Particle characterization- size distribution, pore distribution- of precursor, micronized powder and cataslyst

这项提案涉及催化剂制造，该行业在北美的销售额为50亿美元。但在全球范围内，来自催化的产品占3万亿美元。尽管催化在我们的日常生活中产生了巨大的影响，但在发展经济和环境过程中仍然存在巨大的挑战。在这个领域工作的困难涉及物质的三个主要阶段-固体、液体和气体之间的相互作用。例如，我们通常从溶液化学开始形成晶体(G-L)。制造过程的下一步可能包括干燥，然后在空气或液体中将晶体粉碎到亚微米级(G-S，L-S)。第三步是造粒或喷雾干燥，以产生具有机械稳定性的微球，如耐磨性、耐磨性和压碎强度，以及正确的颗粒形态--粒度分布、形状、比表面积和孔隙率(L-S、G-L-S)。最后，粉末在高温(1250K)和气体或液体中的压力下用于物理系统(G-S，L-S)。此外，我们小组还在研究反应堆系统，我们正在寻找高温下的固-固反应(G-S-S)。我的团队从事一般催化剂领域的工作，但特别是部分氧化和脱水：在VPO催化剂上将丁烷转化为顺丁烯二酸酐，在Haldor-Topsoe制造的专利催化剂上将甲醇转化为烯烃，以及需要固体氧化剂的化学循环燃烧。在每个程序中，颗粒大小、表面积和孔径分布都是关键因素-在合成阶段，喷雾干燥，最后，作为检查反应器中磨损率的工具(能够区分破碎的颗粒和细小颗粒的淋洗)。这些标准过程将伴随着设备的开发，在设备开发中，我们将尝试修改粒度分析仪，以便能够在线和实时地监控微晶的生长。这一领域的大多数研究都是在异地进行的，关于晶体生长的“最佳”停留时间有很大的变异性。

This proposal concerns catalyst manufacture, which accounts for $5 billion worth of sales in North America.  On a global basis, products derived from catalysis represent $3 trillion.  Despite the enormous impact of catalysis in our daily lives, there remains significant challenges in developing economic and environmental processes  The difficulty in working in this field relates to the interaction between the three primary phases of matter - solids, liquids and gases.  For example, we often begin with solution chemistry to form crystals (G-L).  The next step in the manufacturing process may include drying followed by micronization where the crystals are pulverized to a sub-micron size in air or liquid (G-S, L-S).  The third step involves granulation or spray drying in order to produce micro-spheres that have mechanical stability - attrition resistance, abrasion resistance, and crush strength - as well as the correct particle morphology - size distribution, shape, surface area, and porosity (L-S, G-L-S).  Finally, powders are employed in physical systems at elevated temperatures (1250 K) and pressures in the gas or liquid phase (G-S, L-S).   Our group is also working on reactor systems where we are seeking solid-solid reactions at elevated temperature (G-S-S). My group works in the general field of catalyst but in particular partial oxidation and dehydration: butane to maleic anhydride over a VPO catalyst, methanol to olefins over proprietary catalysts fabricated by Haldor-Topsoe, as well as Chemical Looping Combustion that requires a solid oxidant.  In each of these programs, particle size, surface area and pore size distribution are critical factors - at the synthesis stage, spray drying, and finally as a tool to examine the attrition rates in the reactors (to be able to distinguish between fractured particles and elutriation of fines).  These standard processes will be accompanied by equipment development in which we will attempt to modify the Particle Size Analyzer in order to be capable of monitoring the growth of crystallites on-line and in real time.  Most research in this area is performed ex-situ with a large variability with respect to the "optimum" residence time for crystal growth.