Gold-Titanium Catalyst for Methyl Methacrylate Longevity
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Solution Overview
Problem
Existing catalysts for producing methyl methacrylate from methacrolein and methanol have limited lifespan and reduced activity over time, necessitating the development of a more effective and long-lasting catalyst.
Innovation Solution
A catalyst comprising gold particles with an average diameter of less than 15 nm and a standard deviation of +/-5 nm, dispersed within at least 15 nm of titanium-containing particles, is used in the presence of oxygen to enhance the production of methyl methacrylate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing heterogeneous catalysts are used for producing methyl methacrylate, then the catalytic activity is initially sufficient, but the catalyst lifespan is limited and activity decreases over time
Solution Approach 1:
The patent changes the physical parameters of the gold particles (size reduction to <15 nm with specific standard deviation) and their spatial distribution relative to titanium particles (within 15 nm distance). This parameter optimization maintains high catalytic activity while significantly extending catalyst lifespan from limited hours to over 2000 hours with minimal deactivation
Solution Approach 2:
The patent creates a composite catalyst system combining gold particles and titanium-containing particles in a specific spatial arrangement. This composite structure synergistically combines the catalytic activity of gold with the stability and support properties of titanium, resolving the contradiction between initial activity and long-term reliability
2Productivity
If gold particle size is reduced to enhance activity, then catalytic performance improves initially, but particle stability and longevity may be compromised
Solution Approach 1:
The patent optimizes the gold particle size parameter to be less than 15 nm with a standard deviation of +/- 5 nm. This specific parameter range provides sufficient surface area for high catalytic activity while maintaining adequate structural stability for long-term operation
Solution Approach 2:
The titanium-containing particles act as intermediaries or supports for the small gold particles. The titanium particles provide a stable framework that anchors the small, highly active gold particles, preventing their aggregation and degradation over time, thus maintaining both high activity and long stability
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 exhibits improved longevity and activity, maintaining effectiveness even after extended use, as demonstrated by minimal deactivation over 2000 hours in a pilot plant trial and 15 months of laboratory aging.
Implementation Method 1
a catalyst comprising gold particles and titanium-containing particles, wherein the catalyst comprises gold particles that are within at least 15 nm of at least one titanium-containing particle
Implementation Method 2
the catalyst comprises gold particles that are within at least 15 nm of at least one titanium-containing particle
Data Source
AI summary
A catalyst comprises gold particles and titanium-containing particles. The catalyst comprises gold particles that are within at least 15 nm of at least one titanium-containing particle. The gold particles have an average diameter of less than 15 nm and a standard deviation of +/â5 nm. A method for preparing methyl methacrylate from methacrolein and methanol using the catalyst is also disclosed.