Eggshell Steam Reforming Catalyst with Glycerin-Controlled Active Layer
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Solution Overview
Problem
Existing methods for preparing steam reforming catalysts face challenges in achieving an eggshell distribution of the active phase, leading to inefficient use of catalysts and high production costs, and often require toxic or hazardous chemicals or complex processes.
Innovation Solution
A method involving impregnation of a support with a glycerin solution followed by a nickel salt solution, allowing control of the active phase layer thickness without pH adjustment or specific interactions, suitable for various supports and promoting elements, using nickel nitrate and other promoters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional impregnation methods are used to prepare steam reforming catalysts, then the active phase is distributed throughout the support particles, but this leads to inefficient use of catalyst and higher production costs
Solution Approach 1:
The patent applies local quality by creating an eggshell-type catalyst structure where the active phase (nickel oxide) is concentrated specifically on the outer surface of the support particles rather than being uniformly distributed throughout. This is achieved by impregnating the support with a nickel salt solution followed by calcination, which causes the active phase to form a surface layer. This local concentration of the active phase on the particle surface improves catalyst efficiency by ensuring that the most active regions are where they are needed - at the interface with reactants - while reducing the total amount of catalyst material required.
2Productivity
If high catalyst activity is achieved through conventional methods, then production costs increase due to inefficient catalyst usage
Solution Approach 1:
The patent resolves this contradiction by localizing the active phase to the particle surface through eggshell-type structure formation. This ensures maximum catalyst activity is concentrated where it is most effective - at the reaction interface - thereby achieving high productivity with reduced material consumption and lower production costs.
Solution Approach 2:
The patent utilizes parameter changes by controlling the calcination temperature and duration to facilitate the formation of the eggshell structure. By optimizing these thermal parameters, the nickel salt precursor transforms into nickel oxide in a controlled manner that creates the desired surface-concentrated distribution, achieving high activity with efficient material usage.
3Manufacturing precision
If complex chemical processes and pH adjustment are used to achieve eggshell distribution, then the manufacturing process becomes more complex and requires hazardous chemicals
Solution Approach 1:
The patent applies the taking out principle by removing the complex chemical process steps and pH adjustment requirements from the eggshell formation process. Instead of using complex chemistry to control distribution, the patent uses a simple impregnation followed by calcination sequence, extracting the essential function (achieving surface concentration) while eliminating unnecessary complexity and hazardous chemicals.
Solution Approach 2:
The patent employs this principle by using a simple, inexpensive impregnation and calcination process rather than complex, expensive chemical treatments. The method uses readily available nickel salt solutions and standard thermal processing equipment, avoiding the need for specialized chemical reagents and complex process control systems, thereby reducing both cost and complexity.
4Productivity
If the active phase layer is made thicker to increase catalyst activity, then the production cost increases due to more catalyst material required
Solution Approach 1:
The patent resolves this contradiction by concentrating the active phase locally on the particle surface rather than distributing it throughout the particle volume. This local quality approach ensures that the active phase is present where it is most effective - at the reaction interface - while minimizing the total quantity of catalyst material required. The eggshell structure provides sufficient activity with a thin surface layer rather than requiring a thick distributed layer.
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
Enables the production of catalysts with a controlled active layer on the surface, reducing production costs and enhancing catalyst activity and resistance to coke deposition, suitable for hydrogen production and hydrogen-rich gas processes.
Implementation Method 1
a) impregnating a support with a glycerin solution, in a proportion adjusted to define the penetration of the active phase layer into the support
Implementation Method 2
c) impregnating the glycerin-containing support with a solution containing a nickel soluble salt
Implementation Method 3
The catalyst preparation method involves impregnation of a support with a glycerin solution followed by a nickel salt solution
Implementation Method 4
e) calcining the nickel salt impregnated support to transform this salt into a nickel oxide layer located on the surface or at a small depth of the support particle
Implementation Method 5
calcining the nickel salt impregnated support to transform this salt into a nickel oxide layer
Data Source
AI summary
The present invention addresses to a method of preparing steam reforming catalysts, of the eggshell type, using a solution of glycerin, in polar solvent, preferably water, to occupy the pores of a support. Next, the solvent is removed and the support is impregnated with a nickel salt solution, which may contain promoters such as rare earths. The steps can be repeated until the desired content of the active phase and promoters is reached.