Ferrite-Based Coating Catalyst Rotating Mixing Process
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Solution Overview
Problem
Ferrite-based catalysts used in oxidative dehydrogenation reactions of butene face challenges with heat generation control, leading to reduced selectivity and yield of butadiene, and their physical strength is compromised under high temperature and pressure conditions.
Innovation Solution
A method for preparing a ferrite-based coating catalyst involves mixing a support, a ferrite-based catalyst, and water in a rotating coating machine, with a specific weight ratio of water to support, to enhance the physical strength of the catalyst while maintaining catalytic activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If ferrite-based catalysts are used in oxidative dehydrogenation reactions under high temperature and high pressure conditions, then catalytic activity is improved, but physical strength deteriorates and heat generation increases
Solution Approach 1:
The patent applies composite materials by combining ferrite-based catalyst particles with inert support materials (such as alumina, silica, or activated carbon) to create a composite catalyst structure. The inert support provides mechanical strength and structural stability under high temperature and pressure conditions, while the ferrite-based catalyst maintains its catalytic activity. This composite approach resolves the contradiction by allowing the catalyst to function effectively without compromising physical integrity.
Solution Approach 2:
The patent implements local quality by creating a heterogeneous structure where different regions of the catalyst have different properties. The ferrite-based catalyst regions provide high catalytic activity, while the inert support regions provide mechanical strength and heat dissipation. This spatial differentiation of functions allows the catalyst to simultaneously achieve high activity and maintain physical strength under harsh reaction conditions.
2Productivity
If ferrite-based catalysts are used under high temperature and high pressure conditions, then reaction rate increases, but heat generation becomes excessive and selectivity decreases
Solution Approach 1:
The patent introduces inert support materials as intermediaries between the ferrite catalyst particles and the reaction environment. These inert materials act as heat sinks that absorb excess heat generated during the oxidative dehydrogenation reaction, preventing thermal runaway and maintaining selectivity. The intermediary inert support mediates the thermal management while allowing catalytic activity to proceed at high rates.
Solution Approach 2:
The patent changes the physical and chemical parameters of the catalyst system by incorporating inert materials with specific heat capacities and thermal conductivities. This parameter modification allows the catalyst to operate at higher temperatures and pressures without generating excessive heat, thereby maintaining both high reaction rates and high selectivity through optimized thermal properties.
3Object-generated harmful factors
If inert materials are added to dissipate heat, then heat generation is reduced, but catalytic activity deteriorates
Solution Approach 1:
The patent applies local quality by creating a heterogeneous catalyst structure where inert materials are strategically distributed throughout the catalyst composition. The inert materials are positioned to provide heat dissipation at specific locations without blocking active catalytic sites. This spatial arrangement ensures that heat management functions are provided where needed while catalytic activity is maintained at active regions.
Solution Approach 2:
The patent uses composite materials with optimized ratios of ferrite catalyst to inert support. By carefully controlling the composition and distribution of inert materials within the composite structure, the patent achieves effective heat dissipation while preserving sufficient exposed ferrite surface area to maintain high catalytic activity. The composite structure allows both functions to coexist without mutual interference.
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 method improves the physical strength of the ferrite-based coating catalyst, reducing attrition and maintaining high selectivity and yield of butadiene during oxidative dehydrogenation reactions, even under commercial-scale conditions.
Implementation Method 1
mixing a support, a ferrite-based catalyst, and water in a rotating coating machine
Implementation Method 2
preparing a water-based composition for coating by adding ferritic metal oxide powder, water and dextrin; and subsequently immersing a porous metal oxide material in the water-based composition for coating
Data Source
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AI summary
The method for preparing a ferrite-based coating catalyst according to an exemplary embodiment of the present application comprises: mixing a support, a ferrite-based catalyst, and water in a coating machine which is a rotating body, in which a weight ratio of the water based on a total weight of the support is 0.15 to 0.3.