Zeolite Catalyst Spherical Shape and Void Reduction
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Solution Overview
Problem
Zeolite-based catalysts for fluidized bed reactions face challenges with mechanical strength due to uneven surfaces and non-spherical shapes, leading to reduced fluidity and increased attrition, which affects their performance in maintaining a stable fluidized state and propylene production efficiency.
Innovation Solution
A zeolite-containing catalyst with a reduced void content, an average particle diameter of 20 to 300 µm, and a void area ratio of 30% or less, produced by spray drying an acidic raw material slurry containing zeolite and colloidal silica with a specific water-soluble compound, resulting in a more spherical and mechanically strong catalyst.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If zeolite is molded with support component using conventional methods (spray drying buffered silica sol), then catalyst can be produced, but the catalyst particles exhibit uneven surfaces and non-spherical shapes leading to poor fluidity and low mechanical strength
Solution Approach 1:
The invention changes the chemical composition parameters of the silica sol by using colloidal silica instead of buffered silica sol, and controls the pH within 2-7 during spray drying. This parameter change results in catalyst particles with smooth surfaces and spherical shapes, improving both fluidity and mechanical strength while maintaining catalytic activity
2Strength
If zeolite is molded with support component using conventional methods, then catalyst can be produced, but the catalyst exhibits low mechanical strength and high attrition during fluidized bed reaction
Solution Approach 1:
The invention creates a composite material structure where zeolite particles are embedded in a silica matrix formed from colloidal silica. The silica matrix acts as a binder that provides mechanical strength and reduces attrition, while the zeolite maintains its catalytic function. This composite structure significantly improves mechanical strength and reduces attrition loss during fluidized bed operation
3Reliability
If conventional catalyst production methods are used, then catalyst can be manufactured, but the void content is high resulting in poor mechanical strength and reduced catalyst performance
Solution Approach 1:
The invention performs preliminary action by forming a dense silica matrix structure before the final catalyst formation. The colloidal silica creates a compact framework that minimizes void spaces, and this pre-formed structure provides mechanical strength and improves catalyst performance during subsequent fluidized bed reactions
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 exhibits excellent shape, fluidity, and mechanical strength, enhancing its performance in fluidized bed reactions and propylene production by minimizing attrition and maintaining a stable fluidized state over extended periods.
Implementation Method 1
spray drying the slurry to produce a hydrocarbon conversion catalyst
Implementation Method 2
the molded product is calcined
Data Source
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AI summary
The present invention provides a zeolite-containing catalyst having excellent shape, fluidity and mechanical strength as a catalyst for a fluidized bed reaction. The present invention provides a zeolite-containing catalyst which is a particulate catalyst containing zeolite and silica, wherein the catalyst has an average particle diameter of 20 to 300 µm and the ratio of the void area in the cross-section of the particle is 30% or less relative to the cross-section area of the particle.