STTR Phase I: An Innovative Spray Pyrolysis Process for Producing Pyrochlore Catalysts

STTR 第一阶段：用于生产烧绿石催化剂的创新喷雾热解工艺

• 批准号: 1417144
• 负责人: Jeffrey Harrison
• 金额: $ 22.5万
• 依托单位: Pyrochem Catalyst Company
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2014
• 资助国家: 美国
• 起止时间: 2014-07-01 至 2015-12-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1417144&HistoricalAwards=false
• 关键词: STTR; Phase; Innovative; Spray; Pyrolysis

The broader impact/commercial potential of this project is the development of a continuous and low-cost spray-pyrolysis process for making mixed metal oxide (MMO) materials that can be used in the petroleum and chemicals synthesis, precursors for solar panels, electrode materials, fuel cells, oxygen selective membranes, and chemical sensors. Of particular interest are crystalline pyrochlore mixed metal oxides for catalyzing chemical reactions because they offer atomic dispersion of the catalytic metals and the ability to influence activity and selectivity through the control of the elemental composition. As catalysts, crystalline MMOs offer unparalleled thermal stability, resistance to poisons and lifetimes that exceed conventional supported metals. The problem has been that MMOs require a time-consuming and costly batch process for producing crystalline materials and this has limited their use to mainly niche applications. In contrast, the spray pyrolysis process uses similar solution chemistry but creates very small droplet size and high temperatures to rapidly form the crystalline materials. While the process has been applied to pure oxides, this represents the first application to MMOs. The development of a continuous and low cost process can finally unlock the potential of MMOs for new and existing applications. This Small Business Innovation Research Phase 1 project focuses specifically on identifying the process parameters of a continuous spray pyrolysis process that control MMO particle size, crystallinity, surface morphology, surface area and catalytic activity for certain chemical reactions. The process parameters of interest include temperature, multiple reaction zones, droplet size, flow patterns, droplet residence time and metal solution concentrations. For this project, the spray pyrolysis process will target the production of crystalline pyrochlore materials used as catalysts in the partial oxidation and reforming of hydrocarbons. These materials (synthesized in batch mode) have demonstrated superior performance for steam reforming, CO2 reforming and partial oxidation reactions important in syngas and hydrogen production, so there is an excellent baseline for comparison of performance. The project, led by Pyrochem Catalyst Company (New Brighton, PA) brings together expertise from the National Energy and Technology Labs (the original inventors of the catalyst), the University of West Virginia and the University of Louisville. Collectively, the team?s objective is to create a clear understanding of the physical and chemical attributes of the spray pyrolysis process so that it can be scaled to demonstration and ultimately commercial capacities.

该项目的更广泛的影响/商业潜力是开发可在石油和化学物质合成中使用的混合金属氧化物（MMO）材料的连续和低成本喷雾过程，这是太阳能电池板，电极材料，燃料电池，氧气选择性膜和化学传感器的前体。特别令人感兴趣的是晶层混合金属氧化物用于催化化学反应，因为它们提供了催化金属的原子分散体以及通过控制元素组成来影响活性和选择性的能力。作为催化剂，Crystalline MMO具有无与伦比的热稳定性，对超过常规支撑金属的毒物和寿命的抗性。问题是MMO需要耗时且昂贵的批处理过程来生产结晶材料，这将其用于主要利基应用的用途限制了。相反，喷雾热解过程使用相似的溶液化学反应，但产生了很小的液滴尺寸和高温以迅速形成晶体材料。尽管该过程已应用于纯氧化物，但这代表了对MMO的首次应用。连续和低成本过程的开发最终可以释放MMO的潜在新应用和现有应用程序。这项小型企业创新研究阶段1项目专门针对识别连续喷雾热解过程的过程参数，该过程控制某些化学反应的MMO粒径，结晶度，表面形态，表面积和催化活性。感兴趣的过程参数包括温度，多个反应区，液滴尺寸，流动模式，液滴停留时间和金属溶液浓度。对于该项目，喷雾热解过程将针对晶体氧化和碳氢化合物改革中用作催化剂的结晶岩岩材料的产生。这些材料（以批处理模式合成）证明了在蒸汽重整，二氧化碳的重整和部分氧化反应中对合成气和氢产生重要的氧化反应的表现出色，因此有一个很好的基准来比较性能。该项目由Pyrochem Catalyst Company（宾夕法尼亚州新布莱顿）领导，汇集了国家能源和技术实验室（Catalyst的原始发明者），西弗吉尼亚大学和路易斯维尔大学的专业知识。总体而言，团队的目标是对喷雾热解过程的物理和化学属性有清晰的了解，以便将其缩放到演示和最终的商业能力。