Method and device for producing shell catalysts

Patent metadata

Field	Value
Publication number	US-9737886-B2
Application number	US-201414785629-A
Country	US
Kind code	B2
Filing date	Apr 15, 2014
Priority date	Apr 19, 2013
Publication date	Aug 22, 2017
Grant date	Aug 22, 2017

Abstract

Disclosed herein is a process and an apparatus for producing coated catalysts. A process of the present disclosure includes providing a composition containing a liquid and a catalytically active material and/or a precursor thereof in a stock vessel, providing a support material in a vessel which is rotatable about a longitudinal axis, transporting the composition from the stock vessel through a first conduit to a spray nozzle, transporting a propellant fluid through a second conduit to the spray nozzle, atomizing the composition and propellant fluid in the nozzle to produce an aerosol that flows into the vessel and impregnates the support material present therein, heating the vessel so the liquid present in the aerosol evaporates from the support material and the finely divided support material which has been treated with catalytically active material and/or a precursor thereof is dried, and discharging the vaporized liquid from the vessel.

First claim

The invention claimed is:

1. A process for producing coated catalysts, comprising:
a) providing a composition containing a liquid and at least one of a catalytically active material or a precursor thereof in a stock vessel;
b) providing a support material in a vessel which is rotatable about a longitudinal axis;
c) transporting the composition from the stock vessel through a first conduit to a spray nozzle;
d) transporting a propellant fluid through a second conduit to the spray nozzle;
e) atomizing the composition and propellant fluid in the nozzle to produce an aerosol which flows into the vessel and impregnates the support material present therein;
f) heating the vessel so that the liquid present in the aerosol evaporates from the support material and the support material which has been treated with catalytically active material and/or a precursor thereof is dried; and
g) at least one of discharging or extracting the vaporized liquid from the vessel.

2. The process of claim 1 , wherein the spraying fluid is an inert gas which is heated before transport through the second conduit and/or during transport through the second conduit.

3. The process of claim 1 , wherein the composition containing a liquid and a catalytically active material and/or a precursor thereof is heated in the stock vessel.

4. The process of claim 1 , wherein the composition containing a liquid and a catalytically active material and/or a precursor thereof is pushed from the stock vessel into the first conduit by introduction of a propellant fluid into the stock vessel or by means of a metering pump.

5. The process of claim 1 , wherein the composition containing a liquid and a catalytically active material and/or a precursor thereof in the stock vessel is a solution or dispersion of a catalytically active material and/or a precursor thereof in the liquid, where the solution can be stirred in the stock vessel.

6. The process of claim 1 , wherein the first conduit runs within the second conduit and a concentric hollow space through which the propellant fluid is supplied to the nozzle is formed between the exterior wall of the first conduit and the interior wall of the second conduit.

7. The process of claim 1 , wherein the nozzle is a supersonic expansion nozzle.

8. The process of claim 1 , wherein the support material in the rotatably mounted vessel is an inorganic support material.

9. The process of claim 1 , wherein the axis of rotation of the rotatable vessel runs in the longitudinal direction of this vessel and is inclined from the horizontal by an angle of from 20° to 75°.

10. The process of claim 1 , wherein functional internals which serve for mixing of the support material are present in the interior of the rotatable vessel.

11. The process of claim 1 , wherein the impregnated support material is taken from the vessel after evaporation of the liquid and is subjected to calcination at temperatures of from 500 to 900° C.

12. A process for producing coated catalysts, comprising:
i) providing at least one of a solution or dispersion of at least one of a catalytically active material or a precursor thereof in a liquid, which is initially placed in a stock vessel;
ii) providing a support material in a vessel which is rotatable about a longitudinal axis;
iii) introducing an inert gas into the stock vessel so that the solution or dispersion present therein is conveyed into an inner capillary and at its end enters a supersonic expansion nozzle;
iv) introducing a propellant fluid into an outer capillary in which the inner capillary runs so as to define a concentric hollow space through the two capillaries in which the propellant fluid moves and at the outlet end of which the propellant fluid enters the supersonic expansion nozzle;
v) atomizing the propellant fluid and the solution or dispersion in the supersonic expansion nozzle so as to produce an aerosol which flows into the vessel, with widening of the jet of the aerosol occurring;
vi) contacting the aerosol with the support material in the vessel so that the aerosol impregnates the support material and the aerosol deposits on the surface and/or in layers close to the surface of the support material;
vii) heating of the vessel so that the liquid present in the aerosol evaporates from the support material; and
viii) at least one of discharging or extracting the vaporized liquid from the vessel.

13. The process of claim 12 , wherein at least one of the propellant fluid or the composition in the stock vessel are heated to such a temperature that part of the liquid present in the aerosol evaporates in the vessel even before impingement of the aerosol onto the support material, so that the penetration depth of the aerosol into the support material can be set in a targeted manner.

14. The process of claim 1 , wherein the rotatable vessel rotates continuously about an axis running in the longitudinal direction of the spray nozzle at a rotational speed v=3-300 min −1 .

15. The process of claim 1 , wherein the spraying rate d/dt m s =m s for the composition containing the liquid and the catalytically active material and/or a precursor thereof is set so that a functional relationship is established between spraying rate m s and evaporation rate d/dt m v ={dot over (m)} v of the liquid, where {dot over (m)} s =a·{dot over (m)} v and 0.5<a<3.5.

16. An apparatus for applying a catalytically active material and/or a precursor thereof to support material, which contains the following elements:
A) stock vessel for a composition containing a liquid and a catalytically active material and/or a precursor thereof;
B) vessel which is rotatable about a longitudinal axis for a support material;
C) spray nozzle which opens into the rotatable vessel;
D) first conduit which is arranged between stock vessel and spray nozzle and serves for transport of the composition from the stock vessel to the spray nozzle; and
E) second conduit which serves for transport of a propellant fluid to the spray nozzle.

17. The apparatus of claim 16 , wherein the stock vessel is equipped with a stirring device.

18. The apparatus of claim 16 , wherein the stock vessel and the rotatable vessel are equipped with heating devices.

19. The apparatus of claim 16 , wherein a stock vessel equipped with a heating device is provided for a propellant fluid and is connected to the second conduit and/or in that the second conduit is equipped with a heating device.

20. The apparatus of claim 16 , wherein the first conduit runs within the second conduit so that a concentric hollow space is formed between the exterior wall of the first conduit and the interior wall of the second conduit.

21. The apparatus of claim 20 , wherein the concentric hollow space has a gap diameter which at a given gas admission pressure increases the flow velocity of the propellant fluid flowing in the hollow space by a multiple and in that the end of the second conduit which points in the direction of the rotatable vessel has a logarithmic opening so that a supersonic nozzle is formed.

22. The apparatus of claim 16 , wherein the nozzle is a supersonic nozzle.

23. The apparatus of claim 20 , wherein the end of the first conduit which opens in the direction of the vessel is movable in the direction of the longitudinal axis and in that the exterior wall of the second conduit is widened at the end opening in the direction of the vessel so that a nozzle in which the liquid stream exiting from the end of the

Assignees

• Thyssenkrupp Ind Solutions Ag

Inventors

• Noll Oliver
• Walther Guido
• Evert Sigrid
• Martin Andreas

Classifications

• B01J37/0223

  by rotation · CPC title

• B01J37/0211

  using a colloidal suspension · CPC title

• B01J37/0201 Primary

  Impregnation · CPC title

• B01J37/0054

  Drying of aerosols · CPC title

• B01J37/08

  Heat treatment {(B01J37/0009, B01J37/0018 take precedence)} · CPC title