Fluidized Bed Water Gas Shift Catalyst Wear Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing catalysts used in fixed bed sorption enhanced water gas shift reactions are not suitable for fluidized bed processes due to issues with particle sizes and wear, and they do not meet the conditions required for high-temperature, high-pressure synthetic gas processes.
Innovation Solution
A water gas shift reaction catalyst composition including an active component, a support, an inorganic binder, a promoter, and a stabilizer, specifically designed for fluidized bed processes, with a formulation that includes transition metal oxides, alumina, hydrotalcite, clays, and ceramics, and a method of preparing the catalyst by spraying and drying a slurry composition to achieve optimal particle size and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing fixed bed catalysts are used in fluidized bed processes, then CO conversion activity may be maintained, but particle size and wear resistance become insufficient
Solution Approach 1:
The patent changes the physical and chemical parameters of the catalyst by incorporating specific wear-resistant materials (alumina, hydrotalcite, clays, ceramics) and optimizing the particle size distribution (0.01-3 μm) to achieve both high CO conversion activity and excellent wear resistance suitable for fluidized bed operations
Solution Approach 2:
The patent creates a composite catalyst material combining active components (transition metal oxides) with multiple support materials (alumina, hydrotalcite, clays, ceramics) to achieve synergistic effects that simultaneously provide catalytic activity, mechanical strength, and wear resistance
2Productivity
If catalysts are designed for high-temperature, high-pressure synthetic gas processes, then process efficiency improves, but catalyst formulation complexity increases
Solution Approach 1:
The patent designs a multi-functional catalyst formulation where the same material composition (transition metal oxides supported on alumina, hydrotalcite, clays, or ceramics) simultaneously provides high-temperature stability, high-pressure resistance, CO conversion activity, and wear resistance, eliminating the need for separate optimization for each condition
3Manufacturing precision
If slurry spraying and drying method is used to prepare catalyst, then particle size control and wear resistance improve, but manufacturing process complexity increases
Solution Approach 1:
The patent applies preliminary action by preparing the catalyst as a slurry with controlled composition and properties before spraying and drying, which allows precise control of particle size (0.01-3 μm) and uniform distribution of active components, achieving high manufacturing precision while maintaining reasonable process complexity
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 ensures high CO conversion ratios and wear resistance, enabling efficient carbon monoxide conversion to carbon dioxide and hydrogen, while being suitable for large-scale industrial processes like integrated gasification combined cycle processes, reducing CO2 collection costs and improving hydrogen production yield.
Implementation Method 1
a water gas shift reaction catalyst composition including an active component, a support, an inorganic binder, a promoter, and a stabilizer
Implementation Method 2
a method of preparing the catalyst by spraying and drying a slurry composition
Data Source
AI summary
The present invention relates to an aqueous gas-converting catalyst composition comprising: an active component; a support; an inorganic binder; at least one accelerator selected from the group consisting of cobalt oxide, molybdenum oxide, nickel oxide, calcium oxide, barium oxide, strontium oxide, magnesium oxide, zirconium oxide, manganese oxide and barium titania; and at least one stabilizer selected from the group consisting of magnesium oxide, zirconium oxide, stabilized zirconia, and hydrotalcite. The catalyst according to the present invention can effectively capture and separate carbon dioxide due to the excellent physical properties thereof such as packing density and abrasion resistance, and high CO conversion. Also, according to the present invention, mass production is facilitated by applying a spraying technique, and overall costs are lowered because of high yield. Thus, the present invention can be applied as a low cost pre-combustion CO2 capturing technique to an integrated gasification combined cycle, fuel cells, coal liquefaction, compound production, and the like.