Catalyst Carrier Preparation via Potassium Removal
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Solution Overview
Problem
The variability in potassium-containing compounds in thermally decomposable materials used for catalyst carrier production leads to batch-to-batch inconsistencies and performance issues in olefin epoxidation catalysts, affecting selectivity and stability over time.
Innovation Solution
Treating the thermally decomposable material to reduce potassium concentrations before forming the carrier, resulting in a more consistent catalyst performance by minimizing the deposition of potassium-containing compounds during the impregnation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If burnout materials are used to create pores in the carrier, then porosity and catalytic activity are improved, but batch-to-batch consistency deteriorates due to variability in potassium-containing compounds
Solution Approach 1:
The patent applies preliminary action by treating the burnout material with water before use to remove potassium-containing compounds. This pre-treatment step eliminates the source of variability in potassium content that causes batch-to-batch inconsistencies, while preserving the porosity-enhancing function of the burnout material.
Solution Approach 2:
The patent changes the physical-chemical parameters of the burnout material by washing it with water to reduce potassium content. This parameter change (removing potassium-containing compounds) resolves the contradiction by maintaining porosity while improving batch-to-batch consistency of catalyst performance.
2Stability of the object's composition
If potassium-containing compounds are present in the carrier, then pore formation is achieved, but catalyst selectivity and stability deteriorate over time
Solution Approach 1:
The patent applies the extraction principle by removing potassium-containing compounds from the burnout material through water washing. This extraction eliminates the harmful potassium leachables that cause selectivity deterioration over time, while the burnout material's porosity function is preserved.
Solution Approach 2:
The patent converts the harmful effect of potassium-containing compounds into a benefit by using water treatment to selectively remove only the harmful potassium leachables while retaining the beneficial porosity-creating function of the burnout material. The harmful aspect is eliminated while the useful aspect is preserved.
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 enhances the consistency and longevity of catalyst performance, maintaining higher selectivity and activity levels, thereby extending the catalyst's operational life and improving process efficiency.
Implementation Method 1
heating the mixture to a temperature sufficient to thermally decompose the thermally decomposable material and sinter the heat sinterable material
Implementation Method 2
heating the mixture to a temperature sufficient to thermally decompose the thermally decomposable material and sinter the heat sinterable material
Data Source
AI summary
A process for preparing a catalyst comprising depositing a metal on a carrier prepared by: - treating one or more thermally decomposable materials in particulate form comprising potassium under conditions sufficient to reduce the total quantity of potassium in the thermally decomposable material, - preparing a mixture comprising the treated thermally decomposable material and a heat sinterable material, and - heating the mixture to sinter the heat sinterable material and to thermally decompose the treated thermally decomposable material to form the carrier; the catalyst; a process for preparing an olefin oxide by reacting an olefin with oxygen in the presence of the catalyst; and a method of using an olefin oxide for making a 1,2- alkanediol, a 1,2-alkanediol ether or an alkanolamine.