Annular Unsupported Catalyst Strength Optimization
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Solution Overview
Problem
Existing annular unsupported catalysts used for catalytic partial oxidation of propene to acrolein or isobutene/tert-butanol to methacrolein do not meet requirements for activity and selectivity, with side crushing strength being insufficient for effective catalyst performance.
Innovation Solution
A process to prepare annular unsupported catalysts with a side crushing strength of ≥12 N and ≤23 N by optimizing the particle size, geometry, and thermal treatment of the catalyst precursor bodies, using a finely divided shapeable mixture and shaping assistants like graphite, to enhance the catalyst's structural integrity and activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the side crushing strength of annular unsupported catalyst precursor bodies is increased to improve catalyst performance, then the structural integrity and durability of the catalyst is improved, but the manufacturing complexity and difficulty of shaping the precursor bodies increases
Solution Approach 1:
The patent applies preliminary action by adding shaping assistants and reinforcing assistants to the finely divided mixture before the shaping process. These assistants are incorporated in advance to ensure the precursor bodies achieve the required side crushing strength (≥10 N) during subsequent thermal treatment, thereby resolving the contradiction between achieving sufficient strength and maintaining manufacturing simplicity.
Solution Approach 2:
The patent uses shaping assistants and reinforcing assistants as intermediary substances that facilitate the shaping process while ensuring the precursor bodies achieve adequate mechanical strength. These intermediaries enable the formation of structurally sound catalyst precursor bodies without requiring complex manufacturing equipment or processes, thus resolving the contradiction between strength requirements and manufacturing complexity.
2Productivity
If the particle size of the finely divided mixture is optimized to improve catalyst activity and selectivity, then the catalytic performance is enhanced, but the manufacturing precision required to achieve the desired particle size distribution increases
Solution Approach 1:
The patent applies parameter changes by optimizing the particle size of the finely divided mixture within specific ranges (with at least 80% by weight of particles having a largest dimension of 20-500 μm). By controlling this critical parameter and using appropriate shaping assistants, the patent achieves both high catalytic activity and selectivity while avoiding excessive manufacturing precision requirements through the use of standard classification equipment.
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 process results in catalysts with increased activity and selectivity for the targeted product formation, with improved side crushing strength and specific surface area, leading to enhanced performance in catalytic partial oxidation reactions.
Implementation Method 1
converting these to the annular unsupported catalysts by thermally treating at elevated temperature
Data Source
AI summary
A process for preparing annular unsupported catalysts by thermally treating annular shaped unsupported catalyst precursor bodies, wherein the side crushing strength of the annular shaped unsupported catalyst precursor bodies is ≧12 N and ≦23 N; such precursor bodies per se; annular unsupported catalysts having a specific pore structure; and a method of using such annular unsupported catalysts for the catalytic partial oxidative preparation in the gas phase of (meth)acrolein.