Cobalt Catalyst Cubic Phase Hydrogenation
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Solution Overview
Problem
Existing methods for producing alcohols from carboxylic acids through catalytic hydrogenation have low industrially acceptable activity, as they lack a cubic phase in the catalyst, which is crucial for enhanced catalytic activity and durability.
Innovation Solution
A catalyst containing Co metal with 20% or more of the cubic phase, combined with co-catalysts such as Zr, Y, La, Ce, Si, Al, Sc, V, and Mo, and optionally Pt or Pd, is used for hydrogenation, with a reduction rate of Co exceeding 40% and an oxide film formed on the surface to stabilize the catalyst.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts are used for hydrogenation of carboxylic acids, then the process can proceed, but the catalytic activity is low and not industrially acceptable
Solution Approach 1:
The patent applies parameter changes by controlling the reduction temperature (400-900°C) and reduction atmosphere to achieve a specific cubic phase content (20% or more) of Co metal in the catalyst. This phase transformation from non-cubic to cubic structure fundamentally changes the catalytic properties, resolving the low activity problem of conventional catalysts
Solution Approach 2:
The patent uses composite materials by combining Co metal with specific co-catalysts (Al, Zr, Mo, Y, La, Ce, Si, Sc, V) in defined ratios. This composite structure enhances both the cubic phase formation and overall catalytic performance, achieving industrially acceptable activity levels
2Productivity
If the catalyst is reduced to increase Co metal content, then activity improves, but the catalyst becomes unstable without surface stabilization
Solution Approach 1:
The patent applies preliminary action by forming an oxide film on the catalyst surface through controlled oxidation after reduction. This pre-stabilization step prevents catalyst degradation during storage and handling while maintaining the active reduced state, resolving the stability issue
Solution Approach 2:
The patent uses an inert atmosphere containing 0.1-5% oxygen to form the protective oxide film. This controlled oxidative environment provides the necessary surface stabilization without fully oxidizing the active Co metal sites, balancing stability and 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
This approach results in a catalyst with high industrially acceptable catalytic activity, enabling the production of alcohols from carboxylic acids at high yield, improving both activity and durability.
Implementation Method 1
hydrogenating a carboxylic acid with a catalyst
Implementation Method 2
hydrogenating a carboxylic acid with a catalyst
Implementation Method 3
the oxide film is formed by placing the catalyst in a flow of an inert gas containing 0.1 to 5% by volume of oxygen
Data Source
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AI summary
The present invention provides a catalyst for producing alcohols from carboxylic acids by hydrogenation, containing Co metal as an essential component and one or more elements selected from Zr, Y, La, Ce, Si, Al, Sc, V and Mo as a first co-catalyst component, and having 20% or more of cubic phase in the crystal phase of the Co metal, the method for producing the catalyst, and the method for producing an alcohol from a carboxylic acid as a raw material by hydrogenation using the catalyst.