Single-Firing (Meth)Acrylic Acid Catalyst Preparation
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Solution Overview
Problem
The existing methods for preparing (meth)acrylic acid catalysts face challenges with lengthy firing processes that decrease productivity and complicate equipment, leading to increased risks and inefficiencies.
Innovation Solution
A method involving the preparation of a catalyst using a mixed gas of air and nitrogen during a single firing process, comprising the steps of mixing molybdenum and vanadium precursors with other elements, forming a slurry, drying, pulverizing, and molding, followed by firing with a specific gas mixture to achieve Chemical Formula 1, simplifying the process and reducing equipment size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a two-stage firing process (primary firing and secondary firing) is used to prepare the catalyst, then the catalyst quality and performance are improved, but the production time increases and equipment complexity increases
Solution Approach 1:
The patent combines the primary firing and secondary firing processes into a single integrated firing step. The catalyst precursor is fired directly at temperatures of 300-600°C for 1-24 hours in one continuous operation, eliminating the need for separate primary and secondary firing stages while maintaining catalyst performance through optimized single-stage firing parameters
2Manufacturing precision
If a two-stage firing process (primary firing and secondary firing) is used to prepare the catalyst, then the catalyst quality and performance are improved, but the equipment complexity increases
Solution Approach 1:
The patent merges the requirements for both primary and secondary firing into a single firing unit operation. By optimizing the single-stage firing temperature range (300-600°C) and duration (1-24 hours), the process achieves the desired catalyst quality without requiring multiple specialized firing equipment, thereby reducing equipment complexity
3Manufacturing precision
If the firing process is extended to ensure complete catalyst formation, then the catalyst performance is improved, but the production efficiency decreases
Solution Approach 1:
The patent optimizes the firing parameters by establishing a specific temperature range (300-600°C) and time duration (1-24 hours) for the single-stage firing process. This parameter optimization ensures complete catalyst formation and high performance while minimizing the required firing time, thereby balancing catalyst quality with production efficiency
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 simplifies and automates the catalyst preparation, reduces risks, and produces a catalyst with high conversion rates and selectivity for (meth)acrylic acid, while minimizing equipment size and costs.
Implementation Method 1
preparing a first solution including a molybdenum precursor and a vanadium precursor; preparing a second solution including a precursor including an M 2
Implementation Method 2
drying the uniform solution or slurry using a drier
Implementation Method 3
The extruded catalyst is subjected to a firing process, which is an additional heat treatment, to prepare a final catalyst
Data Source
AI summary
The present invention provides a catalyst for preparing (meth)acrylic acid and a method for preparing a catalyst for preparing (meth)acrylic acid.