Shell Catalyst Production in Single Coating Device
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Solution Overview
Problem
Current methods for producing shell catalysts for vinyl acetate monomer (VAM) and allyl acetate are time-consuming, costly, and result in significant noble metal loss due to mechanical stress and inefficient handling processes, leading to suboptimal activity and selectivity.
Innovation Solution
A method where all production steps are conducted in a single device, minimizing mechanical stress and noble metal abrasion, with the support bodies remaining static during reduction and drying, and applying alkali acetate before metal precursor compounds to enhance metal distribution and retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If support bodies are transferred between multiple devices for different production steps, then each production step can be performed with specialized equipment, but the mechanical stress and noble metal abrasion increase significantly
Solution Approach 1:
The patent combines multiple production steps (coating, drying, reduction, and alkali acetate application) into a single integrated device. The support bodies remain in the same device throughout the entire production process, eliminating the need for transfer between multiple specialized devices. This merging approach maintains production process capability while eliminating mechanical stress from repeated handling and transfer operations, thereby preventing noble metal abrasion and loss.
Solution Approach 2:
The single device used in the patent performs multiple functions: it serves as a coating device for applying metal precursor compounds, a drying device for removing solvent, a reduction device for converting metal oxides to elemental metals, and an application device for alkali acetate. This multi-functional device eliminates the need for multiple specialized devices while maintaining all necessary production capabilities, thereby reducing mechanical stress and noble metal loss.
2Ease of manufacture
If support bodies are repeatedly handled and transferred between devices, then production steps can be optimized independently, but the production time increases due to multiple introduction and removal operations
Solution Approach 1:
The patent merges multiple production steps into a single continuous operation within one device. The support bodies undergo coating, drying, reduction, and alkali acetate application without being removed from the device between steps. This eliminates the time-consuming introduction and removal operations that would occur if separate devices were used for each step, significantly reducing total production time.
Solution Approach 2:
The production process in the patent proceeds continuously within a single device without interruption or transfer of support bodies between steps. The coating, drying, reduction, and alkali acetate application occur in sequence without breaking the continuous action, eliminating idle time associated with transferring support bodies between multiple devices and optimizing overall production efficiency.
3Ease of manufacture
If conventional multi-device production methods are used, then each step can be controlled independently, but the noble metal yield decreases due to losses during decanting and handling
Solution Approach 1:
The patent combines all production steps into one integrated device, eliminating the decanting and transfer operations between multiple devices that cause noble metal loss. The support bodies remain in the same device throughout coating, drying, reduction, and alkali acetate application, preventing mechanical stress and abrasion that would otherwise lead to noble metal yield decreases.
Solution Approach 2:
The patent eliminates the harmful effect of mechanical stress from repeated handling by using a single-device approach. By removing the decanting and transfer operations that cause noble metal abrasion and loss, the process converts what would be a harmful multi-device approach into a beneficial single-device approach that maximizes noble metal yield while maintaining all necessary production capabilities.
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 reduces production time and noble metal loss, resulting in a shell catalyst with higher activity and selectivity, achieving a noble metal yield of up to 97% compared to conventional methods, which typically yield around 94%.
Implementation Method 1
The metal components of the precursor compounds are then converted to the elemental metals in a reduction furnace
Implementation Method 2
the support body is dried in a drying device
Data Source
Figure 1~2
AI summary
The present invention relates to a method for producing a shell catalyst, characterized by performing the steps of applying the catalytically active metals to a support, drying and reduction in a coating device, without removing the supports from the coating device during these steps. The present invention also relates to a shell catalyst that can be obtained by the method according to the invention as well as the use of the shell catalyst produced using the method according to the invention for producing alkenyl carboxylic acid esters, in particular vinyl acetate monomer (VAM) from ethylene and allyl acetate monomer from propylene by means of oxy-acetylation.