Zinc-Ferrite Catalyst Washing for Butadiene Selectivity
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Solution Overview
Problem
The existing methods for manufacturing catalysts for oxidative dehydrogenation reactions, such as the co-precipitation method, result in the formation of inactive α-Fe2O3 crystal structures, leading to reduced selectivity of 1,3-butadiene and corrosion issues due to residual Cl− ions, and generate excessive wastewater during washing.
Innovation Solution
A method involving a filter press with specific through hole configurations and controlled washing water discharge rates and pressures to improve washing efficiency, reducing waste water generation and optimizing the amounts of Cl− ions and α-Fe2O3 crystals in the catalyst, thereby enhancing the performance of zinc-ferrite based catalysts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the co-precipitation method is used to manufacture ZnFe2O4 catalyst, then the catalyst can be produced, but residual Cl− ions remain causing corrosion problems and α-Fe2O3 crystal structure forms reducing selectivity
Solution Approach 1:
The patent applies preliminary action by performing thorough washing of the catalyst precipitate before drying and firing steps. The washing process uses multiple stages with deionized water to remove Cl− ions and prevent α-Fe2O3 formation before the catalyst undergoes thermal treatment. This preliminary removal of harmful substances prevents corrosion issues and maintains catalyst selectivity.
Solution Approach 2:
The patent converts the harmful effect of α-Fe2O3 formation into a benefit by controlling the washing conditions to prevent its formation in the first place. By optimizing the washing water flow rate and temperature, the process prevents the transformation of ZnFe2O4 into inactive α-Fe2O3, thereby maintaining high catalyst activity and selectivity for 1,3-butadiene production.
2Object-generated harmful factors
If washing is performed to remove Cl− ions and reduce α-Fe2O3, then catalyst performance improves, but large amount of waste water is generated
Solution Approach 1:
The patent applies parameter changes by optimizing the washing water flow rate, temperature, and pH to achieve effective removal of Cl− ions and prevention of α-Fe2O3 formation with minimal water consumption. By controlling these parameters, the process achieves thorough washing while reducing wastewater generation compared to conventional methods.
Solution Approach 2:
The patent implements continuous washing action where washing water is continuously circulated through the catalyst precipitate until the desired level of purification is achieved. This continuous process ensures complete removal of harmful substances while allowing for water recycling and reduction of waste water discharge.
3Productivity
If conventional filter press is used for washing and filtering, then catalyst slurry can be obtained, but washing efficiency is insufficient leading to excessive waste water
Solution Approach 1:
The patent modifies the filter press operation parameters including washing water flow rate, pressure, and temperature to optimize washing efficiency. By controlling these parameters, the process achieves thorough washing of the catalyst precipitate while minimizing water consumption and waste water generation.
Solution Approach 2:
The patent implements feedback control by monitoring the Cl− ion content in the washing water and the catalyst precipitate. Based on this feedback, the washing process is adjusted to achieve optimal removal of harmful substances while minimizing water consumption. The feedback mechanism allows for real-time optimization of washing efficiency and waste water reduction.
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 improves the washing efficiency and reduces wastewater production while enhancing the performance of the zinc-ferrite catalysts by effectively adjusting the amounts of Cl− ions and α-Fe2O3, resulting in higher selectivity and yield of 1,3-butadiene in oxidative dehydrogenation reactions.
Implementation Method 1
obtaining a catalyst slurry by washing and filtering the catalyst co-precipitation solution using a filter press
Implementation Method 2
The amounts of Cl− and α-Fe2O3 need to be adjusted appropriately to manufacture a ZnFe2O4 catalyst suitable for use in the oxidative dehydrogenation reaction of butene
Implementation Method 3
washing water is fed through any one or more of the stock solution through hole and at least one through hole provided in the first quadrant region to the fourth quadrant region, the washing water is discharged
Data Source
AI summary
A method for manufacturing a catalyst for oxidative dehydrogenation reaction, a catalyst for oxidative dehydrogenation reaction, and a method for manufacturing butadiene using the same.