Copper Oxide Catalyst Reductive Amination Cost Stability
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Solution Overview
Problem
Existing processes for reductive amination of aldehydes and ketones face challenges with high procurement costs due to limited availability of Pd catalysts, insufficient mechanical stability, and short service life, making them unsuitable for industrial-scale applications.
Innovation Solution
A process using a heterogeneous copper oxide hydrogenation catalyst with a catalytically active composition comprising at least 24% by weight of copper oxygen compounds, which allows for high yield and selectivity in the liquid phase reaction of aldehydes and ketones with nitrogen compounds, offering improved mechanical stability and longer service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If Pd/C catalyst is used for reductive amination, then high conversion and selectivity are achieved, but procurement costs increase due to limited availability of Pd
Solution Approach 1:
The patent replaces expensive palladium catalyst with a cheaper copper oxide catalyst that can be used in industrial scale processes. The copper oxide catalyst achieves comparable conversion and selectivity while being more economically viable due to lower material costs and better availability.
Solution Approach 2:
The patent changes the catalyst material from palladium to copper oxide and adjusts reaction parameters (temperature 50-200°C, pressure 1-30 MPa) to optimize performance. This parameter change enables cost-effective industrial production while maintaining high conversion and selectivity.
2Manufacturing precision
If Pd/C catalyst is used for reductive amination, then high conversion is achieved, but mechanical stability and service life are insufficient
Solution Approach 1:
The patent replaces Pd/C catalyst with copper oxide catalyst that demonstrates superior mechanical stability and service life for industrial applications. The copper oxide catalyst maintains structural integrity under reaction conditions and can be used continuously without frequent replacement.
Solution Approach 2:
The patent uses copper oxide as a composite catalyst material that combines catalytic activity with mechanical stability. The copper oxide structure provides both the necessary catalytic function for high conversion and the mechanical robustness required for long service life in industrial reactors.
3Manufacturing precision
If laboratory-scale Pd/C catalyst process is used, then high selectivity is achieved, but the process is not suitable for industrial scale due to catalyst availability and cost
Solution Approach 1:
The patent replaces expensive Pd/C catalyst with affordable copper oxide catalyst, enabling industrial-scale production. The copper oxide catalyst maintains high selectivity while being economically viable for large-scale manufacturing of amines.
Solution Approach 2:
The patent optimizes reaction parameters for industrial scale including temperature (50-200°C), pressure (1-30 MPa), and liquid-phase reaction conditions. These parameter changes enable scalable production while maintaining the high selectivity achieved in laboratory settings.
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 process achieves high conversion, yield, and selectivity while reducing costs and improving catalyst stability, making it suitable for industrial-scale production of amines.
Implementation Method 1
subsequent hydrogenation of the resulting reaction product in the liquid phase and in the presence of hydrogen and of a heterogeneous copper oxide hydrogenation catalyst
Implementation Method 2
in the presence of hydrogen and of a heterogeneous copper oxide hydrogenation catalyst at a temperature of 20 to 230° C.
Data Source
AI summary
A process for preparing an amine by reacting an aldehyde and/or ketone with a nitrogen compound selected from the group consisting of ammonia and primary and secondary amines, and subsequent hydrogenation of the resulting reaction product in the liquid phase and in the presence of hydrogen and a heterogeneous copper oxide hydrogenation catalyst at a temperature of 20 to 230° C., wherein the aldehyde and/or ketone is reacted with the nitrogen compound either together with the hydrogenation in the liquid phase and in the presence of the hydrogen and of the catalyst (alternative 1) or in a step preceding the hydrogenation (alternative 2), and wherein the catalytically active composition of the catalyst, prior to reduction thereof with hydrogen, comprises at least 24% by weight of oxygen compounds of copper, calculated as Cu.