One-Step Synthesis of Methyl Acrylate Using Methyl Acetate with Formaldehyde in a Fluidized Bed Reactor

A fluidized bed process for the one-step synthesis of methyl acrylate (MA) using methyl acetate (Ma) and formaldehyde (FA) was developed for the first time. New spherical antiwear acid–base catalysts Cs–P/γ-Al2O3 were prepared using ultrasonic impregnation method and characterized with XRD, BET, SEM, PSD, ICP, TG/DTA, NH3-TPD, and CO2-TPD methods. Catalytic performance was evaluated, and 10.0 wt % Cs–5.0 wt % P/γ-Al2O3 with weak acid–base sites was determined to be the best catalyst for MA production. Response surface methodology (RSM) was employed to optimize aldol condensation of Ma with FA over 10.0 wt % Cs–5.0 wt % P/γ-Al2O3. The effects of various process parameters such as reaction temperature, molar ratio of Ma and FA, and liquid hourly space velocity (LHSV) on MA yield were addressed by Box–Behnken experimental design (BBD). The coefficient of determination (R 2) of this model was 0.997, and 39.5 mol % yield of MA was obtained after optimization. The developed catalyst exhibited high stability, with no significant decrease in catalytic activity after 1000 h of lifetime evaluation.