CN102553596B - 一种在金属基板上制备催化剂涂层的方法 - Google Patents

一种在金属基板上制备催化剂涂层的方法 Download PDF

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CN102553596B
CN102553596B CN2010105970684A CN201010597068A CN102553596B CN 102553596 B CN102553596 B CN 102553596B CN 2010105970684 A CN2010105970684 A CN 2010105970684A CN 201010597068 A CN201010597068 A CN 201010597068A CN 102553596 B CN102553596 B CN 102553596B
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metal substrate
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catalyst coat
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CN102553596A (zh
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张忠涛
程易
翟绪丽
金涌
李建忠
王桂芝
张志翔
苑慧敏
王凤荣
徐显明
万书宝
李方伟
马逢伯
魏静
赵吉娜
刘丽军
张大伟
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Tsinghua University
Petrochina Co Ltd
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Abstract

本发明涉及一种在金属基板上制备催化剂涂层的方法；用高温火焰粉末喷枪在金属基板上热喷涂一层α-氧化铝纳米颗粒，温度2500～3500℃，压力0.2-1.2MPa；涂覆铝溶胶，铝溶胶水溶液重量浓度为2～30％，pH为0.5～4；干燥温度为50～150℃，干燥时间为0.5～24小时，焙烧温度为200～1200℃，焙烧时间为0.5～24小时；浸渍活性组分，浸渍温度为20～120℃，时间为0.5～24小时，干燥温度为50～150℃，干燥时间为0.5～24小时，焙烧温度为200～1200℃，焙烧时间为0.5～24小时；本方法适用于各种活性组分催化剂涂层的制备。

Description

一种在金属基板上制备催化剂涂层的方法
技术领域
本发明涉及一种在金属基板上制备催化剂涂层的方法。
背景技术
近年来，微尺度反应器作为一项新兴的技术得到越来越多的认可，DuPont、BASF、Bayer、Degussa等公司一直致力于推动和促进微尺度反应器。微尺度反应器是指反应器内流体流动通道在三维空间的其中一维方向的尺寸在几十微米～几毫米尺度的反应器。这种物理尺寸的减小使得一些物理量的梯度(温度梯度、压力梯度、浓度梯度等)显著增大，从而大幅度提高反应器内的传质、传热效率。除了空间上的限制带来的传递性能的强化外，微尺度反应器还可以作为独立的单元进行并联操作。因此，微尺度反应器的处理能力可以通过增加数目来提高，通过数目的放大实现生产规模的放大，不需要向传统反应器那样通过逐级放大反应设备来实现生产规模的放大，可低成本实现产业化和规模化，也可以进行分散式生产。
由于微尺度反应器操作的要求，催化剂通常需要黏附于反应器壁面形成催化剂薄层。金属基体表面催化剂沉积的方法有很多，包括悬浮液沉积、溶胶-凝胶沉积、电泳沉积和电镀沉积等等。由于金属和催化剂的热膨胀系数存在较大的差别，在长时间的高温操作和反复的升温降温过程中，沉积到金属基体表面的催化剂层将出现侵蚀和脱落。尽管国内以及国际在金属基体上的催化剂沉积领域已经进行了大量的研究工作，但是催化剂层的脱落问题一直未能得到很好的解决，因此也限制了高温微尺度反应器的工业化应用发展。
发明内容
本发明的目的是提供一种在金属基板上制备催化剂涂层的方法，解决催化剂涂层的高温脱落问题，而且具有很好的催化性能。
本发明所述的的金属基板上制备催化剂涂层的方法是通过以下技术方案实现的：首先在金属基板上热喷涂一层α-氧化铝纳米颗粒，制得复合基板，然后涂覆铝溶胶，经干燥焙烧后成为γ-氧化铝，提供大比表面积。最后浸渍活性组分，经干燥焙烧获得催化剂涂层。本发明适用于各种活性组分催化剂涂层的制备。
本发明的金属基板上制备催化剂涂层的方法中复合基板的制备方法为：将金属基板预热至熔点附近，采用氧乙炔火焰粉末喷枪，火焰温度2500～3500℃，优选为2800～3200℃，压力0.2-1.2MPa，优选为0.5-0.9MPa。将α-氧化铝纳米颗粒喷涂至金属基板表面，氧化铝层厚度可根据需要调节。与之前各种只是加热氧化铝颗粒的涂覆方法相比，采用此种同时将金属基板加热的方法，会使得部分氧化铝颗粒嵌入到金属体相中，更有利于两者的结合，复合基板示意图如图1所示。
本发明的金属基板上制备催化剂涂层的方法中所述铝溶胶的制备方法为，配制重量浓度为2～30％，优选为5～20％的拟薄水铝石水溶液，调节pH至0.5～4，优选为2～3，然后在40～95℃，优选为60～85℃，加热搅拌0.5～24小时，优选为4～12小时制得。
本发明所述的金属基板上制备催化剂涂层的方法中涂覆铝溶胶的步骤为，将之前所制得复合基板浸入铝溶胶中3min之后，以3cm/min的速度匀速提起，然后室温晾干。
本发明所述的金属基板上制备催化剂涂层的方法中所述铝溶胶的干燥温度为50～150℃，优选为80～120℃，干燥时间为0.5～24小时，优选为4～12小时，焙烧温度为200～1200℃，优选为400～800℃，焙烧时间为0.5～24小时，优选为4～12小时。
本发明所述的金属基板上制备催化剂涂层的方法中所述浸渍活性组分的温度为20～120℃，优选为60～85℃，时间为0.5～24小时，优选为4～12小时。
本发明所述的金属基板上制备催化剂涂层的方法中所述浸渍活性组分后，干燥温度为50～150℃，优选为80～120℃，干燥时间为0.5～24小时，优选为4～12小时，焙烧温度为200～1200℃，优选为400～800℃，焙烧时间为0.5～24小时，优选为4～12小时。
由于本发明在首先的热喷涂步骤中，在加热氧化铝颗粒的同时，也加热金属基板，使得氧化铝颗粒能够部分嵌入金属基板内部，大大增强了两者的结合牢固程度。另外，为活性组分提供大比表面积的γ-氧化铝层由铝溶胶焙烧而得，省略了再涂覆γ-氧化铝溶胶的步骤，也大大减小了催化剂层脱落的可能。
附图说明
图1是复合基板示意图
图2是反应之前Ni基催化剂涂层的超声震荡脱落率数据
图3是反应之后Ni基催化剂涂层的超声震荡脱落率数据
具体实施方式
下面以在金属基板(FeCrAl基板)上制备用于甲烷水蒸气重整反应的Ni基催化剂和Rh基催化剂涂层为例作进一步详细说明。
实施例1：
首先将金属基板放入热喷涂装置中，加热至1200℃，α-氧化铝纳米颗粒放入喷枪料斗中，火焰温度2500～3500℃，压力0.2-1.2MPa，。将纳米颗粒喷涂至金属基板表面，制得复合基板。然后配制10％拟薄水铝石水溶液，用5mol/L硝酸调节pH至2，80℃加热搅拌5小时制得铝溶胶。将之前基板浸入铝溶胶中3min之后，以3cm/min的速度匀速提起，待其室温晾干后，110℃干燥0.5h，600℃焙烧6h。配制浓度为50％的硝酸镍水溶液，将其加热至80℃，将之前所得基板浸入其中，持续6h。取出后110℃干燥老化6h，最后600℃焙烧6h，即制得用于甲烷水蒸气重整反应的Ni基催化剂涂层。采用超声震荡测试脱落率，测试条件为：45KHz，200W。脱落率测试结果如图2所示。从图2中可以看出，脱落率在0.6％以下，而且趋于稳定，较文献报道结果有了数量级的改进。经过20h的甲烷水蒸气重整实验之后(900℃)，催化剂涂层的脱落率测试结果如图3所示。从图3中可以看出，尽管经历了长时间的高温反应，脱落率与反应前相似，低于0.8％，且趋于稳定，说明制得的催化剂涂层完全可以满足高温操作的要求。
实施例2：
首先将金属基板放入热喷涂装置中，加热至1200℃，α-氧化铝纳米颗粒放入喷枪料斗中，火焰温度为2800～3200℃，压力为0.5-0.9MPa。将纳米颗粒喷涂至金属基板表面，制得复合基板。然后配制10％拟薄水铝石水溶液，用5mol/L硝酸调节pH至2，80℃加热搅拌5小时制得铝溶胶。将之前基板浸入铝溶胶中3min之后，以3cm/min的速度匀速提起，待其室温晾干后，110℃干燥0.5h，600℃焙烧6h。配制浓度为25％的硝酸镍水溶液，将其加热至80℃，将之前所得基板浸入其中，持续6h。取出后110℃干燥老化6h，最后600℃焙烧6h，即制得用于甲烷水蒸气重整反应的Ni基催化剂涂层。
实施例3：
首先将金属基板放入热喷涂装置中，加热至1200℃，α-氧化铝纳米颗粒放入喷枪料斗中，火焰温度2500～3500℃，压力0.5-0.9MPa。将纳米颗粒喷涂至金属基板表面，制得复合基板。然后配制10％拟薄水铝石水溶液，用5mol/L硝酸调节pH至2，80℃加热搅拌25小时制得铝溶胶。将之前基板浸入铝溶胶中3min之后，以3cm/min的速度匀速提起，待其室温晾干后，110℃干燥0.5h，600℃焙烧6h。配制适合浓度的氯化铑水溶液，将其加热至80℃，将之前所得基板浸入其中，持续6h。取出后110℃干燥老化6h，最后600℃焙烧6h，即制得用于甲烷水蒸气重整反应的Rh基催化剂涂层。

Claims (7)

1.一种在金属基板上制备催化剂涂层的方法，其特征在于：首先采用高温火焰粉末喷枪将金属基板预热至熔点附近，并在金属基板上热喷涂一层α-氧化铝纳米颗粒，制得复合基板，火焰温度2500～3500℃，压力0.2-1.2MPa；然后涂覆铝溶胶，铝溶胶水溶液重量浓度为2～30％，pH为0.5～4，在40～95℃，加热搅拌0.5～24小时制得；经干燥焙烧后成为γ-氧化铝，干燥温度为50～150℃，干燥时间为0.5～24小时，焙烧温度为200～1200℃，焙烧时间为0.5～24小时；最后浸渍活性组分，经干燥焙烧获得催化剂涂层，浸渍活性组分的温度为20～120℃，时间为0.5～24小时，干燥温度为50～150℃，干燥时间为0.5～24小时，焙烧温度为200～1200℃，焙烧时间为0.5～24小时。
2.根据权利要求1所述的一种在金属基板上制备催化剂涂层的方法，其特征在于：火焰温度为2800～3200℃，压力为0.5-0.9MPa。
3.根据权利要求1所述的一种在金属基板上制备催化剂涂层的方法，其特征在于：铝溶胶为重量浓度5～20％的拟薄水铝石水溶液，pH为2～3，在60～85℃，加热搅拌4～12小时制得。
4.根据权利要求1所述的一种在金属基板上制备催化剂涂层的方法，其特征在于：涂覆铝溶胶时，将之前所制得复合基板浸入铝溶胶中3min之后，以3cm/min的速度匀速提起，然后室温晾干。
5.根据权利要求1所述的一种在金属基板上制备催化剂涂层的方法，其特征在于：铝溶胶的干燥温度为80～120℃，干燥时间为4～12小时，焙烧温度为400～800℃，焙烧时间为4～12小时。
6.根据权利要求1所述的一种在金属基板上制备催化剂涂层的方法，其特征在于：浸渍活性组分的温度为60～85℃，时间为4～12小时。
7.根据权利要求1所述的一种在金属基板上制备催化剂涂层的方法，其特征在于：浸渍活性组分后，干燥温度为80～120℃，干燥时间为4～12小时，焙烧温度为400～800℃，焙烧时间为4～12小时。
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