Vapor-Phase Organic Compound Transfer to Porous Catalyst Supports

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Solution Overview

Problem

Conventional processes for adding organic compounds to hydrotreating catalysts require impregnation steps with solvents, leading to high costs, energy consumption, and safety risks due to the need for drying and potential decomposition of additives at high temperatures.

Innovation Solution

A process where the porous catalyst support and organic compound are brought together in a gaseous state without physical contact, at a temperature below the compound's boiling point, allowing for efficient transfer of the organic compound into the support without the need for solvent-based impregnation and subsequent drying.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional impregnation with solvent is used, then homogeneous distribution of organic compound is achieved, but large amounts of organic compound or solvent are required and additional drying step is needed

Engineering Contradiction:

Improvehomogeneous distributionVSAvoidamount of organic compound

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The patent uses vaporization of the organic compound to transfer it from liquid to gaseous phase, allowing the compound to penetrate the porous support without requiring large amounts of liquid impregnation solution. The vapor phase enables uniform distribution throughout the support structure while minimizing the total quantity of organic compound needed.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The patent replaces the mechanical impregnation process (liquid filling of pores) with a thermal vaporization process. Instead of forcing liquid organic compound into the porous structure mechanically, the compound is vaporized and allowed to deposit uniformly on the support through thermal energy, eliminating the need for large volumes and subsequent drying.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If conventional impregnation with solvent is used, then homogeneous distribution of organic compound is achieved, but additional energy-consuming drying step is required

Engineering Contradiction:

Improvehomogeneous distributionVSAvoidenergy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent employs phase transition from liquid to vapor and then to deposited solid phase, eliminating the intermediate liquid saturation step that requires energy-intensive drying. The vapor-phase deposition allows the organic compound to transition directly to the desired solid state on the support without requiring removal of large amounts of solvent through heating.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The patent substitutes the thermal drying process with a vapor-phase deposition process. Instead of impregnating with liquid and then applying heat to evaporate solvent, the organic compound is vaporized and deposited directly, replacing the two-step liquid-phase process with a more energy-efficient vapor-phase process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If heat treatment at temperature above boiling point is used, then organic compound is transferred to porous solid, but risk of fire and decomposition of additive occurs

Engineering Contradiction:

Improvetransfer efficiencyVSAvoidsafety and compound integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent changes the temperature parameter to remain below the boiling point of the organic compound throughout the process. By maintaining temperatures in the range of 50-200°C (below boiling points of typical organic additives), the process achieves sufficient vapor pressure for transfer while avoiding fire hazards and thermal decomposition that would occur at higher temperatures.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a carrier gas as an intermediary medium to transport the vaporized organic compound from the liquid phase container to the porous support. This intermediary approach allows transfer at lower temperatures without direct heating of the support above the compound's boiling point, eliminating fire risks and decomposition while maintaining transfer efficiency through the carrier gas flow.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 reduces energy consumption, minimizes safety risks, and ensures effective distribution of the organic compound, maintaining its integrity and enhancing catalyst performance without the need for additional drying steps.

Implementation Method 1

at a temperature below the boiling point of the organic compound and under pressure and time conditions such that a fraction of said organic compound is transferred gaseously to the porous solid

Methodology Applied

Scientific EffectVapor pressure: Vapour Pressure

Data Source

PatentUS11236275B2Method for adding an organic compound to a porous solid in the gaseous phase

Publication Date: 2022.02.01 IFP ENERGIES NOUVELLES

AI summary

The invention relates to a process for adding an organic compound to a porous solid wherein the porous solid and the organic compound in the liquid state are brought together simultaneously, without physical contact between the solid and the organic compound in the liquid state, at a temperature below the boiling point of the organic compound and under pressure and time conditions such that a fraction of said organic compound is transferred gaseously to the porous solid.