3-HP Dehydration Catalyst Composition for Acrylic Acid Yield
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Solution Overview
Problem
Existing catalysts for the dehydration of 3-hydroxypropionic acid to produce acrylic acid suffer from low yield and poor processability due to the formation of sodium pyrophosphate and inadequate formation of the calcium pyrophosphate phase, leading to a short catalyst lifespan.
Innovation Solution
A method involving the preparation of a catalyst comprising hydroxyapatite and calcium pyrophosphate phases by dropping a phosphate solution into a calcium salt solution, forming a mixed phase that enhances the catalyst's performance through improved yield and lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If calcium salts and phosphate solutions are generally mixed to prepare apatite cake, then the catalyst can be prepared, but sodium pyrophosphate is formed and the calcium pyrophosphate phase is inadequately formed, leading to low acrylic acid yield and short catalyst lifespan
Solution Approach 1:
The patent inverts the conventional mixing sequence by adding calcium salt solution to phosphate solution instead of adding phosphate solution to calcium salt solution. This reversal prevents the formation of sodium pyrophosphate and promotes adequate formation of the calcium pyrophosphate phase, thereby improving both acrylic acid yield and catalyst lifespan
Solution Approach 2:
The patent changes the mixing parameters including the sequence of addition, molar ratios of calcium to phosphate, and stirring conditions. These parameter changes optimize the formation of calcium pyrophosphate phase while preventing sodium pyrophosphate formation, leading to improved catalytic performance and durability
2Reliability
If single-phase catalysts (hydroxyapatite or calcium pyrophosphate) are used, then the catalyst structure is simple, but the processability is poor and the catalyst lifespan is short
Solution Approach 1:
The patent employs a composite catalyst containing both hydroxyapatite phase and calcium pyrophosphate phase in a controlled weight ratio range (3:7 to 7:3). This composite structure combines the advantages of both phases, improving catalyst processability and lifespan while maintaining reasonable structural complexity
3Productivity
If the conventional method of adding calcium salt solution to phosphate solution is used, then the preparation process is simple, but sodium pyrophosphate is formed leading to low catalyst performance
Solution Approach 1:
The patent reverses the addition sequence to improve acrylic acid yield, accepting increased preparation complexity as a necessary trade-off for achieving superior catalytic performance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The catalyst achieves a high yield of acrylic acid and improved processability by ensuring the formation of a mixed hydroxyapatite and calcium pyrophosphate phase, outperforming single-phase catalysts in terms of yield and efficiency.
Implementation Method 1
preparing an apatite cake by dropping a first phosphate solution into a first calcium salt solution; preparing a calcium pyrophosphate (CaPP) cake by dropping a second phosphate solution into a second calcium salt solution
Implementation Method 2
firing the calcium phosphate cake
Implementation Method 3
3-hydroxypropionic acid (3-HP) may be converted to acrylic acid through a dehydration reaction... using the catalyst
Data Source
AI summary
The present disclosure relates to a method for preparing a catalyst for dehydration reaction of 3-hydroxypropionic acid, the catalyst for dehydration reaction of 3-hydroxypropionic acid, and a method for producing acrylic acid using the same.