MoVNbTe Mixed Oxide M1 Phase Synthesis via Fine TeO2
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Solution Overview
Problem
Current methods for preparing the M1 phase of MoVNbTe mixed oxides are inefficient, as they often require hazardous materials like hydrogen peroxide and poorly soluble niobium oxide, making the process costly and difficult to scale up, while also resulting in incomplete synthesis due to large tellurium dioxide particle sizes.
Innovation Solution
A hydrothermal synthesis method using tellurium dioxide with a particle size smaller than 100 μm, combined with molybdenum trioxide, vanadium pentoxide, and niobium pentoxide, to produce a pure M1 phase MoVNbTe mixed oxide, which involves preparing a mixture, hydrothermal treatment, separation, drying, and activation in an inert gas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods are used to prepare MoVNbTe mixed oxides, then the synthesis can be performed with readily available starting materials, but the reaction is incomplete due to large tellurium dioxide particle sizes and requires hazardous materials like hydrogen peroxide
Solution Approach 1:
The patent changes the particle size parameter of tellurium dioxide from conventional large sizes to specifically smaller than 100 μm, which fundamentally alters the reaction kinetics and completeness. This parameter change enables complete synthesis without requiring hazardous oxidizing agents like hydrogen peroxide, as the fine particles react more efficiently under hydrothermal conditions.
Solution Approach 2:
The patent replaces expensive and hazardous materials (hydrogen peroxide, pre-solubilized tellurium compounds) with inexpensive, stable, and safe alternatives (fine tellurium dioxide powder, water). The inexpensive starting materials achieve better results while eliminating safety concerns and reducing costs.
2Ease of operation
If large tellurium dioxide particle sizes are used, then the starting materials are easier to handle, but the synthesis is incomplete and requires additional processing steps
Solution Approach 1:
The patent optimizes the particle size parameter to a specific range (D90 < 100 μm) that balances handling ease with reaction efficiency. This parameter optimization ensures complete synthesis in a single step without requiring subsequent dissolution or additional processing, thereby improving productivity while maintaining operational simplicity.
3Ease of manufacture
If conventional synthesis methods are used, then the process can be performed with standard equipment, but the catalyst activity is lower due to incomplete M1 phase formation
Solution Approach 1:
The patent changes the particle size parameter of tellurium dioxide to ensure complete M1 phase formation during hydrothermal synthesis. This parameter modification reliably produces high-activity catalysts with consistent phase composition, eliminating the variability and incomplete formation associated with conventional methods while maintaining process simplicity.
4Productivity
If soluble tellurium compounds like telluric acid are used, then the synthesis proceeds more completely, but the cost increases and safety problems arise due to hydrogen peroxide requirements
Solution Approach 1:
The patent replaces expensive and hazardous soluble tellurium compounds (telluric acid requiring hydrogen peroxide preparation) with inexpensive, stable, and safe fine tellurium dioxide powder. The fine particle size ensures complete reaction kinetics match those of soluble compounds, achieving the same productivity without the associated costs and safety hazards.
Solution Approach 2:
The patent converts the potential harm of using insoluble tellurium dioxide (incomplete reaction) into a benefit by optimizing the particle size to fine powders (< 100 μm). This transformation makes the insoluble compound react completely under hydrothermal conditions, achieving the benefits of soluble compounds while retaining the safety and cost advantages of stable oxide materials.
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 method achieves a nearly complete formation of the desired M1 phase, leading to a catalyst material with a higher surface area and improved activity for hydrocarbon oxidation and dehydrogenation reactions, such as propane to acrylic acid and ethane to ethylene, while using inexpensive and safer starting compounds.
Implementation Method 1
b) hydrothermal treatment of the mixture of starting compounds at a temperature of 100° C. to 300° C. to obtain a product suspension
Implementation Method 2
d) activation of the solid in inert gas to obtain the mixed-oxide material
Data Source
AI summary
A simple, scalable, inexpensive, and reproducible method of selectively preparing the M1 phase of a MoVNbTe mixed oxide in a hydrothermal synthesis using tellurium dioxide is disclosed which can utilize inexpensive metal oxides as starting compounds.