Rhenium Promoted Epoxidation Catalyst Pore Optimization
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Solution Overview
Problem
Conventional shaped porous bodies for catalysts often face challenges in optimizing multiple desired properties such as high surface area, low diffusion resistance, and purity, leading to conflicting performance characteristics.
Innovation Solution
The development of shaped porous bodies with a minimized percentage of total pore volume in pores less than one micron and a maximized percentage in pores between 1 and 5 microns, combined with a surface area of at least 1.0 m2/g, which enhances catalytic activity and efficiency by reducing diffusion resistance while maintaining acceptable surface area for reactant loading and dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional shaped porous bodies are used with high surface area, then catalytic loading and dispersion are improved, but diffusion resistance increases due to pores less than one micron
Solution Approach 1:
The patent changes the pore size distribution parameter by minimizing pores less than one micron and maximizing pores between one and five microns, while maintaining surface area of at least 1.0 m2/g. This parameter optimization resolves the contradiction by reducing diffusion resistance through larger pores while preserving sufficient surface area for catalytic function.
2Quantity of substance
If pores less than one micron are maximized to increase surface area, then reactant loading is improved, but mass transfer efficiency deteriorates due to high diffusion resistance
Solution Approach 1:
The patent optimizes the pore size distribution parameter by minimizing the fraction of pores less than one micron and maximizing pores between one and five microns, while maintaining adequate surface area. This resolves the contradiction by improving mass transfer efficiency through larger pores while preserving sufficient surface area for reactant loading.
3Reliability
If multiple desired properties are optimized simultaneously, then overall catalyst performance is improved, but the complexity of preparing shaped porous bodies increases
Solution Approach 1:
The patent identifies and optimizes key parameters including pore size distribution (minimizing pores <1 micron, maximizing 1-5 microns) and surface area (at least 1.0 m2/g). By focusing on these critical parameters, the patent achieves improved catalyst performance while managing preparation complexity through targeted optimization rather than attempting to control all possible properties simultaneously.
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 approach results in catalysts with improved activity and efficiency, as demonstrated by increased ethylene oxide production and reduced operating temperatures, without compromising selectivity or stability, thus enhancing the performance of epoxidation processes.
Implementation Method 1
diffusion resistance issues presented in conventional shaped porous bodies having a greater fraction of total pore volume in pores having diameters of less than one micron can substantially be avoided
Implementation Method 2
provide enhanced surface area on which the reactions or separations can take place
Implementation Method 3
rhenium-promoted epoxidation catalysts as well as methods for making the catalysts and for their use in the production of other end-use products
Data Source
AI summary
The present invention provides rhenium-promoted epoxidation catalysts based upon shaped porous bodies comprising a minimized percentage of their total pore volume being present in pores having diameters of less than one micron, and a surface area of at least about 1.0 m2/g. Processes of making the catalysts and using them in epoxidation processes are also provided.