Nickel Catalyst Hydrogenation for High-Concentration Bio-Based Adipic Acid
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Solution Overview
Problem
Existing methods for producing biobased adipic acid face challenges such as high costs due to the use of precious metal catalysts, low substrate concentration, high energy consumption, poor gas-liquid dispersion, safety hazards from hydrogen, and difficulty in achieving continuous industrial production.
Innovation Solution
A nickel-based hydrogenation catalyst is developed using a precipitation-deposition method, which is cost-effective, highly active, and selective, allowing for high substrate concentration and continuous production in batch or microreaction systems, enhancing catalytic performance and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precious metal catalysts (Pd, Pt) are used for catalytic hydrogenation of muconic acid, then high yield and selectivity of adipic acid are achieved, but production cost increases significantly
Solution Approach 1:
The patent replaces expensive precious metal catalysts (Pd, Pt) with a cost-effective nickel-based catalyst supported on basic alumina. This substitution dramatically reduces production costs while maintaining high catalytic activity and selectivity for adipic acid synthesis from muconic acid
Solution Approach 2:
The patent employs a composite catalyst system consisting of nickel metal particles dispersed on basic alumina support. This composite structure combines the high catalytic activity of nickel with the basic properties of alumina, creating a synergistic effect that achieves both cost reduction and maintained manufacturing precision
2Ease of operation
If low substrate concentration (≤10 g/L) is used in catalytic hydrogenation, then reaction conditions are easier to control, but production intensity and reactor efficiency decrease significantly
Solution Approach 1:
The patent fundamentally changes the substrate concentration parameter from traditional low levels (≤10 g/L) to high levels (200 g/L). This parameter change is enabled by the improved catalyst system, which maintains reaction controllability while dramatically increasing production intensity and reactor efficiency
3Productivity
If organic solvents (ethanol, amyl alcohol) are used for catalytic hydrogenation, then reaction efficiency is improved, but environmental greenness and sustainability are reduced
Solution Approach 1:
The patent changes the solvent parameter from organic solvents (ethanol, amyl alcohol) to water as the reaction medium. This substitution maintains reaction efficiency while eliminating the environmental harm associated with organic solvent usage, achieving a green and sustainable hydrogenation process
4Productivity
If high hydrogen pressure (3.4 MPa) is applied for catalytic hydrogenation, then conversion rate of muconic acid is improved, but safety risks and energy consumption increase
Solution Approach 1:
The patent reduces the hydrogen pressure parameter from high levels (3.4 MPa) to moderate levels (0.5-3.0 MPa). This parameter reduction lowers safety risks and energy consumption while maintaining high conversion rates through the enhanced catalytic activity of the nickel-based catalyst system
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 method achieves a high yield of biobased adipic acid with 100% selectivity and 200 g/L substrate concentration, reducing production costs and enabling efficient, safe, and scalable industrial production.
Implementation Method 1
catalytic hydrogenation of biobased muconic acid... under the action of the nickel-based hydrogenation catalyst
Implementation Method 2
catalytic hydrogenation of biobased muconic acid... to prepare biobased adipic acid
Implementation Method 3
A nickel-based hydrogenation catalyst is developed using a precipitation-deposition method
Implementation Method 4
A nickel-based hydrogenation catalyst is developed using a precipitation-deposition method
Data Source
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AI summary
The present invention relates to a preparation method of biobased adipic acid. In the method, by using a nickel-based hydrogenation catalyst provided by the present invention, when a substrate concentration is as high as 200 g/L, the reaction of biobased sodium muconate and hydrogen is catalyzed in a batch reactor and a micro packed bed to prepare sodium adipate, and the yield of a target product is close to 100 mol%. Wherein the biobased sodium muconate is biobased sodium muconate obtained by microbial fermentation. The method has the advantages of short reaction path, good economy, and easy large-scale preparation, and lays a solid foundation for the industrialization of green synthesis of the biobased adipic acid.