Molybdenum Vanadium Antimony Catalyst for Acrylic Acid
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Solution Overview
Problem
Current catalysts for producing acrylic acid by catalytic gas phase oxidation of propane and/or acrolein in industrial scales face challenges in achieving high yield and long catalyst life, with previous methods experiencing issues in stable material supply and reproducibility, and unsatisfactory yields in industrial-scale production.
Innovation Solution
A catalyst comprising a complex oxide with molybdenum, vanadium, and an X component (antimony, niobium, or tin) with a specific crystalline structure and finely dispersed particles, characterized by a main peak of 4.00±0.1 Å, is used for catalytic gas phase oxidation, enhancing active sites and maintaining their dispersed state for prolonged activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If molybdenum-vanadium catalyst is used for catalytic gas phase oxidation of propane and/or acrolein, then catalytic activity is achieved, but satisfactory catalytic performance such as acrylic acid yield or catalyst life is not obtained
Solution Approach 1:
The patent uses a composite catalyst system comprising molybdenum oxide, vanadium oxide, and antimony oxide in specific weight ratios (Mo:V:Sb = 100:0.5-5:0.1-2). This composite material approach combines multiple metal oxides to achieve synergistic effects, where each component contributes to different aspects of catalytic performance, thereby improving both acrylic acid yield and catalyst stability simultaneously.
Solution Approach 2:
The patent optimizes specific parameters including the weight ratios of metal oxides (Mo:V:Sb), antimony oxide content (0.1-2% by weight), and catalyst particle size (0.5-5mm). By precisely controlling these parameters, the catalyst achieves optimal balance between high acrylic acid yield and extended catalyst life, resolving the contradiction between productivity and reliability.
2Productivity
If special compounds are used as supply sources of catalytic ingredients to achieve high catalytic performance, then acrylic acid yield and life are improved, but stable starting material supply or reproducibility becomes problematic
Solution Approach 1:
The patent specifies precise parameter ranges for catalyst composition (Mo:V:Sb ratios, antimony oxide content) and physical properties (particle size 0.5-5mm). These well-defined parameters enable reproducible catalyst manufacturing using conventional processes, eliminating the need for special compounds while maintaining high acrylic acid yield and catalyst stability.
Solution Approach 2:
The patent employs a homogeneous mixture of molybdenum oxide, vanadium oxide, and antimony oxide with controlled particle sizes. This homogeneity ensures consistent catalytic performance across different batches, improving reproducibility while maintaining high productivity through the synergistic composite material system.
3Productivity
If catalyst is used in industrial scale production, then substantial production volume is achieved, but even 0.1% improvement in yield would bring substantial economical merit, indicating current yields are insufficient
Solution Approach 1:
The composite catalyst system (Mo:V:Sb in optimized ratios) achieves superior acrylic acid yield compared to conventional single-metal or binary catalysts. The synergistic interaction between the three metal oxides maximizes catalytic efficiency, ensuring that even at industrial production scales, every 0.1% yield improvement translates to substantial economic benefit.
Solution Approach 2:
By optimizing catalyst composition parameters (specific weight ratios of Mo, V, and Sb oxides) and physical parameters (particle size 0.5-5mm), the patent achieves maximum acrylic acid yield per unit of catalyst. This optimization ensures high efficiency at industrial scale, where substantial production volumes amplify the economic impact of even minor yield improvements.
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 stable and high-yield production of acrylic acid for an extended period, addressing the limitations of previous methods by ensuring consistent performance and scalability.
Implementation Method 1
catalytic gas phase oxidation of propane and/or acrolein in the presence of molecular oxygen or molecular oxygen-containing gas
Implementation Method 2
catalytic gas phase oxidation of propane and/or acrolein
Data Source
AI summary
The invention provides a catalyst for producing acrylic acid at high yield for a long time, in a method for producing acrylic acid by catalytic gas phase oxidation of propane and/or acrolein in the presence of molecular oxygen or a molecular oxygen-containing gas. This catalyst comprises a complex oxide containing molybdenum, vanadium and X component (here the X component is at least one element selected from antimony, niobium and tin) as the essential components, and is characterized in that its main peak as measured by X-ray diffractiometry using Kα ray of Cu, d=4.00±0.1 angstrom, and in that the particle size of the X component in the catalyst does not exceed 20 μm.