Direct Syngas–Methanol Conversion to Propanal Using Heterogeneous Catalysts
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Solution Overview
Problem
There is a lack of an efficient, large-scale industrial process for the direct conversion of syngas and methanol to propanal using heterogeneous catalysts, which could significantly impact various industrial value chains including the production of propylene and methacrylic acid.
Innovation Solution
A process utilizing heterogeneous catalysts comprising transition metals like Co, Ni, Cu, Fe, Mn, Mo, W, Ru, Re, Rh, and carbon with specific structures, particularly non-graphitizing carbon with dispersed cobalt nanoparticles, is used to convert syngas and methanol directly to propanal, followed by subsequent processes to propylene and methacrolein, offering higher selectivity and reduced complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional processes convert methanol via intermediate dimethylether into propylene or olefin mixtures, then the conversion pathway is established, but the process complexity increases and selectivity decreases
Solution Approach 1:
The invention extracts and eliminates the intermediate dimethylether step from the conventional methanol-to-propylene pathway. By using a heterogeneous catalyst system that directly converts methanol, CO, and H2 to propanal and subsequently to propylene, the process removes the complex intermediate stages while improving overall selectivity and simplifying the reaction network.
Solution Approach 2:
The invention introduces a heterogeneous catalyst system comprising transition metals (Co, Ni, Cu, Fe, Mn, Mo, W, Ru, Re, Rh) on carbon supports as an intermediary that enables direct conversion. This catalyst mediator facilitates the transformation from methanol through propanal to propylene in a more selective and less complex manner than conventional homogeneous or multi-step processes.
2Productivity
If established processes are used for converting methanol to propylene, then the conversion pathway is known, but the selectivity and efficiency are reduced
Solution Approach 1:
The invention changes key process parameters by employing a heterogeneous catalyst system with specific transition metals on carbon supports, operating at temperatures of 125-240°C and pressures of 30-300 bar with CO/H2 molar ratios of 0.5-1.5. These parameter changes enable direct conversion of methanol to propanal with high selectivity, improving both productivity and reliability compared to conventional processes.
Solution Approach 2:
The invention uses composite heterogeneous catalysts combining transition metals (Co, Ni, Cu, Fe, Mn, Mo, W, Ru, Re, Rh) with carbon materials (graphitic, carbidic, aromatic, or amorphous non-graphitizing structures). This composite approach leverages the synergistic effects of metal catalytic activity and carbon support stability, achieving superior conversion efficiency and selectivity for propanal production.
3Ease of manufacture
If gas-phase oxidation of isobutene or tert-butanol is used to produce methacrolein, then the process is established, but alternative routes from syngas and methanol could provide economic advantages
Solution Approach 1:
The invention segments the production pathway into distinct catalytic steps: first, direct conversion of methanol, CO, and H2 to propanal using heterogeneous catalysts; second, subsequent conversion of propanal to methacrolein. This segmentation allows optimization of each step independently, improving overall economic attractiveness and efficiency compared to conventional single-step processes from isobutene or tert-butanol.
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
This process achieves higher selectivity and less complexity in converting methanol to propylene and methacrylic acid, providing economically attractive routes and enabling efficient downstream processing to methyl methacrylate.
Implementation Method 1
process for the selective production of propanal from methanol, carbon monoxide and hydrogen, using heterogeneous catalysts comprising one or more transition metals selected from Co, Ni, Cu, Fe, Mn, Mo, W, Ru, Re, Rh, and carbon
Implementation Method 2
heterogeneous catalysts comprising one or more transition metals selected from Co, Ni, Cu, Fe, Mn, Mo, W, Ru, Re, Rh, and carbon, exhibiting a structure selected from graphitic, carbidic, aromatic or amorphous non-graphitizing
Data Source
AI summary
The present invention relates to processes for the selective production of propanal from methanol, carbon monoxide and hydrogen, using heterogeneous catalysts comprising one or more transition metals selected from Co, Ni, Cu, Fe, Mn, Mo, W, Ru, Re, Rh, and carbon, exhibiting a structure selected from graphitic, carbidic, aromatic or amorphous non-graphitizing.