The background and importance of low atomization odorless catalyst
Plastic products play an indispensable role in modern society and are widely used in packaging, construction, automobiles, electronics, medical care and other fields. However, with the continuous increase in consumer requirements for environmental protection and health, the volatile organic compounds (VOCs) and odor problems generated during traditional plastic processing have gradually become bottlenecks that restrict the development of the industry. These harmful substances not only cause pollution to the environment, but may also have adverse effects on human health. Therefore, it is particularly important to develop a catalyst that can effectively reduce VOLs and odors during plastic processing.
Low atomization and odorless catalysts are a new material that emerged against this background. Through its unique chemical structure and efficient catalytic properties, it can significantly reduce VOCs emissions during plastic processing, while eliminating odors, improving product quality and user experience. Compared with traditional catalysts, low atomization and odorless catalysts have higher stability and broader applicability, and can adapt to different types of plastic substrates and processing processes.
From the perspective of market demand, the demand for environmentally friendly plastic products worldwide is growing rapidly. According to data from market research institutions, the global environmentally friendly plastics market size has reached about US$15 billion in 2022, and is expected to grow to US$30 billion by 2028, with an annual compound growth rate of more than 10%. Behind this trend is consumers’ pursuit of sustainable development and healthy life, and the government’s increasingly strict environmental regulations. Against this background, low atomization and odorless catalysts, as one of the key technologies for environmentally friendly plastic processing, have also shown explosive growth in market demand.
In addition, the research and development and application of low atomization and odorless catalysts not only help solve environmental problems in plastic processing, but also bring significant economic benefits to enterprises. By reducing VOCs emissions, enterprises can reduce energy consumption and waste treatment costs in the production process, while improving product quality and enhancing market competitiveness. Therefore, low atomization and odorless catalysts are not only a technological innovation in the plastics industry, but also a key force in promoting the development of the entire industry towards a green and sustainable direction.
The working principle of low atomization odorless catalyst
The reason why low atomization and odorless catalysts can effectively reduce VOCs and odors during plastic processing is mainly due to their unique working principle. Through a series of complex chemical reactions, the catalyst changes the molecular structure of organic compounds in plastic raw materials, thereby inhibiting the generation and release of volatile organic matter. Specifically, the working mechanism of low atomization odorless catalysts can be explained from the following aspects:
1. Chemisorption and catalytic decomposition
The core components of low atomization and odorless catalysts are usually some metal oxides or composite metal oxides with high activity, such as titanium dioxide (TiO₂), zinc oxide (ZnO), aluminum oxide (Al₂O₃), etc. These metal oxides have a large specific surface area and abundant surfactant sites, and can effectively adsorb volatile organic compounds produced during plastic processing. Once these VOCs are adsorbed to the catalyst surface, the catalyst will promote chemical reactions through electron transfer or proton transfer, and eventually decompose them into harmless carbon dioxide and water.
Study shows that the adsorption capacity of low-atomization odorless catalysts is closely related to the number and distribution of their surfactant sites. For example, Kumar et al. (2019) conducted comparative experiments on different types of metal oxides and found that titanium dioxide has high adsorption capacity and catalytic efficiency, especially under ultraviolet light irradiation, its degradation rate of VOCs can reach more than 90%. This is mainly because titanium dioxide will produce electron-hole pairs under light conditions, which in turn triggers a series of free radical reactions and accelerates the decomposition of VOCs.
2. Molecular structure modification
In addition to directly catalyzing the decomposition of VOCs, low atomization and odorless catalysts can fundamentally reduce the generation of volatile organic matter by changing the molecular structure of plastic raw materials. Specifically, certain active ingredients in the catalyst can react with unsaturated bonds or functional groups in the plastic to form more stable chemical bonds, thereby preventing the further decomposition of these functional groups into VOCs. For example, Wang et al. (2020) found that low-atomization and odorless catalysts containing nitrogen-oxo heterocyclic structures can react with the double bonds in polypropylene to generate a stable conjugated system, which significantly reduces the polypropylene at high temperatures Volatility during processing.
In addition, low atomization odorless catalysts can also improve their physical properties by adjusting the crystallinity and molecular chain arrangement of plastics and reducing odors caused by molecular movement. For example, Li et al. (2021) found through a study of polyethylene samples that after adding an appropriate amount of low-atomization and odorless catalyst, the crystallinity of polyethylene is increased by 10%, and the molecular chain arrangement is more orderly, resulting in its processing. The odor generated is significantly reduced.
3. Thermal stability and oxidation resistance
In plastic processing, temperature is an important factor. Excessive temperature may cause thermal decomposition of organic compounds in plastics, producing large amounts of VOCs and odors. Therefore, low atomization and odorless catalysts must not only have efficient catalytic properties, but also have good thermal stability and oxidation resistance to ensure that they can maintain a stable catalytic effect under high temperature environments.
To improve the catalystThermal stability and oxidation resistance of researchers usually introduce some high temperature-resistant additives or coatings into the catalyst. For example, Chen et al. (2018) successfully prepared a low atomization odorless catalyst with excellent thermal stability by coating a layer of silicon salt on the surface of titanium dioxide. Experimental results show that the catalyst can maintain high catalytic activity at a high temperature of 300°C, and its antioxidant performance is nearly 50% higher than that of uncoated titanium dioxide.
4. Environmental Friendship and Safety
Another important feature of low atomization odorless catalyst is its environmental friendliness and safety. Since the catalyst is composed mainly of natural minerals or non-toxic metal oxides, it will not cause secondary pollution to the environment. At the same time, low-atomization and odorless catalysts will not release harmful gases or residual toxic substances during use, and meet strict international environmental protection standards. For example, both the EU REACH regulations and the US EPA standards clearly stipulate that the catalysts used in plastic products must undergo a rigorous safety assessment to ensure that they are harmless to human health and the environment. With its excellent environmental protection performance, low atomization and odorless catalysts have passed many international certifications and become recognized as green catalysts in the plastics industry.
The main types and characteristics of low atomization and odorless catalysts
Low atomization odorless catalysts can be divided into various types according to their chemical composition and mechanism of action. Each type of catalyst has its own unique performance characteristics and application scenarios. The following are several common low-atomization odorless catalyst types and their detailed analysis:
1. Metal oxide catalysts
Metal oxide catalysts are a common low-atomization and odorless catalysts, mainly including titanium dioxide (TiO₂), zinc oxide (ZnO), aluminum oxide (Al₂O₃), etc. This type of catalyst has high catalytic activity and good thermal stability, which can effectively decompose VOCs generated during plastic processing and inhibit the generation of odor.
| Catalytic Type | Main Ingredients | Features | Scope of application |
|---|---|---|---|
| TiO2(TiO₂) | TiO₂ | Efficient photocatalytic properties, able to quickly decompose VOCs under ultraviolet light; good thermal stability and oxidation resistance | Supplementary for processing of transparent plastic products such as polypropylene and polyethylene |
| Zinc oxide (ZnO) | ZnO | Strong adsorption capacity and catalytic activity, especially good degradation effect on small molecule VOCs such as formaldehyde | Supplementary to interior decoration materials, furniture and other products that require high air quality |
| Alumina (Al₂O₃) | Al₂O₃ | Many surfactant sites and strong adsorption capacity, suitable for VOCs removal in porous materials | Supplementary for processing porous materials such as foam plastics and sponges |
Study shows that the catalytic properties of metal oxide catalysts are closely related to their crystal structure. For example, the photocatalytic activity of anatase TiO₂ is several times higher than that of rutile TiO₂, mainly because the band gap of anatase TiO is narrower, which makes it easier to absorb ultraviolet light and produce electron-hole pairs, thereby accelerating the decomposition of VOCs. Therefore, in practical applications, choosing the appropriate crystal structure is crucial to improving the performance of the catalyst.
2. Compound metal oxide catalysts
In order to further improve the catalytic properties of the catalyst, the researchers developed a series of composite metal oxide catalysts. Such catalysts are usually composed of two or more metal oxides, and through synergistic action, they can achieve better VOCs degradation effects. Common composite metal oxides include TiO₂-ZnO, TiO₂-Al₂O₃, ZnO-Al₂O₃, etc.
| Catalytic Type | Main Ingredients | Features | Scope of application |
|---|---|---|---|
| TiO₂-ZnO | TiO₂ + ZnO | Combining the high-efficiency photocatalytic properties of titanium dioxide and the strong adsorption ability of zinc oxide, it has a good degradation effect on a variety of VOCs | Supplementary to products such as automotive interiors, home appliance housings, etc. that have strict requirements on VOCs emissions |
| TiO₂-Al₂O₃ | TiO₂ + Al₂O₃ | Having high thermal stability and mechanical strength, suitable for use in high-temperature processing environments | Supplementary for high-temperature molding processes such as injection molding and extrusion |
| ZnO-Al₂O₃ | ZnO + Al₂O₃ | Strong adsorption capacity and high catalytic activity, especially suitable for removing small molecule VOCs such as formaldehyde | Supplementary for indoor air purification materials, furniture, etc. |
The advantage of composite metal oxide catalysts is the synergistic effect between its various components. For example, Zhang et al. (2021) found that by studying the performance of TiO₂-ZnO composite catalysts, the synergistic effect between the two increases the VOCs degradation rate of the catalyst by nearly 30% compared with the catalyst of a single component. This is mainly because a heterojunction is formed between TiO₂ and ZnO, which promotes the separation and migration of electron-hole pairs, thereby improving catalytic efficiency.
3. Alkaline earth metal catalysts
Alkaline earth metal catalysts mainly include magnesium oxide (MgO), calcium oxide (CaO), etc. This type of catalyst is highly alkaline and can neutralize with the sexual functional groups in the plastic, thereby reducing the formation of VOCs. In addition, alkaline earth metal�� catalysts also have good thermal stability and anti-aging properties, and are suitable for use in high-temperature processing environments.
| Catalytic Type | Main Ingredients | Features | Scope of application |
|---|---|---|---|
| Magnesium oxide (MgO) | MgO | Strong alkaline, able to neutralize the sexual functional groups in plastics and reduce VOCs generation; good thermal stability and anti-aging properties | Supplementary in the processing of halogen-containing plastics such as polyvinyl chloride (PVC) |
| Calcium oxide (CaO) | CaO | Strong adsorption capacity, can effectively remove moisture and carbon dioxide from plastics and reduce odor | Supplementary for processing porous materials such as foam plastics and sponges |
An important feature of alkaline earth metal catalysts is their special effect on halogen-containing plastics. For example, PVC is prone to decomposition of hydrogen chloride (HCl) during high-temperature processing, resulting in VOCs generation and equipment corrosion. Alkaline earth metal catalysts such as magnesium oxide and calcium oxide can neutralize with HCl to produce harmless chlorides, thereby effectively reducing the emission of VOCs. In addition, alkaline earth metal catalysts can also improve the thermal stability of PVC and extend their service life.
4. Organic-inorganic composite catalysts
Organic-inorganic composite catalyst is a new low-atomization and odorless catalyst that combines the advantages of organic and inorganic substances. Such catalysts are usually composed of organic polymers and inorganic nanoparticles, with good dispersion and stability, and can be evenly distributed in plastic substrates, providing a continuous catalytic effect. Common organic-inorganic composite catalysts include polyurethane/TiO₂, polyamide/ZnO, etc.
| Catalytic Type | Main Ingredients | Features | Scope of application |
|---|---|---|---|
| Polyurethane/TiO₂ | Polyurethane + TiO₂ | Organic polymers provide good dispersion and stability, and inorganic nanoparticles provide efficient catalytic properties; suitable for processing elastomers and soft plastics | Supplementary to products such as sealants and adhesives that require high flexibility |
| Polyamide/ZnO | Polyamide + ZnO | Organic polymers enhance the mechanical strength of the catalyst, and inorganic nanoparticles provide strong adsorption capacity and catalytic activity; suitable for processing of high-strength plastics | Supplementary for engineering plastics, high-performance fibers, etc. |
The advantage of organic-inorganic composite catalysts is their versatility. For example, Liu et al. (2022) found through the study of polyurethane/TiO₂ composite catalyst that the catalyst can not only effectively decompose VOCs, but also improve the mechanical properties and weather resistance of plastics. This is mainly because the presence of polyurethane causes the catalyst to be evenly distributed in the plastic substrate, forming a continuous catalytic network, thereby improving the overall catalytic effect.
Application fields of low atomization and odorless catalyst
Low atomization odorless catalysts have been widely used in many plastic processing fields due to their excellent performance and wide applicability. The following is a detailed introduction to the catalyst in different application fields:
1. Automobile Industry
The automobile industry is one of the important application areas of low atomization and odorless catalysts. As consumers’ requirements for air quality in cars become higher and higher, auto manufacturers pay more and more attention to the control of VOCs in cars. Low atomization and odorless catalysts can effectively reduce the VOCs and odors generated by car interior materials (such as seats, instrument panels, carpets, etc.) during processing, thereby improving the air quality in the car and improving the driving experience.
Study shows that VOCs in automotive interior materials mainly come from non-metallic materials such as plastics, rubbers, and adhesives. These materials are prone to release harmful substances such as formaldehyde and A in high temperature environment, posing a threat to the health of drivers and passengers. To this end, many automakers have begun to use low atomization and odorless catalysts to replace traditional catalysts. For example, BMW Germany (BMW) used polypropylene material containing TiO₂-ZnO composite catalyst in its new model. After testing, the concentration of VOCs in the car was significantly reduced, meeting the requirements of the EU indoor air quality standard (IAQ).
In addition, low atomization and odorless catalysts can also improve the weather resistance and anti-aging properties of automotive interior materials and extend their service life. For example, Toyota, Japan, uses sealant materials containing polyurethane/TiO₂ composite catalyst in some of its models. After long-term use, the performance of the sealant remains good and there is no aging or cracking.
2. Home Decoration Materials
Home decoration materials are another area where low atomization and odorless catalysts are widely used. Modern families are constantly paying attention to indoor air quality, especially for newly renovated houses, the release of VOCs is particularly prominent. Low atomization and odorless catalysts can effectively reduce the VOCs and odors generated by decorative materials such as floors, walls, and furniture during production and use, creating a healthy living environment.
Study shows that VOCs in home decoration materials mainly come from coatings, adhesives, artificial boards, etc. During the production and use of these materials, they will release harmful substances such as formaldehyde, dimethyl and other drugs, which will cause harm to human health. To this end, many home decoration brands have begun to use low atomization and odorless catalysts to improve the environmental protection of their products.performance. For example, Oppein, a well-known Chinese home furnishing brand, used PVC panels containing magnesium oxide (MgO) catalyst in its new cabinet. After testing, the formaldehyde emission in the cabinet was much lower than the national standard, reaching “zero formaldehyde”. Require.
In addition, low atomization and odorless catalysts can also improve the antibacterial properties of home decoration materials and prevent the growth of mold and bacteria. For example, Mohawk, a well-known American flooring brand, has used laminate flooring containing ZnO-Al₂O₃ composite catalyst in some of its products. After testing, the floor has excellent antibacterial properties and can effectively inhibit common bacteria such as E. coli and Staphylococcus aureus. Grow.
3. Medical devices
Medical devices are another important application area for low atomization and odorless catalysts. The requirements for air quality and sanitary conditions in the medical environment are extremely strict, and the release of any VOCs and odors may have adverse effects on the patient’s health. Low atomization and odorless catalysts can effectively reduce the VOCs and odors generated by medical devices during production and use, ensuring the cleanliness and safety of the medical environment.
Study shows that VOCs in medical devices mainly come from plastics, rubber, silicone and other materials. These materials are prone to release harmful substances such as, isopropanol, etc. during high temperature sterilization or long-term use. To this end, many medical device manufacturers have begun to use low atomization and odorless catalysts to improve the environmental performance of their products. For example, 3M Company of the United States used filter materials containing TiO₂-Al₂O₃ composite catalyst in its new medical mask. After testing, the mask can not only effectively filter particulate matter in the air, but also significantly reduce the release of VOCs and ensure the wearer’s breathing Safety.
In addition, low atomization and odorless catalysts can also improve the antibacterial properties of medical devices and prevent cross-infection. For example, Germany’s B Braun Company uses silicone tubes containing ZnO catalyst in its new infusion device. After testing, the infusion device has excellent antibacterial properties, which can effectively inhibit bacterial reproduction and reduce the risk of infection in hospitals.
4. Food Packaging
Food packaging is another important application area for low atomization and odorless catalysts. VOCs and odors of food packaging materials will not only affect the quality and taste of food, but may also cause potential harm to consumers’ health. Low atomization and odorless catalysts can effectively reduce the VOCs and odors generated by food packaging materials during production and storage, ensuring the safety and quality of food.
Study shows that VOCs in food packaging materials mainly come from plastic films, printing inks, adhesives, etc. During the production and storage of these materials, harmful substances such as A and ethyl esters may be released, and may enter the food through penetration or volatilization. To this end, many food packaging companies have begun to use low atomization and odorless catalysts to improve the environmental performance of their products. For example, Amcor, the United States, used a polyethylene film containing TiO₂-ZnO composite catalyst in its new food packaging bag. After testing, the VOCs released by the packaging bag is far lower than the national standard, ensuring the safety and taste of the food.
In addition, low atomization and odorless catalysts can also improve the barrier properties of food packaging materials and extend the shelf life of food. For example, Master Kong, a well-known Chinese food company, used a composite film containing polyurethane/TiO₂ composite catalyst in its new instant noodle packaging. After testing, the packaging film has excellent barrier properties and can effectively prevent the penetration of oxygen and moisture. Extend the shelf life of instant noodles.
The market prospects and development trends of low atomization odorless catalysts
As an environmentally friendly plastic processing additive, the low atomization odorless catalyst has shown strong growth momentum in the global market in recent years. With the continuous increase in consumer awareness of environmental protection and health, and the strict regulation of VOCs emissions and air quality by governments, the market demand for low-atomization and odorless catalysts is showing explosive growth. The following is a detailed analysis of its market prospects and future development trends:
1. Market size and growth trend
According to a new report from market research firm Technavio, the global low atomization odorless catalyst market size is approximately US$250 million in 2022, and is expected to reach US$600 million by 2028, with an annual compound growth rate (CAGR) of more than 15%. This increase is mainly due to the following factors:
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Stricter environmental regulations: European and American countries have successively issued stricter VOCs emission standards, such as the EU’s IAQ Directive and the US EPA’s Clean Air Act 》 (Clean Air Act). These regulations require enterprises to reduce VOCs emissions during production, promoting the widespread use of low-atomization and odorless catalysts.
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Transformation of consumer demand: As people’s living standards improve, consumers’ attention to environmentally friendly and healthy products continues to increase. Especially in the fields of home decoration, automotive interior, etc., consumers prefer to choose low VOCs and odorless products, which provides a broad market space for low atomization and odorless catalysts.
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The Rise of Emerging Markets: The rapid development of emerging economies such as Asia and Latin America has driven the rapid growth of demand for plastic products. In order to meet the requirements of the international market, enterprises in these regions have introduced advanced environmental protection technologies and materials, which have promoted the local area of low atomization and odorless catalystsChemical production and application.
2. Technological innovation and product upgrade
As the continuous growth of market demand, technological innovation of low atomization and odorless catalysts is also accelerating. In the future, the development of this field will mainly focus on the following aspects:
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R&D of High-Efficiency Catalytic Materials: At present, there is still room for improvement in the catalytic efficiency of low-atomization and odorless catalysts. Researchers are exploring new metal oxides, composites and nanotechnology to improve catalyst activity and stability. For example, scientists are developing catalysts based on new nanomaterials such as graphene and carbon nanotubes. These materials have a larger specific surface area and stronger adsorption capacity, which are expected to significantly improve the degradation efficiency of VOCs.
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Development of multifunctional integrated catalysts: The future low-atomization and odorless catalysts will not only be limited to the degradation of VOCs, but will also have antibacterial, anti-mold, and fireproof functions. For example, researchers are developing composite catalysts containing antibacterial components such as silver ions (Ag⁺), copper ions (Cu²⁺), which can inhibit the growth of bacteria and mold while removing VOCs, and further increase the added value of the product.
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Intelligent and automated production: With the advent of the Industry 4.0 era, intelligent manufacturing and automated production will become important development directions for the low-atomization and odorless catalyst industry. By introducing advanced technologies such as the Internet of Things (IoT), big data, artificial intelligence (AI), enterprises can realize the full process monitoring and optimization of catalyst production, improve production efficiency and reduce costs. For example, BASF, Germany is building an intelligent factory, using AI algorithms to optimize the formulation and production process of catalysts, greatly improving the quality and consistency of products.
3. Sustainable Development and Circular Economy
In the context of global advocacy of sustainable development, the development and application of low-atomization and odorless catalysts will also pay more attention to environmental protection and resource recycling. In the future, the development of this field will focus on the following aspects:
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Application of renewable materials: Traditional low-atomization odorless catalysts mainly rely on non-renewable resources such as metal oxides, and pose risks of resource depletion and environmental pollution. To this end, researchers are exploring the use of renewable resources such as bio-based materials and plant extracts to prepare catalysts. For example, the research team at the University of São Paulo in Brazil successfully developed a low atomization odorless catalyst based on lignin that not only has good catalytic properties, but also achieves complete biodegradation, in line with the concept of a circular economy.
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Recycling and Reuse of Waste Catalysts: With the widespread use of low-atomization and odorless catalysts, how to deal with waste catalysts has become an urgent problem. Researchers are developing efficient recycling techniques to extract metal elements from waste catalysts and re-used to produce new catalysts. For example, a research team at the University of Michigan in the United States has developed a hydrometallurgy process that can recover up to 90% of metal oxides from waste catalysts, realizing the recycling of resources.
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Green manufacturing and low-carbon emissions: The future production of low-atomization and odorless catalysts will pay more attention to energy conservation and emission reduction and low-carbon emissions. Enterprises will reduce the carbon footprint in the production process by optimizing production processes and using clean energy. For example, Royal DSM is implementing a “green manufacturing” strategy, using renewable energy such as solar and wind energy to power catalyst production, significantly reducing the company’s carbon emissions.
4. International Cooperation and Standardization
With the global development of the low atomization and odorless catalyst market, the process of international cooperation and standardization is also accelerating. In the future, the development of this field will pay more attention to the following aspects:
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Transnational Cooperation and Technology Exchange: In order to cope with global market competition, cooperation and technology exchanges between enterprises in various countries will be more frequent. By establishing joint R&D centers, technology transfer and other methods, enterprises can share new scientific research results and production experience, and promote the rapid development of low-atomization and odorless catalyst technology. For example, the Chinese Academy of Sciences has established a long-term cooperative relationship with the Max Planck Institute in Germany to jointly carry out basic research and application development of low-atomization and odorless catalysts, and achieved many breakthrough results.
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Development and Promotion of International Standards: With the widespread application of low-atomization and odorless catalysts, it has become a consensus in the industry to formulate unified international standards. Organizations such as the International Organization for Standardization (ISO), the European Commission for Standardization (CEN) are actively promoting the formulation and promotion of relevant standards to ensure the quality and safety of products. For example, the ISO 16000 series standards cover the detection and evaluation of indoor air quality, providing an important reference for the application of low atomization and odorless catalysts.
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Global Supply Chain Integration: The future low atomization and odorless catalyst market will pay more attention to the integration of global supply chains. By optimizing supply chain management, enterprises can reduce procurement costs, improve production efficiency, and enhance market competitiveness. For example, DuPont is building a global supply chain platform to�The procurement, production and manufacturing, logistics and distribution of raw materials and other links have achieved the global production and sales of low-atomization and odorless catalysts.
Conclusion
To sum up, as an environmentally friendly plastic processing additive, low-atomization and odorless catalysts have been used to rely on their efficient VOCs degradation performance and odor-free characteristics, and have been used in the automotive industry, home decoration, medical devices, food packaging, etc., in the automotive industry, home decoration, medical devices, food packaging, etc. The field has been widely used. With the increasing global environmental awareness and the growing market demand, the market prospects for low-atomization and odorless catalysts are very broad. In the future, the development of this field will mainly focus on technological innovation, product upgrades, sustainable development and international cooperation, and promote the plastics industry to move towards a green and sustainable direction.
The successful application of low atomization odorless catalyst not only solves environmental problems in plastic processing, but also brings significant economic and social benefits to the enterprise. By reducing VOCs emissions, enterprises can reduce production costs, improve product quality, and enhance market competitiveness. At the same time, the promotion of low atomization and odorless catalysts will also help improve people’s living and working environment, improve the quality of life, and promote the sustainable development of society.
In short, low atomization and odorless catalysts are an important technological innovation in the plastics industry, and their wide application will make positive contributions to the global environmental protection cause.