Geometric Catalyst Bodies for Propene Oxidation
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Solution Overview
Problem
Geometric shaped catalyst bodies for heterogeneously catalyzed partial gas-phase oxidation of propene to acrolein and isobutene face challenges in maintaining high initial activity and selectivity over long periods without reducing long-term stability, particularly due to the exclusion of bismuth in prior art catalysts.
Innovation Solution
A process for producing geometric shaped catalyst bodies with a multi-element oxide composition that includes tungsten, nickel, cobalt, alkali metals, and other elements, specifically incorporating bismuth, to enhance initial selectivity and activity while maintaining long-term stability, through a controlled stoichiometric and particle size optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bismuth is excluded from the catalyst composition, then the catalyst structure is simpler and manufacturing is easier, but the initial selectivity and activity are reduced
Solution Approach 1:
The patent applies parameter changes by systematically varying the stoichiometric coefficients (a, b, c, d, e, f, g, h, i, p) of multiple elements including bismuth in the multi-element oxide formula. By optimizing these parameters within specific ranges, the catalyst achieves enhanced initial selectivity and activity while maintaining structural complexity at acceptable levels.
Solution Approach 2:
The patent employs composite materials by creating a multi-element oxide catalyst containing bismuth combined with tungsten, nickel, cobalt, and other metals in specific proportions. This composite approach allows the catalyst to leverage the synergistic effects of different elements to achieve high initial selectivity and activity that cannot be obtained with single-element catalysts.
2Productivity
If bismuth is included in the catalyst composition, then the initial selectivity and activity are enhanced, but the manufacturing complexity increases
Solution Approach 1:
The patent manages manufacturing complexity by establishing specific parameter ranges for the multi-element oxide composition. By defining acceptable ranges for stoichiometric coefficients and particle size parameters, the patent provides guidance for standardized manufacturing processes that can produce the complex catalyst systematically rather than requiring ad-hoc adjustments.
Solution Approach 2:
The patent applies preliminary action by pre-defining the optimal composition ranges and particle size parameters before manufacturing. This allows the complex multi-element oxide to be produced through controlled processes where the composition is established in advance, reducing the complexity of manufacturing by providing clear specifications rather than requiring complex real-time adjustments.
3Productivity
If the catalyst operates at higher temperatures, then the reaction rate increases, but the catalyst life and stability are reduced
Solution Approach 1:
The patent applies parameter changes by optimizing the composition parameters (stoichiometric coefficients and particle size) to enable the catalyst to operate effectively at lower temperatures. The specific multi-element oxide formulation with bismuth and other metals allows the catalyst to maintain high reaction rates at reduced temperatures, thereby extending catalyst life and improving stability while maintaining productivity.
4Productivity
If the particle diameter is reduced, then the surface area increases and activity improves, but the manufacturing precision requirements increase
Solution Approach 1:
The patent manages manufacturing precision by defining specific ranges for particle diameter parameters (d50A1, d90A2) and stoichiometric coefficients. By establishing acceptable ranges rather than requiring single precise values, the patent enables the production of fine particles with high surface area and activity while maintaining manufacturability through standardized processes that can consistently achieve the specified ranges.
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 optimized catalyst bodies exhibit increased initial activity and selectivity for propene to acrolein and isobutene conversion, with improved long-term stability and reduced operating temperatures, effectively prolonging catalyst life and efficiency.
Implementation Method 1
catalysts KS (geometric shaped catalyst bodies KS) are suitable for carrying out heterogeneously catalyzed partial oxidations of alkanes, alkanols, alkenes and/or alkenals having 3 to 6 carbon atoms in the gas phase
Implementation Method 2
complete oxidation of an organic compound with molecular oxygen is understood in this document to mean that the organic compound is reacted under the reactive action of molecular oxygen in such a way that the carbon contained in the organic compound as a whole is converted into oxides of carbon and in the organic compound as a whole contained hydrogen is converted into oxides of hydrogen
Implementation Method 3
the shaped bodies V are thermally treated at elevated temperature to obtain the geometric shaped catalyst bodies KS
Data Source
AI summary
The invention relates to a method for producing geometric catalyst moulded bodies (K), the active mass thereof being a multi-element oxide in the stoichiometry [BiaZ1 bOx]p[BicMo12FedZ2 eZ3 fZ4 gZ5 hZ6 iOy]1. Said method consists of forming a fine particle oxide BiaZ1 bOx and, from element sources, a fine particle mixture in the stoichiometry BicMo12FedZ2 eZ3 fZ4 gZ5 hZ6 i and said mixture is mixed according to the ratio p:1, forming moulded bodies with the mixture when are then thermally treated and 0< c ≤ 0,8.