Porous Ceramic Particles via Batch Spray Fluidization
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Solution Overview
Problem
The production of porous ceramic particles with balanced properties such as porosity, surface area, and crush strength for catalytic applications is challenging due to the conflicting requirements of these properties, and existing continuous spray fluidization processes are inefficient and costly, requiring complex post-processing and material recycling.
Innovation Solution
A batch mode spray fluidization process is used to form porous ceramic particles with controlled porosity and size distribution, involving multiple cycles to achieve uniform particle size and shape without the need for post-processing, thereby optimizing porosity, surface area, and crush strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If porosity of ceramic particles is increased to achieve minimum surface area and high water absorption, then surface area and water absorption are improved, but crush strength is reduced
Solution Approach 1:
The patent applies local quality by creating particles with non-uniform density distribution, where the outer shell has higher density and strength while the core maintains porosity for surface area and water absorption. This is achieved through the spray fluidization process that forms a layered structure with a dense outer layer and porous core, allowing simultaneous optimization of surface area (through core porosity) and crush strength (through outer shell density).
Solution Approach 2:
The patent employs composite material structure by combining regions of different density and porosity within the same particle. The particle consists of a porous core region providing surface area and water absorption, surrounded by a denser shell region providing mechanical strength. This composite approach allows the particle to exhibit both high surface area and high crush strength that would be mutually exclusive in uniform structures.
2Manufacturing precision
If continuous spray fluidization process is used to produce ceramic particles with desired porosity and narrow size distribution, then particle quality is improved, but manufacturing complexity and cost increase due to required post-processing operations
Solution Approach 1:
The patent applies preliminary action by incorporating all necessary particle formation steps within the spray fluidization process itself, including nucleation, growth, and size normalization, before the particles exit the reactor. The process inherently produces particles with narrow size distribution and desired porosity without requiring subsequent mechanical screening or grinding operations, thereby simplifying the overall manufacturing process while maintaining high precision.
Solution Approach 2:
The spray fluidization process exhibits self-service characteristics where the particles automatically achieve their final size and porosity characteristics through the fluidization dynamics and spray deposition mechanisms. The process self-regulates particle growth and size distribution through the interaction of spray atoms with fluidized particles, eliminating the need for external post-processing interventions and reducing manufacturing complexity.
3Productivity
If continuous spray fluidization process is used for large production, then productivity is maintained, but material waste increases due to oversized fractions requiring recycling or disposal
Solution Approach 1:
The patent applies parameter changes by optimizing the spray fluidization process parameters (spray rate, fluidization velocity, residence time, temperature) to produce particles within the desired size range in a single pass. By carefully controlling these parameters, the process achieves narrow size distribution that minimizes oversized fractions, thereby reducing material waste while maintaining high productivity. The process can be adjusted to match specific product requirements without requiring post-processing rejection and recycling.
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
This method efficiently produces porous ceramic particles with desired properties in a cost-effective manner, ensuring uniformity and reducing material waste, thus enhancing their performance as catalyst carriers.
Implementation Method 1
forming the plurality of porous ceramic particles using a spray fluidization forming process
Implementation Method 2
spray fluidization forming process
Implementation Method 3
The plurality of porous ceramic particles formed by the spray fluidization forming process may include an average porosity of at least about 0.01 cc/g and not greater than about 1.60 cc/g
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A method of forming a plurality of porous ceramic particles may include forming the plurality of porous ceramic particles using a spray tluidization forming process conducted in a batch mode. The batch mode may include at least two batch spray fluidization forming cycles. The plurality of porous ceramic particles formed by the spray fluidization forming process may include an average porosity of at least about 0.01 cc/g and not greater than about 1.6 cc/g. The plurality of porous ceramic particles formed by the spray tluidization forming- process may farther include an average particle size of at least about 200 microns and not greater than about 2000 microns. Each ceramic particle of the plurality of porous ceramic particles may include a cross-sectional structure including a core region and a layered region overlying the core region.