Ruthenium-Based Catalyst for Benzoic Acid Hydrogenation
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Solution Overview
Problem
The existing methods for benzoic acid hydrogenation, particularly using Pd/C catalysts, face challenges such as low reaction activity, severe process conditions, catalyst poisoning, and high noble metal consumption, along with difficulties in separating the catalyst from reaction materials and products.
Innovation Solution
A hydrogenation catalyst comprising a carrier, ruthenium as the active component, and auxiliary components like nickel, iron, or cobalt, supported on the carrier with an alkali metal element, is used in a two-step process within a fixed bed reactor, enabling continuous hydrogenation under mild conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If Pd/C catalyst is used for benzoic acid hydrogenation, then the reaction can proceed, but the reaction activity is low and severe process conditions are required
Solution Approach 1:
The patent changes the chemical composition parameters of the catalyst by replacing Pd/C with Ru-based catalyst containing auxiliary components (Ni, Fe, or Co) and alkali metal elements. This compositional parameter change enables the reaction to proceed under milder conditions (lower temperature and pressure) while maintaining or improving reaction activity.
Solution Approach 2:
The patent creates a composite catalyst material combining Ru as the active component with auxiliary components (Ni, Fe, or Co) and alkali metal elements supported on a carrier. This composite structure synergistically enhances catalytic activity and allows the reaction to proceed under milder conditions compared to conventional Pd/C catalyst.
2Productivity
If tank hydrogenation process is used, then the reaction can be carried out, but the process is complicated and product is in contact with catalyst for long time causing secondary reactions
Solution Approach 1:
The patent segments the hydrogenation process into a continuous flow system with distinct zones: reactant feeding zone, catalytic reaction zone with fixed bed catalyst, and product collection zone. This segmentation allows the product to quickly separate from the catalyst after reaction, minimizing contact time and secondary reactions while simplifying the overall process flow.
Solution Approach 2:
The patent implements continuous hydrogenation using a fixed bed reactor where reactants continuously flow through the catalyst bed, undergo hydrogenation, and exit as products. This continuous operation eliminates the batch processing steps, reduces complexity, and ensures minimal product-catalyst contact time while maintaining high reaction efficiency.
3Reliability
If powder catalyst is used, then the catalytic function is provided, but separation from reaction materials and products is difficult and losses are large
Solution Approach 1:
The patent uses a porous carrier material to support the Ru-based catalyst. The porous structure provides high surface area for catalytic activity while maintaining a fixed bed configuration that enables easy separation from reaction materials and products. This eliminates the filtration and regeneration losses associated with powder catalysts.
Solution Approach 2:
The patent employs a Ru-based catalyst with auxiliary components that is designed for continuous operation in a fixed bed reactor. While Ru is a noble metal, the catalyst structure enables long service life with minimal loss, and the auxiliary components enhance activity allowing for lower noble metal loading, effectively reducing overall catalyst consumption and cost.
4Productivity
If Pd/C catalyst is used, then hydrogenation can occur, but noble metal consumption is high
Solution Approach 1:
The patent changes the catalyst composition by replacing Pd with Ru as the active component and adding auxiliary components (Ni, Fe, or Co) with alkali metal elements. This compositional parameter change maintains or enhances catalytic activity while reducing dependence on expensive noble metals, thereby lowering noble metal content and consumption.
Solution Approach 2:
The patent uses a Ru-based catalyst system where Ru, while still a noble metal, is combined with auxiliary components that enhance catalytic activity. This allows for lower loading of noble metal while maintaining high activity, and the continuous fixed bed operation minimizes catalyst loss, effectively reducing noble metal consumption compared to Pd/C systems.
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
This approach enhances catalytic activity at low temperatures, reduces noble metal content, and facilitates continuous and stable operation, improving production efficiency and product quality while minimizing catalyst loss.
Implementation Method 1
A hydrogenation catalyst comprising a carrier, and active component, auxiliary component and alkali metal element supported on the carrier, wherein the active component is ruthenium, and the auxiliary component is one or two or more selected from the group consisting of nickel, iron and cobalt
Data Source
AI summary
Disclosed are hydrogenation catalysts and a method for a benzoic acid hydrogenation reaction. The hydrogenation catalysts comprise a carrier, and an active component, an auxiliary component, and an alkali metal element that are loaded on the carrier. The active component is ruthenium. The auxiliary component is one or two or more of nickel, iron and cobalt. The method for the hydrogenation reaction comprises a first hydrogenation step and a second hydrogenation step. A first hydrogenation catalyst and a second hydrogenation catalyst are the hydrogenation catalyst. The hydrogenation catalysts according to the present invention have high catalytic activity at a low temperature, and can react under relatively mild reaction conditions. The hydrogenation reaction method according to the present invention can implement the continuous and stable operation of a device, and meets industrial-scale operation requirements.