Rutile Titanium Dioxide Support for Maleic Acid Hydrogenation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing catalysts for producing 1,4-butanediol (BDO), gamma-butyrolactone (GBL), and tetrahydrofuran (THF) face issues such as carbon support degradation, high pressure differentials, and low crush strength, leading to inefficiencies and increased costs due to the generation of fines and flaking, which affect the hydrogenation process of maleic acid.
Innovation Solution
A hydrogenation catalyst comprising one or more active hydrogenation catalyst components on a support comprising titanium dioxide in the rutile crystalline phase is used, which provides a harder and more uniform support, reducing the need for sodium, iron, and silver, and allowing for a more economical process with improved catalyst life and production rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If carbon support is used in existing catalysts, then catalyst activity is achieved, but carbon support degradation occurs leading to fines generation and flaking
Solution Approach 1:
The patent replaces the durable but problematic carbon support with a more economical inorganic support material that achieves the necessary catalyst stability without generating fines and flaking. This substitution eliminates the harmful effects associated with carbon support degradation while maintaining catalytic activity through appropriate metal component selection and optimization.
Solution Approach 2:
The patent employs a composite catalyst structure consisting of metal components (such as palladium, platinum, or other noble metals) supported on an inorganic support material. This composite approach combines the high catalytic activity of noble metals with the structural stability and mechanical strength of inorganic supports, thereby avoiding the degradation issues inherent in carbon-based supports while maintaining or enhancing overall catalyst performance.
2Productivity
If existing catalyst formulations are used, then hydrogenation activity is achieved, but high pressure differentials and low crush strength occur
Solution Approach 1:
The patent modifies the physical and chemical parameters of the catalyst support, transitioning from carbon-based materials to inorganic supports with superior mechanical properties. This parameter change includes selecting support materials with higher crush strength and better pressure differential characteristics, while simultaneously optimizing metal loading, particle size distribution, and pore structure to maintain high hydrogenation activity under improved mechanical conditions.
3Productivity
If multiple metals (sodium, iron, silver) are included in catalyst, then catalytic activity is enhanced, but catalyst cost increases
Solution Approach 1:
The patent extracts and eliminates unnecessary metal components (such as sodium, iron, and silver) from the catalyst formulation, retaining only the essential active metal components required for hydrogenation activity. This simplification reduces material costs while maintaining or improving production efficiency through optimized catalyst design that relies on the inherent activity of the retained metal components supported on the inorganic support material.
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 use of a titanium dioxide support in the rutile crystalline phase enhances the production of 1,4-butanediol, minimizes gamma-butyrolactone production, and reduces overall catalyst costs by eliminating the need for certain metals and improving the stability and longevity of the catalyst, thus increasing the process's economic viability and efficiency.
Implementation Method 1
a support comprising titanium dioxide in the rutile crystalline phase
Implementation Method 2
catalytically hydrogenating a hydrogenatable precursor in contact with a hydrogen-containing gas and a hydrogenation catalyst comprising one or more active hydrogenation catalyst components
Implementation Method 3
hydrogenation of maleic acid to 1,4-butanediol
Data Source
AI summary
This invention relates to a process for catalytically hydrogenating a hydrogenatable precursor in contact with a hydrogen-containing gas and a hydrogenation catalyst comprising one or more active hydrogenation catalyst components on a support comprising titanium dioxide in the rutile crystalline phase to produce 1,4-butanediol and, optionally, gamma-butyrolactone and/or tetrahydrofuran.