STTR Phase II: Scale-Up of An Innovative Spray Pyrolysis Process for Producing Pyrochlore Catalysts

STTR 第二阶段：扩大用于生产烧绿石催化剂的创新喷雾热解工艺

• 批准号: 1555958
• 负责人: Jeffrey Harrison
• 金额: $ 75万
• 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: 2016
• 资助国家: 美国
• 起止时间: 2016-02-15 至 2021-10-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1555958&HistoricalAwards=false
• 关键词: STTR; Phase; II; Scale; Up

The broader impact/commercial potential of this Business Innovation Research Phase II project is to commercialize Pyrochem Catalyst Company's (PCC) catalyst materials. These catalyst materials are unique in that the catalytically active metal is atomically dispersed in a rigid crystalline matrix. This imparts unparalleled thermal stability, even at temperatures in excess of 1000°C. Conventional catalysts typically require much higher precious metal loadings (as much as 20 times) to achieve the same activity as the materials developed in this project and at high temperatures those active metals can agglomerate into large clusters reducing their performance and the lifetime of the catalyst. The series of catalysts developed in this project are designed in a way that all precious metal is optimally utilized and protected. This includes resistance from sulfur poisoning and the accumulation of carbon when operating under severe conditions. This makes these materials ideal for high temperature processes such as steam methane reforming for hydrogen generation, autothermal reforming for syngas production, syngas generation in oxygen transport membranes (OTM), and exhaust oxidation in automotive catalytic convertors. The objectives of this Phase II STTR program are to build on the success of the Phase I objectives that developed a low cost and continuous catalyst manufacturing method for producing the pyrochlore powders that are the basis for the proposed catalyst product. The method may be equally effective for producing other types of mixed metal oxides like perovskites and fluorites. In Phase II, PCC will construct and test a scaled-up production platform, following the design elements of the proof of concept demonstrated in Phase I. The new unit will be designed to manufacture proprietary pyrochlore powders at a rate with a hundred-fold increase over production rates of the Phase I unit. The Phase II technical efforts also examine a range of catalyst synthesis parameters like oxidant gas concentration/composition, temperature distribution in the production unit, precursor residence times, synthesis solution chemistry, and optimizing heat and mass transport. Through a subaward, powders produced from the process will be characterized and tested for activity by the National Energy Technology Labs, Morgantown, WV. The overall goal of this project is the development of a high throughput / high yield manufacturing process that produces high performance catalysts for commercial sale.

该业务创新研究阶段II项目的更广泛的影响/商业潜力是将Pyrochem Catalyst Company（PCC）催化剂材料商业化。这些催化剂材料是独一无二的，因为催化活性金属在原子上分散在刚性晶体基质中。这意味着即使在超过1000°C的温度下，无与伦比的热稳定性也是如此。传统的催化剂通常需要更高的贵金属载荷（多达20次）才能达到与本项目中开发的材料相同的活动，并且在高温下，这些活性金属可以将其组成大型簇，以降低其性能和催化剂的寿命。该项目中开发的一系列催化剂的设计方式是最佳利用和保护的所有贵金属。这包括在严重条件下运行时硫中毒的抗性和碳的积累。这使得这些材料非常适合高温过程，例如用于氢生成的蒸汽甲烷改革，合成气生产的自热重整，氧气转运机理（OTM）的生成合成器（OTM）以及汽车催化转化器中的排气氧化。该II期STTR计划的目标是建立在I期目标的成功基础上，该目标开发了低成本和连续的催化剂制造方法，用于生产该方法对生产其他类型的混合金属氧化物（如钙钛矿）和氟矿石等其他类型的混合金属氧化物同样有效。在第二阶段，PCC将按照第1阶段所示的概念证明的设计要素来构建和测试扩大的生产平台。新单元将以以比I期单元的生产率提高一百倍的速率来制造专有的Pyrochlore粉末。第二阶段的技术工作还检查了一系列催化剂合成参数，例如氧化物气体浓度/成分，生产单元中的温度分布，前体停留时间，合成溶液化学性质以及优化热量和质量运输。通过一个子宣告，该过程产生的粉末将由西弗吉尼亚州摩根敦的国家能源技术实验室进行表征和测试。该项目的总体目标是开发高吞吐量 /高收益制造过程，该过程产生了用于商业销售的高性能催化剂。