Catalyst Production via Mass Loss Rate Control
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Solution Overview
Problem
Existing catalysts for producing unsaturated carboxylic acids by gas phase catalytic oxidation of unsaturated aldehydes are not satisfactory in achieving high raw material conversion rates and end product selectivity.
Innovation Solution
A catalyst comprising molybdenum (Mo), vanadium (V), and copper (Cu) is produced using a method that involves a drying step, a forming step where the dried product is supported on a carrier, and a calcining step, with specific conditions regarding mass loss rates and heat treatment temperatures to enhance catalytic activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalyst preparation methods are used (mixing, suspending, drying, pulverizing catalyst component elements), then the catalyst can be produced with basic mechanical strength, but the raw material conversion rate and end product selectivity are not satisfactory
Solution Approach 1:
The invention changes the physical and chemical parameters of the catalyst preparation process, specifically controlling the mass loss rate of the dried powder at 300°C to be 5% or less, and controlling the difference in mass loss rate between 370°C and 300°C to be 1-6%. These parameter changes lead to improved catalytic activity and selectivity.
Solution Approach 2:
The invention performs preliminary heat treatment of the dried powder before supporting it on the carrier. This preliminary action of controlling the mass loss rate characteristics at specific temperatures prepares the catalyst components in an optimal state, which subsequently improves both conversion rate and selectivity.
2Productivity
If the mass loss rate of dried powder at 300°C is controlled to be low (≤5%), then catalytic activity is improved, but the heat treatment process becomes more complex and time-consuming
Solution Approach 1:
The invention specifies precise parameter ranges for heat treatment: temperature of 270-330°C and time of 30 minutes to 2 hours. By defining these specific parameters, the complex heat treatment process becomes controllable and reproducible, achieving high catalytic activity without excessive complexity.
3Reliability
If the difference in mass loss rate between 370°C and 300°C is controlled to be 1-6%, then end product selectivity is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The invention establishes a specific parameter range (1-6% difference in mass loss rate) that balances manufacturing feasibility with performance requirements. This parameter control ensures improved selectivity while maintaining reasonable manufacturing precision standards.
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 increased raw material conversion rates and end product selectivity, thereby improving the yield of unsaturated carboxylic acids such as acrylic acid during gas phase catalytic oxidation.
Implementation Method 1
a drying step of obtaining a dried product by drying and heat-treating a starting material mixed liquid
Implementation Method 2
a first mass loss rate of the powder to be supported at 300°C is less than 5 percent by mass, and the difference between a second mass loss rate of the powder to be supported at 370°C and the first mass loss rate of the powder to be supported at 300°C is not less than 1 percent by mass and not more than 6 percent by mass
Implementation Method 3
a calcining step of calcining the catalyst precursor to form the catalyst
Implementation Method 4
catalysts used to produce unsaturated carboxylic acids by gas phase catalytic oxidation of an unsaturated aldehyde with oxygen-containing gas
Implementation Method 5
gas phase catalytic oxidation of an unsaturated aldehyde with oxygen-containing gas
Data Source
AI summary
The present invention aims to provide a catalyst capable of further improving the raw material conversion rate and the end product selectivity. The present invention provides a method for producing a catalyst for unsaturated carboxylic acid synthesis, the method comprising: a drying step of obtaining a dried product by drying and heat-treating a starting material mixed liquid in which supply source compounds of respective catalyst component elements are integrated; a forming step of forming a catalyst precursor by supporting powder to be supported on a carrier comprising a particle aggregate, the powder to be supported being either the dried product or obtained from the dried product; and a calcining step of calcining the catalyst precursor to form the catalyst, wherein a first mass loss rate of the powder to be supported at 300°C is less than 5 percent by mass, and the difference between a second mass loss rate of the powder to be supported at 370°C and the first mass loss rate of the powder to be supported at 300°C is not less than 1 percent by mass and not more than 6 percent by mass.