CN111450900A - 一种圆筒形多孔载体及其制备方法以及一种催化剂及其应用 - Google Patents

一种圆筒形多孔载体及其制备方法以及一种催化剂及其应用 Download PDF

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CN111450900A
CN111450900A CN202010381848.9A CN202010381848A CN111450900A CN 111450900 A CN111450900 A CN 111450900A CN 202010381848 A CN202010381848 A CN 202010381848A CN 111450900 A CN111450900 A CN 111450900A
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荣卫龙
张舒乐
郭勇
盛守祥
于洋
任骞
边波
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Shandong Aiyipu Environmental Protection Technology Co ltd
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Abstract

本发明涉及催化剂技术领域，提供了一种圆筒形多孔载体及其制备方法以及一种催化剂及其应用。本发明将圆筒形多孔载体的载体层设置成波纹状或者蜂窝状，可以增加载体层的表面积，提高气体和载体层的接触面积，且本发明的载体为圆筒形结构，在应用时，气体可以从筒壁穿过，再从筒中心的未密封端流出，能够大大降低气体的阻力。利用本发明的圆筒形多孔载体制备催化剂，可以显著降低气体穿过催化剂层时的阻力，从而能降低系统的运行成本；此外，本发明提供的催化剂安装方便，成本低，具有广阔的应用前景。

Description

一种圆筒形多孔载体及其制备方法以及一种催化剂及其应用
技术领域
本发明涉及催化剂技术领域，尤其涉及一种圆筒形多孔载体及其制备方法以及一种催化剂及其应用。
背景技术
在各种化工催化工艺过程中，气固相反应是最常见的催化工艺，其中催化剂大多是固体，为了提高反应效率，一般尽可能提高催化剂的反应面积以及加强气体的流动来提高传质效果，比如将催化剂加工成球形、三叶草形、蜂窝形等多孔材料，或者采用相似的多孔载体来负载催化剂，这种催化过程是将固体催化剂做成填料层，需要反应的气体由上至下、由下至上或者水平均匀穿过催化剂层，来实现催化的效果。
但是，气体在流过催化层时，由于受限于流通截面尺寸大小，均存在阻力大的问题，导致整体工艺系统运行成本较高。
发明内容
有鉴于此，本发明提供了一种圆筒形多孔载体及其制备方法以及一种催化剂及其应用。本发明提供的圆筒形多孔载体气体流通面积大、阻力小，利用该圆筒形多孔载体制备成催化剂，气体可以较低的流速穿过催化剂层。
为了实现上述发明目的，本发明提供以下技术方案：
一种圆筒形多孔载体，包括支撑骨架和设置在所述支撑骨架外侧表面的载体层；所述支撑骨架为一端密封、一端敞口的圆筒结构，所述支撑骨架的筒壁上设置有贯穿筒壁的的孔洞；所述载体层呈波纹状或蜂窝状，
当所述载体层呈波纹状时，所述载体层由条状波纹纸和条状平面纸在支撑骨架侧面纵向间隔排列形成；
当所述载体层呈蜂窝状时，所述载体层由平板状蜂窝载体在支撑骨架侧面包裹形成；
所述载体层的材质为玻璃纤维或者陶瓷纤维。
优选的，所述支撑骨架的外径为100～1000mm。
优选的，所述载体层的厚度为5～500mm。
优选的，所述圆筒形多孔载体的长度为0.5～10m。
优选的，所述条状波纹纸和条状平面纸的宽度独立地为5～500mm。
本发明提供了上述方案所述圆筒形多孔载体的制备方法，当所述载体层呈波纹状时，所述制备方法包括以下步骤：
将纤维平面纸制备成波纹纸，然后沿垂直于波纹传播的方向进行裁切，得到条状波纹纸；
将纤维平面纸进行裁切，得到条状平面纸；
将条状纤维纸和条状平面纸间隔排列并粘贴在支撑骨架外侧表面，得到所述圆筒形多孔载体；
当所述载体层呈蜂窝状时，所述制备方法包括以下步骤：将平板状蜂窝载体卷成筒状，然后固定在支撑骨架外侧表面，得到圆筒形多孔载体；
其中：所述纤维平面纸为玻璃纤维平面纸或陶瓷纤维平面纸；所述平板状蜂窝载体的材质为玻璃纤维或陶瓷纤维。
本发明还提供了一种催化剂，包括载体和负载在所述载体上的活性组分，所述载体为上述方案所述的圆筒形多孔载体或上述方案所述制备方法制备的圆筒形多孔载体；所述活性组分负载在圆筒形多孔载体的载体层上。
优选的，所述活性组分包括TiO2、WO3、V2O5、SiO2、Al2O3、ZrO2、MnO2、Pt、Pb、Ni、Cu、Rh、Ag和Pd中的一种或几种。
本发明还提供了上述方案所述的催化剂在汽车尾气处理中的应用。
本发明还提供了上述方案所述的催化剂作为合成氨催化剂、合成气制甲醇催化剂、催化加氢催化剂、乙烯环氧化制环氧乙烷Ag催化剂或催化裂化催化剂的应用。
本发明提供了一种圆筒形多孔载体，所述载体包括支撑骨架和设置在支撑骨架外侧表面的载体层；所述支撑骨架为一端密封，一端敞口的圆筒结构，所示支撑骨架的筒壁上设置有贯穿筒壁的孔洞；所述载体层的表面呈凹凸波纹状或蜂窝状，所述载体的材质为玻璃纤维或者陶瓷纤维。本发明将圆筒形多孔载体的载体层设置成呈波纹状或蜂窝状，可以增加载体层的表面积，提高气体和载体层的接触面积，且本发明的载体为圆筒形结构，在应用时，气体从筒壁穿过，再经筒中心从未密封端流出，无需自上而下穿过，能够大大降低气体的阻力。
本发明还提供了一种催化剂，包括上述方案所述的圆筒形多孔载体和负载在载体上的活性组分。本发明利用圆筒形多孔载体制备催化剂，活性组分负载在圆筒形多孔载体筒壁的载体层上，在应用时，气体由外至内穿过催化剂层与活性组分接触，然后通过圆筒内部的通道排出，气体与催化剂层的接触面积大，穿过催化剂层的阻力小，能够以较低的流速穿过，从而能降低系统的运行成本；此外，本发明提供的催化剂安装方便，成本低，具有广阔的应用前景。
附图说明
图1为载体层呈波纹状的圆筒形多孔载体的结构示意图；
图2为载体层呈蜂窝状的圆筒形多孔载体的结构示意图；
图1～2中：1-支撑骨架，2-载体层；
图3为圆筒形多孔载体表面波纹状载体层的结构示意图；图3中：3-条状波纹纸，4-条状平面纸；
图4为催化剂的结构示意图；
图5为催化剂的俯视图；
图6为气体流过普通蜂窝形催化剂的结构示意图。
具体实施方式
本发明提供了一种圆筒形多孔载体，包括支撑骨架和设置在支撑骨架外侧表面的载体层；所述支撑骨架为一端密封，一端敞口的圆筒结构，所述支撑骨架的筒壁上设置有贯穿筒壁的孔洞；所述载体层呈凹凸波纹状或蜂窝状；
当所述载体层表面呈凹凸波纹状时，所述载体层由条状波纹纸和条状平面纸在支撑骨架侧面纵向间隔排列形成；
当所述载体层表面呈蜂窝状时，所述载体层由平板状蜂窝载体在支撑骨架侧面包裹形成；
所述载体层的材质为玻璃纤维或者陶瓷纤维。
当所述载体层呈波纹状时，所述圆筒形多孔载体的结构如图1所示，当所述载体层呈蜂窝状时，所述圆筒形多孔载体的结构如图2所示，图1～2中：1为支撑骨架，2为载体层。
在本发明中，所述支撑骨架优选为钢丝网筒或者为由多孔网板卷成的圆筒；所述支撑骨架筒壁上的孔洞优选为圆形孔洞，所述圆形孔洞的直径优选为3～50mm；相邻圆形孔洞的圆心距离优选为3～50mm；支撑骨架筒壁上设置孔洞，可以供气体通过；在本发明中，所述支撑骨架的外径优选为100～1000mm，更优选为300～800mm。
在本发明中，当所述载体层表面呈凹凸波纹状时，所述载体层由条状波纹纸和条状平面纸在支撑骨架侧面纵向间隔排列形成，具体的排列方式如图3所示，图3中：3为条状波纹纸，4为条状平面纸；其中条状波纹纸和条状平面纸的宽度边均垂直于支撑骨架表面，本发明对所述条状波纹纸的具体波纹形态没有特殊要求，按照本领域技术人员熟知的波纹纸表面的波纹结构进行设置即可。在本发明中，所述条状波纹纸的宽度优选为5～500mm，更优选为10～400mm；所述条状平面纸的宽度优选为5～500mm，更优选为10～400mm；所述条状波纹纸和条状平面纸的长度优选和支撑骨架侧面的长度相同，以将支撑骨架侧面完全覆盖；由于波纹纸存在凹凸的波纹，和相邻的平面纸之间形成供气体通过的孔道。本发明将载体层设置成凹凸波纹状，可以增加气体和载体层的接触面积。
在本发明中，当所述载体层表面层蜂窝状时，所述载体层由平板状蜂窝载体在支撑骨架侧面包裹形成，所述蜂窝状载体层的蜂窝孔洞优选为长方形或正方形，所述蜂窝孔洞的尺寸优选为2～10mm×2～10mm，更优选为3～8mm×3～8mm；所述蜂窝孔洞的隔墙厚度优选为0.1～2mm，更优选为0.5～1.5mm。本发明将载体层设置成蜂窝状，蜂窝状孔洞供气体通过，且可以增大气体和载体层的接触面积。
所述载体层的厚度优选为5～500mm，更优选为10～400mm，在本发明中，当所述载体层呈波纹状时，由于条状平面纸和条状波纹纸垂直于筒壁，此时的载体层厚度即为条状平面纸或条状波纹纸的宽度；当所述载体层呈蜂窝状时，所述载体层的厚度即为平板状蜂窝载体的厚度；所述圆筒形多孔载体的长度优选为0.5～10m，更优选为1～3m，进一步优选为1.5～2.5m；在本发明的具体实施例中，所述支撑骨架的底部优选设置有底座，顶部优选设置有顶座，以增加载体竖立时的稳定性，本发明所述的圆筒形多孔载体的长度不包括底座和顶座的长度，仅为侧面包裹催化剂层部分的长度。
在本发明中，所述载体层的材质为玻璃纤维或者陶瓷纤维；本发明对所述玻璃纤维或陶瓷纤维的规格没有特殊要求，使用本领域技术人员熟知的即可。
本发明提供了上述方案所述圆筒形多孔载体的制备方法，包括以下步骤：
当所述载体层呈凹凸波纹状时，所述制备方法包括以下步骤：
将纤维平面纸制备成波纹纸，然后沿垂直于波纹传播的方向进行裁切，得到条状波纹纸；
将纤维平面纸进行裁切，得到条状平面纸；
将条状纤维纸和条状平面纸间隔排列并粘贴在支撑骨架外侧，得到所述圆筒形多孔载体。
在本发明中，所述纤维平面纸为玻璃纤维平面纸或陶瓷纤维平面纸；本发明对所述玻璃纤维纸或陶瓷纤维纸没有特殊要求，使用本领域技术人员熟知的即可；本发明对将纤维平面纸制备成波纹纸的方法没有特殊要求，使用本领域技术人员熟知的制备波纹纸的方法进行制备即可；具体的如将玻璃纤维纸进行折叠，形成波纹纸，或者使用两个齿轮对玻璃纤维纸进行滚压，形成波纹纸。
本发明对所述裁切和粘贴的方法没有特殊要求，使用本领域技术人员熟知的裁切和粘贴方法即可。
当所述载体层呈蜂窝状时，所述制备方法包括以下步骤：将平板状蜂窝载体卷成筒状，然后固定在支撑骨架侧面上，得到圆筒形多孔载体。
在本发明中，所述平板状蜂窝载体的材质为玻璃纤维或陶瓷纤维，所述平板状蜂窝载体的蜂窝孔洞尺寸以及隔墙厚度和上述方案相同，在此不再赘述；本发明对所述平板状蜂窝载体的制备方法没有特殊要求，按照本领域技术人员熟知的方法制备即可，具体的如通过模具挤压成型；本发明对将平板状的蜂窝状载体固定在支撑骨架侧面的方法没有特殊要求，使用本领域技术人员熟知的方法，能够牢固固定即可。
本发明还提供了一种催化剂，包括载体和负载在载体上的活性组分，结构如图4～5所示，图4为催化剂的结构示意图，图5为催化剂的俯视图；所述载体为上述方案所述的圆筒形多孔载体。
在本发明中，所述活性组分负载在圆筒形多孔载体的载体层上，在本发明中，将负载有活性组分的载体层称为催化剂层，在应用时，气体由外至内穿过穿过催化剂层，然后通过圆筒中心流出，具体的气体流通方向见图4～5，本发明提供的催化剂由于流通面积大，能够降低气体的阻力，使气体能够以较低的流速穿过催化剂层，并且气体与催化剂的接触面积大，从而能降低系统的运行成本。
在本发明中，所述活性组分优选包括TiO2、WO3、V2O5、SiO2、Al2O3、ZrO2、MnO2、Pt、Pb、Ni、Cu、Rh、Ag和Pd中的一种或几种；本发明优选根据催化剂的具体应用选择活性组分的种类；在本发明的具体实施例中，当活性组分为Pt、Rh、Pb和Al2O3中的一种或几种时，所述催化剂优选作为尾气催化剂，用于汽车尾气处理，应用时安装在汽车尾气排气筒上即可；当活性组分为TiO2、WO3和V2O5中的一种或几种时，所述催化剂优选作为SCR脱硝催化剂使用；当活性组分为Pt、Ni和Cu中的一种或几种时，所述催化剂优选作为催化加氢催化剂使用，可用于石油化工生产中。
在本发明中，所述活性组分的负载量优选为载体重量的5～50％，优选为10～45％。
本发明对所述催化剂的制备方法不做特殊限定，使用本领域技术人员熟知的方法进行制备，能够实现活性组分的负载即可。
本发明还提供了上述方案所述的催化剂在汽车尾气处理中的应用。
本发明还提供了上述方案所述的催化剂作为脱硝催化剂、合成氨催化剂、合成气制甲醇催化剂、催化加氢催化剂、乙烯环氧化制环氧乙烷Ag催化剂和催化裂化催化剂的应用；所述催化剂应用于不同场合时载体上负载的活性组分根据实际情况进行选择即可，活性组分的负载量优选和上述方案一致，在此不再赘述。在本发明的具体实施例中，所述催化剂优选密封端朝下垂直安装在固定床反应器中，优选根据反应器内空间以及催化性能指标计算催化剂的安装根数。
下面将结合本发明中的实施例，对本发明中的技术方案进行清楚、完整地描述。
对比例1
以单根催化剂为例，计算气体穿过催化剂时的阻力，载体上负载的活性组分对气体阻力造成的影响忽略不计。
采用普通的蜂窝催化剂，催化剂的结构为长方体形，气体由下自上穿过，如图6所示，本对比例中长方体形催化剂的截面尺寸为0.15m*0.15m，长度为1m，气体由上至下或者由下至上流过，流通截面积为0.15m*0.15m＝0.0225m2，以气体流量为300m3/h计，气体流经该催化剂时的气体流速为300m3/h/0.0225m2/3600＝3.7037m/s，停留时间为1m/3.7037m/s＝0.27s，根据伯努利方程计算气体阻力为1075Pa。
实施例1
将玻璃纤维平面纸制备成波纹状，然后裁切成宽度为20mm的条状，同时将玻璃纤维平面纸裁切成宽度为20mm的条状，将条状波纹纸和条状平面纸纵向间隔排列并粘贴在支撑骨架外侧表面，支撑骨架的外径为0.15m，长度为1m，支撑骨架筒壁上设置有孔洞，孔洞直径为30mm，催化剂层的厚度为0.02m。
按照气体流量为300m3/h进行计算，气体由载体的四周向中间流过，流通截面积(即圆筒的流通面积)为3.14*0.15*1＝0.471m2，气体流速为300m3/h/0.471m2/3600＝0.177m/s，根据伯努利方程计算气体阻力约1Pa，实测气体阻力为5Pa。
对比例2
一个5m*5m截面的反应器结构，烟气流量500000m3/h，安装常规的长方体形催化剂(催化剂截面和反应器截面相同，高度为3m)，气体流速为：500000m3/h/(5m*5m)/3600＝5.6m/s，催化剂高度3m，烟气经过催化剂的时间为：3m/5.6m/s＝0.54s，气体阻力约1000Pa。
实施例2
按照实施例1的方法制备圆筒形多孔载体，条状波纹纸和条状平面纸的宽度为10mm，支撑骨架的外径为130mm，长度为3m，支撑骨架筒壁上设置有孔洞，孔洞直径为35mm，催化剂层厚度为0.01m。
一个5m*5m截面的反应器结构，烟气流量500000m3/h，安装本发明的圆筒形催化剂，每根圆筒形催化剂尺寸为φ130mm*3m，按照每根催化剂需要需要150mm*150mm的安装空间计算，反应器内共可以安装33*33＝1089根，每根圆筒形催化剂的流通面积为3.14*0.13*3＝1.22m2,总流通面积为1089*1.22＝1328.58m2，气体流速为：50000m3/h/1328.58m2/3600＝0.01m/s，催化剂厚度0.01m，根据伯努利方程计算气体阻力约10Pa，实测气体阻力为15Pa。
实施例3
按照实施例1的方法制备圆筒形多孔载体，条状波纹纸和条状平面纸的宽度为10mm，支撑骨架的外径为160mm，长度为6m，支撑骨架筒壁上设置有孔洞，孔洞直径为50mm，催化剂层厚度为0.01m。
一个7.5m*22m截面的反应器结构，烟气流量为720000m3/h，安装本发明的圆筒形催化剂，一共4000根，每根圆筒形催化剂的流通面积为3.14*0.16*6＝3m2，总流通面积为4000*3＝12000m2，气体流速为：720000m3/h/12000m2/3600＝0.017m/s，根据伯努力方程计算气体阻力约10Pa，实测气体阻力为15Pa。
实施例4
将陶瓷纤维与催化剂混合制成泥状，再通过挤压成型制备平板状蜂窝载体，蜂窝孔洞的尺寸为0.5mm×0.5mm，隔墙厚度优选为0.5mm，将平板状蜂窝载体卷成筒状，然后固定在支撑骨架侧面上，得到圆筒形多孔载体，支撑骨架的外径为0.15m，支撑骨架筒壁上设置有孔洞，孔洞直径为3mm，长度为1m，载体层厚度为0.01m。在气体流量为300m3/h条件下进行测试，气体流通面积为：3.14*0.15*1＝0.471m2，流速为：300m3/h/0.471m2/3600＝0.177m/s，实测气体阻力10Pa。
根据以上实施例可以看出，本发明的圆筒形多孔载体与气体的接触面积大，气体传穿过催化剂层时的阻力小，使用本发明的圆筒形多孔载体制备的催化剂能够显著降低体系的运行成本。
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。

Claims (10)

1.一种圆筒形多孔载体，包括支撑骨架和设置在所述支撑骨架外侧表面的载体层；所述支撑骨架为一端密封、一端敞口的圆筒结构，所述支撑骨架的筒壁上设置有贯穿筒壁的的孔洞；所述载体层呈波纹状或蜂窝状；
当所述载体层呈波纹状时，所述载体层由条状波纹纸和条状平面纸在支撑骨架侧面纵向间隔排列形成；所述条状波纹纸和条状平面纸的宽度边均垂直于支撑骨架侧面；
当所述载体层呈蜂窝状时，所述载体层由平板状蜂窝载体在支撑骨架侧面包裹形成；
所述载体层的材质为玻璃纤维或者陶瓷纤维。
2.根据权利要求1所述的圆筒形多孔载体，其特征在于，所述支撑骨架的外径为100～1000mm。
3.根据权利要求1或2所述的圆筒形多孔载体，其特征在于，所述载体层的厚度为5～500mm。
4.根据权利要求1所述的圆筒形多孔载体，其特征在于，所述圆筒形多孔载体的长度为0.5～10m。
5.根据权利要求1所述的圆筒形多孔载体，其特征在于，所述条状波纹纸和条状平面纸的宽度独立地为5～500mm。
6.权利要求1～5任意一项所述圆筒形多孔载体的制备方法，其特征在于，当所述载体层呈波纹状时，所述制备方法包括以下步骤：
将纤维平面纸制备成波纹纸，然后沿垂直于波纹传播的方向进行裁切，得到条状波纹纸；
将纤维平面纸进行裁切，得到条状平面纸；
将条状纤维纸和条状平面纸间隔排列并粘贴在支撑骨架外侧表面，得到所述圆筒形多孔载体；
当所述载体层呈蜂窝状时，所述制备方法包括以下步骤：将平板状蜂窝载体卷成筒状，然后固定在支撑骨架外侧表面，得到圆筒形多孔载体；
其中：所述纤维平面纸为玻璃纤维平面纸或陶瓷纤维平面纸；所述平板状蜂窝载体的材质为玻璃纤维或陶瓷纤维。
7.一种催化剂，包括载体和负载在所述载体上的活性组分，其特征在于，所述载体为权利要求1～5任意一项所述的圆筒形多孔载体或权利要求6所述制备方法制备的圆筒形多孔载体；所述活性组分负载在圆筒形多孔载体的载体层上。
8.根据权利要求7所述的催化剂，其特征在于，所述活性组分包括TiO2、WO3、V2O5、SiO2、Al2O3、ZrO2、MnO2、Pt、Pb、Ni、Cu、Rh、Ag和Pd中的一种或几种。
9.权利要求7～8任意一项所述的催化剂在汽车尾气处理中的应用。
10.权利要求7～8任意一项所述的催化剂作为脱硝催化剂、合成氨催化剂、合成气制甲醇催化剂、催化加氢催化剂、乙烯环氧化制环氧乙烷Ag催化剂或催化裂化催化剂的应用。
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