Catalyst for Methyl Methacrylate Production via Aldol Condensation
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Solution Overview
Problem
Existing methods for producing methyl methacrylate in the Alpha technology process face challenges in achieving high selectivity and yield, even with catalysts containing porous high surface area silica and specific modifier elements.
Innovation Solution
A catalyst comprising at least one first metal element (boron, magnesium, zirconium, or hafnium) and an alkali metal element, supported on a carrier with silanol groups, where the molar ratio of alkali metal to the first metal element and the BET specific surface area are optimized to enhance dispersion and reaction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a catalyst containing porous high surface area silica with alkali metal and modifier elements is used, then the catalyst structure is well-defined, but the selectivity of methyl methacrylate is insufficient
Solution Approach 1:
The patent changes the chemical composition parameters of the catalyst by introducing specific metal elements (zirconium, hafnium, boron, magnesium) in controlled amounts (0.1-5 wt% each) alongside alkali metals (1-10 wt%). This compositional parameter adjustment optimizes both the structural definition and the selectivity for methyl methacrylate production, resolving the contradiction between well-defined structure and sufficient selectivity.
2Ease of manufacture
If existing catalyst compositions are used in Alpha technology, then the production process is established, but the yield and selectivity of target product are not high enough
Solution Approach 1:
The patent creates a composite catalyst material combining porous high surface area silica support with multiple metal components (alkali metals like Na/K/Cs and transition metals like Zr/Hf/B/Mg). This composite structure leverages the synergistic effects of different materials - the silica provides high surface area and stability, while the metal components enhance catalytic activity and selectivity, thereby improving yield and selectivity within the established Alpha technology framework.
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 significantly improves the selectivity and yield of unsaturated carboxylic acids and esters in aldol condensation reactions, specifically producing methyl methacrylate with enhanced productivity.
Implementation Method 1
A catalyst comprising (i) a compound comprising at least one first metal element selected from boron, magnesium, zirconium, and hafnium, and (ii) an alkali metal element, wherein the compound and the alkali metal element are supported on a carrier having silanol groups
Data Source
AI summary
The present invention is a catalyst comprising:(i) a compound comprising at least one first metal element selected from boron, magnesium, zirconium, and hafnium, and(ii) an alkali metal element,wherein the compound and the alkali metal element are supported on a carrier having silanol groups,an average particle size of the compound of the first metal element is 0.4 nm or more and 50 nm or less,the catalyst satisfies the following formula (1):0.9×10 -21 (g/number)≦ X/(Y×Z)<10.8×10 -21 (g/number),formula (1)in which X is a molar ratio of the alkali metal element to the at least one first metal element in the catalyst, Y is a BET specific surface area of the catalyst (m2/g), and Z is a number of the silanol groups per unit area (number/nm2).