Surface-Roughness Catalyst Composition for Stable Carboxylic Acid Yield
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Solution Overview
Problem
Existing catalysts for producing unsaturated carboxylic acid by catalytic gas-phase oxidation of unsaturated aldehydes lack sufficient catalytic activity, leading to inefficiencies in yield and stability.
Innovation Solution
A catalyst with a specific composition and surface roughness, represented by formula (Mo) 12 (V) a (W) b (Cu) c (Sb) d (X) e (Y) f (Z) g (O) h, where surface roughness S is 11.7 µm to 25.0 µm, carried on an inert carrier like silica or alumina, and produced through controlled granulation, is used in multiple layers in the reaction tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts are used for catalytic gas-phase oxidation of unsaturated aldehydes, then the reaction can proceed, but the catalytic activity is insufficient leading to low yield and poor stability
Solution Approach 1:
The invention changes the physical parameter of surface roughness to a specific range (11.7 μm to 25.0 μm) to optimize catalytic activity. This parameter change resolves the contradiction by creating a surface morphology that enhances reaction efficiency while maintaining catalyst stability over time.
Solution Approach 2:
The catalyst uses a composite composition containing Mo, V, W, Cu, Sb, and oxygen in specific ratios, combined with a carrier material. This composite structure provides both high catalytic activity for improved yield and structural stability for reliable long-term operation.
2Productivity
If catalyst surface roughness is not controlled, then manufacturing is simpler, but catalytic activity is insufficient
Solution Approach 1:
The invention specifies a precise surface roughness parameter range (11.7 μm to 25.0 μm) that optimizes catalytic activity. This parameter control transforms the manufacturing process from a simple operation to one that achieves superior catalytic performance through controlled surface morphology.
3Productivity
If catalyst operates at higher temperatures to improve reaction rate, then productivity increases, but energy cost increases and catalyst thermal deterioration accelerates
Solution Approach 1:
The invention changes the catalytic activity parameter through controlled surface roughness, enabling the reaction to proceed efficiently at lower temperatures. This resolves the contradiction by maintaining high productivity while reducing energy consumption and preventing catalyst thermal deterioration.
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 enhances catalytic activity, improves conversion rates, and reduces energy costs by minimizing gas retention and catalyst agglomeration, resulting in stable and high-yield production of unsaturated carboxylic acid.
Implementation Method 1
catalyst for producing an unsaturated carboxylic acid with a catalytically active component having a composition represented by the following formula (1)... subjecting an unsaturated aldehyde to catalytic gas-phase oxidation in the presence of molecular oxygen or a molecular oxygen-containing gas
Data Source
AI summary
The present disclosure relates to a catalyst for producing an unsaturated carboxylic acid having a catalytically active component having a composition represented by the following formula (1) in which the value of the surface roughness S obtained by measuring the surface roughness with a non-contact shape measuring laser microscope is 11.7 µm or more and 25.0 µm or less. (Mo)12(V)a(W)b(Cu)c(Sb)d(X)e(Y)f(Z)g(O)h (1)