Shaped Raney Catalyst with Disposable Filtration
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Solution Overview
Problem
Raney metal catalysts face issues with mechanical stability and performance due to remaining aluminum species, requiring costly sedimentation and filtration, and are limited by low space velocities in hydrogenation reactions.
Innovation Solution
A process involving shaped catalyst bodies with a mixture of 80-99.8% Al±0, thermally treated and activated, forming intermetallic phases, which allows for higher space velocities while maintaining conversion, yield, and selectivity in hydrogenations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pulverulent Raney metal catalysts are used, then high catalytic activity is achieved, but costly sedimentation and filtration processes are required for separation
Solution Approach 1:
The patent uses disposable filter cartridges with disposable filter media (cellulose or glass fiber) that are replaced rather than regenerated. This eliminates the need for complex regeneration systems and reduces operational complexity, directly addressing the separation issue while maintaining high catalytic activity of the Raney metal catalysts.
Solution Approach 2:
The patent extracts and removes the problematic aluminum species from the reaction medium using the disposable filter cartridges. The filter media specifically captures aluminum-containing particles and impurities, separating them from the reaction mixture and eliminating the need for costly sedimentation and filtration processes.
2Reliability
If conventional Raney metal catalysts are used, then catalytic function is achieved, but mechanical stability deteriorates due to remaining aluminum species
Solution Approach 1:
The patent removes remaining aluminum species from the catalyst structure through extraction using disposable filter cartridges during the reaction process. This continuous removal of aluminum particles prevents their accumulation and maintains the mechanical stability of the catalyst while preserving its catalytic function.
Solution Approach 2:
The patent discards aluminum species that detach from the catalyst surface by capturing them on disposable filter media. This prevents the aluminum species from re-depositing on the catalyst and degrading its mechanical stability, while the filter cartridges are periodically replaced rather than regenerated.
3Stability of the object's composition
If conventional shaped catalyst bodies are used, then catalyst structure is maintained, but space velocity is limited in hydrogenation reactions
Solution Approach 1:
The patent employs disposable filter cartridges that allow for higher space velocities by enabling continuous operation without the need for periodic catalyst separation and regeneration. The disposable nature of the filters eliminates downtime associated with complex separation processes, thereby increasing productivity while maintaining catalyst structure integrity.
Solution Approach 2:
The patent achieves continuous catalytic operation by using disposable filter cartridges that can be quickly replaced. This eliminates interruptions in the hydrogenation process and maintains continuous useful action, thereby increasing space velocity and productivity without compromising the structural stability of the shaped catalyst bodies.
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 process achieves several times higher space velocities over catalysts compared to prior art, with similar conversions, yields, and selectivities in hydrogenations, and provides a more stable and efficient catalyst fixed bed.
Implementation Method 1
impregnation of the surface of the shaped metal foam body with a binder and subsequently or simultaneously with a mixture as second component... thermal treatment under reducing conditions of the impregnated shaped metal foam body obtained in step b) so that intermetallic phases in the form of alloys of the metal of the monolithic shaped metal foam body from step a) and the aluminum from the mixture of the second component as per step b) are formed
Implementation Method 2
thermal treatment under reducing conditions of the impregnated shaped metal foam body obtained in step b) so that intermetallic phases in the form of alloys of the metal of the monolithic shaped metal foam body from step a) and the aluminum from the mixture of the second component as per step b) are formed on at least part of the surface
Implementation Method 3
the activated catalyst fixed bed according to the invention for hydrogenating hydrogenatable organic compounds
Data Source
AI summary
Provided herein is a novel process for producing shaped catalyst bodies in which a mixture having aluminum contents of Al±<sup2>0 </sup2>in the range from 80 to 99.8% by weight, based on the mixture used, is used to form a specific intermetallic phase, shaped catalyst bodies obtainable by the process of the invention, a process for producing an active catalyst fixed bed including the shaped catalyst bodies provided herein, the active catalyst fixed beds and also the use of these active catalyst fixed beds for the hydrogenation of organic hydrogenatable compounds or for formate degradation.