Gradient Noble Metal Catalyst for Fluoroethane Production
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Solution Overview
Problem
Existing methods for producing fluoroethanes, such as HFC-143, suffer from poor selectivity and reactor blockage/corrosion issues, especially when scaled up for mass production.
Innovation Solution
A method involving a reactor filled with a catalyst having a noble metal concentration gradient, where the upstream portion has a lower noble metal concentration than the downstream portion, supporting noble metals on a carrier, and using fluoroethylene in a hydrogenation reaction with hydrogen gas, to produce fluoroethane with high selectivity and reduce reactor issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a uniform noble metal concentration catalyst is used throughout the reactor, then the catalyst structure is simple and easy to manufacture, but the selectivity of fluoroethane production decreases and reactor blockage/corrosion occurs during scaled-up production
Solution Approach 1:
The patent applies local quality by creating a catalyst with non-uniform noble metal concentration distribution. The upstream portion has a first noble metal concentration while the downstream portion has a second noble metal concentration, with the upstream concentration being optimized to prevent polymerization and the downstream concentration optimized to enhance hydrogenation activity. This spatial variation in catalyst properties resolves the contradiction by improving selectivity through localized optimization rather than using a uniform catalyst structure.
2Productivity
If the reactor capacity is increased for mass production, then the productivity increases, but the selectivity decreases and blockage/corrosion of the reactor occurs
Solution Approach 1:
The patent resolves the scalability issue by implementing local quality in the catalyst design. The upstream portion with its specific noble metal concentration is optimized to prevent polymerization reactions that cause blockage, while the downstream portion is optimized for high hydrogenation activity. This localized optimization allows the reactor to be scaled up for mass production while maintaining high selectivity and avoiding the blockage and corrosion problems that occur with uniform catalysts in large-scale operations.
Solution Approach 2:
The patent applies segmentation by dividing the catalyst into distinct upstream and downstream portions with different noble metal concentrations. This segmentation allows each portion to perform its specific function optimally: the upstream portion prevents polymerization and blockage, while the downstream portion ensures high hydrogenation activity and selectivity. This segmented approach enables successful scaling to mass production capacity.
3Productivity
If the noble metal concentration is increased to improve reaction activity, then the reaction rate increases, but the cost of catalyst increases and selectivity may decrease due to excessive hydrogenation
Solution Approach 1:
The patent applies local quality by concentrating the noble metal in the downstream portion where it is most needed for hydrogenation activity, while using less noble metal in the upstream portion where the primary function is to prevent polymerization. This spatial distribution of noble metal optimizes the reaction rate in the downstream region while reducing overall noble metal consumption and preventing excessive hydrogenation that would reduce selectivity.
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 achieves high selectivity in producing fluoroethane with reduced reactor blockage and corrosion, enabling efficient production even at larger scales.
Implementation Method 1
a method involving a reactor filled with a catalyst having a noble metal concentration gradient, where the upstream portion has a lower noble metal concentration than the downstream portion, supporting noble metals on a carrier, and using fluoroethylene in a hydrogenation reaction with hydrogen gas, to produce fluoroethane with high selectivity
Implementation Method 2
each catalyst is formed by supporting a noble metal on a carrier; a reactor for performing the reaction is filled with a catalyst having a noble metal concentration of C1 mass % based on the entire catalyst, and a catalyst having a noble metal concentration of C2 mass % based on the entire catalyst
Data Source
AI summary
The production method according to the present disclosure comprises obtaining a product containing the fluoroethane from a fluoroethylene by a reaction in the presence of catalysts. Each catalyst is formed by supporting a noble metal on a carrier. A reactor for performing the reaction is filled with a catalyst having a noble metal concentration of C1 mass % based on the entire catalyst and a catalyst having a noble metal concentration of C2 mass % based on the entire catalyst to form an upstream portion and a downstream portion, respectively; and C1<C2. The reaction is performed by bringing the fluoroethylene represented by formula (3) and hydrogen gas into contact with the upstream portion and the downstream portion in this order.