Pelletized RuO2/TiO2 Catalyst for Fixed-Bed HCl Oxidation
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Solution Overview
Problem
Existing catalysts for hydrogen chloride oxidation in producing chlorine face challenges with thermal stability, reactor restrictions, and operational limitations, particularly in fixed bed reactors, leading to reduced catalytic activity and durability.
Innovation Solution
A molding catalyst is developed by incorporating 0.5 to 20 parts by weight of a heterogeneous material, 0.1 to 20 parts by weight of ruthenium oxide, and 60 to 99 parts by weight of a support, using a multi-step process involving supporting, drying, and calcining to create a pellet form that can be used in fixed bed reactors without generating differential pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a powder-type catalyst is used in a fixed bed reactor, then the catalyst can be applied to the reaction, but a differential pressure is generated at the front and rear ends of the catalyst bed making operation impossible
Solution Approach 1:
The catalyst form is changed from powder to pellet shape, fundamentally altering the physical parameter of the catalyst. This shape transformation eliminates the differential pressure issue in fixed bed reactors while maintaining catalytic functionality, enabling both applicability and operational feasibility.
Solution Approach 2:
The catalyst is divided into multiple functional components: heterogeneous material (0.5-20 parts), ruthenium oxide (0.1-20 parts), and support material (60-99 parts). This segmentation allows each component to perform its specific function while the overall pellet structure prevents differential pressure problems.
2Productivity
If conventional catalysts are used for hydrogen chloride oxidation, then the reaction can proceed, but the catalyst performance decreases in a short period of several months during high-temperature operation
Solution Approach 1:
The catalyst uses a composite structure combining heterogeneous material, ruthenium oxide, and support material in specific proportions. This composite formulation provides both high reaction activity and long-term stability, maintaining performance over extended periods at high temperatures.
Solution Approach 2:
Instead of using expensive catalysts that require frequent replacement, the invention employs a cost-effective formulation with optimized ratios of materials that extends catalyst life from months to years, reducing both cost and operational disruptions.
3Power
If a supported ruthenium oxide catalyst is used, then high activity at high temperatures can be achieved, but thermal stability and catalyst life cannot be simultaneously satisfied
Solution Approach 1:
The catalyst composition parameters are precisely optimized: heterogeneous material (0.5-20 parts), ruthenium oxide (0.1-20 parts), and support (60-99 parts). This parameter optimization achieves the balance between high activity and thermal stability, allowing the catalyst to maintain both power and reliability simultaneously.
Solution Approach 2:
Different regions of the catalyst pellet have different compositions and functions. The heterogeneous material provides thermal stability, ruthenium oxide provides catalytic activity, and the support provides structural integrity. This local quality distribution allows simultaneous achievement of activity and stability.
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 catalyst enhances thermal stability and catalytic activity, allowing for high durability and versatility across various reactor types, enabling efficient hydrogen chloride oxidation to chlorine.
Implementation Method 1
a ruthenium-based catalyst, a copper-based catalyst, and a cerium-based catalyst. The ruthenium-based catalyst has a lower reaction temperature with a small amount of catalyst than the copper-based catalyst or the cerium-based catalyst.
Implementation Method 2
hydrogen chloride is oxidized with oxygen to form chlorine in an exothermic equilibrium reaction
Implementation Method 3
a molding catalyst is developed by incorporating 0.5 to 20 parts by weight of a heterogeneous material, 0.1 to 20 parts by weight of ruthenium oxide, and 60 to 99 parts by weight of a support, using a multi-step process involving supporting, drying, and calcining to create a pellet form that can be used in fixed bed reactors without generating differential pressure.
Data Source
AI summary
The present invention relates to a method for producing a molding catalyst for obtaining chlorine (Cl2) through an oxidation reaction of hydrogen chloride (HCl), and more specifically, to a method for producing an oxidation reaction molding catalyst by adding heterogeneous material to a ruthenium oxide (RuO2)-supported catalyst having titanium oxide (TiO2) as a supporting body, and molding so as to be usable in a fixed bed reactor to produce chlorine (Cl2) from hydrogen chloride (HCl).