Low-Sodium Pseudo-Boehmite Purification Without Washing
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Solution Overview
Problem
Existing pseudo-boehmite manufacturing processes generate high wastewater volumes due to washing steps to remove metal impurities, particularly sodium ions, leading to inefficiencies and environmental pollution.
Innovation Solution
Incorporating an organic acid source that acts as a metal ion transfer agent and resin protector in the pseudo-boehmite manufacturing process, allowing for effective separation of metal ions without washing, using a cation exchange resin to capture and fix sodium ions, thereby reducing sodium content and eliminating the need for washing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If washing steps are used to remove metal impurities from pseudo-boehmite, then the purity of pseudo-boehmite is improved, but the wastewater discharge volume increases
Solution Approach 1:
The patent introduces an organic acid source as an intermediary substance that mediates between the metal impurities and the cation exchange resin. The organic acid source forms soluble complexes with metal ions, facilitating their transfer to the resin and enabling effective removal without requiring extensive washing steps, thus reducing wastewater discharge while maintaining purity
Solution Approach 2:
The patent changes the chemical parameters of the system by introducing organic acid sources that alter the solubility and complexation behavior of metal ions. This parameter change enables metal ions to be selectively bound by the cation exchange resin without requiring multiple washing operations, thereby reducing wastewater volume while achieving high purity
2Manufacturing precision
If cation exchange resin is used to adsorb metal ions, then the purity of pseudo-boehmite is improved, but the resin may be embedded by pseudo-boehmite reducing its adsorption capacity
Solution Approach 1:
The organic acid source acts as a protective intermediary that forms a barrier between the pseudo-boehmite and the cation exchange resin. This prevents the pseudo-boehmite from embedding into the resin structure, thereby maintaining the resin's adsorption capacity for metal ions while still achieving effective purification
Solution Approach 2:
The patent uses the organic acid source to create a protective layer that replicates the protective function of physical barriers. This layer copies the function of preventing resin embedding without requiring complex physical barrier structures, thus maintaining resin accessibility and adsorption capacity
3Productivity
If washing steps are eliminated to reduce wastewater, then the productivity is improved, but the removal of metal impurities may be insufficient
Solution Approach 1:
The organic acid source serves as a chemical intermediary that enhances the efficiency of metal ion removal in a single step. By forming soluble complexes with metal ions, it enables complete transfer to the cation exchange resin without requiring multiple washing steps, thus maintaining high purification efficiency while improving productivity
Solution Approach 2:
The patent applies preliminary action by pre-treating the system with organic acid sources before the cation exchange process. This preliminary complexation of metal ions ensures that they are readily available for adsorption by the resin, eliminating the need for subsequent washing steps and thereby improving productivity without compromising purification
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 process achieves pseudo-boehmite with low sodium content, reduces wastewater discharge, and enhances alumina surface acidity, making it suitable for hydrogenation catalyst supports with improved properties.
Implementation Method 1
allowing the aged pseudo-boehmite to pass through a cation-exchange resin at a set flow rate, so that metal ion impurities in the aged pseudo-boehmite are removed
Implementation Method 2
the organic acid source can not only capture or displace metal ions, particularly sodium ions, contained or encapsulated in the pseudo-boehmite
Data Source
AI summary
A pseudo-boehmite has a dry basis content of 55-85 wt % and contains a phosphoric acid ester group. The sodium oxide content is not greater than 0.5 wt %, and the phosphorus content (in terms of phosphorus pentoxide) is 1.2-5.7 wt %, relative to 100 wt % of the total weight of the pseudo-boehmite. The pseudo-boehmite has a low sodium content.