Mesoporous Gold Nanoparticle Catalyst Coating for Stable Gas Conversion
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Solution Overview
Problem
Existing catalysts with transition metal nanoparticles face challenges in maintaining catalytic activity under harsh conditions such as vibration and pressurization, and they suffer from gas diffusion resistance and desorption issues, limiting their effectiveness in commercial applications.
Innovation Solution
A porous composite structure catalyst is developed, comprising a porous substrate coated with a catalyst layer containing gold nanoparticles within mesopores, stabilized by a metal oxide unit layer, which is laminated and sintered for enhanced stability and catalytic activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If transition metal nanoparticles are used as catalysts, then catalytic activity is improved due to high surface area, but the nanoparticles suffer from Ostwald ripening, particle migration, and coalescence at high temperatures, making it difficult to maintain long-term catalytic activity
Solution Approach 1:
The patent employs mesoporous silica supports with controlled pore sizes (2-50 nm) to physically confine transition metal nanoparticles, preventing their migration and coalescence. The porous structure provides a large surface area for nanoparticle dispersion while the pore walls act as physical barriers that stabilize the nanoparticles during high-temperature operation, thereby maintaining long-term catalytic activity.
Solution Approach 2:
The patent creates composite catalyst structures by combining transition metal nanoparticles with mesoporous silica supports. This composite approach integrates the high catalytic activity of metal nanoparticles with the structural stability and thermal resistance of silica, resulting in a material that maintains both activity and stability under harsh operating conditions.
2Adaptability or versatility
If catalyst powder is coated on porous substrate to enable scale-up, then applicability to commercial processes is improved, but the coated catalyst powder is desorbed from the porous substrate during long-term operation under harsh conditions
Solution Approach 1:
The patent uses mesoporous silica materials as both the catalyst support and the coating matrix. The porous structure allows for high catalyst loading while the strong interaction between the catalyst particles and the porous matrix prevents desorption during long-term operation, even under harsh conditions such as vibration and pressurization.
Solution Approach 2:
The mesoporous silica acts as an intermediary between the catalyst powder and the porous substrate. It provides a stable interface that anchors the catalyst particles while allowing mass transfer, preventing direct contact between the catalyst and the substrate that could lead to desorption under mechanical stress.
3Productivity
If mesoporous support with pore sizes of 2-50 nm is used to support nanoparticles, then diffusion resistance is reduced and reaction rate is improved, but the support manufactured as powder requires coating on porous substrate which adds complexity
Solution Approach 1:
The patent merges the mesoporous support material with the coating process, creating an integrated structure where the mesoporous silica serves as both the catalyst carrier and the coating matrix. This combination eliminates the need for separate support and coating steps, reducing process complexity while maintaining the high reaction rates enabled by the mesoporous structure.
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 maintains high catalytic activity at room temperature, effectively converts reactant gases into products with low diffusion resistance, and remains stable under harsh conditions, achieving rapid and reliable gas removal.
Implementation Method 1
the catalyst coating layer includes a porous support including mesopores and a composite catalyst, and a gold nanoparticle incorporated within pores of the porous support
Implementation Method 2
due to the characteristics of mesopores, the diffusion resistance of substances is lower than that of microporous supports, and thus they may have the advantage of a fast reaction rate
Implementation Method 3
the catalyst coating layer may be manufactured from an operation of forming a coating layer by coating an aqueous slurry containing one or more binders selected from the group consisting of an inorganic sol binder and a water-soluble polymer binder and a composite catalyst powder on the porous substrate; and an operation of sintering the porous substrate on which the coating layer is formed
Data Source
AI summary
The present invention relates to a porous composite structure catalyst comprising a porous substrate and a catalyst coating layer, wherein the catalyst coating layer comprises: a porous support including meso-pores; and a composite catalyst, which is gold nanoparticles impregnated into pores of the porous support.