Epoxidation Catalyst Preparation via Column Impregnation
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Solution Overview
Problem
Existing heterogenous epoxidation catalysts for olefins are inefficient and require costly steam treatment, which poses safety risks and energy inefficiencies.
Innovation Solution
A method involving the preparation of a titanium on silica catalyst by impregnating silica with titanium tetrachloride in a controlled manner using a column process, followed by calcination and optional alcohol washing, to create a catalyst with high pore volume and surface area, avoiding steam treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steam treatment is used to prepare epoxidation catalysts, then catalyst effectiveness is improved, but safety risks and energy consumption increase
Solution Approach 1:
The patent replaces expensive and hazardous steam treatment with a cheaper, safer alcohol washing process. The alcohol wash effectively removes excess titanium tetrachloride and adjusts catalyst acidity without requiring high-temperature steam, thereby eliminating safety risks while maintaining catalyst effectiveness.
Solution Approach 2:
The patent changes the washing parameter from steam (high temperature, high energy) to alcohol (room temperature, low energy). This parameter change maintains the essential function of removing excess titanium while dramatically reducing energy consumption and safety hazards associated with steam treatment.
2Reliability
If steam treatment is used to prepare epoxidation catalysts, then catalyst effectiveness is improved, but energy consumption increases
Solution Approach 1:
The patent replaces expensive and hazardous steam treatment with a cheaper, safer alcohol washing process. The alcohol wash effectively removes excess titanium tetrachloride and adjusts catalyst acidity without requiring high-temperature steam, thereby eliminating safety risks while maintaining catalyst effectiveness.
Solution Approach 2:
The patent changes the washing parameter from steam (high temperature, high energy) to alcohol (room temperature, low energy). This parameter change maintains the essential function of removing excess titanium while dramatically reducing energy consumption and safety hazards associated with steam treatment.
3Ease of manufacture
If conventional catalyst preparation methods are used, then manufacturing simplicity is maintained, but catalyst performance is insufficient
Solution Approach 1:
The patent applies preliminary action by carefully controlling the impregnation step before calcination. By adding titanium tetrachloride solution to a packed column and allowing controlled absorption, the method ensures uniform titanium distribution and optimal catalyst formation, which significantly improves catalyst performance while maintaining manufacturing simplicity.
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 achieves high peroxide conversion and selectivity, reducing energy costs and safety hazards while maintaining catalyst effectiveness.
Implementation Method 1
adding to the solid-filled column a solution comprising titanium tetrachloride and a hydrocarbon solvent to produce a titanium tetrachloride-impregnated solid
Implementation Method 2
The titanium tetrachloride-impregnated solid is calcined at a temperature from 500°C to 1000°C to produce the catalyst
Data Source
AI summary
A method of preparing epoxidation catalysts is disclosed. The method comprises: (a) adding an inorganic siliceous solid to a column to produce a solid-filled column; (b) adding to the solid-filled column a solution comprising titanium tetrachloride and a hydrocarbon solvent to produce a titanium tetrachloride-impregnated solid; and (c) calcining the titanium tetrachloride- impregnated solid at a temperature from 500°C to 1000°C to produce the catalyst. The inorganic siliceous solid has a pore volume of at least 0.8 cm3/g.