Selective Oxidation Catalyst for Ethylene to Acetic Acid Conversion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for producing acetic acid through the oxidation of C2 hydrocarbons have limited production rates and efficiency, often resulting in the production of ethylene instead of acetic acid.
Innovation Solution
A catalyst comprising molybdenum, vanadium, niobium, and palladium metals or metal-containing compounds is created by forming a slurry, agitating it for at least 15 minutes, and then adding palladium, which is primarily distributed on the surface to enhance the conversion of ethylene to acetic acid, thereby increasing the production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional oxidation catalysts are used for C2 hydrocarbon conversion, then the process is simple, but the production rate of acetic acid is very limited
Solution Approach 1:
The patent uses a composite catalyst containing multiple metal oxides (molybdenum, vanadium, niobium) combined with palladium metal. This composite structure enables both the oxidation of ethane to ethylene and the subsequent conversion of ethylene to acetic acid, significantly improving production rate while managing complexity through synergistic material combinations
Solution Approach 2:
The patent distributes palladium specifically on the surface of the metal oxide catalyst at controlled concentrations (10-500 ppm, preferably 50-300 ppm). This localized placement ensures that palladium is positioned where it is most effective for ethylene conversion, maximizing its catalytic activity while minimizing the amount of expensive metal required
2Productivity
If conventional catalysts are used, then the process is simple to operate, but the conversion rate of ethylene to acetic acid is low
Solution Approach 1:
The patent prepares the metal oxide catalyst support first, then impregnates it with palladium solution, and finally dries and calcines the material. This sequential preparation approach ensures that palladium is properly distributed on the catalyst surface before use, optimizing the conversion rate of ethylene to acetic acid while maintaining a manageable preparation process
Solution Approach 2:
The patent controls the palladium concentration within specific ranges (10-500 ppm, preferably 50-300 ppm) and adjusts preparation parameters such as drying temperature (80-300°C) and calcination conditions. These parameter optimizations maximize the catalytic activity for ethylene conversion while keeping the preparation process practical
3Ease of operation
If palladium is added early in the slurry formation, then the catalyst preparation is simpler, but palladium becomes encapsulated and less accessible to reactants
Solution Approach 1:
The patent prepares the metal oxide slurry and allows it to form the catalyst support structure first, then adds the palladium solution in a subsequent step. This sequential approach ensures that palladium is deposited on the surface of the formed catalyst rather than being trapped inside, making it highly accessible to reactants
Solution Approach 2:
The patent divides the catalyst preparation into distinct stages: slurry formation with metal oxides, followed by separate palladium impregnation, then drying and calcination. This segmentation ensures that each component is properly positioned and prevents encapsulation of palladium, maximizing its accessibility while maintaining a systematic preparation process
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 significantly improves the conversion rate of ethylene to acetic acid, addressing the inefficiencies of conventional methods and increasing the production rate of acetic acid.
Implementation Method 1
the catalyst has at least 50 ppm of Pd distributed on the surface thereof. This can be beneficial for at least improving the conversion rate of ethylene to acetic acid after ethane is first oxidized to ethylene
Implementation Method 2
combining each of a molybdenum, vanadium, and niobium metal or metal-containing compound in water to form a slurry
Implementation Method 3
the slurry is agitated for a period of at least 15 minutes
Implementation Method 4
palladium or a palladium-containing compound, preferably a solution comprising a palladium-containing compound is added to the slurry. Successive addition of palladium provides most of the palladium on the surface of precipitated material
Implementation Method 5
collecting, drying, and calcining the slurry to obtain an active catalyst
Implementation Method 6
collecting, drying, and calcining the slurry to obtain an active catalyst
Implementation Method 7
Gas phase oxidation of C2 hydrocarbon is another process for acetic acid production. In this process, ethane is directly oxidized to form ethylene and then acetic acid
Data Source
AI summary
Methods of producing a catalyst for oxidation of C2 hydrocarbons and methods of using the catalyst are disclosed. Molybdenum, vanadium, and niobium metal or metal containing compounds are used to form a slurry in water. After agitating the slurry for at least 15 minutes, palladium or a palladium containing compound is added to the slurry. After further agitation, a precipitate is collected, dried and calcined to obtain an active catalyst, with palladium primarily distributed on a surface of the catalyst. The active catalyst is capable of catalyzing the conversion of C2 hydrocarbons into acetic acid.