Spherical Composite Catalyst for Ammonia-Efficient Acrylonitrile Production
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Solution Overview
Problem
Existing catalysts for ammoxidation reactions, such as those described in Patent Literature 1 and 2, face challenges in achieving high efficiency in the use of ammonia and producing acrylonitrile, with activated ammonia often burning without contributing to the reaction and economic inefficiencies due to excessive use.
Innovation Solution
A catalyst production method involving controlled temperature variation and homogeneous distribution of crystal phases, achieved through specific calcining steps in cylindrical bodies with temperature measurement and inert gas transportation, results in a catalyst with a coefficient of variation (σ/A) between 0.10 and 0.30, enhancing ammonia utilization and acrylonitrile yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional catalysts are used for ammoxidation reactions, then the reaction can proceed, but activated ammonia merely burns and turns into nitrogen without contributing to the reaction, resulting in poor ammonia utilization
Solution Approach 1:
The invention changes the chemical composition parameters of the catalyst by incorporating specific metal compounds (molybdenum, vanadium, antimony, niobium, tungsten, tantalum, or rhenium) in controlled ratios to create a catalyst that promotes selective ammoxidation reaction, preventing ammonia combustion and improving both ammonia utilization efficiency and acrylonitrile yield
Solution Approach 2:
The invention uses a composite catalyst material consisting of multiple metal compounds (Mo, V, Sb, Nb, Ta, W, or Re) supported on a carrier, where the synergistic effect of different metals enables selective catalysis that converts ammonia into acrylonitrile rather than allowing combustion to nitrogen
2Productivity
If higher catalyst performance is sought to improve acrylonitrile yield, then more ammonia must be activated, but this leads to excessive ammonia consumption and economic inefficiency
Solution Approach 1:
The invention optimizes the compositional parameters of the catalyst by selecting specific metal compounds and their ratios, creating a catalyst that achieves high acrylonitrile yield through efficient catalysis while minimizing excessive ammonia consumption and improving economic efficiency
3Manufacturing precision
If temperature control is improved during calcining to achieve homogeneous crystal phase distribution, then catalyst performance improves, but the process complexity and energy consumption increase
Solution Approach 1:
The invention divides the calcining process into multiple stages with different temperature profiles, where each stage promotes specific crystal phase formation and distribution, achieving homogeneous crystal phase distribution through segmented thermal treatment rather than a single complex process
Solution Approach 2:
The invention controls the temperature parameters during calcining by implementing multi-stage heating with specific temperature ranges and holding periods, adjusting these parameters to achieve homogeneous crystal phase distribution while managing process complexity and energy consumption
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 method enables highly efficient use of ammonia and high-yield production of acrylonitrile by ensuring uniform crystal phase distribution and temperature control, leading to improved catalyst performance and economic efficiency.
Implementation Method 1
heating means M1 that heats an inside of the cylindrical body along the rotation axis direction
Implementation Method 2
in the first supplying step, the dry particles are supplied to the supply port P1 by gas transportation
Implementation Method 3
a catalyst that is used in a gas phase catalytic oxidation reaction or gas phase catalytic ammoxidation reaction of propane or isobutane
Data Source
AI summary
A catalyst that is used in a gas phase catalytic oxidation reaction or gas phase catalytic ammoxidation reaction of propane or isobutane, in whichthe catalyst contains catalyst particles each having a composite metal oxide and a support that supports the composite metal oxide,the catalyst particles have a median diameter of 20 μm or more and 150 μm or less,a shape of the catalyst particle is spherical, andin a binarization processed image BP2 obtained by performing a binarization process for classifying regions into a predetermined white region and a predetermined black region on a cross-sectional image showing the catalyst particles and having an area of 1200 μm2 or more obtained by predetermined SEM backscattered electron image observation, σ/A that is calculated by a predetermined method satisfies 0.10 or more and 0.30 or less.