Organic Carbonate Catalyst Drying Process
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Solution Overview
Problem
Existing catalyst carrier drying processes require high temperatures and use of nitrogen gas, leading to inefficiencies and the formation of inactive titanium dioxide, which reduces catalyst activity and increases costs due to the need for additional equipment and hazardous solvent handling.
Innovation Solution
Using an organic carbonate as both a drying agent and solvent for impregnating the catalyst carrier, which effectively removes water and supports metal-containing compounds, thereby preventing titanium dioxide formation and simplifying the catalyst preparation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high temperature drying and nitrogen gas are used to remove water from catalyst carrier, then water removal efficiency is improved, but energy consumption increases and titanium dioxide formation occurs reducing catalyst activity
Solution Approach 1:
The patent changes the drying parameter from high temperature thermal drying to low temperature chemical drying using organic carbonate. This parameter change allows effective water removal at lower temperatures by utilizing the chemical reaction between organic carbonate and water, thereby reducing energy consumption while maintaining water removal efficiency.
Solution Approach 2:
The patent introduces organic carbonate as an intermediary substance to facilitate water removal. The organic carbonate acts as a drying agent that chemically reacts with water to form removable byproducts, enabling efficient water removal without requiring high temperature energy input that would otherwise be needed.
2Quantity of substance
If high temperature drying is used to remove water from catalyst carrier, then water removal efficiency is improved, but titanium dioxide formation occurs reducing catalyst activity
Solution Approach 1:
The patent changes the drying parameter from high temperature thermal drying to low temperature chemical drying using organic carbonate. This parameter change prevents titanium dioxide formation by avoiding the high temperature conditions that cause Ti(OR)4 decomposition, thereby maintaining catalyst activity while still achieving effective water removal.
Solution Approach 2:
The patent introduces organic carbonate as an intermediary drying agent that chemically reacts with water at low temperatures. This intermediary approach removes water through chemical reaction rather than thermal evaporation, preventing the formation of inactive titanium dioxide and preserving catalyst reliability.
3Quantity of substance
If nitrogen gas is used for drying catalyst carrier, then water removal is achieved, but additional equipment and operational complexity are required
Solution Approach 1:
The patent introduces organic carbonate as a liquid intermediary drying agent that can be directly contacted with the catalyst carrier. This eliminates the need for complex nitrogen gas delivery systems, flow meters, and gas handling equipment, simplifying the overall device complexity while achieving effective water removal.
4Quantity of substance
If conventional drying methods are used, then water removal is achieved, but hazardous solvents and additional safety measures are required
Solution Approach 1:
The patent introduces organic carbonate as a safe intermediary drying agent that does not require hazardous co-solvents like toluene. The organic carbonate itself serves as both the drying agent and the impregnation solvent, eliminating the need for hazardous solvent handling and associated safety equipment while effectively removing water from the catalyst carrier.
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 method achieves efficient water removal at lower temperatures, maintains catalyst activity, reduces equipment needs, and avoids the use of hazardous solvents, resulting in a more efficient and cost-effective catalyst preparation process for producing aromatic carbonates.
Implementation Method 1
drying the carrier by contacting the carrier with a drying agent which comprises an organic carbonate
Implementation Method 2
impregnating the dried carrier with a solution wherein a compound containing the metal is dissolved
Data Source
Figure 1
AI summary
The invention relates to a process for drying a catalyst carrier or drying a catalyst comprising a carrier on which a metal is supported, wherein the carrier or catalyst is contacted with a drying agent which comprises an organic carbonate. Further, the invention relates to a process for preparing a catalyst which comprises a carrier on which a metal is supported, said process comprising drying the carrier by contacting the carrier with a drying agent which comprises an organic carbonate resulting in a dried carrier; and impregnating the dried carrier with a solution wherein a compound containing the metal is dissolved in a solvent which is an organic carbonate or an alcohol. Still further, the invention relates to a process for preparing an aromatic carbonate, such as a diaryl carbonate, using the catalyst thus prepared or dried; and to a process for making a polycarbonate from the diaryl carbonate thus prepared.