Surface-Supported Catalyst Depth Control via Hydrophobic Barrier
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Solution Overview
Problem
Existing methods for supporting catalytic components on carriers struggle to control the depth of catalytic component distribution, leading to inefficiencies and increased costs due to diffusion into the carrier's inner parts, which reduces reaction efficiency and increases production costs, especially when using expensive metals.
Innovation Solution
A method involving preliminary impregnation of a porous carrier with a liquid hydrophobic organic compound to prevent diffusion, followed by volatilization on the surface and contact with an aqueous catalytic metal salt solution, allowing for controlled support of the catalytic metal within a specified depth range of 50 μm to 500 μm, utilizing the properties of hydrophobicity and volatility to maintain the catalytic component on the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the catalytic component is supported deep inside the carrier, then the amount of catalytic component increases, but the reaction efficiency per amount of catalytic component decreases
Solution Approach 1:
The patent applies local quality by creating a concentration gradient of the catalytic component within the carrier. The catalytic component is concentrated in the surface layer (0-0.2mm depth) where it can effectively contribute to catalytic reactions, while the inner parts contain minimal catalytic component. This non-uniform distribution ensures that the catalytic component is placed precisely where it is needed for maximum reaction efficiency.
Solution Approach 2:
The patent uses preliminary action by first impregnating the carrier with an acetone solution containing the palladium compound before final drying. This preliminary impregnation step allows the catalytic component to be selectively deposited and fixed in the surface region, preventing subsequent diffusion into the inner parts and ensuring optimal surface concentration for high reaction efficiency.
2Manufacturing precision
If the catalytic component diffuses into the inner part of the carrier, then the supported depth increases, but the loss of catalytic component increases
Solution Approach 1:
The patent uses an intermediary substance (acetone solution) to control the deposition of the catalytic component. The acetone solution acts as a mediator that facilitates selective impregnation of the carrier surface with the palladium compound. By controlling the acetone solution concentration and drying conditions, the patent prevents unwanted diffusion into the inner parts, thereby reducing catalytic component loss while achieving precise depth control.
3Productivity
If the catalytic component is supported only on the surface, then the reaction efficiency increases, but the amount of catalytic component that can be utilized decreases
Solution Approach 1:
The patent optimizes local quality by creating a controlled concentration gradient where the catalytic component is densely concentrated in the surface layer (0-0.2mm depth) which contains approximately 97% of the total palladium. This ensures that nearly all the catalytic component is positioned in the reaction-active surface region, maximizing both reaction efficiency and utilization of the catalytic component.
4Reliability
If expensive precious metal is used as catalytic component and it diffuses into inner part, then the production cost increases
Solution Approach 1:
The patent applies preliminary action by using acetone solution impregnation followed by controlled drying to fix the precious metal catalyst in the surface region before any diffusion can occur. This preliminary fixation step ensures that expensive precious metals remain concentrated where they are needed, preventing waste and reducing production costs while maintaining high catalytic activity.
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 prevents catalytic component diffusion into the carrier's inner parts, enabling the production of surface-supported catalysts with high catalytic activity at a lower cost and simplifying the production process.
Implementation Method 1
impregnating a porous carrier with a liquid hydrophobic organic compound to allow the compound to diffuse into the inner part of the carrier
Implementation Method 2
the hydrophobic organic compound on the surface of the carrier is volatilized
Implementation Method 3
a reducing agent is brought into contact with the catalytic metal salt on the surface of the carrier to reduce the catalytic metal salt
Data Source
AI summary
A method for supporting a catalytic metal on the surface of a carrier by bringing an aqueous catalytic metal salt solution into contact a porous carrier. The method includes the steps of: impregnating the carrier with a liquid hydrophobic organic compound before bringing the aqueous catalytic metal salt solution into contact with the carrier, and drying the impregnated carrier to volatilize the hydrophobic organic compound on the surface of the carrier, followed by bringing the carrier into contact with the aqueous catalytic metal salt solution; and then bringing a reducing agent into contact with the catalytic metal salt on the surface of the carrier to reduce the catalytic metal salt to undergo insolubilization treatment. The catalytic component is supported in a region from the surface of the carrier to a depth of 50 μm or more and 500 μm or less. The supported state of the catalytic component is made controllable, and the catalytic component can be supported in the inner part of the carrier with a suitable depth.