초록 ▼

Disclosed is a shell-and-tube reactor that may be used for fixed-bed catalytic partial oxidation, the reactor being characterized by including at least one reaction zone of a first-step reaction zone for mainly producing unsaturated aldehydes and a second-step reaction zone for mainly producing unsa

Disclosed is a shell-and-tube reactor that may be used for fixed-bed catalytic partial oxidation, the reactor being characterized by including at least one reaction zone of a first-step reaction zone for mainly producing unsaturated aldehydes and a second-step reaction zone for mainly producing unsaturated acids, wherein at least one reaction zone of the above reaction zones comprises two or more catalytic layers; each of the catalytic layers is packed with a formed product of catalyst that is different in pore density and/or pore size in a catalytically active component; and the pore density and/or pore size is controlled in such a manner that specific surface area of the catalytically active component increases from the inlet of the reactor to the outlet of the reactor. A method for producing unsaturated aldehydes and/or unsaturated fatty acids from olefins using the same reactor is also disclosed. According to the present invention, it is possible to control the temperature efficiently at a hot spot, thereby permitting stable use of a catalyst, and to produce unsaturated aldehydes and/or unsaturated fatty acids with high yield.

대표청구항 ▼

The invention claimed is: 1. A shell-and-tube reactor that may be used for fixed-bed catalytic partial oxidation, the reactor being characterized by including at least one reaction zone of a first-step reaction zone for mainly producing unsaturated aldehydes from olefins and a second-step reaction

The invention claimed is: 1. A shell-and-tube reactor that may be used for fixed-bed catalytic partial oxidation, the reactor being characterized by including at least one reaction zone of a first-step reaction zone for mainly producing unsaturated aldehydes from olefins and a second-step reaction zone for mainly producing unsaturated acids from unsaturated aldehydes, wherein at least one reaction zone of the above reaction zones comprises two or more catalytic layers; each of the catalytic layers is packed with a formed product of catalyst that is different in pore density and/or pore size in a catalytically active component; and the pore density and/or pore size is controlled in such a manner that specific surface area of the catalytically active component increases from the inlet of the reactor to the outlet of the reactor. 2. The shell-and-tube reactor according to claim 1, wherein the formed product of catalyst is a formed catalyst obtained by forming the catalytically active component into a desired shape, or a supported catalyst obtained by supporting the catalytically active component onto an inert carrier having a desired shape. 3. The shell-and-tube reactor according to claim 1, wherein the catalytically active component having a different pore density and/or pore size is obtained by the method comprising the steps of: (a) mixing metal salts forming a metal oxide, as a catalytically active component, to provide an aqueous solution or suspension of catalyst; (b) drying the aqueous solution or suspension of catalyst to provide catalyst powder; and (c) baking the resultant product obtained from the preceding step, the method further comprising a step of adding a sublimable or thermally decomposable material, having a controlled addition amount and/or a controlled particle size, during step (a) or between step (b) and step (c). 4. The shell-and-tube reactor according to claim 3, wherein the sublimable or thermally decomposable material is sublimed or decomposed at 50-200° C. 5. The shell-and-tube reactor according to claim 3, wherein the sublimable or thermally decomposable material is at least one material selected from the group consisting of urea (NH2CONH2), melamine (C3H6N6), ammonium oxalate (C2H8N2O4), methyl oxalate (C4H6O4) and naphthalene (C10H8). 6. The shell-and-tube reactor according to claim 3, wherein the sublimable or thermally decomposable material is present in the form of granular powder having a size of 0.01-50 μm or is present in a liquid state. 7. The shell-and-tube reactor according to claim 3, wherein the sublimable or thermally decomposable material is added in an amount of 0-30 wt % based on the weight of the catalytically active component. 8. The shell-and-tube reactor according to claim 3, wherein the catalyst powder is used after being pulverized into a size of 150 μm or less. 9. The shell-and-tube reactor according to claim 1, wherein the catalytic layer that has the smallest specific surface area of the catalytically active component by controlling the pore density and/or pore size includes the highest-temperature hot spot, and the specific surface area of the catalytically active component is 5-10 m2/g. 10. The shell-and-tube reactor according to claim 1, wherein at least one reaction zone includes a first catalytic layer and a second catalytic layer, packed in two levels; the catalytically active component in the first level has a specific surface area of 5-10 m2/g; and the catalytically active component in the second level has a specific surface area of 10-100 m2/g. 11. The shell-and-tube reactor according to claim 1, wherein at least one reaction zone includes a first catalyst layer, a second catalytic layer and a third catalytic layer, packed in three levels; the catalytically active component in the first level has a specific surface area of 5-10 m2/g; the catalytically active component in the second level has a specific surface area of 10-50 m2/g; and the catalytically active component in the third level has a specific surface area of 50-100 m2/g.