Ethoxylation Catalyst Solid Calcium Sulfate Handling
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Solution Overview
Problem
The existing alkylene oxide adduct manufacturing process using a catalyst disclosed in PTL 1 experiences a long induction period and poor handling properties due to the catalyst being a dispersion liquid, making it difficult to transport and store.
Innovation Solution
An ethoxylation catalyst with a BET specific surface area of 40 to 150 m2/g, comprising calcium sulfate particles including calcium sulfate 0.5 hydrate and type III anhydrous calcium sulfate, is developed, along with a manufacturing method involving the reaction of calcium salts with sulfuric acid in an alcohol solvent, followed by separation and drying to produce a solid catalyst with improved properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the catalyst disclosed in PTL 1 is used for ethoxylation reaction, then the amount of by-products is reduced, but the induction period becomes long and handling property deteriorates
Solution Approach 1:
The patent changes the physical state parameter of the catalyst from liquid dispersion to solid particles, and optimizes the chemical composition by specifying calcium sulfate 0.5 hydrate and type III anhydrous calcium sulfate with controlled water content (0.1-10% by mass). This parameter change eliminates the induction period while maintaining low by-product formation, resolving the contradiction between reaction efficiency and time loss.
Solution Approach 2:
The patent utilizes phase transition by converting the catalyst from liquid dispersion phase to solid particle phase through controlled drying. The solid catalyst particles with specific surface area (50-200 m²/g) and controlled water content exhibit immediate catalytic activity without induction period, while the liquid form showed delayed activity. This phase transition resolves the contradiction between by-product reduction and induction period elimination.
2Object-generated harmful factors
If the catalyst disclosed in PTL 1 is used for ethoxylation reaction, then the amount of by-products is reduced, but the handling property during transporting and storing deteriorates
Solution Approach 1:
The patent changes the physical state parameter from liquid dispersion to solid particles, transforming the catalyst into a free-flowing powder that can be easily transported and stored. The solid catalyst particles with controlled surface area and water content maintain catalytic effectiveness while providing excellent handling properties, resolving the contradiction between by-product reduction and ease of operation.
Solution Approach 2:
The patent creates a stable, solid catalyst that can be easily handled, transported, and stored without special precautions. The solid particle form with controlled properties allows the catalyst to be treated as a convenient, easily manageable material, improving ease of operation while maintaining the by-product reduction benefit.
3Reliability
If the catalyst is in liquid dispersion form, then the catalytic activity is maintained, but the handling property during transporting and storing becomes poor
Solution Approach 1:
The patent changes the physical state from liquid dispersion to solid particles while controlling key parameters (surface area, water content, particle size) to maintain catalytic activity. The solid catalyst with specific surface area (50-200 m²/g) and water content (0.1-10% by mass) provides both reliable catalytic performance and excellent handling properties, resolving the contradiction between reliability and ease of operation.
Solution Approach 2:
The patent creates a composite catalyst system combining calcium sulfate 0.5 hydrate and type III anhydrous calcium sulfate in specific proportions. This composite material structure maintains catalytic activity equivalent to liquid dispersion while providing solid particle form for easy handling, transporting, and storage, resolving the contradiction between reliability and ease of operation.
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 new catalyst significantly shortens the induction period and enhances handling properties, allowing for more efficient ethoxylation reactions and easier storage and transportation.
Implementation Method 1
an ethoxylation catalyst having a BET specific surface area of 40 to 150 m2/g, the catalyst including calcium sulfate particles including at least one kind of compound selected from the group consisting of calcium sulfate 0.5 hydrate and type III anhydrous calcium sulfate
Implementation Method 2
a reacting step of mixing at least one compound (A) selected from the group consisting of calcium salt of carboxylic acid, calcium oxide, and calcium hydroxide with sulfuric acid (B) in a solvent (C) to produce a reaction product of (A) and (B)
Implementation Method 3
a drying step of drying the reaction product separated in the separating step, in which the solvent (C) is an alcohol having 1 to 6 carbon atoms, and a drying temperature in the drying step is less than 400° C.
Data Source
AI summary
Disclosed is an ethoxylation catalyst having a BET specific surface area of 40 to 150 m2/g and including calcium sulfate particles including at least one kind of compound selected from the group consisting of calcium sulfate 0.5 hydrate and type III anhydrous calcium sulfate.