Shell Catalyst for Acrolein Oxidation with Mo-V-W Composition
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Solution Overview
Problem
Existing catalysts used in the heterogeneously catalyzed partial gas phase oxidation of acrolein to acrylic acid suffer from deactivation over time, leading to reduced activity and increased operating costs due to the need for frequent replacement or temperature adjustments, which complicates the process and increases costs.
Innovation Solution
A shell catalyst comprising a support body with a finely divided multi-element oxide containing Mo and V, combined with a finely divided molybdenum oxide substance that forms under elevated temperature and molecular oxygen, is applied to the support body using a binder, effectively delaying deactivation and maintaining catalytic effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the temperature of the fixed catalyst bed is gradually increased to compensate for activity reduction, then the acrolein conversion is maintained, but the aging process of the catalyst accelerates
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition of the catalyst (changing from conventional Mo-V oxides to Mo-V-W oxides with specific molar ratios) to maintain catalytic activity without requiring temperature increases, thereby extending catalyst service life while maintaining reliability
Solution Approach 2:
The patent uses composite materials by combining multiple metal oxides (Mo, V, W) in specific proportions to create a catalyst with enhanced stability and resistance to aging, allowing the catalyst to maintain activity over longer periods without temperature compensation
2Reliability
If the fixed catalyst bed is completely replaced to restore activity, then the catalytic performance is renewed, but the production process is interrupted and costs increase
Solution Approach 1:
The patent applies preliminary action by pre-optimizing the catalyst composition with specific Mo-V-W ratios and particle size distributions that inherently resist deactivation, allowing the catalyst to maintain activity for extended periods without requiring replacement, thus avoiding production interruptions
3Loss of time
If only a portion of the fixed catalyst bed is replaced instead of complete replacement, then the production interruption is reduced, but the process complexity increases
Solution Approach 1:
The patent applies preliminary action by designing a catalyst with optimized composition and structure that maintains high activity over extended periods, eliminating the need for partial replacement operations and their associated complexity
4Reliability
If the working pressure is increased to counteract catalyst deactivation, then the catalytic activity is maintained, but the compression performance requirement increases
Solution Approach 1:
The patent applies parameter changes by modifying the catalyst's chemical composition (Mo-V-W oxide ratios) and physical structure (particle size) to maintain activity without requiring pressure increases, thereby avoiding additional compression requirements
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 shell catalyst significantly extends the service life of the catalyst bed by maintaining high acrolein conversion rates and reducing the need for frequent replacements or temperature adjustments, thereby improving process efficiency and reducing operational costs.
Implementation Method 1
catalysts are particularly suitable for catalyzing the heterogeneously catalyzed partial gas phase oxidation of acrolein to acrylic acid
Implementation Method 2
the active mass is adhered to the surface of the carrier body with the aid of a binder
Data Source
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AI summary
The invention relates to a method for producing a shell catalyst, according to which a fine-particle mixture consisting of a multi-element oxide containing the elements Mo and V, and a molybdenum oxide or a molybdenum oxide forming agent, is applied to the surface of a carrier body as an active substance.