MoVNbTeOx Catalyst for Propane Oxidation Yield
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Solution Overview
Problem
Current catalysts for the selective oxidation of propane to acrylic acid achieve yields of only approximately 50%, which are insufficient for commercialization, and there is a need for higher yields and selectivity in the oxidation of hydrocarbons.
Innovation Solution
A catalyst material comprising molybdenum (Mo), vanadium (V), niobium (Nb), tellurium (Te), nickel (Ni), tungsten (W), and manganese (Mn) with specific molar ratios, thermally treated in a hydrothermal process, is used for the oxidation and oxidative dehydrogenation of hydrocarbons, particularly for the selective oxidation of propane to acrylic acid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If MoVNbTeOx mixed oxide catalysts are used for the oxidation of propane to acrylic acid, then the catalyst system is established with defined phases M1 and M2, but the acrylic acid yield is limited to approximately 50%
Solution Approach 1:
The patent changes the compositional parameters of the catalyst by introducing additional metal elements (Fe, Co, Cu, Zn, or Zr) to the MoVNbTeOx system. This modifies the chemical composition and phase structure of the catalyst, enabling acrylic acid yields to exceed 50% and reach up to 65%, thereby resolving the yield limitation of the base system
Solution Approach 2:
The patent creates a composite catalyst material by combining the MoVNbTeOx base system with additional metal oxides (Fe, Co, Cu, Zn, or Zr). This multi-component composite structure synergistically enhances the catalytic performance, achieving higher acrylic acid yields that were not attainable with the four-element base system alone
2Productivity
If the catalyst composition is optimized to increase acrylic acid yield above 50%, then higher productivity is achieved, but the catalyst complexity increases with additional metal elements
Solution Approach 1:
The patent applies local quality by introducing specific metal elements (Fe, Co, Cu, Zn, or Zr) in controlled, small amounts (0.1-5.0 wt%) into the MoVNbTeOx system. This localized addition of specific elements enhances catalytic performance without requiring a complete redesign of the entire catalyst system, thus managing complexity while improving productivity
3Reliability
If tellurium content is increased in the M2 phase to enhance propylene conversion selectivity, then the M2 phase becomes more active and selective, but the overall catalyst performance is constrained by the base system limitations
Solution Approach 1:
The patent merges the M1 and M2 phases with additional metal oxides (Fe, Co, Cu, Zn, or Zr) to create a synergistic multi-phase catalyst system. This combination allows the M2 phase to maintain its high propylene conversion selectivity while the overall system achieves enhanced acrylic acid yields through cooperative effects among all phases and metal components
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 material achieves previously unattained yields and high selectivities for the oxidation of hydrocarbons, specifically exceeding 50% acrylic acid production, demonstrating improved performance over existing MoVNbTeOx systems.
Implementation Method 1
catalyst material for the oxidation and/or oxidative dehydrogenation of hydrocarbons
Implementation Method 2
thermally treating the aqueous mixture at temperatures of from 150 to 200° C. for at least 1 hour
Implementation Method 3
thermally treating the aqueous mixture at temperatures of from 150 to 200° C. for at least 1 hour
Implementation Method 4
oxidation of propylene to acrylic acid
Implementation Method 5
oxidation and/or oxidative dehydrogenation of hydrocarbons
Data Source
AI summary
A catalyst material for the oxidation and/or oxidative dehydrogenation of hydrocarbons, in particular for the selective oxidation of propane to acrylic acid, is specified, comprising a) molybdenum (Mo), b) vanadium (V), c) niobium (Nb), d) tellurium (Te), e) nickel (Ni), f) tungsten (W) and g) manganese (Mn), in which the molar ratio of at least one element, which is selected from nickel, tungsten and manganese, to molybdenum lies in the range 0.01 to 0.2, more preferably 0.05 to 0.15 and particularly preferably from 0.0025:1 to 0.3:1. Furthermore, a catalyst for the oxidation and/or oxidative dehydrogenation of hydrocarbons, a use of the catalyst material or of the catalyst, a method for producing a catalyst material for the oxidation and/or oxidative dehydrogenation of hydrocarbons and a method for the selective oxidation of propane to acrylic acid is specified.