Catalyst Support Spherical Macrostructure for Alkene Oxide Reactors

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Solution Overview

Problem

Current catalysts for producing ethylene oxide face challenges in maintaining selectivity while increasing surface area, leading to increased pressure drop and reduced production efficiency due to smaller pellet sizes and decreased pore diameter.

Innovation Solution

A catalyst support with a substantially spherical or ellipsoidal macrostructure and surface structures, lacking intra-particle fluid communication channels, which enhances strength and flow uniformity, allowing for higher geometric surface area and porosity without compromising selectivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the pore diameter is decreased to increase specific surface area, then the catalyst activity increases, but the selectivity deteriorates

Engineering Contradiction:

Improvecatalyst activityVSAvoidselectivity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The support structure is segmented into distinct functional zones: smooth flow channels for transport and separate surface structures for catalytic activity. This segmentation allows the support to simultaneously provide high surface area for activity while maintaining proper flow patterns for selectivity, resolving the contradiction between catalyst activity and selectivity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the support are given different properties: the flow channels have smooth surfaces optimized for fluid transport, while the surface structures have high surface area optimized for catalytic activity. This local differentiation allows each region to perform its specific function optimally without compromising the other, thereby maintaining both activity and selectivity

Inventive Principle:

Principle #3Local quality

2Productivity

If the support pellet size is decreased to increase specific surface area, then the catalyst activity increases, but the pressure drop increases

Engineering Contradiction:

Improvecatalyst activityVSAvoidpressure drop

Core Design Contradiction:

ProductivityVSStress or pressure

Solution Approach 1:

The support adopts a spherical or ellipsoidal macrostructure with curved surfaces, which optimizes fluid flow patterns around and through the catalyst. This spherical geometry reduces flow resistance and pressure drop compared to angular shapes, while still providing high surface area through surface structures, thereby maintaining both activity and acceptable pressure drop

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Productivity

If the porosity is increased to increase surface area, then the catalyst activity increases, but the mechanical strength deteriorates

Engineering Contradiction:

Improvecatalyst activityVSAvoidmechanical strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The support is segmented into a load-bearing macrostructure that provides mechanical strength and separate porous surface structures that provide catalytic surface area. This segmentation allows the bulk structure to maintain strength while the surface structures provide high porosity and activity, resolving the contradiction between mechanical strength and catalyst activity

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20240351013A1Catalyst support

Publication Date: 2024.10.24 JEMMTEC LTD

AI summary

A support for a catalyst. The support is for use in a packed-bed reactor for the production of an alkylene oxide. The support includes ceramic material and the support has a substantially spherical or ellipsoidal macrostructure. The support further includes surface structures and has a porosity of ≥0.35 cm3/g. The catalyst may be included in an apparatus and used for the production of an alkylene oxide.