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    Free-standing monolithic catalyst with micro-scale channel dimensions
    7.
    发明授权
    Free-standing monolithic catalyst with micro-scale channel dimensions 失效
    独立式整体式催化剂，具有微尺度通道尺寸

    公开(公告)号：US06670305B2

    公开(公告)日：2003-12-30

    申请号：US09851843

    申请日：2001-05-09

    申请人： Joong-Myeon Bae ,  John David Carter ,  Michael Krumpelt ,  Shabbir Ahmed

    发明人： Joong-Myeon Bae ,  John David Carter ,  Michael Krumpelt ,  Shabbir Ahmed

    IPC分类号： B01J2104

    CPC分类号： B01J37/0244 ,  B01J23/42 ,  B01J23/63 ,  B01J35/04 ,  B01J37/0018 ,  B01J37/0219 ,  C01B3/382 ,  Y02P20/52

    摘要： A monolithic catalyst with micro-scale flow channels and methods of making such a monolithic catalyst are provided. The monolithic catalyst includes a plurality of thin catalyst walls. The walls have a set thickness in a range from 1 to 150 &mgr;m. The thin catalyst walls define a plurality of flow channels. A fugitive material is used to form the flow channels. The flow channels have a set width in a range from 1 to 200 &mgr;m. The flow channels are formed by an organic fugitive material, which burns off during processing. By using the thin catalyst walls and flow channels having a set width in a range from 1 to 200 &mgr;m, a reduced diffusion path length that molecules travel between the bulk gas and the active site is provided. Accelerating the mass transport thus improves the overall reaction rate, which allows processing of more reactants. Thus, the volume of the required catalyst is reduced, allowing more compact reactors. Fabrication methods involve simple, low-cost and scaleable procedures, allowing the flow channel and catalyst dimensions to be easily scaled to a requisite size for a given application. One fabrication method involves tape casting successive layers of fugitive and catalyst materials, and then firing to remove the organic binders and partially sinter the catalyst particles. The slurries can also be cast into thin layers using various processes, including screen printing, wet spraying and spin casting. Another fabrication method for fabricating a supported catalyst involves dipping a pre-shaped metal foil into a slurry containing an active catalyst powder, allowing the catalyst slurry to coat the foil evenly and allowing the catalyst slurry coated foil to dry. The catalyst slurry coated foil is dipped into a solution to form a fugitive coating layer, next the coated metal foil is cut into strips and formed into a selected shape.

    摘要翻译： 提供了具有微尺度流动通道的整体式催化剂和制造这种整体式催化剂的方法。 整体式催化剂包括多个薄的催化剂壁。 墙壁的厚度范围为1至150 mum。 薄催化剂壁限定多个流动通道。 使用逃逸材料形成流动通道。 流道的设定宽度范围为1〜200μm。 流动通道由加工过程中燃烧的有机短暂物质形成。 通过使用具有1至200μm范围内的设定宽度的薄催化剂壁和流动通道，提供分子在大气体和活性位点之间行进的减小的扩散路径长度。 因此，加速质量传递提高了整体反应速率，这允许加工更多的反应物。 因此，所需催化剂的体积减小，允许更紧凑的反应器。 制造方法涉及简单，低成本和可扩展的程序，允许流动通道和催化剂尺寸容易地缩放到给定应用的必要尺寸。 一种制造方法包括将连续的挥发性和催化剂材料层进行带铸，然后焙烧以除去有机粘合剂并部分烧结催化剂颗粒。 浆料也可以使用各种方法浇铸成薄层，包括丝网印刷，湿式喷涂和旋转浇铸。 用于制造负载型催化剂的另一种制造方法包括将预形金属箔浸入含有活性催化剂粉末的浆料中，使催化剂浆料均匀地涂覆箔片，并使涂覆有催化剂浆料的箔片干燥。 将催化剂浆料涂覆的箔浸入溶液中以形成短暂的涂层，接下来将涂覆的金属箔切成条并形成选定的形状。