Oxide-Coated Shaped Catalyst Bodies for Synthetic Gas Reforming
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Solution Overview
Problem
Existing catalysts used in the reforming process face challenges in balancing formability and crushing strength, leading to damage and flow resistance due to mechanical shock, thermal expansion, and coke production, which affects the efficiency and stability of synthetic gas production.
Innovation Solution
A shaped catalyst body is developed with a carrier, metal active particles, and a metal oxide coating layer, incorporating alumina and boehmite, with specific weight percentages and pore sizes, and a binder, allowing for various shapes and high crushing strength to prevent flow resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a pellet-type catalyst is used in the reforming process, then the catalyst can be easily manufactured and loaded, but the catalyst may be damaged due to mechanical shock, thermal expansion, and coke production, leading to reduced crushing strength
Solution Approach 1:
The catalyst is designed as a composite structure with a porous ceramic support (alumina, silica, or titania) providing mechanical strength and stability, metal particles (nickel, cobalt, or iron) providing catalytic activity, and an optional protective coating layer preventing deactivation. This composite approach allows the catalyst to simultaneously achieve ease of manufacture, high crushing strength, and catalytic functionality.
2Stress or pressure
If a pellet with a hole inside is used to lower reactor pressure, then the reactor pressure can be reduced, but the catalyst with weak crushing strength may be damaged during loading and operation
Solution Approach 1:
The catalyst structure incorporates localized features including internal holes or channels in specific regions to reduce pressure, while maintaining high-strength material composition and optimized wall thickness in critical areas to ensure mechanical integrity. The porous support structure provides localized strength enhancement without compromising the pressure-reducing hollow features.
3Reliability
If small pieces are generated from catalyst damage, then pieces may fill gaps between catalyst pellets and cause flow resistance to reformed gas, but using stronger catalyst materials may reduce formability
Solution Approach 1:
The catalyst manufacturing process optimizes parameters including the particle size distribution of raw materials (0.1-10 μm), sintering temperature (1000-1500°C), and sintering time (1-24 hours) to achieve the desired balance between mechanical strength and formability. The porous support structure with controlled pore size (1-100 μm) and porosity (30-70%) enables both high strength and ease of shaping into various catalyst geometries.
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 shaped catalyst body enhances formability and crushing strength, ensuring efficient heat and mass transfer, expanding reaction surface area, and preventing pressure drops during synthetic gas production.
Implementation Method 1
a metal oxide coating layer which is present on at least a portion of surfaces of the metal active particle and carrier
Implementation Method 2
The shaped catalyst body enhances formability and crushing strength, ensuring efficient heat and mass transfer
Implementation Method 3
The shaped catalyst body enhances formability and crushing strength, ensuring efficient heat and mass transfer
Implementation Method 4
synthetic gas is produced from hydrocarbons through a reforming process, mainly using catalysts made of nickel-based alumina or ruthenium-based alumina
Data Source
AI summary
A shaped catalyst body for manufacturing a synthetic gas according to an aspect includes a catalyst including a carrier and a metal active particle supported on the carrier, wherein a metal oxide coating layer is present on at least a portion of surfaces of the metal active particle and carrier.