Shell Catalyst Production via Supersonic Spray Impregnation
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Solution Overview
Problem
Existing methods for producing coated catalysts face challenges such as incomplete surface deposition of catalytically active materials, instability of multi-metal precursor solutions, and inefficient spraying processes, leading to reduced catalyst effectiveness and increased material consumption.
Innovation Solution
A process involving a composition of catalytically active material and/or precursors, combined with a propellant fluid, is atomized using a supersonic nozzle to achieve precise impregnation of carrier materials, ensuring homogeneous distribution and rapid evaporation, thereby minimizing penetration depth and optimizing catalyst loading on the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional spray impregnation processes are used to deposit catalytically active material on support surfaces, then larger batches can be processed with reasonable uniformity, but the active component penetrates into the pores of the support material rather than remaining on the surface
Solution Approach 1:
The invention segments the impregnation process into multiple stages: initial rapid surface deposition followed by controlled pore penetration. This is achieved by using a spray impregnation process that first saturates the surface, then allows gradual penetration into pores, ensuring the active component is primarily located on the surface where it is most effective.
Solution Approach 2:
The support material is pre-treated or pre-positioned to optimize surface reception of the active component. The spray impregnation process is designed to first establish a surface layer of active material before any significant penetration occurs, ensuring optimal surface coverage is achieved before pore infiltration begins.
2Quantity of substance
If the catalytically active component is deposited deep within the pores of the support material, then more material can be accommodated, but the active component cannot diffuse towards or away from the reaction site effectively
Solution Approach 1:
The invention applies local quality by creating different concentrations and distributions of the active component at different locations within the support material. The surface region contains a high concentration of active material for immediate reaction access, while deeper pore regions contain progressively less, optimized for gradual release and diffusion to the surface where reactions occur.
3Manufacturing precision
If sequential impregnation is used to apply multiple metal components, then each component can be deposited separately, but the process requires multiple steps and increases production time
Solution Approach 1:
The invention merges multiple impregnation steps into a single spray impregnation process by using a multi-component precursor solution. Multiple metal components are dissolved or dispersed together in one liquid medium, allowing simultaneous deposition of all required metal components in the correct proportions during a single spraying operation, thereby maintaining manufacturing precision while dramatically improving productivity.
4Manufacturing precision
If dry impregnation is used to saturate the pore volume of the support, then the active component can be distributed throughout the material, but the liquid composition requires precise control to match the pore volume exactly
Solution Approach 1:
The invention replaces the mechanical/gravitational impregnation method with a spray-based delivery system. Instead of relying on the liquid composition to naturally saturate pore volumes through gravity and capillary action (which requires precise volume matching), the spray system delivers the active component through aerosolization and controlled deposition, allowing precise control of distribution uniformity without needing to precisely match liquid volume to pore volume.
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 enables reproducible, efficient, and cost-effective production of coated catalysts with improved surface distribution of catalytically active materials, reducing material consumption and enhancing catalyst performance by ensuring the catalytically active substances are predominantly deposited on the surface of the carrier material.
Implementation Method 1
Atomization of the composition and propellant fluid in the nozzle, generating an aerosol which flows into the container and impregnates the carrier material therein
Implementation Method 2
Heating of the container (1) so that the liquid contained in the aerosol evaporates from the carrier material
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a method for producing shell catalysts, comprising the following measures: a) providing a composition, containing a liquid and a catalytically active material and/or a precursor thereof in a reservoir, b) providing a carrier material in a container that can be rotated about a longitudinal axis, c) transporting the composition from the reservoir to a spray nozzle through a first line, d) transporting a propellant fluid to the spray nozzle through a second line, e) atomising the composition and the propellant fluid in the nozzle in order to produce an aerosol, which flows into the container and impregnates the carrier material located therein, f) heating the container (1) so that the liquid contained in the aerosol evaporates from the carrier material and the carrier material loaded with the catalytically active material and/or a precursor thereof is dried, and g) conducting or suctioning the evaporated liquid from the container. The invention further relates to a device for loading carrier material with a catalytically active material and/or a precursor thereof. Said device contains the following elements: A) a reservoir for a composition, containing a liquid and a catalytically active material and/or a precursor thereof, B) a container for a carrier material, which container can be rotated about a longitudinal axis, C) a spray nozzle, which opens into the rotatable container, D) a first line, which is arranged between the reservoir and the spray nozzle and which is used to transport the composition from the reservoir to the spray nozzle, and E) a second line, which is used to transport a propellant fluid to the spray nozzle. The method and the device allow an active component or active components to be applied to the carrier material gently and in a controlled manner.