Cu-Based Dehydrogenation Catalyst for Acetoin Production
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Solution Overview
Problem
The existing methods for producing acetoin, such as the acetaldehyde condensation process, result in the presence of harmful impurities like sulfur and nitrogen in the final product due to the use of expensive thiazole salt catalysts, which are difficult to separate, and there is a need for an improved industrial implementation.
Innovation Solution
A Cu-based dehydrogenation catalyst is developed, comprising Cu, auxiliary metals, an alkali metal, and a binder, with a ketone additive and solvent, which is used to convert dihydric alcohols like 2,3-butanediol into acetoin, offering high selectivity and reducing impurity content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thiazole salt catalyst is used in acetaldehyde condensation process, then acetoin can be produced, but harmful impurities such as sulfur and nitrogen are introduced and difficult to separate
Solution Approach 1:
The patent changes the fundamental reaction pathway from acetaldehyde condensation to 2,3-butanedione dehydrogenation. This parameter change in reaction type eliminates the need for thiazole salt catalysts, thereby preventing introduction of sulfur and nitrogen impurities while maintaining acetoin production capability
Solution Approach 2:
The patent replaces expensive thiazole salt catalysts with a copper-based catalyst system that is cheaper, more stable, and does not introduce harmful impurities. The copper catalyst can be easily separated and reused, making it economically viable for industrial production
2Productivity
If thiazole salt catalyst is used, then acetoin condensation reaction can proceed, but the catalyst is expensive and difficult to separate from product
Solution Approach 1:
The patent changes the catalyst system from organic thiazole salts to inorganic copper-based catalysts supported on alumina or silica. This parameter change enables easier separation through filtration and reduces catalyst cost while maintaining catalytic activity for acetoin production
Solution Approach 2:
The patent extracts the harmful thiazole salt catalyst from the reaction system and replaces it with a copper-based catalyst that can be easily separated. The copper catalyst is immobilized on solid supports, allowing simple separation from the liquid product phase
3Productivity
If conventional copper catalysts are used for dehydrogenation, then acetoin can be produced, but selectivity and catalytic performance need improvement
Solution Approach 1:
The patent creates composite catalyst materials by combining copper with alkali metals (K, Na) and auxiliary metals (Ni, Zn, Mn) on solid supports (alumina, silica). This composite structure enhances catalytic activity and selectivity for acetoin production compared to conventional copper catalysts
Solution Approach 2:
The patent optimizes the local composition of the catalyst by controlling the content of each component: CuO (20-40%), alkali metal oxide (0.1-5%), auxiliary metal oxide (0.1-10%), and support material (50-80%). This local quality control ensures high selectivity and activity for the dehydrogenation reaction
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 Cu-based catalyst achieves high acetoin selectivity and large-scale industrial feasibility with minimal harmful impurities, making it suitable for food additive production and conforming to technical indexes.
Implementation Method 1
a Cu-based catalyst, in particular to a Cu-based dehydrogenation catalyst... its use as the dehydrogenation catalyst in the production of hydroxyketone compound such as acetoin
Data Source
Figure 1~2
AI summary
The present invention relates to a Cu-based catalyst, a preparation process thereof and its use as the dehydrogenation catalyst in producing a hydroxyketone compound such as acetoin. Said Cu-based catalyst contains copper, at least one auxiliary metal selected from metal of Group IIA, non-noble metal of Group VIII, metal of Group VIB, metal of Group VIIB, metal of Group IIB and lanthanide metal of periodic table of elements, and an alkali metal, and further contains at least one ketone additive selected from a ketone represented by formula (II) and a ketone represented by formula (ll'). Said Cu-based catalyst shows a high the acetoin selectivity as the dehydrogenation catalyst for producing acetoin. R1-C(=O)-CH(OH)-R2 (II) R1-C(=O)-CH(=O)-R2 (II') In formulae (II) and (II'), each group is defined as in the description.