Inclined Ring Catalyst for Low Pressure Loss Oxidation
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Solution Overview
Problem
Catalysts used for gas-phase catalytic oxidation of unsaturated aldehydes like acrolein suffer from high pressure loss, low conversion rates, and reduced selectivity of unsaturated carboxylic acid production, leading to coking issues and reduced yield due to non-uniform reactor loading and small catalyst surface area.
Innovation Solution
A ring-shaped or columnar catalyst with the outer peripheral edge part inclined relative to the center line is used, enhancing the catalyst's surface area and reaction efficiency, reducing pressure loss, and allowing for high selectivity and conversion rates of unsaturated aldehydes to unsaturated carboxylic acids, with the option to regenerate coked catalysts using an oxygen-containing gas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a ring-shaped catalyst or hollow cylindrical catalyst with curved end face is used, then the catalyst can be loaded in a reactor, but the pressure loss is high and the gas amount decreases
Solution Approach 1:
The catalyst employs an asymmetric shape where the outer peripheral edge part is inclined relative to the center line, creating a non-symmetric geometry that optimizes gas flow patterns while maintaining structural integrity for reactor loading
Solution Approach 2:
The invention introduces a specific geometric dimension by inclining the outer peripheral edge part at a defined angle relative to the center line, adding a dimensional parameter that simultaneously addresses loading ease and pressure loss reduction
2Device complexity
If a ring-shaped catalyst is used, then the catalyst structure is simple, but the catalyst surface area is small and conversion rate is low
Solution Approach 1:
The catalyst applies local quality by creating an inclined outer peripheral edge part with different geometric properties from the central axis region, where the inclined surface provides enhanced reaction characteristics while the overall structure remains relatively simple
Solution Approach 2:
The invention changes the geometric parameter of the catalyst shape by inclining the outer peripheral edge part at a specific angle, which modifies the surface area to volume ratio and enhances the conversion rate without significantly complicating the overall structure
3Loss of energy
If the pressure loss is high, then the gas amount decreases, but coking increases and selectivity decreases
Solution Approach 1:
The inclined outer peripheral edge part design preliminarily counteracts the harmful effect of high pressure loss by creating optimized gas flow patterns that prevent coking formation and maintain high selectivity before the reaction proceeds
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 inclined catalyst design reduces pressure loss, suppresses coking, and maintains high conversion rates and selectivity for unsaturated carboxylic acid production, even in coked states, compared to conventional shapes, ensuring efficient and effective gas-phase catalytic oxidation.
Implementation Method 1
causing gas-phase catalytic oxidation of an unsaturated aldehyde such as acrolein and an oxygen-containing gas to produce a corresponding unsaturated carboxylic acid
Data Source
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AI summary
An object of the present invention is to provide a catalyst ensuring that in the case of causing gas-phase catalytic oxidation of an unsaturated aldehyde and an oxygen-containing gas with use of the catalyst to produce a corresponding unsaturated carboxylic acid, the pressure loss can be kept low and an unsaturated carboxylic acid can be produced with high selectivity. The present invention relates to a ring-shaped or columnar catalyst, which is used at the time of producing a corresponding unsaturated carboxylic acid by causing gas-phase catalytic oxidation of an unsaturated aldehyde and an oxygen-containing gas, wherein the outer peripheral edge part is inclined relative to the center line.