Nickel-Gold Core-Shell Catalyst for Ester Production
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Solution Overview
Problem
Current catalysts for producing carboxylic acid esters face challenges with selectivity, catalyst activity, and economic viability due to the use of expensive noble metals like palladium, ruthenium, and gold, and the stability of support materials, leading to inadequate mechanical strength and corrosion resistance.
Innovation Solution
A catalyst comprising oxidized nickel and gold loaded onto a support within a specific atomic ratio of Ni / (Ni + X) from 0.20 to 0.90, using a composite nanoparticle structure with gold at the core and nickel oxide on the surface, supported on an aluminum-containing silica-based composition, enhancing mechanical strength and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If noble metals (palladium, ruthenium, gold) are used as catalysts, then catalytic activity is improved, but manufacturing cost increases
Solution Approach 1:
The invention changes the chemical composition parameter of the catalyst by replacing noble metals with base metals (nickel, copper, silver) and adjusting their oxidation states. The catalyst uses nickel oxide, copper oxide, or silver as active components instead of palladium, ruthenium, or gold, thereby maintaining catalytic activity while significantly reducing manufacturing cost.
Solution Approach 2:
The invention employs inexpensive base metals (nickel, copper, silver) that are much cheaper than noble metals to create a cost-effective catalyst. Although base metals may have different stability characteristics, the catalyst design focuses on achieving adequate activity and selectivity at lower cost, making the process economically viable.
2Ease of manufacture
If conventional supports are used, then catalyst preparation is simple, but mechanical strength and corrosion resistance are insufficient
Solution Approach 1:
The invention uses composite support materials such as silica-alumina, silica-magnesia, or silica-titania instead of conventional single-material supports. These composite supports provide enhanced mechanical strength and corrosion resistance while maintaining porosity and surface area for effective catalyst loading. The combination of different materials creates synergistic effects that improve overall catalyst performance and durability.
3Productivity
If heteropolyacid catalysts are used for methacrylic acid production, then oxidation reaction proceeds, but thermal stability deteriorates causing catalyst decomposition
Solution Approach 1:
The invention replaces heteropolyacid catalysts with base metal oxide catalysts (nickel oxide, copper oxide, or silver). These base metal oxides exhibit better thermal stability under reaction conditions compared to heteropolyacids, preventing catalyst decomposition while maintaining adequate oxidation activity for producing methacrylic acid.
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 catalyst maintains high reactivity and selectivity while reducing costs by using stable nickel compounds instead of noble metals, with improved mechanical strength and corrosion resistance, leading to enhanced catalyst performance and longevity.
Implementation Method 1
a catalyst for use in production of carboxylic acid esters by reacting an aldehyde and an alcohol, or one or more types of alcohols, in the presence of oxygen
Implementation Method 2
producing useful carboxylic acid esters industrially, in the case of methyl methacrylate, for example, may include a process in which methacrylic acid is produced by oxidizing methacrolein with oxygen
Data Source
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AI summary
Disclosed is a catalyst for use in production of carboxylic acid ester by reacting (a) aldehyde and alcohol, or (b) one or more types of alcohols, in the presence of oxygen; wherein oxidized nickel and X (wherein X represents at least one element selected from the group consisting of nickel, palladium, platinum, ruthenium, gold, silver and copper) are loaded onto a support within the range of the atomic ratio of Ni / (Ni + X) of from 0.20 to 0.99.