CuO/MnO2/Al2O3 Catalyst for 1,4-Butanediol Dehydrogenation
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Solution Overview
Problem
Existing copper-based catalysts for the dehydrogenation of 1,4-butanediol to γ-butyrolactone suffer from low catalytic efficiency and longevity, leading to high production costs and equipment downtime due to frequent deactivation, and alternative catalysts containing toxic chromium pose environmental hazards.
Innovation Solution
A CuO/MnO2/Al2O3 catalyst composition is developed through co-precipitation and calcination, with a high CuO content (35-70% by weight) and specific crystalline phases, forming a homogeneous bulk extrudate without a binder, enhancing catalytic activity and reducing deactivation rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If copper metal is placed on a porous support for catalysis, then the catalytic reaction can proceed, but catalytic efficiency is poor and a large amount of byproducts are produced
Solution Approach 1:
The patent applies composite materials by combining copper oxide (CuO) with manganese oxide (MnO2) and aluminum oxide (Al2O3) to form a composite catalyst system. This composite structure synergistically improves catalytic efficiency while reducing harmful byproduct formation, directly resolving the contradiction between productivity and harmful factors.
Solution Approach 2:
The patent changes the chemical state of copper from metallic copper (Cu) to copper oxide (CuO), and optimizes the compositional parameters (35-70% CuO, 15-35% Al2O3, 5-20% MnO2) to achieve superior catalytic performance with reduced byproduct formation, thereby resolving the contradiction between efficiency and harmful emissions.
2Productivity
If catalysts based upon Cu/Cr/Mn, Cu/Cr/Zn, and Cu/Cr are used, then catalytic activity is achieved, but they contain toxic Cr, are difficult to prepare, and are potentially environmentally hazardous
Solution Approach 1:
The patent extracts and eliminates the toxic chromium (Cr) component from the catalyst system while retaining the essential catalytic functionality through the use of CuO/MnO2/Al2O3 composite, thereby maintaining productivity while removing harmful factors.
Solution Approach 2:
The patent converts the harmful effect of chromium toxicity into a benefit by using non-toxic alternative materials (CuO, MnO2, Al2O3) that provide comparable or superior catalytic activity without environmental hazards, thus transforming a harmful situation into a beneficial one.
3Object-affected harmful factors
If CuO catalysts are formed from less toxic materials, then environmental safety is improved, but catalytic efficiency and longevity fall below optimal levels
Solution Approach 1:
The patent uses composite materials combining CuO with MnO2 and Al2O3 to achieve both environmental safety (non-toxic composition) and high catalytic efficiency/longevity, simultaneously resolving the contradiction between reducing harmful factors and maintaining productivity.
Solution Approach 2:
The patent optimizes the compositional parameters (specific weight percentages of CuO, Al2O3, and MnO2) to achieve peak catalytic performance while maintaining non-toxicity, thereby resolving the contradiction between environmental safety and catalytic efficiency.
4Productivity
If a catalyst is used to increase throughput, then production efficiency improves, but catalyst deactivation occurs leading to equipment downtime
Solution Approach 1:
The patent incorporates stabilizing components (MnO2 and Al2O3) in advance to prevent catalyst deactivation, cushioning against the harmful effect of deactivation before it occurs and maintaining reliability during high-throughput operation.
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 exhibits significantly higher catalytic constants and lower deactivation rates, allowing for increased throughput and reduced downtime, thus improving the efficiency and cost-effectiveness of the dehydrogenation process.
Implementation Method 1
CuO/MnO2/Al2O3 catalysts useful for the dehydrogenation of 1,4-butanedial to γ-butyrolactone
Implementation Method 2
co-precipitating a solid catalyst composition from solutions containing a soluble copper salt, a soluble manganese salt, and a soluble aluminum compound
Implementation Method 3
co-precipitating a solid catalyst composition from solutions
Implementation Method 4
calcining the solid catalyst composition under air from about 400 to about 700°C for a time period from about 2 to about 5 hours
Implementation Method 5
calcining the solid catalyst composition under air
Data Source
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AI summary
Disclosed are catalytic compositions having from about 35% to about 75% of Cu by weight, from about 15% to about 35% of Al by weight, and about 5% to about 20% of Mn by weight. The catalytic compositions are bulk homogeneous compositions formed from extruding and calcinating a powder formed from a precipitation reaction of Cu(NO3)2, Mn(NO3)2, Na2Al2O3. The catalytic compositions have one or more crystalline phases of one or more of CuO and CuxMn(3-X)O4 where x is from about 1 to about 1.5, or both. The catalytic compositions are useful for the conversion of 1,4-butane-di-ol to γ-butyrolactone by a dehydrogenation reaction.