Metal Oxide Coated Ceramic Corrugated Plate Catalyst for Citral Intermediates
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Solution Overview
Problem
Current methods for producing citral intermediates, prenol and prenal, face challenges such as low conversion rates, difficult side reaction control, high catalyst costs, and energy-intensive processes, with existing catalysts being difficult to recycle and apply, and raw material limitations.
Innovation Solution
A metal oxide coated ceramic corrugated plate catalyst is developed, comprising a ceramic corrugated plate with a metal oxide active layer formed by titanium and other metals like vanadium, chromium, manganese, iron, zirconium, niobium, and molybdenum, which is prepared through a method involving salt dissolution in titanium sol, spray drying, and high-temperature calcination, enabling stable and efficient catalytic activity for citral intermediate synthesis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing catalysts are used for preparing prenol and prenal, then the catalytic activity is achieved, but the catalyst price is high and recycling is difficult
Solution Approach 1:
The patent uses ceramic corrugated plates with porous structures as catalyst carriers. The porous ceramic material provides high surface area for catalyst deposition while maintaining mechanical strength and thermal stability. This allows for efficient catalytic activity with improved recyclability compared to traditional catalyst systems
Solution Approach 2:
The patent employs composite catalyst systems where metal oxides (such as vanadium, tungsten, molybdenum, or titanium oxides) are deposited on ceramic corrugated plate carriers. This composite structure combines the advantages of ceramic materials (thermal stability, mechanical strength) with metal oxide catalytic activity, achieving both high catalytic performance and ease of recycling
2Quantity of substance
If multi-step reaction route using acetone as raw material is used, then prenol and prenal can be obtained, but the conversion rate is low and side reactions are difficult to control
Solution Approach 1:
The patent optimizes reaction parameters including temperature (80-150°C), pressure, and catalyst composition to improve conversion rates. By carefully controlling these parameters and using the ceramic corrugated plate catalyst system, the process achieves higher conversion rates while maintaining product selectivity and minimizing side reactions
3Quantity of substance
If conventional production methods are used, then citral intermediates can be produced, but energy consumption is high
Solution Approach 1:
The patent implements continuous catalytic reactions using fixed-bed reactors packed with ceramic corrugated plate catalysts. This continuous operation mode eliminates the need for repeated heating and cooling cycles, maintaining steady-state reaction conditions and significantly reducing energy consumption compared to batch processes
4Productivity
If catalyst dosage is increased to improve conversion, then product yield increases, but the complexity of the system and cost increase
Solution Approach 1:
The ceramic corrugated plates serve multiple functions simultaneously: they act as structural support, provide porous surface area for catalyst deposition, facilitate heat transfer, and enable continuous flow reactions. This multi-functionality reduces the need for additional components and simplifies the overall system while maintaining high productivity
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 achieves high purity and yield of prenol and prenal with improved raw material conversion rates and catalyst selectivity, integrating catalysis and separation functions for continuous rectification reactions, addressing the limitations of previous methods.
Implementation Method 1
a metal oxide coated ceramic corrugated plate catalyst, consisting of a ceramic corrugated plate carrier and a metal oxide active layer coated on a surface of the carrier... enabling stable and efficient catalytic activity for citral intermediate synthesis
Implementation Method 2
integrating catalysis and separation functions for continuous rectification reactions
Data Source
AI summary
The present disclosure belongs to the technical field of catalysis, and particularly relates to a metal oxide coated ceramic corrugated plate catalyst, its preparation method and application thereof in preparation of key intermediates of citral. The catalyst consists of a ceramic corrugated plate carrier and a metal oxide active layer coated on a surface of the carrier, wherein the metal oxide active layer is a metal oxide formed by active ingredient titanium and at least four other metal elements selected from vanadium, chromium, manganese, iron, zirconium, niobium and molybdenum.