Porous SiC Catalyst Support for Gas-Phase Olefin Hydroformylation
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Solution Overview
Problem
Existing hydroformylation processes face challenges with costly catalysts like rhodium and cobalt, laborious catalyst recycling, and the need for specific and costly support materials, which are not commercially available, limiting reactor design and increasing production costs.
Innovation Solution
A hydroformylation process using a heterogenized catalyst system on a support composed of a bed of shaped SiC bodies with 20-70% pores between 10 nm to 1000 nm, allowing for easy availability and efficient reactor design, reducing catalyst losses, and eliminating the need for additional washcoats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heterogenized catalyst system is used on a support material, then catalyst losses are reduced and product purification is simplified, but the support materials are not commercially available and must be specifically produced, increasing costs and production time
Solution Approach 1:
The patent replaces expensive, specially produced monolithic support structures with inexpensive, commercially available granulated SiC particles. These simple particles can be easily replaced and do not require complex production processes, thereby reducing costs and making the support immediately available while maintaining catalyst stability.
Solution Approach 2:
The patent utilizes the porous structure of granulated SiC particles to provide adequate surface area and pore volume for catalyst immobilization. The porous nature of the SiC particles allows for effective catalyst support without requiring complex monolithic structures, thus achieving both catalyst stability and ease of manufacture.
2Reliability
If monolithic block supports are used for heterogenized catalysts, then catalyst immobilization is achieved, but the size is limited by mechanical stability, placing limits on reactor design
Solution Approach 1:
The patent divides the support structure from a single monolithic block into numerous small granulated SiC particles. This segmentation allows the catalyst to be immobilized on many small surfaces rather than one large surface, providing the same immobilization effect while allowing flexible reactor design and better flow characteristics.
Solution Approach 2:
The patent creates a composite system by combining granulated SiC particles with the catalyst system. This composite approach allows the benefits of both the mechanical stability of SiC and the catalytic activity of the immobilized catalyst, while the granulated form provides design flexibility for various reactor configurations.
3Ease of operation
If homogeneous catalysis is used, then the process is simple, but large amounts of energy and process outlay are necessary to avoid catalyst losses through recycling steps
Solution Approach 1:
The patent extracts the catalyst from the homogeneous liquid phase and immobilizes it on solid granulated SiC particles. This extraction of the catalyst into a solid support form allows the reaction to proceed with simple gas-phase or slurry-phase mixing without requiring complex recycling systems, thereby reducing energy consumption while maintaining process simplicity.
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 process achieves high conversion rates of C2 to C8 olefins with minimal catalyst residues and reduced production costs, enabling flexible reactor design and efficient product separation.
Implementation Method 1
the catalyst system, which comprises a metal from group 8 or group 9 of the periodic table of the elements, at least one organic phosphorus-containing ligand and a stabilizer, is present in a heterogenized form on a support composed of a porous ceramic material
Implementation Method 2
Hydroformylation involves reacting alkenes (olefins) with a mixture of carbon monoxide and hydrogen (also: synthesis gas or syngas) using a catalyst to give aldehydes
Data Source
AI summary
The invention relates to a process for hydroformylating short-chain olefins, especially C2 to C8 olefins, in which the catalyst system, which comprises a metal from group 8 or group 9 of the periodic table of the elements, at least one organic phosphorus-containing ligand and a stabilizer, is present in a heterogenized form on a support composed of a porous ceramic material, the support consisting of a bed of shaped SiC bodies in which the proportion of pores having a pore diameter in the range between 10 nm to 1000 nm, based on the total amount of pores in the shaped SiC bodies, is 20 to 70%, preferably 25 to 50%.