Perovskite Catalyst Support Lattice Integration
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Solution Overview
Problem
Existing catalyst support structures face instability and promoter depletion under reaction conditions due to metastable phases and uneven promoter distribution, leading to decreased catalyst activity and selectivity.
Innovation Solution
A method of synthesizing a mixed metal oxide compound with a crystallographic phase, such as perovskite, where catalytic promoter elements are incorporated into the crystal lattice to prevent destabilization and exsolution, ensuring stability and uniform distribution of promoters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If promoters are added to the catalyst surface through impregnation or precipitation, then catalytic activity and selectivity are improved, but promoter distribution becomes uneven and promoters become metastable under reaction conditions
Solution Approach 1:
The patent combines the promoter incorporation with the support structure formation by synthesizing mixed metal oxide compounds where promoters are integrated into the crystal lattice during formation. This merging of promoter addition with support synthesis ensures uniform distribution and stable incorporation, eliminating the sequential impregnation approach that causes uneven distribution.
Solution Approach 2:
The patent applies preliminary action by incorporating promoters into the support structure during its synthesis phase, before the catalyst is fully assembled and before reaction conditions are applied. This advance incorporation ensures promoters are uniformly distributed and stabilized in the crystal lattice prior to catalytic operation, preventing later redistribution or depletion.
2Ease of manufacture
If conventional impregnation methods are used to add promoters, then catalyst preparation is simple, but promoters deplete or enrich unevenly under reaction conditions
Solution Approach 1:
The patent creates a composite mixed metal oxide material where the support and promoter are integrated at the atomic level within a single crystal lattice structure. This composite approach replaces the separate support-plus-promoter layering of conventional methods, ensuring uniform promoter distribution and preventing depletion or enrichment under reaction conditions.
3Reliability
If promoters are dispersed on the catalyst surface, then catalytic promotion is achieved, but the catalyst support structure becomes unstable and collapses under reaction conditions
Solution Approach 1:
The patent merges the promoter and support into a single integrated mixed metal oxide crystal lattice structure. This combination ensures that promoter dispersion for catalytic activity is achieved while simultaneously maintaining support structure stability, as the promoters are part of the stable crystal framework rather than separate surface deposits.
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 approach results in a stable catalyst support structure that maintains promoter elements within the lattice under reaction conditions, enhancing catalyst activity and selectivity, and preventing collapse and exsolution, thus improving catalytic performance.
Implementation Method 1
The cations may be locked or positionally anchored in the crystal lattice by ionic bonding to adjacent atoms in the lattice.
Implementation Method 2
Cations of one or more catalytic promoter elements are incorporated into the crystal lattice of the support structure
Data Source
AI summary
A method of preparing a catalyst support structure for use in a catalytic reaction. According to the method, a mixed metal oxide compound which defines a crystal lattice is synthesized. Cations of at least one catalytic promoter element are dispersed within the compound and incorporated into the crystal lattice. The conditions of synthesis are preselected to inhibit destabilization of the catalyst support structure such that the structure remains stable against collapse and exsolution under reaction conditions associated with the catalytic reaction. The metal oxide compound may comprise an oxidic perovskite having the formula A(1-x)A′(x)B(1-y)B′yO3 wherein A and B represent metal cations and A′ and B′ represent cations of the promoter element or elements. Also provided is a catalyst support structure having cations of a promoter element incorporated into its crystal lattice. The support structure is stable against collapse and exsolution under reaction conditions.