Catalyst Support Modification via Organic Solvent Impregnation
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Solution Overview
Problem
In Fischer-Tropsch synthesis, catalyst support dissolution and hydrothermal attack lead to contamination of hydrocarbon products with ultra-fine particulate matter, resulting in loss of active catalyst components and fouling of downstream processes.
Innovation Solution
A method involving impregnation of a catalyst support with a modifying component using a mixture of water and an organic solvent, where the mixture contains at least 2.5% but less than 12% water, to enhance modifying component loading and attrition resistance, while minimizing support dissolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If water is used as the impregnating liquid medium to modify the catalyst support, then the modifying component can be effectively deposited on the support, but the catalyst support dissolves in the aqueous environment leading to contamination with ultra-fine particles
Solution Approach 1:
The patent uses an organic solvent as an intermediary medium to carry the modifying component precursor onto the catalyst support. This organic solvent acts as a bridge that enables effective deposition of the modifying component without creating the aqueous environment that causes support dissolution and ultra-fine particle formation. The organic solvent facilitates the impregnation process while avoiding the harmful effects of water-based systems.
Solution Approach 2:
The patent changes the physical-chemical parameters of the impregnating liquid medium by switching from water-based to organic solvent-based systems. This parameter change fundamentally alters the interaction between the impregnating liquid and the catalyst support, eliminating the dissolution problem while maintaining effective modifying component deposition. The organic solvent provides different solvation characteristics that prevent support dissolution.
2Object-generated harmful factors
If an organic solvent is used to avoid support dissolution, then ultra-fine particle contamination is reduced, but the modifying component loading is insufficient
Solution Approach 1:
The organic solvent serves as an effective intermediary that enables sufficient modifying component loading while avoiding support dissolution. By selecting appropriate organic solvents with suitable solvation properties, the patent achieves both high modifying component deposition and prevention of ultra-fine particle contamination simultaneously.
Solution Approach 2:
The patent employs composite material strategies by combining the catalyst support with the modifying component through the organic solvent medium. This composite approach allows the modifying component to be effectively incorporated into the support structure without creating harmful ultra-fine particles, achieving both high loading and contamination-free product.
3Reliability
If the catalyst support is modified to reduce dissolution, then attrition resistance improves, but the process complexity increases
Solution Approach 1:
The organic solvent acts as a simple yet effective intermediary that enables support modification to improve attrition resistance. The modification process remains relatively straightforward by using the organic solvent to deposit the modifying component, avoiding the need for complex aqueous-based modification procedures while achieving enhanced support stability and reduced attrition.
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 results in higher modifying component loading, reduced solubility of the catalyst support, and improved attrition resistance, leading to better utilization and reduced wastage of the modifying component, thereby minimizing contamination and fouling.
Implementation Method 1
contacting a catalyst support material with a modifying component precursor in an impregnating liquid medium wherein the impregnating liquid medium comprises a mixture of water and an organic liquid solvent
Implementation Method 2
Catalyst support dissolution during aqueous impregnation of the catalyst support with the active catalyst component... which may result in precipitation and coating of the bulk support material with a physically bonded amorphous layer of the support material
Implementation Method 3
reducing the catalyst precursor, thereby activating the catalyst precursor and obtaining the catalyst
Data Source
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AI summary
A method of preparing a modified catalyst support comprises contacting a catalyst support material with a modifying component precursor in an impregnating liquid medium. The impregnating liquid medium comprises a mixture of water and an organic liquid solvent for the modifying component precursor. The mixture contains less than 17% by volume water based on the total volume of the impregnating liquid medium. The modifying component precursor comprises a compound of a modifying component selected from the group consisting of Si, Zr, Co, Ti, Cu, Zn, Mn, Ba, Ni, Al, Fe, V, Hf, Th, Ce, Ta, W, La and mixtures of two or more thereof. A modifying component containing catalyst support material is thus obtained. Optionally, the modifying component containing catalyst support material is calcined at a temperature above 100°C to obtain a modified catalyst support.