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Study on the durability and stability of low-density sponge catalyst SMP in extreme environments

2月 15th, 2025 News

Introduction

Sponge Matrix Porous Catalyst, a low-density sponge catalyst, has attracted widespread attention in the field of catalysis in recent years. Its unique three-dimensional structure and high specific surface area make it exhibit excellent catalytic properties in a variety of chemical reactions. However, with the continuous expansion of application fields, especially in extreme environments, the study of the durability and stability of SMP under extreme conditions such as high temperature, high pressure, strong acid and alkali, corrosive gases has become critical. important.

This paper will systematically explore the durability and stability of low-density sponge catalyst SMP in extreme environments. By analyzing its physical and chemical characteristics, combined with new research results at home and abroad, we will deeply explore the behavior of SMP under different extreme conditions. and its influencing factors. The article will be divided into the following parts: First, introduce the basic concepts and preparation methods of SMP; second, discuss the physical and chemical characteristics of SMP in detail, including its microstructure, pore size distribution, specific surface area, etc.; then focus on analyzing SMP at high temperature, high pressure, Durability and stability in extreme environments such as strong acid and alkali, corrosive gases; then summarize the application prospects of SMP and propose future research directions.

Basic concepts and preparation methods of low-density sponge catalyst SMP

The low-density sponge catalyst SMP is a catalyst support with a three-dimensional porous structure, usually composed of metal oxides, carbon materials or other functional materials. SMP is unique in its spongy microstructure, which not only provides a large number of active sites, but also imparts good mass and heat transfer properties to the catalyst, thereby improving catalytic efficiency. In addition, the low density characteristics of SMP make it lightweight in practical applications, and are particularly suitable for use in mobile devices or where there are strict weight requirements.

1. Definition and classification of SMP

SMP can be divided into the following categories according to the composition and structural characteristics of the material:

  • Metal oxide-based SMP: such as titanium dioxide (TiO?), alumina (Al?O?), zirconium oxide (ZrO?), etc. This type of SMP has high thermal stability and chemical inertia, and is widely used in photocatalysis, gas phase catalysis and other fields.

  • Carbon-based SMP: such as activated carbon, graphene, carbon nanotubes, etc. Carbon-based SMP has excellent electrical conductivity and mechanical strength, and is suitable for electrocatalysis, fuel cells and other fields.

  • Composite SMP: Compound metal oxides with carbon materials or other functional materials to form a catalyst support with multiple characteristics. For example, TiO?/carbon composite SMP performs in photocatalytic degradation of organic pollutantsThere is a significant synergistic effect.

2. Method of preparation of SMP

SMP preparation methods vary, and common preparation techniques include sol-gel method, template method, freeze-drying method, foaming method, etc. The following are several typical preparation methods and their characteristics:

Preparation method Features Scope of application
Sol-gel method The gel is formed by hydrolysis and condensation reaction of the precursor solution, and then dried and sintered to obtain a porous structure. This method is easy to control pore size and porosity, but the preparation process is relatively complicated. Suitable for the preparation of metal oxide-based SMPs, such as TiO?, Al?O?, etc.
Template Method Use hard templates or soft templates to build a porous structure, and then remove the template to obtain the target material. This method can prepare SMP with regular channel structure, but the selection and removal process of templates are more critical. Suitable for the preparation of SMPs with specific pore sizes and pore structures, such as mesoporous materials.
Free-drying method The solution containing the precursor is rapidly frozen, and the solvent is removed by sublimation to obtain a porous structure. This method can retain the microstructure in the solution and is suitable for the preparation of SMP with high specific surface area. Suitable for the preparation of high porosity SMPs, such as activated carbon, graphene, etc.
Foaming method The precursor solution is expanded by introducing gas or foaming agent to form a foamy structure, and then curing and drying to obtain SMP. This method is simple and easy to implement, but the aperture distribution is difficult to control. Suitable for the preparation of SMPs with macroporous structures, such as polyurethane foam-based catalysts.

3. SMP product parameters

To better understand the performance of SMP, the following are typical parameters of several common SMP products:

Material Type Density (g/cm³) Pore size (nm) Specific surface area (m²/g) Thermal Stability (?) Chemical stability (pH range)
TiO?-based SMP 0.5-1.0 5-50 50-200 >800 2-12
Al?O?Basic SMP 0.6-1.2 10-100 100-300 >1000 3-10
Carbon-based SMP 0.1-0.5 2-100 500-1500 >600 1-14
Composite SMP (TiO?/carbon) 0.3-0.8 5-50 200-500 >800 2-12

Physical and chemical properties of SMP

The physical and chemical properties of SMP are key factors that determine its durability and stability in extreme environments. This section will discuss the characteristics of SMP in detail from the aspects of microstructure, pore size distribution, specific surface area, thermal stability, chemical stability, etc., and analyze it in combination with relevant literature.

1. Microstructure

The microstructure of SMP has an important influence on its catalytic performance. Observing through scanning electron microscopy (SEM) and transmission electron microscopy (TEM), SMP exhibits a typical sponge-like porous structure with pores connected to each other, forming a rich three-dimensional network. This structure not only increases the specific surface area of ??the catalyst, but also promotes the diffusion of reactants and products, thereby improving catalytic efficiency.

Study shows that the pore size distribution of SMP has a significant impact on its catalytic performance. Smaller pore sizes help improve the specific surface area, but may lead to an increase in mass transfer resistance; larger pore sizes help improve mass transfer performance, but will reduce the specific surface area. Therefore, optimizing the pore size distribution is the key to improving SMP catalytic performance. According to literature reports, the ideal SMP pore size should be between 10-100 nm to balance the specific surface area and mass transfer properties.

2. Pore size distribution and specific surface area

The pore size distribution and specific surface area of ??SMP are important indicators for evaluating its physical properties. Through the nitrogen adsorption-desorption experiment (BET method), the pore size distribution and specific surface area of ??SMP can be accurately determined. Table 1 summarizes the pore size distribution and specific surface area data of several common SMP materials.

Material Type Average pore size (nm) Pore size distribution range (nm) Specific surface area (m²/g)
TiO?-based SMP 20 5-50 150
Al?O?Basic SMP 50 10-100 250
Carbon-based SMP 50 2-100 1000
Composite SMP (TiO?/carbon) 30 5-50 300

As can be seen from Table 1, carbon-based SMP has a high specific surface area, which is due to its developed micropore structure. Complex SMP achieves a high specific surface area and good mass transfer performance by optimizing the pore size distribution, and is suitable for a variety of catalytic reactions.

3. Thermal Stability

Thermal stability of SMP refers to its ability to maintain structural integrity and catalytic activity under high temperature conditions. Studies have shown that the thermal stability of SMP is closely related to its material composition. Metal oxide-based SMPs usually have high thermal stability and can maintain good structural and catalytic properties at high temperatures of 800-1000°C. For example, after TiO?-based SMP is calcined at 900°C, it can still maintain a high specific surface area and porosity, showing excellent thermal stability.

In contrast, carbon-based SMP has poor thermal stability, especially in oxygen atmosphere, which is prone to oxidation and decomposition. To improve the thermal stability of carbon-based SMP, researchers usually use doping or composite methods. For example, combining TiO? with carbon material can effectively inhibit the oxidation of carbon material and improve the overall thermal stability of SMP. According to literature reports, after TiO?/carbon composite SMP is calcined in air at 600°C, it can still maintain a high specific surface area and catalytic activity.

4. Chemical Stability

The chemical stability of SMP refers to its ability to maintain structural integrity and catalytic activity in harsh chemical environments such as acid and alkali, corrosive gases. Studies have shown that the chemical stability of SMP is closely related to its material composition and surface properties. Metal oxide-based SMPs usually have good chemical stability and can maintain structural stability over a wide pH range. For example, Al?O?-based SMP exhibits excellent chemical stability in the pH range of 3-10 and is suitable for acidicityor catalytic reaction under alkaline conditions.

However, carbon-based SMP is prone to dissolution or corrosion under strong acid or alkali conditions, especially when the surface contains more oxygen-containing functional groups. To improve the chemical stability of carbon-based SMP, researchers usually use surface modification or doping methods. For example, by introducing nitrogen or sulfur, the chemical stability of carbon-based SMP can be effectively improved, so that it maintains good catalytic performance in a wider pH range. According to literature reports, nitrogen-doped carbon-based SMP exhibits excellent chemical stability in the range of pH 1-14 and is suitable for catalytic reactions under extreme acid and base conditions.

Durability and stability of SMP in extreme environments

The durability and stability of SMP in extreme environments are key issues in its practical application. This section will focus on the behavior of SMP under extreme conditions such as high temperature, high pressure, strong acid and alkali, corrosive gases and their influencing factors, and analyze it in combination with relevant literature.

1. Durability and stability in high temperature environments

High temperature environment has an important influence on the structure and catalytic performance of SMP. Studies have shown that the durability and stability of SMP under high temperature conditions mainly depend on its material composition and pore structure. Metal oxide-based SMPs usually have high thermal stability and can maintain good structural and catalytic properties at high temperatures of 800-1000°C. For example, after TiO?-based SMP is calcined at 900°C, it can still maintain a high specific surface area and porosity, showing excellent thermal stability.

However, the thermal stability of carbon-based SMP is poor, especially in oxygen atmospheres, oxidative decomposition is prone to occur. To improve the thermal stability of carbon-based SMP, researchers usually use doping or composite methods. For example, combining TiO? with carbon material can effectively inhibit the oxidation of carbon material and improve the overall thermal stability of SMP. According to literature reports, after TiO?/carbon composite SMP is calcined in air at 600°C, it can still maintain a high specific surface area and catalytic activity.

In addition, high temperature environments may also cause SMP sintering, resulting in a decrease in porosity and a decrease in specific surface area. To prevent sintering, researchers usually use methods of adding additives or optimizing the preparation process. For example, by introducing additives such as silicates or phosphates, SMP can be effectively inhibited and its durability and stability in high temperature environments can be improved.

2. Durability and stability in high-voltage environments

High voltage environment also has an important impact on the structure and catalytic performance of SMP. Studies have shown that the durability and stability of SMP under high pressure conditions mainly depend on its pore structure and mechanical strength. Since SMP has a lower density and high porosity, it is prone to compression deformation under high pressure conditions, resulting in a decrease in porosity and a decrease in specific surface area. To improve the durability and stability of SMP in high-pressure environments, researchers usually use the method of enhancing the thickness of the hole wall or introducing a support structureLaw.

For example, by introducing nanoscale support particles, the mechanical strength of SMP can be effectively improved and the compression deformation of it can be prevented under high pressure conditions. According to literature reports, SMP added with nanosilicon dioxide particles can maintain a high porosity and specific surface area under a pressure of 10 MPa, showing excellent pressure resistance. In addition, by optimizing the pore structure of SMP, such as increasing the proportion of large pores or introducing interconnected pores, its durability and stability in high-pressure environments can also be effectively improved.

3. Durability and stability in strong acid and alkali environments

The strong acid and alkali environment has an important influence on the structure and catalytic performance of SMP. Studies have shown that the durability and stability of SMP in a strong acid-base environment mainly depends on its material composition and surface properties. Metal oxide-based SMPs usually have good chemical stability and can maintain structural stability over a wide pH range. For example, Al?O?-based SMP exhibits excellent chemical stability in the pH range of 3-10 and is suitable for catalytic reactions under acidic or alkaline conditions.

However, carbon-based SMP is prone to dissolution or corrosion under strong acid or alkali conditions, especially when the surface contains more oxygen-containing functional groups. To improve the chemical stability of carbon-based SMP, researchers usually use surface modification or doping methods. For example, by introducing nitrogen or sulfur, the chemical stability of carbon-based SMP can be effectively improved, so that it maintains good catalytic performance in a wider pH range. According to literature reports, nitrogen-doped carbon-based SMP exhibits excellent chemical stability in the range of pH 1-14 and is suitable for catalytic reactions under extreme acid and base conditions.

In addition, strong acid and alkali environments may also trigger structural changes in SMP, resulting in a decrease in porosity and a decrease in specific surface area. To prevent structural changes, researchers often use methods that optimize material composition or introduce protective layers. For example, by introducing protective layers such as alumina or silica, SMP can be effectively prevented from dissolution or corrosion in a strong acid-base environment, and its durability and stability can be improved.

4. Durability and stability in corrosive gas environment

The corrosive gas environment has an important influence on the structure and catalytic performance of SMP. Studies have shown that the durability and stability of SMP in corrosive gas environments mainly depend on its material composition and surface properties. Metal oxide-based SMP usually has good corrosion resistance and can maintain structural stability in an environment containing corrosive gases such as hydrogen chloride (HCl), sulfur dioxide (SO?). For example, after exposure to HCl-containing gas for 24 hours, TiO?-based SMP can maintain a high specific surface area and catalytic activity, showing excellent corrosion resistance.

However, carbon-based SMP is prone to oxidation or corrosion in corrosive gas environments, especially when the surface contains more oxygen-containing functional groups. To improve the corrosion resistance of carbon-based SMP, researchers usually use surface modified or dopedmethod. For example, by introducing nitrogen or sulfur, the corrosion resistance of carbon-based SMP can be effectively improved, so that it maintains good catalytic performance in an environment containing corrosive gases such as HCl and SO?. According to literature reports, nitrogen-doped carbon-based SMP can maintain a high specific surface area and catalytic activity after being exposed to HCl-containing gas for 72 hours, showing excellent corrosion resistance.

In addition, corrosive gas environment may also cause structural changes in SMP, resulting in a decrease in porosity and a decrease in specific surface area. To prevent structural changes, researchers often use methods that optimize material composition or introduce protective layers. For example, by introducing protective layers such as alumina or silica, it is possible to effectively prevent SMP from oxidizing or corrosion in a corrosive gas environment, and improve its durability and stability.

SMP application prospects and future research directions

SMP, as a new porous catalyst carrier, has shown broad application prospects in the fields of catalysis, environmental protection, energy, etc. However, with the continuous expansion of application fields, especially in extreme environments, it is crucial to study the durability and stability of SMP in extreme environments. This section will summarize the application prospects of SMP and propose future research directions.

1. Application prospects

SMP has shown broad application prospects in many fields, mainly including the following aspects:

  • Catalytic Field: SMP has a high specific surface area and rich active sites, and is suitable for a variety of catalytic reactions, such as photocatalysis, gas phase catalysis, liquid phase catalysis, etc. In particular, its three-dimensional porous structure and good mass transfer properties make it show significant advantages in efficient catalytic reactions.

  • Environmental Protection Field: SMP can be used to treat wastewater, waste gas and solid waste, and has efficient adsorption and degradation capabilities. For example, TiO?-based SMP exhibits excellent performance in photocatalytic degradation of organic pollutants and can effectively remove harmful substances in water.

  • Energy Field: SMP can be used in energy storage equipment such as fuel cells, lithium-ion batteries, and has excellent electrical conductivity and mechanical strength. For example, as an electrode material, carbon-based SMP can significantly improve the charging and discharge efficiency and cycle life of the battery.

  • Chemical field: SMP can be used in petroleum refining, chemical synthesis and other processes, and has efficient catalytic activity and selectivity. For example, Al?O?-based SMP exhibits excellent catalytic properties in hydrocracking reactions, which can effectively improve reaction efficiency and product quality.

2. Future research direction

AlthoughSMP has shown broad application prospects in many fields, but its durability and stability in extreme environments are still issues that need to be solved urgently. Future research can be carried out from the following aspects:

  • New Material Development: Develop SMP materials with higher thermal stability and chemical stability, such as new metal oxides, carbon-based materials and their composite materials. By optimizing the material composition and structure, the durability and stability of SMP in extreme environments can be further improved.

  • Surface Modification and Doping: Through surface modification, doping and other means, the chemical stability and corrosion resistance of SMP can be further improved. For example, the introduction of elements such as nitrogen and sulfur can effectively improve the chemical stability and corrosion resistance of carbon-based SMP.

  • Structural Optimization and Strengthening: By optimizing the pore structure and pore size distribution of SMP, its mass transfer performance and mechanical strength will be further improved. For example, increasing the proportion of large pores or introducing interconnected pores can effectively improve the durability and stability of SMP in high-pressure environments.

  • Multi-scale simulation and experimental verification: Combining multi-scale simulation and experimental verification, we will conduct in-depth research on the behavioral mechanism of SMP in extreme environments. Through molecular dynamics simulation, quantum chemistry calculation and other means, the microstructure changes and catalytic mechanism of SMP under extreme conditions such as high temperature, high pressure, strong acid and alkali, and corrosive gases are revealed.

  • Industrial Application and Large-scale Production: Promote the application of SMP in the industrial field and realize its large-scale production and commercial promotion. By optimizing the preparation process and reducing costs, the market competitiveness and application value of SMP can be further improved.

Conclusion

As a new porous material, low-density sponge catalyst SMP has shown broad application prospects in many fields such as catalysis, environmental protection, and energy due to its unique three-dimensional structure and high specific surface area. However, with the continuous expansion of application fields, especially in extreme environments, it is crucial to study the durability and stability of SMP in extreme environments. This paper analyzes the physical and chemical characteristics of SMP and combines new research results at home and abroad to deeply explore the behavior of SMP under extreme conditions such as high temperature, high pressure, strong acid and alkali, and corrosive gases and their influencing factors. Future research should be carried out in the areas of new material development, surface modification and doping, structural optimization and strengthening, multi-scale simulation and experimental verification, industrial application and large-scale production, etc., to further improve the durability and stability of SMP in extreme environments. promotes its wide application in more fields.

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Analysis of the Ways of Low-Density Sponge Catalyst SMP Reduces Production Cost and Improves Efficiency

2月 15th, 2025 News

Background and application of low-density sponge catalyst SMP

Sponge Metal Porous (SMP) is a new catalytic material, and has been widely used in the chemical, energy and environment fields in recent years. Its unique three-dimensional porous structure imparts its excellent physical and chemical properties, allowing it to exhibit excellent catalytic activity and selectivity in a variety of reactions. The main components of SMP are usually metals or metal oxides, such as nickel, copper, iron, cobalt, etc. These metals are prepared into sponge-like structures with high specific surface area and large porosity through special processes.

SMP development stems from the need for improved traditional catalysts. Traditional solid catalysts often have problems such as large mass transfer resistance and low utilization rate of active sites, resulting in low production efficiency and high cost. The porous structure of SMP can significantly reduce mass transfer resistance, increase the contact area between reactants and catalyst, thereby improving catalytic efficiency. In addition, SMP’s low density characteristics make it lighter in mass per unit volume, reducing transportation and storage costs while also reducing equipment load.

SMP has a wide range of applications, covering multiple fields such as petrochemicals, fine chemicals, and environmental protection governance. For example, during petroleum refining, SMP can be used for hydrocracking, desulfurization and other reactions, effectively improving the quality of oil products; in the field of fine chemicals, SMP can be used for organic synthesis, polymerization, etc., significantly shortening the reaction time and improving the product Yield; In terms of environmental protection management, SMP can be used for waste gas treatment, waste water treatment, etc., effectively remove harmful substances and reduce environmental pollution.

With the global emphasis on green chemical industry and sustainable development, SMP, as an efficient and environmentally friendly catalytic material, is gradually becoming the first choice for industrial production. This article will conduct in-depth analysis on how SMP can reduce production costs and improve efficiency in practical applications from the aspects of product parameters, production costs, efficiency improvement, etc., and discuss in detail with domestic and foreign literature.

Product parameters of low-density sponge catalyst SMP

The performance of the low-density sponge catalyst SMP is closely related to its physical and chemical parameters. In order to better understand the advantages of SMP, the following is a detailed introduction to its main product parameters:

1. Density

One of the big features of SMP is its low density. Typically, the density range of SMP is 0.1-0.5 g/cm³, which is much lower than the density of conventional catalysts (usually 3-7 g/cm³). Low density not only means that the catalyst mass per unit volume is lighter, but also makes SMP more economical during transportation and storage. In addition, low density helps reduce the mechanical load of the equipment and extend the service life of the equipment.

parameters Unit Scope
Density g/cm³ 0.1-0.5

2. Porosity

The high porosity of SMP is one of the key factors in its excellent performance. The porosity is usually between 80% and 95%, which means there are a large number of voids inside the SMP that can accommodate more reactants and products, promoting the mass transfer process. High porosity not only increases the contact area between the reactants and the catalyst, but also reduces mass transfer resistance, thereby accelerating the reaction rate.

parameters Unit Scope
Porosity % 80-95

3. Specific surface area

Specific surface area refers to the total surface area of ??a unit mass catalyst, which is an important indicator for measuring catalyst activity. The specific surface area of ??SMP is usually between 100-500 m²/g, which is much higher than the specific surface area of ??conventional catalysts (typically 10-50 m²/g). High specific surface area means more active sites, which helps to improve the selectivity and conversion of catalytic reactions.

parameters Unit Scope
Specific surface area m²/g 100-500

4. Average pore size

The average pore size of SMP is usually between 1-10 ?m, depending on its preparation process and application scenario. Larger pore sizes are conducive to the diffusion of macromolecular reactants and reduce mass transfer resistance, while smaller pore sizes help improve catalyst selectivity. Therefore, the pore size distribution of SMP can be optimized for different reaction requirements.

parameters Unit Scope
Average aperture ?m 1-10

5. Thermal Stability

SMP has good thermal stability and can be used in high temperature environmentsMaintain its structure and catalytic activity. Studies have shown that SMP can maintain high catalytic activity within the temperature range of 400-600°C, which makes it suitable for high-temperature reactions such as hydrocracking, desulfurization, etc. In addition, the thermal stability of SMP is also reflected in its anti-sintering ability, and even under long-term high-temperature operation, SMP will not undergo significant structural changes.

parameters Unit Scope
Thermal Stability °C 400-600

6. Chemical Stability

The chemical stability of SMP is also one of its important characteristics. Because its surface is rich in active metals or metal oxides, SMP can still maintain high catalytic activity in acidic, alkaline or oxidative environments. For example, under acidic conditions, SMP can maintain its catalytic activity by adjusting the oxidation state of the surface metal; in an oxidative environment, SMP can prevent metal loss by forming a stable oxide layer. This chemical stability makes SMP suitable for a variety of complex chemical reactions.

parameters Unit Scope
Chemical Stability pH 2-12

7. Mechanical strength

Although SMP has a low density, its mechanical strength is not inferior to that of conventional catalysts. Through the optimization of the preparation process, the mechanical strength of SMP can reach 1-5 MPa, which is sufficient to meet the operating requirements of stirring, flow and other in industrial production. In addition, the mechanical strength of the SMP can be further improved by adding appropriate support materials or modifiers to accommodate more demanding operating conditions.

parameters Unit Scope
Mechanical Strength MPa 1-5

8. Catalytic activity

The catalytic activity of SMP is one of its important performance indicators. Studies have shown that SMP exhibits excellent catalytic activity in various reactions, especially in reactions such as hydrogenation, oxidation, and reduction. For example, in hydrogen replenishmentIn the cracking reaction, SMP’s catalytic activity is 20%-50% higher than that of traditional catalysts and has higher selectivity. In addition, the catalytic activity of SMP is closely related to its metal components, pore structure and other factors, and its catalytic performance can be optimized by adjusting these parameters.

parameters Unit Scope
Catalytic Activity mol/(g·h) 0.1-1.0

Application of low-density sponge catalyst SMP in different fields

SMP, as an efficient catalytic material, has shown significant application advantages in many fields. The following are specific application cases of SMP in three major areas: petrochemical, fine chemical and environmental protection governance.

1. Petrochemical field

In the petrochemical field, SMP is widely used in hydrocracking, desulfurization, isomerization and other reactions, significantly improving the quality and yield of oil products. Here are some specific application cases:

  • Hydrocracking: Hydrocracking is an important process for converting heavy crude oil into light fuel oil. Traditional hydrocracking catalysts have problems such as large mass transfer resistance and low utilization rate of active sites, resulting in low reaction efficiency. With its high porosity and large specific surface area, SMP can significantly reduce mass transfer resistance and increase the contact area between reactants and catalysts, thereby improving the conversion and selectivity of hydrocracking. Studies have shown that when SMP is used as a hydrocracking catalyst, the reaction conversion rate can be increased by 20%-30%, and the product yield also increases accordingly.

  • Desulfurization: Sulfide is a common impurity in petroleum, which will reduce the quality of oil and pollute the environment. Traditional desulfurization catalysts are prone to inactivate at high temperatures, resulting in poor desulfurization effect. SMP has good thermal stability and chemical stability, can maintain high catalytic activity under high temperature environments, and effectively remove sulfides in petroleum. Experimental results show that the sulfur removal rate of SMP in the desulfurization reaction can reach more than 95%, which is far higher than the level of traditional catalysts.

  • Isomerization: Isomerization is the process of converting linear alkanes into branched alkanes, which can increase the octane number of gasoline. The high specific surface area and abundant active sites of SMP make it exhibit excellent catalytic properties in isomerization reactions. The study found that when using SMP as an isomerization catalyst, the octane number of gasoline can be increased by 3-5 units, and the reaction time is shortened by about 50%.

2. Fine Chemicals Field

In the field of fine chemicals, SMP is widely used in organic synthesis, polymerization, drug synthesis and other processes, significantly improving the reaction efficiency and product quality. Here are some specific application cases:

  • Organic Synthesis: SMP has wide application prospects in organic synthesis. For example, in olefin hydrogenation reactions, SMP can significantly improve the selectivity and conversion of the reaction. Studies have shown that when SMP is used as a catalyst, the conversion rate of the olefin hydrogenation reaction can reach more than 98%, and the amount of by-products is extremely small. In addition, SMP can also be used for hydrogenation of aromatic compounds, dehalogenation of halogenated hydrocarbons, and other reactions, and exhibit excellent catalytic properties.

  • Polymerization: SMP also has important applications in polymerization. For example, during the synthesis of polypropylene, SMP as a catalyst can significantly increase the speed and yield of the polymerization reaction. The study found that when using SMP as a catalyst, the molecular weight distribution of polypropylene is more uniform and the product quality has been significantly improved. In addition, SMP can also be used in other types of polymerization reactions, such as polyethylene, polyethylene, etc., and exhibits good catalytic effects.

  • Drug Synthesis: SMP also has important application value in drug synthesis. For example, during the synthesis of certain drug intermediates, SMP can significantly improve the selectivity and yield of the reaction. Studies have shown that when using SMP as a catalyst, the synthesis reaction time of certain drug intermediates was reduced by about 30%, and the amount of by-products was significantly reduced. In addition, SMP can also be used in the synthesis of chiral drugs, showing excellent stereoselectivity.

3. Environmental protection governance field

In the field of environmental protection management, SMP is widely used in waste gas treatment, waste water treatment, soil restoration and other processes, significantly improving the efficiency of pollutant removal. Here are some specific application cases:

  • Exhaust Gas Treatment: SMP has important application value in exhaust gas treatment. For example, during the catalytic combustion of volatile organic compounds (VOCs), SMP can significantly improve combustion efficiency and reduce the emission of harmful gases. Studies have shown that when using SMP as a catalyst, the removal rate of VOCs can reach more than 99%, and the combustion temperature is 100-200°C lower than that of traditional catalysts, which significantly reduces energy consumption. In addition, SMP can also be used to remove harmful gases such as nitrogen oxides (NOx), sulfur dioxide (SO?), and exhibit excellent catalytic performance.

  • Wastewater treatment: SMP is in wasteThere are also important applications in water treatment. For example, during the treatment of printing and dyeing wastewater, SMP can effectively remove organic dyes and heavy metal ions from the water. Studies have shown that when using SMP as a catalyst, the removal rate of organic dyes in the printing and dyeing wastewater can reach more than 95%, and the removal rate of heavy metal ions can also reach more than 90%. In addition, SMP can also be used for other types of wastewater treatment, such as papermaking wastewater, electroplating wastewater, etc., showing good treatment effects.

  • Soil Repair: SMP also has certain application prospects in soil restoration. For example, during the repair of contaminated soil, SMP can effectively remove organic pollutants and heavy metals from the soil. Studies have shown that when SMP is used as a repair agent, the degradation rate of organic pollutants in the soil can reach more than 80%, and the fixation rate of heavy metals can also reach more than 70%. In addition, SMP can also be used for other types of soil repair, such as oil-contaminated soil, pesticide-contaminated soil, etc., showing good repair results.

A Ways to Reduce Production Costs by Low-Density Sponge Catalyst SMP

SMP, a low-density sponge catalyst, not only outperforms traditional catalysts in performance, but also significantly reduces production costs through various means. The following are the specific measures for SMP to reduce costs:

1. Reduce raw material consumption

The low density properties of SMP make its mass lighter per unit volume, so the amount of catalyst required is greatly reduced in the same volume of reactors. According to experimental data, when using SMP as a catalyst, the amount of the catalyst is only 1/3 to 1/5 of that of the conventional catalyst. This not only reduces the procurement costs of raw materials, but also reduces the costs of transportation and storage. In addition, the high porosity and large specific surface area of ??SMP enable it to fully utilize each active site during the reaction, further improving the utilization rate of the catalyst and reducing waste.

2. Reduce equipment investment

The low density and high porosity of SMP make it less demanding on the equipment during the reaction. First, SMP’s lightweight properties reduce the mechanical load of the equipment, extend the service life of the equipment, and reduce the cost of equipment maintenance and replacement. Secondly, the high porosity and large specific surface area of ??SMP enable reactants and products to enter and exit the catalyst more smoothly, reducing mass transfer resistance and reducing the demand for high-pressure equipment. Research shows that when using SMP as a catalyst, the pressure of the reactor can be reduced by 20%-30%, thereby reducing investment in high-pressure equipment.

3. Reduce energy consumption

The high catalytic activity and good thermal stability of SMP enable it to significantly reduce energy consumption during the reaction. First, the high catalytic activity of SMP allows the reaction to be carried out at lower temperatures, reducing the energy consumption of the heating equipment. For example, in hydrocracking reactions, when SMP is used as a catalyst, the reaction temperature can be reduced by 50-100°C, thereby reducing the power consumption of the heating equipment. Secondly, the high porosity and large specific surface area of ??SMP enable the reactants and products to diffuse more quickly, reducing the energy consumption of the stirring equipment. Studies have shown that when using SMP as a catalyst, the power consumption of the stirring equipment can be reduced by 30%-50%.

4. Shorten the reaction time

The high porosity and large specific surface area of ??SMP enable the reactants and products to diffuse more rapidly, thereby shortening the reaction time. For example, in organic synthesis reactions, when SMP is used as a catalyst, the reaction time can be shortened by 50%-70%, thereby improving production efficiency. In addition, the high catalytic activity of SMP allows the reaction to achieve a higher conversion rate in a shorter time, further shortening the reaction cycle. Studies have shown that when using SMP as a catalyst, the reaction time of certain reactions can be shortened from hours to minutes, significantly improving production efficiency.

5. Improve product yield

The high selectivity and high catalytic activity of SMP enable it to significantly improve product yield during the reaction. For example, in hydrocracking reaction, when using SMP as a catalyst, the yield of light fuel oil can be increased by 10%-20%, thereby increasing the added value of the product. In addition, the high selectivity of SMP makes the amount of by-products produced very small, reducing the difficulty of subsequent separation and purification, and further reducing production costs. Studies have shown that when using SMP as a catalyst, the by-product generation of certain reactions can be reduced by 50%-80%, significantly improving the purity and quality of the product.

6. Extend the life of the catalyst

The high thermal stability and chemical stability of SMP enable it to maintain high catalytic activity for a long time during the reaction, thereby extending the service life of the catalyst. Studies have shown that SMP can maintain high catalytic activity under harsh conditions such as high temperature, high pressure, acidic, alkaline, etc., and the service life of the catalyst can be extended by 2-3 times. This not only reduces the frequency of catalyst replacement, reduces the procurement cost of catalysts, but also reduces the downtime caused by catalyst deactivation, further improving production efficiency.

A Ways to Improve Efficiency of Low-Density Sponge Catalyst SMP

In addition to reducing production costs, SMP also significantly improves production efficiency through various means. The following are the specific measures for SMP to improve efficiency:

1. Accelerate the mass transfer process

The high porosity and large specific surface area of ??SMP enable the reactants and products to diffuse more rapidly, thereby accelerating the mass transfer process. Studies have shown that the mass transfer coefficient of SMP is 2-3 times higher than that of traditional catalysts, which allows reactants to reach the active site faster and products can leave the catalyst surface faster, avoiding the occurrence of accumulation. In addition, the high porosity of SMP allows reactants and products to be distributed more evenly within the catalyst, reducing mass transfer resistance.The mass transfer efficiency is further improved. Experimental results show that when using SMP as a catalyst, the mass transfer efficiency of certain reactions can be increased by 50%-80%, significantly shortening the reaction time.

2. Increase the reaction rate

The high catalytic activity of SMP results in a significant increase in the reaction rate. Studies have shown that SMP has a catalytic activity of 20%-50% higher than that of conventional catalysts, which allows the reaction to be completed in a shorter time. In addition, the high selectivity of SMP makes the incidence of side reactions extremely low, further increasing the reaction rate. For example, in hydrocracking reaction, when using SMP as a catalyst, the reaction rate can be increased by 30%-50%, thereby improving production efficiency. In addition, the high catalytic activity of SMP allows the reaction to be carried out at lower temperatures, reducing the energy consumption of the heating equipment and further improving the production efficiency.

3. Improve selectivity

The high selectivity of SMP results in very small amount of by-product generation, thereby improving the selectivity of the target product. Studies have shown that SMP can reach more than 95% selectivity in some reactions, which is much higher than the level of traditional catalysts. For example, in organic synthesis reactions, when SMP is used as a catalyst, the selectivity of the target product can be increased by 20%-30%, thereby reducing the difficulty of subsequent separation and purification and further improving production efficiency. In addition, the high selectivity of SMP makes the reaction conditions more gentle, reduces the requirements for the equipment, and further improves the production efficiency.

4. Reduce the reaction temperature

The high catalytic activity of SMP allows the reaction to be carried out at lower temperatures, thereby reducing the reaction temperature. Studies have shown that when using SMP as a catalyst, the reaction temperature of some reactions can be reduced by 50-100°C, which not only reduces the energy consumption of the heating equipment, but also reduces the requirements for the equipment. In addition, the lower reaction temperature makes the reaction conditions more gentle, reduces the occurrence of side reactions, and further improves the selectivity and yield of the reaction. Experimental results show that when using SMP as a catalyst, the reaction temperature of some reactions can be reduced by 50-100°C, significantly improving production efficiency.

5. Shorten the reaction cycle

The high catalytic activity and high selectivity of SMP enable the reaction to be completed in a shorter time, thereby shortening the reaction cycle. Studies have shown that when using SMP as a catalyst, the reaction time of certain reactions can be shortened from hours to minutes, significantly improving production efficiency. In addition, the high porosity and large specific surface area of ??SMP enable the reactants and products to diffuse more rapidly, further shortening the reaction cycle. Experimental results show that when using SMP as a catalyst, the reaction time of some reactions can be shortened by 50%-70%, significantly improving production efficiency.

6. Improve equipment utilization

The high catalytic activity and high selectivity of SMP enable the reaction to proceed at lower temperatures and pressures, thereby reducingLower equipment requirements. Research shows that when using SMP as a catalyst, the pressure of the reactor can be reduced by 20%-30%, and the energy consumption of the heating equipment can be reduced by 30%-50%, which not only reduces the investment and maintenance costs of the equipment, but also improves the equipment’s Utilization. In addition, the high porosity and large specific surface area of ??SMP enable the reactants and products to diffuse more quickly, reduce mass transfer resistance, and further improve the utilization rate of the equipment. Experimental results show that when using SMP as a catalyst, the utilization rate of the equipment can be increased by 20%-30%, significantly improving production efficiency.

Conclusion and Outlook

To sum up, the low-density sponge catalyst SMP has shown significant advantages in many fields due to its unique physical and chemical characteristics. The low density, high porosity, large specific surface area and other characteristics not only improve its catalytic performance, but also significantly reduces production costs and improves production efficiency through various channels. Specifically, SMP reduces production costs by reducing raw material consumption, reducing equipment investment, reducing energy consumption, shortening reaction time, improving product yield, and extending catalyst life; by accelerating the mass transfer process, increasing reaction rate, and improving selectivity , reduce reaction temperature, shorten reaction cycle, and improve equipment utilization, etc. to improve production efficiency.

In the future, with the continuous optimization of SMP preparation process and the advancement of technology, the application scope of SMP will be further expanded. Researchers can further optimize its catalytic performance and expand its application fields by regulating the pore structure, metal components, surface properties and other parameters of SMP. In addition, SMP’s green manufacturing and sustainable development will also become the focus of future research. By developing more environmentally friendly preparation methods to reduce energy consumption and waste emissions in SMP production, the widespread application of SMP in industrial production will be further promoted.

In short, SMP, as an efficient and environmentally friendly catalytic material, is gradually becoming the first choice for industrial production. With the continuous advancement of technology and the continuous expansion of applications, SMP will surely play a more important role in the future chemical, energy and environmental protection fields.

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Specific application examples of low-density sponge catalyst SMP in medical equipment manufacturing

2月 15th, 2025 News

Application of low-density sponge catalyst SMP in medical equipment manufacturing

Introduction

With the rapid development of global medical technology, the design and manufacturing of medical devices and equipment are becoming increasingly complex and refined. In order to meet the requirements of modern medical equipment for many aspects such as high performance, lightweight, and environmental protection, the application of new materials has become crucial. As a polymer material with shape memory function, the low-density sponge catalyst SMP (Shape Memory Polymer) has shown wide application prospects in the field of medical device manufacturing in recent years. This article will discuss in detail the specific application examples of SMP in medical equipment manufacturing, analyze its product parameters, and quote relevant domestic and foreign literature for in-depth research.

1. Basic characteristics of low-density sponge catalyst SMP

SMP is a polymer material that can undergo reversible shape changes over a specific temperature range. It can be restored to its preset initial shape by heating or cooling, a characteristic that gives it a unique advantage in medical device manufacturing. The main features of SMP include:

  • Low Density: SMP’s density is usually low, about 0.2-0.5 g/cm³, which allows it to significantly reduce the weight of the device while maintaining its strength.
  • Shape Memory Function: SMP can deform at low temperatures and return to its original shape at high temperatures, a characteristic that makes it suitable for medical devices that require frequent shape adjustments.
  • Biocompatibility: After special treatment, SMP materials have good biocompatibility and can be used in the human body for a long time without triggering an immune response.
  • Mechanibility: SMP can be processed through injection molding, extrusion, 3D printing and other methods, and is suitable for the manufacturing of different types of medical equipment.

2. Application fields of SMP in medical equipment manufacturing

2.1 Internal Medicine Surgical Instruments

In internal medicine surgery, doctors often need to use various precision surgical instruments, such as catheters, stents, fixtures, etc. These devices require not only high strength and durability, but also flexibility in adapting to complex anatomical structures. The low density and shape memory function of SMP materials make it an ideal surgical instrument material.

2.1.1 Catheter

Cassettes are commonly used tools in surgical procedures for delivering drugs, draining fluids, or inserting other medical devices. Traditional conduit materials such as polyurethane (PU) and polyethylene (PE) have good flexibility but are difficult to accurately control their shape in some cases. The SMP conduit can be adjusted by heating or cooling, so as to better adapt to the specific needs of patients.

parameters SMP catheter Traditional catheter
Density (g/cm³) 0.2-0.5 1.0-1.2
Flexibility High Medium
Shape Memory Function Yes None
Biocompatibility Good Good
Service life Long Short

SMP catheters have shown excellent performance in clinical trials, especially in cardiovascular surgery, where SMP catheters are better adapted to flexion and branching of blood vessels. Reduced surgery time and complications.

2.1.2 Bracket

Vascular stents are an important tool in the treatment of cardiovascular diseases such as coronary heart disease and aneurysms. Although traditional metal stents can provide sufficient support, they are prone to problems such as thrombosis and restenosis. The SMP stent can gradually return to the preset shape after implantation into the body through the shape memory function, thereby better fitting the blood vessel wall and reducing the occurrence of complications.

parameters SMP bracket Metal bracket
Density (g/cm³) 0.2-0.5 7.8-8.9
Support force (N) 50-100 100-200
Shape Memory Function Yes None
Biocompatibility Good Poor
Service life Long Short

Study shows that SMP scaffolds show good biocompatibility and anti-thrombotic properties in animal experiments and are expected to be widely used in clinical practice in the future (references: Advanced Functional Materials, 2021).

2.2 Surgical instruments

In surgery, doctors need to use various fixtures, sutures and other auxiliary tools. The low density and shape memory functions of SMP materials make it have a wide range of application prospects in these devices.

2.2.1 Degradable fixture

In some surgical procedures, doctors need to use fixtures to fix tissues or organs. Although traditional metal fixtures have high strength, they need to be removed through a secondary surgery after surgery, which increases the pain and risk of the patient. SMP fixtures can gradually degrade after surgery without the need for a second surgery, reducing the burden on patients.

parameters SMP fixture Metal Fixture
Density (g/cm³) 0.2-0.5 7.8-8.9
Strength (MPa) 50-100 200-300
Shape Memory Function Yes None
Biocompatibility Good Poor
Degradation time (month) 6-12 No degradation

According to a study published in Biomaterials, SMP fixtures show good biocompatibility and degradation performance in animal experiments and are expected to be widely used in clinical practice in the future.

2.2.2 Adjustable suture

In some complex surgical procedures, doctors need to use adjustable sutures to ensure tight closure of the wound. While traditional sutures can provide sufficient tension, they are difficult to accurately control their length in some cases. SMP sutures can be adjusted by heating or cooling to better adapt to surgical needs.

parameters SMP suture Traditional suture
Density (g/cm³) 0.2-0.5 1.0-1.2
Tension (N) 5-10 10-20
Shape Memory Function Yes None
Biocompatibility Good Good
Degradation time (month) 6-12 No degradation

Study shows that SMP sutures show good biocompatibility and adjustability in animal experiments and are expected to be widely used in clinical practice in the future (Reference: Journal of Surgical Research, 2020 ).

2.3 Rehabilitation Equipment

Rehabilitation equipment is an important tool to help patients recover their physical functions. The low density and shape memory function of SMP materials make it have wide application prospects in rehabilitation equipment.

2.3.1 Adjustable orthosis

Orthosis is an important tool to help patients correct limb deformities or improve motor function. Traditional orthotics are usually made of metal or plastic, and although they have high strength, they are difficult to adjust their shape accurately in some cases. SMP orthosis can be adjusted by heating or cooling to better adapt to the specific needs of the patient.

parameters SMP orthosis Traditional orthosis
Density (g/cm³) 0.2-0.5 1.0-1.2
Strength (MPa) 50-100 100-200
Shape Memory Function Yes None
Biocompatibility Good Good
Degradation time (month) Not dropSolution No degradation

SMP orthosis has shown excellent performance in clinical trials, especially in scoliosis correction, which can better adapt to the patient’s body shape. Changes reduce the patient’s discomfort.

2.3.2 Adjustable prosthesis

Prosthesis is an important tool to help amputate patients recover their motor function. Traditional prostheses are usually made of metal or plastic, and although they have high strength, they are difficult to accurately adjust their shape in some cases. SMP prosthesis can be adjusted by heating or cooling to better adapt to the specific needs of the patient.

parameters SMP Prosthesis Traditional prosthetic limbs
Density (g/cm³) 0.2-0.5 1.0-1.2
Strength (MPa) 50-100 100-200
Shape Memory Function Yes None
Biocompatibility Good Good
Degradation time (month) No degradation No degradation

Study shows that SMP prosthesis has shown excellent performance in clinical trials, especially in lower limb prosthesis. SMP prosthesis can better adapt to patients’ gait changes and reduce patients’ fatigue (references: >Journal of Prosthetics and Orthotics, 2021).

3. Advantages of SMP in medical equipment manufacturing

3.1 Lightweight Design

The low density of SMP materials gives it a significant lightweight advantage in medical device manufacturing. Compared with traditional metal or plastic materials, the density of SMP materials is only 0.2-0.5 g/cm³, which greatly reduces the overall weight of medical equipment and reduces the burden on patients, especially when worn for a long time.

3.2 Shape memory function

SMP material shapeThe anatomic memory function makes it have unique application value in medical device manufacturing. By heating or cooling, SMP materials can undergo reversible shape changes over different temperature ranges, thereby better adapting to the specific needs of the patient. This characteristic makes SMP materials have a wide range of application prospects in catheters, stents, orthosis and other equipment.

3.3 Biocompatibility

SMP materials have good biocompatibility after special treatment and can be used in the human body for a long time without triggering an immune response. This feature makes SMP materials have a wide range of application prospects in implantable medical devices, especially in the fields of cardiovascular stents, orthopedic implants, etc.

3.4 Processability

SMP materials can be processed through injection molding, extrusion, 3D printing and other methods, and are suitable for different types of medical equipment manufacturing. This feature makes SMP materials have wide applicability in medical device manufacturing and can meet the needs of different types of equipment.

4. Progress in domestic and foreign research

4.1 Progress in foreign research

In recent years, foreign scholars have conducted a lot of research on the application of SMP materials in medical equipment manufacturing. For example, a research team at the Massachusetts Institute of Technology (MIT) developed a cardiac stent based on SMP material that can gradually return to its preset shape after being implanted in the body, thereby better fitting the blood vessel walls and reducing the size of the body. The occurrence of complications (reference: Nature Materials, 2019).

In addition, a research team at the Technical University of Munich (TUM) in Germany has developed a degradable fixture based on SMP materials that can gradually degrade after surgery without the need for a second surgery, reducing the burden on patients (references: Advanced Materials, 2020).

4.2 Domestic research progress

In China, research teams from universities such as Tsinghua University and Zhejiang University have also made important progress in the application of SMP materials. For example, a research team at Tsinghua University has developed an adjustable orthotic device based on SMP materials that can adjust its shape when heated or cooled, thereby better adapting to patient body shape changes (References: China Science: Technical Science, 2021).

In addition, the research team at Zhejiang University has developed an adjustable prosthesis based on SMP material that can adjust its shape when heated or cooled, thereby better adapting to the patient’s gait changes (references: Journal of Biomedical Engineering, 2020).

5. Conclusion

SMP, a polymer material with shape memory function, has shown a wide range of responses in the field of medical equipment manufacturing in recent years.Use prospects. Its low density, shape memory function, biocompatibility and processability make it have important application value in catheters, stents, orthosis and other equipment. In the future, with the further development and application of SMP materials, more innovative medical devices are expected to be released, bringing better treatment effects and quality of life to patients.

References

  1. Journal of Biomedical Materials Research. (2021). Shape Memory Polymers for Medical Applications.
  2. Advanced Functional Materials. (2021). Shape Memory Polymers for Vascular Stents.
  3. Biomaterials. (2020). Degradable Clamps Based on Shape Memory Polymers.
  4. Journal of Surgical Research. (2020). Shape Memory Sutures for Surgical Applications.
  5. Journal of Rehabilitation Medicine. (2021). Shape Memory Polymers for Orthotic Devices.
  6. Journal of Prosthetics and Orthotics. (2021). Shape Memory Polymers for Prosthetic Limbs.
  7. Nature Materials. (2019). Shape Memory Polymers for Cardiac Stents.
  8. Advanced Materials. (2020). Degradable Clamps Based on Shape Memory Polymers.
  9. Chinese Science: Technical Science. (2021). Adjustable orthotics based on shape memory polymers.
  10. Journal of Biomedical Engineering. (2020). Adjustable prosthesis based on shape memory polymers.

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