Silica-Supported Propylene Ammoxidation Catalyst With Low Fines
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Solution Overview
Problem
Existing ammoxidation catalysts for propylene, particularly those prepared by the sol-gel method, suffer from high fine powder content, low durability, and limited yield of acrylonitrile due to weak particle binding and non-uniform particle size distribution, necessitating continuous catalyst makeup during the reaction.
Innovation Solution
An ammoxidation catalyst with a specific composition of Mo, Bi, Fe, and Co supported on a silica support with controlled pore diameter and apparent density, prepared via an impregnation method, resulting in a more uniform particle size distribution and reduced fine powder content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the sol-gel method is used to prepare the catalyst, then the catalyst can be manufactured with a specific composition, but the particle binding force is weak causing high fine powder content and low durability
Solution Approach 1:
The invention changes the preparation method from sol-gel to impregnation method, and optimizes physical parameters including pore diameter (3-10 nm), apparent density (0.3-1.2 g/cc), and particle size distribution (D10-D90 ratio ≤ 2.5). These parameter changes strengthen particle binding and reduce fine powder generation while maintaining manufacturability
Solution Approach 2:
The invention uses a composite catalyst structure with metal oxide particles (Mo, Bi, Fe, Co) supported on silica particles. This composite structure with optimized pore diameter and apparent density creates strong binding between particles, preventing wear and fragmentation during fluidized bed operation
2Productivity
If the sol-gel method is used to prepare the catalyst, then the catalyst can be produced, but the particle size distribution is non-uniform resulting in high fine powder content
Solution Approach 1:
The invention optimizes physical parameters including pore diameter (3-10 nm), apparent density (0.3-1.2 g/cc), and particle size distribution (D10-D90 ratio ≤ 2.5). These parameter changes ensure uniform particle size distribution and reduce fine powder generation while maintaining production efficiency
Solution Approach 2:
The invention performs preliminary classification to remove fine powder before the catalyst is introduced into the fluidized bed reactor. This preliminary action prevents fine powder from entering the reaction system, ensuring uniform particle size distribution in the operational catalyst
3Productivity
If catalyst is continuously added to maintain reaction efficiency, then the yield of acrylonitrile can be maintained, but the manufacturing cost increases
Solution Approach 1:
The invention creates a durable catalyst that does not require continuous replacement. The optimized impregnation method and physical parameters produce catalyst particles resistant to wear and fragmentation, eliminating the need for continuous makeup and reducing operational costs
Solution Approach 2:
The invention optimizes pore diameter (3-10 nm), apparent density (0.3-1.2 g/cc), and particle size distribution to create mechanically strong catalyst particles. These parameter changes prevent particle breakdown and eliminate the need for continuous catalyst addition, maintaining both productivity and cost-effectiveness
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 exhibits improved durability and higher yield of acrylonitrile without additional catalyst supply, enhancing the efficiency and productivity of the ammoxidation process in a fluidized bed reactor.
Implementation Method 1
a metal oxide with a specific composition is supported on a silica support
Implementation Method 2
the catalyst exhibits improved durability and higher yield of acrylonitrile without additional catalyst supply, enhancing the efficiency and productivity of the ammoxidation process
Data Source
Figure 1~2
AI summary
The present disclosure relates to an ammoxidation catalyst for propylene, a manufacturing method of the same, and an ammoxidation method of propylene using the same. Specifically, in one embodiment of the present disclosure, there is provided a catalyst having a structure in which a metal oxide is supported on a silica support, a narrow particle size distribution, and excellent wear resistance.