Uniformly Dispersed Metal Catalyst via Sulfur Gradient
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Solution Overview
Problem
Existing metal loaded catalysts face challenges in achieving uniform dispersion of catalytic metals throughout the catalyst carrier, leading to reduced catalytic activity and increased risk of deactivation due to sintering or coking, as the metals tend to accumulate on the outer shell rather than being evenly distributed inside the carrier.
Innovation Solution
The method involves uniformly dispersing sulfur or a sulfur compound throughout the catalyst carrier cross-section, allowing for the uniform loading of catalytic metals like platinum, ensuring they are dispersed throughout the carrier, thereby enhancing their distribution and activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the catalyst carrier is impregnated with a solution of catalyst metal compound, then the catalyst metal is loaded on the carrier, but the metal tends to accumulate on the outer shell rather than being uniformly dispersed throughout the carrier
Solution Approach 1:
The patent applies local quality by treating different regions of the catalyst carrier differently - the outer shell and inner core receive different amounts of sulfur treatment. This creates spatial variation in metal adsorption capacity, allowing uniform distribution throughout the carrier cross-section while controlling overall metal loading amount.
Solution Approach 2:
The patent changes the chemical parameter of the carrier by introducing sulfur compounds that modify the surface properties and adsorption characteristics of different regions. This parameter change (sulfur content distribution) controls the metal distribution pattern, transforming the egg-shell structure into a uniform distribution structure.
2Reliability
If a high amount of active metal is loaded on the outer shell of the catalyst particles, then the catalytic activity increases, but the density of active metal particles increases leading to insufficient dispersion and catalyst deactivation due to sintering or coking
Solution Approach 1:
The patent creates local quality differences in sulfur distribution within the carrier structure, with higher sulfur content in outer regions and lower in inner regions. This spatial variation in sulfur content controls metal particle dispersion, preventing excessive density and sintering while maintaining high catalytic activity through optimized local metal loading.
Solution Approach 2:
The patent performs preliminary action by pre-treating the carrier with sulfur compounds before metal loading. This preliminary sulfur treatment creates a controlled adsorption landscape that guides subsequent metal distribution, preventing aggregation and sintering by ensuring optimal metal spacing from the outset.
3Area of stationary object
If the catalyst metal is uniformly dispersed throughout the carrier, then the surface area utilization improves, but it is difficult to achieve thorough uniform dispersion and concentration gradients may appear toward the center of catalyst particles
Solution Approach 1:
The patent applies local quality by creating a gradient sulfur distribution within the carrier - higher sulfur concentration in outer shell regions and lower concentration toward the center. This spatially varying sulfur content controls metal adsorption, achieving uniform metal distribution throughout the carrier cross-section by compensating for diffusion limitations and concentration gradients.
Solution Approach 2:
The patent uses sulfur compounds as an intermediary substance that mediates between the impregnation solution and the carrier structure. The sulfur compounds create intermediate adsorption sites that guide metal compound distribution, enabling uniform metal dispersion throughout the carrier by acting as a distributing intermediary during the impregnation process.
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 results in a highly dispersed metal catalyst with improved catalytic activity, selectivity, and extended lifespan, as the metals are evenly distributed, reducing the likelihood of deactivation and optimizing the use of the catalyst's surface area.
Implementation Method 1
since the adsorbability of a platinum compound to the alumina carrier is high, the platinum compound is adsorbed and fixed as it is to the outer shell part of the alumina carrier
Implementation Method 2
the obtained porous catalyst carrier is impregnated with a solution of a catalyst metal compound
Implementation Method 3
the dried matter is calcined, e.g., at 350 to 800°C for 0.5 to 24 hours to form a calcined matter loading the catalyst metal compound
Implementation Method 4
the obtained calcined matter loading the catalyst metal compound is subjected to hydrogen reduction, e.g., at 250 to 800°C for 0.5 to 24 hours
Data Source
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AI summary
Provided are: a uniformly, highly dispersed metal catalyst including a catalyst carrier and a catalyst metal being loaded thereon dispersed throughout the carrier, the uniformly, highly dispersed metal catalyst having excellent performances with respect to catalytic activity, selectivity, life, etc.; and a method of producing the same. The uniformly, highly dispersed metal catalyst includes a catalyst carrier made of a metal oxide and a catalyst metal having catalytic activity, the catalyst metal being loaded on the catalyst carrier, in which the catalyst carrier is a sulfur-containing catalyst carrier having sulfur or a sulfur compound almost evenly distributed throughout the carrier and the catalyst metal is loaded on the sulfur-containing catalyst carrier in a substantially evenly dispersed manner over the entire carrier substantially according to the distribution of the sulfur or the sulfur compound.