Egg-shell type catalyst manufacturing device and manufacturing method using dipping liquid and microwave rapid drying

Abstract

The present invention relates to an eggshell-type catalyst manufacturing device and manufacturing method comprising: a body of a catalyst manufacturing device configured such that the upper part of the body is inclined downward so as to be filled with a catalyst active substance solution, which is an immersion liquid; a support supply hopper installed on the upper part of the catalyst manufacturing device body for supplying a catalyst support to the catalyst active substance solution; a coating unit installed as a set comprising an active substance solution immersion device for immersing the catalyst support supplied by the support supply hopper in the catalyst active substance solution filled on the upper part of the catalyst manufacturing device body, and a microwave rapid drying device for rapidly heating and drying the catalyst active substance solution coated on the catalyst support immediately thereafter; a screw conveyor that passes through the coating unit while transporting the catalyst support and serves to turn the catalyst support over for immersion in the catalyst active substance solution and rapid heating and drying; and a finished catalyst collection hopper for collecting and discharging finished catalyst particles, wherein the catalyst active substance component is evenly distributed near the surface of the catalyst particles, and thus has an excellent effect of significantly increasing production efficiency by enabling continuous automated production of eggshell-type catalysts.

Description

Technology Field

[0001] The present invention relates to the continuous automated production of eggshell-type catalysts, and more specifically, to an apparatus and method for producing eggshell-type catalysts capable of producing an eggshell-type catalyst having a structure in which the catalytic active material component is evenly distributed near the surface of the catalyst particles, by a continuously automated system comprising a coating unit in which an active material solution immersion device and a microwave rapid drying device are installed as a set in the process of immersing a catalyst support in a catalytic active material solution and rapidly heating and drying. Background Technology

[0002] Generally, to manufacture a catalyst, a catalyst support is immersed in a solution of a catalytic active material so that the catalytic active material is supported on the catalyst support, or a solution of a catalytic active material is sprayed onto the catalyst support and then heated and dried so that the catalytic active material is coated on the catalyst support.

[0003] In this case, the catalytic active material easily enters and is distributed not only on the surface of the catalyst support but also inside the pores. This is not economical because it increases the amount of expensive catalytic active material used.

[0004] To improve this, there is an eggshell type catalyst having a structure in which the catalytic active material component is spread evenly near the surface of the catalyst particles.

[0005] Since most catalytic reactions occur on the surface of the catalytic active material, it is desirable to have a large coating of the catalytic active material on the surface of the catalyst support.

[0006] Eggshell type catalysts are economical because they allow catalytic reactions to occur effectively by coating the surface of a catalyst support with a catalytic active material so that the catalytic active material spreads evenly near the surface of the catalyst particles, and they can save the catalytic active material by reducing the amount of catalytic active material that enters the pores of the catalyst support.

[0007] Conventionally, to manufacture eggshell-type catalysts, it was common practice to immerse a catalyst support in a solution of catalytic active material and then dry it in an oven at 80°C.

[0008] However, immersing the catalyst active material solution on the surface of the catalyst support or oven drying presented a difficult problem in preventing the solution from entering the pores of the catalyst support.

[0009] In addition, there was a problem in that it was difficult to expel the vapor generated as the catalytic active material solution dried inside the pores of the catalyst support to accelerate the drying process.

[0010] As illustrated in Figure 3 of Korean Patent Publication No. 10-2025-0154063 (published on October 28, 2025), “Method for manufacturing an eggshell structure catalyst” (hereinafter referred to as “Prior Art 1”), there was a problem in that a significant amount of the catalyst active material solution entered the pores of the catalyst support during oven drying and vacuum oven drying.

[0011] In addition, there was a problem in that the production efficiency was significantly reduced because the coating device for manufacturing eggshell-type catalysts, which allows the catalytic active material to be supported on the catalyst support or the process of spraying a solution of the catalytic active material onto the catalyst support and then heating and drying it to coat the catalytic active material onto the catalyst support, was performed intermittently manually, so continuous automated production could not be achieved.

[0012] The coating devices currently used to manufacture eggshell-type catalysts have disadvantages such as significantly reduced applicability due to these problems, being uneconomical, and having low production efficiency; therefore, there is an urgent need for an improved manufacturing device to produce eggshell-type catalysts more economically and effectively. Prior art literature

[0013] Korean Patent Publication No. 10-2025-0154063 (Published Oct. 28, 2025), "Method for manufacturing an eggshell structure catalyst"; Korean Patent Publication No. 10-2023-0097109 (Published June 30, 2023), "Method for manufacturing a core-shell catalyst"; Korean Patent Publication No. 10-2010-0047198 (Published May 7, 2010), "Method for manufacturing a shell catalyst and a corresponding shell catalyst"; Korean Registered Patent Publication No. 10-0822669 (Published April 17, 2008), "Method for manufacturing a catalyst and a catalyst manufactured thereby" The problem to be solved

[0014] To solve the above problems, the objective of the present invention is to provide an eggshell type catalyst manufacturing apparatus that enables the continuous and automated production of an eggshell type catalyst having a structure in which the catalytic active material component is spread evenly near the surface of the catalyst particles, thereby significantly increasing production efficiency. This is achieved by immersing a catalyst support in a catalytic active material solution using an active material solution immersion device, and then immediately using a microwave rapid drying device to rapidly heat and dry the catalyst support coated with the catalytic active material solution before the catalytic active material solution enters the pores of the catalyst support, so that the catalytic active material is effectively coated on the surface of the catalyst support.

[0015] In addition, another objective of the present invention is to provide a method for manufacturing an eggshell-type catalyst that enables continuous and automated production of the eggshell-type catalyst by using an eggshell-type catalyst manufacturing apparatus including an active substance solution immersion device and a coating unit which is a microwave rapid drying device, to immerse a catalyst support in a catalyst active substance solution and rapidly heat-dry it. means of solving the problem

[0016] In order to achieve the above objective of providing an eggshell-type catalyst manufacturing apparatus capable of significantly increasing production efficiency by enabling the continuous automated production of an eggshell-type catalyst having a structure in which catalytic active material components are evenly distributed near the surface of catalyst particles,

[0017] 1) An eggshell-type catalyst manufacturing apparatus having a structure in which a catalytic active material component is evenly distributed near the surface of the catalyst particles,

[0018] The catalyst manufacturing device body is configured such that the upper part of the body is inclined downward so as to be filled with a catalyst active material solution, which is an immersion liquid; a support supply hopper installed on the upper part of the catalyst manufacturing device body to supply a catalyst support to the catalyst active material solution; a coating unit installed as a set comprising an active material solution immersion device that immerses the catalyst support supplied by the support supply hopper in the catalyst active material solution filled on the upper part of the catalyst manufacturing device body, and a microwave rapid drying device that rapidly heats and dries the catalyst active material solution coated on the catalyst support immediately thereafter; a screw conveyor installed so that a screw rotates from the upper part of the body filled with the catalyst active material solution at the lower part within the catalyst manufacturing device body, which serves to overturn the catalyst support while conveying it and passing through the coating unit for immersion in the catalyst active material solution and rapid heat drying; and a finished catalyst collection hopper for collecting and discharging finished catalyst particles.

[0019] 2) The eggshell type catalyst manufacturing apparatus of the present invention is also characterized in that the catalyst support is an inorganic oxide composed of one type selected from the group consisting of nickel, magnesium, manganese, vanadium, silicon, cerium, zinc, aluminum, phosphorus, zirconium, iron, and titanium, or a combination of two or more types.

[0020] 3) The eggshell-type catalyst manufacturing apparatus of the present invention further comprises, wherein the catalytic active material used in the catalytic active material solution in which the catalyst support is immersed in the active material solution immersion apparatus comprises: a catalytic component selected from the group consisting of P, Zn, Ga, Ni, Cr, Zr, Mg, Sn, Ce, and In for the decomposition of fluorinated gases such as CF4, SF6, NF3, and HFCs; a catalytic component selected from the group consisting of Ru, Rh, Sm, Pd, Ir, Cu, Co, Ce, and Zn for the N2O decomposition reaction; a catalytic component selected from the group consisting of Pt, Pd, Ag, Mn, Fe, Cu, Ce, and Sn for the NOx and N2O selective catalytic reduction (SCR); and a catalytic component selected from the group consisting of Ru, Rh, Pd, Ir, Au, Cu, Mn, Sn, Te, Ni, Cr, Fe, Co, Mo, Ce, Se, and Ba for the ammonia decomposition hydrogen production. It is characterized by being composed of one or a combination of two or more of the following: a catalyst component selected from the group consisting of Ru, Rh, Ir, La, Ni, Co, Zr, Ce, Mg, and Zn in natural gas reforming hydrogen production; a catalyst component selected from the group consisting of Ru, Rh, Pd, Pt, Ir, Au, Cu, Ce, Cr, Ni, and Zn in carbon monoxide oxidation; a catalyst component selected from the group consisting of Pt, Ba, La, Au, Fe, Co, Cu, Zn, Mn, Cr, and Ce in carbon monoxide water gas shift (WGS); and a catalyst component selected from the group consisting of Pt, Au, Pd, Cr, Cu, and Mn in VOC oxidation.

[0021] 4) The eggshell type catalyst manufacturing apparatus of the present invention is also characterized by being configured such that the catalyst particles discharged from the finished catalyst collection hopper are recirculated to an active material solution immersion device through a support supply hopper and repeatedly coated thinly and uniformly by a coating unit, thereby spreading the catalytic active material components evenly near the surface of the catalyst particles.

[0022] 5) The eggshell type catalyst manufacturing apparatus of the present invention is also characterized in that the rapid heating drying in the microwave rapid drying apparatus is performed by heating for 5 seconds to 10 minutes at a temperature range of 50℃ to 500℃.

[0023] 6) The eggshell type catalyst manufacturing apparatus of the present invention is further characterized in that the catalyst particles discharged from the finished catalyst collection hopper are sent to an active material solution immersion device through a support supply hopper in a next stage eggshell type catalyst manufacturing apparatus connected in series with one or more others, and are then thinly and uniformly coated by a coating unit, thereby repeating this process step by step so that the catalytic active material components are evenly spread near the surface of the catalyst particles.

[0024] 7) The eggshell type catalyst manufacturing device of the present invention is also characterized by supplying a desired catalyst active material component by connecting a supply line of another active material solution from an active material solution storage tank containing a catalyst active material solution of another catalyst active material component to an active material solution immersion device of the next stage eggshell type catalyst manufacturing device, which is additionally connected in series with one or more of the above.

[0025] 8) The eggshell type catalyst manufacturing device of the present invention is also characterized in that the output of the microwave rapid drying device is in the output range of 500 watts (W) to 3,000 watts (W).

[0026] 9) The eggshell-type catalyst manufacturing apparatus of the present invention also, within the body of the catalyst manufacturing apparatus It is characterized by being configured such that a partition is installed at the top to separate a support material supply hopper and an active material solution immersion device, a microwave rapid drying device, and a finished catalyst collection hopper.

[0027] In another aspect of the present invention, in order to achieve the other objective of providing a method for manufacturing an eggshell-type catalyst capable of continuous and automated production by using an eggshell-type catalyst manufacturing apparatus including an active substance solution immersion device and a coating unit which is a microwave rapid drying device, wherein a catalyst support is immersed in a catalyst active substance solution and rapidly heated and dried,

[0028] 10) A method for manufacturing an eggshell-type catalyst having a structure in which a catalytic active material component is evenly distributed near the surface of the catalyst particles,

[0029] (A) A step of filling a catalyst active material solution supplied from an active material solution storage tank containing a catalyst active material solution into an active material solution immersion device of a catalyst manufacturing device body configured such that the upper part of the body is inclined downward so as to be filled with a catalyst active material solution, and

[0030] (B) A step in which a catalyst support supplied by a support supply hopper installed on the upper part of the body of the catalyst manufacturing device is immersed in a catalyst active material solution of an active material solution immersion device, and

[0031] (C) A step of inverting a catalyst support coated with a catalyst active material solution while transporting it by a screw conveyor inside the body of a catalyst manufacturing device,

[0032] (D) A step of rapidly heating and drying a catalyst support coated with a catalyst active material solution using a microwave rapid drying device,

[0033] (E) The method includes the step of collecting the completed catalyst particles into a completed catalyst collection hopper and discharging them, and

[0034] The present invention is characterized by using an eggshell-type catalyst manufacturing apparatus of any one of 1) to 9) above.

[0035] Accordingly, the eggshell type catalyst manufacturing apparatus and method of the present invention enable the continuous and automated production of an eggshell type catalyst having a structure in which a catalytic active material component is evenly distributed near the surface of the catalyst particles, thereby significantly increasing production efficiency. Effects of the invention

[0036] According to the present invention, after immersing a catalyst support in an active material solution immersion device filled with a catalyst active material solution, the catalyst support coated with the catalyst active material solution is transported by flipping it over by a screw conveyor, and then rapidly heat-drying the catalyst support coated with the catalyst active material solution using a microwave rapid drying device before the catalyst active material solution enters the pores of the catalyst support so that the catalyst active material is effectively coated on the surface of the catalyst support, thereby enabling the continuous automated production of an eggshell type catalyst having a structure in which the catalyst active material component is evenly spread near the surface of the catalyst particles, thus providing an excellent effect of dramatically increasing production efficiency.

[0037] In addition, by installing a coating unit consisting of an active material solution immersion device and a microwave rapid drying device as a set and connecting one or more eggshell-type catalyst manufacturing devices in series, it is possible to supply a variety of desired catalyst active material components by connecting a supply line of another active material solution from an active material solution storage tank containing a catalyst active material solution of another catalyst active material component to the active material solution immersion device of the next stage eggshell-type catalyst manufacturing device. Brief explanation of the drawing

[0038] FIG. 1 is a schematic diagram showing a coating unit comprising an active substance solution immersion device and a microwave rapid drying device according to an embodiment of the present invention. FIG. 2 is a drawing specifically showing an eggshell type catalyst manufacturing apparatus according to one embodiment of the present invention. FIG. 3 is a flowchart schematically illustrating a method for manufacturing an eggshell type catalyst according to an embodiment of the present invention. Figure 4 is a drawing based on Figure 3 of the prior art 1 above. Specific details for implementing the invention

[0039] The present invention will be described in detail below.

[0040] Prior to this, terms and words used in the description and claims of the present invention shall not be interpreted as being limited to their ordinary or dictionary meanings, but shall be interpreted in a meaning and concept consistent with the technical spirit of the present invention, based on the principle that the inventor may appropriately define the concept of the terms to best describe his invention.

[0041] Furthermore, unless specifically determined otherwise in this specification, singular expressions do not exclude a plural meaning.

[0042] An eggshell type catalyst refers to a catalyst having a structure in which the catalytic active material component is spread throughout the area near the surface of the catalyst particles.

[0043] In the present invention, the catalytic active material comprises a catalytic active metal, and the catalytic active material solution represents an immersion solution for immersing a catalyst support in an active material solution immersion device.

[0044] Catalyst supports are materials that support catalysts; although they themselves are inactive, they are widely used because they possess the following functions. Dispersing a catalyst on a catalyst support increases the surface area of ​​the catalyst, prevents sintering to improve catalyst stability, and enhances the catalyst's activity, selectivity, or resistance to catalyst poisons.

[0045] In the present invention, catalyst particles refer to catalyst supports coated with a catalytic active material. The catalyst support can be in various forms, such as pellets, beads, or powders, and the optimal form of the catalyst support can be selected as needed.

[0046] The drying process is a fundamental process essential across various industrial sectors, and hot air drying is commonly applied.

[0047] The above hot air drying method utilizes the principle of surface heating for the object to be dried; since hot air is applied from the outside to evaporate moisture within the object, drying proceeds externally, requiring a surprisingly long time to remove internal moisture.

[0048] However, these hot-air drying methods have the disadvantages of low energy efficiency and high operating costs, so there is a need to develop alternative drying methods.

[0049] As one of the drying methods that can replace the aforementioned hot air drying method, there is a microwave drying method specifically adopted and used in the present invention.

[0050] Microwave drying utilizes the principle of volumetric heating, which pushes moisture from within the object to the outside. Since heat is generated by the movement of water molecules from within the object, it has the advantage of enabling uniform heating and drying from the inside out.

[0051] As a result, the microwave drying method is attracting attention as a useful technology that can replace the conventional hot air drying method, as it not only offers the advantage of being usable in various environmental conditions for drying objects, but also provides energy efficiency that is more than 20% higher than the conventional hot air drying method.

[0052] In the present invention, after immersing a catalyst support in an active material solution immersion device filled with a catalyst active material solution, the catalyst support coated with the catalyst active material is immediately transported by flipping it over using a screw conveyor, and then rapidly heat-dried the catalyst support coated with the catalyst active material solution using a microwave rapid drying device utilizing this microwave drying method before the catalyst active material solution enters the pores of the catalyst support, thereby enabling the continuous automated production of an eggshell type catalyst having a structure in which the catalyst active material component is evenly distributed near the surface of the catalyst particles, thus significantly increasing production efficiency.

[0053] Hereinafter, preferred embodiments of the eggshell type catalyst manufacturing apparatus and manufacturing method of the present invention will be described in detail with reference to the drawings through the following examples. However, the following examples are provided merely for illustrative purposes to facilitate a better understanding of the present invention, and the scope of protection of the present invention as defined by the claims is not intended to be limited by the following examples.

[0055] <에그쉘 타입 촉매 제조 장치>

[0056] FIG. 1 is a schematic diagram showing a coating unit consisting of an active substance solution immersion device and a microwave rapid drying device according to an embodiment of the present invention, and FIG. 2 is a detailed diagram showing an eggshell type catalyst manufacturing device according to an embodiment of the present invention.

[0057] Referring to FIG. 1 and 2, the eggshell type catalyst manufacturing apparatus of the present invention can continuously produce an eggshell type catalyst with increased production efficiency in an automated system by sequentially passing a catalyst support through a coating unit in which an active substance solution immersion device (300) and a microwave rapid drying device (400) are installed as a set, thereby having a structure in which the catalytic active substance component is evenly spread near the surface of the catalyst particles.

[0058] In addition, to coat the catalyst support with a thin and uniform catalytic active material component, the catalyst support can be immersed in a catalytic active material solution and rapidly dried by microwave several times.

[0059] To achieve this, the catalyst particles discharged from the finished catalyst collection hopper (600) after sequentially passing through the coating unit of the eggshell type catalyst manufacturing device are recirculated to the active material solution immersion device (300) through the support supply hopper (200), and the catalyst active material component is repeatedly coated thinly and uniformly onto the catalyst support by the coating unit, thereby allowing the catalyst active material component to spread evenly near the surface of the catalyst particles.

[0060] On the other hand, one or more eggshell-type catalyst manufacturing devices can be additionally connected in series (not shown) so that catalyst particles discharged from the finished catalyst collection hopper (600) of the eggshell-type catalyst manufacturing device of the previous stage are sent to the active material solution immersion device (300) of the next stage eggshell-type catalyst manufacturing device through the support supply hopper (200), and the catalyst active material component is repeatedly coated thinly and uniformly onto the catalyst support by a coating unit, thereby configuring the catalyst active material component to spread evenly near the surface of the catalyst particles.

[0061] In FIG. 1, the coating unit is shown by transporting the catalyst support from the upper left direction to the lower right direction and installing the active material solution immersion device (300) and the microwave rapid drying device (400) in that order, but the coating unit can also be installed by transporting the catalyst support from the right direction to the left direction and installing the active material solution immersion device (300) and the microwave rapid drying device (400) in that order.

[0062] FIG. 2 is a drawing specifically showing an eggshell type catalyst coating device according to an embodiment of the present invention.

[0063] Referring to FIG. 2, the eggshell-type catalyst manufacturing apparatus of the present invention, having a structure in which a catalytic active substance component is evenly distributed near the surface of a catalyst particle, comprises: a catalyst manufacturing apparatus body (100) configured such that the upper part of the body is inclined downward so as to fill with a catalytic active substance solution, which is an immersion liquid; and a device installed on the upper part of the catalyst manufacturing apparatus body (100). It may comprise: a support supply hopper (200) for supplying a catalyst support to a catalyst active material solution; a coating unit in which a set of a catalyst active material solution immersion device (300) for immersing the catalyst support supplied by the support supply hopper (200) in the catalyst active material solution filled at the top of the catalyst manufacturing device body (100) and a microwave rapid drying device (400) for rapidly heating and drying the catalyst active material solution coated on the catalyst support are installed; a screw conveyor (500) installed so that a screw rotates from the top of the body filled with the catalyst active material solution at the bottom within the catalyst manufacturing device body (100), which serves to overturn the catalyst support for immersion in the catalyst active material solution and rapid heating and drying while passing through the coating unit; and a finished catalyst collection hopper (600) for collecting and discharging finished catalyst particles.

[0064] And in FIG. 2, the devices are shown installed so that they proceed from the upper left direction to the lower right direction, but they may also be installed so that they proceed sequentially from the right direction to the left direction.

[0065] In the eggshell type catalyst manufacturing device of the present invention, the upper part of the catalyst manufacturing device body (100) is configured to be inclined downward so as to be filled with a catalyst active material solution, which is an immersion liquid, and the catalyst active material solution is supplied from an active material solution storage tank containing the catalyst active material solution.

[0066] Such catalytic active material solutions may consist of one catalytic active material component or a mixture of two or more catalytic active material components.

[0067] In addition, in the eggshell type catalyst manufacturing device of the present invention, although the catalyst manufacturing device body (100) is shown as a single body in FIG. 2, the active material solution immersion device (300) and the microwave rapid drying device (400) may be separated under a configuration condition in which a coating unit is installed as a set, which includes an active material solution immersion device (300) and a microwave rapid drying device (400) that rapidly heats and dries the catalyst active material solution coated on the catalyst support immediately afterward, depending on the needs considering the site conditions, and a screw conveyor (500) that passes through the coating unit while transporting the catalyst support and plays the role of turning the catalyst support over for immersion of the catalyst active material solution and rapid heat drying.

[0068] In the eggshell type catalyst manufacturing apparatus of the present invention, a support supply hopper (200) is installed on the upper part of the catalyst manufacturing apparatus body (100), which is configured such that the upper part of the body is inclined downward, to supply a catalyst support that supports a catalyst active material component to a catalyst active material solution.

[0069] The catalyst support supplied from the support supply hopper (200) of the eggshell type catalyst manufacturing apparatus of the present invention may be an inorganic oxide composed of one type selected from the group consisting of nickel, magnesium, manganese, vanadium, silicon, cerium, zinc, aluminum, phosphorus, zirconium, iron, and titanium, or a combination of two or more types.

[0070] In addition, the form of the catalyst support supplied from the support supply hopper (200) can be various forms such as pellets, beads, and powder, and the optimal form of the catalyst support can be selected as needed.

[0071] In addition, an active material solution immersion device (300) is configured such that the upper part of the catalyst manufacturing device body (100) is inclined, and a certain amount of catalyst active material solution is filled and maintained in the lower part, and a catalyst support supplied by a support supply hopper (200) is immersed in the catalyst active material solution, which is the immersion liquid.

[0072] At this stage, if the catalyst active material is continuously immersed in the solution, it may penetrate into the pores of the catalyst support; therefore, it is desirable to prevent it from entering the pores as much as possible, as this reduces the amount of catalyst active material used and is therefore more economical.

[0073] In this invention, for this purpose, a coating unit is arranged in a set comprising an active material solution immersion device (300) that immerses a catalyst active material solution in a catalyst support among eggshell type catalyst manufacturing devices, and a microwave rapid drying device (400) that rapidly heats and dries the catalyst active material solution coated on the catalyst support immediately thereafter.

[0074] That is, since the catalytic reaction mostly occurs on the surface of the catalytic active material, it is desirable to have a large amount of coating of the catalytic active material on the surface of the catalyst support, and the catalytic effect is excellent when the catalytic active material component is spread evenly near the surface of the catalyst particles. The eggshell type catalyst manufacturing device of the present invention can more effectively and easily coat a certain amount of the required catalytic active material component on the surface of the catalyst support by means of a coating unit installed as a set, which is an optimal combination of an active material solution immersion device (300) that immerses a catalytic active material solution in a catalyst support and a microwave rapid drying device (400) that immediately follows and rapidly heats and dries the immersed catalytic active material solution.

[0075] Accordingly, the structure may have a catalytic active material component spread evenly near the surface of the catalyst particles, such as the rapid drying catalyst shown in Figure 4 by citing Figure 3 of the prior art 1.

[0076] In the present invention, the active substance solution immersion device (300) is connected to an active substance solution storage tank containing a catalytic active substance solution by an active substance solution supply line, and since a commonly known general device is used to continuously fill and maintain a certain amount of catalytic active substance solution in the active substance solution immersion device (300) from the active substance solution storage tank through the active substance solution supply line, or to drain and replace the used catalytic active substance solution through a hole, the illustration is omitted.

[0077] Here, with an active material solution immersion device (300) and a microwave rapid drying device (400) that rapidly heats and dries the immersed catalytic active material solution immediately afterward installed as a set, a catalytic active material solution of the same catalytic active material component can be supplied to the active material solution immersion device (300) by an active material solution supply line from an active material solution storage tank containing a catalytic active material solution of the same catalytic active material component.

[0078] In addition, one or more eggshell-type catalyst manufacturing devices may be connected in series (not shown) so that catalyst particles discharged from the finished catalyst collection hopper (600) of the previous eggshell-type catalyst manufacturing device are sent to the active material solution immersion device (300) of the next eggshell-type catalyst manufacturing device through the support supply hopper (200) and repeatedly coated by a coating unit, and a different active material solution supply line may be installed from an active material solution storage tank containing a catalyst active material solution of another catalyst active material component to the active material solution immersion device (300) to selectively supply a catalyst active material solution of a desired catalyst active material component.

[0079] In the active material solution immersion device (300) used in the eggshell type catalyst manufacturing device of the present invention, which immerses a catalyst active material solution in a catalyst support, a catalyst active material component suitable for each of the various catalytic reactions can be applied.

[0080] The catalyst active material component used in the catalyst active material solution in which the catalyst support is immersed in the above-mentioned active material solution immersion device (300) is a catalyst component selected from the group consisting of P, Zn, Ga, Ni, Cr, Zr, Mg, Sn, Ce, and In in the decomposition of fluorinated gases such as CF4, SF6, NF3, and HFCs; a catalyst component selected from the group consisting of Ru, Rh, Sm, Pd, Ir, Cu, Co, Ce, and Zn in the N2O decomposition reaction; a catalyst component selected from the group consisting of Pt, Pd, Ag, Mn, Fe, Cu, Ce, and Sn in the NOx and N2O selective catalytic reduction (SCR) reaction; and a catalyst component selected from the group consisting of Ru, Rh, Pd, Ir, Au, Cu, Mn, Sn, Te, Ni, Cr, Fe, Co, Mo, Ce, Se, and Ba in the ammonia decomposition hydrogen production. It may be composed of one or a combination of two or more of the following: a catalyst component selected from the group consisting of Ru, Rh, Ir, La, Ni, Co, Zr, Ce, Mg, and Zn in natural gas reforming hydrogen production; a catalyst component selected from the group consisting of Ru, Rh, Pd, Pt, Ir, Au, Cu, Ce, Cr, Ni, and Zn in carbon monoxide oxidation; a catalyst component selected from the group consisting of Pt, Ba, La, Au, Fe, Co, Cu, Zn, Mn, Cr, and Ce in carbon monoxide water gas shift (WGS); and a catalyst component selected from the group consisting of Pt, Au, Pd, Cr, Cu, and Mn in VOC oxidation.

[0081] Here, N2O (nitrous oxide), which is the target of the N2O decomposition reaction among the components of the catalytic active material, is mainly utilized in the deposition process during semiconductor manufacturing, which is a high-tech field. It can be emitted as a residual gas after use in the semiconductor manufacturing process or generated and emitted due to chemical reactions during the process. Although N2O (nitrous oxide) is used as an important special gas in the semiconductor process, it is also a powerful greenhouse gas with a global warming potential (GWP) about 300 times higher than carbon dioxide and remains in the atmosphere for about 120 years, so there is growing interest in its use and disposal methods.

[0082] In the N2O decomposition reaction that can be used in the eggshell type catalyst manufacturing apparatus of the present invention, the catalyst component selected from the group consisting of Ru, Rh, Sm, Pd, Ir, Cu, Co, Ce, and Zn can be applied particularly effectively to directly decompose N2O (nitrous oxide) into nitrogen and oxygen for treating residual gas emitted after use in semiconductor processes in catalytic decomposition, which is one of the most popular technologies recently.

[0083] In addition, in the Selective Catalytic Reduction (SCR) of NOx and N2O, a catalyst component selected from the group consisting of Pt, Pd, Ag, Mn, Fe, Cu, Ce, and Sn can also be applied to the removal of N2O (nitrous oxide), so that nitrogen oxides are treated by converting them into nitrogen and water using a reducing agent.

[0084] The semiconductor industry, a high-tech sector, is showing continuous growth, and solving the problem of increasing N2O (nitrous oxide) emissions resulting from this is very important in terms of environmental regulations and corporate social responsibility. The eggshell type catalyst manufacturing device of the present invention enables the continuous and automated production of eggshell type catalysts, thereby dramatically increasing production efficiency. This can actively contribute to the commercialization of eco-friendly and efficient catalyst decomposition technology, such as treating N2O (nitrous oxide) emitted as residual gas after use in semiconductor processes.

[0085] In addition, regarding the catalytic component selected from the group consisting of P, Zn, Ga, Ni, Cr, Zr, Mg, Sn, Ce, and In for the decomposition of fluorinated gases such as CF4, SF6, NF3, and HFCs that can be used in the eggshell-type catalyst manufacturing apparatus of the present invention, hydrogen fluorinated gases (HFCs) are a type of perfluorocarbon (PFCs), and perfluorocarbons (PFCs) are one of the greenhouse gases that cause global warming; in Korea, they are mainly used in semiconductor manufacturing processes such as semiconductor cleaning agents. Since perfluorocarbons (PFCs) have a Global Warming Potential (GWP) approximately 7,000 times that of carbon dioxide and account for 4.2% of total domestic greenhouse gas emissions, the manufacturing of this catalytic component for decomposing fluorinated gases such as CF4, SF6, NF3, and HFCs is related to human health problems caused by the use of perfluorocarbons (PFCs) in semiconductor manufacturing processes such as semiconductor cleaning agents, and It can be of great help in solving global environmental problems.

[0086] Meanwhile, catalyst components selected from the group consisting of Ru, Rh, Pd, Ir, Au, Cu, Mn, Sn, Te, Ni, Cr, Fe, Co, Mo, Ce, Se, and Ba in ammonia decomposition hydrogen production can be particularly applied to ammonia-based hydrogen production technology for greenhouse gas reduction (GAG290), which is a carbon-neutral green technology related to hydrogen and ammonia.

[0087] In the eggshell type catalyst manufacturing apparatus of the present invention, in addition to the catalyst active material components listed above, various catalyst active material components can be used in the catalyst active material solution depending on the catalytic reaction to which the eggshell type catalyst can be applied.

[0088] In the coating unit of the eggshell-type catalyst manufacturing device of the present invention, as another embodiment, an active material solution immersion device (300) for immersing a catalyst active material solution in a catalyst support and a microwave rapid drying device (400) for rapidly heating and drying the immersed catalyst active material solution are installed as a set. Then, one or more eggshell-type catalyst manufacturing devices are additionally connected in series (not shown), and catalyst particles discharged from the finished catalyst collection hopper (600) of the eggshell-type catalyst manufacturing device in the previous stage are sent to the active material solution immersion device (300) of the eggshell-type catalyst manufacturing device in the next stage through the support supply hopper (200) to be repeatedly coated thinly and uniformly by the coating unit. At the same time, a different active material solution supply line is connected to the active material solution immersion device (300) from an active material solution storage tank containing a catalyst active material solution with a different catalyst active material component, so that a desired catalyst active material component can be selectively supplied.

[0089] Thus, when using the catalytic active material components listed above in a catalytic active material solution, a combination of various components is applied according to the catalytic reaction and coated thinly and uniformly on the surface of the catalyst particles, thereby easily obtaining a complex catalytic effect.

[0090] The rapid heating drying according to the present invention allows the catalyst active material component to be concentrated on the surface of the catalyst support by immersing the catalyst active material solution, which is the immersion liquid, into the catalyst support using an active material solution immersion device (300), and then immediately afterward, before the catalyst active material solution enters the pores of the catalyst support, rapidly heating and drying it with a microwave rapid drying device (400) capable of rapid heating.

[0091] Since the catalyst support may break due to thermal shock if heated suddenly to a high temperature, the above rapid heating drying is performed by heating in a temperature range of 50℃ to 500℃ for 5 seconds to 10 minutes.

[0092] If the heating temperature is less than 50°C, the solution of the catalytic active material on the surface of the catalyst support is not rapidly heated and dried, and if it exceeds 500°C, the catalyst support may be unable to withstand thermal shock.

[0093] If the heating time is less than 5 seconds, the solution of the catalytic active material on the surface of the catalyst support is not dried sufficiently, and if the drying time is longer than 10 minutes, drying is done well but the catalyst manufacturing process time becomes too long and the solution of the catalytic active material may enter the pores of the catalyst support. This heating time may more preferably be 5 seconds to 5 minutes.

[0094] Meanwhile, in the present invention, before supplying the catalyst support from the support supply hopper (200) to the active material solution immersion device (300), the catalyst support is first preheated in a temperature range of 50°C to 500°C using a separate heater (not shown), and then supplied to the active material solution immersion device (300) filled with the immersion liquid, which is the catalyst active material solution. After immersing the preheated catalyst support in the catalyst active material solution using the active material solution immersion device (300), rapid heating and drying can be performed more effectively immediately using a microwave rapid drying device (400).

[0095] This allows a portion of the catalyst active material solution to be heated and dried when the preheated catalyst support is immersed in the immersion solution, thereby effectively preventing the catalyst active material solution from seeping into the pores of the catalyst support along with rapid heating and drying by the microwave rapid drying device (400), making it easier to coat most of the catalyst active material onto the surface of the catalyst support.

[0096] In the present invention, the output of the microwave rapid drying device (400) can be used in an output range of 500 watts (W) to 3,000 watts (W). If the output is less than 500 watts (W), the solution of the catalytic active material on the surface of the catalyst support is not rapidly heated and dried well, and if it exceeds 3,000 watts (W), the rapid heating and drying time is shortened, but the catalyst support may be overheated and difficult to withstand due to thermal shock.

[0097] The eggshell type catalyst manufacturing device of the present invention may be equipped with a screw conveyor (500) that is installed so that a screw rotates within the catalyst manufacturing device body (100) and transports the catalyst support supplied from the support supply hopper (200) while flipping it over.

[0098] The screw conveyor (500) of the present invention is composed of a screw (510) and a rotating shaft (520), and the screw (510), which rotates according to the rotation of the rotating shaft (520) within the body (100) of the catalyst manufacturing device, is installed in a spiral shape that facilitates the transport of the catalyst support, and can effectively turn over the catalyst support while transporting it for immersion of the catalyst active material solution and rapid heating and drying as it passes through the coating unit.

[0099] To this end, protrusions or partitions (not shown) are formed on the surface of the screw (510) to facilitate the transport of the catalyst support, and the screw (510) rotates and transports the catalyst support so that it is easy to lift and flip it over.

[0100] In addition, the rotational speed of the rotating shaft (520) in the screw conveyor (500) can be adjusted to a speed suitable for manufacturing an eggshell type catalyst having a structure in which the catalytic active material component is spread evenly near the surface of the catalyst particles.

[0101] The eggshell type catalyst manufacturing device of the present invention may have a completed catalyst collection hopper (600) installed on the upper side of the catalyst manufacturing device body (100) for collecting and discharging catalyst particles that have been completed by immersing the catalyst active material solution in an active material solution immersion device (300) and rapidly heating and drying it in a microwave rapid drying device (400) on the lower side.

[0102] The catalyst particles that have passed through the above-mentioned completed catalyst collection hopper (600) can be stored in a catalyst storage tank. Here, the catalyst storage tank may be a standard container commonly used, and since its size may vary depending on site conditions, a specific illustration thereof is omitted.

[0103] In the coating unit of the eggshell type catalyst manufacturing apparatus of the present invention, as another embodiment, the catalyst particles discharged from the finished catalyst collection hopper (600) are recirculated through the coating unit, which is equipped with a set of active substance solution immersion device (300) that immerses a catalyst support in a catalyst active substance solution, and a microwave rapid drying device (400) that rapidly heats and dries the catalyst active substance solution coated on the catalyst support immediately afterward, and are then recirculated to the active substance aqueous solution immersion device (300) through the support supply hopper (200) so that the catalyst active substance components are further spread more evenly near the surface of the catalyst particles by the coating unit through a coating unit that is equipped with an active substance solution immersion device (300) that immerses a catalyst support in a catalyst active substance solution, which is an immersion liquid, and immediately afterward, rapidly heats and dries the catalyst active substance solution coated on the catalyst support.

[0104] In another embodiment of the present invention, the catalyst support is immersed in a catalyst active substance solution while passing through a coating unit, and immediately afterwards, the catalyst active substance aqueous solution coated on the catalyst support is rapidly heated and dried by a microwave rapid drying device (400). The catalyst particles discharged from the completed catalyst collection hopper (600) are then recirculated through the support supply hopper (200) to the active substance aqueous solution immersion device (300) to repeatedly coat the catalyst active substance components thinly and uniformly by the coating unit. The number of times the catalyst particles are recirculated can continue until the required amount of catalyst active substance for manufacturing an eggshell type catalyst having a structure in which the catalyst active substance components are spread evenly near the surface of the catalyst particles is coated on the catalyst particles.

[0105] In addition, as another embodiment of the present invention, one or more eggshell-type catalyst manufacturing devices may be additionally connected in series (not shown) so that catalyst particles discharged from the finished catalyst collection hopper (600) of the eggshell-type catalyst manufacturing device of the previous stage are sent to the active material solution immersion device (300) of the eggshell-type catalyst manufacturing device of the next stage through the support supply hopper (200) and the catalyst active material component is repeatedly coated thinly and uniformly by a coating unit so that the catalyst active material component is more evenly spread near the surface of the catalyst particles.

[0106] Here, the number of series of eggshell-type catalyst manufacturing devices connected in series, which are sent to an active material solution immersion device (300) through a support supply hopper (200) of the next stage eggshell-type catalyst manufacturing device and repeatedly coated thinly and uniformly by a coating unit, can be installed until the required amount of catalytic active material for manufacturing an eggshell-type catalyst having a structure in which the catalytic active material component is spread evenly near the surface of the catalyst particle is coated on the catalyst particle.

[0107] Accordingly, by coating the catalytic active material solution relatively thinner and more uniformly while rapidly heating and drying, the expensive catalytic active material is prevented from entering the pores as much as possible, thereby reducing the amount of catalytic active material used, which is very economical and desirable.

[0108] This can be achieved by increasing the rotational speed of the rotating shaft (520) in the screw conveyor (500) to shorten the time the catalyst support is immersed in the active material solution immersion device (300) and then transporting the catalyst support, which is coated with the catalyst active material solution relatively thinner and more uniformly, and then rapidly heating and drying it with a microwave rapid drying device (400).

[0109] The eggshell type catalyst manufacturing device of the present invention may also have a partition (700) installed in the upper part of the catalyst manufacturing device body (100) to separate a support supply hopper (200), an active material solution immersion device (300), a microwave rapid drying device (400), and a finished catalyst collection hopper (500).

[0110] These partitions (700) can operate effectively in stages according to the function and operation of each device constituting the eggshell type catalyst manufacturing device, and in particular, can prevent microwaves harmful to the human body, etc. generated from the microwave rapid drying device (400) from leaking out to the outside.

[0112] <에그쉘 타입 촉매 제조 방법>

[0113] The eggshell type catalyst of the present invention is produced by immersing a catalyst support in a catalyst active material solution using an eggshell type catalyst manufacturing apparatus including the active material solution immersion apparatus (300) described above and a coating unit, such as a microwave rapid drying apparatus (400), and then immediately rapidly heating and drying it. The steps of each manufacturing method are explained with reference to the flowchart in FIG. 3, which schematically shows the method for manufacturing an eggshell type catalyst according to an embodiment of the present invention.

[0114] Accordingly, the present invention relates to a method for manufacturing an eggshell-type catalyst having a structure in which a catalytic active material component is evenly distributed near the surface of catalyst particles, wherein

[0115] (A) A step of filling the immersion solution of a catalyst active material into the immersion device (300) of the catalyst manufacturing device body (100), which is configured such that the upper part of the body is inclined downward so as to fill the catalyst active material solution, and

[0116] (B) A step in which a catalyst support supplied by a support supply hopper (200) installed on the upper part of the body of the catalyst manufacturing device is immersed in a catalyst active material solution of an active material solution immersion device (300), and

[0117] (C) A step of inverting a catalyst support coated with a catalyst active material solution while transporting it by a screw conveyor (500) within a catalyst manufacturing device body (100),

[0118] (D) A step of rapidly heating and drying a catalyst support coated with a catalyst active material solution using a microwave rapid drying device (400),

[0119] (E) The process includes the step of collecting the completed catalyst particles into a completed catalyst collection hopper (600) and discharging them.

[0120] A method for manufacturing an eggshell-type catalyst is further provided, characterized by using any one of the eggshell-type catalyst manufacturing devices described above.

[0121] That is, the eggshell type catalyst manufacturing method according to the present invention is described in a manner that utilizes any one of the configurations of the various embodiments of the eggshell type catalyst manufacturing apparatus described above, in order to omit redundant descriptions of eggshell type catalyst manufacturing apparatuses that are substantially identical in configuration and belong only to different categories, particularly when describing and explaining the eggshell type catalyst manufacturing method.

[0123] The foregoing description is merely an illustrative explanation of the technical concept of the present invention, and those skilled in the art to which the present invention pertains will be able to make various modifications and variations within the scope of the essential characteristics of the present invention. Accordingly, the embodiments disclosed in the present invention are intended to explain, not limit, the technical concept of the present invention, and the scope of the technical concept of the present invention is not limited by these embodiments. The scope of protection of the present invention shall be interpreted by the claims below, and all technical concepts within an equivalent scope shall be interpreted as being included within the scope of rights of the present invention. Explanation of the symbols

[0124] 100...Catalyst manufacturing device body 200...Support material supply hopper 300...Active substance solution immersion device 400...Microwave rapid drying device 500...Screw conveyor 510...Screw 520...Rotation axis 600...Completed catalyst collection hopper 700...partition

Claims

Claim 1 An eggshell-type catalyst manufacturing apparatus having a structure in which a catalytic active substance component is evenly distributed near the surface of catalyst particles, comprising: a catalyst manufacturing apparatus body configured such that the upper part of the body slopes downward to allow filling with a catalytic active substance solution, which is an immersion liquid; and a device installed on the upper part of the catalyst manufacturing apparatus body. A support supply hopper for supplying a catalyst support to a catalyst active material solution; a coating unit equipped with a set comprising an active material solution immersion device for immersing the catalyst support supplied by the support supply hopper in the catalyst active material solution filled at the top of the catalyst manufacturing device body, and a microwave rapid drying device for rapidly heating and drying the catalyst active material solution coated on the catalyst support immediately thereafter; and a screw conveyor installed within the catalyst manufacturing device body such that a screw rotates from the top of the body filled with the catalyst active material solution at the bottom, which conveys the catalyst support, passes through the coating unit, and serves to turn the catalyst support over for immersion in the catalyst active material solution and rapid heating and drying. An eggshell type catalyst manufacturing apparatus using an immersion solution and microwave rapid drying, comprising a completed catalyst collection hopper for collecting and discharging completed catalyst particles, wherein rapid heating drying in the microwave rapid drying apparatus is performed by heating for 5 seconds to 10 minutes at a temperature range of 50°C to 500°C, the output of the microwave rapid drying apparatus is in an output range of 500 watts (W) to 3,000 watts (W), and a partition is configured to be installed in the upper part of the body of the catalyst manufacturing apparatus to separate a support supply hopper and an active material solution immersion device, the microwave rapid drying apparatus, and the completed catalyst collection hopper. Claim 2 An eggshell type catalyst manufacturing apparatus using an immersion solution and microwave rapid drying, wherein, in claim 1, the catalyst support is an inorganic oxide composed of one selected from the group consisting of nickel, magnesium, manganese, vanadium, silicon, cerium, zinc, aluminum, phosphorus, zirconium, iron, and titanium, or a combination of two or more. Claim 3 In claim 1, the catalytic active material used in the catalytic active material solution in which the catalyst support is immersed in the active material solution immersion device comprises: a catalytic component selected from the group consisting of P, Zn, Ga, Ni, Cr, Zr, Mg, Sn, Ce, and In for the decomposition of fluorinated gases such as CF4, SF6, NF3, and HFCs; a catalytic component selected from the group consisting of Ru, Rh, Sm, Pd, Ir, Cu, Co, Ce, and Zn for the N2O decomposition reaction; a catalytic component selected from the group consisting of Pt, Pd, Ag, Mn, Fe, Cu, Ce, and Sn for the NOx and N2O selective catalytic reduction (SCR); and a catalytic component selected from the group consisting of Ru, Rh, Pd, Ir, Au, Cu, Mn, Sn, Te, Ni, Cr, Fe, Co, Mo, Ce, Se, and Ba for the hydrogen production from the decomposition of ammonia. An eggshell-type catalyst manufacturing apparatus using an immersion solution and microwave rapid drying, characterized by being composed of one or a combination of two or more of the following: a catalyst component selected from the group consisting of Ru, Rh, Ir, La, Ni, Co, Zr, Ce, Mg, and Zn in natural gas reforming hydrogen production; a catalyst component selected from the group consisting of Ru, Rh, Pd, Pt, Ir, Au, Cu, Ce, Cr, Ni, and Zn in carbon monoxide oxidation; a catalyst component selected from the group consisting of Pt, Ba, La, Au, Fe, Co, Cu, Zn, Mn, Cr, and Ce in carbon monoxide water gas shift (WGS) reaction; and a catalyst component selected from the group consisting of Pt, Au, Pd, Cr, Cu, and Mn in VOC oxidation. Claim 4 An eggshell type catalyst manufacturing apparatus using an immersion solution and microwave rapid drying, characterized in that, in claim 1, the catalyst particles discharged from the finished catalyst collection hopper are recirculated to an active material solution immersion device through a support supply hopper and repeatedly coated thinly and uniformly by a coating unit so that the catalyst active material component is evenly spread near the surface of the catalyst particles. Claim 5 delete Claim 6 An eggshell-type catalyst manufacturing apparatus using an immersion solution and microwave rapid drying, characterized in that, in claim 1, catalyst particles discharged from the completed catalyst collection hopper are sent to an active material solution immersion device through a support supply hopper in a next-stage eggshell-type catalyst manufacturing apparatus connected in series with one or more others, and then coated thinly and uniformly by a coating unit, thereby repeating this process step by step so that the catalyst active material component is evenly spread near the surface of the catalyst particles. Claim 7 An eggshell-type catalyst manufacturing apparatus using an immersion solution and microwave rapid drying, characterized in that, in the eggshell-type catalyst manufacturing apparatus of claim 6, one or more of the following stages are additionally connected in series, a different active material solution supply line is connected from an active material solution storage tank containing a catalyst active material solution of another catalyst active material component to an active material solution immersion device of the following stage eggshell-type catalyst manufacturing apparatus to supply a desired catalyst active material component. Claim 8 delete Claim 9 delete Claim 10 A method for manufacturing an eggshell-type catalyst having a structure in which a catalytic active substance component is evenly distributed near the surface of the catalyst particles, comprising: (A) a step of filling a catalyst active substance solution supplied from an active substance solution storage tank containing the catalyst active substance solution into an active substance solution immersion device of a catalyst manufacturing device body configured such that the upper part of the body is inclined downward to fill the immersion liquid, which is a catalyst active substance solution; (B) a step of immersing a catalyst support supplied by a support supply hopper installed on the upper part of the catalyst manufacturing device body into the catalyst active substance solution of the active substance solution immersion device; (C) a step of inverting the catalyst support coated with the catalyst active substance solution while transporting it by a screw conveyor inside the catalyst manufacturing device body; (D) a step of rapidly heating and drying the catalyst support coated with the catalyst active substance solution by a microwave rapid drying device; and (E) a step of collecting and discharging the completed catalyst particles into a completed catalyst collection hopper, characterized by using an eggshell-type catalyst manufacturing device according to any one of claims 1 to 4, 6, and 7. Method for preparing an eggshell-type catalyst using immersion solution and microwave rapid drying.

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