Supported Catalyst Production for Acetic Acid Yield
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Solution Overview
Problem
Existing methods for producing acetic acid from ethylene and oxygen result in low yield and high carbon dioxide by-product generation, leading to increased production costs and environmental impact, with catalyst deterioration issues during reaction.
Innovation Solution
A supported catalyst is produced by impregnating a carrier with compounds from Groups 8, 9, and 10, copper, silver, and zinc chlorides, and chloroauric acid, followed by alkaline treatment and reduction, and optionally loading heteropoly acids, to enhance catalytic activity and minimize carbon dioxide production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing catalysts are used for acetic acid production from ethylene and oxygen, then the production process can proceed, but the yield of acetic acid is low and carbon dioxide by-product generation is high
Solution Approach 1:
The patent uses a composite catalyst system comprising palladium metal (0.1-5 wt%) combined with heteropoly acids (5-50 wt%) supported on a carrier. This composite structure synergistically enhances acetic acid selectivity and yield while suppressing carbon dioxide formation, resolving the contradiction between productivity and harmful by-product generation
Solution Approach 2:
The patent creates eggshell-type catalysts where palladium is selectively distributed on the outer surface of the carrier (within 0.5-2 mm from the surface) rather than uniformly throughout. This localized distribution optimizes the catalyst structure to enhance acetic acid production while minimizing carbon dioxide by-product formation
2Productivity
If multi-step catalyst preparation processes are used to achieve high catalytic activity, then catalyst activity is improved, but the preparation process becomes long and complex
Solution Approach 1:
The patent combines multiple catalyst components (palladium compound, heteropoly acid, and optionally metal oxide) into a single integrated catalyst system prepared through streamlined impregnation and reduction steps. This merging of preparation steps reduces process time while maintaining high catalytic activity through synergistic component interactions
Solution Approach 2:
The patent performs preliminary impregnation of the carrier with palladium compound and heteropoly acid before reduction treatment. This preliminary preparation allows subsequent reduction to simultaneously activate both components, reducing overall preparation time while ensuring high catalytic activity
3Reliability
If conventional catalyst preparation methods are used, then catalyst can be produced, but catalyst deterioration occurs during reaction
Solution Approach 1:
The patent creates a composite catalyst structure where heteropoly acids are combined with palladium metal and supported on a stable carrier material. This composite structure protects the active components from deterioration during reaction, enhancing both reliability and operational lifetime
Solution Approach 2:
The patent uses an alumina or silica carrier that provides an inert support environment for the palladium and heteropoly acid components. This inert support protects the catalyst from degradation during the oxidation reaction, extending catalyst lifetime while maintaining 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 process increases acetic acid yield while reducing carbon dioxide by-product generation, improving catalyst stability and maintaining high activity over time, thus lowering production costs and environmental impact.
Implementation Method 1
Third step: A step of reduction treatment of the palladium-containing compound to produce palladium metal
Implementation Method 2
a supported catalyst that allows industrially advantageous production of lower aliphatic carboxylic acids such as acetic acid from oxygen and lower olefins such as ethylene
Implementation Method 3
Eggshell-type catalysts are catalysts having the palladium in the carrier positioned on the surface of the carrier. Because reaction substrates do not readily diffuse into the internal regions of catalyst carriers, the metal components supported in the carrier have low probability of contacting the reaction substrates
Data Source
AI summary
A process for production of a supported catalyst that, when used for production of lower aliphatic carboxylic acids from oxygen and lower olefins, improves yields of the lower aliphatic carboxylic acids and minimizes production of carbon dioxide gas (CO2) by-product compared to the prior art. A compound comprising at least one element selected from elements of Groups 8, 9 and 10 of the Periodic Table, at least one chloride of an element selected from copper, silver and zinc, and a chloroauric acid salt, are loaded on a carrier, after which there are further loaded a compound comprising at least one element selected from gallium, indium, thallium, germanium, tin, lead, phosphorus, arsenic, antimony, bismuth, sulfur, selenium, tellurium and polonium, and a heteropoly acid.