Fixed-Bed Oxidative Esterification Reactor for Low Byproduct Formation
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Solution Overview
Problem
Existing oxidative esterification processes for producing methyl methacrylate face challenges such as catalyst attrition in slurry reactors, reduced space-time yield with fixed bed reactors, and difficulty in separating byproducts like methyl isobutyrate, which is difficult to remove due to its similarity to the desired product.
Innovation Solution
A process using a reactor system with a noble metal-containing catalyst, operating at high methanol concentrations and controlled conditions to minimize byproduct formation, particularly methyl isobutyrate, by employing a catalyst with specific noble metal and titanium-containing particles in a fixed bed configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If slurry catalysts with particle size less than 200 μm are used, then catalyst activity is improved, but catalyst attrition increases and filtration becomes difficult
Solution Approach 1:
The patent changes the particle size parameter from less than 200 μm (slurry catalysts) to 200-710 μm (fixed bed catalysts), resolving the contradiction by finding an optimal size range that maintains activity while reducing attrition and filtration issues
2Reliability
If larger catalyst particles (200-710 μm) are used in fixed bed reactors, then catalyst attrition is reduced and filtration is easier, but space-time yield decreases
Solution Approach 1:
The patent optimizes the particle size parameter to the range of 200-710 μm, which is larger than conventional slurry catalysts but carefully controlled to avoid excessive mass transfer limitations, thereby achieving both reduced attrition and maintained space-time yield
3Productivity
If methanol is provided in excess to maximize methacrolein conversion, then conversion efficiency is improved, but separation of product from recycle stream becomes more difficult
Solution Approach 1:
The patent optimizes the methanol to methacrolein molar ratio parameter to fall within 2:1 to 10:1, balancing conversion efficiency with separation feasibility. This controlled excess of methanol maintains high conversion while managing the complexity of downstream separation processes
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 process enhances selectivity and reduces byproduct formation, achieving high methanol concentrations in the product stream while maintaining low levels of methyl isobutyrate, thereby improving the efficiency and purity of methyl methacrylate production.
Implementation Method 1
conversion of methacrolein and methanol in the presence of oxygen to methyl methacrylate using a heterogeneous catalyst
Implementation Method 2
oxidative esterification of methacrolein and methanol using a heterogeneous catalyst
Data Source
AI summary
A process for the production of methyl methacrylate via the oxidative esterification in a reactor system comprises introducing a reaction mixture comprising methacrolein, methanol, and an oxygen-containing gas to the reactor system comprising a noble metal-containing catalyst. A methanol concentration of the reaction mixture entering the reactor is greater than 32 wt % based on the total weight of methanol and methacrolein entering the reactor system. The methanol concentration in the product stream exiting the reactor system is at least 65 wt % based on the total weight of the methanol and methacrolein exiting the reactor system. The product stream exiting the reactor system comprises greater than 0.1 ppm and less than 5000 ppm methyl isobutyrate.