Composite Metal Oxide Catalyst for Alkene Oxidation
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Solution Overview
Problem
Current catalysts for manufacturing unsaturated aldehydes and carboxylic acids from alkenes in gas-phase oxidation reactions suffer from low yield, leading to increased manufacturing costs, by-product accumulation, and reduced catalyst activity due to thermal stress and pressure issues, which necessitate higher reaction temperatures and frequent system cleaning.
Innovation Solution
A composite metal oxide catalyst with specific atomic ratios of molybdenum, bismuth, iron, cobalt, and nickel, using ammonium molybdate and bismuth nitrate as raw materials, dissolved in water and nitric acid solutions within specified ranges, and calcined at controlled temperatures to enhance selectivity and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts are used for gas-phase oxidation of alkenes, then the manufacturing process can proceed, but the yield of unsaturated aldehyde and/or carboxylic acid is low, leading to increased manufacturing costs
Solution Approach 1:
The patent applies parameter changes by optimizing the atomic ratios of metal components in the catalyst. Specifically, it regulates the atomic ratio of iron to cobalt and/or nickel within a specified range, and controls the atomic ratio of cobalt to molybdenum and iron, to achieve high yield and selectivity in the oxidation reaction
Solution Approach 2:
The patent uses a composite metal oxide catalyst containing multiple metal components (iron, cobalt, nickel, and molybdenum) in specific proportions. This composite structure synergistically improves both the activity and selectivity of the catalyst, thereby increasing the yield of the desired product
2Productivity
If operation continues at low yield, then manufacturing can proceed, but by-products accumulate on catalyst surface and gas passage, increasing purification time and operation costs
Solution Approach 1:
By changing the catalyst composition parameters to achieve high selectivity, the patent minimizes by-product formation. The optimized atomic ratios ensure that the oxidation reaction predominantly produces the desired unsaturated aldehyde and/or carboxylic acid, reducing the time and cost associated with purification operations
3Reliability
If reaction temperature is increased to compensate for catalyst deactivation, then catalyst activity can be maintained, but thermal stress causes lowering of catalyst life and selectivity
Solution Approach 1:
The patent changes the compositional parameters of the catalyst to create a more stable formulation. The specific atomic ratios of iron, cobalt, nickel, and molybdenum enhance the thermal stability and resistance to deactivation, allowing the catalyst to maintain high activity over extended periods without requiring temperature increases that would accelerate degradation
4Reliability
If reaction temperature is increased to maintain catalyst activity, then catalyst activity is improved, but selectivity is reduced resulting in decreased yield
Solution Approach 1:
The composite metal oxide catalyst with optimized composition simultaneously enhances both activity and selectivity. The synergistic interaction between iron, cobalt, nickel, and molybdenum components in specific atomic ratios ensures high catalytic activity while maintaining excellent selectivity for the desired product, even at moderate reaction temperatures
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 for unsaturated aldehydes and carboxylic acids, enabling stable, long-term operation at lower costs and reducing by-product accumulation and thermal stress, thus improving catalyst longevity and system efficiency.
Implementation Method 1
a catalyst for manufacturing an unsaturated aldehyde and/or an unsaturated carboxylic acid, comprising a compound represented by the following formula (1)... used on the occasion of subjecting an alkene to gas-phase oxidation with molecular oxygen or a molecular oxygen-containing gas in the presence of an oxidation catalyst
Data Source
Figure 1
AI summary
A method for preparing a catalyst for manufacturing an unsaturated aldehyde and/or an unsaturated carboxylic acid, wherein molybdenum component raw materials are set as only ammonium molybdate and the weight of water for dissolving this is at most 8.5 fold with respect to the weight of the molybdenum included in the ammonium molybdate and bismuth component raw materials are set as only bismuth nitrate and the weight of a nitric acid aqueous solution for dissolving this is at least 2.3 fold with respect to the weight of the bismuth included in the bismuth nitrate, wherein the nitric acid concentration of the nitric acid aqueous solution for dissolving the bismuth nitrate is at least 10 wt%.