Gas-Phase Oxidation Catalyst Solid Acid Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional gas-phase oxidation catalysts using inactive supports have insufficient yield and short catalytic activity, leading to increased production costs due to complex and expensive processes for preparing solid superacids.
Innovation Solution
A gas-phase oxidation catalyst with a support having a solid acid of specific acid strength (-5.6 ≤ H0 ≤ 1.5) is used, where the acid strength is easily controlled by adjusting the calcination temperature, and a complex oxide containing molybdenum and vanadium is supported on this acid, improving catalytic performance and simplifying catalyst preparation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional gas-phase oxidation catalysts using inactive supports are used, then the catalyst structure is simple, but the yield of final product is insufficient and catalytic activity decreases quickly
Solution Approach 1:
The invention changes the key parameter of the support from inactive to active solid acid with specific acid strength (H0 ≤ -11.93), which fundamentally improves both the yield and catalyst life. This parameter change transforms the support's chemical properties to actively participate in and enhance the catalytic oxidation process.
Solution Approach 2:
The invention creates a composite catalyst system combining solid acid support with complex oxide active components (molybdenum and vanadium). This composite structure synergistically combines the acid-catalyzed dehydration function of the solid acid support with the oxidation function of the complex oxide, achieving high yield and extended catalyst life.
2Reliability
If solid superacid is included to improve activity and stability, then catalytic performance is enhanced, but the process for preparing the solid superacid becomes complicated and production cost increases
Solution Approach 1:
The invention replaces expensive and complex solid superacids with a simpler, more economical solid acid support that can be readily prepared through conventional calcination processes. This substitution maintains catalyst stability while significantly reducing preparation complexity and cost.
Solution Approach 2:
The invention specifies a practical acid strength range (H0 ≤ -11.93) that achieves effective catalysis without requiring the extreme conditions or complex synthesis procedures needed for solid superacids. This parameter optimization balances performance with manufacturability.
3Productivity
If solid superacid is used to improve catalytic activity, then the yield improves, but the production cost of catalyst inevitably increases
Solution Approach 1:
The invention substitutes costly solid superacids with inexpensive solid acid supports that can be prepared through simple calcination of conventional materials. This replacement maintains high acrylic acid yield while dramatically reducing catalyst production cost.
Solution Approach 2:
The solid acid support serves multiple functions: it provides the necessary acid catalysis for dehydration, supports the active complex oxide components, and maintains structural stability. This multi-functionality eliminates the need for additional expensive additives or complex preparation steps.
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
This approach enhances the yield and stability of the catalyst, allowing for high-yield production of acrylic acid while reducing production costs by simplifying the catalyst preparation process and maintaining high conversion rates of starting materials.
Implementation Method 1
gas-phase catalytic oxidation of acrolein with molecular oxygen
Implementation Method 2
gas-phase catalytic oxidation of acrolein with molecular oxygen
Implementation Method 3
the acid strength can be varied by modifying the temperature of the heat treatment
Data Source
AI summary
A support for a gas-phase oxidation catalyst, the support including a solid acid, of which acid strength (H0) meets an inequality: -5.6 ≤ H0 ≤ 1.5; a gas-phase oxidation catalyst including the above support and a complex oxide containing molybdenum and vanadium as essential components, the complex oxide being supported on the support; a process for producing acrylic acid by gas-phase catalytic oxidation of acrolein with molecular oxygen, the process including carrying out the gas-phase catalytic oxidation in a presence of the above gas-phase oxidation catalyst; and a process for producing the above support, the process including controlling an acid strength (H0) of a solid acid so as to meet an inequality: -5.6 ≤ H0 ≤ 1.5 by adjusting a calcination temperature in a preparation of the solid acid contained in the support.