Supported Catalyst Synthesis Device Pressure Control

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Solution Overview

Problem

Existing methods for synthesizing supported catalysts with solid solution fine particles struggle to achieve particle sizes of 0.5 to 2 nm, and they face challenges in stable mass production due to issues with particle coarsening and the introduction of support particles into the synthesis apparatus.

Innovation Solution

A supported catalyst synthesis device is designed with a mechanism to control pressure at the point where liquids containing a reducing agent, metal elements, and support particles are joined, allowing for the stable synthesis and collection of supported catalysts with controlled particle size and flow conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a batch-wise synthesis is carried out by gradually adding noble metal salt solution to high boiling point reducing agent heated to high temperature, then the synthesis can proceed, but the particle size becomes coarse making it difficult to mass-produce alloys having small particle size

Engineering Contradiction:

Improveparticle sizeVSAvoidmass production capability

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces the conventional batch-wise mechanical mixing method with a continuous flow reaction system. Liquid containing noble metal salt and liquid containing reducing agent are mixed in a microreactor under continuous flow conditions, enabling precise control of particle size while maintaining mass production capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the reaction parameters by using a microreactor system with controlled residence time, temperature, and pressure. These parameter changes enable the synthesis of fine particles with controlled size distribution while maintaining continuous production capability.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If support particles are introduced into the apparatus using conventional methods, then the supported catalyst can be synthesized, but the support particles are retained in and block the back pressure valve making it impossible for the synthesis reaction to proceed at desired flow velocity, pressure, and temperature

Engineering Contradiction:

Improveintroduction of support particlesVSAvoidflow velocity, pressure, and temperature control

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent extracts the support particle introduction step from the main reaction flow by using a separate injection system. Support particles are introduced through a dedicated port into the liquid flow, preventing them from blocking the back pressure valve while still enabling their incorporation into the catalyst synthesis.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses liquid as an intermediary medium to transport support particles into the reaction zone. The particles are carried by the liquid flow into the microreactor, allowing smooth integration without direct contact with the back pressure valve.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If the particle size of solid solution fine particles is reduced to 0.5 to 2 nm, then the surface area increases improving catalytic activity, but the reducing power required to reduce the particle size is insufficient requiring further increased reducing power

Engineering Contradiction:

Improveparticle sizeVSAvoidreducing power

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent changes the reducing power parameter by using a microreactor system with controlled temperature and pressure conditions. The continuous flow of reducing agent through the microreactor provides sufficient reducing power to achieve particle sizes of 0.5 to 2 nm while maintaining energy efficiency.

Inventive Principle:

Principle #35Parameter changes

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 device effectively reduces the particle size of single-metal or solid solution fine particles to 0.5 to 2 nm and enables stable mass production of supported catalysts, overcoming previous limitations in particle size and production stability.

Implementation Method 1

a reaction unit (D) that joins flows of a liquid containing a reducing agent, a liquid containing elements to constitute single-metal fine particles or solid solution fine particles to be supported, and a liquid containing support particles

Methodology Applied

Scientific EffectChemical reduction: Reduction

Data Source

PatentUS12330145B2Supported catalyst synthesis device and fine particle synthesis device

Publication Date: 2025.06.17 FURUYA KINZOKU KK

AI summary

The supported catalyst synthesis device according to the present disclosure includes a first source for a liquid containing a reducing agent; a second source for a liquid containing elements to constitute single-metal fine particles or solid solution fine particles to be supported; a third source for a liquid containing support particles; a reaction unit that joins flows of these liquids; a liquid feed route connecting between the first source and the reaction unit; a liquid feed route connecting between the second source and the reaction unit; a liquid feed route connecting between the third source and the reaction unit; and a collection unit, connected to the reaction unit via a pipe, to collect a produced reaction product, and further includes a pressure adjustment mechanism connected to the collection unit.