Zero-Valent Iron Phosphorus Carbon Catalyst for Continuous Tetrachloropropane Synthesis
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Solution Overview
Problem
Current methods for producing 1,1,1,3-tetrachloropropane rely on batch tank reactions, which are inefficient due to difficult catalyst separation, long production times, limited yield, and high energy consumption, making them unsuitable for large-scale industrial production.
Innovation Solution
A catalyst comprising zero-valent iron and phosphorus co-modified carbon material, where zero-valent iron is supported on a carbon carrier and phosphate functional groups are formed on the surface, allowing for continuous production through gas-solid reactions in a fixed bed reactor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch tank reaction with liquid cocatalyst is used, then the reaction can proceed, but the catalyst separation is difficult and production time is long
Solution Approach 1:
The invention changes the physical state of the cocatalyst from liquid to solid by converting it into a phosphate-functionalized carbon material. This parameter change enables the catalyst to be easily separated from the reaction mixture through filtration, eliminating the difficult separation process associated with liquid cocatalysts and significantly reducing production time.
Solution Approach 2:
The invention creates a composite catalyst system consisting of iron powder supported on phosphate-functionalized carbon material. This composite structure integrates the catalytic activity of iron with the ease of separation properties of solid carbon material, resolving both the productivity and ease of operation issues simultaneously.
2Productivity
If batch tank reaction is used, then the reaction can proceed, but the yield per tank is limited and energy consumption is high
Solution Approach 1:
The invention enables continuous flow reaction by using a fixed bed reactor packed with the solid catalyst. Reactants continuously flow through the catalyst bed, allowing uninterrupted production. This eliminates the periodic stopping and starting of batch reactions, increasing yield per tank and reducing energy consumption associated with repeated heating and cooling cycles.
3Productivity
If liquid cocatalyst is used, then the catalytic reaction can proceed, but the process requires batch operation
Solution Approach 1:
The invention changes the physical state parameter of the cocatalyst from liquid to solid form through phosphate functionalization of carbon material. This transformation enables the reaction system to adapt from batch operation to continuous flow operation, significantly improving production efficiency while maintaining catalytic activity.
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
This solution eliminates the need for liquid cocatalysts, enabling direct use of the solid catalyst in a gas-solid fixed bed reactor for continuous synthesis of 1,1,1,3-tetrachloropropane with improved efficiency and scalability.
Implementation Method 1
This chemical is obtained by catalyzing oligomerization based on tetrachloromethane and ethylene as raw materials. The catalyst comprises a zero-valent iron and phosphorus co-modified carbon material which comprises a carbon material as a carrier, a zero-valent iron supported onto the carrier and serving as an active component
Implementation Method 2
a zero-valent iron supported onto the carrier
Data Source
AI summary
A catalyst for continuous production of 1,1,1,3-tetrachloropropane through gas-solid reaction as well as a preparation method and use thereof are provided. The catalyst includes a zero-valent iron and phosphorus co-modified carbon material which includes a carbon material as a carrier, a zero-valent iron supported onto the carrier and serving as an active component, and a phosphate functional group formed on the surface of the carbon material. The preparation method includes: co-modifying a carbon material using a ferric salt and organic phosphorus to obtain the catalyst for continuous production of 1,1,1,3-tetrachloropropane through gas-solid reaction. The present application further provides a method for continuous production of 1,1,1,3-tetrachloropropane through gas-solid reaction. The catalyst provided in the present application integrates active component zero-valent iron and auxiliary component phosphate functional group on the carbon material, thereby realizing the continuous production of 1,1,1,3-tetrachloropropane on a gas-solid fixed bed reactor.