What question did this study set out to answer?

The aim is to develop a cost-effective catalyst for the synthesis of methyl acrylate through aldol condensation.

February 21, 2026

K–Zr/SiO 2 Catalyst for Efficient Aldol Condensation of Methyl Acetate and Formaldehyde

Key Points

The aim is to develop a cost-effective catalyst for the synthesis of methyl acrylate through aldol condensation.
Designed K–Zr/SiO2 catalysts via coimpregnation technique.
Characterized the catalysts using XRD, FT-IR, N2 physisorption, NH3/CO2-TPD, Py-IR, XPS.
Optimized reaction conditions (T = 380 °C, LHSV = 0.8 h–1).
Achieved 34.15% conversion of methyl acetate.
Reached 92.55% selectivity for methyl acrylate.
Demonstrated a space-time yield of 2.34 mmol·gCat–1·h–1.
Maintained 95% activity after four regeneration cycles.

Abstract

Cost-effective catalysts for methyl acrylate (MA) synthesis via the aldol condensation of methyl acetate (Ma) and formaldehyde (FA) remain a challenge. This study presents a series of K–Zr/SiO2 bifunctional catalysts designed by coimpregnation to achieve synergistic acid–base regulation. Characterizations (XRD, FT-IR, N2 physisorption, NH3/CO2-TPD, Py-IR, XPS) show that Zr incorporation enhances K dispersion, modulates surface acidity/basicity, and promotes the aldol condensation reaction process. The 4K-3Zr/SiO2 catalyst achieved 34.15% Ma conversion, 92.55% MA selectivity, and 2.34 mmol·gCat–1·h–1 space-time yield under optimized conditions (T = 380 °C, LHSV = 0.8 h–1, Ma:FA:MeOH = 1:2:2). Mechanistic studies show that Si–O–K and Si–O–Zr act as Lewis base and Lewis acid sites, respectively, balancing acid–base ratios and suppressing side reactions. The catalyst maintained 95% activity after four regeneration cycles, confirming its industrial feasibility. This work offers a strategy for designing cost-effective K-type catalysts in MA synthesis, highlighting the importance of acid–base synergy.

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