Silane-Treated Glass Fiber Catalyst for High Mechanical Strength
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Solution Overview
Problem
Existing catalysts for producing unsaturated aldehydes and carboxylic acids face issues with mechanical strength and yield, particularly due to hot spots leading to reduced service life and production efficiency, and existing methods to enhance mechanical strength do not adequately address yield and catalytic performance.
Innovation Solution
A novel catalyst comprising silane-treated glass fibers and a catalytic active component composed of molybdenum, bismuth, nickel, cobalt, and iron, with specific elemental ratios, supported on an inert carrier and calcined at high temperatures to achieve high mechanical strength and high yield production of unsaturated aldehydes and carboxylic acids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a catalyst with large average particle diameter and high calcining temperature is used, then catalytic activity is improved, but mechanical strength is lowered and catalyst breaks during storage and filling
Solution Approach 1:
The patent uses a composite catalyst structure combining alumina carrier with silica-alumina coating layer. This composite design provides both high catalytic activity (from the active components on the carrier) and high mechanical strength (from the structured coating), resolving the contradiction between activity and strength.
Solution Approach 2:
The catalyst employs a porous coating structure with controlled porosity that maintains mechanical integrity while allowing reactant diffusion. The porous alumina coating with silica-alumina layer provides structural support preventing catalyst breakage during storage and filling, while maintaining catalytic performance.
2Strength
If inorganic fibers are added to enhance mechanical strength, then attrition resistance is improved, but yield of unsaturated aldehyde or carboxylic acid is insufficient
Solution Approach 1:
The patent applies local quality modification by creating a coated structure where the coating layer (silica-alumina) is specifically applied to the surface of the alumina carrier. This localized modification provides mechanical strength enhancement at the surface level without compromising the catalytic active components embedded in the carrier, thus maintaining high yield while improving attrition resistance.
3Productivity
If catalyst layer becomes thick to accommodate large particle diameter, then catalytic activity is improved, but strain in active component layer is generated and mechanical strength is lowered
Solution Approach 1:
The catalyst is segmented into distinct functional layers: an alumina carrier providing structural support, and a silica-alumina coating layer providing additional mechanical strength and strain relief. This segmentation allows the active components to be distributed throughout the carrier while the coating prevents excessive strain accumulation, maintaining both activity and structural stability.
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 catalyst achieves high mechanical strength and high yield production of unsaturated aldehydes and carboxylic acids, with improved resistance to attrition and prolonged catalyst service life, while maintaining catalytic performance.
Implementation Method 1
silane-treated glass fibers... achieving high mechanical strength and high yield production... improved resistance to attrition
Implementation Method 2
the generation of a hot spot leads to shortening of a catalyst service life or lowering of a yield to be caused due to an excessive oxidation reaction
Implementation Method 3
a calcining temperature of the catalyst... typically, it means a maximum temperature of the temperature of calcining or drying to be carried out for the catalytic active component
Data Source
AI summary
An object of the invention is to provide a novel catalyst having high mechanical strength and capable of obtaining an unsaturated aldehyde or an unsaturated carboxylic acid in a high yield and a method for producing the same, and a method for producing an unsaturated aldehyde and/or an unsaturated carboxylic acid using the catalyst. By containing silane-treated glass fibers in a catalytic active component composed of molybdenum and bismuth as essential components, high mechanical strength is revealed, and it is possible to obtain an unsaturated aldehyde or an unsaturated carboxylic acid in a high yield.