Shaped Catalyst Production via Centrifugal Granulation
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Solution Overview
Problem
Conventional catalysts for producing butadiene and unsaturated aldehydes/ acids lack sufficient mechanical strength and catalytic performance, particularly in terms of selectivity and stability, due to low relative centrifugal forces used in their production processes.
Innovation Solution
A process for producing a shaped catalyst by tumbling granulation with a specific relative centrifugal force of 1 to 35 G, using a complex metal oxide composition and supporting it on an inert substrate, which enhances both mechanical strength and catalytic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional tumbling granulation method with low relative centrifugal force is used, then catalyst production is simple, but mechanical strength and catalytic performance are insufficient
Solution Approach 1:
The patent applies parameter changes by optimizing the relative centrifugal force from conventional low values to a specific range of 10-35 G during tumbling granulation. This parameter modification directly improves mechanical strength and catalytic performance while maintaining the overall tumbling granulation process framework, thus resolving the contradiction between strength improvement and process complexity
Solution Approach 2:
The patent introduces dynamic control of rotation speed and rotation radius in the tumbling granulation apparatus to achieve the desired relative centrifugal force range. By dynamically adjusting these parameters during the granulation process, the system achieves optimal mechanical strength and catalytic performance without requiring fundamentally different equipment or processes
2Reliability
If conventional tumbling granulation with low relative centrifugal force is used, then production process is simple, but selectivity and stability are insufficient
Solution Approach 1:
The patent modifies the relative centrifugal force parameter to 10-35 G during tumbling granulation, which directly enhances catalyst selectivity and operational stability. This parameter optimization improves reliability without fundamentally changing the production process complexity
Solution Approach 2:
The patent replaces conventional low-force mechanical granulation with a controlled high-relative-centrifugal-force tumbling system. This substitution improves catalyst performance stability by ensuring more uniform particle formation and better mechanical properties, while the process remains within the framework of mechanical tumbling granulation
3Productivity
If high relative centrifugal force is applied during tumbling granulation, then mechanical strength and catalytic performance are improved, but production complexity increases
Solution Approach 1:
The patent optimizes the relative centrifugal force to a specific range of 10-35 G, which improves catalyst productivity and performance efficiency. By defining this specific parameter range, the patent achieves high performance without excessive process complexity, as the change is confined to controllable operational parameters rather than fundamental process redesign
Solution Approach 2:
The patent employs dynamic control of rotation speed and rotation radius to achieve the desired relative centrifugal force. This dynamic approach allows flexible adjustment to maintain optimal performance while adapting to different production scales and requirements, thereby managing complexity effectively
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 resulting catalyst exhibits high mechanical strength and catalytic performance, achieving efficient conversion and yield in reactions such as butadiene production from n-butene and unsaturated aldehyde/acid production from unsaturated hydrocarbons.
Implementation Method 1
a production process by a tumbling granulation method is disclosed. Specifically, a spherical support necessary for attaining a desired catalyst diameter is placed in a tumbling granulation apparatus and a liquid as a binder and a catalyst-active ingredient and/or a precursor thereof are sprinkled on the support with rotating the shaping machine
Data Source
AI summary
There is provided a process for producing a shaped catalyst for a fixed bed oxidation reaction or a fixed bed oxidative dehydrogenation reaction, the catalyst having both of sufficient mechanical strength and catalyst performance, and the catalyst is produced by supporting a catalyst powder containing a complex metal oxide having molybdenum as an essential ingredient on an inert support by a tumbling granulation method at a relative centrifugal force of 1 to 35 G.