Cu/Ce-Zr Catalyst for Biomass Ketone Conversion
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Solution Overview
Problem
Existing catalysts for converting low-molecular weight ketones and alcohals from biomass fermentation into high-value aliphatic ketones face challenges with copper leaching and uneven dispersion, leading to reduced durability and catalytic activity.
Innovation Solution
A Cu/Ce—Zr-based catalyst is developed, with a mixed support of Ce and Zr oxides that stabilizes copper and adjusts base sites, allowing for efficient conversion of acetone and butanol into aliphatic ketones through controlled dispersion and oxygen storage capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If copper-based catalysts are used for converting low-molecular weight ketones and alcohols into aliphatic ketones, then catalytic activity is improved, but copper leaching occurs leading to reduced durability
Solution Approach 1:
The patent introduces a mixed oxide support (CeO2-ZrO2) as an intermediary between copper and the reaction environment. This support acts as a mediator that stabilizes copper particles through strong metal-support interactions, preventing copper leaching while maintaining catalytic activity. The mixed oxide support with specific basicity and oxygen storage capacity creates a stable environment for copper species.
Solution Approach 2:
The patent creates a composite catalyst system combining copper with a mixed oxide support (CeO2-ZrO2). This composite structure integrates the high catalytic activity of copper with the stabilizing properties of the mixed oxide support, achieving both high activity and durability. The composite material approach allows synergistic effects between copper and the support.
2Ease of manufacture
If copper is loaded on single metal oxide supports, then catalyst preparation is simplified, but copper dispersion becomes uneven reducing catalytic performance
Solution Approach 1:
The patent uses a mixed oxide support (CeO2-ZrO2) instead of single metal oxide supports. The mixed oxide provides a more uniform surface with diverse active sites that promote even copper dispersion. The combination of ceria and zirconia creates a synergistic effect that improves copper distribution uniformity while maintaining ease of preparation through conventional impregnation methods.
Solution Approach 2:
The mixed oxide support provides different local environments with varying basicity and oxygen storage capacities. These local variations in support properties create optimal conditions for uniform copper dispersion across the catalyst surface, with different regions providing complementary functions for copper stabilization.
3Productivity
If basicity of the support is increased to promote aldol condensation, then conversion efficiency improves, but copper stability decreases leading to increased leaching
Solution Approach 1:
The mixed oxide support (CeO2-ZrO2) combines materials with complementary properties: ceria provides high oxygen storage capacity and moderate basicity, while zirconia contributes to structural stability and copper anchoring. This composite achieves the optimal balance between basicity for aldol condensation and stability for copper retention.
Solution Approach 2:
The patent optimizes the Ce/Zr ratio in the mixed oxide support to achieve the desired balance between basicity and copper stability. By adjusting the composition parameters of the mixed oxide, the catalyst achieves optimal conversion efficiency while maintaining copper stability against leaching.
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 achieves high yields of fuel-range aliphatic ketones with improved durability and catalytic activity, suppressing copper leaching and maintaining performance over extended reaction times.
Implementation Method 1
metal sites for alcohol dehydrogenation
Implementation Method 2
base sites for condensation
Implementation Method 3
an aldol condensation reaction between acetone and an alcohol
Implementation Method 4
oxygen storage capacity
Implementation Method 5
improve the dispersion of loaded metal particles
Implementation Method 6
improve the dispersion of loaded metal particles due to a large specific surface area
Data Source
AI summary
The present disclosure discloses: a bifunctional Cu/Ce—Zr-based catalyst suitable for reacting a ketone and alcohol which are contained in a fermented product of biomass and have a low molecular weight, and converting same into an aliphatic ketone having an increased carbon number; a method for producing the catalyst; and a method for producing a fuel-range aliphatic ketone, such as gasoline and air fuel, by using the catalyst.