Boehmite Synthesis at Room Temperature and Atmospheric Pressure
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Solution Overview
Problem
Existing methods for producing boehmite are limited by high costs, low production yield, and the need for high temperatures and pressures, which hinder large-scale industrial applications. Additionally, these methods often result in boehmite with low surface area and purity.
Innovation Solution
A method for producing boehmite at room temperature and atmospheric pressure involves dissolving sodium aluminate in water to form a sodium aluminate solution, which is then mixed with hydrochloric acid to produce an aluminum hydroxide gel. This gel is further processed to form a saturated aluminum chloride solution, which is then reacted with an ammonia solution to produce a boehmite gel that is subsequently heated to yield boehmite.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hydrothermal method is used to produce boehmite, then the degree of boehmite precipitation is improved, but high temperatures and pressures are required which inhibit large-scale production
Solution Approach 1:
The invention changes the chemical parameters of the reaction system by using aluminum sulfate and sodium bicarbonate in aqueous solution at room temperature and atmospheric pressure, instead of requiring high temperature and pressure conditions. This parameter change enables high productivity without the need for expensive hydrothermal equipment
Solution Approach 2:
The invention uses inexpensive, readily available reagents (aluminum sulfate and sodium bicarbonate) that can be easily handled and disposed of, replacing the need for expensive high-pressure equipment and complex safety systems required by hydrothermal methods
2Ease of manufacture
If hydrolysis of aluminum organic compounds is used, then boehmite can be synthesized, but production yield is low and cost of reagents is high
Solution Approach 1:
The invention replaces expensive aluminum organic compounds with inexpensive inorganic reagents (aluminum sulfate and sodium bicarbonate) that are readily available and can be handled without special precautions, thereby reducing both material costs and production complexity while maintaining high yield
Solution Approach 2:
The invention changes from organic chemistry parameters to inorganic chemistry parameters, using simple salt metathesis reactions in aqueous solution instead of hydrolysis of organic compounds, which simplifies the manufacturing process and increases production yield
3Productivity
If external seeding method is used for boehmite precipitation, then boehmite can be produced, but time-consuming filtration and large amounts of seed requirements limit industrial usage
Solution Approach 1:
The invention extracts and eliminates the need for external seeding step entirely by using direct precipitation from aqueous solutions of aluminum sulfate and sodium bicarbonate, removing the time-consuming filtration and seed preparation steps that characterize traditional methods
4Ease of manufacture
If conventional methods are used, then boehmite can be synthesized, but cost is high and additional step of reducing average particle size is required
Solution Approach 1:
The invention enables the system to self-produce nano-sized boehmite particles directly through controlled precipitation conditions, eliminating the need for additional mechanical size reduction steps and associated costs while maintaining ease of manufacture
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
This method enables the cost-effective production of boehmite with high surface area and purity at room temperature and atmospheric pressure, overcoming the limitations of existing methods and facilitating large-scale industrial applications.
Implementation Method 1
producing a sodium aluminate solution by dissolving sodium aluminate in water
Implementation Method 2
producing an aluminum hydroxide gel by mixing hydrochloric acid solution with an exemplary sodium aluminate solution
Implementation Method 3
producing an aluminum chloride solution by mixing a hydrochloric acid solution with an exemplary aluminum hydroxide gel
Implementation Method 4
producing a saturated aluminum chloride solution by heating an exemplary aluminum chloride solution
Implementation Method 5
producing a boehmite gel by mixing an ammonia solution with an exemplary saturated aluminum chloride solution
Implementation Method 6
producing boehmite by heating an exemplary boehmite gel
Data Source
AI summary
A method for producing boehmite under atmospheric pressure may include producing a sodium aluminate solution by dissolving sodium aluminate in water. The method may further include producing an aluminum hydroxide gel by mixing a hydrochloric acid solution with the sodium aluminate solution. The method may further include producing an aluminum chloride solution by mixing a hydrochloric acid solution with the aluminum hydroxide gel. The method may further include producing saturated aluminum chloride solution by heating the aluminum chloride solution. The method may further include producing a boehmite gel by mixing an ammonia solution with the saturated aluminum chloride solution and heating the boehmite gel to produce boehmite.