Copper Zinc Calcium Silicate Hydrogenation Catalyst
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Solution Overview
Problem
Catalysts used for hydrogenating nitrobenzene to produce aniline have limited catalyst lifetime, requiring frequent changes and increasing labor and costs due to coking and pressure loss issues.
Innovation Solution
A hydrogenation catalyst composition comprising copper, zinc, and auxiliary components like magnesium or aluminum, supported on calcium silicate with a specific BET surface area, which suppresses coking and extends catalyst lifetime by preventing sintering and maintaining high catalytic activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If catalysts containing no chromium oxide are used, then health hazards and environmental pollution are reduced, but catalyst lifetime is shortened
Solution Approach 1:
The patent uses a composite catalyst system combining copper oxide (active component) with zinc oxide and calcium silicate (support materials). This composite structure prevents coking on the copper oxide surface while maintaining high catalytic activity, thereby extending catalyst lifetime without using chromium oxide
Solution Approach 2:
Zinc oxide acts as an intermediary substance between the copper oxide active component and the reaction environment. It prevents direct contact between the catalyst surface and coke-forming species, reducing coking while maintaining catalytic function for extended periods
2Productivity
If high conversion is achieved with existing chromium-free catalysts, then productivity is improved, but catalyst must be changed frequently due to short lifetime
Solution Approach 1:
The patent achieves continuous high conversion (99% or higher) over extended periods (3000 hours or more) by using the copper oxide-zinc oxide-calcium silicate composite catalyst. The zinc oxide component continuously prevents coking during the reaction, maintaining high activity without interruption or frequent catalyst replacement
Solution Approach 2:
The patent optimizes the ratio of zinc oxide to copper oxide (0.1 to 5.0 by weight) and controls the calcination temperature (600-900°C) to achieve the desired catalyst performance. These parameter changes ensure high conversion while extending catalyst lifetime, eliminating the need for frequent catalyst changes
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 composition achieves high raw material conversion and consistent catalytic reactions for an extended period, reducing the need for frequent catalyst changes and minimizing coking and pressure loss, thereby enhancing productivity and reducing operational costs.
Implementation Method 1
a composition comprising copper, zinc and at least one member selected from the group consisting of aluminum oxide, silicon oxide, calcium oxide and their composite oxides, can suppress coking in the catalytic reaction
Implementation Method 2
enables a consistent catalytic reaction for a long period of time
Implementation Method 3
a hydrogenation catalyst consisting essentially of from 20 to 50 wt% of copper, from 1 to 15 wt% of zinc, optionally an auxiliary catalyst component selected from the group consisting of magnesium, strontium, barium and aluminum, and calcium silicate
Implementation Method 4
a calcination step of calcining the mixture at a temperature of at least 680°C and less than 800°C for 1 hour to 24 hours
Data Source
AI summary
The present invention provides a composition which, in a catalytic reaction, particularly in a hydrogenation reaction of an aromatic nitro compound, exhibits a high raw material conversion comparable to that of the prior art, whereby a consistent catalytic reaction can be conducted over a long period of time. The composition is characterized by comprising from 20 to 50 wt% of copper, from 1 to 15 wt% of zinc, and an oxide containing at least one member selected from the group consisting of aluminum, silicon and calcium. The composition preferably contains at least one member selected from the group consisting of magnesium, strontium, barium, and aluminum.