Nanosized Self-Assembled Catalyst for Styrene Oxide Hydrogenation
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Solution Overview
Problem
Existing methods for preparing β-phenylethanol by hydrogenation of styrene oxide face challenges such as poor mass transfer, catalyst deactivation, and complex product separation, leading to reduced selectivity and yield.
Innovation Solution
A micro reaction channel system loaded with a nanosized self-assembled catalyst having uniform macropores, combined with an ultrasonic field, is used for the hydrogenation of styrene oxide. This system enhances mass and heat transfer, preventing catalyst pore blockage and allowing for solvent-free reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional heterogeneous catalytic process is used, then catalyst recovery is easier, but mass transfer efficiency is poor leading to low selectivity and yield
Solution Approach 1:
The patent uses nanosized catalyst particles (1-100 nm) with uniform macropores segmented into specific size ranges (first macropores: 50-200 nm, second macropores: 200-500 nm) to improve mass transfer efficiency while maintaining heterogeneous catalysis advantages. This segmentation of pore structures enables efficient reactant penetration and product diffusion, achieving high selectivity (>99%) and yield without sacrificing catalyst recovery ease.
2Productivity
If auxiliary agents (alkali) are added to improve selectivity, then β-phenylethanol selectivity increases, but catalyst life shortens and product separation becomes difficult
Solution Approach 1:
The patent extracts and eliminates the need for auxiliary alkali agents by designing a dual macropore catalyst structure that inherently achieves high selectivity through optimized mass transfer. The uniform macropores (first: 50-200 nm, second: 200-500 nm) enable efficient hydrogen transport and reaction, achieving >99% selectivity without adding NaOH, KOH, or other alkali substances that would otherwise shorten catalyst life and complicate separation.
Solution Approach 2:
The patent changes the physical-chemical parameters of the catalyst by controlling pore size distribution (macropores of 50-500 nm), particle size (1-100 nm), and metal content (0.1-10 wt%) to achieve high selectivity without auxiliary agents. This parameter optimization allows the catalyst to maintain high activity and selectivity for extended periods, extending catalyst life while avoiding the deactivation issues caused by alkali addition.
3Temperature
If strong exothermic reaction is controlled by adding solvent, then heat of reaction is controlled, but production efficiency decreases and separation process becomes complex
Solution Approach 1:
The patent employs porous catalyst materials with uniform macropores (50-500 nm) that provide excellent heat transfer characteristics. The porous structure with controlled pore size enables efficient heat dissipation during the exothermic hydrogenation reaction, controlling temperature rise without requiring external solvents. This maintains high production efficiency while simplifying the separation process.
4Productivity
If catalyst pores are blocked by high-boiling substances, then reaction selectivity decreases, but this leads to catalyst deactivation
Solution Approach 1:
The patent designs a catalyst with uniform dual macropore structure (first: 50-200 nm, second: 200-500 nm) that prevents pore blockage by high-boiling substances. The uniform macropore distribution and adequate pore size enable efficient product diffusion, preventing accumulation of high-boiling by-products that would otherwise block pores and deactivate the catalyst. This maintains high reaction selectivity and catalyst stability over extended operation periods.
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 approach achieves high selectivity (>99%) and yield of β-phenylethanol, simplifies product separation, reduces production costs, and prolongs catalyst life, making the process more efficient and scalable.
Implementation Method 1
an ultrasonic field generator for applying an ultrasonic field to the micro reaction channel
Implementation Method 2
a method for preparing β-phenylethanol by hydrogenation using styrene oxide as a raw material
Implementation Method 3
a micro reaction channel loaded with a catalyst
Implementation Method 4
Since styrene oxide hydrogenation is a strong exothermic reaction, in order to control the heat of reaction
Data Source
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AI summary
Disclosed is a method for preparing β-phenylethanol. The method comprises the following steps: (1) reducing a catalyst in a reactor in advance; (2) introducing pre-heated hydrogen gas to warm the reactor to a predetermined temperature; and (3) introducing a raw material styrene oxide to perform a hydrogenation reaction so as to obtain the β-phenylethanol. The catalyst is Ni-Cu/Al2O3 nanosized self-assembled catalyst. The reactor is an ultrasonic field micro-packed bed reactor. The method of the present invention enables the selectivity of the β-phenylethanol to reach 99% or more.