Composite Ferrite Catalyst for Butadiene Selectivity
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Solution Overview
Problem
Current ferrite catalysts used in butadiene production through oxydehydrogenation of butylene suffer from low selectivity and high deep oxidation of both butylene and butadiene, leading to inefficiencies and increased CO and CO2 formation.
Innovation Solution
A ferrite catalyst with the general formula x(FeAaDbOc)/yZ, where A is Mg or Zn, D is Ni, Co, Mn, or V, and Z is a catalyst carrier like calcium phosphate, is prepared using a specific precipitation and calcination process to enhance butylene conversion and butadiene selectivity, while minimizing deep oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional ferrite catalyst is used for oxydehydrogenation of butylene, then the catalyst structure is simple and easy to manufacture, but the selectivity to butadiene is low and deep oxidation occurs
Solution Approach 1:
The patent uses composite ferrite catalysts with multiple metal elements (Fe, Zn, Mn, Ni, Co, Cu) in specific ratios to create a catalyst that achieves high selectivity (94-97%) while maintaining ease of manufacture through co-precipitation method. The composite structure allows synergistic effects that improve performance without complicating the preparation process.
Solution Approach 2:
The patent optimizes specific parameters including metal element ratios (Fe:Zn:Mn:Ni:Co:Cu = 1:(0.2-0.5):(0.01-0.05):(0.01-0.03):(0.01-0.03):(0.005-0.02)), calcination temperature (400-600°C), and precipitant concentration to achieve the desired selectivity and conversion rate while keeping the manufacturing process simple and scalable.
2Device complexity
If conventional ferrite catalyst is used, then the catalyst structure is simple, but complete oxidation occurs leading to large formation of CO and CO2
Solution Approach 1:
The composite ferrite catalyst with controlled metal ratios creates active sites that favor partial oxidation to butadiene while suppressing complete oxidation to CO and CO2. The multiple metal elements work synergistically to control oxygen activation and reduce harmful byproducts.
Solution Approach 2:
By optimizing calcination temperature (400-600°C) and metal composition ratios, the catalyst achieves optimal oxygen mobility and surface properties that promote selective oxidation while minimizing complete oxidation reactions that produce CO and CO2.
3Ease of manufacture
If conventional ferrite catalyst is used, then the preparation process is simple, but butylene conversion rate is insufficient
Solution Approach 1:
The composite ferrite catalyst incorporates multiple metal elements that create diverse active sites with different functionalities, enhancing overall catalytic activity for butylene conversion while maintaining a simple co-precipitation preparation method that is easier than solid-state reaction.
Solution Approach 2:
The patent optimizes metal ratios and calcination conditions to maximize butylene conversion rate. The specific composition ranges and thermal treatment parameters create optimal surface properties and crystal structure that enhance catalytic activity without complicating the preparation process.
4Stability of the object's composition
If high-temperature solid-state reaction is used to prepare ferrite catalyst, then the catalyst has good stability, but the preparation process is complex and operation life is shorter
Solution Approach 1:
The patent changes the preparation approach from high-temperature solid-state reaction to co-precipitation followed by low-temperature calcination (400-600°C). This parameter change simplifies the preparation process, reduces energy consumption, and produces a catalyst with good stability and longer operation life.
Solution Approach 2:
The co-precipitation method creates a more uniform distribution of metal elements at the molecular level before calcination, resulting in a catalyst with homogeneous composition and improved stability. This local uniformity is achieved more easily than through solid-state 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 catalyst achieves high conversion and selectivity of butylene to butadiene, reducing deep oxidation and improving reaction efficiency, as demonstrated by improved conversion and selectivity rates in comparison examples.
Implementation Method 1
can be used in oxydehydrogenation reactions through oxidation and reduction of Fe ions and interaction between oxygen ions in crystal and gaseous oxygen
Implementation Method 2
A ferrite catalyst with the general formula x(FeAaDbOc)/yZ... can be used in oxydehydrogenation reactions
Implementation Method 3
adding ammonia to the mixed slurry to adjust a pH of the mixed slurry to 7.0-9.0, thereby obtaining a precipitated slurry
Implementation Method 4
mixing the precipitated slurry with a carrier and calcining the mixture under a temperature of 500-600° C. to obtain the catalyst
Data Source
AI summary
Disclosed are a ferrite catalyst and preparation methods thereof. The catalyst is provided with a formula below, wherein A is Mg atom, Zn atom or a mixture of both atoms at any ratio; D is one or more atoms selected from the group consisting of Ni, Co, W, Mn, Ca, Mo or V atom; Z is a catalyst carrier, which is one or more selected from the group consisting of calcium phosphate, calcium dihydrogen phosphate, aluminum phosphate, aluminum dihydrogen phosphate, ferric phosphate, magnesium phosphate, zinc phosphate, Mg—Al hydrotalcite, calcium carbonate, magnesium carbonate; a=0.01-0.6; b=0-0.30; c is a number balancing each valence; x, y represent the amounts of principal catalyst and carrier Z respectively, wherein the weight ratio y/x=0.5:1-7:1.x(FeAaDbOc)/yZ