Bimodal Pore Catalyst for Acrolein Dehydration
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Solution Overview
Problem
Current catalysts for producing acrolein and acrylic acid from glycerin suffer from decreased yield and stability due to the formation of by-products, which complicates separation and increases costs, and existing methods rely on fossil-based raw materials, contributing to environmental issues.
Innovation Solution
A process using a supported catalyst with a bimodal pore structure, specifically a W-containing metal oxide on a carrier with a high ratio of macropore to mesopore volume, enhances catalytic activity and longevity, allowing for higher yields of acrolein and acrylic acid while minimizing by-product formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts are used for producing acrolein and acrylic acid from glycerin, then the production process can proceed, but the yield decreases and stability is reduced due to by-product formation
Solution Approach 1:
The patent applies porous materials by using a catalyst support with a bimodal pore structure containing both mesopores (2-50 nm) and macropores (50-300 nm). The specific pore size distribution and volume ratio (0.3-2.0) optimize mass transfer and reduce by-product formation, thereby maintaining high yield and catalyst stability over extended periods.
Solution Approach 2:
The patent uses composite materials by combining a metal oxide catalyst (such as Ga2O3, ZnO, or mixed oxides) with a porous ceramic support material. This composite structure provides both catalytic activity and structural stability, preventing catalyst deactivation while maintaining high productivity for acrolein and acrylic acid production.
2Ease of manufacture
If conventional catalysts are used, then the process can operate, but by-product formation complicates separation and increases costs
Solution Approach 1:
The bimodal pore structure with optimized macropore and mesopore volumes facilitates selective mass transfer, allowing reactants to access active sites while preventing the formation of polymeric by-products. This reduces separation complexity and operational costs.
3Duration of action of stationary object
If existing catalysts are used, then production can continue, but catalytic activity decreases over time requiring frequent replacement
Solution Approach 1:
The composite catalyst system combines metal oxide active phases with a stable porous ceramic support, creating a structurally robust material that maintains high catalytic activity for acrolein and acrylic acid production over extended periods without requiring frequent replacement.
4Productivity
If fossil-based raw materials are used for producing acrolein and acrylic acid, then industrial production can proceed, but environmental issues and CO2 emissions increase
Solution Approach 1:
The patent changes the fundamental parameter of raw material source from fossil-based propylene to bio-based glycerin. This parameter change enables sustainable production of acrolein and acrylic acid with reduced environmental impact while maintaining industrial production capability through optimized catalytic dehydration processes.
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
This approach maintains high acrolein and acrylic acid yields over extended periods, reduces by-product formation, and utilizes renewable resources, addressing environmental concerns and operational costs.
Implementation Method 1
catalytic dehydration of glycerin in the presence of a novel catalyst system
Implementation Method 2
supported on a carrier having a bimodal pore structure and a high pore volume and distribution
Implementation Method 3
Acrylic acid is obtained by selective oxidation of acrolein in the second step
Data Source
AI summary
The present invention relates to the production of acrolein, acrylic acid or methacrylic acid by dehydration reaction of renewable raw material such as glycerin or hydroxycarboxylic acids, in the presence of a novel catalyst system supported on a carrier having a bimodal structure and a high pore volume and distribution. The dehydration reactions can be carried out for longer operation duration, so that acrolein, acrylic acid or methacrylic acid can be produced at higher productivity and for longer running time.