Ring-Shaped Catalyst Curved End Face Reduces Pressure Loss
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Solution Overview
Problem
Conventional catalysts for gas-phase catalytic oxidation reactions of olefins and tertiary butanols to produce unsaturated aldehydes and carboxylic acids suffer from high pressure loss, low conversion rates, and low selectivity, leading to reduced yields and frequent coking issues due to their shape and surface area characteristics.
Innovation Solution
A ring-shaped catalyst with a straight body part and a hollow body part, where the straight body part is shorter than the hollow body part and concavely curved at one end, providing a larger surface area and improved fluidity to reduce pressure loss and coking, while maintaining high yield production of unsaturated aldehydes and carboxylic acids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional catalyst shapes (ring-shaped or hollow cylindrical with curved end face) are used, then the catalyst can be molded for heterogeneous catalytic reaction, but the pressure loss is high and gas volume is reduced
Solution Approach 1:
The catalyst employs a hollow cylindrical body with a specifically curved end face where the curvature radius is 0.05 to 0.2 times the outer radius. This controlled curvature optimizes gas flow patterns around the catalyst, reducing turbulence and pressure loss while maintaining effective catalytic contact area.
Solution Approach 2:
The invention changes the geometric parameters of the catalyst by defining specific relationships between the curvature radius, outer radius, and other dimensions. This parameter optimization resolves the contradiction between maintaining catalyst shape integrity and minimizing pressure loss in the reactor system.
2Shape
If conventional catalyst shapes are used, then the catalyst can be molded, but the conversion rate and selectivity are low
Solution Approach 1:
The catalyst design applies local quality by creating a specific curved region at the end face with a defined curvature radius range. This localized geometric feature optimizes gas distribution and flow patterns at the catalyst surface, enhancing conversion rate and selectivity without compromising the overall catalyst structure.
Solution Approach 2:
The controlled curvature of the end face (with radius 0.05 to 0.2 times the outer radius) creates optimal flow patterns that improve gas-catalyst contact efficiency, thereby increasing both conversion rate and selectivity for the desired products.
3Shape
If gas volume is reduced due to high pressure loss, then catalyst shape is maintained, but coking is accelerated
Solution Approach 1:
By optimizing the geometric parameters of the catalyst (curvature radius, outer radius, height ratios), the invention maintains adequate gas volume flow despite the molded catalyst structure. This prevents the conditions that lead to coking while preserving the catalyst shape and structural integrity.
Solution Approach 2:
The curved end face design improves gas flow distribution and prevents stagnant zones where coking would occur. The specific curvature radius range ensures smooth gas flow that reduces localized heating and carbide deposition on the catalyst surface.
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 proposed catalyst design significantly reduces pressure loss, suppresses coking, and enhances the yield of unsaturated aldehydes and carboxylic acids, maintaining efficiency even in a coked state compared to conventional catalysts, thereby increasing the frequency of decoking and overall reaction efficiency.
Implementation Method 1
gas-phase catalytic oxidation reaction of an olefin or a tertiary butanol is conducted to produce a corresponding unsaturated aldehyde and/or unsaturated carboxylic acid
Implementation Method 2
gas-phase catalytic oxidation reaction of an olefin or a tertiary butanol
Implementation Method 3
gas-phase catalytic oxidation of an unsaturated aldehyde is conducted to produce a corresponding unsaturated carboxylic acid
Implementation Method 4
gas-phase catalytic oxidation of an unsaturated aldehyde
Data Source
Figure 1(A)~2(B)
Figure 3(A)~4(B)
Figure 5(A)~6(B)
AI summary
An object of the present invention is to provide a catalyst ensuring that when a gas-phase catalytic oxidation reaction of a material substance is conducted using a catalyst to produce a target substance, the pressure loss and coking are suppressed and the target substance can be produced in high yield. The present invention is related to a ring-shaped catalyst having a straight body part and a hollow body part, which is used when a gas-phase catalytic oxidation reaction of a material substance is conducted to produce a target substance, wherein a length of the straight body part is shorter than a length of the hollow body part and at least at one end part, a region from an end part of the straight body part to an end part of the hollow body part is concavely curved.