Protected Nickel Catalyst Preparation via Hydrocarbon Resin Coating
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Solution Overview
Problem
Current methods for protecting nickel powder catalysts used in hydrocarbon resin hydrogenation are inadequate, as they can lead to contamination of the product, spontaneous ignition, and require additional stabilization steps, and are not suitable for fine powder catalysts due to incomplete coating and incompatibility with hydrocarbon resin feedstocks.
Innovation Solution
A process involving a polymer with specific weight average molecular weight, glass transition temperature, and viscosity is used to create a protected nickel catalyst by mixing it with a molten polymer in an inert atmosphere, ensuring a homogeneous distribution and high polymer content to prevent contamination and spontaneous ignition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hardened vegetable oil or fat is used as protective material for the catalyst, then the catalyst is protected from oxidation and dust formation, but the protective coating is incompatible with hydrocarbon resin feedstock leading to product contamination
Solution Approach 1:
The patent changes the chemical composition parameters of the protective coating from hardened vegetable oil/fat to a hydrocarbon resin that matches the feedstock properties. This parameter change ensures compatibility between the protective coating and hydrocarbon resin feedstock, preventing contamination while maintaining catalyst protection functionality.
Solution Approach 2:
The protective coating is designed to be temporary and consumable during the hydrogenation process. The hydrocarbon resin coating is intentionally allowed to be consumed or transformed during reaction, eliminating the need for permanent protective coatings that would cause contamination.
2Reliability
If inert material coating is applied to protect catalyst from oxidation, then catalyst stability is improved, but fine powder catalysts receive incomplete coating leading to oxidation and decreased reduction value ratio
Solution Approach 1:
The patent uses a slurry preparation method where the catalyst is mixed with hydrocarbon resin and solvent to form a homogeneous liquid suspension. This hydraulic approach ensures complete and uniform coating of fine powder catalyst particles, eliminating incomplete coverage issues.
Solution Approach 2:
The protective coating is applied as a homogeneous slurry mixture of catalyst, hydrocarbon resin, and solvent. This homogeneous distribution ensures that all catalyst particles receive complete and uniform coating, achieving consistent protection and maintaining high reduction value ratio.
3Object-affected harmful factors
If stabilized nickel powder catalyst is used to prevent spontaneous ignition, then safety is improved, but additional lengthy stabilization steps are required increasing process time and cost
Solution Approach 1:
The catalyst is protected with hydrocarbon resin coating as a preliminary step before hydrogenation. This preliminary protective action prevents spontaneous ignition during storage and handling, eliminating the need for lengthy post-production stabilization steps.
Solution Approach 2:
The hydrocarbon resin coating creates an inert protective environment around the catalyst particles, preventing contact with oxygen and eliminating spontaneous ignition risk. This inert barrier provides immediate safety without requiring extended stabilization periods.
4Ease of operation
If protected catalyst powder is processed into flakes or droplets by remelting, then handling is improved, but pore filling occurs due to capillary action causing viscosity increase and processing difficulty
Solution Approach 1:
The hydrocarbon resin forms a flexible protective shell around the catalyst particles. This shell maintains particle integrity during handling and processing, allowing easy handling of flakes or droplets without requiring remelting that would cause pore filling and viscosity issues.
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 protected catalyst can be used directly in hydrocarbon resin hydrogenation without affecting product properties, is stable against spontaneous ignition, and prevents dust formation, offering improved safety, handling, and economic feasibility.
Implementation Method 1
the non-coated catalyst surface of the catalyst would oxidize upon exposure to air leading to a decrease in the reduction value ratio (RVR)
Implementation Method 2
a process for hydrogenating a hydrocarbon resin feedstock using the protected metal catalyst
Data Source
AI summary
The invention is in the field of catalysis. More specifically, the invention relates to a process for preparing a protected metal catalyst on a support; a matrix particle comprising the protected metal catalyst; and, a process for hydrogenating a hydrocarbon resin feedstock using the protected metal catalyst.