Catalyst Production via Stirred Impregnation
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Solution Overview
Problem
Conventional methods for producing catalysts for gas-phase catalytic ammoxidation of propane result in low yields of unsaturated nitriles due to catalyst breakage and poor dispersibility of specific elements during large-scale production.
Innovation Solution
A method involving spray drying, calcination, impregnation with specific elements, and controlled stirring power to produce a catalyst with improved mechanical strength and dispersibility, represented by the formula Mo1VaNbbAcXdZeOn, where specific elements are evenly distributed within the composite oxide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large amount of catalyst is produced using conventional impregnation methods, then the production volume increases, but catalyst breakage occurs and dispersibility of specific elements deteriorates
Solution Approach 1:
The patent applies preliminary action by conducting the impregnation step before calcination, where the composite oxide is impregnated with a solution containing specific elements (tungsten, molybdenum, tellurium, niobium, vanadium, boron, bismuth, manganese, iron, antimony, phosphorus, or rare earth elements) while controlling the liquid-to-solid ratio. This preliminary impregnation ensures uniform distribution of elements before the calcination process, preventing breakage and maintaining dispersibility even when producing large amounts of catalyst.
2Quantity of substance
If conventional impregnation methods are used for large-scale catalyst production, then the production scale increases, but the yield of unsaturated nitriles decreases due to catalyst breakage
Solution Approach 1:
The patent applies parameter changes by controlling the liquid-to-solid ratio during impregnation within the range of 0.05 to 0.5 mL/g, and by controlling the stirring speed during impregnation and drying within the range of 10 to 100 rpm. These parameter optimizations prevent catalyst breakage while ensuring uniform element distribution, thereby maintaining high unsaturated nitrile yields even at large production scales.
3Ease of manufacture
If conventional impregnation methods are used, then the process is simple, but unevenness occurs in drying and dispersibility of elements becomes poor
Solution Approach 1:
The patent applies dynamics by introducing controlled stirring during both the impregnation and drying steps, with stirring speeds maintained between 10 to 100 rpm. This dynamic stirring prevents settling and ensures uniform distribution of the solution containing specific elements throughout the composite oxide particles, eliminating unevenness in drying while maintaining element dispersibility.
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 enables high-yield production of unsaturated nitriles by preventing catalyst breakage and ensuring uniform distribution of elements, enhancing the catalyst's performance in large-scale industrial applications.
Implementation Method 1
an impregnation step of impregnating the composite oxide with a solution containing at least one specific element selected from the group consisting of tungsten, molybdenum, tellurium, niobium, vanadium, boron, bismuth, manganese, iron, antimony, phosphorus and rare earth elements
Implementation Method 2
a second drying step of drying the impregnated composite oxide
Data Source
AI summary
The present invention provides a method for producing a catalyst to be used for a gas-phase catalytic ammoxidation reaction of propane, the method comprising a preparation step of dissolving or dispersing a raw material to thereby obtain a prepared raw material liquid, a first drying step of drying the prepared raw material liquid to thereby obtain a dried material, a calcination step of calcining the dried material to thereby obtain a composite oxide having a predetermined composition, an impregnation step of impregnating the composite oxide with a solution containing at least one specific element selected from the group consisting of tungsten, molybdenum, tellurium, niobium, vanadium, boron, bismuth, manganese, iron, antimony, phosphorus and rare earth elements to thereby obtain an impregnated composite oxide, and a second drying step of drying the impregnated composite oxide, wherein at least one of the impregnation step o and the second drying step is a step of impregnating the composite oxide or drying the impregnated composite oxide while stirring by a specific stirring power.