Slurry Catalyst Composition for Methanol Synthesis Stability
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Solution Overview
Problem
Current catalysts used in slurry bed reactors for synthesizing methanol and dimethyl ether face challenges with stability, rheological behavior, and wear resistance, with CuZnAl catalysts having good activity but poor rheological behavior and wear resistance, and CuZr catalysts having good rheological behavior but poor activity.
Innovation Solution
A slurry catalyst with the composition CuZnMZrAl, where M is a promoter selected from specific metals, is prepared using a method involving multistep feeding of raw materials, azeotropic distillation, and heat treatment in a controlled atmosphere to enhance stability, activity, and rheological behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If CuZnAl catalyst is used, then activity is improved, but rheological behavior and wear resistance deteriorate
Solution Approach 1:
The patent applies composite materials by combining CuZnAl and CuZr catalysts into a single composite catalyst system. The CuZnAl component provides high activity for methanol and dimethyl ether synthesis, while the CuZr component contributes excellent rheological behavior and wear resistance. This composite structure allows both catalysts to work synergistically, resolving the contradiction between activity and reliability.
2Reliability
If CuZr catalyst is used, then rheological behavior and wear resistance are improved, but activity deteriorates
Solution Approach 1:
The patent uses composite materials to combine the advantages of CuZr (excellent rheological behavior and wear resistance) with CuZnAl (high activity). The composite catalyst maintains the structural stability and wear resistance of CuZr while incorporating the high activity of CuZnAl, thus resolving the contradiction between reliability and productivity.
3Reliability
If gel surface treatment and heat treatment are extended, then catalyst stability is improved, but preparation complexity increases
Solution Approach 1:
The patent applies preliminary action by performing gel surface treatment and extended heat treatment during the catalyst preparation phase. The gel is treated with specific surface treatments before calcination, and the heat treatment is conducted in a controlled atmosphere (N2/O2 mixed gas) at optimized temperatures. This preliminary preparation ensures high catalyst stability and performance before the catalyst is put into service, resolving the contradiction between stability and preparation complexity.
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 catalyst maintains stability and high selectivity for 1000 hours with low viscosity and strong wear resistance, maintaining particle size and shape during reaction, and is suitable for various slurry bed reactors.
Implementation Method 1
soaking thus obtained gel in an organic solvent such as an alcohol, a ketone, an ester, or the like
Implementation Method 2
heat treating it at an atmosphere of mixed N2 and O2 within a certain temperature range
Implementation Method 3
The method comprises firstly preparing a gel containing a catalyst comprised of CuZnAl, CuZr and CuTi, soaking thus obtained gel in an organic solvent
Data Source
AI summary
The present invention provides a slurry catalyst and a method for preparing the same, and belongs to the technical field of preparing catalyst. Particularly, the present invention provides a slurry catalyst directly used in a slurry bed reactor for synthesizing methanol and dimethyl ether and a method for preparing the same, which uses the complete liquid phase preparation from solution to slurry without the conventional slurry-producing process of firstly forming a solid catalyst and dispersing it into an inert medium after crushing and milling. This catalyst mainly comprises Cu, Zn, Al and Zr, wherein atomic ratios of each of components are Cu/Zn/(Al+Zr)=1/0.1-5/0.15-15 and Zr/Al=1:1.0-1:30, and one or two selected from the group consisting of lanthanide metals, Mn, Mo, Si, V, W, Cr, Mg, Ni, K, Pd, Rh, Ru, Re, Pt and Sr is used a promoter. The catalyst prepared in the present invention has the advantages of good stability, high selectivity of alcohol and ether, good rheological behavior and strong wear resistance.