Olefin Epoxidation Catalyst Carrier Pore Optimization
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Solution Overview
Problem
Catalysts for olefin epoxidation face challenges in maintaining selectivity and stability over time, leading to reduced efficiency and the need for increased reaction temperatures, which can be detrimental to equipment and product yield.
Innovation Solution
A catalyst carrier with a specific pore size distribution and surface area is developed, comprising alumina and an alkaline earth metal silicate bond material, optimizing pore volume in the range of 0.1 to 10 μm and surface area of at least 1.3 m2/g, to enhance catalyst activity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional carrier with low surface area is used, then catalyst activity is maintained, but the area available for silver deposition is limited
Solution Approach 1:
The patent changes the physical parameters of the carrier by controlling pore size distribution (at least 70% of pore volume in pores with diameters of 0.2 to 10 μm) and surface area (at least 1 m²/g), which allows increased surface area for silver deposition while maintaining appropriate pore structures for catalyst activity
Solution Approach 2:
The patent utilizes porous alumina carrier materials with specifically controlled pore size distributions, where the porous structure provides both increased surface area for metal deposition and appropriate pore volumes for maintaining catalyst activity and reactant diffusion
2Reliability
If reaction temperature is increased to maintain selectivity over time, then catalyst selectivity is improved, but equipment stress and energy consumption increase
Solution Approach 1:
The patent applies preliminary action by pre-optimizing the carrier properties (pore size distribution and surface area) before catalyst operation, which establishes stable catalyst performance from the outset and maintains selectivity without requiring temperature increases over time
Solution Approach 2:
The patent creates an optimized carrier model with specific pore size distribution (at least 70% in 0.2 to 10 μm range) that replicates ideal conditions for maintaining catalyst selectivity, allowing the catalyst to perform consistently without temperature adjustments
3Shape
If platelet morphology alumina is used, then carrier structure is formed, but the surface area and pore size distribution may not be optimized for catalyst performance
Solution Approach 1:
The patent applies local quality by specifying that at least 70% of the pore volume should be in pores with diameters of 0.2 to 10 μm, creating locally optimized regions within the carrier that provide both structural integrity and high surface area for catalyst deposition
Solution Approach 2:
The patent transitions from focusing solely on particle morphology (2D/3D shape) to controlling pore size distribution as a critical dimension, specifying that the pore volume distribution (at least 70% in 0.2 to 10 μm range) is the key parameter for optimizing both structure and surface area
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 optimized catalyst carrier significantly improves selectivity and stability, allowing for longer catalyst life and more efficient olefin oxide production at lower temperatures, thereby enhancing process efficiency.
Implementation Method 1
firing the mixture to form the catalyst carrier
Implementation Method 2
an alkaline earth metal silicate bond material
Implementation Method 3
a silver component, usually with one or more additional elements deposited therewith, on a carrier
Data Source
AI summary
A carrier, which comprises non-platelet alumina and/or a bond material, has a surface area of at least 1.3 m2/g, a total pore volume and a pore size distribution such that at least 80% of the total pore volume is contained in pores with diameters in the range of from 0.1 to 10 μm, and at least 80% of the pore volume contained in the pores with diameters in the range of from 0.1 to 10 μm is contained in pores with diameters in the range of from 0.3 to 10 μm, and a process for the preparation of a carrier which comprises forming a mixture comprising:a) from 50 to 95 weight percent of a first particulate α-alumina having a median particle size (d50) of from 5 to 100 μm;b) from 5 to 50 weight percent of a second particulate α-alumina having a d50 which is less than the d50 of the first particulate α-alumina and which is in the range of from 1 to 10 μm; andc) an alkaline earth metal silicate bond material; weight percent being based on the total weight of α-alumina in the mixture; and firing the mixture to form the carrier.