Catalyst Pore Volume Control for Acrylic Acid Production
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Solution Overview
Problem
Catalysts used for producing unsaturated aldehyde and unsaturated carboxylic acids, such as acrolein and acrylic acid, face inefficiencies in reaction yield and stability, particularly at high temperatures and under high load conditions, leading to reduced catalyst strength and instability.
Innovation Solution
A catalyst comprising Mo, Bi, Co, Ni, and Fe with specific pore volume ratios and atomic ratios, optimized through a controlled pulverization process, is developed to enhance conversion rates and selectivity of unsaturated aldehyde and unsaturated carboxylic acid production, maintaining catalyst strength and preventing powdering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If catalyst temperature is increased to enhance activity, then conversion rate improves, but side reactions increase and yield decreases
Solution Approach 1:
The patent applies parameter changes by precisely controlling catalyst pore volume (0.12-0.19 ml/g) and pore diameter distribution (1-100 μm) to optimize reaction conditions. This allows the catalyst to maintain high conversion rates while suppressing side reactions through optimized mass transfer and heat transfer characteristics within the pore structure.
Solution Approach 2:
The patent utilizes porous materials by designing a catalyst with specific pore volume and pore diameter characteristics. The porous structure enables controlled diffusion of reactants and products, allowing high conversion rates while minimizing side reactions through optimized transport pathways within the catalyst pores.
2Duration of action of stationary object
If catalyst is used for long period, then production continues, but catalyst strength decreases and powdering occurs
Solution Approach 1:
The patent applies parameter changes by optimizing the pore volume (0.12-0.19 ml/g) and pore diameter distribution of the catalyst. These parameter optimizations enhance the mechanical strength and structural stability of the catalyst, enabling it to maintain integrity and resist powdering during prolonged operation periods.
3Productivity
If high load is applied to catalyst, then productivity increases, but selectivity decreases and yield reduces
Solution Approach 1:
The patent utilizes porous materials with specifically controlled pore volume (0.12-0.19 ml/g) and pore diameter (1-100 μm) to maintain high selectivity under high load conditions. The porous structure provides optimized mass transfer pathways that prevent diffusion limitations and maintain product selectivity even at high production rates.
Solution Approach 2:
The patent applies parameter changes by optimizing the pore volume and pore diameter distribution to enable the catalyst to operate efficiently at high loads while maintaining high selectivity. The specific parameter ranges allow the catalyst to handle increased throughput without compromising product quality or 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 catalyst achieves high selectivity and yield of unsaturated aldehyde and unsaturated carboxylic acid even under high load conditions, with improved stability and reduced powdering, allowing for efficient long-term catalytic gas phase oxidation reactions.
Implementation Method 1
catalytic gas phase oxidation of olefin having 3 or 4 carbon atoms and oxygen-containing gas
Data Source
AI summary
A catalyst for producing unsaturated aldehyde and unsaturated carboxylic acid, wherein the cumulative pore volume (A) of pores having a pore diameter of 1 µm or more and 100 µm or less, in the catalyst, is 0.12 ml/g or more and 0.19 ml/g or less, and the ratio (A/B) of the cumulative pore volume (A) to the cumulative pore volume (B) of pores having a pore diameter of 1 µm or more and 100 µm or less, in a pulverized product not passing through a Tyler 6 mesh, in a pulverized product obtained by pulverization of the catalyst under a particular condition is 0.30 or more and 0.87 or less.