Heterogeneous Catalyst Surface Modification via Organoaluminium Immersion
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Solution Overview
Problem
Existing processes for modifying heterogeneous catalysts, such as bimetallic catalysts, require complex and costly equipment, high energy inputs, and are not scalable for commercial use, leading to challenges in preventing carbon deposition and sintering that reduce catalyst activity and lifespan.
Innovation Solution
A process involving the use of an organoaluminium compound as a precursor to modify the catalyst surface, which involves contacting the catalyst with a solution of the compound, reacting, and repeating the process to achieve multiple modifying layers, followed by calcination, all at room temperature and atmospheric pressure without the need for specialized reactors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If atomic layer deposition method is used to functionalize catalyst surface, then catalyst stability and resistance to coking is improved, but device complexity and processing cost increases due to requirement of specially designed chemical reactor with vacuum control
Solution Approach 1:
The patent replaces the complex mechanical vacuum system with a simple atmospheric pressure liquid immersion process. Instead of using vacuum chambers and vapor deposition equipment, the invention uses liquid precursors that react with the catalyst surface at atmospheric pressure, eliminating the need for sophisticated reactor systems while achieving the same surface functionalization effect
Solution Approach 2:
The patent uses liquid phase chemistry instead of vapor phase deposition. By immersing the catalyst in liquid precursor solutions, the process exploits liquid-phase reaction mechanisms to achieve surface modification without requiring vacuum equipment, thereby simplifying the device while maintaining catalyst stability improvements
2Reliability
If atomic layer deposition is used for catalyst modification, then catalyst resistance to sintering and coking is improved, but energy consumption increases due to high temperature requirements
Solution Approach 1:
The patent changes the temperature parameter from high temperature vapor phase conditions to room temperature liquid phase conditions. By using liquid precursors that react at ambient temperatures, the process achieves the same surface functionalization and sintering resistance without the high energy input required for vapor deposition and high temperature processing
3Reliability
If conventional catalyst modification methods are used, then catalyst activity is maintained, but scalability for commercial use is limited due to complex equipment requirements
Solution Approach 1:
The patent divides the modification process into simple sequential steps that can be performed in standard laboratory equipment: immersion in precursor solution, drying, and optional heating. This segmentation into discrete, equipment-independent steps enables easy scaling from laboratory to commercial production without requiring specialized reactors
Solution Approach 2:
The patent creates a universal modification process that can be applied to various catalyst types using standard equipment. The liquid immersion method works with different catalyst supports and metal loadings, and can be performed in conventional flasks or reactors, making it universally applicable and easily scalable for commercial use
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 effectively reduces carbon deposition and sintering, enhances catalyst stability and activity, and extends the catalyst's lifespan by 30-40% without altering key properties like surface area or metal dispersion, making it a more economical and scalable solution.
Implementation Method 1
contacting the catalyst with a solution of the compound, reacting, and repeating the process to achieve multiple modifying layers
Implementation Method 2
contacting the heterogeneous catalyst with a solution of organometallic compound; allowing the heterogeneous catalyst to react with the solution
Implementation Method 3
followed by calcination, all at room temperature and atmospheric pressure
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3
AI summary
The present disclosure relates to a process and system for modifying heterogeneous catalysts by contacting them with chemical compounds. Specifically, the present disclosure relates to an easy and convenient process for surface functionalizing of a heterogeneous catalyst such as polymetallic catalyst including bimetallic catalyst by employing precursor of inorganic compound, wherein the precursor is organometallic compound and wherein the inorganic compound includes but is not limited to a metal based inorganic compound such as aluminium oxide. The present disclosure thus provides for easy and convenient process and system for surface modification/functionalization of heterogeneous catalysts by employing precursor of inorganic compound at conditions including but not limiting to room temperature and atmospheric pressure.