Selective Propanal Elimination in Acrolein Streams via Mo Catalyst
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Solution Overview
Problem
The production of acrolein and acrylic acid from glycerol results in high levels of propanal impurities, which are difficult to separate and lead to costly purification steps and reduced product quality, limiting the applications of these chemicals due to their toxic and corrosive properties.
Innovation Solution
A process involving a catalyst comprising at least molybdenum and additional elements such as P, Si, W, Ti, Zr, V, Nb, Ta, Cr, Mn, Fe, Co, Ni, Cu, Zn, Ga, In, Sn, Ag, As, Ge, B, Bi, La, Ba, Sb, Te, Ce, Pb is used to selectively eliminate propanal from acrolein-rich streams, converting it more than acrolein and preventing its conversion to propionic acid, thereby reducing propanal content to less than 5000 ppm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional oxidation of propylene or dehydration of glycerol is used to produce acrolein, then acrolein and acrylic acid can be manufactured, but high levels of propanal impurities are formed which are difficult to separate and reduce product quality
Solution Approach 1:
The invention changes the chemical parameters by introducing a selective oxidation step using oxygen in the presence of a catalyst (mixed oxides containing Mo, V, Bi, Fe, and promoters) that specifically oxidizes propanal to acrolein. This parameter change transforms the impurity removal approach from physical separation to chemical conversion, achieving propanal elimination while maintaining acrolein production
Solution Approach 2:
The invention converts the harmful propanal impurity into a beneficial product (additional acrolein) by using selective oxidation. Instead of merely removing propanal through difficult separation processes, the process exploits the propanal presence as a feedstock for additional acrolein production, turning a quality problem into a productivity advantage
2Productivity
If propanal is present in acrolein streams, then the acrolein can be produced, but costly purification steps are required and application range is limited due to toxic and corrosive properties
Solution Approach 1:
The invention eliminates the need for costly purification steps by converting propanal to acrolein in situ. The harmful impurity is transformed into a valuable product through catalytic oxidation, eliminating separation costs and expanding application range to processes sensitive to propanal contamination
Solution Approach 2:
The invention changes the process parameters by adding a selective oxidation step that operates under conditions favoring propanal conversion while minimizing acrolein degradation. This parameter optimization achieves both impurity removal and product enhancement without requiring additional purification equipment or operations
3Manufacturing precision
If selective oxidation of propanal is implemented, then propanal content is reduced and product quality enhanced, but additional catalyst and process steps are required
Solution Approach 1:
The invention merges the propanal removal function with the existing acrolein production process by implementing selective oxidation in the same reactor system. The catalyst bed is integrated into the flow path, combining impurity conversion with main product generation in a single operational unit, thereby minimizing additional equipment complexity
Solution Approach 2:
The catalyst system serves multiple functions: it catalyzes the selective oxidation of propanal to acrolein while also maintaining the primary acrolein production reaction. This multi-functionality reduces the need for separate processing units and simplifies the overall process architecture despite the enhanced functionality
4Object-affected harmful factors
If glycerol is used as a renewable starting material instead of propylene, then environmental impact is reduced, but propanal impurities are formed in greater amounts
Solution Approach 1:
The invention addresses the higher propanal formation from glycerol by converting this impurity into additional acrolein product through selective oxidation. This approach maintains the environmental advantage of using renewable glycerol while eliminating the disadvantage of higher impurity levels, effectively making the renewable pathway as efficient as fossil-based propylene oxidation
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 approach effectively reduces the propanal content in acrolein and acrylic acid streams, enhancing their quality and broadening their application range while using a non-fossil carbon source, and allows for the production of bio-sourced acrylic acid with low propionic acid content.
Implementation Method 1
by passing the said stream in gas phase in the presence of oxygen through a catalyst comprising at least molybdenum and at least one element selected from P, Si, W, Ti, Zr, V, Nb, Ta, Cr, Mn, Fe, Co, Ni, Cu, Zn, Ga, In, Tl, Sn, Ag, As, Ge, B, Bi, La, Ba, Sb, Te, Ce, Pb
Implementation Method 2
selective elimination of propanal in an acrolein-rich stream by passing the said stream in gas phase in the presence of oxygen through a catalyst
Data Source
AI summary
The present invention relates to the selective elimination of propanal in acrolein-rich streams to produce acrolein and/or acrylic acid and/or acrylonitrile and/or methylmercaptopropionaldehyde containing low amount of propanal and/or propionic acid and/or propionitrile. One subject of the present invention is a process for manufacturing acrolein comprising a step of selective elimination of propanal in an acrolein-rich stream in contact with a catalyst comprising at least molybdenum. Another subject of the present invention is a process for manufacturing acrylic acid from glycerol including a step of selective elimination of propanal in an acrolein- rich stream in contact with a catalyst comprising at least molybdenum.