Bi-functional Catalyst for Glycol Production
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Solution Overview
Problem
Current methods for producing glycols from carbohydrate feedstocks are inefficient, resulting in low product purity and high energy and chemical component usage, making the process economically unviable.
Innovation Solution
A bi-functional catalyst system comprising a heterogeneous hydrogenation catalyst and a soluble retro-Aldol catalyst is used to convert carbohydrate feeds into ethylene glycol and propylene glycol under controlled hydrogenation conditions, optimizing temperature, pressure, and pH to achieve high glycol yields and catalyst stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional catalyst systems are used for glycol production from carbohydrates, then the process can proceed, but product purity is low and energy consumption is high
Solution Approach 1:
The patent combines two catalyst systems into a single bi-functional catalyst: a hydrogenation catalyst (Groups 8-10 metals) and a retro-Aldol catalyst (tungsten or molybdenum compounds). This merged catalyst system simultaneously performs both hydrogenation and retro-Aldol reactions, achieving high product purity (ethylene glycol and propylene glycol) while reducing energy consumption by eliminating the need for separate catalytic steps and reducing overall process complexity.
Solution Approach 2:
The bi-functional catalyst system performs multiple functions within a single catalyst: it catalyzes both hydrogenation reactions (adding hydrogen to carbohydrates) and retro-Aldol reactions (cleaving C-C bonds). This multi-functionality allows the process to achieve high glycol yields and purity while operating under milder conditions, thereby reducing energy consumption compared to conventional multi-step processes.
2Productivity
If conventional multi-step processing is used, then glycols can be produced, but the process is economically unviable due to high chemical component usage
Solution Approach 1:
The patent merges hydrogenation and retro-Aldol catalysis into a single bi-functional catalyst system, eliminating the need for separate chemical additives and processing steps. This integration reduces chemical component usage while maintaining high glycol yield, making the process economically viable by reducing costs associated with chemical reagents and process complexity.
3Productivity
If existing catalyst systems are used, then conversion can occur, but catalyst stability and longevity are insufficient
Solution Approach 1:
The patent employs a composite catalyst system combining hydrogenation catalysts (noble or non-noble metals from Groups 8-10) with retro-Aldol catalysts (tungsten or molybdenum compounds). This composite approach creates a synergistic effect where the combined catalyst system achieves both high conversion rates and extended longevity, as each catalyst component contributes its specific functionality while the combination provides mutual stabilization and reduced deactivation.
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 purity glycol production with a high percentage recovery, low energy consumption, and extended catalyst longevity, making the glycol production process more economical compared to previous methods.
Implementation Method 1
contacting, in a first reactor under hydrogenation conditions, the carbohydrate feed with a bi-functional catalyst system
Implementation Method 2
The bi-functional catalyst system may include a heterogeneous hydrogenation catalyst, and a soluble retro-Aldol catalyst
Data Source
Figure 1
AI summary
Implementations of the disclosed subject matter provide methods for producing ethylene glycol from a carbohydrate feed may include contacting, in a first reactor under hydrogenation conditions, the carbohydrate feed with a bi-functional catalyst system. The bi-functional catalyst system may include a heterogeneous hydrogenation catalyst, and a soluble retro-Aldol catalyst. The carbohydrate feed may include a concentration of carbohydrate, in the total solution entering the first reactor, of 5-40 wt% in a solvent. An intermediate product stream may be obtained from the first reactor including ethylene glycol. The hydrogenation conditions may include a temperature in the range of from 180-250°C.