Catalyst Particle Shape for Unsaturated Carboxylic Acid Production
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Solution Overview
Problem
Existing catalysts for producing unsaturated aldehydes and unsaturated carboxylic acids suffer from insufficient catalytic activity, leading to inefficiencies in yield and stability during industrial production processes.
Innovation Solution
A catalyst with a sphericity parameter SPHT3 of 0.9820 or less, composed of specific elements and carried on an inert carrier, is developed to enhance catalytic activity by optimizing particle shape and composition, including a catalytically active component represented by certain atomic ratios and carried on inert carriers like silica or alumina.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts are used for producing unsaturated aldehydes and unsaturated carboxylic acids, then the production process can proceed, but the catalytic activity is insufficient leading to low yield and poor stability
Solution Approach 1:
The patent applies parameter changes by precisely controlling the sphericity parameter SPHT3 to be 0.9820 or less, and optimizing the particle diameter within specific ranges (3.0-8.0mm for carried catalysts, 0.5-2.0mm for non-carried catalysts). It also optimizes the atomic ratios of catalytically active components (Mo: 10-20 atoms, V: 1-5 atoms, W: 1-5 atoms, Cu: 1-5 atoms, Sb: 0.5-2.0 atoms per 100 Mo atoms) to achieve both high catalytic activity and stability in the oxidation reaction
Solution Approach 2:
The patent employs composite materials by combining multiple catalytically active components (Mo, V, W, Cu, Sb) in specific ratios to form a synergistic catalyst system. The catalyst may also be carried on inert carriers such as silica or alumina, creating a composite structure that enhances both activity and stability while reducing by-product formation
2Productivity
If catalyst particle shape is not optimized, then manufacturing is simpler, but catalytic activity and yield are insufficient
Solution Approach 1:
The patent applies parameter changes by precisely controlling the sphericity parameter SPHT3 to be 0.9820 or less, and optimizing the particle diameter within specific ranges (3.0-8.0mm for carried catalysts, 0.5-2.0mm for non-carried catalysts). This precise parameter control enhances catalytic activity and yield while maintaining feasible manufacturing through established granulation and size classification techniques
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 maintains high catalytic activity, improving conversion rates and reducing energy costs by minimizing thermal stress and maintaining stability over time, while reducing by-products like CO and CO2.
Implementation Method 1
a method for producing a corresponding unsaturated aldehyde or unsaturated carboxylic acid using propylene, isobutylene, t-butyl alcohol, or the like as a raw material, or a catalytic gas phase oxidation method for producing 1,3-butadiene from butenes
Data Source
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AI summary
The present invention relates to a catalyst having a value of a sphericity parameter SPHT3 obtained by particle shape measurement by a dynamic image analysis method of 0.9820 or less. Here, the sphericity parameter SPHT3 is a value obtained by the following equation (I). SPHT3 = 4πA/P2 ···(I) In the equation (I), A is the area of a particle photographed by the dynamic image analysis method, and P is the perimeter of the particle.