Mixed-Phase Alumina HCl Oxidation Catalyst Against Pulverization
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Solution Overview
Problem
Existing hydrogen chloride oxidation catalysts suffer from pulverization after long-term use, which leads to clogging and reduced chlorine production efficiency.
Innovation Solution
A hydrogen chloride oxidation catalyst comprising alumina as a carrier with supported copper, alkali metal, and rare-earth elements, characterized by specific X-ray diffraction peak ratios, surface area, pore diameter, and particle size, which enhances catalytic activity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a hydrogen chloride oxidation catalyst is used for a long period, then chlorine production continues, but the catalyst shape collapses and pulverizes
Solution Approach 1:
The patent applies parameter changes by precisely controlling the calcination temperature (550-980°C) and time to transform γ-alumina into a mixed-phase structure containing both γ-alumina and α-alumina. This phase transformation changes the physical and chemical parameters of the carrier, resulting in enhanced mechanical strength and resistance to pulverization while maintaining catalytic activity over extended periods
Solution Approach 2:
The patent creates a composite material structure by forming a mixed-phase alumina carrier containing both γ-alumina and α-alumina phases. The γ-alumina provides high surface area and catalytic activity, while the α-alumina provides structural stability and resistance to collapse. This composite phase structure resolves the contradiction between maintaining catalyst shape and extending service life
2Productivity
If the catalyst activity is increased to improve chlorine yield, then production efficiency improves, but the catalyst may become more prone to pulverization
Solution Approach 1:
The patent applies local quality by creating distinct functional zones within the catalyst structure: the γ-alumina phases provide high surface area and catalytic activity for chlorine production, while the α-alumina phases provide structural support and mechanical stability. The supported metal components (copper, alkali metal, rare-earth element) are localized on the carrier surface where they can maximize catalytic effect without compromising overall structural integrity
Solution Approach 2:
The patent uses composite materials by combining multiple metal components (copper, alkali metal, and rare-earth element) on the mixed-phase alumina carrier. This composite formulation enhances catalytic activity for hydrogen chloride oxidation while the stable α-alumina phase in the carrier prevents pulverization, thus achieving both high productivity and reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The catalyst effectively suppresses pulverization and maintains high catalytic activity over extended periods, improving chlorine yield and production efficiency.
Implementation Method 1
a hydrogen chloride oxidation catalyst for oxidizing hydrogen chloride, the hydrogen chloride oxidation catalyst including: a carrier containing alumina as a main component; and copper, an alkali metal, and a rare-earth element, all of which are supported on the carrier
Implementation Method 2
in an X-ray diffraction pattern measured with an X-ray diffractometer using CuKα rays
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A hydrogen chloride oxidation catalyst is a catalyst for oxidizing hydrogen chloride. The hydrogen chloride oxidation catalyst includes a carrier, and also copper, an alkali metal, and a rare-earth element. The carrier contains alumina as a main component. The copper, the alkali metal, and the rare-earth element are supported on the carrier. In an X-ray diffraction pattern measured with an X-ray diffractometer using CuKα rays, the ratio of a peak at 2θ = 65.2° in the X-ray diffraction pattern with respect to a peak intensity of a (440) plane of alumina crystal is 0.0015 or more and 0.500 or less.