Ketoacid Upgrading via Zeolite-Embedded Catalyst
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Solution Overview
Problem
Existing methods for upgrading ketoacids to intermediates for the fuel and chemical industry face challenges in achieving high selectivity and preventing catalyst deactivation at low temperatures, while also minimizing side reactions such as hydrogenation.
Innovation Solution
A method involving the dimerization or oligomerization of ketoacids using a heterogeneous catalyst with an acidic zeolite embedded in a mesoporous matrix, which promotes C—C-coupling reactions without significant hydrogenation, allowing for high oligomer production even at moderate temperatures and reducing the risk of side reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional solid metal oxide catalyst systems are used for upgrading ketoacid, then reasonable conversion results are achieved, but selectivity is limited and catalyst deactivation occurs rapidly
Solution Approach 1:
The patent employs a composite catalyst system combining solid metal oxide particles (e.g., WO3, MoO3, V2O5) supported on a porous carrier material (e.g., silica, alumina, zeolite). This composite structure synergistically enhances both selectivity for desired products (dimers, oligomers, gamma-valerolactone) and catalyst stability, preventing rapid deactivation while maintaining high conversion rates.
Solution Approach 2:
The patent utilizes porous carrier materials with controlled pore sizes and surface areas to support the metal oxide catalysts. The porous structure provides high surface area for catalytic activity, facilitates mass transport of reactants and products, and enhances catalyst stability by preventing particle aggregation and sintering, thereby resolving the contradiction between selectivity and stability.
2Productivity
If reaction temperature is increased to improve conversion rate, then productivity increases, but side reactions such as hydrogenation occur more significantly
Solution Approach 1:
The patent optimizes reaction parameters including temperature (100-300°C), pressure (1-50 bar), and catalyst composition to achieve high conversion rates while minimizing side reactions. By carefully controlling these parameters and using selective metal oxide catalysts, the process maintains high productivity with improved selectivity for desired oligomeric products.
Solution Approach 2:
The patent employs specific metal oxide catalysts (WO3, MoO3, V2O5) that have been shown to selectively promote C-C coupling reactions over hydrogenation. These catalysts effectively 'copy' the desired reaction pathway, guiding the reaction toward oligomeric products even at elevated temperatures where side reactions might otherwise dominate.
3Manufacturing precision
If reaction temperature is lowered to reduce side reactions, then selectivity improves, but catalyst deactivation occurs more rapidly
Solution Approach 1:
The composite catalyst system combines metal oxide active sites with stable porous carrier materials, creating a robust catalyst that maintains high selectivity at lower temperatures while resisting deactivation. The carrier material provides structural stability and prevents metal oxide particle aggregation, extending catalyst lifetime even under mild reaction conditions.
Solution Approach 2:
The patent develops catalyst formulations that are cost-effective and can be easily replaced or regenerated. By using abundant metal oxides (WO3, MoO3, V2O5) on inexpensive porous carriers, the process achieves high selectivity at low temperatures with acceptable catalyst lifetimes, making the system economically viable even if catalyst replacement is needed periodically.
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 achieves high selectivity and stability in producing oligomers, reducing catalyst deactivation and side reactions, thereby enhancing the efficiency of ketoacid upgrading while maintaining catalyst performance at low temperatures.
Implementation Method 1
dimerising and/or oligomerising the at least one ketoacid in the feedstock in the presence of a heterogeneous catalyst to obtain a dimer/oligomer product
Data Source
AI summary
The present invention relates to a method using a specific catalyst for upgrading ketoacid to intermediates for fuel and chemical industry, intermediates obtained by the method and to their use.