Boron-Substituted Zeolite Catalyst Clusters for Hydrothermal Stability
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Solution Overview
Problem
Existing supported catalysts lack improved heat resistance, particularly in high-temperature exhaust gas purification applications, where conventional catalysts degrade in hydrothermal conditions, reducing their low-temperature activity for NOx and CO oxidation.
Innovation Solution
A cluster-supporting catalyst is developed using boron-substituted zeolite particles, where catalyst metal clusters with a positive charge are supported on acid sites within the pores through electrostatic interaction, maintaining stability and catalytic activity even after hydrothermal endurance treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional zeolite carriers are used to support catalyst metal particles, then the catalyst can be manufactured with standard materials and processes, but the heat resistance deteriorates in high-temperature hydrothermal conditions
Solution Approach 1:
The patent applies parameter changes by substituting aluminum atoms with boron atoms in the zeolite framework, changing the chemical composition parameter to achieve higher heat resistance and structural stability in hydrothermal conditions while maintaining the zeolite's catalytic functionality
Solution Approach 2:
The patent creates a composite material system by combining boron-substituted zeolite with catalyst metal clusters (such as Pt, Pd, Rh), forming a hybrid catalyst that leverages the thermal stability of boron-substituted zeolite and the catalytic activity of metal clusters
2Reliability
If catalyst metal particles are supported on conventional zeolite carriers, then the catalyst can be produced using standard ion exchange methods, but the low-temperature catalytic activity deteriorates after thermal endurance treatment
Solution Approach 1:
The patent changes the chemical composition parameter of the zeolite carrier by substituting aluminum with boron, which fundamentally alters the thermal and hydrothermal stability parameters, allowing the catalyst to maintain its low-temperature activity after endurance treatment
Solution Approach 2:
The patent performs preliminary substitution of aluminum atoms with boron atoms before introducing the catalyst metal clusters, pre-establishing a thermally stable framework that will preserve catalytic activity throughout the catalyst's service life
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 exhibits enhanced heat resistance and sustained low-temperature catalytic activity for NOx reduction and CO oxidation, maintaining performance under hydrothermal conditions.
Implementation Method 1
catalyst metal clusters having a positive charge, and supported on acid sites within the pores of the boron-substituted zeolite particles
Implementation Method 2
substituting at least part of aluminum atom in aluminosilicate zeolite with boron atom, calcium atom, indium atom, etc.
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
Cluster-supporting catalyst having an improved heat resistivity, and method for producing the same are provided. The cluster-supporting catalyst of the present invention comprises boron-substitute zeolite particles (20), and catalyst metal clusters (16) supported within the pores of the boron-substitute zeolite particles. The method of the present invention for producing a cluster-supporting catalyst, includes the following steps: providing a dispersion liquid containing a dispersion medium and boron-substitute zeolite particles (20) dispersed in the dispersion medium; and in the dispersion liquid, forming catalyst metal clusters (16) having a positive charge, and supporting the catalyst metal clusters on the acid sites within the pores of the boron-substitute zeolite particles through an electrostatic interaction.