Mesoporous Oxide-Catalyst Complex with High Dispersion
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Solution Overview
Problem
Current methods for preparing mesoporous metal oxide catalysts are complex and require multiple steps, with low catalyst dispersion and high manufacturing costs, limiting their efficiency and application in processes like hydrocarbon reforming.
Innovation Solution
A method involving the direct inclusion of a catalyst metal in the lattice structure of a mesoporous metal oxide, followed by calcination and selective reduction, to achieve a high degree of catalyst dispersion and large pore area, using precursors like alkoxides and nitrates, and solvents such as alcohol and aqueous acid, at controlled temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional multi-step preparation methods (deposition precipitation, coprecipitation, wet impregnation) are used to prepare mesoporous metal oxide catalysts, then the catalyst can be prepared with supported metal on metal oxide carrier, but the process complexity increases with multiple steps including surface treatment and acid-base property selection
Solution Approach 1:
The patent combines the metal oxide carrier preparation and metal catalyst support steps into a single coprecipitation process. The metal oxide precursor and metal catalyst precursor are mixed together in solution before precipitation, allowing simultaneous formation of the carrier structure and catalyst distribution. This eliminates separate surface treatment steps while achieving uniform catalyst dispersion (30-90%) on the mesoporous carrier.
Solution Approach 2:
The coprecipitation method serves multiple functions simultaneously: it forms the mesoporous metal oxide carrier structure, distributes the metal catalyst uniformly throughout the precursor mixture, and creates the final catalyst product in one process. This multi-functional approach replaces conventional sequential steps including carrier preparation, surface treatment, catalyst deposition, and heat treatment.
2Manufacturing precision
If additional processes like surface treatment and acid-base property selection are used to increase metal catalyst dispersion, then the catalyst dispersion improves, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent performs preliminary mixing of the metal oxide precursor and metal catalyst precursor in solution before the precipitation step. This preliminary distribution ensures uniform catalyst dispersion throughout the carrier precursor matrix before the structure is formed. The uniform molecular-level mixing in solution phase prevents catalyst aggregation and eliminates the need for subsequent surface treatment steps to improve dispersion.
3Manufacturing precision
If conventional preparation methods are used, then catalysts can be prepared with nanometer-scale metal particles, but the manufacturing cost increases due to multiple process steps
Solution Approach 1:
The patent controls particle size and catalyst dispersion by adjusting solution parameters including precursor concentration ratios, pH value during precipitation, and aging temperature. By optimizing these parameters, the method achieves nanometer-scale metal particles (uniform distribution) while simplifying the process to a single coprecipitation step, thereby reducing manufacturing cost compared to conventional multi-step methods.
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 resulting mesoporous oxide-catalyst complex exhibits high catalyst dispersion (30-90%) and large surface area, effectively preventing carbon deposition in hydrocarbon reforming, enabling continuous reforming reactions with reduced manufacturing costs.
Implementation Method 1
forming from the mixture a mesoporous structure in which a catalyst metal is included in a lattice structure of a metal oxide
Implementation Method 2
calcining the mesoporous structure to obtain a mesoporous metal oxide complex
Implementation Method 3
selectively reducing a catalyst metal oxide of the mesoporous metal oxide complex to prepare the mesoporous oxide-catalyst complex
Data Source
AI summary
A mesoporous oxide-catalyst complex including: a mesoporous metal oxide; and a catalyst metal supported on the mesoporous metal oxide, wherein the catalyst on the mesoporous metal oxide has a degree of dispersion of about 30 to about 90 percent.