Oxide Catalyst Production via W-Containing Solid Calcination
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Solution Overview
Problem
Existing processes for producing unsaturated carboxylic acids or nitriles from propane or isobutane using oxide catalysts are complex and lack industrial scalability, with issues related to selectivity and yield due to the need for impregnation and post-treatment steps, and the addition of metal compounds which can be detrimental if not optimized.
Innovation Solution
A process involving the calcination of a raw material mixture containing Mo, V, Nb, and optional elements like Sb, Te, and W, with specific atomic ratios and distribution of W within the catalyst particles, to produce an oxide catalyst suitable for gas-phase catalytic oxidation or ammoxidation reactions, enhancing yield and scalability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If impregnation with metal oxide solution is used to produce oxide catalyst, then catalyst activity can be improved, but production steps become complex and industrial scalability is reduced
Solution Approach 1:
The invention extracts and eliminates the impregnation step from the catalyst production process. Instead of impregnating the catalyst support with metal oxide solution followed by drying and calcination, the patent directly forms the active oxide species on the support surface through a simplified thermal treatment process, removing unnecessary production steps while maintaining catalyst activity
Solution Approach 2:
The invention performs preliminary action by pre-mixing the metal compound and support material in specific atomic ratios before thermal treatment. This pre-mixing ensures uniform distribution of metal species on the support surface, eliminating the need for subsequent impregnation steps while achieving the desired catalyst activity and composition
2Reliability
If additives are added to catalyst to improve selectivity and yield, then product selectivity can be enhanced, but excessive or insufficient addition reduces selectivity and yield
Solution Approach 1:
The invention changes the critical parameter of additive concentration by defining specific atomic ratio ranges for W/Mo (0.001-0.3) and precise W content (0.1-5.0 wt%). This parameter optimization ensures maximum product selectivity and yield while avoiding the detrimental effects of excessive or insufficient additive addition. The patent establishes precise compositional parameters that balance catalytic performance with manufacturing feasibility
Solution Approach 2:
The invention applies local quality by distributing W compounds specifically on the catalyst surface rather than uniformly throughout the bulk material. This surface-localized distribution is achieved through the specific preparation method where W compounds are mixed with the support and calcined, creating a composition gradient that enhances selectivity while using minimal amounts of expensive additives
3Reliability
If multiple post-treatment steps are applied to calcined catalyst, then catalyst performance can be improved, but production complexity and time increase
Solution Approach 1:
The invention merges multiple post-treatment steps into a single integrated thermal treatment process. Instead of separate impregnation, drying, and calcination steps, the patent combines these operations by directly heating the pre-mixed catalyst composition to achieve both activation and surface modification in one continuous process, significantly reducing production time while maintaining or improving catalyst performance
Solution Approach 2:
The thermal treatment step in the invention serves multiple functions simultaneously: it activates the catalyst by forming active oxide species, distributes metal compounds uniformly on the support surface, and creates the desired surface chemistry for high selectivity. This multi-functional approach eliminates the need for separate post-treatment steps, reducing both time and complexity
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 process results in an oxide catalyst that enables high-yield production of unsaturated acids or nitriles, suitable for large-scale industrial applications with improved selectivity and reduced complexity, by optimizing the distribution and concentration of W within the catalyst particles.
Implementation Method 1
calcining the dry powder, wherein the calcining step (III) comprises (b-1) the step of calcining the dry powder in the presence of a W-containing compound solid
Implementation Method 2
a process for producing an oxide catalyst for use in the gas-phase catalytic oxidation reaction or the gas-phase ammoxidation reaction
Implementation Method 3
a process for producing an oxide catalyst for use in the gas-phase catalytic oxidation reaction or the gas-phase ammoxidation reaction of propane or isobutane
Data Source
Figure 1
AI summary
Disclosed is a process for producing an oxide catalyst for use in the gas-phase catalytic oxidation reaction or the like of propane or the like , the process comprising the steps of: (I) obtaining a preparation containing compounds of Mo, V, Nb, and Sb or Te at the predetermined atomic ratios; (II) drying the preparation to obtain a dry powder; and (III) calcining the dry powder, wherein the step (III) comprises the step of calcining the dry powder in the presence of a compound containing W in the form of a solid to obtain a pre-stage calcined powder or a mainly calcined powder, or the step of calcining the dry powder and calcining the obtained pre-stage calcined powder in the presence of the solid to obtain a mainly calcined powder, the solid satisfies the predetermined conditions, and the oxide catalyst comprises a catalytic component having the predetermined composition.