Formic Acid Catalyst Regeneration via Low-Pressure Gas Circulation
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Solution Overview
Problem
The existing methods for catalytic generation of formic acid and regeneration of catalysts are costly and inefficient due to the need for high-pressure reaction vessels and complex safety measures, which increase operational expenses and reduce process efficiency.
Innovation Solution
A method involving a vanadyl ion, vanadate ion, or polyoxometallate ion catalyst, operating at temperatures between 70°C and 160°C, with a high oxygen-containing gas mixture at pressures between 2 and 16 bar, where CO and CO2 are managed to maintain an optimal gas composition, allowing for efficient catalyst oxidation and formic acid production at reduced pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high oxygen partial pressure (1-500 bar) is used to accelerate catalyst oxidation, then the oxidation rate is improved, but the equipment cost and safety requirements increase significantly
Solution Approach 1:
The patent changes the pressure parameter from high (1-500 bar) to low (1-16 bar) while maintaining effective catalyst oxidation through optimized gas composition and continuous gas circulation, thereby reducing equipment complexity and safety requirements while preserving oxidation effectiveness
Solution Approach 2:
The patent implements continuous gas circulation and replenishment to maintain constant oxygen partial pressure and remove accumulated CO/CO2, ensuring continuous effective oxidation of the catalyst without requiring high initial pressure, thus achieving high oxidation rate with low-pressure equipment
2Productivity
If high pressure reaction vessels are used to maintain oxygen partial pressure, then the oxidation efficiency is improved, but the manufacturing cost and operational complexity increase
Solution Approach 1:
The patent changes the pressure parameter from high to low range and compensates by optimizing gas flow rate, oxygen concentration, and circulation continuity, achieving high oxidation efficiency with standard-pressure equipment that is cheaper and easier to manufacture
Solution Approach 2:
The patent monitors gas composition (O2, CO, CO2 levels) and adjusts gas flow and composition in real-time to maintain optimal oxidation conditions, ensuring high oxidation efficiency without requiring expensive high-pressure vessels
3Stress or pressure
If CO and CO2 accumulate in the gas phase, then the pressure can be maintained, but the oxidation of the catalyst is inhibited and formic acid yield decreases
Solution Approach 1:
The patent implements continuous gas circulation and replenishment to continuously remove CO and CO2 from the system while maintaining constant oxygen partial pressure, preventing catalyst oxidation inhibition and maintaining high formic acid yield throughout the reaction
Solution Approach 2:
The patent uses a gas circulation system as an intermediary to separate the functions of pressure maintenance and composition control, allowing pressure to be maintained at low levels while CO/CO2 are continuously removed through controlled gas exchange
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 approach enables cost-effective and efficient production of formic acid by maintaining high oxygen partial pressures, reducing equipment costs, and optimizing gas composition to enhance yield and reaction rate, while ensuring efficient catalyst regeneration.
Implementation Method 1
regeneration of the catalyst reduced in the process with little overpressure... the oxidation of the catalyst reduced in the process
Implementation Method 2
The CO and/or CO2 produced during the reaction passes from the solution into the gas
Data Source
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AI summary
The invention relates to a method for catalytically producing formic acid and regenerating the catalyst used in the process. A vanadyl ion, vandate ion, or polyoxometallate ion, which is used as the catalyst, of the general formula [PMoxVyO40]n- is brought into contact with an alpha hydroxyl aldehyde, an alpha hydroxy carboxylic acid, a carbohydrate, a glycoside, or a polymer, which contains a carbon chain and which comprises at least one OH group that is bound to the carbon chain as a substituent in a repeating manner and/or an O, N, or S atom contained in the carbon chain in a repeating manner, in a liquid solution (12) in a vessel (10) at a temperature above 70 °C and below 160 °C, wherein 6 ≤ x ≤ 11, 1 ≤ y ≤ 6, 3 < n < 10, and x + y = 12, where n, x, and y is each a whole number. The catalyst reduced in the process is returned to its starting state by oxidation. For this purpose, the solution (12) is brought into contact with a gas (18) which contains a volume percent of oxygen of at least 18% at a pressure of at least 2 bar and maximally 16 bar by means of a mixing device or via a liquid-non-permeable gas-permeable membrane. CO and/or CO2 resulting during the reaction and merging with the gas (18) is discharged in such a quantity that the volume percent of CO and CO2 combined does not exceed 80% in the gas (18).