Particulate Alumina Droplet Processing for Catalyst Support Strength
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Solution Overview
Problem
Existing processes for preparing particulate alumina do not adequately achieve a high side crushing strength and low packed apparent bulk density, which are essential for effective use as a catalyst support.
Innovation Solution
A novel process involving the preparation of alumina droplets in a non-polar organic solvent system, followed by aging in an aqueous solution with a pH of 12 to 14, results in particulate alumina with enhanced physical integrity and reduced bulk density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional processes are used to prepare particulate alumina, then the basic structural properties are achieved, but the side crushing strength is insufficient
Solution Approach 1:
The patent applies parameter changes by controlling the pH of the aqueous solution to be in the range of 12 to 14 during the aging process, and maintaining the temperature in the range of 85 to 110°C. These specific parameter adjustments transform the precursor particles into particulate alumina with enhanced side crushing strength and physical integrity, directly resolving the contradiction between strength and reliability.
2Weight of stationary object
If conventional processes are used to prepare particulate alumina, then the basic physical properties are achieved, but the packed apparent bulk density is too high
Solution Approach 1:
The patent utilizes parameter changes by conducting the aging process at controlled temperatures (85-110°C) and pH levels (12-14), which results in particulate alumina with low packed apparent bulk density. This reduction in bulk density improves the effectiveness of the alumina as a catalyst support by enhancing porosity and surface area availability.
3Ease of manufacture
If the pH of the aqueous solution is not optimized, then the process is simpler, but the physical integrity and strength of particulate alumina are insufficient
Solution Approach 1:
The patent implements parameter changes by specifying the pH of the aqueous solution to be in the range of 12 to 14 during aging. This controlled pH adjustment is achieved through straightforward chemical means while producing particulate alumina with significantly enhanced side crushing strength, balancing process simplicity with product strength.
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 process produces particulate alumina with high side crushing strength and low packed apparent bulk density, making it suitable for use as a catalyst support.
Implementation Method 1
heating the droplets obtained in (ii) in a non-polar organic solvent system, to a temperature in the range of from 85 to 100° C., to obtain precursor particles
Implementation Method 2
heating the precursor particles obtained in (iii) in an aqueous solution S2 to a temperature in the range of from 85 to 110° C., wherein the pH of the aqueous solution S2 is in the range of from 12 to 14, to obtain particulate alumina
Implementation Method 3
aging in an aqueous solution with a pH of 12 to 14, results in particulate alumina with enhanced physical integrity
Data Source
AI summary
The present invention relates to a process for the preparation of particulate alumina, the process comprising (i) preparing a mixture comprising water and one or more sources of alumina; (ii) spraying the mixture for forming droplets; (iii) heating the droplets in a non-polar organic solvent system to a specific temperature, to obtain precursor particles; (iv) heating the precursor particles in an aqueous solution to a specific temperature, wherein the pH of said aqueous solution is adjusted to a value in the range of from 12 to 14. Further, the present invention relates to a particulate alumina as obtained and/or obtainable by said process. Yet further, the present invention relates to a particulate alumina having a side crushing strength in the range of from 9 to 25 N/mm and a packed apparent bulk density in the range of from 0.45 to 0.55 g/cm3 and use thereof.