of the particles in the electric field or magnetic field as needed, specifically 20 seconds. The length of the orientation time can affect the orientation degree of the particles and the uniformity of the particle size distribution;

[0057] S4. Stop the electric field or magnetic field: After the orientation process is completed, stop applying the electric field or magnetic field to stop the particles from moving in an orientation direction and keep them in the orientation state;

[0058] S5. Separating and collecting particles: Separate and collect the oriented particles as needed.

[0059] In this embodiment, in step 5, the soluble polymer includes polyvinyl alcohol (PVA). PVA is a water-soluble polymer with good dispersibility and stability. It can form hydrogen bonds or physical adsorption with the surface of particles, effectively preventing aggregation and deposition of particles.

[0060] Sodium polyacrylate (sodium polyacrylate, PAA): PAA is a negatively charged polymer that can interact with the positive charges on the particle surface to form electrostatic repulsion, thereby enhancing the dispersion and stability of the particles;

[0061] Polyvinylpyrrolidone (PVP): PVP is a polymer with good solubility that can form physical adsorption or chemical bonds with the surface of particles to improve the dispersibility and stability of particles. Example

[0062] The difference from Example 1 is: Figure 1 The present invention provides a technical solution: a low-cost aerosol preparation process for catalyst powder, which specifically includes the following steps:

[0063] Step 1: providing a solid catalyst material with catalytic activity;

[0064] Step 2: placing the solid catalyst material in a pretreatment device for surface activation treatment;

[0065] Step 3: Perform secondary surface activity treatment;

[0066] Step 4: Place the solid catalyst material that has been treated with surface activity in an aerosolization device, and use the aerosolization device to convert the solid catalyst material into tiny particles with a particle size of 10 μm;

[0067] Step 5: During the aerosolization process, an adjustable gas mixture is introduced to control the particle size and shape. Then, an electric or magnetic field is used to directional control the particles to obtain a more uniform particle size distribution. A soluble polymer is then introduced to enhance the stability and dispersibility of the particles.

[0068] Step 6: Collect and separate the obtained catalyst powder.

[0069] In this embodiment, the solid catalyst material in step 1 is composed of the following composition: 50% Fe, 20% Co, 0.6% Ni, and the remaining component is Si, so as to achieve low-cost preparation.

[0070] In this embodiment, the particle size of the solid catalyst material in step 1 is in the range of 80 μm.

[0071] In this embodiment, the surface activation treatment in step 2 and step 3 is achieved by plasma treatment and chemical modification to improve the surface activity and catalytic performance of the catalyst material.

[0072] In this embodiment, the gas atomization equipment in step 4 includes an ultrasonic atomizer and a rotary spray dryer, wherein the ultrasonic atomizer has a multi-stage nozzle system and a circulating gas recovery device, and the rotary spray dryer has adjustable gas flow and temperature control functions.

[0073] In this embodiment, the surface active treatment method in step three is the same as the surface active treatment method in step two, and the treatment time is 13 minutes.

[0074] In this embodiment, in step five, the gas mixture specifically includes nitrogen or argon; wherein the injection content of the gas mixture is 10 L / min.

[0075] In this embodiment, in step 5, the method for controlling the orientation of the particles by the action of an electric field or a magnetic field is as follows:

[0076] S1. Create an electric or magnetic field by using electrodes, electromagnetic coils, or magnets, ensuring that the strength and direction of the electric or magnetic field are sufficient to exert the desired directional force on the particles;

[0077] S2. Applying an electric field or a magnetic field: placing the particle suspension in an electric field or a magnetic field and applying a voltage of 10V or a current of 4mA, or adjusting the strength and direction of the magnetic field, so that the particles move in a directed manner under the action of the electric field or the magnetic field;

[0078] S3. Control the orientation time: Control the orientation time of the particles in the electric field or magnetic field as needed, specifically 40 seconds. The length of the orientation time can affect the orientation degree of the particles and the uniformity of the particle size distribution;

[0079] S4. Stop the electric field or magnetic field: After the orientation process is completed, stop applying the electric field or magnetic field to stop the particles from moving in an orientation direction and keep them in the orientation state;

[0080] S5. Separating and collecting particles: Separate and collect the oriented particles as needed. Example

[0081] The difference from the above embodiment is: Figure 1 The present invention provides a technical solution: a low-cost aerosol preparation process for catalyst powder, which specifically includes the following steps:

[0082] Step 1: providing a solid catalyst material with catalytic activity;

[0083] Step 2: placing the solid catalyst material in a pretreatment device for surface activation treatment;

[0084] Step 3: Perform secondary surface activity treatment;

[0085] Step 4: Place the solid catalyst material that has been treated with surface activity in an aerosolization device, and use the aerosolization device to convert the solid catalyst material into tiny particles with a particle size of 20 μm;

[0086] Step 5: During the aerosolization process, an adjustable gas mixture is introduced to control the particle size and shape. Then, an electric or magnetic field is used to directional control the particles to obtain a more uniform particle size distribution. A soluble polymer is then introduced to enhance the stability and dispersibility of the particles.

[0087] Step 6: Collect and separate the obtained catalyst powder.

[0088] In this embodiment, the solid catalyst material in step 1 is composed of the following composition: Fe is 60%, Co is 25%, Ni is 0.8%, and the remaining component is Si, so as to achieve low-cost preparation.

[0089] In this embodiment, the particle size of the solid catalyst material in step 1 is in the range of 100 μm.

[0090] In this embodiment, the surface activity treatment in steps 2 and 3 is achieved by any two methods of ion implantation and chemical modification to improve the surface activity and catalytic performance of the catalyst material. Ion implantation refers to when a beam of ions is shot at a solid material in a vacuum, the ion beam knocks the atoms or molecules of the solid material out of the surface of the solid material. This phenomenon is called sputtering; and when the ion beam hits the solid material, it bounces back from the surface of the solid material or passes through the solid material. These phenomena are called scattering. Another phenomenon is that after the ion beam hits the solid material, it is resisted by the solid material and its speed slowly decreases, and eventually it stays in the solid material.

[0091] In this embodiment, the gas atomization equipment in step 4 includes an ultrasonic atomizer and a rotary spray dryer, wherein the ultrasonic atomizer has a multi-stage nozzle system and a circulating gas recovery device, and the rotary spray dryer has adjustable gas flow and temperature control functions.

[0092] In this embodiment, the surface active treatment method in step three is the same as the surface active treatment method in step two, and the treatment time is 18 minutes.

[0093] In this embodiment, in step five, the gas mixture specifically includes nitrogen or argon; wherein the injection content of the gas mixture is 13 L / min.

[0094] In this embodiment, in step 5, the method for controlling the orientation of the particles by the action of an electric field or a magnetic field is as follows:

[0095] S1. Create an electric or magnetic field by using electrodes, electromagnetic coils, or magnets, ensuring that the strength and direction of the electric or magnetic field are sufficient to exert the desired directional force on the particles;

[0096] S2. Applying an electric field or a magnetic field: placing the particle suspension in an electric field or a magnetic field and applying a voltage of 5 to 13 V or a current of 3 to 6 mA, or adjusting the strength and direction of the magnetic field, so that the particles move in a directed manner under the action of the electric field or the magnetic field;

[0097] S3. Control the orientation time: Control the orientation time of the particles in the electric field or magnetic field as needed, specifically 20 to 60 seconds. The length of the orientation time can affect the orientation degree of the particles and the uniformity of the particle size distribution;

[0098] S4. Stop the electric field or magnetic field: After the orientation process is completed, stop applying the electric field or magnetic field to stop the particles from moving in an orientation direction and keep them in the orientation state;

[0099] S5. Separating and collecting particles: Separate and collect the oriented particles as needed.

[0100] Although the embodiments of the present invention have been shown and described (see the above detailed description for details), it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the invention, and the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A low-cost aerosolized preparation process for catalyst powder, characterized by: The specific steps include: Step 1: providing a solid catalyst material with catalytic activity; Step 2: placing the solid catalyst material in a pretreatment device for surface activation treatment; Step 3: Perform secondary surface activity treatment; Step 4: Place the solid catalyst material that has been treated with surface activity in an aerosolization device, and use the aerosolization device to convert the solid catalyst material into tiny particles with a particle size of 8 to 20 μm; Step 5: During the aerosolization process, an adjustable gas mixture is introduced to control the particle size and shape. The particles are oriented and controlled by electric or magnetic fields to obtain a more uniform particle size distribution. A soluble polymer is then introduced to enhance the stability and dispersibility of the particles. Step 6: Collecting and separating the resulting catalyst powder; The solid catalyst material in step 1 is composed of the following components: Fe is 40-60%; Co is 15-25%; Ni is 0.1-0.8%; The remaining component is Si; The surface activation treatment in step 2 and step 3 is achieved by at least two methods selected from the group consisting of plasma treatment, ion implantation, and chemical modification; The aerosolization equipment in step 4 includes an ultrasonic atomizer and a rotary spray dryer; wherein: The ultrasonic atomizer has a multi-stage nozzle system and a circulating gas recovery device; The rotary spray dryer has adjustable gas flow and temperature control functions; In step 5, the gas mixture specifically includes nitrogen or argon; wherein the injection rate of the gas mixture is 5 to 13 L / min; In step 5, the method for controlling the orientation of the particles by the action of an electric field or a magnetic field is as follows: S1. Create an electric or magnetic field by using electrodes, electromagnetic coils, or magnets, ensuring that the strength and direction of the electric or magnetic field are sufficient to exert the desired directional force on the particles; S2. Applying an electric field or a magnetic field: placing the particle suspension in an electric field or a magnetic field and applying a voltage of 5 to 13 V or a current of 3 to 6 mA, or adjusting the strength and direction of the magnetic field, so that the particles move in a directed manner under the action of the electric field or the magnetic field; S3. Control the orientation time: Control the orientation time of the particles in the electric field or magnetic field as needed, specifically 20 to 60 seconds; S4. Stop the electric field or magnetic field: After the orientation process is completed, stop applying the electric field or magnetic field to stop the particles from moving in an orientation direction and keep them in the orientation state; S5. Separating and collecting particles: Separate and collect the oriented particles as needed.

2. The gas atomization preparation process of a low-cost catalyst powder according to claim 1, characterized in that: The particle size of the solid catalyst material in step 1 is in the range of 40 to 100 μm.

3. The gas atomization preparation process of a low-cost catalyst powder according to claim 1, characterized in that: The surface active treatment method in step three is the same as that in step two, and the treatment time is 8 to 18 minutes.

4. The gas atomization preparation process of a low-cost catalyst powder according to claim 1, characterized in that: In the step 5, the soluble polymer includes polyvinyl alcohol, sodium polyacrylate, and polyvinyl pyrrolidone.

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