Platinum Rhodium Catalyst Gauze Ignition Reliability
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Solution Overview
Problem
Metal catalyst gauze enhanced ignition startup problems, including difficulty in igniting reactants with new, contaminated, or damaged catalysts, result in significant production losses and yield impacts due to contamination and high activation energy requirements.
Innovation Solution
Incorporating 0.25 to 1.5 wt.% of previously used, uncontaminated metal catalyst gauze pieces on a new metal catalyst gauze, such as platinum/rhodium, to reduce activation energy and promote reliable ignition at the catalyst surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If new metal catalyst gauze is used, then catalyst cost is reduced and reactor availability is improved, but ignition reliability deteriorates due to high activation energy and contamination susceptibility
Solution Approach 1:
The invention applies preliminary action by pre-treating the new catalyst gauze with pieces of used catalyst gauze before actual use. The used catalyst pieces are placed on the new catalyst surface to provide pre-formed active sites, eliminating the need for complex chemical pre-treatment processes and enabling reliable ignition from the start
Solution Approach 2:
The used catalyst gauze pieces serve as an intermediary between the inactive new catalyst and the reactant gases. These pieces provide temporary active catalytic sites that facilitate initial ignition, which then spreads to the surrounding new catalyst surface, bridging the gap between fresh catalyst installation and full operational capability
2Reliability
If catalyst activation energy is reduced by conventional methods (increasing feed temperature, pressure, or flammability), then ignition reliability improves, but energy consumption increases and operating conditions become more severe
Solution Approach 1:
The invention applies self-service by using the catalyst itself (in the form of used gauze pieces) to provide the activation function rather than relying on external energy input. The used catalyst pieces contain pre-formed active sites that naturally lower activation energy without requiring additional feed preheating or pressure increases
Solution Approach 2:
The invention changes the physical parameter of the catalyst surface by introducing used catalyst pieces with different surface properties. This physical modification provides active sites that reduce activation energy, achieving reliable ignition without changing feed temperature, pressure, or composition parameters
3Temperature
If catalyst surface area is increased to improve ignition, then ignition temperature decreases, but catalyst cost increases due to additional precious metal requirements
Solution Approach 1:
The invention applies local quality by concentrating the active catalyst material in specific localized areas (pieces of used gauze) rather than uniformly distributing precious metals throughout the entire new catalyst surface. This provides high ignition activity at key locations while minimizing overall precious metal usage
Solution Approach 2:
The invention creates a composite catalyst structure combining new catalyst gauze with embedded pieces of used catalyst gauze. This composite provides the benefits of both fresh catalyst (availability, cost) and used catalyst (active sites, low ignition temperature) without requiring additional precious metals beyond what is already in the new gauze
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
Enables reliable ignition of new, used, contaminated, or damaged catalysts at relatively low temperatures, reducing reactor downtime and increasing yield by facilitating quick ignition within 15 minutes, similar to used catalysts with higher surface areas.
Implementation Method 1
one or more pieces of previously used metal catalyst gauze... that facilitate the improving the catalyst enhanced ignition of gaseous reactants at the surface of metal catalysts in catalyzed oxidation reactions
Data Source
AI summary
The present invention provides materials for improving the ignition of gaseous reactants in metal catalyzed oxidation reactions comprising a metal catalyst gauze, preferably, a platinum/rhodium catalyst gauze, having in contact therewith, from 0.25 to 1.5 wt. %, based on the weight of the metal catalyst gauze, of one or more pieces of previously used metal catalyst gauze. Further, methods of making the metal catalyst materials comprise shaping the pieces of previously used metal catalyst gauze and placing them equidistant from each other in contact with or on the surface of the metal catalyst gauze. And methods of using the materials comprise feeding into the reactor a gas mixture of oxygen or air and one or more reactant gases, and igniting the gas mixture at the surface of one or more or all of the pieces of previously used metal catalyst.