Silica-Phosphate Catalyst Mechanical Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Silica-based catalysts face challenges in mechanical strength and resistance due to their physical integrity issues, making them unsuitable for long-term use in industrial processes, particularly in catalytic reactors where they are exposed to crushing, attrition, and pressure variations.
Innovation Solution
A novel material comprising a mixture of precipitated silica, colloidal silica, and potassium or cesium phosphate salts, formed into shape through a process involving mixing, extrusion, and optional hydrothermal treatment, which enhances mechanical strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If silica-based catalysts are used in conventional extrusion equipment, then the catalyst can be formed into shape, but the mechanical strength and physical integrity are insufficient to withstand crushing, attrition, and pressure variations
Solution Approach 1:
The patent uses a composite material system consisting of silica support combined with binder materials (such as alumina, silica-alumina, or other ceramic binders) to create a mechanically stronger catalyst formulation. This composite approach allows the catalyst to maintain its shaped form while withstanding the mechanical stresses of industrial processing including crushing, attrition, and pressure variations in catalytic reactors
2Reliability
If silica-based catalysts are used in industrial processes, then the catalytic function is achieved, but the physical integrity deteriorates under crushing, attrition, and pressure variations
Solution Approach 1:
The invention employs composite materials combining silica with binder substances to create a catalyst that maintains both its catalytic effectiveness and physical integrity. The binder component provides mechanical strength and structural stability, allowing the catalyst to withstand industrial processing conditions while maintaining its active sites for catalysis
Solution Approach 2:
The patent modifies the physical and chemical parameters of the catalyst formulation by adjusting the composition ratios of silica to binder materials, optimizing the balance between catalytic activity and mechanical strength. This parameter optimization ensures the catalyst maintains sufficient physical integrity under industrial operating conditions while preserving its catalytic function
3Ease of manufacture
If conventional silica extrusion methods are used, then the production process is simple, but the resulting catalyst lacks sufficient mechanical strength for long-term industrial use
Solution Approach 1:
The patent maintains the simplicity of the extrusion manufacturing process while improving mechanical strength by formulating a composite catalyst material. The mixture of silica and binder materials can be directly extruded using conventional equipment, eliminating the need for complex manufacturing steps while producing a mechanically robust catalyst suitable for long-term industrial application
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 resulting material exhibits improved mechanical strength, allowing it to withstand the demands of industrial processes and maintain effectiveness over long periods, particularly when used as a catalyst for converting lactic acid to acrylic acid.
Implementation Method 1
a step of mixing at least one precipitated silica powder and at least one colloidal silica sol with at least one powder of at least one potassium phosphate salt and/or at least one cesium phosphate salt
Implementation Method 2
a step of preparing calcined extrudates and optionally a final hydrothermal treatment step
Implementation Method 3
The novel material is useful as a catalyst for the conversion of lactic acid to acrylic acid
Data Source
AI summary
This disclosure relates to a novel material based on potassium phosphate salt or cesium phosphate salt and silica, comprising at least one source of silica formed into shape with at least one powder of a potassium phosphate or cesium phosphate salt and the use of this material for the preparation of acrylic acid. The disclosure also relates to a process for preparing said material, comprising at least one step of mixing at least one powder of at least one source of silica with at least one powder of at least one potassium phosphate or cesium phosphate salt and at least one solvent, a step of forming into shape preferably by extrusion of the mixture obtained on conclusion of the mixing step and a step of preparing calcined extrudates and optionally a final hydrothermal treatment step.