Porous Catalyst Body With Controlled Pores to Suppress Powdering
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Solution Overview
Problem
Existing α-olefin dimerization catalysts suffer from powdering issues during long-term reactions, particularly in liquid phase processes, leading to difficulties in continuous operation and non-uniform physical properties, and there is a need for a porous formed body with improved powdering suppression and controlled pore size and shape.
Innovation Solution
A porous formed body composed of a porous formed body containing an alkali metal carbonate or bicarbonate, with specific pore volume, median pore diameter, crushing strength, and inclusion of compounds like metal oxides or zeolite, which is produced by supporting the alkali metal on the formed body and heat treating it to enhance stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional catalyst supports are used for long-term α-olefin dimerization reactions, then catalytic activity can be maintained, but the catalyst support undergoes powdering leading to difficulty in continuous operation
Solution Approach 1:
The patent changes the physical and chemical parameters of the catalyst support by controlling pore volume (0.10-1.00 mL/g), median pore diameter (0.01-10.0 μm), and crushing strength (7-147 N). These parameter optimizations prevent powdering during long-term reactions while maintaining continuous operation capability
Solution Approach 2:
The patent uses composite materials combining porous formed bodies (alumina, silica, or silica-alumina) with alkali metal carbonates or bicarbonates. This composite structure provides both mechanical strength to prevent powdering and catalytic activity for sustained operation
2Ease of manufacture
If water is used for forming catalyst support pellets, then filling in the forming die becomes easier, but dissolution of potassium bicarbonate occurs resulting in nonuniform physical properties
Solution Approach 1:
The patent changes the forming method from water-based to dry powder compaction or organic solvent-based forming. This eliminates water-induced dissolution of potassium bicarbonate while achieving uniform physical properties through controlled compaction density and pore structure
Solution Approach 2:
The patent uses organic solvents or dry powder compaction as intermediaries instead of water for the forming process. This intermediary approach allows pellet formation without causing dissolution of the alkali metal bicarbonate, maintaining compositional uniformity
3Ease of manufacture
If pore size is not controlled in the catalyst support, then manufacturing is simpler, but reaction selectivity and catalyst performance are insufficient
Solution Approach 1:
The patent optimizes pore size parameters (volume: 0.10-1.00 mL/g, median diameter: 0.01-10.0 μm) through controlled formation processes. This precision control enhances reaction selectivity and catalyst performance while maintaining manufacturing feasibility through standardized production methods
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 resulting catalyst exhibits excellent powdering suppression, allowing for prolonged and efficient α-olefin dimerization reactions with enhanced reaction selectivity and catalyst life.
Implementation Method 1
a porous formed body (Y), comprising: a porous formed body (X)... and an alkali metal carbonate or an alkali metal bicarbonate, wherein a content of the alkali metal carbonate or the alkali metal bicarbonate is in a range of from 1 part by mass to 230 parts by mass, with respect to 100 parts by mass of the porous formed body (X)
Implementation Method 2
which is produced by supporting the alkali metal on the formed body and heat treating it to enhance stability
Data Source
AI summary
A porous formed body (Y) including a porous formed body (X) that satisfies the following (x-1) to (x-3), and an alkali metal carbonate or an alkali metal bicarbonate, in which a content of the alkali metal carbonate or the alkali metal bicarbonate is in a range of from 1 part by mass to 230 parts by mass, with respect to 100 parts by mass of the porous formed body (X), and a production method thereof, an α-olefin dimerization catalyst and a production method thereof, and a method of producing an α-olefin dimer: requirement (x-1): a volume of pores with a pore diameter in a range of from 0.01 µm to 100 µm is from 0.10 mL/g to 1.00 mL/g; requirement (x-2): a median pore diameter of pores with a pore diameter in a range of from 0.01 µm to 100 µm is from more than 0.01 µm to 10.0 µm; and requirement (x-3): a crushing strength is from 0.7 kgf to 15.0 kgf.