Coke-Based Catalyst for 1,3-Butadiene Dehydration

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Solution Overview

Problem

Current processes for producing 1,3-butadiene are energy-consuming and emit high CO2 levels, and existing catalysts for dehydration reactions suffer from durability issues and secondary reaction products that lead to catalyst deactivation.

Innovation Solution

A catalyst comprising coke, characterized by at least two peaks in the 1450 cm−1 to 1700 cm−1 wavelength range upon DRIFTS analysis, is used for the dehydration of alkenols to produce 1,3-butadiene, which is formed during the catalytic dehydration reaction and can be derived from biosynthetic processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional catalysts are used for dehydration reactions, then the production of 1,3-butadiene can be achieved, but the catalysts suffer from durability issues and deactivation due to secondary reaction products

Engineering Contradiction:

Improvecatalyst durabilityVSAvoidsecondary reaction products causing deactivation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent applies the principle of converting harm into benefit by utilizing coke, traditionally considered a harmful deactivation product, as the active catalytic component. The catalyst comprises 20-80 wt% coke that has been treated to develop acid sites, transforming the harmful carbon deposits into the beneficial active phase that drives the dehydration reaction while resisting deactivation

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent applies parameter changes by treating coke through controlled oxidation at 200-400°C to modify its chemical properties. This treatment introduces oxygen-containing functional groups and acid sites on the coke surface, fundamentally changing its reactivity and transforming it from an inert deactivation product into an active catalyst with enhanced durability

Inventive Principle:

Principle #35Parameter changes

2Productivity

If existing catalytic systems are used for dehydration of alkenols, then diene production can occur, but energy consumption is high and CO2 emissions are significant

Engineering Contradiction:

Improvediene production efficiencyVSAvoidenergy consumption and CO2 emissions

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent applies self-service by using bio-based alkenols derived from renewable biomass resources as feedstocks. This eliminates the need for energy-intensive steam cracking processes currently used to produce butadiene from petroleum, thereby reducing energy consumption and CO2 emissions while maintaining high productivity through the efficient dehydration reaction catalyzed by the coke-based catalyst

Inventive Principle:

Principle #25Self-service

3Productivity

If traditional dehydration catalysts are employed, then the reaction can proceed, but secondary products are formed that lead to catalyst deactivation

Engineering Contradiction:

Improvereaction efficiencyVSAvoidsecondary products causing deactivation

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent transforms the harmful secondary products (coke deposits) into the beneficial active catalytic phase. By controlling the oxidation treatment to create acid sites on the coke surface, the catalyst system converts what would normally be deactivation products into the active components that drive the dehydration reaction with high efficiency and sustained activity

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 catalyst provides high yield and selectivity for 1,3-butadiene production with reduced formation of secondary products that deactivate the catalyst, thus improving process efficiency and environmental impact.

Implementation Method 1

a catalyst comprising coke, characterised in that said coke, upon analysis by infrared spectroscopy in diffuse reflection

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

the dehydration of at least one alkenol having a number of carbon atoms greater than or equal to 4

Methodology Applied

Scientific EffectDehydration reaction:

Implementation Method 3

upon analysis by infrared spectroscopy in diffuse reflection ('Diffuse Reflectance Infrared Fourier Transform Spectroscopy'—DRIFTS), has at least two peaks at a wavelength comprised between 1450 cm−1 and 1700 cm−1

Methodology Applied

Scientific EffectInfrared absorption: Absorption (EM radiation)

Data Source

PatentUS20220339610A1Catalyst comprising coke and process for the production of dienes

Publication Date: 2022.10.27 VERSALIS SPA

AI summary

A catalyst having coke wherein the coke, upon analysis by infrared spectroscopy in diffuse reflection, has at least two peaks at a wavelength between 1450 cm−1 and 1700 cm−1.The aforesaid catalyst having coke can be advantageously used in a process for the production of a diene, preferably a conjugated diene, more preferably 1,3-butadiene, said process having the dehydration of at least one alkenol having a number of carbon atoms greater than or equal to 4.Preferably, the alkenol having a number of carbon atoms greater than or equal to 4 can be obtained directly from biosynthetic processes, or through catalytic dehydration processes of at least one diol.When the alkenol is a butenol, the diol is preferably a butanediol, more preferably 1,3-butanediol, even more preferably bio-1,3-butanediol, i.e. 1,3-butanediol deriving from biosynthetic processes.When the diol is 1,3-butanediol, or bio-1,3-butanediol, the diene obtained with the process is, respectively, 1,3-butadiene, or bio-1,3-butadiene.