Molybdenum-Bismuth-Cobalt Catalyst Crystallinity Control
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Solution Overview
Problem
Current catalysts for producing acrolein and acrylic acid from propylene by gas-phase catalytic oxidation with molecular oxygen suffer from unsatisfactory yield, catalytic life, and performance deterioration over time, particularly in industrial-scale operations.
Innovation Solution
A catalyst with a catalytic active component comprising molybdenum, bismuth, and cobalt, prepared by adding an aqueous solution containing cobalt and bismuth to a molybdenum solution within 30 seconds to 10 minutes, with specific crystallinity ranges measured by X-ray diffraction analysis, enhancing catalytic activity, selectivity, and catalyst life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional molybdenum-bismuth-containing catalysts are used to improve acrolein yield, then catalytic activity increases, but catalyst life deteriorates due to rapid performance degradation
Solution Approach 1:
The patent changes the crystallinity parameter of the catalytic active component from conventional high crystallinity to specifically 4% or more and 18% or less, which fundamentally alters the catalyst's performance characteristics to achieve both high productivity and long catalyst life
Solution Approach 2:
The patent creates a composite catalyst system containing molybdenum, bismuth, and cobalt in specific ratios, where the synergistic interaction between these metals produces a catalyst that simultaneously achieves high acrolein yield and extended operational life
2Speed
If catalyst crystallinity is increased to improve catalytic activity, then reaction rate increases, but selectivity deteriorates leading to lower acrolein yield
Solution Approach 1:
The patent optimizes the crystallinity parameter to a specific range (4-18%) that balances reaction rate and selectivity, avoiding both too-low crystallinity which gives poor activity and too-high crystallinity which reduces selectivity
3Productivity
If catalyst loading is increased to maintain high yield, then productivity increases, but performance deterioration accelerates reducing catalyst life
Solution Approach 1:
The patent changes the fundamental parameter of crystallinity to create a more stable catalyst structure that resists deactivation, allowing the catalyst to maintain high productivity over extended operational periods without premature performance loss
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 provides stable high yields of acrolein and acrylic acid over a long period, maintaining performance without significant deterioration, even under continuous operation.
Implementation Method 1
catalyst for producing acrolein and/or acrylic acid from propylene by gas-phase catalytic oxidation with molecular oxygen
Implementation Method 2
gas-phase catalytic oxidation of propylene with molecular oxygen
Implementation Method 3
the catalytic active component contains a crystalline part showing a peak at 2θ = 26.5 ± 0.5°, measured by an X-ray diffraction analysis with Cu-Kα radiation
Data Source
AI summary
A catalyst for producing acrolein and/or acrylic acid from propylene by gas-phase catalytic oxidation with molecular oxygen-containing gas, comprising a catalytic active component containing molybdenum, bismuth and cobalt as essential elements, and having a crystallinity T of 4% or more and 18% or less in the 2θ range of 5° to 90°, measured by an X-ray diffraction analysis with Cu-Kα radiation; and a process for producing acrolein and/or acrylic acid by gas-phase catalytic oxidation of propylene with molecular oxygen, comprising the step of conducting the gas-phase catalytic oxidation in the presence of the catalyst. According to the catalyst and the process for producing acrolein and/or acrylic acid of the present invention, it is possible to stably produce acrolein and/or acrylic acid at a high yield for a long period.