Metal Alloy Oxidative Catalysts for Glucaric Acid Production
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Solution Overview
Problem
Conventional processes for manufacturing dicarboxylic acids, such as glucaric acid, are energy intensive, use toxic and corrosive chemicals, and generate significant toxic by-products, with low oxidation activity and inefficient catalyst separation.
Innovation Solution
A process forming an alloy catalyst by combining metal precursors of different metals, such as platinum and copper, with a solid support, using a reducing agent like sodium borohydride, to enhance oxidation activity and selectivity for carboxylic acid production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional processes use toxic and corrosive oxidants and catalysts such as nitric acid, cyanides, and halogen-containing solid catalysts, then oxidation reactions can proceed, but the processes generate significant toxic by-products and require energy intensive separation procedures
Solution Approach 1:
The patent changes the chemical parameters by replacing conventional toxic oxidants (nitric acid, cyanides, halogen-containing catalysts) with hydrogen peroxide as the oxidant and employing metal alloy catalysts (such as Pt-Cu, Pd-Cu, or Rh-Cu alloys) supported on solid supports like TiO2, CeO2, or Al2O3. This parameter change eliminates the formation of toxic by-products while maintaining high oxidation rates for converting glucose to glucaric acid.
Solution Approach 2:
The patent employs readily available metal precursors (such as H2PtCl6, CuCl2, PdCl2, or RhCl3) that are reduced in situ to form active alloy catalysts. These catalysts are designed to be effective at low concentrations and can be easily separated from the reaction mixture through filtration, eliminating the need for complex separation procedures required by conventional catalysts.
2Reliability
If conventional processes use expensive catalysts, then catalytic activity is achieved, but the separation of catalysts from the reaction medium requires chemical and energy intensive procedures
Solution Approach 1:
The patent changes the physical state and support parameters of the catalyst by immobilizing metal alloy particles on solid supports (TiO2, CeO2, Al2O3). This transformation allows the catalyst to remain in a fixed solid phase during the liquid-phase oxidation reaction, enabling simple filtration for separation without requiring complex chemical procedures or energy-intensive processes.
Solution Approach 2:
The solid support acts as an intermediary carrier that holds the active metal alloy catalyst particles. This intermediary structure provides a stable platform for the catalyst while facilitating easy separation from the reaction medium through simple filtration, thus decoupling the catalytic function from the separation complexity.
3Reliability
If noble metal catalysts are used to form dicarboxylic acids, then catalytic function is provided, but the reported oxidation activity is low
Solution Approach 1:
The patent creates composite metal alloy catalysts by combining noble metals (Pt, Pd, or Rh) with base metals (Cu, Ni, or Zn) in specific ratios. This composite structure leverages the high catalytic activity of noble metals while the base metals enhance the overall oxidation activity and prevent agglomeration of noble metal particles. The synergistic effect of the alloy composition significantly improves oxidation activity compared to using pure noble metals alone.
Solution Approach 2:
The patent optimizes the local composition and distribution of metals within the catalyst structure by controlling the reduction process and metal precursor ratios. The alloy catalysts exhibit different local compositions at the surface versus the bulk, with the surface enriched in active metal sites that facilitate oxidation. This local quality optimization ensures maximum catalytic function with enhanced oxidation activity.
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 alloy catalysts demonstrate improved catalytic activity and selectivity for forming dicarboxylic acids like glucaric acid, reducing energy consumption and by-product generation, and allowing for easier catalyst separation and reuse.
Implementation Method 1
adding a reducing agent to the combined solution to form the alloy catalyst
Implementation Method 2
contacting a substrate with an oxidant in the presence of an alloy catalyst to form one or more carboxylic acids
Data Source
AI summary
In a first aspect, the present invention is directed to a process for forming a metal alloy catalyst. Another aspect of the present invention is directed to a process for oxidizing a substrate that includes contacting a substrate with an oxidant in the presence of a metal alloy catalyst to form one or more carboxylic acids. Suitable substrates include sugars, polyols, furfural alcohols, and polyhydroxycarboxylic acids. The oxidation process may use the alloy catalyst formed from the process of the first aspect of the invention.