Zn-Modified Ti-MWW Zeolite Molding With Fewer Catalyst Prep Steps
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Solution Overview
Problem
Existing processes for preparing TiMWW catalysts, such as those described in WO 2013/117536 A, are multi-stage and not economically optimal, necessitating a more efficient shaping process for titanium-containing zeolitic materials with framework type MWW, particularly for industrial-scale applications like propene epoxidation.
Innovation Solution
A process that incorporates zinc during the shaping step of titanium-containing zeolitic materials with framework type MWW, involving an aqueous suspension under autogenous pressure, followed by separation and calcination, to produce a molding with improved properties and reduced steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multi-stage process is used to prepare TiMWW catalysts as described in WO 2013/117536 A, then the catalysts exhibit excellent characteristics for epoxidation, but the process is not economically optimal and involves multiple steps
Solution Approach 1:
The patent combines the shaping step and zinc incorporation step into a single integrated process. The molding is shaped and zinc is incorporated simultaneously during the heating step under autogenous pressure, eliminating the need for separate shaping and zinc addition steps required in the multi-stage process of WO 2013/117536 A.
Solution Approach 2:
The patent performs zinc incorporation during the shaping step itself, rather than as a subsequent separate step. By preparing the aqueous suspension with zinc source and molding together before heating, the zinc is incorporated into the molding structure during the shaping process, streamlining the overall procedure.
2Reliability
If a multi-stage process is used to prepare TiMWW catalysts, then the catalysts exhibit excellent characteristics, but the process involves more steps and is less economical
Solution Approach 1:
The patent merges multiple operations (shaping, zinc incorporation, and heating under autogenous pressure) into a single integrated process step, reducing the total number of stages from multiple steps in WO 2013/117536 A to a more streamlined sequence that improves process efficiency and economy.
3Device complexity
If zinc is incorporated during the shaping step, then the process becomes more economical and eliminates one step, but requires heating under autogenous pressure to 100-200°C
Solution Approach 1:
The patent specifies heating under autogenous pressure to a temperature range of 100-200°C to optimize zinc incorporation during the shaping step. This temperature parameter change enables the simultaneous shaping and zinc incorporation while maintaining process simplicity and economic advantage.
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 achieves catalysts with the same or improved properties as existing multi-stage methods while being more economical, suitable for industrial-scale processes.
Implementation Method 1
heating the aqueous suspension prepared in (ii) under autogenous pressure to a temperature of the liquid phase of the aqueous suspension in the range of from 100 to 200 °C
Data Source
AI summary
A process for preparing a molding comprising zinc and a titanium-containing zeolitic material having framework type MWW, comprising (i) providing a molding comprising a titanium-containing zeolitic material having framework type MWW; (ii) preparing an aqueous suspension comprising a zinc source and the molding comprising a titanium-containing zeolitic material having framework type MWW prepared in (i); (iii) heating the aqueous suspension prepared in (ii) under autogenous pressure to a temperature of the liquid phase of the aqueous suspension in the range of from 100 to 200 °C, obtaining an aqueous suspension comprising a molding comprising zinc and a titanium-containing zeolitic material having framework type MWW; (iv) separating the molding comprising zinc and a titanium-containing zeolitic material having framework type MWW from the liquid phase of the suspension obtained in (iii).