Zeolite Catalyst Synthesis for Alkyl Acrylate Yield
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Solution Overview
Problem
Existing methods for producing alkyl acrylate from alkyl lactate have low yields and require intermediate products, making them inefficient and costly.
Innovation Solution
A catalyst is synthesized without using an organic structure directing agent, comprising a zeolite obtained through hydrothermal synthesis, calcination, and ion-exchange with potassium ions, which is then used to convert alkyl lactate into alkyl acrylate in the presence of alkanol.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to produce alkyl acrylate from alkyl lactate, then the process can be completed, but the yield is low and synthesis time is long due to requiring intermediate products
Solution Approach 1:
The patent extracts and eliminates the intermediate product step from the conventional synthesis pathway. By using a modified ZSM-5 catalyst with specific pore structure and acidity, the reaction proceeds directly from alkyl lactate to alkyl acrylate without forming the intermediate ester, thereby reducing synthesis time and improving yield.
Solution Approach 2:
The patent changes the catalyst parameters by modifying the ZSM-5 zeolite structure through controlled synthesis conditions (temperature, pressure, catalyst precursor ratios) to optimize the dehydration reaction. This creates a catalyst with enhanced activity and selectivity for direct conversion, eliminating the need for intermediate products.
2Productivity
If conventional ZSM-5 catalyst is used, then the reaction can proceed, but the yield of alkyl acrylate is insufficient
Solution Approach 1:
The patent applies local quality modification to the ZSM-5 catalyst by creating specific active sites within the zeolite structure. Through controlled hydrothermal synthesis and ion exchange, certain regions of the catalyst are optimized for dehydration activity while maintaining the overall ZSM-5 structure, thereby improving yield and reaction efficiency.
Solution Approach 2:
The patent creates a composite catalyst system by combining ZSM-5 zeolite with other catalytic components or modifying the zeolite structure through ion exchange (e.g., potassium ion exchange). This composite approach enhances the catalytic activity and selectivity for alkyl acrylate production while maintaining the benefits of the ZSM-5 framework.
3Manufacturing precision
If organic structure directing agents are used in catalyst synthesis, then the catalyst structure can be controlled, but the process becomes more complex and costly
Solution Approach 1:
The patent employs self-service by allowing the zeolite structure to form spontaneously through hydrothermal synthesis without requiring external organic structure directing agents. The catalyst precursor mixture self-organizes into the desired ZSM-5 structure through controlled hydrothermal conditions, simplifying the synthesis process while maintaining structural precision.
Solution Approach 2:
The patent eliminates the need for expensive and potentially harmful organic structure directing agents by using simple inorganic precursors and hydrothermal conditions. The temporary hydrothermal environment facilitates structure formation without requiring persistent organic templates, thereby reducing cost and environmental impact while achieving the same structural control.
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 achieves higher yields and lower costs compared to conventional processes, while also being environmentally friendly by omitting the use of organic structure directing agents.
Implementation Method 1
obtaining alkyl acrylate by contacting alkyl lactate with the catalyst in presence of alkanol
Implementation Method 2
obtaining the zeolite by hydrothermal synthesis of the mixed solution
Implementation Method 3
obtaining the catalyst by adding and reacting the zeolite to a solution including a potassium salt to ion-exchange the zeolite with potassium ions
Implementation Method 4
calcining the zeolite
Data Source
AI summary
A method of producing a catalyst for synthesizing alkyl acrylate from alkyl lactate and a method of producing alkyl acrylate using the catalyst are disclosed herein. More specifically, a catalyst including zeolite is produced by a method that does not use an organic structure directing agent, and a dehydration reaction of alkyl lactate is promoted using the catalyst, thereby obtaining alkyl acrylate in a yield higher than obtained by conventional methods.