Hydrotalcite Catalyst for Ethanol Conversion to N-Butanol

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Solution Overview

Problem

Current methods for producing n-butanol are energy-intensive, rely on non-renewable petroleum-based feedstocks, and involve complex processes with low selectivity and high toxicity, making them inefficient and unsustainable.

Innovation Solution

A catalyst comprising thermally decomposed hydrotalcite mixed with metal oxides, specifically formulated with Mg, Ni, Pt, Pd, Zn, Co, Fe, or Cu, is used to convert ethanol into n-butanol and higher alcohols, reducing the need for syngas and acetaldehyde, and improving selectivity and efficiency through a multi-step reaction mechanism.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If hydroformylation is used to produce n-butanol, then n-butanol can be produced from propylene and syngas, but the process requires high energy costs and uses non-renewable petroleum-based feedstocks

Engineering Contradiction:

Improven-butanol productionVSAvoidenergy costs

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent changes the feedstock parameter from petroleum-based propylene and syngas to renewable ethanol, fundamentally altering the energy source and feedstock composition to achieve sustainable n-butanol production while maintaining productivity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the complex hydroformylation process with a catalytic conversion system using ethanol as feedstock, substituting the traditional multi-step chemical process with a more efficient single-step reaction that reduces energy consumption

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If hydroformylation is used to produce n-butanol, then n-butanol can be produced from propylene and syngas, but the process involves high complexity with multiple reactors and homogenous catalysts

Engineering Contradiction:

Improven-butanol productionVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent segments the complex hydroformylation process into simpler components by using a single reactor system with heterogeneous catalysts instead of multiple reactors with homogenous catalysts, reducing overall process complexity while maintaining productivity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates a universal catalyst system that can handle multiple reaction steps (dehydrogenation, aldol condensation, hydrogenation) simultaneously, replacing the need for separate specialized reactors and catalysts with a single multi-functional catalytic system

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If aldol condensation reaction is used to produce n-butanol, then n-butanol can be produced from acetaldehyde, but the process has high toxicity and limited availability of acetaldehyde

Engineering Contradiction:

Improven-butanol productionVSAvoidtoxicity

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent uses ethanol as an intermediary feedstock that can be readily converted to acetaldehyde in situ, eliminating the need to handle toxic acetaldehyde directly while maintaining the aldol condensation pathway for n-butanol production

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent converts the potential harm of using toxic acetaldehyde into a benefit by using ethanol (a safer, more abundant feedstock) that can be converted to acetaldehyde during the reaction process, thereby eliminating toxicity issues while maintaining productivity

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Productivity

If direct fermentation is used to produce n-butanol, then n-butanol can be produced from sugars, but the process has long process times and large separation requirements

Engineering Contradiction:

Improven-butanol productionVSAvoidprocess time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces the biological fermentation process with a catalytic chemical conversion process, substituting microbial metabolism with heterogeneous catalysis that operates much faster and requires no complex separation systems, thereby reducing process time while maintaining productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enhances the production of n-butanol and higher alcohols with improved selectivity and efficiency, utilizing renewable ethanol as a feedstock, thereby reducing energy costs and environmental impact.

Implementation Method 1

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

heating a hydrotalcite above a decomposition temperature, forming a decomposed hydrotalcite in response to the heating

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Data Source

PatentUS10669221B2Composition of catalysts for conversion of ethanol to N-butanol and higher alcohols

Publication Date: 2020.06.02 VIRIDIS CHEMICAL LLC

AI summary

A method of producing a catalyst can include heating a hydrotalcite above a decomposition temperature, forming a decomposed hydrotalcite in response to the heating, combining the decomposed hydrotalcite with a metal salt to form a catalyst mixture, and heating the catalyst mixture to convert the metal salt to a metal oxide. The resulting metal oxide combined with the decomposed hydrotalcite forms the catalyst.