Hydrocarbon Catalyst Particle Size Control
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Solution Overview
Problem
Hydrocarbon conversion catalysts face inefficiencies due to particle size limitations, where large particles hinder diffusion in reactions and small particles are lost, leading to environmental and economic issues, and existing methods for controlling particle size are costly and ineffective.
Innovation Solution
A method involving the removal of more than 50% of particles above and below specified thresholds, followed by reprocessing to adjust particle size, using techniques like air classification and milling, and re-spray-drying to enhance catalyst performance and reduce losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the average particle size of catalyst is reduced to increase surface area, then catalytic activity is improved, but diffusion limitations worsen and small particles are lost to the environment
Solution Approach 1:
The catalyst population is segmented into different size ranges with distinct functions: particles above 20 microns provide catalytic activity with good diffusion, while particles below 20 microns are removed to prevent loss. This segmentation allows optimization of different size ranges for different purposes.
Solution Approach 2:
The invention changes the particle size distribution parameter by removing particles below a threshold size (e.g., 20 microns) while retaining and potentially increasing the proportion of larger particles. This parameter change resolves the contradiction by eliminating the harmful small particles while maintaining catalytic activity through the remaining larger particles.
2Ease of operation
If particles below 20 microns are retained in the catalyst system, then fluidization performance is improved, but environmental release and economic losses increase
Solution Approach 1:
The harmful small particles (below 20 microns) are extracted and removed from the catalyst system using classification equipment. This extraction eliminates the environmental pollution problem while the fluidization performance is maintained through proper design of the remaining particle size distribution.
Solution Approach 2:
The invention converts the harmful small particles into a benefit by collecting them through classification and potentially reusing them in a controlled manner, such as incorporating them into new catalyst formulations or using them for purposes where their small size is advantageous, thereby transforming the pollution problem into a resource.
3Manufacturing precision
If existing classification methods are used to control particle size, then particle size distribution is adjusted, but catalyst losses and costs increase
Solution Approach 1:
The invention optimizes the classification parameters by setting the cutoff threshold at 20 microns, which is the optimal point where particles are large enough to prevent loss but small enough to maintain good catalytic performance. This parameter optimization minimizes catalyst loss while achieving precise particle size control.
Solution Approach 2:
The classification system uses feedback from particle size measurement to adjust operating parameters and minimize catalyst loss. By monitoring the particle size distribution and adjusting classification settings accordingly, the system achieves precise control while recovering and reusing classified particles, reducing overall losses.
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 approach improves catalyst performance by optimizing particle size distribution, reducing losses, and enhancing diffusion characteristics, leading to increased yields and reduced environmental impact.
Implementation Method 1
removal of more than 50% of particles above and also more than 50% of particles below a specified threshold... using techniques like air classification and milling
Implementation Method 2
reprocessing the removed particles to reduce particle size... using techniques like air classification and milling
Implementation Method 3
A binder, generally a low molecular weight oligomer of silica (Silica Sol), or aluminum chlohydrol (Alumina Sol) is commonly added to the mixture, which is spray dried to form the particles
Data Source
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AI summary
An improved hydrocarbon conversion catalyst is obtained through removal and modification by various means, of detrimental large and/or small particle fractions. Such modified fractions may be reused in the same or similar processes. The improved catalyst is advantageous to a wide range of hydrocarbon conversion processes.