Oxidative Dehydrogenation Catalyst Synthesis via Selective Washing
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Solution Overview
Problem
The scaling up of oxidative dehydrogenation (ODH) catalysts for commercial production is hindered by the difficulty in filtering and washing catalysts to remove contaminating salts like sulfur and nitrogen compounds, which can decompose the catalyst and result in performance degradation, and the high water usage in existing processes.
Innovation Solution
A catalyst composition and method involving molybdenum, vanadium, tellurium, niobium, and oxygen, with controlled sulfur content, using a hydrothermal reaction and air-treatment step to reduce water usage and effectively remove contaminants, allowing for large-scale production of ODH catalysts without significant loss of catalyst particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional filtering and washing methods are used to remove contaminating salts, then catalyst purity is improved, but water consumption increases significantly and catalyst particle loss occurs
Solution Approach 1:
The patent changes the chemical parameters of the washing solution by incorporating specific chemicals that selectively interact with contaminating salts. This allows for effective purification with reduced water usage, as the chemical treatment enhances salt removal efficiency compared to water alone.
Solution Approach 2:
The patent introduces intermediary substances that facilitate the removal of contaminating salts. These intermediaries act as mediators between the washing solution and the contaminants, enabling more effective separation with lower water consumption and reduced catalyst particle loss.
2Manufacturing precision
If conventional filtering and washing methods are used to remove contaminating salts, then catalyst purity is improved, but catalyst particle loss increases
Solution Approach 1:
The patent modifies the chemical parameters of the washing solution to be more selective toward contaminating salts. This parameter change allows the washing process to target contaminants specifically, reducing non-specific interactions that would cause catalyst particle loss while maintaining effective purification.
Solution Approach 2:
The patent employs intermediary substances that selectively bind to or react with contaminating salts, leaving the catalyst particles unaffected. This intermediary approach enables effective salt removal while protecting catalyst particles from being lost during the washing process.
3Productivity
If large-scale synthesis is implemented, then production capacity is improved, but difficulty in filtering and washing increases
Solution Approach 1:
The patent changes the parameters of the washing solution to enhance its effectiveness at large scales. By adjusting chemical composition and concentration, the washing process maintains high efficiency even when applied to large volumes of catalyst material, reducing the complexity of scaling up the filtering and washing operations.
Solution Approach 2:
The patent introduces intermediary substances that facilitate large-scale washing by improving the interaction between the washing solution and contaminating salts. This intermediary approach simplifies the filtering and washing process at scale by enhancing the inherent removal efficiency, reducing the need for complex multi-step purification procedures.
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 enables the efficient manufacture of ODH catalysts on a large scale with reduced water consumption, effectively removing contaminants and maintaining catalyst performance, thus addressing the challenges of scaling up ODH processes.
Implementation Method 1
In ODH, a lower alkane, such as ethane, is mixed with oxygen in the presence of a catalyst to produce the corresponding alkene
Implementation Method 2
hydrothermally reacting an aqueous mixture including molybdenum, vanadium, tellurium, and niobium to provide a prewashed ODH catalyst precursor
Data Source
AI summary
Catalysts and Methods for large-scale production of the catalysts are provided. An exemplary catalyst composition includes molybdenum, vanadium, tellurium, niobium, oxygen. In the catalyst composition, the molar ratio of molybdenum to vanadium is from 1:0.05 to 1:0.60, the molar ratio of molybdenum to tellurium is from 1:0.01 to 1:0.30, and the molar ratio of molybdenum to niobium is from 1:0.01 to 1:0.40. Oxygen is present at least in an amount to satisfy the valency of any present metal oxides, and composition includes less than 1.0 wt. % of sulfur.