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Discussion on the difference between low atomization and odorless catalysts and traditional catalysts

2月 10th, 2025 News

The background and significance of low atomization and odorless catalyst

With the global emphasis on environmental protection and sustainable development, the environmental pressure faced by the chemical industry in the production process is increasing. Although traditional catalysts have played an important role in improving reaction efficiency and reducing costs, they have also brought some problems that cannot be ignored in practical applications, such as the emission of volatile organic compounds (VOCs), odor problems and human health. potential hazards. These problems not only affect the production environment, but may also have adverse effects on surrounding communities, which in turn triggers public opinion and legal risks.

A low atomization odorless catalyst is developed as a new catalyst to meet these challenges. Its core advantage is that it can significantly reduce or eliminate the atomization and odor problems caused by traditional catalysts during use while maintaining efficient catalytic performance. Atomization refers to the catalyst evaporating into a gaseous state under high temperature or high pressure conditions, forming tiny particles suspended in the air. These particles will not only affect the air quality, but may also cause corrosion and blockage to the equipment. The problem of odor is caused by the decomposition or evaporation of certain components in the catalyst during the reaction, producing a pungent odor, affecting the working environment and physical health of the operator.

The emergence of low atomization and odorless catalysts not only help improve the production environment and reduce environmental pollution, but also enhance the social responsibility image of enterprises, which is in line with the current global development trend of green chemical industry. In addition, the application of this type of catalyst can help enterprises meet increasingly stringent environmental protection regulations and reduce legal risks and economic costs caused by environmental pollution problems. Therefore, the research and application of low atomization odorless catalysts have important practical significance and broad market prospects.

Types and characteristics of traditional catalysts

Traditional catalysts are widely used in petrochemical, fine chemical, pharmaceutical, material synthesis and other fields. According to their physical form and chemical composition, they can be divided into three categories: liquid catalyst, solid catalyst and gas catalyst. Each type of catalyst has its own unique characteristics and application scenarios. The main characteristics of these three types of catalysts will be described in detail below.

1. Liquid Catalyst

Liquid catalysts are a type of catalysts that have been widely used for a long time. They usually exist in liquid form and can be evenly dispersed in the reaction system to provide efficient catalytic activity. Common liquid catalysts include base catalysts, metal salt solutions, homogeneous organometallic catalysts, etc.

  • Basic Catalyst: Base catalysts are one of the common liquid catalysts and are widely used in reactions such as esterification, hydrolysis, and hydrogenation. For example, strong sulfur and phosphorus are often used in esterification reactions, while alkaline substances such as sodium hydroxide and potassium hydroxide are often used in saponification reactions. The advantages of alkali catalysts are high catalytic efficiency and mild reaction conditions, but the disadvantages are that they are prone to corrosive equipment and may generate a large amount of wastewater during use, increasing the cost of treatment.

  • Metal Salt Solution: The metal salt solution catalyst is mainly composed of an aqueous solution composed of transition metal ions (such as iron, copper, cobalt, nickel, etc.) and anions such as halogen, nitrone, sulfur, etc. This type of catalyst is widely used in redox reactions, coordination polymerization reactions and other fields. For example, ferric chloride is often used for the hydroxylation reaction of phenols, while nitroxide is used for the halogenation reaction of olefins. The advantages of metal salt solution catalysts are high catalytic activity and good selectivity, but the disadvantage is that some metal ions are toxic and may cause harm to the environment and human health.

  • Horizontal Organometal Catalyst: Homogeneous Organometal Catalyst is a complex formed by organic ligands and metal centers, and is commonly found in the fields of organic synthesis, hydrogenation reaction, olefin polymerization, etc. For example, palladium carbon catalysts are widely used in the hydrogenation reaction of organic compounds, while titanium ester catalysts are used in the synthesis of polypropylene. The advantages of homogeneous organometallic catalysts are high catalytic activity, good selectivity, and mild reaction conditions, but the disadvantage is that the catalyst is costly and difficult to recover after the reaction is over, which easily leads to waste of resources.

2. Solid Catalyst

Solid catalysts are catalysts present in solid form, usually with a large specific surface area and pore structure, which can provide more active sites and thereby improve catalytic efficiency. Common solid catalysts include metal catalysts, molecular sieves, activated carbon, metal oxides, etc.

  • Metal Catalyst: Metal catalysts are an important category of solid catalysts, mainly including precious metals (such as platinum, palladium, gold, silver, etc.) and non-precious metals (such as iron, copper, nickel, cobalt, etc.) wait). Metal catalysts are widely used in hydrogenation, dehydrogenation, oxidation, reduction and other reactions. For example, platinum carbon catalysts are commonly used in hydrogenation reactions, while nickel catalysts are used in Fischer-Tropsch synthesis reactions. The advantages of metal catalysts are high catalytic activity and good stability, but the disadvantage is that the cost of precious metal catalysts is higher, while the selectivity of non-precious metal catalysts is poor.

  • Molecular sieve: Molecular sieve is a type of silicon-aluminum salt material with regular pore structure, which is widely used in adsorption, separation, catalysis and other fields. The molecular sieve catalyst is characterized by a highly ordered pore structure, which can selectively adsorb and catalyze molecules of specific sizes, so it is used in catalytic cracking, isomerization, alkylation and other reactions.??Express excellent performance. The advantages of molecular sieve catalysts are good selectivity and high catalytic efficiency, but the disadvantages are complex preparation process and high cost.

  • Activated Carbon: Activated Carbon is a porous carbon material with a large specific surface area and rich surface functional groups. It is widely used in adsorption, catalysis, purification and other fields. The activated carbon catalyst is characterized by its strong adsorption capacity and high catalytic activity, and is suitable for gas and liquid phase reactions. For example, activated carbon is often used in reactions such as waste gas treatment, waste water treatment, dye degradation, etc. The advantage of activated carbon catalysts is that they are cheap and have a wide range of sources, but the disadvantage is that they are low in catalytic activity and are prone to inactivation.

  • Metal Oxide: Metal oxide catalysts are compounds composed of metal elements and oxygen elements, and are widely used in oxidation, reduction, photocatalysis and other fields. Common metal oxide catalysts include titanium dioxide, zinc oxide, iron oxide, etc. For example, titanium dioxide is often used for photocatalytic degradation of organic pollutants, while zinc oxide is used for ammonia synthesis reactions. The advantages of metal oxide catalysts are good stability and high catalytic activity, but the disadvantages are poor selectivity and some metal oxides have certain toxicity.

3. Gas Catalyst

Gas catalysts are catalysts present in gaseous form and are usually used in gas phase reactions. The characteristics of gas catalysts are fast reaction speed and low mass transfer resistance, which are suitable for reactions under high temperature and high pressure conditions. Common gas catalysts include halogen gas, oxygen, nitrogen, etc.

  • Halogen gases: Halogen gases (such as chlorine, bromine, iodine, etc.) are widely used in halogenation reactions, oxidation reactions and other fields. For example, chlorine is often used for halogenation of olefins, while bromine is used for bromination of aromatic compounds. The advantages of halogen gas catalysts are high reactivity and good selectivity, but the disadvantage is that they have strong corrosiveness and toxicity, and the reaction conditions need to be strictly controlled during use.

  • Oxygen: Oxygen is a commonly used oxidant and is widely used in combustion, oxidation, photosynthesis and other fields. When oxygen is used as a gas catalyst, it usually works in concert with other catalysts (such as metal oxides, enzymes, etc.) to improve catalytic efficiency. For example, oxygen and titanium dioxide can effectively degrade organic pollutants. The advantages of oxygen catalysts are that they have a wide range of sources and are low in cost, but the disadvantage is that the reaction conditions are relatively harsh and usually require higher temperatures and pressures.

  • Nitrogen: Nitrogen is an inert gas and is usually used to protect the reaction system and prevent interference from other gases (such as oxygen, water vapor, etc.). Nitrogen itself is not catalytically active, but can act as a support gas in some reactions to help transport other catalysts or reactants. For example, in ammonia synthesis reaction, nitrogen and hydrogen form ammonia under the action of an iron catalyst. The advantages of nitrogen catalysts are high safety and mild reaction conditions, but the disadvantage is that they have low catalytic activity and usually require synergistic action with other catalysts.

Technical principles of low atomization and odorless catalyst

The reason why low-atomization and odorless catalysts can significantly reduce or eliminate atomization phenomena and odor problems while maintaining high-efficiency catalytic performance is mainly due to their unique technical principles and design ideas. Compared with traditional catalysts, low-atomization and odorless catalysts achieve effective control of atomization and odor by improving the chemical composition, physical form and reaction mechanism of the catalyst.

1. Chemical composition optimization

One of the core technologies of low atomization odorless catalysts is to optimize the chemical composition of the catalyst. In traditional catalysts, some components are prone to volatilization into gaseous states under high temperature or high pressure conditions, forming tiny particles suspended in the air, resulting in the occurrence of atomization. In addition, some catalyst components may decompose or volatilize during the reaction, producing a pungent odor and affecting the operating environment. To solve these problems, developers of low-atomization and odorless catalysts have reduced the use of volatile components by adjusting the chemical composition of the catalyst, or selected more stable chemicals as catalytic active components.

For example, some low atomization odorless catalysts use nanoscale metal oxides as active components, which have high thermal and chemical stability and can maintain good catalytic properties under high temperature conditions. Without volatilization or decomposition. Studies have shown that the specific surface area of ??nano-scale metal oxides is large and can provide more active sites, thereby improving catalytic efficiency. At the same time, the small size effect of nanomaterials makes it have lower surface energy, reducing the aggregation between catalyst particles and further reducing the possibility of atomization.

In addition, the low atomization odorless catalyst further enhances the stability and volatile resistance of the catalyst by introducing functional additives. For example, some catalysts are added with silicone compounds or polymer coatings, which can form a protective film on the surface of the catalyst to prevent volatilization and decomposition of the catalyst components. The experimental results show that the volatility of the coated catalyst under high temperature conditions has been significantly reduced, and the catalytic performance has been effectively improved.

2. Physical form innovation

In addition to chemical composition optimization, the physical morphology design of low-atomization and odorless catalysts is also one of its key technologies.. Traditional catalysts usually exist in powder or granular form. These forms of catalysts are prone to flying and diffusing during use, resulting in atomization. In order to solve this problem, the developers of low-atomization and odorless catalysts have developed a variety of new catalyst forms by innovating the physical forms of the catalyst, such as microsphere catalysts, fiber catalysts, thin-film catalysts, etc.

  • Microsphere Catalyst: Microsphere Catalyst is a spherical catalyst composed of micro- or nano-sized particles, with a high specific surface area and good fluidity. The spherical structure of the microsphere catalyst reduces the contact area between the catalyst particles, reducing friction and collision between the particles, thereby reducing the flying and diffusion of the catalyst. In addition, the spherical structure of the microsphere catalyst can provide more active sites and improve catalytic efficiency. Studies have shown that the atomization rate of microsphere catalysts in gas phase reactions is more than 50% lower than that of traditional powder catalysts.

  • Fiber Catalyst: Fiber Catalyst is a catalyst composed of nanofibers, with a high aspect ratio and a large specific surface area. The special form of fiber catalyst allows the catalyst to be evenly distributed during the reaction process, reducing the aggregation and settlement of the catalyst, thereby reducing the possibility of atomization. In addition, the high aspect ratio of the fiber catalyst can provide more mass transfer channels, promote contact between reactants and catalysts, and improve catalytic efficiency. The experimental results show that the atomization rate of fiber catalysts in liquid phase reaction is reduced by more than 70% compared with traditional particle catalysts.

  • Film Catalyst: A thin film catalyst is a thin layer of catalyst composed of nanoscale catalyst particles, usually coated on the surface of the support or made into a self-supporting film. The thin-layer structure of the thin film catalyst allows the catalyst to quickly transfer mass and heat during the reaction process, reducing the volatility and decomposition of the catalyst. In addition, the thin-layer structure of the thin-film catalyst can provide more active sites and improve catalytic efficiency. Studies have shown that the atomization rate of thin-film catalysts in high-temperature reactions is reduced by more than 80% compared with traditional bulk catalysts.

3. Reaction mechanism regulation

Another key technology of low atomization odorless catalyst is the regulation of the reaction mechanism. During the reaction of traditional catalysts, certain intermediate or by-products may volatilize or decompose, creating a pungent odor. To solve this problem, the developers of low-atomization odorless catalysts optimized the catalyst’s catalytic path by regulating the reaction mechanism, reducing the generation of intermediate products and by-products, thereby reducing the occurrence of odor problems.

For example, in certain oxidation reactions, conventional catalysts may produce peroxides or aldehyde byproducts that are prone to volatilization under high temperature conditions and produce pungent odors. To solve this problem, the low-atomization odorless catalyst regulates the reaction path by introducing selective oxidation aids, so that the reaction mainly produces the target product, while reducing the generation of peroxides and aldehyde by-products. The experimental results show that the odor problem of catalysts regulated by the reaction mechanism has been significantly improved in the oxidation reaction and the operating environment has been significantly optimized.

In addition, the low atomization odorless catalyst also realizes synchronous catalysis of multiple reaction steps by introducing a multifunctional catalyst. For example, in some complex multi-step reactions, a conventional catalyst can only catalyze a specific step, while other steps require additional catalysts or additives to complete. To solve this problem, the low-atomization odorless catalyst realizes synchronous catalysis of multiple reaction steps by introducing a multifunctional catalyst, reducing the accumulation of intermediate products, thereby reducing the occurrence of odor problems. Studies have shown that the catalytic efficiency of multifunctional catalysts in multi-step reactions is more than 30% higher than that of traditional single catalysts, and the odor problem is effectively controlled.

Comparison of performance of low atomization odorless catalyst and traditional catalyst

In order to more intuitively demonstrate the advantages of low-atomization odorless catalysts over traditional catalysts, the following will compare them in detail from the aspects of catalytic activity, selectivity, stability, atomization rate, and odor degree, and combine them with specific Application cases are analyzed. For ease of comparison, we divided different types of catalysts into three categories: liquid catalyst, solid catalyst and gas catalyst, and listed the corresponding parameter table.

1. Catalytic activity

Catalytic activity is one of the important indicators for evaluating catalyst performance, and is usually measured by parameters such as reaction rate constant, conversion rate, and yield. The following is a comparison of the catalytic activity of low atomization odorless catalysts and traditional catalysts:

Category Traditional catalyst Low atomization odorless catalyst Remarks
Liquid Catalyst Basic catalysts, metal salt solutions, homogeneous organometallic catalysts Nanoscale metal oxides and silicone coating catalysts The catalytic activity of low atomization odorless catalysts is slightly higher than that of traditional catalysts, and is more prominent in high temperature conditions.
Solid Catalyst Metal catalysts, molecular sieves, activated carbon, metal oxides Microsphere catalysts, fiber catalysts, thin film catalysts Chief of low atomization odorless catalystThe chemical activity is significantly improved, especially in gas-phase and liquid phase reactions.
Gas Catalyst Halogen gas, oxygen, nitrogen Functional gas catalysts (such as nitrogen oxides) The catalytic activity of low atomization odorless catalyst is comparable to that of traditional catalysts, but it is more stable under high temperature and high pressure conditions.

2. Selectivity

Selectivity refers to the catalyst’s ability to select the target product during the reaction, which is usually measured by parameters such as selectivity coefficient and by-product generation. The following is a comparison of the selectivity of low-atomization odorless catalysts and traditional catalysts:

Category Traditional catalyst Low atomization odorless catalyst Remarks
Liquid Catalyst Basic catalysts, metal salt solutions, homogeneous organometallic catalysts Nanoscale metal oxides and silicone coating catalysts The selectivity of low-atomization odorless catalysts is significantly improved, especially the selectivity control of complex reactions is more accurate.
Solid Catalyst Metal catalysts, molecular sieves, activated carbon, metal oxides Microsphere catalysts, fiber catalysts, thin film catalysts The selectivity of low atomization odorless catalysts is significantly improved, especially in multi-step reactions, which perform better.
Gas Catalyst Halogen gas, oxygen, nitrogen Functional gas catalysts (such as nitrogen oxides) The selectivity of low atomization odorless catalyst is comparable to that of traditional catalysts, but it is more stable under high temperature and high pressure conditions.

3. Stability

Stability refers to the ability of a catalyst to maintain catalytic activity and structural integrity during long-term use, which is usually measured by the catalyst’s service life, heat resistance, and anti-toxicity parameters. The following is a comparison of the stability of low atomization odorless catalysts and traditional catalysts:

Category Traditional catalyst Low atomization odorless catalyst Remarks
Liquid Catalyst Basic catalysts, metal salt solutions, homogeneous organometallic catalysts Nanoscale metal oxides and silicone coating catalysts The stability of low atomization odorless catalysts is significantly improved, especially in high temperature conditions.
Solid Catalyst Metal catalysts, molecular sieves, activated carbon, metal oxides Microsphere catalysts, fiber catalysts, thin film catalysts The stability of low atomization odorless catalysts is significantly improved, especially in heterogeneous reactions.
Gas Catalyst Halogen gas, oxygen, nitrogen Functional gas catalysts (such as nitrogen oxides) The stability of low atomization odorless catalyst is comparable to that of traditional catalysts, but it is more stable under high temperature and high pressure conditions.

4. Atomization rate

The atomization rate refers to the proportion of the catalyst evaporated into gaseous states and formed tiny particles during use, which is usually measured by parameters such as particle concentration and volatility rate in the air. The following is a comparison of low atomization odorless catalysts and traditional catalysts in terms of atomization rate:

Category Traditional catalyst Low atomization odorless catalyst Remarks
Liquid Catalyst Basic catalysts, metal salt solutions, homogeneous organometallic catalysts Nanoscale metal oxides and silicone coating catalysts The atomization rate of low atomization odorless catalysts is significantly reduced, especially in high temperature conditions.
Solid Catalyst Metal catalysts, molecular sieves, activated carbon, metal oxides Microsphere catalysts, fiber catalysts, thin film catalysts The atomization rate of low atomization odorless catalysts is significantly reduced, especially in heterogeneous reactions.
Gas Catalyst Halogen gas, oxygen, nitrogen Functional gas catalysts (such as nitrogen oxides) The atomization rate of low atomization odorless catalyst is comparable to that of traditional catalysts, but it is more stable under high temperature and high pressure conditions.

5. Odor degree

The degree of odor refers to the intensity of the pungent odor produced by the catalyst during use, which is usually measured by parameters such as the concentration of volatile organic compounds (VOCs) in the air, the odor intensity level, etc. The following is a comparison of the odor degree of low atomization and traditional catalysts:

Category Traditional catalyst Low atomization odorless catalyst Remarks
Liquid Catalyst Basic catalysts, metal salt solutions, homogeneous organometallic catalysts Nanoscale metal oxides and silicone coating catalysts The odor degree of low atomization odorless catalyst is significantly reduced, especially in high temperature conditions.
Solid Catalyst Metal catalysts, molecular sieves, activated carbon, metal oxides Microsphere catalysts, fiber catalysts, thin film catalysts The odor degree of low atomization odorless catalyst is significantly reduced, especially in heterogeneous reactions.
Gas Catalyst Halogen gas, oxygen, nitrogen Functional gas catalysts (such as nitrogen oxides) The odor degree of low atomization odorless catalyst is comparable to that of traditional catalysts, but it is more stable under high temperature and high pressure conditions.

Application Case Analysis

In order to better understand the practical application effects of low atomization odorless catalysts, the following will analyze the application of low atomization odorless catalysts in different fields in detail based on specific industrial cases.

1. Petrochemical field

In the petrochemical field, low atomization and odorless catalysts are mainly used in catalytic cracking, hydrorefining, alkylation and other reactions. Traditional petroleum catalysts are prone to evaporation under high temperature conditions, producing a large number of atomized particles and odors, affecting the production environment and the normal operation of the equipment. For example, in catalytic cracking reactions, traditional zeolite catalysts volatilize under high temperature conditions, causing catalyst particles to enter the gas stream, increasing the difficulty of subsequent treatment. In addition, traditional catalysts will also produce harmful gases such as hydrogen sulfide during use, affecting the health of operators.

In contrast, low atomization odorless catalysts perform better in catalytic cracking reactions. A petrochemical company has adopted a low-atomization odorless catalyst based on nano-scale metal oxides. This catalyst not only has high catalytic activity and selectivity, but also exhibits excellent stability under high temperature conditions and has almost no atomization. A phenomenon occurs. The experimental results show that after using low atomization and odorless catalyst, the conversion rate of the catalytic cracking reaction increased by 10%, the selectivity of the product increased by 5%, and the production environment was significantly improved, and the health of the operators was effectively guaranteed.

2. Fine Chemicals Field

In the field of fine chemicals, low atomization and odorless catalysts are mainly used in organic synthesis, hydrogenation reaction, oxidation reaction, etc. Traditional fine chemical catalysts often produce a large amount of odor during use, affecting the operating environment and product quality. For example, in some organic synthesis reactions, traditional homogeneous organometallic catalysts will decompose under high temperature conditions, creating a pungent odor, affecting the working environment of the operator. In addition, the volatile nature of traditional catalysts may also cause impurities in the product, affecting product quality.

In contrast, low atomization odorless catalysts perform better in the field of fine chemicals. A pharmaceutical company has adopted a low-atomization odorless catalyst based on silicone coating. This catalyst not only has high catalytic activity and selectivity, but also produces almost no odor under high temperature conditions. The experimental results show that after using low atomization and odorless catalyst, the yield of the organic synthesis reaction increased by 15%, the purity of the product reached more than 99.5%, and the operating environment was significantly improved, and the product quality was effectively improved.

3. Pharmaceutical field

In the pharmaceutical field, low atomization and odorless catalysts are mainly used in drug synthesis, chiral catalysis, biocatalysis, etc. Traditional pharmaceutical catalysts often produce a large number of volatile organic compounds (VOCs) during use, affecting the production environment and the quality of drugs. For example, in some drug synthesis reactions, traditional homogeneous organometallic catalysts volatilize under high temperature conditions, creating pungent odors, affecting the health of the operators. In addition, the volatility of traditional catalysts may also cause impurities in the drug, affecting the safety and effectiveness of the drug.

In contrast, low atomization odorless catalysts perform better in the pharmaceutical field. A pharmaceutical company has adopted a low-atomization odorless catalyst based on nano-scale metal oxides. This catalyst not only has high catalytic activity and selectivity, but also exhibits excellent stability under high temperature conditions and has almost no atomization. A phenomenon occurs. The experimental results show that after using low atomization and odorless catalyst, the yield of drug synthesis reaction was increased by 20%, the purity of the product reached more than 99.9%, and the production environment was significantly improved, and the safety and effectiveness of the drug were effectively Assure.

4. Field of Materials Synthesis

In the field of material synthesis, low atomization and odorless catalysts are mainly used in polymerization reactions, nanomaterial synthesis, photocatalytic reactions, etc. Traditional material synthesis catalysts often produce a large number of volatile organic compounds (VOCs) during use, affecting the production environment and the quality of materials. For example, in some polymerization reactions, traditional homogeneous organometallic catalysts volatilize under high temperature conditions, creating pungent odors that affect the health of the operator. In addition, the volatility of traditional catalysts may also cause impurities in the material, affecting the performance of the material.

In contrast, low atomization odorless catalysts perform better in the field of material synthesis. A material company has adopted a low-atomization odorless catalyst based on microsphere catalysts. This catalyst not only has high catalytic activity and selectivity, but also produces almost no odor under high temperature conditions. Experimental results show that after using low atomization and odorless catalyst, the conversion rate of the polymerization reaction was increased by 15%, the purity of the material reached more than 99.8%, and the production environment was significantly improved, and the performance of the material was effectively improved.

Future development trends of low atomization odorless catalysts

With the global emphasis on environmental protection and sustainable development, low atomization and odorless catalysts, as a new generation of green catalysts, will surely be in the future chemical industry.plays an increasingly important role in ?. In the future, the development trend of low atomization odorless catalysts will mainly focus on the following aspects:

1. Application of Nanotechnology

Nanotechnology is one of the cutting-edge technologies that have developed rapidly in recent years. Nanomaterials have shown great potential in the field of catalysts due to their unique physicochemical properties. In the future, the research and development of low-atomization and odorless catalysts will pay more attention to the application of nanotechnology and develop more nanocatalysts with high activity, high selectivity and high stability. For example, nanometal oxides, nanocarbon materials, nanocomposite materials, etc. will become important development directions for low atomization and odorless catalysts. Studies have shown that nanocatalysts have a large specific surface area and abundant active sites, which can achieve efficient catalysis under low temperature conditions, while reducing the occurrence of atomization and odor problems.

2. Deepening of the concept of green chemistry

Green chemistry is an important development direction of the modern chemical industry, aiming to achieve sustainable development of chemical production by reducing or eliminating the use and emissions of harmful substances. In the future, the research and development of low-atomization and odorless catalysts will pay more attention to the deepening of green chemistry concepts and develop more green catalysts that meet environmental protection requirements. For example, renewable resources are used as catalyst raw materials to reduce the use of harmful solvents, and develop a non-toxic and harmless catalyst system. In addition, the green chemistry concept will also promote the application of low-atomization and odorless catalysts in more fields, such as biomass conversion, carbon dioxide fixation, water treatment, etc.

3. The integration of intelligence and automation technology

With the rapid development of intelligent and automation technologies, the future research and development of low-atomization and odorless catalysts will pay more attention to the integration with intelligent and automation technologies. For example, by introducing technologies such as intelligent sensors, big data analysis, artificial intelligence, etc., real-time monitoring and optimization of catalyst performance can be achieved, and the efficiency and life of catalysts can be improved. In addition, intelligent and automated technologies will promote the application of low-atomization and odorless catalysts in continuous production, such as continuous flow reactors, micro reactors, etc., further improving production efficiency and product quality.

4. Development of multifunctional catalysts

Multifunctional catalyst refers to the synchronous catalysis of multiple reaction steps in the same reaction system, which has the advantages of high efficiency, energy saving, and environmental protection. In the future, the research and development of low-atomization and odorless catalysts will pay more attention to the development of multifunctional catalysts, and achieve efficient catalysis of complex reactions by introducing a variety of active components and additives. For example, a multifunctional catalyst can realize oxidation, reduction, hydrogenation and other reactions in the same reaction system have been developed to reduce the accumulation of intermediate products and reduce energy consumption and environmental pollution. In addition, multifunctional catalysts will also promote the application of low-atomization and odorless catalysts in multi-step reactions, such as drug synthesis, material synthesis, etc.

5. Strengthening of interdisciplinary research

The research and development of low-atomized odorless catalysts involves multiple disciplines such as chemistry, materials science, physics, and biology. The strengthening of interdisciplinary research will provide new ideas and technical support for the innovative development of low-atomized odorless catalysts. For example, by introducing advanced synthesis techniques in materials science, new catalysts with higher catalytic properties were developed; by introducing quantum mechanical calculations in physics, the microscopic reaction mechanism of catalysts was revealed; by introducing enzyme catalytic techniques in biology, Develop biocatalysts with higher selectivity. The strengthening of interdisciplinary research will inject new vitality into the future development of low-atomization odorless catalysts.

Conclusion

To sum up, as a new green catalyst, low atomization and odorless catalyst has significant technical advantages and broad application prospects. Compared with traditional catalysts, low-atomization and odorless catalysts achieve effective control of atomization and odor by optimizing chemical composition, innovating physical forms, and regulating reaction mechanisms, while maintaining efficient catalytic performance. In many fields such as petrochemical, fine chemical, pharmaceutical, material synthesis, etc., low atomization and odorless catalysts have shown excellent performance and significant environmental benefits.

In the future, with the continuous development of nanotechnology, green chemistry, intelligent technology, multifunctional catalysts, interdisciplinary research and other fields, low atomization and odorless catalysts will surely be widely used in more fields, promoting the greenness of the chemical industry in the chemical industry Transformation and sustainable development. We have reason to believe that low atomization and odorless catalysts will become an important development direction for the chemical industry in the future and will make greater contributions to achieving clean production and environmental protection.

The role of low-atomization and odorless catalysts in medical equipment manufacturing

2月 10th, 2025 News

Definition and background of low atomization odorless catalyst

Low-Fogging, Odorless Catalysts (LF-OC) are a chemical additives widely used in medical equipment manufacturing, mainly used to promote the curing reaction of polymer materials. Its “low atomization” property means that during use, the catalyst does not produce obvious volatile organic compounds (VOCs), thereby reducing potential harm to the environment and operators; while “odorless” means that it is No odor will be emitted during use, avoiding pollution to the medical environment and impact on patients and medical staff.

With the rapid development of the global medical industry, the demand for medical equipment has continued to increase, especially during the epidemic, the demand for high-quality and high-performance medical equipment is more urgent. Although traditional catalysts can meet basic curing needs, they are often accompanied by certain limitations in actual applications, such as high volatility and strong odor. These disadvantages not only affect production efficiency, but also can pose a potential threat to the health of the operator. Therefore, the development and application of low atomization odorless catalysts have become an important topic in the field of medical equipment manufacturing.

The low atomization odorless catalyst has a wide range of applications, covering all areas from disposable medical devices to high-end medical devices. For example, in the production of disposable medical devices such as syringes, catheters, and respiratory masks, low-atomization and odorless catalysts can ensure that the surface of the product is smooth and bubble-free, while avoiding the odor problems caused by traditional catalysts. In the manufacturing process of large medical equipment such as CT machines and MRI machines, low atomization and odorless catalysts can help improve the accuracy and stability of the equipment and extend the service life of the equipment.

In recent years, with the increase in environmental awareness and technological advancement, more and more countries and regions have begun to formulate strict regulations to limit the emission of volatile organic compounds. For example, the EU’s Chemical Registration, Evaluation, Authorization and Restriction Regulations (REACH) and the US’s Clean Air Act both put forward strict requirements on VOC emissions in medical device manufacturing. In this context, the research and development and application of low atomization and odorless catalysts not only meet environmental protection requirements, but also significantly improve the quality and safety of medical equipment, which is of great practical significance.

Special requirements for catalysts in medical equipment manufacturing

In the medical device manufacturing process, the choice of catalyst is crucial because it directly affects the performance, safety and environmental protection of the product. In order to meet the strict requirements of the medical industry for high quality and high reliability, low atomization and odorless catalysts must have the following key characteristics:

1. High-efficient catalytic activity

Efficient catalytic activity is the basis for ensuring the smooth progress of the polymerization reaction. In medical equipment manufacturing, catalysts need to be able to rapidly initiate polymerization at lower temperatures, shorten curing time, and improve production efficiency. In addition, the activity of the catalyst should be stable and not affected by external environmental factors (such as temperature and humidity). Studies have shown that ideal low atomization odorless catalysts should exhibit excellent catalytic performance from room temperature to 60°C and achieve uniform curing effects on different substrates.

2. Low atomization and odorless properties

The core advantage of the low atomization odorless catalyst is that it can minimize the release of volatile organic compounds (VOCs) during use and does not produce any odor. This characteristic is particularly important for the manufacturing of medical equipment, because hospitals and other medical institutions have extremely high requirements for air quality, and the release of any odor or harmful gases may have an adverse impact on the health of patients and medical staff. According to the U.S. Environmental Protection Agency (EPA) standards, the catalysts used in the manufacturing of medical equipment should control VOC emissions below 100 grams per liter to ensure that indoor air quality complies with relevant regulations.

3. Biocompatibility and safety

Medical equipment directly contacts the human body, so the biocompatibility and safety of catalysts are key factors that cannot be ignored. Low atomization odorless catalysts should pass rigorous biocompatibility tests to ensure that they do not have adverse reactions to human tissues, such as allergies, inflammation or toxic effects. The ISO 10993 series of standards issued by the International Organization for Standardization (ISO) provides detailed guidance on biocompatibility testing of medical devices, and catalyst manufacturers must follow these standards for product development and quality control. In addition, the catalyst should also have good chemical stability and durability to ensure that it will not decompose or deteriorate during long-term use, thereby avoiding potential threats to the safety of medical equipment.

4. Environmental and sustainable

With the continuous improvement of global environmental awareness, medical equipment manufacturing companies pay more and more attention to the environmental protection performance of catalysts. Low atomization and odorless catalysts should not only reduce VOC emissions, but also use renewable resources as raw materials as possible to reduce the burden on the environment. For example, some new catalysts use vegetable oil derivatives as basic materials, which have good biodegradability and low toxicity. In addition, the production and use of catalysts should also comply with the principles of green chemistry, reduce energy consumption and waste generation, and promote the sustainable development of the medical equipment manufacturing industry.

5. Wide applicability

There are many types of medical equipment, covering multiple fields such as disposable consumables, implantable devices, diagnostic equipment, etc. Therefore, the applicability of catalysts is also an important consideration. Low atomization and odorless catalysts should be suitable for a variety of polymer materials, such as polyurethane, silicone rubber, epoxy resin, etc., to meet the needs of different application scenarios. For example, in the manufacturing of implantable instruments such as cardiac stents and artificial joints, catalysts need to have excellent mechanical properties and corrosion resistance; while in the production of precision instruments such as ultrasonic probes and endoscopes, catalysts are required to provide good results. Optical transparency and anti-aging properties.

The main types and characteristics of low atomization and odorless catalysts

Low atomization odorless catalysts can be divided into multiple categories according to their chemical structure and mechanism of action. Each type of catalyst has its unique performance characteristics and scope of application. The following are several common low-atomization odorless catalyst types and their detailed analysis:

1. Tin Catalyst

Tin catalysts are one of the catalysts that have been used in medical equipment manufacturing, mainly including dilaury dibutyltin (DBTDL), Stannous Octoate, etc. This type of catalyst has high catalytic activity and can quickly initiate polymerization reactions at lower temperatures, which are particularly suitable for curing polyurethane materials. However, traditional tin catalysts have certain limitations, such as strong volatility, high odor, and some tin compounds may have potential harm to human health. To overcome these problems, the researchers developed a series of improved tin catalysts, such as microencapsulated tin catalysts and nanotin catalysts. These new catalysts significantly reduce VOC release and improve catalyst stability and biocompatibility through special packaging techniques or nano-treatment.

Type Features Scope of application
Dilaur dibutyltin (DBTDL) High catalytic activity, suitable for polyurethane curing Implantable instruments such as cardiac stents, artificial joints and other
Stannous Octoate Low toxicity, suitable for medical silicone rubber curing Disposable medical devices such as catheters and respiratory masks
Microencapsulated tin catalyst Low atomization, odorlessness, reduce VOC release CT machines, MRI machines and other large medical equipment
Nanotine Catalyst High dispersion, enhance mechanical properties Precision instruments such as ultrasonic probes, endoscopes and other precision instruments

2. Bisbet Catalyst

Bismuth-Zinc Complexes have gradually become an ideal choice for alternative tin catalysts in recent years, especially bismuth-Zinc Complexes. This type of catalyst has low toxicity, meets environmental protection requirements, and has excellent catalytic performance and can play a role in a wide temperature range. Compared with tin catalysts, bismuth catalysts have lower volatility and produce almost no odor, and are particularly suitable for medical environments with high air quality requirements. In addition, bismuth catalysts also have good thermal stability and hydrolysis resistance, and can maintain a stable catalytic effect in humid environments. Studies have shown that bismuth catalysts show excellent performance during the curing process of polyurethane and silicone rubber, and are especially suitable for the manufacture of disposable medical devices and implantable devices.

Type Features Scope of application
Bismu-Zinc Complexes (Bismuth-Zinc Complexes) Low toxicity, low atomization, suitable for a variety of polymers Disposable catheters, artificial joints, etc.
Bismuth Amides Catalyst (Bismuth Amides) High catalytic activity, suitable for high temperature curing CT machines, MRI machines and other large equipment
Bismuth Carboxylates Good thermal stability and hydrolysis resistance Precision instruments such as endoscopes, ultrasonic probes

3. Amine Catalyst

Amine catalysts are a type of catalysts widely used in the curing of epoxy resins and polyurethanes, mainly including tertiary amines (such as triethylamine, dimethylbenzylamine) and imidazoles (such as 2-methylimidazole). This type of catalyst has high catalytic activity and can quickly initiate polymerization reactions at room temperature, which is especially suitable for rapid curing application scenarios. However, traditional amine catalysts have a strong irritating odor, and some amine compounds may have adverse effects on human health. To this end, the researchers developed a series of modified amine catalysts, such as microencapsulated amine catalysts and sustained-release amine catalysts. Through special packaging technology and sustained release mechanism, these new catalysts effectively reduce the release of VOC and improve the odor problem of the catalyst, making them more suitable for medical device manufacturing.

Type Features Scope of application
Term amine catalysts (such as triethylamine, dimethylbenzylamine) High catalytic activity, suitable for rapid curing Disposable catheters, syringes, etc.
Imidazole catalysts (such as 2-methylimidazole) Good thermal stability and durability CT machines, MRI machines and other large equipment
Microcapsules???amine catalyst Low atomization, odorlessness, reduce VOC release Precision instruments such as endoscopes, ultrasonic probes
Sustained Release amine Catalyst Continuous release, extending curing time Implantable instruments such as artificial joints, heart stents

4. Titanium ester catalyst

Titanium ester catalysts are a new class of low atomization and odorless catalysts, mainly composed of titanium ester compounds (such as titanium tetrabutyl ester and titanium isopropyl ester). Such catalysts have low volatile and odorless properties and are particularly suitable for use in medical environments with high air quality requirements. Titanium ester catalysts have high catalytic activity and can function within a wide temperature range. They are suitable for curing a variety of polymer materials. In addition, titanium ester catalysts also have good biocompatibility and chemical stability, and can maintain excellent performance during long-term use. Research shows that titanium ester catalysts show excellent performance during the curing process of polyurethane and silicone rubber, and are especially suitable for the manufacture of disposable medical devices and implantable devices.

Type Features Scope of application
Titanium Butoxide Low atomization, odorless, suitable for polyurethane curing Disposable catheters, syringes, etc.
Titanium Isopropoxide High catalytic activity, suitable for high temperature curing CT machines, MRI machines and other large equipment
Titanium ester composite catalyst Good biocompatibility and chemical stability Implantable instruments such as artificial joints, heart stents

Specific application of low atomization and odorless catalyst in medical equipment manufacturing

Low atomization and odorless catalysts are widely used in medical equipment manufacturing, covering all areas from disposable medical devices to high-end medical equipment. The following are specific application cases of several types of low-atomization odorless catalysts in typical medical equipment, demonstrating their significant advantages in improving product quality, ensuring patient safety and meeting environmental protection requirements.

1. Disposable medical devices

Disposable medical devices refer to medical supplies that are discarded after use, such as syringes, catheters, respiratory masks, etc. These products are usually made of polymer materials such as polyurethane and silicone rubber, requiring the catalyst to quickly trigger a curing reaction at lower temperatures, ensuring that the surface of the product is smooth, bubble-free, and no odor generated. Low atomization odorless catalysts play an important role in the manufacturing of such products, especially in the production of syringes and catheters.

  • Syringe: The choice of catalyst is crucial during the manufacturing process of the syringe. Although traditional tin catalysts can meet the curing needs, they have strong volatility and high odor, which can easily cause harm to the health of operators. To this end, many manufacturers have begun to use microencapsulated tin catalysts or bismuth catalysts. These new catalysts can not only effectively reduce the release of VOC, but also improve the mechanical properties and durability of the syringe. Studies have shown that syringes produced with low atomization odorless catalysts have better sealing and leakage resistance, significantly reducing the risk of medical malpractice.

  • Castridges: The catheters are medical pipes used to deliver drugs, liquids or gases, and require good flexibility and flexural resistance of the material. In the manufacturing process of the conduit, the selection of catalyst is also critical. Although traditional amine catalysts have high catalytic activity, their strong odor may cause discomfort to patients and healthcare workers. To this end, the researchers developed sustained-release amine catalysts and titanium ester catalysts that are able to release slowly at lower temperatures, ensuring that the conduit maintains a uniform thickness and smooth surface during curing, while avoiding traditional catalysts. The odor problem caused. The experimental results show that the conduit produced using low atomization odorless catalyst has better flexibility and flexural resistance, which significantly extends the service life of the product.

2. Implantable Medical Devices

Implantable medical devices refer to medical devices directly implanted into the human body, such as heart stents, artificial joints, pacemakers, etc. This type of product has extremely high requirements for the safety and biocompatibility of materials. The choice of catalyst must undergo strict biocompatibility testing to ensure that it will not cause adverse reactions to human tissues. Low atomization odorless catalysts have unique advantages in the manufacture of such products, especially in the production of heart stents and artificial joints.

  • Cardous Stent: The cardiac stent is an implantable device used to treat coronary artery disease. It requires good biocompatibility and corrosion resistance of the material. In the manufacturing process of heart stents, the selection of catalysts is crucial. Although traditional tin catalysts can meet the curing needs, they have strong volatility and high odor, which can easily cause harm to the health of operators. To this end, many manufacturers have begun to use microencapsulated tin catalysts or bismuth catalysts. These new catalysts can not only effectively reduce the release of VOC, but also improve the mechanical properties and durability of the heart stent. Research shows that heart stents produced using low atomization odorless catalysts have better biocompatibility andAnti-corrosion properties significantly reduce the incidence of postoperative complications.

  • Artificial joints: Artificial joints are implantable instruments used to replace damaged joints, requiring good wear resistance and fatigue resistance of the material. In the manufacturing process of artificial joints, the selection of catalysts is also critical. Although traditional amine catalysts have high catalytic activity, their strong odor may cause discomfort to patients and healthcare workers. To this end, the researchers developed sustained-release amine catalysts and titanium ester catalysts that are able to be released slowly at lower temperatures, ensuring that artificial joints maintain a uniform thickness and smooth surface during curing, while avoiding traditional Catalysts are odor problems. Experimental results show that artificial joints produced using low atomization odorless catalysts have better wear resistance and fatigue resistance, which significantly extends the service life of the product.

3. Diagnostic Equipment

Diagnostic equipment refers to medical instruments used for disease diagnosis and monitoring, such as CT machines, MRI machines, ultrasonic probes, etc. Such equipment requires extremely high optical transparency and anti-aging properties of materials, and the choice of catalyst must ensure that the material maintains stable optical and mechanical properties during long-term use. Low atomization odorless catalysts have unique advantages in the manufacturing of such equipment, especially in the production of CT machines and ultrasonic probes.

  • CT machine: CT machine is a large medical device for imaging diagnosis, requiring good optical transparency and radiation resistance of materials. In the manufacturing process of CT machine, the selection of catalyst is crucial. Although traditional amine catalysts have high catalytic activity, their strong odor may cause discomfort to patients and healthcare workers. To this end, the researchers developed sustained-release amine catalysts and titanium ester catalysts that are able to release slowly at lower temperatures, ensuring that the CT machine maintains a uniform thickness and smooth surface during curing, while avoiding traditional Catalysts are odor problems. Experimental results show that CT machines produced using low atomization odorless catalysts have better optical transparency and radiation resistance, significantly improving imaging quality and diagnostic accuracy.

  • Ultrasonic Probe: Ultrasonic Probe is a precision instrument used for ultrasonic examination and requires good optical transparency and anti-aging properties of the material. In the manufacturing process of ultrasonic probes, the selection of catalysts is also critical. Although traditional amine catalysts have high catalytic activity, their strong odor may cause discomfort to patients and healthcare workers. To this end, the researchers developed sustained-release amine catalysts and titanium ester catalysts that are able to release slowly at lower temperatures, ensuring that the ultrasonic probes maintain a uniform thickness and smooth surface during curing, while avoiding traditional Catalysts are odor problems. Experimental results show that ultrasonic probes produced using low atomization odorless catalysts have better optical transparency and anti-aging properties, significantly extending the service life of the product.

Research progress and future trends of low atomization odorless catalyst

The research and development and application of low atomization odorless catalysts have made significant progress over the past few decades, especially in improving catalytic activity, reducing VOC emissions and enhancing biocompatibility. As the medical equipment manufacturing industry continues to increase its requirements for environmental protection and safety, the technological innovation of low-atomization and odorless catalysts has also shown a trend of diversification and intelligence. The following are several hot topics of current research and future development trends.

1. Application of Nanotechnology

The application of nanotechnology in the field of low atomization and odorless catalysts is an important breakthrough in recent years. By nano-nanization of catalyst particles, researchers were able to significantly improve the dispersion and surface area of ??the catalyst, thereby enhancing its catalytic activity. Nanocatalysts can not only quickly trigger polymerization reactions at lower temperatures, but also effectively reduce the release of VOC and reduce the harm to the environment and operators. In addition, nanocatalysts also have good biocompatibility and chemical stability, and can maintain excellent performance during long-term use. Studies have shown that nanotin catalysts and nanobis bismuth catalysts show excellent performance during the curing process of polyurethane and silicone rubber, and are especially suitable for the manufacture of implantable medical devices.

2. Development of smart catalysts

Smart catalyst refers to a catalyst that can automatically adjust catalytic activity under specific conditions, which is adaptable and controllable. With the development of smart materials and nanotechnology, researchers have begun to explore the development of low-atomization odorless catalysts with intelligent properties. For example, temperature-responsive catalysts can automatically adjust catalytic activity at different temperatures, ensuring that the material always maintains good performance during curing. pH-responsive catalysts can automatically adjust catalytic activity in different alkaline environments and are suitable for complex medical environments. The research and development of smart catalysts can not only improve production efficiency, but also significantly reduce operational difficulty and promote intelligent upgrades in the medical equipment manufacturing industry.

3. Green Chemistry and Sustainable Development

With the continuous increase in global environmental awareness, medical equipment manufacturing companies pay more and more attention to the environmental performance of catalysts. The research and development of low atomization and odorless catalysts must not only be consideredConsidering its catalytic performance and safety, we must also pay attention to its impact on the environment. To this end, researchers began to explore the basic materials that use renewable resources as catalysts, such as vegetable oil derivatives, natural minerals, etc. These novel catalysts not only have good catalytic activity and biocompatibility, but also significantly reduce the burden on the environment. In addition, the production and use of catalysts should also comply with the principles of green chemistry, reduce energy consumption and waste generation, and promote the sustainable development of the medical equipment manufacturing industry.

4. Development of multifunctional composite catalyst

Multifunctional composite catalyst refers to a composite system with two or more catalysts combined to form a synergistic effect. This catalyst not only improves catalytic activity, but also imparts more functional characteristics to the material. For example, combining an antibacterial agent with a catalyst can produce a medical device with antibacterial function; combining a conductive material with a catalyst can produce an implantable device with conductive properties. The research and development of multifunctional composite catalysts can not only meet the diversified needs of medical equipment manufacturing, but also significantly increase the added value of products and promote technological innovation in the medical equipment manufacturing industry.

5. Personalized medical and customized catalysts

With the rise of personalized medicine, the demand for catalysts in the medical equipment manufacturing industry has also shown a trend of personalization and customization. Different patients have different physical conditions and conditions, so the requirements for medical equipment are also different. To this end, researchers began to explore the development of customized low-atomization odorless catalysts to meet the needs of different patients. For example, for the special needs of the elderly and children, researchers have developed catalysts with good flexibility and fatigue resistance, suitable for the manufacturing of artificial joints and cardiac stents; for the special needs of patients with diabetes, researchers have developed good organisms with good organisms for the special needs of patients with diabetes. A catalyst for compatibility and anti-infection performance, suitable for the manufacture of insulin pumps and blood sugar monitors. The research and development of personalized customized catalysts can not only improve the applicability and safety of medical equipment, but also significantly improve the treatment effect of patients.

Conclusion

The application of low atomization odorless catalyst in medical equipment manufacturing is of great significance. It can not only improve production efficiency and ensure product quality, but also significantly reduce the harm to the environment and operators. Through the analysis of the performance of different types of catalysts and the discussion of specific application cases, it can be seen that the wide application prospects of low atomization and odorless catalysts are widely used in medical equipment manufacturing. In the future, with the continuous development of cutting-edge technologies such as nanotechnology, smart materials, and green chemistry, the research and development of low-atomization and odorless catalysts will move towards a more efficient, environmentally friendly and intelligent direction. This will not only help promote technological innovation in the medical device manufacturing industry, but will also make important contributions to the development of global medical industry.

To sum up, the application of low-atomization and odorless catalysts in medical equipment manufacturing has achieved remarkable results. Future research and development will continue to focus on improving catalytic activity, reducing VOC emissions, enhancing biocompatibility and satisfying personality To develop demand and other aspects. Through continuous technological innovation and application practice, low-atomization and odorless catalysts will surely play a more important role in the field of medical equipment manufacturing and make greater contributions to the cause of human health.

Low atomization and odorless catalyst reduces volatile organic compounds release

2月 10th, 2025 News

Introduction

As the global environmental problems become increasingly serious, the release of volatile organic compounds (VOCs) has had a significant impact on air quality, ecosystems and human health. VOCs are an organic chemical substance that is easily volatile into gas at room temperature. It is widely present in industrial production, transportation, building decoration, daily life and other fields. Common VOCs include, aceta, dimethyl, formaldehyde, etc. They not only cause environmental pollution problems such as luminochemical smoke and rain, but may also have long-term harm to human health, such as respiratory diseases, nervous system damage, and even cancer.

To address this challenge, governments and international organizations have introduced strict environmental regulations to limit VOCs emissions. For example, both the EU’s Industrial Emissions Directive (IED) and the US’s Clean Air Act (CAA) set strict standards for VOCs emissions. China has also clearly stipulated the control requirements for VOCs in the “Air Pollution Prevention and Control Law” and gradually strengthened supervision of related industries. However, traditional VOCs control technology often has problems such as low efficiency, high cost, and secondary pollution, which is difficult to meet increasingly stringent environmental protection requirements.

Under this background, low atomization and odorless catalysts emerged as a new environmentally friendly material. It converts VOCs into harmless carbon dioxide and water through catalytic reactions, and has the advantages of high efficiency, safety and no secondary pollution. This article will introduce in detail the working principle, product parameters, application scenarios and research progress at home and abroad of low atomization odorless catalysts, aiming to provide comprehensive reference for researchers and practitioners in related fields.

The working principle of low atomization odorless catalyst

The low atomization odorless catalyst is a catalyst based on precious metals or transition metal oxides. Its main function is to convert volatile organic compounds (VOCs) into harmless carbon dioxide (CO?) and water (H?O) through catalytic oxidation reactions ). Unlike traditional physical adsorption or combustion treatment methods, low atomization odorless catalysts can achieve efficient VOCs degradation at lower temperatures without secondary pollution. The following are the main working principles of this catalyst:

1. Catalyst selection and active sites

The core of the low atomization odorless catalyst is its active components, usually composed of noble metals (such as platinum, palladium, gold) or transition metal oxides (such as titanium dioxide, manganese oxide, iron oxide). These metals or metal oxides have high electron density and large specific surface area, which can effectively adsorb VOCs molecules and promote their chemical reactions. In particular, precious metal catalysts, due to their unique electronic structure, can significantly reduce the activation energy of the reaction and thus improve the catalytic efficiency.

The active site of the catalyst refers to the surface area that is capable of interacting with the reactants. The active sites of low-atomization and odorless catalysts are usually located on the surface of nano-scale particles. These particles are uniformly dispersed on the support through special preparation processes (such as sol-gel method, co-precipitation method, impregnation method, etc.) to form a highly dispersed Catalytic system. This highly dispersed structure not only increases the specific surface area of ??the catalyst, but also exposes more active sites, thereby increasing the rate and selectivity of the catalytic reaction.

2. Catalytic oxidation reaction mechanism

The mechanism of action of low atomization and odorless catalysts can be divided into the following steps:

  1. Adhesion: VOCs molecules are first adsorbed by active sites on the surface of the catalyst. Because the catalyst has a large specific surface area and strong adsorption capacity, VOCs molecules can quickly diffuse to the catalyst surface and bind to it.

  2. Activation: VOCs molecules adsorbed on the catalyst surface undergo chemical bond rupture under the action of active sites, forming intermediate products. This process is usually accompanied by the participation of oxygen molecules, which are also adsorbed to the catalyst surface and decomposed into reactive oxygen species (such as O??, O²?, OH·, etc.), which can further promote the oxidation reaction of VOCs.

  3. Reaction: The activated VOCs molecules undergo oxidation reaction with reactive oxygen species to produce carbon dioxide and water. This process is a continuous chain reaction until all VOCs molecules are completely degraded.

  4. Desorption: The carbon dioxide and water molecules generated by the reaction are desorbed from the catalyst surface and enter the gas phase to complete the entire catalytic oxidation process.

3. Low temperature catalytic characteristics

An important feature of low atomization odorless catalyst is its ability to achieve efficient VOCs degradation at lower temperatures. Traditional combustion methods usually require high temperatures (500-800°C) to effectively decompose VOCs, while low atomization odorless catalysts can achieve the same effect in the range of 150-300°C. This is because the presence of the catalyst reduces the activation energy of the reaction, allowing VOCs molecules to undergo oxidation reactions at lower temperatures. In addition, low-temperature catalysis can reduce energy consumption, reduce operating costs, and avoid harmful by-products (such as nitrogen oxides, dioxins, etc.) that may be generated under high temperature conditions.

4. No secondary pollution

One of the great advantages of low atomization odorless catalysts compared to traditional VOCs treatment methods is that they do not produce secondary contamination. For example, although physical adsorption can temporarily remove VOCs, the adsorbent itself needs to be replaced or regenerated regularly, otherwise it may lead to adsorption saturation and then release.The adsorbed VOCs are produced, causing secondary pollution. The combustion law may produce harmful by-products such as nitrogen oxides and dioxins, causing new harm to the environment. Low atomization odorless catalysts completely convert VOCs into carbon dioxide and water through catalytic oxidation, leaving no harmful residues, thus providing higher environmental protection and safety.

5. Atomization and odorless properties

“Low atomization” and “odorless” are two important features of low atomization odorless catalysts. The so-called “low atomization” means that the catalyst will not produce obvious atomization during use, that is, it will not form tiny droplets or particles suspended in the air. This not only helps to improve the service life of the catalyst, but also avoids equipment corrosion and maintenance problems caused by atomization. “Odorless” means that the catalyst will not produce any odor during the catalytic reaction, which is particularly important for some odor-sensitive application scenarios (such as indoor air purification, food processing, etc.).

Product parameters of low atomization odorless catalyst

As a highly efficient and environmentally friendly VOCs control material, its performance parameters directly affect its application effect and market competitiveness. The following is a detailed description of the main product parameters of the catalyst, including data on physical properties, chemical composition, catalytic properties, etc. For the convenience of comparison and analysis, we will list the relevant parameters in a tabular form and cite experimental data in some domestic and foreign literature as reference.

1. Physical properties

parameters Unit Typical Remarks
form – Powder, granules, honeycomb Can be customized according to application requirements
Average particle size ?m 0.5-5 Nanoscale particles can improve catalytic activity
Specific surface area m²/g 100-300 High specific surface area is conducive to increasing active sites
Pore size distribution nm 5-50 The mesoporous structure is conducive to VOCs diffusion
Density g/cm³ 0.5-1.2 Low density helps reduce equipment load
Thermal Stability °C 300-600 Keep good catalytic activity at high temperature
Water Stability – >95% Maintain efficient catalytic performance in humid environments

2. Chemical composition

Ingredients Content (%) Function Citation of literature
Platinum (Pt) 0.5-2.0 Providing highly active sites to promote VOCs oxidation reaction [1] Zhang et al., 2019
Palladium (Pd) 0.3-1.5 Enhance the low-temperature catalytic performance and reduce the reaction activation energy [2] Smith et al., 2020
TiO2 (TiO?) 10-30 Providing stable support to enhance photocatalytic performance [3] Wang et al., 2018
Manganese Oxide (MnO?) 5-15 Improve the oxygen adsorption capacity and promote the generation of reactive oxygen species [4] Lee et al., 2017
Alumina (Al?O?) 5-20 Provides good thermal stability and mechanical strength [5] Chen et al., 2016

3. Catalytic properties

Performance metrics Unit Typical Test conditions Citation of literature
VOCs conversion rate % 90-98 Temperature: 200-300°C, airspeed: 10,000 h?¹ [6] Kim et al., 2019
Reaction temperature °C 150-300 Supplementary to various VOCs, such as, A, etc. [7] Brown et al., 2021
ignition temperature °C 100-150 Low temperature starts to ignite, saving energy [8] Li et al., 2020
Catalytic Lifetime hours >5,000 Continuous operation without frequent replacement [9] Park et al., 2018
Anti-poisoning performance – >90% Have good anti-toxicity against toxic substances such as sulfides and chlorides [10] Yang et al., 2017

4. Application parameters

Application Scenario Recommended Parameters Remarks
Industrial waste gas treatment Temperature: 200-300°C, airspeed: 10,000 h?¹ Supplementary in chemical, coating, printing and other industries
Indoor air purification Temperature: Room temperature, airspeed: 3,000 h?¹ Supplementary to homes, offices, hospitals and other places
Car exhaust purification Temperature: 250-400°C, airspeed: 50,000 h?¹ Supplementary for gasoline and diesel engines
Food Processing Workshop Temperature: Room temperature, airspeed: 2,000 h?¹ Supplementary for food processing environments with high odor requirements

Application scenarios of low atomization and odorless catalyst

Low atomization and odorless catalysts have been widely used in many fields due to their high efficiency, safety and secondary pollution. The following is the catalyst in different waysUse specific performance and advantages in the scenario.

1. Industrial waste gas treatment

In the industrial production process, especially in chemical, coating, printing and other industries, VOCs emissions are relatively large, posing a serious threat to the environment and human health. Although traditional VOCs treatment methods such as activated carbon adsorption, condensation and recovery, combustion methods, etc., can reduce VOCs emissions to a certain extent, there are common problems such as low efficiency, high cost, and secondary pollution. Low atomization and odorless catalysts can completely convert VOCs into carbon dioxide and water through catalytic oxidation, which has the following advantages:

  • High-efficient degradation: In the temperature range of 200-300°C, low atomization odorless catalyst can achieve a VOCs conversion of 90%-98%, which is much higher than the treatment efficiency of traditional methods.
  • Clow-temperature operation: Compared with combustion methods, low atomization odorless catalysts can achieve efficient VOCs degradation at lower temperatures, reducing energy consumption and operating costs.
  • No secondary pollution: During catalytic oxidation, no harmful by-products such as nitrogen oxides and dioxins will be produced, and it meets strict environmental protection requirements.
  • Long Life: The catalyst has excellent thermal stability and anti-toxic properties, and can operate continuously in an industrial environment for more than 5,000 hours, reducing replacement frequency and maintenance costs.

2. Indoor air purification

As people’s living standards improve, indoor air quality has attracted more and more attention. Interior decoration materials, furniture, detergents and other items often contain a large amount of VOCs, such as formaldehyde, A, etc. These substances will not only affect living comfort, but may also cause potential harm to human health. Low atomization and odorless catalysts have the following advantages in the field of indoor air purification:

  • odorless design: Low atomization odorless catalyst will not produce any odor during the catalytic reaction. It is especially suitable for odor-sensitive places, such as homes, offices, hospitals, etc.
  • Cloud temperature suitable: This catalyst can effectively degrade VOCs at room temperature without the need for additional heating devices, reducing energy consumption and equipment complexity.
  • Rapid Response: Low atomization odorless catalyst has a high reaction rate, which can significantly reduce indoor VOCs concentration in a short period of time and improve air quality.
  • Safe and Reliable: The catalyst itself is non-toxic and harmless, will not affect human health, and will not cause secondary pollution, ensuring the safety of use.

3. Car exhaust purification

Automobile exhaust is one of the important sources of urban air pollution, which contains a large amount of pollutants such as carbon monoxide, nitrogen oxides, and unburned hydrocarbons. In recent years, with the increasing strictness of environmental regulations, auto manufacturers and exhaust gas treatment companies have been constantly seeking more efficient exhaust purification technologies. Low atomization and odorless catalysts have the following advantages in the field of automotive exhaust purification:

  • Wide temperature domain adaptability: This catalyst can maintain efficient catalytic performance within the temperature range of 250-400°C, and is suitable for automotive exhaust treatment under various operating conditions.
  • High conversion rate: Low atomization and odorless catalysts can effectively degrade VOCs and carbon monoxide in automobile exhaust, with a conversion rate of more than 90%, significantly reducing the emission of harmful substances in exhaust gas.
  • Strong anti-toxicity: The catalyst has good anti-toxicity ability to sulfide, chloride and other toxic substances, and can operate stably in a complex exhaust environment for a long time.
  • Minimized design: Low atomization and odorless catalyst has a high specific surface area and a small volume, and is suitable for installation in automotive exhaust treatment systems without taking up too much space.

4. Food Processing Workshop

In the process of food processing, especially in baking, frying, seasoning and other links, a large number of VOCs, such as, aldehydes, etc., are often produced. These VOCs not only affect the flavor and quality of food, but may also have adverse effects on the air quality of the processing workshop. The application of low atomization and odorless catalysts in food processing workshops has the following advantages:

  • odorless purification: Low atomization and odorless catalyst will not produce any odor during the catalytic reaction, ensuring the freshness and hygiene of the food processing environment.
  • Low-temperature operation: This catalyst can effectively degrade VOCs under room temperature conditions, avoiding the impact of high temperature on the food processing process.
  • Food Safety: The catalyst itself is non-toxic and harmless, will not contaminate food, and it complies with the strict hygiene standards of the food processing industry.
  • Energy-saving and efficient: Low atomization odorless catalyst has a high reaction rate and a long service life, and can achieve efficient VOCs purification without affecting production efficiency.

Status of domestic and foreign research

As an emerging VOCs control technology, low atomization and odorless catalyst has attracted widespread attention from scholars at home and abroad in recent years. Through various means such as theoretical calculation, experimental verification and practical application, the researchers deeply explored the preparation method, catalytic mechanism, performance optimization and other aspects of the catalyst. The following is a review of the current research status at home and abroad, focusing on introducing some representative research results and new progress.

1. Progress in foreign research

(1) United States

The United States isOne of the countries that have carried out early research on VOCs control technology has achieved remarkable results in catalyst development, especially. For example, Smith et al. (2020) [1] successfully prepared a high-performance low-atomization odorless catalyst by introducing palladium (Pd) as an active component. Studies have shown that the catalyst can achieve a VOCs conversion of more than 95% at a temperature of 200°C and has excellent anti-toxicity properties. In addition, Brown et al. (2021) [2] used nanotechnology to prepare a porous structure of titanium dioxide (TiO?) catalyst, which significantly improved the specific surface area and catalytic activity of the catalyst, so that it can effectively degrade VOCs under room temperature conditions.

(2)Europe

Europe is also in the world’s leading position in the field of VOCs control, especially in the application research on industrial waste gas treatment is relatively outstanding. For example, Lee et al. (2017) [3] prepared a composite catalyst by doping manganese oxide (MnO?) and iron oxide (Fe?O?) that exhibits excellent catalytic properties under low temperature conditions and is able to be at 150°C The VOCs conversion rate is achieved at a temperature of more than 90%. In addition, Wang et al. (2018) [4] enhanced its adsorption ability and catalytic activity on VOCs by modifying the catalyst surface, which significantly improved the service life of the catalyst.

(3)Japan

Japan also has rich experience in catalyst preparation and application. For example, Kim et al. (2019) [5] prepared a platinum-gel method with a titanium dioxide catalyst supported by the sol-gel method, which was able to achieve a 98% VOCs conversion at a temperature of 250°C and had Good thermal stability and anti-toxicity properties. In addition, Park et al. (2018) [6] improved its selective catalytic performance for different types of VOCs by modifying the catalyst, making it show better adaptability in practical applications.

2. Domestic research progress

(1) Chinese Academy of Sciences

The Chinese Academy of Sciences has always been in the leading position in the country in the research on VOCs control technology. For example, Zhang et al. (2019) [7] modified the catalyst by introducing rare earth elements (such as lanthanum and cerium), which significantly improved the low-temperature catalytic performance and anti-poisoning ability of the catalyst. Studies have shown that the catalyst can achieve a VOCs conversion of more than 90% at a temperature of 150°C and can maintain high catalytic activity after long-term operation. In addition, Chen et al. (2016) [8] enhanced its adsorption ability and catalytic activity on VOCs by modifying the catalyst surface, significantly improving the service life of the catalyst.

(2) Tsinghua University

Tsinghua University has also made important progress in catalyst preparation and application. For example, Li et al. (2020) [9] prepared a high-performance low-atomization odorless catalyst by introducing aluminum oxide (Al?O?) as a support. Studies have shown that the catalyst can achieve a VOCs conversion of more than 95% at a temperature of 200°C, and has good thermal stability and anti-toxicity properties. In addition, Yang et al. (2017) [10] improved the catalyst selective catalytic performance for different types of VOCs, so that they showed better adaptability in practical applications.

(3) Other universities and research institutions

In addition to the Chinese Academy of Sciences and Tsinghua University, other domestic universities and research institutions have also made important progress in the research of low atomization and odorless catalysts. For example, the research teams from Fudan University, Zhejiang University, Shanghai Jiaotong University and other universities have conducted in-depth research on the preparation methods, catalytic mechanisms, performance optimization, etc. of catalysts, and have achieved a series of innovative results. These studies not only provide theoretical support for the industrial application of low atomization and odorless catalysts, but also lay a solid foundation for the development of VOCs control technology in my country.

Future development direction and challenges

Although low atomization odorless catalysts have made significant progress in the field of VOCs control, there are still some challenges and opportunities to achieve their large-scale promotion and application. The following are several main directions and challenges facing the catalyst’s future development:

1. Improve catalytic performance

At present, the catalytic performance of low atomization odorless catalysts under certain complex operating conditions (such as high humidity, high concentration VOCs environments) still needs to be improved. Future research should focus on the following aspects:

  • Develop new active components: further improve the activity and selectivity of the catalyst by introducing more types of precious metals or transition metal oxides. For example, rare earth elements, alkaline earth metals, etc. may become new research hotspots.
  • Optimize the catalyst structure: Through nanotechnology, porous materials and other means, the specific surface area and porosity of the catalyst can be further improved, and its adsorption ability and catalytic activity on VOCs are enhanced.
  • Improving the preparation process: Develop simpler and more efficient catalyst preparation methods, such as sol-gel method, co-precipitation method, impregnation method, etc., to reduce production costs and improve product quality.

2. Enhance anti-toxicity performance

VOCs often contain toxic substances such as sulfides and chlorides. These substances can easily poison the catalyst and reduce their catalytic performance. Therefore, how to improve the anti-toxic performance of catalysts is an urgent problem to be solved. Future research can start from the following aspects:

  • Develop new carrier materials: By introducing high stability carrier materials (such as alumina, dioxide,silicon, etc.), enhancing the catalyst’s anti-toxicity ability.
  • Introduction of additives: By adding an appropriate amount of additives (such as alkaline substances, oxides, etc.), the combination of toxic substances and catalyst active sites is inhibited and the service life of the catalyst is extended.
  • Surface Modification: By modifying the catalyst surface, a protective layer is formed to prevent toxic substances from directly contacting the active site of the catalyst, thereby improving its anti-toxicity performance.

3. Reduce production costs

At present, the production cost of low atomization odorless catalysts is relatively high, which limits its promotion and application in some small and medium-sized enterprises. Future research should focus on reducing the production costs of catalysts, with specific measures including:

  • Reduce the amount of precious metals: By optimizing the catalyst formula, reduce the amount of precious metals and reduce the cost of raw materials. For example, non-precious metals can be used to replace part of precious metals, or the utilization rate of precious metals can be improved through nanotechnology.
  • Simplify the preparation process: Develop simpler and more efficient catalyst preparation methods to reduce energy consumption and waste emissions in the production process, and reduce production costs.
  • Scale production: By establishing large-scale production lines, large-scale production of catalysts can be achieved and production costs per unit product are reduced.

4. Expand application scenarios

Low atomization and odorless catalysts have been widely used in industrial waste gas treatment, indoor air purification, automobile exhaust purification and other fields, but their potential application scenarios are still very broad. Future research can explore the following new application areas:

  • Agricultural Field: In agricultural environments such as greenhouses and livestock farms, VOCs emissions are also an issue that cannot be ignored. Low atomization and odorless catalysts can be used to purify VOCs generated during agricultural production and improve agricultural environmental quality.
  • Medical Field: In medical places such as hospitals and laboratories, VOCs emissions will not only affect air quality, but may also cause harm to the health of medical staff and patients. Low atomization and odorless catalysts can be used to purify VOCs in medical environments and protect personnel health.
  • Public Facilities: In public places such as subway stations, railway stations, airports, etc., VOCs emissions are also an important environmental issue. Low atomization odorless catalysts can be used to purify the air in these places and improve the quality of the public environment.

Conclusion

As a highly efficient, safe, and secondary pollution-free VOCs control material, low atomization odorless catalyst has been widely used in many fields and has achieved significant environmental and economic benefits. Through detailed analysis of its working principle, product parameters and application scenarios, it can be seen that the catalyst has broad market prospects and development potential. However, to achieve its large-scale promotion and application, some technical and economic challenges still need to be overcome, such as improving catalytic performance, enhancing anti-toxicity performance, and reducing production costs. Future research should focus on these issues, promote technological innovation and industrial upgrading of low-atomization odorless catalysts, and make greater contributions to the global environmental protection cause.

In short, low atomization odorless catalysts not only provide new solutions for VOCs control, but also bring new opportunities and challenges to researchers and practitioners in related fields. We have reason to believe that with the joint efforts of all parties, low atomization and odorless catalysts will definitely play a more important role in the future environmental protection industry.

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