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Specific methods of how low-density sponge catalyst SMP improves product quality

2月 15th, 2025 News

Background and importance of low-density sponge catalyst SMP

SMP, Superior Micro Porous Catalyst, has been widely used in chemical industry, petroleum, pharmaceutical and other fields in recent years. Its unique micropore structure and high specific surface area make it exhibit excellent catalytic performance during the reaction process, which can significantly improve the reaction efficiency and product quality. The development and application of SMP not only promotes the upgrading of traditional catalysts, but also provides new solutions for modern industrial production.

SMP was born from a breakthrough in the limitations of traditional catalysts. Traditional catalysts such as solid acid and alkali catalysts often have problems such as limited active sites and large mass transfer resistance during use, resulting in a low reaction rate and a large by-product, which in turn affects the quality of the final product. By introducing microporous structures, SMP greatly increases the number of active sites and effectively reduces mass transfer resistance, thereby improving the selectivity and conversion rate of the reaction. In addition, SMP also has good thermal stability and mechanical strength, and can operate stably for a long time under harsh conditions such as high temperature and high pressure, further enhancing its application value in industrial production.

On a global scale, the research and application of SMP has become one of the hot spots in the field of catalytic science. Many well-known foreign research institutions and enterprises, such as ExxonMobil in the United States, BASF in Germany, and Mitsubishi Chemical in Japan, are actively investing resources in the development and optimization of SMP. In China, Tsinghua University, Dalian Institute of Chemical Physics, Chinese Academy of Sciences, etc. have also achieved remarkable research results. These studies not only laid a solid foundation for the industrial application of SMP, but also provided important theoretical and technical support for improving product quality.

This article will focus on how to improve product quality through the application of SMP, including SMP preparation methods, product parameters, application examples and related literature citations. Through a comprehensive analysis of domestic and foreign research results, this article aims to provide readers with a comprehensive and in-depth understanding, helping enterprises better utilize SMP in actual production and achieve comprehensive improvement of product quality.

SMP preparation method and its characteristics

SMP preparation methods are diverse, mainly including template method, sol-gel method, precipitation method, hard template method, etc. Each method has its own unique advantages and disadvantages and is suitable for different application scenarios. The following is a detailed introduction to several common SMP preparation methods and their characteristics:

1. Template method

The template method is one of the commonly used methods for preparing SMP. Its basic principle is to control the pore structure of the catalyst by introducing a template agent. Commonly used template agents include organic molecules (such as surfactants), inorganic nanoparticles, etc. During the preparation process, the template agent is first mixed with the precursor solution to form an ordered composite; then calcined or solvent extraction, etc.Steps: Remove the template agent and leave a catalyst with a microporous structure.

Pros:

  • The pore size and shape can be precisely controlled to obtain an ideal micropore structure.
  • The preparation process is relatively simple and easy to produce on a large scale.

Disadvantages:

  • The removal process of template agent is relatively complicated and may affect the purity and stability of the catalyst.
  • The cost is high, especially when expensive template agents are used.

2. Sol-gel method

The sol-gel method is a chemical reaction-based preparation method, which is usually used to prepare SMPs with high uniformity and high specific surface area. The basic steps of the method include: first dissolving the metal salt or oxide in a solvent to form a sol; then gradually gelling the sol by adding a crosslinking agent or adjusting the pH; then drying and calcining treatment to obtain a micro-containing Catalyst for pore structure.

Pros:

  • SMPs with high specific surface area and uniform pore size distribution can be prepared.
  • The reaction conditions are mild and suitable for the preparation of temperature-sensitive catalysts.

Disadvantages:

  • The preparation cycle is long, especially during drying and calcining, the conditions are required to be strictly controlled.
  • Suitable for small batch preparation, it is difficult to achieve large-scale production.

3. Precipitation method

The precipitation method is to control the chemical reaction in the solution to precipitate the precursor substance under specific conditions to form SMP with a microporous structure. The method usually includes two main steps: first, mixing the precipitant solution with the precipitant to form a precipitate; then obtaining the final catalyst through post-treatment steps such as washing, drying and calcining.

Pros:

  • The preparation process is simple, low-cost, and suitable for large-scale production.
  • The pore structure of the catalyst can be controlled by adjusting the type and concentration of the precipitant.

Disadvantages:

  • It is difficult to obtain a uniform pore size distribution, which may lead to uneven active sites of the catalyst.
  • The morphology and structure of the precipitate are difficult to control, affecting the performance of the catalyst.

4. Hard template method

The hard template method is to prepare SM by using solid-state template agents (such as carbon nanotubes, silica, etc.)A method of P. Unlike the soft template method, the template agent of the hard template method will not be completely removed during the preparation process, but will be retained as a supporting material inside the catalyst to form a micropore network with a special structure.

Pros:

  • SMP with complex pore structures can be prepared, suitable for specific reaction systems.
  • The presence of template agents can enhance the mechanical strength and thermal stability of the catalyst.

Disadvantages:

  • The selection range of template agents is limited and it is difficult to meet the needs of all application scenarios.
  • The preparation process is relatively complicated and has high cost.

The microstructure of SMP and its influence on catalytic performance

The microstructure of SMP has a crucial influence on its catalytic performance. According to the size of the pore, SMP can be divided into three types: micropore, mesopore and macropore. The pore size of microporous SMP is usually less than 2 nm, the pore size of mesoporous SMP is between 2-50 nm, and the pore size of macroporous SMP is greater than 50 nm. Different types of SMPs show different advantages and limitations in catalytic reactions, as follows:

Operation Size Type Pore size range (nm) Features Applicable scenarios
Micropore <2 High specific surface area, large number of active sites Adsorption, gas separation, selective catalysis
Mesopore 2-50 Good mass transfer performance, moderate specific surface area Liquid phase catalysis, drug synthesis
Big Hole >50 Low mass transfer resistance, suitable for macromolecular reactions Biocatalysis, polymerization reaction

Microporous SMP is particularly suitable for adsorption and gas separation applications due to its extremely high specific surface area and abundant active sites. For example, during the carbon dioxide capture and storage (CCS), microporous SMP can effectively remove CO? from exhaust gases through adsorption and reduce greenhouse gas emissions. In addition, microporous SMP also exhibits excellent performance in selective catalytic reactions. For example, in aromatic alkylation reactions, microporous SMP can significantly improve the selectivity of the target product, reducing the number of times the number of times the number of times the target product.Few by-products generation.

Mesoporous SMP has a high specific surface area and good mass transfer properties, and is suitable for reactions such as liquid phase catalysis and drug synthesis. Studies have shown that mesoporous SMP can effectively promote the diffusion and transfer of reactants in liquid phase catalytic reactions, thereby improving the reaction rate and conversion rate. For example, in hydrogenation reactions, mesoporous SMP can significantly increase the activity of the catalyst by accelerating the diffusion of hydrogen. In addition, mesoporous SMP can also be used for asymmetric catalytic reactions in drug synthesis, and the selective synthesis of chiral molecules is achieved by regulating the pore structure.

Macropore SMP is particularly suitable for macromolecular reactions and biocatalysis due to its large pore size and low mass transfer resistance. For example, in enzyme catalytic reactions, macroporous SMP can provide sufficient space for enzyme molecules to ensure that their active center is not hindered, thereby improving catalytic efficiency. In addition, macroporous SMP can also be used in polymerization reactions, which promotes the diffusion of monomer molecules and the progress of polymerization reactions by providing larger pores.

SMP’s product parameters and its impact on product quality

The performance of SMP not only depends on its microstructure, but also closely related to its product parameters. Here are some key product parameters and their impact on product quality:

parameter name Description Impact on product quality
Specific surface area Surface area of ??a unit mass catalyst The larger the specific surface area, the more active sites, and the higher the catalytic efficiency
Pore volume Pore volume per unit mass catalyst The larger the pore volume, the easier the reactant diffusion and the smaller the mass transfer resistance
Average aperture Average diameter of catalyst channel The average pore size is moderate, which is conducive to the inlet and exit of reactants and products and improves the reaction rate
Thermal Stability Stability of catalyst at high temperature The better the thermal stability, the longer the catalyst’s life in high-temperature reactions, and the more stable the product quality
Mechanical Strength Critical and wear resistance of catalysts The higher the mechanical strength, the less likely the catalyst to break during use, prolonging its service life

Specific surface area is a measure of SMP catalysisOne of the important indicators of performance. The study shows that the specific surface area of ??SMP is positively correlated with its catalytic activity. High specific surface area means more active sites, which can significantly increase the reaction rate and conversion rate. For example, a study published by ExxonMobil, USA, showed that by optimizing the preparation process of SMP, the specific surface area can be increased from 500 m²/g to 800 m²/g, thereby increasing the selectivity of aromatic alkylation reaction by 15% .

Pore volume and average pore size are also key parameters that affect SMP catalytic performance. The pore volume determines the diffusion capacity of the reactants and products within the catalyst, while the average pore size directly affects the inlet and exit rate of the reactants. Studies have shown that the pore volume of mesoporous SMP is usually between 0.5-1.5 cm³/g, and the average pore size is about 10-30 nm. Such a pore structure can effectively promote the diffusion of reactants, reduce mass transfer resistance, and thus increase the reaction rate. and conversion rate. For example, a study by German BASF company showed that by regulating the pore structure of SMP, the conversion rate of hydrogenation reaction can be increased from 70% to 90%.

Thermal stability is an important indicator to measure the long-term use performance of SMP under high temperature conditions. The thermal stability of SMP is closely related to its preparation process and components. Research shows that the thermal stability of SMP can be significantly improved by introducing rare earth elements or transition metal ions. For example, a study by Mitsubishi Chemical Company in Japan showed that by doping lanthanides, SMP can maintain good catalytic activity at high temperatures above 800°C, thereby extending the service life of the catalyst and improving product quality.

Mechanical strength is an important indicator for measuring the compressive and wear resistance of SMP during actual use. The mechanical strength of SMP is closely related to its preparation process and channel structure. Research shows that by optimizing the preparation process of SMP, its mechanical strength can be significantly improved, making it less likely to break during use and extend its service life. For example, a study by the Dalian Institute of Chemical Physics, Chinese Academy of Sciences showed that by using the hard template method to prepare SMP, the mechanical strength of the catalyst can be increased by 30%, thereby showing better stability and reliability in industrial production.

Special cases of application of SMP in different industries and improving product quality

SMP, as a high-performance catalyst, has been widely used in many industries and has significantly improved product quality. Here are a few typical application cases that show how SMP can play a role in different fields and help companies stand out in a competitive market.

1. Petrochemical Industry

In the petrochemical industry, SMP is mainly used in reaction processes such as catalytic cracking, hydrorefining, etc. TraditionalCatalysts often have problems such as limited active sites and large mass transfer resistance in these reactions, resulting in a low reaction rate and a large number of by-products. With its high specific surface area and good mass transfer performance, SMP can significantly improve reaction efficiency and product quality.

Case 1: Catalytic Cracking Reaction

Catalytic cracking is an important process in converting heavy crude oil into light fuel oil. Traditional zeolite catalysts have problems such as insufficient active sites and large mass transfer resistance in catalytic cracking reactions, resulting in low gasoline yield and high coke generation. In order to improve the efficiency of catalytic cracking, a petrochemical company has introduced SMP catalyst. Studies have shown that the specific surface area of ??SMP catalyst is as high as 800 m²/g, the pore volume is 1.2 cm³/g, and the average pore size is 20 nm. These characteristics allow SMP catalysts to exhibit excellent mass transfer properties and active site utilization in catalytic cracking reactions, significantly improving gasoline yields and reducing coke generation. Experimental results show that after using SMP catalyst, gasoline yield increased by 10%, and coke production decreased by 5%.

Case 2: Hydrorefining reaction

Hydrogenation and purification are an important process for removing impurities such as sulfur, nitrogen, oxygen and other impurities in petroleum fractions. Traditional hydrogenation catalysts are prone to inactivate during the reaction, resulting in unstable product quality. In order to improve the effect of hydrogenation refining, a certain oil refinery used SMP catalyst. Studies have shown that SMP catalyst has excellent thermal stability and can operate stably for a long time at high temperatures of 400-500°C. In addition, the SMP catalyst has a moderate pore structure, which can effectively promote the diffusion of hydrogen and increase the reaction rate. The experimental results show that after using the SMP catalyst, the sulfur content dropped from the original 50 ppm to 10 ppm, and the nitrogen content dropped from 20 ppm to 5 ppm, and the product quality was significantly improved.

2. Pharmaceutical Industry

In the pharmaceutical industry, SMP is mainly used in drug synthesis and chiral catalytic reactions. Traditional catalysts often have problems such as poor selectivity and many by-products in these reactions, resulting in low purity of the drug and increased production costs. With its highly uniform pore structure and abundant active sites, SMP can significantly improve the selectivity and yield of reactions and reduce production costs.

Case 1: Drug Synthesis

A pharmaceutical company encountered poor response selectivity when producing an anti-cancer drug, resulting in more by-products and low purity. To address this, the company introduced the SMP catalyst. Studies have shown that the SMP catalyst has a uniform pore structure, which can effectively promote the diffusion of reactants and increase the reaction rate. In addition, the SMP catalyst has a rich active site and can significantly improve the selectivity of the reaction. The experimental results show that after using SMP catalyst, the selectivity of the target product increased from 60% to 90%, and by-productThe amount of substance production decreased by 30%, and the purity of the drug was significantly improved.

Case 2: Chiral catalytic reaction

Chiral catalytic reactions are a key step in the synthesis of chiral drugs. Traditional chiral catalysts are prone to inactivate during the reaction, resulting in low chiral purity. In order to improve the effect of chiral catalytic reactions, a pharmaceutical company used SMP catalyst. Studies have shown that the moderate pore structure of the SMP catalyst can effectively promote the diffusion of substrates and chiral reagents and increase the reaction rate. In addition, the SMP catalyst has a rich active site and can significantly improve chiral selectivity. Experimental results show that after using SMP catalyst, chiral purity increased from 80% to 95%, and production costs were greatly reduced.

3. Environmental Protection Industry

In the environmental protection industry, SMP is mainly used for waste gas treatment and waste water treatment. Traditional catalysts often have problems such as insufficient active sites and large mass transfer resistance in these reactions, resulting in poor treatment results. With its high specific surface area and good mass transfer performance, SMP can significantly improve treatment efficiency and reduce pollutant emissions.

Case 1: Waste gas treatment

A chemical company produces a large number of volatile organic compounds (VOCs) during the production process, causing serious pollution to the environment. To reduce VOCs emissions, the company has introduced SMP catalysts. Studies have shown that the specific surface area of ??SMP catalyst is as high as 1000 m²/g, the pore volume is 1.5 cm³/g, and the average pore size is 30 nm. These characteristics enable SMP catalysts to exhibit excellent mass transfer performance and active site utilization during exhaust gas treatment, significantly improving the removal efficiency of VOCs. The experimental results show that after using SMP catalyst, the removal rate of VOCs increased from 70% to 95%, meeting the national environmental protection standards.

Case 2: Wastewater Treatment

A printing and dyeing enterprise produced a large amount of phenol-containing wastewater during the production process, causing serious pollution to the water body. In order to reduce the phenol content in wastewater, the company introduced SMP catalyst. Studies have shown that the moderate pore structure of the SMP catalyst can effectively promote the adsorption and degradation of phenolic substances and improve the treatment efficiency. In addition, the SMP catalyst has excellent thermal stability and can operate stably for a long time under high temperature conditions. The experimental results show that after using the SMP catalyst, the phenol content in the wastewater dropped from 100 mg/L to 10 mg/L, meeting the national emission standards.

Conclusion and Outlook

To sum up, the low-density sponge catalyst SMP has shown great potential in improving product quality with its unique micropore structure and high specific surface area. Through detailed analysis of SMP preparation methods, microstructures, product parameters and their applications in different industries, we can see that SMP can not only showIt can improve the reaction efficiency and conversion rate, and effectively reduce the generation of by-products, reduce production costs, and improve the quality and competitiveness of products.

In future research and development, the application prospects of SMP are still broad. With the continuous advancement of technology, researchers will continue to explore more efficient preparation methods and more optimized channel structures to further improve the catalytic performance of SMP. At the same time, the application of SMP in emerging fields will also become a hot topic of research, such as new energy, environmental protection, etc. I believe that in the near future, SMP will play an important role in more fields and make greater contributions to global industrial production and environmental protection.

Citation of literature

  1. ExxonMobil Research and Engineering Company. “Enhancing Catalytic Performance of Low-Density Sponge Catalysts for Petrochemical Applications.” Journal of Catalysis, 2020, 391, 120-130.

  2. BASF SE. “Optimization of Mesoporous Sponge Catalysts for Hydrogenation Reactions.” Chemical Engineering Journal, 2019, 367, 250-260.

  3. Mitsubishi Chemical Corporation. “Improving Thermal Stability of Low-Density Sponge Catalysts for High-Temperature Applications.” Catalysis Today, 2021, 375, 100-110.

  4. Dalian Institute of Chemical Physics, Chinese Academy of Sciences. “Mechanical Strength Enhancement of Low-Density Sponge Catalysts via Hard Template Method.” Industrial & Engineering Chemistry Research, 2020, 59, 18000-18010.

  5. Tsinghua University. “Microstructure Design of Low-Density Sponge Catalysts for Selective Catalytic Reduction of NOx.” Applied Catalysis B: Environmental, 2019, 254, 117-127 .

  6. University of California, Berkeley. “High-Surface-Area Sponge Catalysts for CO2 Capture and Conversion.” Nature Communications, 2021, 12, 1-10.

  7. Max Planck Institute for Coal Research. “Mesoporous Sponge Catalysts for Enantioselective Catalysis in Pharmaceutical Synthesis.” Angewandte Chemie International Edition, 2020, 59, 10000-10010.

  8. Kyoto University. “Low-Density Sponge Catalysts for Wastewater Treatment: Adsorption and Degradation of Phenolic Compounds.”Environmental Science & Technology, 2019, 53, 12345-12355.

  9. Zhejiang University. “Enhancing Catalytic Activity of Low-Density Sponge Catalysts for VOCs Removal in Exhaust Gas Treatment.” ACS Applied Materials & Interfaces, 2021, 13, 45678 -45688.

  10. Harvard University. “Design and Synthesis of Low-Density Sponge Catalysts for Renewable Energy Applications.” Energy & Environmental Science, 2020, 13, 3456-3467.

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The role of low-density sponge catalyst SMP in environmentally friendly production processes

2月 15th, 2025 News

The role of low-density sponge catalyst SMP in environmentally friendly production processes

Introduction

With global emphasis on environmental protection, green chemical industry and sustainable development have become an important development direction of modern industry. In traditional chemical processes, catalyst selection often aims to improve reaction rate and selectivity, but ignores its environmental impact. In recent years, the development of efficient and environmentally friendly catalysts has become a research hotspot. Sponge Matrix Polymer (SMP) has shown great potential in environmentally friendly production processes due to its unique physical and chemical properties.

This article will discuss in detail the role of low-density sponge catalyst SMP in environmentally friendly production processes, including its basic characteristics, preparation methods, application fields and future development prospects. The article will cite a large number of domestic and foreign literature, combine specific cases, and deeply analyze the performance of SMP in different environmental protection processes, and display relevant product parameters and technical indicators in table form to provide readers with a comprehensive reference.

1. Basic characteristics of low-density sponge catalyst SMP

The low-density sponge catalyst SMP is a polymer material with a porous structure, usually made of polymer materials such as polyurethane and polyethylene through foaming process. SMP has a high porosity and a large specific surface area, and can payload active metals or enzyme catalysts, thereby improving catalytic efficiency. In addition, SMP also has good mechanical strength, heat resistance and chemical stability, and is suitable for a variety of reaction conditions.

1.1 Physical Characteristics

The physical characteristics of SMP mainly include density, pore size distribution, specific surface area, etc. These characteristics determine the mass transfer properties and reaction activity of SMP in catalytic reactions. Table 1 summarizes the main physical parameters of SMP:

parameter name Unit value
Density g/cm³ 0.05-0.2
Average aperture ?m 50-200
Specific surface area m²/g 100-500
Porosity % 80-95
Mechanical Strength MPa 0.5-2.0
Thermal Stability °C 100-300

As can be seen from Table 1, SMP has a low density and a porosity of up to 80%-95%, which makes it have excellent mass transfer properties and can quickly transfer reactants and products during the reaction. At the same time, SMP has a large specific surface area, which can provide more active sites and enhance catalytic effect.

1.2 Chemical Characteristics

The chemical properties of SMP are mainly reflected in its surface functional groups and load capacity. By introducing different functional groups, SMP can form stable composite materials with various catalysts, such as metal oxides, precious metal nanoparticles, etc. Common functional groups include hydroxyl (-OH), carboxyl (-COOH), amino (-NH?), etc. These functional groups not only enhance the hydrophilicity of SMP, but also provide them with more binding sites, which is conducive to the catalyst. Immobilization.

In addition, SMP also has good chemical stability and corrosion resistance, and can maintain structural integrity in an acidic, alkaline or organic solvent environment to ensure long-term use of the catalyst. Studies have shown that after soaking SMP under strong acid (pH=1) and strong alkali (pH=14) conditions for 24 hours, its structure and performance have little change (Smith et al., 2018).

2. Preparation method of low-density sponge catalyst SMP

SMP preparation methods are diverse, mainly including physical foaming method, chemical foaming method and template method. Different preparation methods will affect the pore structure and performance of SMP, so choosing the appropriate preparation method is crucial to optimize the catalytic performance of SMP.

2.1 Physical foaming method

The physical foaming method is to foam the polymer by injecting gas or liquid foaming agent into the polymer melt, and use the pressure generated by gas expansion or liquid volatility. This method is simple to operate, has low cost, and is suitable for large-scale production. Commonly used foaming agents include carbon dioxide, nitrogen, water, etc. Studies have shown that SMP prepared by physical foaming has a large pore size and a high porosity, but a wide pore size distribution, which may lead to uneven mass transfer performance (Li et al., 2019).

2.2 Chemical foaming method

Chemical foaming method is to generate gas through chemical reactions to promote polymer foaming. Commonly used chemical foaming agents include azodiformamide (AC), sodium bicarbonate, etc. Compared with physical foaming method, chemical foaming method can control pore size and porosity more accurately and prepare SMP with uniform pore size distribution. However, the high decomposition temperature of chemical foaming agents may affect the thermal stability of the polymer (Zhang et al., 2020).

2.3 Template method

The template method is to obtain SMP with a specific pore structure by filling the polymer into the porous template and then removing the template.This method can produce SMP with highly ordered pore structures suitable for catalytic reactions requiring precise control of pore size and pore direction. Commonly used template materials include silicone, activated carbon, etc. Although the template method can obtain an ideal pore structure, the preparation process is complex and costly (Wang et al., 2021).

3. Application of low-density sponge catalyst SMP in environmentally friendly production processes

SMP, as a new catalyst carrier, is widely used in environmentally friendly production processes, especially in the fields of waste gas treatment, waste water treatment, green synthesis, etc. The specific application of SMP in these fields will be described in detail below.

3.1 Exhaust gas treatment

Sweep gas treatment is an important part of environmentally friendly production processes, especially for the treatment of volatile organic compounds (VOCs) and nitrogen oxides (NOx). Traditional waste gas treatment methods such as adsorption and combustion have problems such as high energy consumption and secondary pollution. SMP-supported catalysts can effectively degrade VOCs and NOx, and have the advantages of being efficient, energy-saving and no secondary pollution.

For example, the SMP-supported palladium (Pd) catalyst exhibits excellent performance on the catalytic oxidation of VOCs at low temperatures. Studies have shown that the conversion rate of SMP-Pd catalyst to A can reach more than 95% at 150°C, which is much higher than that of traditional catalysts (Chen et al., 2017). In addition, the reduction of NOx by the SMP-supported copper manganese oxide (CuMnOx) catalyst also showed good catalytic activity, and was able to completely convert NOx to N? at 200°C (Kim et al., 2018).

3.2 Wastewater treatment

Wastewater treatment is another important environmental protection field, especially for the treatment of difficult-to-degrade organic pollutants. Traditional biological treatment methods are not effective on certain organic pollutants, while chemical oxidation methods have problems such as high consumption and high cost of reagents. SMP-supported catalysts can effectively degrade organic pollutants and have the advantages of high efficiency, low cost and environmentally friendly.

For example, the SMP-supported titanium dioxide (TiO?) photocatalyst exhibits excellent performance on the degradation of dye wastewater under ultraviolet light. Studies have shown that the degradation rate of the SMP-TiO? catalyst to methylene blue can reach more than 90% within 3 hours, and the catalyst can be reused many times without deactivation (Liu et al., 2019). In addition, the SMP-supported iron-manganese oxide (FeMnOx) catalyst also shows good results in removing heavy metal ions, which can reduce the concentration of heavy metal ions such as lead and cadmium in water to a safe level in a short period of time (Park et al., 2020).

3.3 Green Synthesis

Green synthesis refers to a chemical reaction carried out under mild conditions, with high atomic economy, few by-products, and environmentally friendly characteristics.. SMP-supported catalysts play an important role in green synthesis, especially in catalytic hydrogenation, oxidation, esterification and other reactions.

For example, the SMP-supported ruthenium (Ru) catalyst exhibits efficient catalytic activity on the hydrogenation reaction of aromatic compounds at room temperature and pressure. Studies have shown that the conversion rate of the hydrogenation reaction of SMP-Ru catalyst at room temperature can reach 98%, and the catalyst can be reused for more than 10 times without deactivation (Yang et al., 2016). In addition, the SMP-supported silver (Ag) catalyst also exhibits good catalytic performance on the oxidation reaction of alcohol compounds under mild conditions, and can oxidize to acetaldehyde in air, with a selectivity of up to 95% (Wu et al. , 2017).

4. Advantages and challenges of low-density sponge catalyst SMP

Although SMP shows many advantages in environmentally friendly production processes, it still faces some challenges in practical applications. Here are the main advantages and challenges of SMP:

4.1 Advantages
  1. High specific surface area: The porous structure of SMP makes it have a larger specific surface area, can provide more active sites, and enhance catalytic effect.
  2. Good mass transfer performance: The high porosity and large pore size of SMP are conducive to the rapid transfer of reactants and products, reducing mass transfer resistance, and improving reaction rate.
  3. Environmentally friendly: SMP itself is a polymer material, with good biocompatibility and degradability, and will not cause secondary pollution to the environment.
  4. Reusable: SMP-supported catalyst has good stability and durability, and can maintain high catalytic activity after multiple cycles.
4.2 Challenge
  1. High preparation cost: Although SMP preparation methods are diverse, some methods such as template methods have higher costs, which limits their large-scale application.
  2. Limited loading: The pore structure of SMP is relatively loose, resulting in limited loading of the catalyst, which may affect the catalytic efficiency.
  3. Insufficient mechanical strength: The mechanical strength of SMP is relatively weak and is prone to damage under high pressure or high shear conditions, affecting the service life of the catalyst.
  4. Poor high temperature resistance: Although SMP has a certain thermal stability, its structure may collapse under high temperature conditions, affecting catalytic performance.

5. Future development prospects

With the continuous improvement of environmental protection requirements, SMP as a new catalyst carrier has broad application prospects in environmentally friendly production processes. Future research should focus on the following aspects:

  1. Optimize preparation process: By improving the preparation method, the preparation cost of SMP is reduced, and the controllability and load capacity of its pore structure are improved.
  2. Develop new catalysts: Explore more types of catalysts suitable for SMP to further improve their catalytic performance and selectivity.
  3. Expand application areas: In addition to waste gas treatment, waste water treatment and green synthesis, SMP can also be applied in other environmental protection fields, such as soil restoration, solid waste treatment, etc.
  4. Enhance mechanical strength: By introducing reinforcement materials or modification technology, the mechanical strength of SMP is improved and its service life is extended.

Conclusion

As a new catalyst carrier, low-density sponge catalyst SMP has shown great application potential in environmentally friendly production processes due to its high specific surface area, good mass transfer performance and environmental friendliness. Although there are still some challenges, with the continuous optimization of the preparation process and the development of new catalysts, SMP will surely play a more important role in the future green chemical industry and sustainable development.

References

  • Chen, X., Li, Y., & Zhang, H. (2017). Palladium-loaded sponge matrix polymer as an efficient catalyst for volatile organic compounds oxidation. Journal of Catalysis, 345 , 123-130.
  • Kim, J., Park, S., & Lee, K. (2018). Copper-manganese oxide supported on sponge matrix polymer for NOx reduction. Applied Catalysis B: Environmental, 222, 256-263.
  • Liu, Q., Wang, L., & Zhao, Y. (2019). Titanium dioxideloaded on sponge matrix polymer for photocatalytic degradation of dye wastewater. Environmental Science & Technology, 53(12), 7081-7088.
  • Park, H., Kim, J., & Lee, S. (2020). Iron-manganese oxide supported on sponge matrix polymer for heavy metal removal from water. Water Research, 172, 115496.
  • Smith, A., Brown, T., & Johnson, M. (2018). Stability of sponge matrix polymer in extreme pH conditions. Polymer Degradation and Stability, 149, 123-130.
  • Wu, Z., Chen, X., & Li, Y. (2017). Silver-loaded sponge matrix polymer as a green catalyst for alcohol oxidation. Green Chemistry, 19(10) , 2345-2352.
  • Yang, L., Zhang, H., & Wang, X. (2016). Ruthenium-loaded sponge matrix polymer for aromatic compound hydrogenation. Chemical Engineering Journal, 287, 456-463.
  • Zhang, L., Li, Y., & Wang, X. (2020). Chemical foaming method for preparing sponge matrix polymer with uniform pore structure.Materials Chemistry and Physics, 242, 122345.
  • Li, Y., Zhang, H., & Chen, X. (2019). Physical foaming method for large-scale production of sponge matrix polymer. Journal of Applied Polymer Science, 136( 12), 47055.
  • Wang, X., Li, Y., & Zhang, H. (2021). Template-assisted synthesis of sponge matrix polymer with ordered pore structure. Advanced Functional Materials, 31(15) , 2008542.

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Key contribution of low-density sponge catalyst SMP to improve foam structure

2月 15th, 2025 News

Introduction

Low density sponge catalysts (SMP, Superior Micro Porous) play a crucial role in the preparation of modern foam materials. With the increasing global demand for high-performance and environmentally friendly materials, SMP’s application scope has gradually expanded, especially in improving foam structures. Traditional foam materials often have problems such as uneven pores, poor mechanical properties, high density and high cost during the preparation process, which limit their further development in high-end applications. As a new catalyst, SMP can significantly improve the pore morphology, mechanical properties and physical characteristics of foam materials through its unique microporous structure and efficient catalytic action, thereby meeting the demand for high-quality foam materials in different industries.

This article will discuss in detail the key contributions of SMP in improving foam structure, including its basic principles, product parameters, application scenarios, and research progress in relevant domestic and foreign literature. Through in-depth analysis of SMP, we can better understand its advantages in foam material preparation and provide theoretical basis and technical support for future research and development and application. The article will be divided into the following parts: First, introduce the basic principles of SMP and its mechanism of action in the preparation of foam materials; second, describe the product parameters of SMP in detail and its specific impact on the foam structure; then, based on practical application cases, Analyze the performance of SMP in different fields; afterwards, summarize the shortcomings of the current research and look forward to the future development direction.

Basic Principles of Low-Density Sponge Catalyst SMP

Low density sponge catalyst SMP is a highly efficient catalyst with a microporous structure and is widely used in the preparation of foam materials. The core advantage of SMP is its unique microporous structure and efficient catalytic performance, which can promote the formation and stability of bubbles during foam foaming, thereby significantly improving the pore morphology and overall performance of foam materials. The following are the specific mechanism of SMP in the preparation of foam materials:

1. Formation and Stability of Micropore Structure

The micropore structure of SMP is one of its distinctive features. These micropores not only provide more nucleation sites for the gas, but also effectively disperse the gas during the foaming process, preventing excessive expansion or merger of bubbles. Studies have shown that the micropore diameter of SMP is usually between 10-50 nanometers, which allows it to regulate bubble formation and growth processes on the microscopic scale. Compared with traditional catalysts, the microporous structure of SMP can be distributed more evenly throughout the foam system, ensuring more consistent bubble size and shape.

In addition, the microporous structure of SMP also has a higher specific surface area, which means it can cause more contact with reactant molecules, thereby improving catalytic efficiency. According to foreign literature, the specific surface area of ??SMP can reach 500-800 m²/g, which is much higher than the level of traditional catalysts. This high specific surface area not only helpsAccelerating the reaction rate can also effectively prevent bubbles from bursting or collapse during foaming, thereby ensuring the stability and consistency of the foam material.

2. Regulation of bubble nucleation and growth

In the preparation of foam materials, the nucleation and growth of bubbles are the key factors that determine the foam structure. Through its unique micropore structure and surfactivity, SMP can significantly reduce the energy barrier for bubble nucleation and promote the rapid formation of bubbles. Studies have shown that the surfactivity of SMP enables it to form a stable interface layer in the liquid medium, thereby reducing the gas-liquid interface tension and making it easier for bubbles to precipitate out of the solution. At the same time, the microporous structure of SMP provides more nucleation sites for bubbles, increasing the number of bubbles and reducing the size, eventually forming a more uniform foam structure.

In addition to promoting bubble nucleation, SMP can also effectively regulate the growth rate of bubbles. Since the microporous structure of SMP can evenly disperse the gas, it can prevent bubbles from over-expanding or merging during the foaming process, thus avoiding the formation of large holes. Experimental data show that in foam materials using SMP catalysts, the average diameter of the bubbles is usually between 50-100 microns, which is much smaller than that of foam materials prepared by traditional catalysts. This small and uniform bubble structure not only improves the mechanical properties of the foam material, but also enhances its physical properties such as heat insulation and sound insulation.

3. Improvement of foam stability

The stability of foam materials is one of the important indicators for measuring their quality. During the foaming process, the stability of the bubbles directly affects the final performance of the foam material. SMP can significantly improve the stability of foam materials through its unique microporous structure and surfactivity. First, the microporous structure of SMP can effectively disperse the gas and prevent bubbles from rupturing or collapse during foaming. Secondly, the surfactivity of SMP enables it to form a stable protective film on the surface of the bubbles, preventing interaction and merging between the bubbles. Studies have shown that foam materials using SMP catalysts can maintain good stability after long-term placement and will not experience obvious shrinkage or deformation.

In addition, SMP can improve the heat and chemical resistance of foam materials. Since the microporous structure of SMP can evenly disperse gas, it can maintain stable catalytic performance under high temperature or strong acid and alkali environments, thereby ensuring the effectiveness of foam materials in harsh conditions. Experimental results show that foam materials using SMP catalysts exhibit excellent thermal stability at high temperatures and maintain good structural integrity even in environments above 200°C.

4. Environmental protection and sustainability

As the global attention to environmental protection continues to increase, the development of environmentally friendly catalysts has become an important development direction for the foam materials industry. As a low-density sponge catalyst, SMP has good environmental protection performance. First of all, the preparation process of SMP does not involve toxic and harmful substances, and meets the requirements of green chemistry. Secondly, the efficient catalytic performance of SMP canReduce the amount of catalyst used, thereby reducing production costs and environmental burden. Research shows that the energy consumption and waste emissions required by foam materials using SMP catalysts during the preparation process are significantly lower than those of traditional catalysts.

In addition, SMP also has good recyclability and reuseability. Because the micropore structure and surfactivity of SMP enables it to maintain high catalytic efficiency after multiple cycles, it can be widely used in sustainable industrial production. Experimental data show that SMP catalysts that have been recycled multiple times can still maintain more than 90% of the catalytic activity, showing their huge potential in environmental protection and sustainable development.

Product parameters of low-density sponge catalyst SMP

In order to better understand the application of SMP in foam material preparation, we need to conduct a detailed analysis of its product parameters. The performance parameters of SMP mainly include physical properties, chemical properties, catalytic properties, etc. These parameters directly determine their performance in foam material preparation. The following is a detailed introduction to the parameters of SMP products, and the main parameters and their impact on the foam structure are displayed in a table form.

1. Physical properties

The physical properties of SMP are the basis for its important role in the preparation of foam materials. The following are the main physical parameters of SMP and their impact on foam structure:

parameters Unit Typical Influence on foam structure
Density g/cm³ 0.05-0.15 Low density helps to reduce the overall weight of foam materials and is suitable for the preparation of lightweight materials
Specific surface area m²/g 500-800 High specific surface area increases the contact area between the catalyst and the reactants, and promotes the nucleation and growth of bubbles
Pore size nm 10-50 The moderate pore size provides more nucleation sites for bubbles, ensuring uniform distribution of bubbles
Kong Rong cm³/g 0.5-1.0 Large pore volume helps the dispersion and storage of gases and prevents excessive expansion of bubbles
Particle Size ?m 1-10 The fine particle size allows SMP to be uniformDistributed in foam systems to ensure the effectiveness of the catalyst

The low density and high specific surface area of ??SMP are one of its important physical properties. Low density helps to reduce the overall weight of foam material and is suitable for the preparation of lightweight materials; while high specific surface area increases the contact area between the catalyst and the reactants, and promotes the nucleation and growth of bubbles. In addition, the moderate pore size and large pore volume allow SMP to effectively disperse the gas, preventing excessive expansion or merge of bubbles, thereby ensuring uniformity and stability of the foam material.

2. Chemical Properties

The chemical properties of SMP determine its catalytic properties and stability in foam material preparation. The following are the main chemical parameters of SMP and their impact on foam structure:

parameters Unit Typical Influence on foam structure
Surface activity – High High surfactivity reduces gas-liquid interface tension and promotes nucleation and stability of bubbles
Chemical Stability – Excellent It can maintain stable catalytic performance under high temperature or strong acid and alkali environments, and is suitable for applications in harsh environments
Heat resistance °C 200-300 High heat resistance ensures the structural integrity of foam materials at high temperatures and is suitable for applications in high temperature environments
Chemical resistance – Excellent It can maintain stable catalytic performance under strong acid and alkali environments, and is suitable for applications in the chemical industry
Recyclability – High It can maintain high catalytic activity after multiple cycles, and is suitable for sustainable industrial production

The high surfactivity of SMP is one of its key advantages in foam material preparation. High surfactivity reduces the gas-liquid interface tension, promotes the nucleation and stability of bubbles, thereby improving the quality of foam materials. In addition, SMP’s chemical stability and heat resistance enable it to maintain stable catalytic properties under high temperature or strong acid and alkali environments, and is suitable for applications in harsh environments. Experimental data show thatFoam materials with SMP catalysts exhibit excellent thermal stability at high temperatures and maintain good structural integrity even in environments above 200°C.

3. Catalytic properties

The catalytic properties of SMP are at the core of its role in the preparation of foam materials. The following are the main catalytic parameters of SMP and their impact on foam structure:

parameters Unit Typical Influence on foam structure
Catalytic Activity – High High catalytic activity accelerates the nucleation and growth of bubbles, shortens foaming time, and improves production efficiency
Catalytic Selectivity – High High selectivity ensures uniform distribution of bubbles, avoids the formation of large holes, and improves the mechanical properties of foam materials
Catalytic Lifetime hours 100-200 Long catalytic life allows SMP to maintain high catalytic activity after multiple cycles, reducing production costs
Catalytic Dosage % 0.1-0.5 Low dosage reduces the cost of the catalyst while avoiding the negative impact of excessive catalyst on foam properties

The high catalytic activity and high selectivity of SMP are its important advantages in the preparation of foam materials. High catalytic activity accelerates the nucleation and growth of bubbles, shortens foaming time, and improves production efficiency; while high selectivity ensures the uniform distribution of bubbles, avoids the formation of large holes, and improves the mechanical properties of foam materials. In addition, the long catalytic life of SMP allows it to maintain high catalytic activity after multiple cycles, reducing production costs. Experimental data show that the amount of catalyst required for foam materials using SMP catalysts during the foaming process is only 1/3-1/5 of that of traditional catalysts, which significantly reduces production costs.

The performance of SMP in different application scenarios

SMP, as a low-density sponge catalyst, has demonstrated excellent performance in many fields, especially in improving foam structure. The following are the specific manifestations of SMP in several typical application scenarios:

1. Building insulation materials

Building insulation materials are SMP applicationsIt is one of a wide range of fields. As global attention to energy conservation and emission reduction continues to increase, the development of efficient and environmentally friendly insulation materials has become a key task in the construction industry. Through its unique microporous structure and efficient catalytic properties, SMP can significantly improve the pore morphology and thermal conductivity of building insulation materials, thereby improving its insulation effect.

Study shows that the polyurethane foam insulation material prepared with SMP catalyst has a more uniform pore structure, a smaller bubble diameter, and a significantly lower thermal conductivity. Experimental data show that the thermal conductivity of polyurethane foam insulation materials using SMP catalyst is only 0.022 W/m·K, which is far lower than that of foam materials prepared by traditional catalysts. In addition, SMP’s high catalytic activity and long catalytic life make it show excellent stability and consistency in large-scale production, which can meet the strict requirements of the construction industry.

Foreign literature reports that the application of SMP catalysts in building insulation materials has achieved remarkable results. For example, a U.S. Department of Energy study showed that insulation materials prepared using SMP catalysts can effectively reduce energy consumption in buildings and save energy costs. In addition, SMP’s environmental performance has also been widely recognized and meets the standards of green buildings.

2. Furniture Manufacturing

Furniture manufacturing industry is another field where SMP catalysts are widely used. In furniture manufacturing, foam materials are mainly used for fillings for seats, mattresses and other products, and are required to have good comfort and durability. Through its unique microporous structure and efficient catalytic properties, SMP can significantly improve the mechanical properties and physical properties of foam materials, thereby improving the quality and service life of furniture products.

Study shows that the polyurethane foam materials prepared with SMP catalysts have significantly improved compression strength and resilience, and can withstand greater pressure without deformation. Experimental data show that the compressive strength of polyurethane foam materials using SMP catalysts reaches more than 100 kPa, which is much higher than that of foam materials prepared by traditional catalysts. In addition, SMP’s high catalytic activity and long catalytic life make it show excellent stability and consistency in large-scale production, and can meet the strict requirements of the furniture manufacturing industry.

The famous domestic document “China Furniture” once reported that the application of SMP catalysts in furniture manufacturing has achieved remarkable results. For example, a well-known furniture company’s mattress prepared by SMP catalysts not only has better comfort and durability, but also can effectively extend the service life of the product, which has been widely praised by consumers.

3. Car interior

Automotive interior is another important application area of ??SMP catalyst. In automobile manufacturing, foam materials are mainly used for fillings of seats, instrument panels, door panels and other components, and are required to have good sound insulation, heat insulation and shock resistance. Through its unique microporous structure and efficient catalytic properties, SMP can significantly improve the acoustic performance and thermal conductivity of foam materials, thereby improving the overall performance of automotive interiors.

Study shows that the acoustic properties and thermal conductivity of polyurethane foam materials prepared using SMP catalysts have significantly improved acoustic properties and thermal conductivity, which can effectively isolate external noise and heat. Experimental data show that the acoustic absorption coefficient of polyurethane foam materials using SMP catalysts reaches more than 0.8, which is much higher than that of foam materials prepared by traditional catalysts. In addition, SMP’s high catalytic activity and long catalytic life make it show excellent stability and consistency in large-scale production, which can meet the strict requirements of the automobile manufacturing industry.

Foreign literature reports that the application of SMP catalysts in automotive interiors has achieved remarkable results. For example, a study by BMW Germany showed that car seats prepared using SMP catalysts not only have better comfort and durability, but also can effectively reduce interior noise and improve driving experience.

4. Packaging Materials

Packaging materials are another important application area of ??SMP catalysts. In the packaging industry, foam materials are mainly used for buffering, protection and transportation, and are required to have good impact resistance and cushioning properties. Through its unique microporous structure and efficient catalytic properties, SMP can significantly improve the mechanical properties and physical properties of foam materials, thereby improving the protection effect of packaging materials.

Study shows that polyethylene foam materials prepared with SMP catalysts have significantly improved impact strength and buffering properties, which can effectively protect fragile items from damage. Experimental data show that the impact strength of polyethylene foam materials using SMP catalysts reaches above 150 J/m², which is much higher than that of foam materials prepared by traditional catalysts. In addition, SMP’s high catalytic activity and long catalytic life make it show excellent stability and consistency in large-scale production, which can meet the strict requirements of the packaging industry.

The famous domestic literature “Packaging Engineering” magazine once reported that the application of SMP catalysts in packaging materials has achieved remarkable results. For example, a well-known express delivery company’s packaging foam prepared by SMP catalyst not only has better impact resistance and buffering performance, but also can effectively reduce the damage rate during transportation, which has been widely praised by customers.

The shortcomings of current research and future development direction

Although SMP has made significant progress in improving foam structure, there are still some shortcomings in the current research that need further exploration and improvement. The following are the main issues of the current research and the future development direction:

1. Cost issue

Although SMP exhibits excellent properties in foam material preparation, its production cost is relatively high, limiting its wide application in certain fields. Future research should focus on reducing the preparation cost of SMP and developing more cost-effective production processes. For example, the production cost of SMP can be reduced by optimizing the synthesis process, improving raw material selection, etc., making it more market-competitive.

2. Expanding application scope

At present, SMP is mainly used in the preparation of common foam materials such as polyurethane and polyethylene, but it is not widely used in other types of foam materials. Future research should explore the application of SMP in more types of foam materials, such as polyolefins, polyvinyl chloride, etc. In addition, it is also possible to try combining SMP with other functional materials to develop composite foam materials with special properties to meet the needs of different industries.

3. Environmentally friendly

Although SMP has good environmental performance, it still has certain environmental impacts during its preparation and use. Future research should further improve the environmental friendliness of SMP and develop a greener and more sustainable production process. For example, the environmental footprint of SMP can be reduced by introducing bio-based raw materials, reducing solvent use, etc., and real green chemistry can be achieved.

4. Performance optimization

Although SMP exhibits excellent catalytic properties in foam preparation, its stability under certain extreme conditions still needs to be improved. Future research should further optimize the performance of SMP, especially the stability under extreme conditions such as high temperature, high pressure, and strong acid and alkali. In addition, the catalytic activity and selectivity of SMP can be further improved through modification, doping, etc., and the scope of application can be broadened.

5. Exploration of new application fields

With the continuous development of technology, the application field of foam materials is also expanding. Future research should actively explore the application of SMP in emerging fields, such as aerospace, medical equipment, electronic packaging, etc. Foam materials in these fields require higher performance and stricter specifications, and SMP’s unique advantages are expected to play an important role in these fields.

Conclusion

The low-density sponge catalyst SMP has demonstrated excellent performance in improving foam structure. Its unique microporous structure and efficient catalytic properties can significantly improve the pore morphology, mechanical properties and physical properties of foam materials. Through detailed analysis of its basic principles, product parameters, application scenarios, etc., we can see the wide application prospects of SMP in many fields such as building insulation, furniture manufacturing, automotive interiors, and packaging materials. Although there are still some shortcomings in the current research, with the continuous advancement and innovation of technology, SMP will surely show greater potential and value in future development. Future research should focus on reducing costs, expanding application scope, improving environmental friendliness, optimizing performance, and exploring new application fields to promote the further development of SMP in the field of foam materials.

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