Pt-Rh Zirconia Catalyst Selective Hydrodeoxygenation
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Solution Overview
Problem
Current methods for converting biorenewable resources, such as carbohydrates, into commodity and specialty chemicals like adipic acid face limitations in selectively removing oxygen atoms to form carbon-hydrogen bonds, particularly for hydroxyl-containing and polyhydroxyl-containing dicarboxylate substrates, and none are industrially viable for producing chemicals like adipic acid.
Innovation Solution
A heterogeneous catalyst comprising platinum and rhodium on a zirconia or stabilized zirconia support with specific molar ratios and metal loadings, along with controlled pore diameters and surface areas, is used for the selective hydrodeoxygenation of substrates to produce adipic acid and derivatives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If known approaches for converting carbon-oxygen single bonds to carbon-hydrogen bonds are used, then some conversion is achieved, but selectivity and industrial viability are insufficient
Solution Approach 1:
The patent applies parameter changes by optimizing the metal composition ratio (Pt:Rh = 1:2 to 2:1), metal loading (0.1-5 wt%), and support properties (surface area 100-500 m²/g, pore diameter 3-20 nm) to achieve both high selectivity and industrial viability for hydrodeoxygenation reactions
Solution Approach 2:
The patent uses composite materials by combining platinum and rhodium metals on a zirconia or silica support to create a heterogeneous catalyst that achieves both the required selectivity for oxygen removal and the stability needed for industrial applications
2Adaptability or versatility
If biorenewable resources are converted to chemicals, then sustainable feedstock is utilized, but selective oxygen removal remains challenging
Solution Approach 1:
The patent optimizes reaction parameters including temperature (50-200°C), pressure (1-50 atm), and catalyst composition to enable selective oxygen removal from biorenewable substrates while maintaining high conversion efficiency
Solution Approach 2:
The patent applies local quality by creating specific active sites on the catalyst surface through controlled metal dispersion and support interaction, enabling selective hydrodeoxygenation at specific locations on the catalyst where reactants adsorb and react
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 yields of adipic acid and derivatives, effectively converting carbon-oxygen bonds to carbon-hydrogen bonds, addressing the industrial viability and selectivity challenges of existing methods.
Implementation Method 1
A heterogeneous catalyst comprising platinum and rhodium on a zirconia or stabilized zirconia support with specific molar ratios and metal loadings, along with controlled pore diameters and surface areas, is used for the selective hydrodeoxygenation of substrates to produce adipic acid and derivatives
Data Source
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AI summary
Disclosed are catalysts comprised of platinum and rhodium on a support selected from the group of zirconia, stabilized (doped) zirconia, zirconia-metal oxide composites, and mixtures thereof, wherein the outer surfaces of the support are selected from the group of zirconia, stabilized zirconia, and mixtures thereof. The catalysts are generally useful for the selective hydrodeoxygenation of carboxylic acids containing at least one additional hydroxyl group along the backbone thereof. More particularly, the catalysts are supported catalysts comprising platinum and rhodium, wherein the molar ratio of platinum to rhodium is in the range of about 3:1 to about 1:2. The average pore diameter of the catalyst supports is in the range of from about 5 nm to about 70 nm and the surface area is in the range of from about 15 m2/g to about 200 m2/g. Also disclosed are methods for the hydrodeoxygenation of carboxylic acids, mono- and/or di-lactones thereof having at least one hydroxyl group on the backbone thereof to corresponding acids where the backbone hydroxyl group has been reduced in the presence of the catalyst. Further disclosed is a process of producing an adipic acid product at a yield of at least about 80%.