Heterogeneous Catalyst for Adipic Acid Conversion
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Solution Overview
Problem
Current processes for producing 1,6-hexanediol from adipic acid are inefficient due to high temperature and pressure requirements, severe reaction conditions, and unsatisfactory catalyst performance, making them economically undesirable and not commercially viable.
Innovation Solution
A chemocatalytic process converting adipic acid to 1,6-hexanediol using a heterogeneous catalyst comprising Pt, Rh, Mo, W, or their mixtures, supported on materials like SiO2, ZrO2, and zeolites, under controlled temperature and pressure conditions, which enhances selectivity and activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydrogenation catalysts (cobalt, rhenium, Raney nickel) are used, then the hydrogenation reaction can proceed, but the reaction conditions become severe and catalyst performance is unsatisfactory
Solution Approach 1:
The patent changes the chemical parameters of the catalyst by using platinum group metals (Pt, Pd, Rh) combined with transition metals (Mo, W, Re) in specific ratios, transforming the catalyst's activity and selectivity properties to achieve high conversion at milder temperatures and pressures
Solution Approach 2:
The patent employs composite catalyst systems combining platinum group metals with transition metals (Mo, W, Re) supported on oxide carriers, creating a synergistic effect that enhances catalytic performance while reducing the severity of reaction conditions
2Productivity
If cobalt catalysts are used for direct hydrogenation of carboxylic acid salts, then the conversion can be achieved, but the reaction conditions become extreme
Solution Approach 1:
The patent modifies the catalyst's physical and chemical parameters by selecting platinum group metals combined with transition metals in specific weight ratios (0.1-10 wt% Pt/Pd/Rh and 0.1-20 wt% Mo/W/Re), enabling high productivity under moderate pressure conditions instead of extreme pressures
3Reliability
If Mitsubishi's ruthenium, tin, and platinum catalysts are used, then direct hydrogenation of adipic acid and hydroxycaproic acid mixture can be achieved, but the temperatures and pressures are economically undesirable
Solution Approach 1:
The patent optimizes the catalyst composition parameters by using Pt/Pd/Rh combined with Mo/W/Re in specific ratios, achieving high catalyst activity that reduces the energy input (temperature and pressure) required for the reaction, thereby lowering energy costs
Solution Approach 2:
The patent employs catalysts with extended stability and reusability, reducing the frequency of catalyst replacement and the overall energy investment required over the catalyst's operational life, making the process economically viable
4Productivity
If conventional processes with esterification step are used, then 1,6-hexanediol can be produced, but the process complexity increases and economic viability decreases
Solution Approach 1:
The patent merges the hydrogenation step directly with the carboxylic acid substrate without requiring separate esterification and hydrogenation steps, simplifying the overall process while maintaining high production efficiency through the optimized catalyst system
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 high yields of 1,6-hexanediol, up to 70%, with improved catalyst performance and reduced energy costs, making it a more economically viable option for industrial production.
Implementation Method 1
chemocatalytically converting an adipic acid substrate to 1,6-hexanediol by reacting the substrate with hydrogen in the presence of particular heterogeneous catalysts
Data Source
AI summary
Processes are disclosed for the conversion of adipic acid to 1,6-hexanediol employing a chemocatalytic reaction in which an adipic acid substrate is reacted with hydrogen in the presence of particular heterogeneous catalysts including a first metal and a second metal on a support. The adipic acid substrate includes adipic acid, mono-esters of adipic acid, di-esters of adipic acid, and salts thereof. The first metal is selected form the group of Pt, Rh and mixtures thereof and the second metal is selected from the group of Mo, W, Re and mixtures thereof.