Composite Oxide Catalyst Precursors for Faster, Safer Drying
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Solution Overview
Problem
Existing methods for preparing (meth)acrylic acid catalysts face issues with suspension drying efficiency, generation of nitric acid and ammonia, equipment corrosion, and worker safety due to the use of nitrate and ammonium salts as precursor compounds.
Innovation Solution
A method involving the use of molybdenum-based, bismuth-based, and other metal compounds, with specific metal organic acid salts and oxides, to form a molybdenum-bismuth-based composite metal oxide catalyst, enhancing suspension drying efficiency and reducing nitric acid and ammonia generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If nitrate or ammonium salt is used as precursor compound, then the catalyst can be prepared through co-precipitation method, but the drying efficiency of suspension is reduced and nitric acid and ammonia are generated causing equipment corrosion and safety issues
Solution Approach 1:
The patent changes the chemical parameters of the precursor compounds by replacing nitrate and ammonium salts with acetate and formate salts. This substitution fundamentally alters the decomposition behavior during drying, eliminating the generation of nitric acid and ammonia while maintaining the co-precipitation preparation method. The new precursors decompose to produce carbon dioxide and water vapor instead of harmful acidic gases.
2Ease of manufacture
If nitrate is used as precursor compound, then the catalyst preparation can proceed with standard co-precipitation method, but the suspension drying efficiency is reduced requiring longer drying time
Solution Approach 1:
The patent modifies the chemical composition parameters by substituting nitrate precursors with acetate and formate precursors. These alternative compounds have superior drying characteristics that enable faster water removal from the suspension during the drying process, thereby reducing the drying time required while preserving the simplicity of the co-precipitation manufacturing method.
3Productivity
If ammonia and NOx materials are generated during catalyst preparation, then the catalyst can be formed through conventional methods, but equipment corrosion occurs and worker safety is compromised
Solution Approach 1:
The patent converts the potentially harmful decomposition products of nitrate precursors into benign substances by replacing them with acetate and formate precursors. The new precursors decompose during drying to produce carbon dioxide and water vapor instead of corrosive nitric acid and toxic ammonia, thereby eliminating equipment corrosion risks and improving worker safety while maintaining catalyst production efficiency.
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 method improves catalyst preparation time, increases (meth)acrylic acid yield, and minimizes hazardous substance generation, resulting in a more efficient and safer catalyst production process.
Implementation Method 1
preparing a first catalyst suspension including a molybdenum-based compound; a bismuth-based compound
Implementation Method 2
improve the drying efficiency of a suspension
Data Source
AI summary
The present invention relates to a method for preparing a catalyst for preparing (meth)acrylic acid and a method for preparing (meth)acrylic acid.