Supported Catalyst Granulation for Mechanical Strength
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Solution Overview
Problem
Existing methods for producing spherical supported catalysts, such as those used in gas-solid catalytic reactions, face challenges in achieving optimal mechanical strength and catalytic performance, particularly in terms of attrition resistance and uniform active component support, which affects reaction yield and temperature efficiency.
Innovation Solution
A method involving the formulation of composite metal oxides like Mo12(V)a(W)b(Cu)c(Sb)d(X)e(Y)f(Z)g(O)h, where specific elements and ratios are used, combined with a rolling granulation process at controlled centrifugal acceleration, to produce catalysts with enhanced mechanical strength and catalytic performance by shaping and supporting on spherical carriers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rolling granulation method is used to produce spherical supported catalysts, then the catalysts can be uniformly filled in reaction tubes and are easy to handle, but the mechanical strength and attrition resistance are insufficient
Solution Approach 1:
The patent uses composite metal oxides (Mo-V-W-Cu-Sb system) as the catalyst material, combining multiple metallic elements to create a composite structure that inherently provides both catalytic activity and improved mechanical strength. The composite nature of the catalyst particles enhances their resistance to attrition while maintaining spherical shape for easy handling.
Solution Approach 2:
The patent optimizes the granulation parameters including rotation speed of the bottom plate, liquid binder composition and amount, and drying conditions. By carefully controlling these parameters, the catalyst particles achieve optimal mechanical strength and hardness while maintaining their spherical shape, resolving the contradiction between ease of handling and mechanical strength.
2Strength
If the catalyst is produced with higher mechanical strength, then attrition resistance improves, but catalytic performance and reaction yield may be compromised
Solution Approach 1:
The composite metal oxide structure (Mo-V-W-Cu-Sb) provides dual functionality: the specific combination of metallic elements delivers high catalytic activity for the target reaction, while the composite structure itself contributes to mechanical strength and attrition resistance. This eliminates the need to sacrifice catalytic performance for mechanical strength.
Solution Approach 2:
The patent creates a heterogeneous structure where different regions of the catalyst particle have different compositions and properties. The outer shell and core regions are optimized differently, with the surface providing catalytic active sites and the interior providing structural support, allowing simultaneous optimization of both catalytic performance and mechanical strength.
3Productivity
If the active component is uniformly supported on the catalyst, then catalytic performance improves, but the manufacturing complexity increases
Solution Approach 1:
The patent applies liquid binder containing active component precursors to the spherical carriers before granulation, allowing uniform distribution to be achieved during the granulation process itself. This preliminary preparation step simplifies the overall manufacturing process by combining multiple functions (active component distribution, binder application, and granulation) into a single operation.
Solution Approach 2:
The rolling granulation process itself facilitates uniform distribution of the active component through the mechanical action of rotation and tumbling. The process uses its own mechanical motion to achieve uniform coating and distribution, eliminating the need for separate, complex distribution equipment or multiple processing steps.
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 results in catalysts with improved mechanical strength and catalytic performance, reducing attrition resistance and increasing reaction efficiency, making them suitable for industrial-scale use in producing acrylic and methacrylic acids.
Implementation Method 1
shaping is carried out in a state of inclining a rotary tray at 30° against the horizontal plane while rotating at 15 rpm... its relative centrifugal acceleration is unclear
Data Source
AI summary
Provided is a method for producing an unsaturated carboxylic acid using a catalyst having both a high catalytic performance and a high mechanical strength. In the method, a supported catalyst obtained by feeding a liquid binder component and a catalytic active component containing molybdenum and vanadium and/or a precursor thereof into a rolling granulator and conducting granulation at a relative centrifugal acceleration of 0.5 G or more and 30 G or less is used.