Metal-Treated Solid Oxide Catalyst for Olefin Carboxylation
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Solution Overview
Problem
Current methods for producing acrylic acid and other α,β-unsaturated carboxylic acids are inefficient and rely on fossil fuel-derived precursors, with a need for more sustainable and cost-effective catalytic processes that utilize renewable resources like carbon dioxide.
Innovation Solution
The use of metal-treated chemically-modified solid oxides, such as sulfur oxoacid anion-modified or phosphorus oxoacid anion-modified solid oxides, to catalyze the reaction between transition metal precursors and carbon dioxide and olefins, allowing for the formation of α,β-unsaturated carboxylic acids at lower transition metal concentrations and facilitating easier product separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional two-stage oxidation of propylene is used to produce acrylic acid, then production efficiency is maintained, but reliance on fossil fuels increases and sustainability decreases
Solution Approach 1:
The invention changes the fundamental parameters of the synthesis route by replacing propylene oxidation with CO2 carboxylation, transforming the carbon source from fossil-derived to renewable, thereby improving sustainability without sacrificing production viability
Solution Approach 2:
The patent employs inexpensive, readily available materials such as common solvents (acetonitrile, dichloromethane, toluene) and standard chemical reagents, replacing complex expensive catalyst systems while achieving comparable or superior results
2Productivity
If high concentrations of transition metal catalysts are used in the carboxylation reaction, then reaction rate is improved, but product separation becomes more difficult and cost increases
Solution Approach 1:
The invention optimizes the catalyst concentration parameter to a specific range (0.01-10 mM) that balances reaction rate with ease of separation, and changes the physical state of the catalyst system by using soluble metal salts that form insoluble carboxylate products
Solution Approach 2:
The metal carboxylate product is extracted from the reaction mixture by filtration or precipitation, separating it from the soluble catalyst and ligand components, thereby simplifying product isolation and reducing contamination
3Productivity
If conventional catalyst systems are used for olefin carboxylation, then catalytic activity is achieved, but catalyst cost and complexity increase
Solution Approach 1:
The patent replaces expensive, complex catalyst systems with inexpensive metal salts (NiCl2, ZnCl2, CuCl2) combined with commercially available ligands, achieving comparable catalytic activity with dramatically reduced cost and complexity
Solution Approach 2:
The invention creates a composite catalyst system by combining simple metal salts with organic ligands (phosphines, amines, carboxylic acids) to form coordinated complexes that exhibit enhanced catalytic activity while maintaining simplicity
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 increases the yield of α,β-unsaturated carboxylic acids, reduces the need for fossil fuels, and simplifies the separation of products, making the process more sustainable and economically viable.
Implementation Method 1
utilizing as an activator a metal-treated chemically-modified solid oxide... When a transition metal precursor compound is treated with an olefin such as ethylene and carbon dioxide (CO2) in the presence of the metal-treated chemically-modified solid oxide activator... an α,β-unsaturated carboxylic acid or the salt thereof is formed
Data Source
AI summary
This disclosure provides for routes of synthesis of acrylic acid and other a,b-unsaturated carboxylic acids and their salts, including catalytic methods. For example, there is provided a process for producing an α,β-unsaturated carboxylic acid or a salt thereof, the process comprising: (1) contacting in any order, a group 8-11 transition metal precursor, an olefin, carbon dioxide, a diluent, and a metal-treated chemically-modified solid oxide such as a sulfur oxoacid anion-modified solid oxide, a phosphorus oxoacid anion-modified solid oxide, or a halide ion-modified solid oxide, to provide a reaction mixture; and (2) applying reaction conditions to the reaction mixture suitable to produce the α,β-unsaturated carboxylic acid or the salt thereof. Methods of regenerating the metal-treated chemically-modified solid oxide are described.