Polymer Coating Limits Catalyst Self-Heating
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Solution Overview
Problem
Activated catalysts used in hydrocarbon treatment processes are chemically unstable, leading to self-heating and toxic gas emissions, posing safety risks and efficiency challenges during storage, transport, and handling, with existing coating solutions failing to adequately address these issues.
Innovation Solution
A coating process involving a thin protective layer of film-forming polymer applied to activated catalyst particles using a specific spraying method within a hot gas flow, forming a continuous layer that reduces self-heating and toxic gas emissions while maintaining catalyst activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a thick protective coating is applied to activated catalyst particles, then self-heating and toxic gas emissions are reduced, but catalyst loading density decreases and reactor efficiency is reduced
Solution Approach 1:
The patent applies a thin film coating (0.1-20 μm) of film-forming polymer on catalyst particles to provide protection against self-heating and toxic gas emissions. This thin film approach maintains high catalyst loading density in the reactor while still providing adequate protection, resolving the contradiction between safety and productivity.
Solution Approach 2:
The patent changes the coating thickness parameter to an optimized range (0.1-20 μm) that is sufficient to reduce harmful effects but thin enough to maintain high loading density. This parameter optimization resolves the contradiction by finding the optimal balance between protection and productivity.
2Object-affected harmful factors
If activated catalysts are stored in an inert atmosphere, then self-heating and toxic gas emissions are prevented, but operational complexity and costs increase
Solution Approach 1:
The thin film polymer coating acts as a protective barrier that stabilizes activated catalysts during storage and transport without requiring inert atmospheres. This eliminates the complexity of inert atmosphere storage systems while maintaining safety.
Solution Approach 2:
The coating provides self-protection functionality to the catalyst particles, enabling them to resist oxidation and self-heating autonomously during storage and handling without external inert atmosphere support.
3Reliability
If a protective coating is applied to catalyst particles, then safety during storage and transport is improved, but catalyst activity may be reduced
Solution Approach 1:
The thin film coating provides safety protection while maintaining catalyst activity through its minimal thickness and appropriate material selection that does not significantly block active sites or mass transfer.
Solution Approach 2:
The coating thickness is optimized to 0.1-20 μm, which is sufficient for safety but thin enough to maintain catalyst activity. The film-forming polymer material is selected to be compatible with catalyst function, resolving the contradiction between safety and activity.
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
Significantly reduces self-heating and toxic gas emissions, allowing for safe storage, transport, and handling of catalysts without the need for inert atmospheres, while preserving the catalyst's efficiency and activity.
Implementation Method 1
the metal sulfides present on the surface of the catalyst particles are reactive and give rise to exothermic oxidation reactions
Implementation Method 2
catalyst particles are placed in motion either in a perforated drum continuously traversed by a gas flow of temperature greater than 25°C or in a fluidized bed by means of a gas flow of temperature greater than 25°C
Implementation Method 3
a liquid composition containing one or more film-forming polymer(s) is sprayed onto the moving particles
Implementation Method 4
until a protective layer containing said film-forming polymer and having an average thickness of 0.1 to 20 μm is obtained on the surface of said particles
Data Source
AI summary
The present invention relates to a method for limiting the self-heating of activated catalysts in particulate form, in which the catalyst particles are set in motion within a stream of hot gas passing through them, and a liquid composition containing one or more film-forming polymer(s) is sprayed onto the moving particles until a protective layer containing said film-forming polymer and having an average thickness of 20 µm or less is obtained on the surface of said particles. The present invention also relates to the use of this method for reducing the quantities of toxic gases that may be emitted by activated catalysts, as well as to an activated hydrocarbon hydroconversion catalyst coated with a continuous protective layer, obtainable by this method.