Chromium-Free Gas-Phase Fluorination Catalyst
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Solution Overview
Problem
Current chromium-containing fluorinated catalysts used in gas-phase fluorination are toxic and carcinogenic, leading to environmental and health hazards, and existing chromium-free alternatives have low catalytic activity and poor thermal stability.
Innovation Solution
A chromium-free gas phase fluorination catalyst is developed using a precursor comprising iron, a rare earth metal, and element A (Ca, Al, or Ti), which is roasted and fluorinated to create a catalyst with high catalytic activity and long service life, suitable for producing hydrofluoroolefins and hydrochlorofluoroolefins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If chromium-containing fluorinated catalysts are used for gas-phase fluorination, then catalytic activity is achieved, but toxicity and carcinogenicity increase causing environmental and health hazards
Solution Approach 1:
The patent removes chromium (the harmful substance) from the catalyst composition entirely, extracting only the necessary catalytic function. The chromium-free catalyst uses alternative metals (Fe, Co, Ni, Mn, Zn, Cu, or their mixtures) that provide catalytic activity without the toxic and carcinogenic properties of chromium, thus eliminating environmental and health hazards while maintaining productivity.
Solution Approach 2:
The patent changes the chemical composition parameters of the catalyst by replacing chromium with non-toxic metal alternatives. The catalyst composition is modified to contain 1-20 wt% of alternative metals combined with fluorinated support materials, achieving the same catalytic function through parameter substitution rather than using harmful substances.
2Object-affected harmful factors
If existing chromium-free catalysts are used to eliminate toxicity, then environmental safety is improved, but catalytic activity and thermal stability deteriorate
Solution Approach 1:
The patent employs composite material structure by combining multiple non-toxic metal components (Fe, Co, Ni, Mn, Zn, Cu or their mixtures) with fluorinated support materials. This composite approach creates a synergistic effect where the combination of materials provides both the required catalytic activity and thermal stability that single-component chromium-free catalysts lack, while maintaining environmental safety.
Solution Approach 2:
The patent designs a multi-functional catalyst system where the alternative metal components serve multiple functions: providing catalytic activity for fluorination reactions, maintaining thermal stability at high reaction temperatures, and ensuring environmental safety. This universal catalyst can handle various fluorination reactions effectively without the drawbacks of previous chromium-free alternatives.
3Object-affected harmful factors
If chromium-free catalysts with alternative metals are used, then environmental impact is reduced, but service life and catalytic performance decrease
Solution Approach 1:
The patent optimizes the concentration parameters of alternative metals in the catalyst (1-20 wt%) and adjusts the fluorination degree of the support material to achieve the right balance between environmental safety and long service life. By carefully controlling these parameters, the catalyst maintains high activity over extended periods without the environmental hazards of chromium.
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
The catalyst exhibits excellent catalytic activity and long service life, reducing environmental impact and health risks by minimizing waste and toxic substance exposure, with high conversion rates and selectivity for target compounds over extended reaction times.
Implementation Method 1
the precursor is subjected to roasting and fluorination treating to obtain the chromium-free gas phase fluorination catalyst
Implementation Method 2
the precursor is subjected to roasting and fluorination treating to obtain the chromium-free gas phase fluorination catalyst
Implementation Method 3
Fluorinated catalysts play a critical role in gas-phase fluorination reaction of halohydrocarbons
Data Source
AI summary
Disclosed in the present invention are a chromium-free gas phase fluorination catalyst and an application thereof. The precursor of the related chromium-free gas phase fluorination catalyst consists of a compound containing iron element, a compound containing rare earth metal element and a compound containing element A, wherein element A is one selected from Ca, Al, Mg and Ti, the precursor is subjected to roasting and fluorination treating to obtain the chromium-free gas phase fluorination catalyst. The precursor of the catalyst is roasted at 400-500° C. and fluoridized with hydrogen fluoride at 350-450° C. to obtain the chromium-free gas phase fluorination catalyst. The catalyst has characteristics of being chromium-free and environment-friendly, good catalytic activity and long life etc. The catalyst can be used for preparing hydrofluoroolefins or hydrochlorofluoroolefins from halohydrocarbons.