Process for converting sugars to glycols
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Solution Overview
Problem
Conventional methods for producing glycols from sugars are inefficient and not competitive with ethylene-based routes, and existing catalysts are susceptible to corrosion, leading to reduced selectivity and catalyst lifetime.
Innovation Solution
A nickel-rhenium alloy catalyst is produced by impregnating alpha-alumina particles with nickel and rhenium-containing salts, followed by drying, calcining, reducing, and passivating to create a catalyst suitable for converting sugars to glycols in an aqueous medium, which is less susceptible to corrosion and enhances selectivity and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional ethylene-based routes are used to produce glycols, then production efficiency is high, but dependence on petroleum feedstocks increases and sustainability decreases
Solution Approach 1:
The invention changes the chemical parameters of the reaction system by using sugars as feedstock instead of ethylene, and by employing a nickel-rhenium alloy catalyst with specific composition ratios (Ni:Re = 95:5 to 5:95 wt%). This parameter change enables efficient glycol production from renewable biomass feedstocks, resolving the contradiction between maintaining high productivity and increasing feedstock versatility.
Solution Approach 2:
The invention uses a composite catalyst system consisting of nickel-rhenium alloy particles supported on alumina or silica carriers. This composite material structure combines the catalytic activity of nickel-rhenium alloy with the structural stability and surface area of oxide supports, enabling efficient conversion of sugars to glycols while maintaining high productivity comparable to conventional ethylene-based routes.
2Productivity
If existing catalysts are used for sugar conversion, then glycol production is achieved, but catalyst corrosion increases leading to reduced selectivity and shorter lifetime
Solution Approach 1:
The invention employs a composite catalyst structure where nickel-rhenium alloy particles are supported on stable oxide carriers such as alumina or silica. The alumina or silica support provides structural stability and resistance to corrosion in aqueous reaction media, while the nickel-rhenium alloy maintains high catalytic activity. This composite structure resolves the contradiction between achieving high glycol production and ensuring long catalyst lifetime by protecting the active metal components from corrosion.
Solution Approach 2:
The invention optimizes the composition parameters of the catalyst by using specific nickel-to-rhenium ratios (95:5 to 5:95 wt%) and controlling the particle size and distribution on the support. These parameter optimizations enhance the catalyst's resistance to corrosion and sintering, thereby improving reliability and extending catalyst lifetime while maintaining high productivity for glycol production from sugars.
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 nickel-rhenium alloy catalyst selectively converts sugars to glycols with higher yields and longer catalyst lifetime, reducing byproduct formation and maintaining conversion selectivity.
Implementation Method 1
contacting the reaction mixture and hydrogen at conditions suitable for hydrogenolysis of the sugar to glycol
Implementation Method 2
drying of the precursor-impregnated alpha-alumina particles in a fluidized bed at a first temperature
Data Source
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AI summary
Glycols may be produced from sugars using a nickel-rhenium catalyst that includes a nickel-rhenium alloy on the alpha-alumina particles. The nickel-rhenium catalyst may be produced by impregnating alpha-alumina particles with catalyst precursors including a nickel-containing salt and a rhenium-containing salt to produce precursor-impregnated alpha-alumina particles. The precursor-impregnated alpha-alumina particles may then be dried in a fluidized bed and then calcined, reduced, and passivated to produce a nickel-rhenium catalyst.