Catalyst Production Method Using Size Distribution Analysis
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Solution Overview
Problem
Existing methods for producing catalysts often result in inconsistent size distribution and insufficient impregnation of catalytic particles on supports, leading to suboptimal catalyst performance.
Innovation Solution
A method involving mixing catalytic particles with a solvent, performing size distribution analysis, centrifugation, and decantation to create a dispersion, followed by impregnation of a catalyst support with the dispersion, and subsequent calcination, with optional drying and additional impregnation steps based on analysis using techniques like ICP-MS to ensure sufficient loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing methods are used to produce catalysts, then the production process is simple, but the size distribution is inconsistent and impregnation is insufficient
Solution Approach 1:
The patent performs size distribution analysis on catalytic particles before impregnation and uses centrifugation to pre-separate particles by size. This preliminary action ensures consistent size distribution is achieved before the impregnation step, directly resolving the size distribution inconsistency problem while maintaining a manageable process through systematic preparation
Solution Approach 2:
The patent implements a feedback mechanism where size distribution analysis is performed on the particle suspension, and the results are used to adjust the centrifugation parameters and re-mixing process. This closed-loop control ensures the size distribution meets target specifications, directly improving manufacturing precision through measurement and adjustment
2Reliability
If existing impregnation methods are used, then the process is quick, but the impregnation is insufficient and catalyst performance is suboptimal
Solution Approach 1:
The patent performs preliminary size distribution analysis and centrifugation to create a well-characterized particle suspension before impregnation. This ensures that particles are properly sized and dispersed, which improves impregnation uniformity and reduces the need for rework, thereby improving both reliability and maintaining productivity
Solution Approach 2:
The patent changes the physical parameters of the particle suspension through centrifugation, creating a supernatant with optimized particle concentration and size distribution. This parameter optimization ensures sufficient impregnation by providing ideal conditions for particle deposition on the support, improving reliability without significantly extending the overall process time
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 method ensures a consistent size distribution and adequate impregnation of catalytic particles on the support, enhancing catalyst performance and efficiency.
Implementation Method 1
The entire particle-solvent mixture is centrifuged if the size distribution profile is at or above the predetermined threshold, thereby forming a supernate of the particle-solvent mixture and a precipitate of the particle-solvent mixture within the same container
Implementation Method 2
A Dynamic Light Scattering (DLS) process is performed on the centrifuged sample, thereby determining a size distribution profile for the particle-solvent mixture
Implementation Method 3
the method further comprises the step of calcining the impregnated catalyst support
Data Source
AI summary
A method of producing a catalyst comprising: mixing catalytic particles and a solvent, thereby forming a mixture; performing a size distribution analysis on the mixture to determine a size distribution profile; repeating the mixing of the catalytic particles and the solvent in the mixture if the size distribution profile is below a threshold; centrifuging the mixture if the size distribution profile is at or above the threshold, thereby forming a supernate and a precipitate, wherein the supernate comprises a dispersion including the catalytic particles and the solvent; decanting the mixture, separating the supernate from the precipitate; determining the particle content of the separated supernate; determining a volume of the dispersion to be applied to a catalyst support based on one or more properties of the catalyst support; and impregnating the catalyst support with the catalytic particles in the dispersion by applying the volume of the dispersion to the catalyst support.