Sn-MWW Catalyst Oxidation Selectivity
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Solution Overview
Problem
Current methods for Baeyer-Villiger oxidation, particularly using tin-containing zeolite Beta, face challenges such as low selectivity, difficult catalyst synthesis, and high costs due to the use of peroxyacetic acid, which limits industrial scalability and safety.
Innovation Solution
A process utilizing a tin-containing zeolitic material with an MWW-type framework structure and low boron content, specifically a Sn-MWW catalyst, for the oxidation of organic carbonyl compounds, achieving high conversion and selectivity by reacting with hydrogen peroxide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tin-containing zeolite Beta is used for Baeyer-Villiger oxidation, then the reaction can proceed, but selectivity to product is low (at most 20%)
Solution Approach 1:
The patent changes the framework structure parameter from Beta to MWW-type zeolite, and adjusts the boron content parameter to low levels (at most 0.0025 mol B2O3 per mol SiO2). These parameter changes result in significantly improved selectivity (up to 95% or higher) while maintaining high conversion, resolving the contradiction between selectivity and productivity.
2Reliability
If tin-containing zeolite Beta is used, then oxidation reaction occurs, but catalyst synthesis is difficult and time-consuming (more than 15 days)
Solution Approach 1:
The patent changes the framework structure from Beta to MWW-type and optimizes the hydrothermal synthesis parameters including temperature (100-200°C), time (0.5-24 hours), and pH (2-12). These parameter changes reduce synthesis time to under 24 hours while maintaining catalyst activity, resolving the contradiction between catalyst reliability and synthesis time.
3Reliability
If high tin loading (4.7 wt%) is used in MWW zeolite, then catalyst activity may be high, but synthesis becomes complex requiring deboronation step
Solution Approach 1:
The patent changes the tin content parameter to low levels (0.01-2.0 wt%) and optimizes the hydrothermal synthesis conditions with pH 2-12 and temperature 100-200°C. This eliminates the need for separate deboronation steps and complex multi-step synthesis procedures, achieving both catalyst activity and synthesis simplicity simultaneously.
4Productivity
If peroxyacetic acid is used for oxidation, then reaction efficiency is acceptable, but cost-effectiveness and safety are poor
Solution Approach 1:
The patent changes the oxidant from peroxyacetic acid to hydrogen peroxide, adjusting the oxidant concentration parameter to 1-30% H2O2. Hydrogen peroxide is cheaper, safer, and environmentally friendly while maintaining high reaction efficiency with the Sn-MWW catalyst, resolving the contradiction between productivity and safety/cost.
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 process achieves high conversion and selectivity of organic carbonyl compounds, overcoming the limitations of previous methods by using a Sn-MWW catalyst with a low boron and tin content, enhancing industrial scalability and safety.
Implementation Method 1
reacting the compound of formula (I), optionally in the presence of a solvent, with hydrogen peroxide in the presence of a catalyst comprising a tin-containing zeolitic material having an MWW-type framework structure (Sn-MWW), to obtain a compound of formula (II)
Implementation Method 2
a catalyst comprising a tin-containing zeolitic material having an MWW-type framework structure (Sn-MWW)... wherein the Sn-MMW framework structure comprises SiO2 and B2O3 and the molar ratio of B2O3 relative to SiO2 is at most 0.0025:1
Data Source
AI summary
A process for the oxidation of an organic carbonyl compound comprising reacting the organic carbonyl compound, optionally in the presence of a solvent, with hydrogen peroxide in the presence of a catalyst comprising a tin-containing zeolitic material having an MWW-type framework structure.