Mixed-Phase Bismuth Molybdate Catalyst for Butadiene Production
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Solution Overview
Problem
Current methods for producing 1,3-butadiene through oxidative dehydrogenation of n-butene are inefficient due to high temperature and pressure requirements, low yields, and the need for additional separation processes, especially when using C4 mixtures containing n-butane, which limits economic viability and catalyst selectivity.
Innovation Solution
A mixed-phase bismuth molybdate catalyst comprising 1 to 40 wt% α-bismuth molybdate (Bi2Mo3O12) and 60 to 99 wt% γ-bismuth molybdate (Bi2MoO6) is used to catalyze the oxidative dehydrogenation of a C4 mixture, eliminating the need for additional separation processes and allowing high-value 1,3-butadiene production from inexpensive C4 raffinate-3 containing n-butane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If steam cracking is used to produce butadiene, then large-scale production is achieved, but additional separation processes and raffinate components are produced
Solution Approach 1:
The invention extracts and utilizes the previously wasted C4 raffinate stream from steam cracking processes as a feedstock for butadiene production. By taking out this side stream that contains n-butane and n-butene, the process converts a waste product into a valuable resource, enabling butadiene production without requiring additional naphtha cracking capacity
Solution Approach 2:
The invention merges the C4 raffinate treatment process with butadiene production by using oxidative dehydrogenation catalysts that selectively convert n-butane and n-butene in the raffinate to butadiene. This combines what were previously separate processes (raffinate handling and butadiene production) into an integrated system that eliminates additional separation equipment
2Productivity
If direct dehydrogenation of n-butene is used, then butadiene is produced, but high temperature and pressure conditions are required resulting in poor thermodynamic properties
Solution Approach 1:
The invention changes the reaction parameters by using oxidative dehydrogenation instead of direct dehydrogenation. This chemical parameter change (adding oxygen to the reaction) fundamentally alters the thermodynamics, allowing the reaction to proceed at lower temperatures with improved equilibrium conversion and butadiene yield
Solution Approach 2:
The invention employs composite catalyst systems that combine metal components (such as Fe, Mo, Bi, or V) with oxide supports to achieve high activity for oxidative dehydrogenation. These composite catalyst materials enable the reaction to proceed under milder conditions with high selectivity to butadiene, overcoming the thermodynamic limitations of direct dehydrogenation
3Ease of manufacture
If C4 mixture containing n-butane is used as reactant, then inexpensive feedstock is utilized, but catalyst selectivity and activity are reduced
Solution Approach 1:
The invention applies local quality by designing catalysts with specific active sites that are selectively tuned to interact with n-butane and n-butene molecules in the C4 mixture. The catalyst composition and structure are locally optimized at the molecular level to favor butadiene formation pathways while minimizing side reactions, even in the presence of other C4 components
Solution Approach 2:
The invention changes catalyst parameters (composition, structure, and preparation conditions) to achieve high selectivity for oxidative dehydrogenation of n-butane and n-butene. By adjusting catalyst parameters such as metal loading, oxide phase composition, and surface area, the catalyst maintains high butadiene selectivity when processing inexpensive C4 mixtures containing n-butane
4Temperature
If oxidative dehydrogenation is used, then reaction temperature is decreased, but side reactions including complete oxidation occur
Solution Approach 1:
The invention optimizes reaction parameters (temperature, oxygen-to-hydrocarbon ratio, contact time) to maximize butadiene selectivity while minimizing complete oxidation. By carefully controlling these parameters, the process achieves high conversion with minimal side reactions, as the oxidative dehydrogenation pathway is favored under optimized conditions
Solution Approach 2:
The invention uses composite catalysts with specific metal-oxide compositions that promote selective oxidative dehydrogenation while suppressing complete oxidation. The synergistic interaction between different metal components and oxide supports creates active sites that favor partial oxidation to butadiene while resisting total oxidation to CO2 and H2O
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
This approach achieves high activity and selectivity for 1,3-butadiene production, maintaining catalytic performance over time, even with high n-butane concentrations, and simplifies the synthesis and application of the catalyst, ensuring reproducibility and economic efficiency.
Implementation Method 1
a bismuth molybdate catalyst, a method of preparing the same, and a method of preparing 1,3-butadiene using the same, in which a highly active mixed-phase bismuth molybdate catalyst, comprising single-phase α- and γ-bismuth molybdate catalysts, is prepared, and, in the presence of such a catalyst, high value-added 1,3-butadiene can be prepared
Implementation Method 2
The oxidative dehydrogenation of n-butene (1-butene, trans-2-butene, cis-2-butene) is a reaction between n-butene and oxygen that produces 1,3-butadiene and water
Data Source
AI summary
This invention relates to a bismuth molybdate catalyst, a preparation method thereof, and a method of preparing 1,3-butadiene using the same, and to a bismuth molybdate catalyst, a preparation method thereof, and a method of preparing 1,3-butadiene using the same, in which 1,3-butadiene can be prepared through oxidative dehydrogenation directly using a C4 mixture including n-butene and n-butane as a reactant in the presence of a mixed-phase bismuth molybdate catalyst including α-bismuth molybdate (Bi2Mo3On) and γ-bismuth molybdate (Bi2MoO6). According to this invention, the C4 raffinate, containing many impurities, is used as a reactant, without an additional n-butane separation process, thus obtaining 1,3-butadiene at high yield. Unlike complicated multicomponent-based metal oxides, the catalyst of the invention has simple constituents and synthesis routes, and can be easily formed through physical mixing, and thus is very advantageous in assuring reproducibility and can be directly applied to commercial processes.