Zeolite Solid Acid Catalyst for Refining Lifespan
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Solution Overview
Problem
Catalyst structural bodies in petroleum refining processes face issues with catalyst particle aggregation and reduced lifespan due to forces and heat from reformed materials, leading to frequent replacement and resource inefficiency, and zeolite-based solid acid catalysts suffer from deactivation over time due to aluminum element removal and coke deposition.
Innovation Solution
A functional structural body comprising a zeolite-type compound with interconnected channels and embedded solid acid nanoparticles, where the nanoparticles are larger than the channel diameter but smaller than the enlarged pore diameter, preventing aggregation and maintaining catalytic activity over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If catalyst particles are supported on or near the surface of the support, then catalytic activity is initially high, but catalyst particles move and aggregate due to forces and heat from fluid flow, reducing lifespan
Solution Approach 1:
The catalyst particles are embedded within the porous interior of the support material, nesting the catalytic function inside the structural matrix. This internal positioning prevents particle movement and aggregation while maintaining catalytic activity through the porous network, resolving the contradiction between reliability and manufacturing complexity
Solution Approach 2:
The support material utilizes its porous structure to host catalyst particles within the pore network. The pores provide a confined environment that prevents particle migration while allowing reactant access, thereby extending catalyst lifespan without requiring complex external positioning mechanisms
2Reliability
If catalyst particles are embedded deep within the support structure, then particle aggregation is prevented, but access to catalyst active sites may be reduced
Solution Approach 1:
The porous structure of the support material creates a network of channels and cavities that allow reactants to diffuse throughout the interior where catalyst particles are embedded. This ensures that catalyst particles positioned deep within the structure remain accessible to reactants, maintaining high catalytic activity while preventing aggregation
Solution Approach 2:
The catalyst particles are distributed throughout the three-dimensional porous network of the support rather than being confined to a two-dimensional surface. This dimensional transition allows particles to be embedded within the bulk structure while maintaining accessibility through the volumetric pore network, balancing stability and productivity
3Productivity
If solid acid catalysts are used in petroleum refining, then catalytic cracking efficiency is improved, but aluminum element removal and coke deposition cause deactivation over time
Solution Approach 1:
The catalyst structure utilizes parameters of the porous network (pore size, surface area, volume) to create an environment that mitigates deactivation. The controlled pore dimensions and high surface area to volume ratio of the embedded particles reduce coke deposition and aluminum leaching, extending catalyst activity duration while maintaining cracking efficiency
Solution Approach 2:
The system combines the solid acid catalyst material with the porous support structure to create a composite catalyst system. This composite structure provides both the catalytic activity needed for cracking and the structural framework that prevents deactivation, achieving both high productivity and extended duration of action
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 solution extends the lifespan of the catalyst by preventing aggregation and maintaining catalytic activity, reducing the need for frequent replacement and promoting resource savings, while also allowing for stable operation in petroleum refining processes without the need for hydrogen.
Implementation Method 1
a functional structural body comprising a zeolite-type compound with interconnected channels and embedded solid acid nanoparticles
Data Source
AI summary
A functional structural body that can realize a prolonged life time by suppressing the decrease in function and that can fulfill resource saving without requiring a complicated replacement operation is provided. A functional structural body includes a skeletal body of a porous structure composed of a zeolite-type compound; and at least one solid acid present in the skeletal body, the skeletal body has channels connecting with each other, and the solid acid is present at least in the channels of the skeletal body.