Hollow Microsphere Catalyst Support Density Reduction
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Solution Overview
Problem
Catalyst supports in the oil and petrochemical industry face a challenge in reducing weight while maintaining mechanical strength and catalytic performance, as increasing pore volume to reduce density can weaken the support and affect reaction diffusion and active site access.
Innovation Solution
Incorporating hollow inorganic microspheres into a calcined support matrix, specifically in the form of extrudates, pellets, or beads, with a content of 0.3% to 50% by weight, which maintains the support's mechanical and catalytic performance qualities by reducing density without altering the pore distribution or making the microspheres' cavities accessible to the active phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the pore volume of the support is increased to reduce density, then the weight of the catalyst is reduced, but the mechanical strength of the grains is weakened
Solution Approach 1:
The support is formulated as a composite material combining porous oxide (alumina, silica, titanium oxide, magnesia), clays, and hollow glass spheres. This composite structure allows the porous oxide matrix to provide mechanical strength while the hollow glass spheres contribute to reduced density and increased pore volume, thus resolving the contradiction between weight reduction and strength maintenance
Solution Approach 2:
The support utilizes porous oxide materials with controlled porosity profiles to achieve the desired balance between weight reduction and mechanical strength. The porous structure provides the necessary pore volume for catalytic function while maintaining structural integrity through the oxide matrix
2Weight of moving object
If the pore volume of the support is increased to reduce density, then the weight of the catalyst is reduced, but the catalytic performance is adversely affected
Solution Approach 1:
The support exhibits a differentiated porosity profile with distinct pore size distributions in different regions: macropores (50 nm to 100 μm) for bulk diffusion, mesopores (2-50 nm) for intermediate transport, and micropores (<2 nm) for active site access. This local quality differentiation ensures that each pore size range serves specific catalytic functions, maintaining performance while enabling weight reduction through optimized pore volume
Solution Approach 2:
The composite nature of the support combining porous oxide with hollow glass spheres creates a multi-scale porous structure that maintains catalytic performance. The hollow spheres contribute to macroporosity and bulk diffusion pathways while the porous oxide matrix provides the necessary meso- and microporosity for reactant access to active sites
3Weight of moving object
If the porous texture is modified to increase pore volume, then the density is reduced, but the diffusion of reactants and products is adversely affected
Solution Approach 1:
The support is designed with a hierarchical porosity structure where different pore size ranges serve specific diffusion functions: macropores for bulk transport, mesopores for intermediate diffusion, and micropores for active site access. This local differentiation of pore quality ensures that diffusion requirements are met at each scale while maintaining overall low density
Solution Approach 2:
The introduction of hollow glass spheres adds a three-dimensional macroporous network to the porous oxide matrix, creating multi-scale pore pathways that enhance bulk diffusion without compromising the microporous structure necessary for active site access. This dimensional addition resolves the contradiction between density reduction and diffusion maintenance
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 use of hollow microspheres achieves a significant reduction in support density while preserving mechanical strength and catalytic performance, ensuring the support's properties are maintained, allowing for efficient use in hydrocarbon treatment and petrochemical processes.
Implementation Method 1
Incorporating hollow inorganic microspheres into a calcined support matrix... which maintains the support's mechanical and catalytic performance qualities by reducing density
Data Source
AI summary
The present invention relates to a calcined medium, in particular a catalyst or a catalyst medium or an adsorbent/absorbent mass, in particular in the form of extrudates, pellets, granules or beads, the medium comprising a porous matrix comprising carbonates, clays, zeolites, oxides, or metal and/or silicon hydroxides, and the matrix incorporating hollow mineral microspheres having a different composition in a content of between 0.3 and 50% by weight, in particular between 0.5 and 15% by weight, of the matrix.