Molten Salt Catalyst Preparation Process for Precise Metal Loading
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Solution Overview
Problem
Existing methods for preparing catalysts with high metallic active phase loading using molten salts are inefficient due to lack of precise control over metal deposition, excessive metal loss, and hazardous handling of toxic precursors, making them unsuitable for liquid phase reactors and increasing costs.
Innovation Solution
A process involving a porous oxide support contacted with a metal salt of low melting point (20-150°C) for 5 minutes to 5 hours, followed by heating, optional drying, and calcination at temperatures above 200°C, allowing for controlled metal deposition and reduced precursor amounts, resulting in a catalyst suitable for various industrial processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If molten salt method is used to prepare high metal loading catalyst, then metal loading amount increases, but metal loss by attrition increases excessively
Solution Approach 1:
The support particles are pre-coated with a binder material before metal deposition, creating a protective layer that prevents metal attrition. This preliminary action of coating the support with binder resolves the contradiction by protecting the metal phase while allowing high metal loading
Solution Approach 2:
The catalyst is formulated as a composite material comprising metal phase, oxide support, and binder material in specific proportions. This composite structure combines the high metal loading capability with attrition resistance through the binder network that holds metal particles in place
2Quantity of substance
If multiple impregnation steps are used to achieve high metal content, then metal loading increases, but process complexity increases
Solution Approach 1:
Multiple impregnation steps are merged into a single impregnation step by using a binder material that enables higher metal uptake in one pass. This merging reduces process complexity while achieving the same or higher metal content through the binder-mediated deposition mechanism
3Quantity of substance
If large amounts of metal precursor are used, then metal loading increases, but handling hazards and costs increase
Solution Approach 1:
The process parameters are optimized to reduce the metal precursor to support weight ratio from the conventional 4:1 to 1:1 or lower while achieving high metal loading through multiple factors including binder material, optimized impregnation conditions, and controlled drying/reduction parameters. This parameter optimization reduces handling hazards and costs
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 process enables precise control of metal loading, reduces hazardous material handling, and decreases costs by minimizing precursor usage, while producing catalysts suitable for slurry reactors and other industrial applications.
Implementation Method 1
heating with stirring at a temperature between the melting point of said metal salt and 200° C.
Implementation Method 2
contacted with at least one metal salt... for a period of between 5 minutes and 5 hours in order to form a solid mixture
Implementation Method 3
optionally, the solid obtained at the end of step b) is dried at a temperature below 200° C.
Implementation Method 4
the solid obtained at the end of step b) or c) is calcined at a temperature above 200° C. and below or equal to 1100° C.
Data Source
AI summary
Process for preparing a catalyst or a trapping mass comprising the following steps:bringing a porous oxide support into contact with a metal salt comprising at least one metal belonging to groups VIB, VIIB, VIIIB, IB or IIB, of which the melting point of said metal salt is between 20° C. and 150° C., for a period of between 5 minutes and 5 hours in order to form a solid mixture, the weight ratio of said metal salt to said porous oxide support being between 0.1 and 1;heating the solid mixture with stirring at a temperature between the melting point of said metal salt and 200° C. and for 5 minutes to 12 hours;calcining the solid obtained in the preceding step at a temperature above 200° C. and below or equal to 1100° C. under an inert atmosphere or under an oxygen-containing atmosphere.