Supported Non-Noble Metal Catalyst for Atmospheric Ketone Coupling
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Solution Overview
Problem
Existing ketone synthesis methods are cumbersome, costly, and result in low product selectivity, requiring high-pressure hydrogen and complex catalyst systems, with challenges in catalyst design and separation.
Innovation Solution
A method for preparing a supported transition metal catalyst using non-noble metals, involving steps of dissolving transition metal salts in water, adding a porous carrier, drying, calcining, and reducing to create a catalyst suitable for condensation coupling reactions between α-H-containing ketones and alcohols at atmospheric pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional oxidative dehydrogenation or aldol condensation methods are used, then ketones can be synthesized, but the process becomes cumbersome and product selectivity decreases
Solution Approach 1:
The patent segments the traditional multi-step process (oxidative dehydrogenation, aldol condensation, dehydration, hydrogenation) into a single integrated condensation coupling reaction step, simplifying the overall process while maintaining high productivity
Solution Approach 2:
The supported transition metal catalyst performs multiple functions simultaneously: it catalyzes both the condensation and coupling reactions in one step, eliminating the need for separate catalysts and reaction steps for each transformation
2Reliability
If supported noble metal catalysts or complex oxide catalysts are used, then catalytic activity can be achieved, but catalyst costs increase significantly
Solution Approach 1:
The patent replaces expensive noble metal catalysts with inexpensive non-noble metal catalysts (Fe, Co, Ni, Cu, Zn) supported on affordable carriers, dramatically reducing catalyst cost while maintaining sufficient catalytic activity for the reaction
Solution Approach 2:
The patent creates composite catalyst materials by combining non-noble metals with porous supports (activated carbon, silica gel, alumina, molecular sieves), achieving both cost-effectiveness and enhanced catalytic performance through synergistic effects
3Reliability
If high-pressure hydrogen conditions are applied, then hydrogenation can be achieved, but reaction conditions become more severe and equipment requirements increase
Solution Approach 1:
The patent changes the reaction parameters from high-pressure hydrogen conditions to atmospheric pressure operation, simplifying the reaction conditions and equipment requirements while achieving effective hydrogenation through the borane reagent system
Solution Approach 2:
The patent replaces the mechanical high-pressure hydrogen system with a chemical hydrogen source (borane reagent), substituting complex pressure control equipment with simpler chemical reaction conditions
4Productivity
If multiple reaction steps are employed, then complete transformation can be achieved, but reaction time and process duration increase
Solution Approach 1:
The patent merges four separate reaction steps (oxidative dehydrogenation, aldol condensation, dehydration, hydrogenation) into a single integrated condensation coupling reaction, achieving complete transformation in one operation and significantly reducing total reaction time
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 achieves high selectivity and conversion rates for high-carbon ketone synthesis, reducing costs and simplifying the process by eliminating the need for high-pressure hydrogen and additional solvents, with stable performance for industrial applications.
Implementation Method 1
using the supported transition metal catalyst prepared by the method described above as a reaction catalyst, and an α-H-containing ketone and an alcohol as reactive substrates; and conducting condensation coupling reaction
Implementation Method 2
adding a porous catalyst carrier to the solution obtained in step S1 and stirring at atmospheric temperature to be uniform
Implementation Method 3
placing the mixed solution obtained in step S2 in an oven and drying at a temperature of 80-110° C. to a constant weight
Implementation Method 4
heating the dry mass obtained in step S3 to a calcining temperature of 250-390° C. in a calcining device and calcining for 5-8 hours
Implementation Method 5
heating the calcined product obtained in step S4 to a reduction temperature of 250-450° C. in a reaction device and reducing in a reducing atmosphere
Data Source
AI summary
A method for preparing a supported transition metal catalyst, and the supported transition metal catalyst and use thereof in condensation coupling synthesis of a high-carbon ketone from an α-H-containing ketone and an alcohol are provided. Preparation process of the supported transition metal catalyst includes adding a porous catalyst carrier to a solution of a transition metal salts, followed by standing, drying, calcining, and reducing. The transition metal salt is at least one selected from the group consisting of transition metal nitrates, transition metal formates, transition metal oxalates, and transition metal acetates, and the transition metal is a non-noble metal selected from the group consisting of transition metal elements from Groups VIIB, VIII, IB and IIB of the periodic table of the chemical elements.