Complex Oxide Catalyst Composition Control
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Solution Overview
Problem
The composition of protrusions on the surface of catalysts used for vapor-phase catalytic oxidation or ammoxidation of propane or isobutane differs from the core catalyst, leading to deviations from optimal composition ratios after protrusion removal, affecting catalyst performance.
Innovation Solution
A complex oxide catalyst with a specific composition ratio of Mo, V, Sb, Nb, and Z elements, optimized by controlling the vanadium and antimony ratios, and incorporating a method to remove protrusions using an air stream, ensuring the catalyst maintains the desired metal composition ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the composition of the catalyst is optimized at the preparation stage, then the catalyst performance is improved, but the protrusion removal step causes deviation from the optimal composition ratio
Solution Approach 1:
The invention applies preliminary action by adjusting the composition ratio of metals in the raw material formulation stage to compensate for the protrusion removal step. Specifically, the raw material is formulated with higher vanadium and antimony content than the final desired composition, so that after protrusion removal, the remaining core material achieves the optimal composition ratio for catalyst performance.
Solution Approach 2:
The invention changes the parameter of metal composition ratio in the raw material formulation. By adjusting the vanadium to molybdenum ratio and antimony to molybdenum ratio in the initial formulation, the invention compensates for the compositional changes that occur during protrusion removal, ensuring the final catalyst maintains optimal performance characteristics.
2Productivity
If protrusions are removed from the catalyst surface, then the yield of target product is maintained, but the composition of the catalyst deviates from the optimal value
Solution Approach 1:
The invention changes the compositional parameters of the raw material formulation to account for protrusion removal. The raw material is formulated with specific excess amounts of vanadium and antimony, and the invention calculates the appropriate composition ratios in advance to ensure that after protrusion removal, the remaining catalyst material maintains the optimal composition for high target product yield.
Solution Approach 2:
The invention incorporates feedback by monitoring and adjusting the composition ratio based on the protrusion removal process. The invention determines the composition of protrusions and uses this information to adjust the raw material formulation, ensuring that the final catalyst composition remains optimal for maintaining high target product yield.
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 solution provides a catalyst with optimized metal composition ratios, enhancing its catalytic ability and maintaining high performance by ensuring the composition remains optimal after protrusion removal.
Implementation Method 1
a step of removing the protrusion existing on the surface of the particle of the calcined product by an air stream
Data Source
AI summary
A method for producing a complex oxide catalyst containing a complex oxide represented by the formula:Mo1VaSbbNbcWdZeOn (wherein a component Z represents an element such as La, Ce, Pr, Yb, Y, Sc, Sr, and Ba; a, b, c, d, e, and n each represent an atomic ratio of an element to one Mo atom; 0.1≦a≦0.4, 0.1≦b≦0.4, 0.01≦c≦0.3, 0≦d≦0.2, and 0≦e≦0.1; an atomic ratio a/b is 0.85≦a/b<1.0, and an atomic ratio a/c is 1.4<a/c<2.3.), the method including: a step of preparing a specific raw material-formulated solution containing Mo, V, Sb, Nb, W, and Z; a step of drying the raw material-formulated solution to obtain a dry powder; a step of pre-stage calcining the dry powder to obtain a pre-stage calcined product; a step of main-calcining the pre-stage calcined product to obtain a calcined product having a protrusion on the surface of the particle; and a step of removing the protrusion by an air stream, wherein the reduction rate of the pre-stage calcined product is 8 to 12%, and the specific surface area of the calcined product is 7 to 20 m2/g.