Copper Phyllosilicate Catalyst Strength via Plastic Deformation
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Solution Overview
Problem
Existing processes for producing copper phyllosilicate shaped bodies are laborious and result in catalysts with low strength, making them unsuitable for industrial use due to the need for high copper loading and optimal dispersion within a silica matrix.
Innovation Solution
A process involving a plastically deformable material comprising SiO2 and Cu sources with aqueous ammonia, shaped to form blanks with longitudinal expansion, then thermally treated under controlled conditions to produce copper phyllosilicate catalysts with high copper content and strength, eliminating the need for liquid separation and reducing equipment requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pulverulent copper phyllosilicates are produced from aqueous suspensions and processed into shaped bodies, then copper phyllosilicate catalysts can be obtained, but the shaped bodies have low strength and the process is very laborious
Solution Approach 1:
The patent applies preliminary action by forming shaped bodies (blanks) from a plastically deformable mixture of copper phyllosilicate precursor, silica source, and organic binder before the final calcination step. This allows the shaped structure to be established while the material is still pliable, and the organic binder provides temporary cohesion that is removed during subsequent thermal treatment, resulting in strong shaped bodies without requiring laborious post-shaping operations
Solution Approach 2:
The patent uses composite materials by combining copper phyllosilicate precursor, silica source, and organic binder in a plastically deformable mixture. The organic binder acts as a temporary matrix that holds the shaped structure together during handling and drying, and is subsequently removed during calcination, leaving behind a strong shaped catalyst body with the desired mechanical properties
2Quantity of substance
If high copper loading is used in the catalyst (12-35% by weight), then catalytic activity is improved, but dispersion of copper in the silica matrix becomes more difficult to maintain
Solution Approach 1:
The patent applies local quality by ensuring uniform distribution of copper phyllosilicate precursor particles throughout the plastically deformable mixture with the silica source and organic binder. This homogeneous mixing at the precursor stage, combined with the shaping process, ensures that copper is evenly distributed throughout the final shaped body, maintaining good dispersion even at high copper loadings of 12-35% by weight
Solution Approach 2:
The patent uses parameter changes by controlling the composition ratios, particle size distribution, and moisture content of the plastically deformable mixture to achieve optimal packing and uniform copper distribution. The specific parameters of the mixture (solid-to-liquid ratio, particle size) are optimized to maintain copper dispersion while accommodating high copper loadings
3Ease of manufacture
If the mass quotient Q=msolid/mliquid is kept between 0.2 and 1, then the material remains plastically deformable for shaping, but the solid content is limited
Solution Approach 1:
The patent applies parameter changes by optimizing the mass quotient Q=msolid/mliquid to be between 0.2 and 1, which provides the ideal balance between plastic deformability and solid content. This parameter range ensures the mixture is pliable enough for shaping operations while containing sufficient solid materials (copper phyllosilicate precursor and silica source) to form the final catalyst structure, with the organic binder providing necessary cohesion
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 process yields copper phyllosilicate catalysts with high porosity and side crush strength, enabling their commercial use in chemical transformations like hydrogenation and dehydrogenation, surpassing the strength and activity of catalysts produced by prior art methods.
Implementation Method 1
thermally treating the blanks so as to obtain shaped bodies comprising copper phyllosilicate
Implementation Method 2
providing a plastically deformable material comprising at least one SiO2 source, at least one Cu source and aqueous ammonia solution
Implementation Method 3
the Cu source is soluble in aqueous ammonia solution
Implementation Method 4
the SiO2 source is an SiO2-containing solid having a BET surface area of at least 50 m2/g
Data Source
AI summary
The present invention relates to processes for producing copper phyllosilicate shaped bodies, comprising the steps of:providing a plastically deformable material comprising at least one SiO2 source, at least one Cu source and aqueous ammonia solution,shaping the plastically deformable material so as to obtain blanks having a longitudinal expansion of at least 0.1 mm in all directions in space,thermally treating the blanks so as to obtain shaped bodies comprising copper phyllosilicate.The present invention further relates to the shaped bodies obtainable by the processes according to the invention.These shaped bodies are used, as precursor of copper/silica catalysts, in numerous chemical transformations, for example for the hydrogenation of aldehydes and ketones to alcohols or in the dehydrogenation of alcohols.