Liquid Phase Catalysis for Unsaturated Carboxylic Acids
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Solution Overview
Problem
Existing methods for producing α,β ethylenically unsaturated carboxylic acids or esters, such as methacrylic acid and methyl methacrylate, require high temperatures, leading to increased costs and the formation of unwanted by-products due to the use of heterogeneous systems.
Innovation Solution
A liquid phase reaction process using a basic metal salt, preferably caesium or rubidium carbonate, is employed to catalyze the reaction between formaldehyde and a non-cyclic carboxylic acid ester, maintaining temperatures below 300°C and minimizing by-product formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If high temperatures are used in heterogeneous catalytic systems, then reaction rate is improved, but by-product formation increases and production costs increase
Solution Approach 1:
The invention changes the temperature parameter from high (350-408°C in prior art) to moderate (100-250°C), and changes the catalyst phase from heterogeneous to homogeneous (metal salts dissolved in reaction medium), achieving both high reaction rates and high selectivity without by-product formation
Solution Approach 2:
The invention introduces metal salts (caesium, rubidium, potassium, or barium salts of carboxylic acids, phosphoric acid, or sulfuric acid) as intermediary catalysts that enable the reaction to proceed at lower temperatures with high selectivity, replacing the high-temperature heterogeneous catalytic system
2Speed
If high temperatures are used in heterogeneous catalytic systems, then reaction rate is improved, but production costs increase
Solution Approach 1:
The invention changes the temperature parameter from high (350-408°C in prior art) to moderate (100-250°C), reducing energy consumption and production costs while maintaining high reaction rates through homogeneous catalysis with metal salts
Solution Approach 2:
The invention uses simple, inexpensive metal salts (caesium, rubidium, potassium, or barium salts) as catalysts that can be easily handled and dissolved, replacing expensive high-temperature heterogeneous catalytic systems and associated equipment
3Productivity
If heterogeneous catalytic systems are used, then reaction efficiency is improved, but selectivity decreases due to by-product formation
Solution Approach 1:
The invention introduces metal salts (caesium, rubidium, potassium, or barium salts of carboxylic acids, phosphoric acid, or sulfuric acid) as intermediary catalysts that enable the reaction to proceed at lower temperatures with high selectivity, replacing the high-temperature heterogeneous catalytic system
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 process significantly improves yield and selectivity while reducing the production of unwanted side products, allowing for efficient production of methacrylic acid and methyl methacrylate at lower temperatures with high selectivity.
Implementation Method 1
by the liquid phase reaction of formaldehyde or a suitable source thereof with a non-cyclic carboxylic acid ester in the presence of a basic metal salt
Data Source
AI summary
The present invention relates to a process for the production of an ethylenically unsaturated carboxylic acid or ester, preferably α,ß ethylenically unsaturated carboxylic acids or esters, by the liquid phase reaction of formaldehyde or a suitable source thereof with a non-cyclic carboxylic acid ester in the presence of a basic metal salt.