Multicomponent Bismuth Molybdate Catalyst for Butadiene Production
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Solution Overview
Problem
Current methods for producing 1,3-butadiene, such as naphtha cracking and direct dehydrogenation, are energy-intensive and inefficient, and existing catalysts require complex compositions and additional separation processes, making them unsuitable for commercial production from C4 mixtures with high n-butane content.
Innovation Solution
A multicomponent bismuth molybdate catalyst with a simple composition of four metal components (divalent cationic metal, trivalent cationic metal, bismuth, and molybdenum) is prepared through coprecipitation, allowing for high activity in oxidative dehydrogenation of n-butene without additional separation processes, using a C4 mixture with high n-butane content as a reactant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If naphtha cracking is used to produce 1,3-butadiene, then high production volume is achieved, but energy consumption increases and additional separation processes are required
Solution Approach 1:
The patent extracts and utilizes the C4 fraction (containing n-butane and n-butene) that would otherwise be wasted by-product from naphtha cracking. By using this extracted fraction as the reactant for oxidative dehydrogenation, the process converts a low-value by-product into high-value 1,3-butadiene, thereby reducing energy consumption and eliminating the need for additional separation processes while maintaining high production volume
Solution Approach 2:
The patent creates a multi-functional process where the C4 fraction serves dual purposes: it is both the reactant for 1,3-butadiene production and the feedstock that would normally require separation. The oxidative dehydrogenation process simultaneously achieves 1,3-butadiene production and n-butane conversion, eliminating the need for separate separation units while maintaining high productivity
2Manufacturing precision
If direct dehydrogenation of n-butene is used to produce 1,3-butadiene, then high purity product is achieved, but the process becomes thermodynamically disadvantageous requiring high temperature and low pressure
Solution Approach 1:
The patent employs oxidative dehydrogenation using oxygen as a reactant instead of simple dehydrogenation. The oxidation process provides thermodynamic driving force that allows the reaction to proceed at lower temperatures while maintaining high product purity. The oxidative pathway converts n-butene to 1,3-butadiene through a mechanism that is both thermodynamically favorable and kinetically efficient, eliminating the need for high-temperature conditions
3Productivity
If existing catalysts are used for oxidative dehydrogenation, then high activity is achieved, but catalyst composition becomes complex requiring multiple metal components
Solution Approach 1:
The patent develops a composite catalyst material consisting of bismuth molybdate combined with specific metal components (Fe, Ni, Co, Cu, or Zn). This composite structure synergistically combines the high catalytic activity of bismuth molybdate with the promotional effects of the added metals, achieving high activity for oxidative dehydrogenation while maintaining a relatively simple and reproducible composition that can be manufactured at scale
4Ease of operation
If C4 mixture with high n-butane content is used as reactant, then process simplicity is improved, but catalyst selectivity becomes difficult to control
Solution Approach 1:
The patent optimizes the catalyst composition parameters by systematically varying the ratios of bismuth, molybdenum, and the additional metal components (Fe, Ni, Co, Cu, or Zn). By adjusting these compositional parameters, the catalyst achieves high selectivity for 1,3-butadiene production even when processing C4 mixtures with high n-butane content, thereby maintaining both process simplicity and manufacturing precision simultaneously
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 simplifies catalyst synthesis, ensures reproducibility, and enables high-yield production of 1,3-butadiene from inexpensive C4 mixtures, overcoming the limitations of complex catalyst compositions and energy inefficiencies in existing processes.
Implementation Method 1
the oxidative dehydrogenation of n-butene is a reaction for producing 1,3-butadiene through removal of two hydrogens from n-butene using oxygen as a reactant
Implementation Method 2
a method of preparing multicomponent bismuth molybdate catalysts having a simple composition of four metal components... high activity for the inventive reaction
Implementation Method 3
preparing a first solution including a precursor of a trivalent cationic metal including iron, a precursor of a divalent cationic metal selected from among magnesium, manganese, cobalt, nickel, copper and zinc, and a bismuth precursor; preparing a second solution in which a molybdenum precursor is dissolved; adding the first solution in droplets to the second solution so that coprecipitation occurs
Data Source
AI summary
A method of preparing multicomponent bismuth molybdate catalysts composed of four metal components and a method of preparing 1,3-butadiene using the catalyst, and particularly, to multicomponent bismuth molybdate catalysts composed of a divalent cationic metal, a trivalent cationic metal, bismuth and molybdenum, a preparation method thereof, and a method of preparing 1,3-butadiene from a C4 mixture including n-butene and n-butane using oxidative dehydrogenation are described.