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Operation Guide for Optimizing the Parameter Setting of Low-Density Sponge Catalyst SMP

2月 15th, 2025 News

Introduction

SMP (Super Micro Porous) is a low-density sponge catalyst that plays a crucial role in modern foaming processes. With the increasing demand for lightweight materials, especially in the automotive, aerospace, construction and packaging industries, the application of low-density sponge materials is becoming more and more extensive. As an efficient foaming catalyst, SMP can significantly improve the efficiency and product quality of the foaming process. However, to fully realize its potential, precise optimization of its foaming process parameters must be carried out. This article will explore in detail the optimized foaming process parameter settings of low-density sponge catalyst SMP, aiming to provide a comprehensive operating guide for engineers and researchers in relevant fields.

This article will first introduce the basic characteristics of SMP and its mechanism of action in the foaming process, and then conduct in-depth analysis of the key parameters affecting the foaming quality, including temperature, pressure, catalyst dosage, type and concentration of foaming agents. By citing new research literature at home and abroad and combining practical application cases, we will explore how to achieve good foaming effect by adjusting these parameters. In addition, this article will provide a series of practical experimental design and data analysis methods to help readers better understand and master the optimization technology of SMP catalysts.

After

, this paper will summarize the advantages and challenges of SMP catalysts in low-density sponge foaming, and look forward to future research directions and development trends. Through reading this article, readers will be able to gain an in-depth understanding of the working principle of SMP catalysts and master the key technologies for optimizing the foaming process, so as to achieve better results in actual production.

Basic Characteristics of Low-Density Sponge Catalyst SMP

Super Micro Porous, a low-density sponge catalyst, is a highly efficient catalyst designed for foaming processes, with unique physical and chemical properties that enable it to exhibit excellent performance during foaming. The main components of SMP catalysts usually include metal salts, organic acids, amine compounds, etc., which form a microporous structure after special process processing, which can effectively promote the progress of foaming reaction. Here are some key characteristics of SMP catalysts:

1. Micropore structure and high specific surface area

The major feature of SMP catalyst is its microporous structure. This structure not only increases the specific surface area of ??the catalyst, but also provides more active sites, allowing the catalyst to contact the foaming agent and other reactants more efficiently. According to foreign literature, the specific surface area of ??SMP catalyst can reach 500-800 m²/g, which is much higher than that of traditional catalysts. This feature allows SMP to achieve efficient catalytic effects at lower dosages, thereby reducing costs and improving production efficiency.

2. Good thermal and chemical stability

SMP catalysts have excellent thermal stability and chemistryStability, able to maintain activity over a wide temperature range. Studies have shown that SMP catalysts can maintain high catalytic activity within the temperature range of 100-200°C, which provides greater flexibility for temperature control during foaming. In addition, SMP catalysts have good compatibility with a variety of foaming agents and polymer substrates, and will not cause side reactions or affect the performance of the final product.

3. Fast reaction rate

The microporous structure and high specific surface area of ??the SMP catalyst make it have an extremely fast reaction rate. During the foaming process, SMP can quickly decompose the foaming agent, generate a large amount of gas, and promote the formation and expansion of the foam. Compared with traditional catalysts, the reaction rate of SMP can be increased by 2-3 times, thereby shortening foaming time and improving production efficiency. Foreign literature points out that the foaming time using SMP catalyst can be shortened from the traditional 30-60 minutes to 10-20 minutes, significantly increasing the production capacity of the production line.

4. Controlable bubble size and distribution

Another important characteristic of SMP catalyst is its ability to accurately control the size and distribution of bubbles. By adjusting the amount of catalyst and foaming conditions, bubbles of different sizes and shapes can be achieved, thereby meeting the needs of different application scenarios. For example, in car seat foam, larger bubbles can provide better cushioning; while in building insulation materials, smaller and uniform bubbles can help improve thermal insulation. Research shows that SMP catalyst can reduce the coefficient of variation of bubble size to below 5%, ensuring product uniformity and stability.

5. Environmental

As the global focus on environmental protection is increasing, the design of SMP catalysts has also fully taken into account environmental protection factors. SMP catalysts do not contain harmful substances, such as heavy metals or volatile organic compounds (VOCs), and meet international environmental standards. In addition, the efficient catalytic properties of SMP catalysts reduce the use of foaming agents and reduce energy consumption and waste emissions during the production process. Famous domestic literature points out that the foaming process using SMP catalyst can reduce the amount of foaming agent by more than 30%, significantly reducing the impact on the environment.

Mechanism of action of SMP catalyst in foaming process

The mechanism of action of SMP catalyst in the foaming process is mainly reflected in the following aspects: promoting the decomposition of foaming agents, regulating the generation and growth of bubbles, and improving the stability of foam structure. Through an in-depth understanding of these mechanisms, the foaming process parameters can be better optimized and product quality can be improved.

1. Promote the decomposition of foaming agents

Footing agents are the key raw materials for gas production during foaming. Common foaming agents include azodiamorphamide (AC), sodium bicarbonate (NaHCO?) etc. The SMP catalyst absorbs and activates the foaming agent molecules to reduce the activation energy required for their decomposition, thereby accelerating the decomposition reaction of the foaming agent. Specifically, the microporous structure of the SMP catalyst can capture foaming agent molecules, so that they form active intermediates on the surface of the catalyst, and then undergo decomposition reactions. Studies have shown that SMP catalyst can reduce the decomposition temperature of the foaming agent by 10-20°C, significantly improving the foaming efficiency.

2. Controll the generation and growth of bubbles

The generation and growth of bubbles is one of the key steps in the foaming process. SMP catalysts affect the generation and growth process of bubbles by regulating the decomposition rate of the foaming agent and the gas release rate. In the early stage of foaming, the SMP catalyst can quickly decompose the foaming agent and produce a large number of tiny bubble cores. As the reaction progresses, the SMP catalyst continues to promote gas release, promoting expansion and merging of bubbles. By adjusting the amount of catalyst and foaming conditions, the bubble generation rate and growth rate of air bubbles can be controlled to obtain an ideal foam structure.

3. Improve the stability of foam structure

The stability of the foam structure directly affects the performance of the final product. SMP catalyst improves the stability of foam structure by regulating the size and distribution of bubbles. On the one hand, the SMP catalyst can inhibit excessive expansion and rupture of bubbles and prevent foam from collapsing; on the other hand, the SMP catalyst can promote uniform distribution between bubbles and avoid large holes or bubble aggregation. Research shows that foam products using SMP catalysts have higher closed cell ratios and lower porosity, which significantly improves the mechanical strength and thermal insulation properties of the products.

Key parameters affecting the foaming effect of SMP catalyst

In the process of foaming of low-density sponge, multiple parameters jointly affect the effect of the SMP catalyst. In order to achieve an optimal foaming effect, these parameters must be accurately controlled and optimized. The following are the main parameters that affect the foaming effect of SMP catalyst:

1. Temperature

Temperature is one of the important parameters in the foaming process, which directly affects the decomposition rate of the foaming agent and the gas release rate. Generally speaking, the higher the temperature, the faster the decomposition rate of the foaming agent, the faster the gas is released, and the faster the foam expands. However, excessively high temperatures may cause excessive expansion or even burst of bubbles, affecting the stability of the foam structure. Therefore, it is crucial to choose the right foaming temperature.

According to foreign literature, the optimal foaming temperature range of SMP catalyst is 120-180°C. Within this temperature range, the SMP catalyst can fully exert its catalytic effect, promote the rapid decomposition of the foaming agent, while maintaining the stability and uniformity of the bubbles. Studies have shown that when the temperature is below 120°C, the decomposition rate of the foam is slow, resulting in insufficient foam expansion.;When the temperature is higher than 180°C, the bubbles are prone to over-expanding and bursting, resulting in loose foam structure. Therefore, it is recommended that in actual production, the appropriate foaming temperature should be selected according to the specific type of foaming agent and product requirements.

2. Suppression

The influence of pressure on the foaming process is mainly reflected in the bubble generation and growth stages. Under low pressure conditions, gas is prone to escape, resulting in a decrease in the number of bubbles and an increase in the foam density; while under high pressure conditions, it is difficult for gases to escape, an increase in the number of bubbles and an decrease in the foam density. Therefore, proper pressure control is essential to obtain an ideal foam structure.

Study shows that the optimal foaming pressure range for SMP catalysts is 0.1-0.5 MPa. Within this pressure range, the gas can smoothly enter the polymer substrate to form a uniform bubble structure. Excessively high or too low pressure will affect the generation and growth of bubbles, resulting in uneven foam structure. In addition, pressure can affect the size and distribution of bubbles. Generally speaking, lower pressures are conducive to the formation of larger bubbles, while higher pressures are conducive to the formation of smaller and uniform bubbles. Therefore, in actual production, appropriate pressure conditions should be selected according to the performance requirements of the product.

3. Catalytic Dosage

The amount of SMP catalyst is used directly determines its catalytic effect. An appropriate amount of catalyst can promote the rapid decomposition of the foaming agent and improve the foaming efficiency; while an excessive amount of catalyst may cause the foaming agent to decompose too quickly and release too much gas, affecting the stability of the foam structure. Therefore, it is crucial to choose the right amount of catalyst.

According to domestic and foreign literature, the optimal amount of SMP catalyst is 0.5-2.0 wt% (relative to the mass of polymer substrate). Within this range, SMP catalysts can fully exert their catalytic effects, promote rapid decomposition of foaming agents, while maintaining the stability and uniformity of bubbles. Studies have shown that when the catalyst usage is less than 0.5 wt%, the decomposition rate of the foaming agent is slow, resulting in insufficient foam expansion; and when the catalyst usage is higher than 2.0 wt%, the blowing agent decomposes too quickly and the gas is released too much. Causes bubbles to over-expand and rupture. Therefore, it is recommended that in actual production, the appropriate amount of catalyst is selected according to the specific type of foaming agent and product requirements.

4. Type and concentration of foaming agent

The type and concentration of foaming agent have an important influence on the foaming effect. Different foaming agents have different decomposition temperatures and gas release characteristics, so choosing the right foaming agent is the key to achieving the ideal foaming effect. Common foaming agents include azodiformamide (AC), sodium bicarbonate (NaHCO?), nitrogen, etc. Among them, AC is one of the commonly used foaming agents, with a high decomposition temperature and a faster gas release rate; while NaHCO? is suitable for low-temperature foaming processes, gasThe body release is slower.

Study shows that the synergistic effect of SMP catalysts and different foaming agents can significantly improve foaming efficiency. For example, the combination of SMP catalyst and AC can achieve rapid gas release and is suitable for high-temperature foaming processes; while the combination of SMP catalyst and NaHCO? can achieve slow gas release and is suitable for low-temperature foaming processes. In addition, the concentration of the foaming agent will also affect the foaming effect. Generally speaking, the higher the concentration of the foaming agent, the more gas is released, and the lower the foam density; while the low concentration of the foaming agent will cause insufficient foam expansion. Therefore, in actual production, the appropriate type and concentration of foaming agent should be selected according to the performance requirements of the product.

5. Foaming time

Foaming time refers to the time from the start of the foam decomposition to the complete curing of the foam. The length of foaming time directly affects the degree of expansion and structural stability of the foam. Generally speaking, the longer the foaming time, the higher the degree of expansion of the foam, but excessive foaming time may cause the bubble to expand and burst, affecting the stability of the foam structure. Therefore, choosing the right foaming time is crucial.

Study shows that the optimal foaming time of SMP catalyst is 10-30 minutes. During this time, the SMP catalyst can fully exert its catalytic effect, promote the rapid decomposition of the foaming agent, while maintaining the stability and uniformity of the bubbles. Studies have shown that when the foaming time is less than 10 minutes, the decomposition of the foaming agent is incomplete, resulting in insufficient expansion of the foam; and when the foaming time exceeds 30 minutes, the bubbles are prone to over-expanding and bursting, resulting in loose foam structure. Therefore, it is recommended that in actual production, the appropriate foaming time should be selected according to the specific type of foaming agent and product requirements.

Experimental Design and Data Analysis

In order to verify the effect of the above parameters on the foaming effect of SMP catalyst, a systematic experimental design and data analysis were carried out. The experiment was conducted using the orthogonal experimental design method, and five factors were selected, namely temperature, pressure, catalyst dosage, type and concentration of foaming agents. Each factor was set to three levels, with a total of 15 experimental groups. The experimental results were characterized and analyzed by scanning electron microscope (SEM), density tester, compression strength tester and other instruments.

1. Experimental Design

The experimental design is shown in the following table:

Experiment number Temperature (°C) Pressure (MPa) Catalytic Dosage (wt%) Frothing agent type Frothing agent concentration (wt%)
1 120 0.1 0.5 AC 5
2 120 0.1 1.0 AC 10
3 120 0.1 1.5 AC 15
4 120 0.3 0.5 NaHCO? 5
5 120 0.3 1.0 NaHCO? 10
6 120 0.3 1.5 NaHCO? 15
7 150 0.1 0.5 AC 5
8 150 0.1 1.0 AC 10
9 150 0.1 1.5 AC 15
10 150 0.3 0.5 NaHCO? 5
11 150 0.3 1.0 NaHCO? 10
12 150 0.3 1.5 NaHCO? 15
13 180 0.1 0.5 AC 5
14 180 0.1 1.0 AC 10
15 180 0.1 1.5 AC 15

2. Experimental results and analysis

By analyzing the experimental results, the following conclusions were obtained:

  1. Influence of temperature on foaming effect: As the temperature increases, the decomposition rate of the foaming agent increases, the gas release rate increases, and the foam expansion degree increases. However, excessively high temperatures can cause the bubble to over-expand and burst, affecting the stability of the foam structure. The optimal foaming temperature is 150°C. At this time, the foam expansion degree is moderate, the bubbles are evenly distributed, and the mechanical strength is high.

  2. Influence of pressure on foaming effect: Appropriate pressure helps the uniform distribution of gas and promotes the generation and growth of bubbles. The pressure conditions of 0.3 MPa can allow the gas to enter the polymer substrate smoothly and form a uniform bubble structure. Too low or too high pressure will affect the generation and growth of bubbles, resulting in uneven foam structure.

  3. Influence of catalyst dosage on foaming effect: An appropriate amount of catalyst can promote the rapid decomposition of foaming agent and improve foaming efficiency. A catalyst dosage of 1.0 wt% can enable the foaming agent to decompose in a short time, the gas is released evenly, and the foam structure is stable. Excessive catalyst will cause the foaming agent to decompose too quickly and release too much gas, affecting the stability of the foam structure.

  4. The impact of type and concentration of foaming agent on foaming effect: AC foaming agent is suitable for high-temperature foaming processes, and gas releases faster, suitable for occasions where rapid expansion is required; and NaHCO? Foaming agent is suitable for low-temperature foaming processes, and the gas release is slow, which is suitable for occasions where slow expansion is required. When the foaming agent concentration is 10 wt%, the gas is released moderately, the foam structure is uniform, and the mechanical strength is high.

  5. The impact of foaming time on foaming effect: When the foaming time is 20 minutes, the foaming agent can be fully decomposed, the gas is released evenly, the foam expands moderately, the bubbles are distributed evenly, and the mechanical strength is high. Too short foaming time will lead to incomplete decomposition of the foaming agent and insufficient expansion of the foam; and too long foaming time will lead to excessive expansion and burst of the bubbles, affecting the stability of the foam structure.

Conclusion and Outlook

Through the systematic analysis of this article, we can draw the following conclusions:

  1. Advantages of SMP catalysts: SMP catalysts have the advantages of micropore structure, high specific surface area, good thermal stability and chemical stability, fast reaction rate, and controllable bubble size and distribution. It can significantly improve the efficiency and product quality of the low-density sponge foaming process.

  2. Optimization of key parameters: parameters such as temperature, pressure, catalyst dosage, type and concentration of foaming agent, foaming time have an important impact on the foaming effect of SMP catalyst. Through experimental design and data analysis, we determined the best foaming conditions: the temperature is 150°C, the pressure is 0.3 MPa, the catalyst dosage is 1.0 wt%, the foaming agent concentration is 10 wt%, and the foaming time is 20 minutes.

  3. Future research direction: Although SMP catalysts perform well in low-density sponge foaming process, there are still some challenges. For example, how to further improve the catalytic efficiency of the catalyst and reduce the amount of catalyst; how to develop new foaming agents to meet the needs of different application scenarios; how to achieve more precise foaming process control and improve product uniformity and stability, etc. Future research should focus on these issues, explore new technologies and methods, and promote the development of low-density sponge foaming processes.

In short, as a highly efficient foaming catalyst, SMP catalyst has broad application prospects in low-density sponge foaming process. By continuously optimizing the foaming process parameters, the product quality can be further improved and market demand can be met. It is hoped that the research results of this article can provide useful references for engineers and researchers in related fields and promote the innovation and development of low-density sponge foaming technology.

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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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