Supported Composite Catalyst for Ester Synthesis

Solution Overview

Problem

Existing methods for using nickel and nickel compounds as catalysts in chemical synthesis, such as forming carboxylic acid esters from aldehydes and alcohols, face issues with target product selectivity, catalyst activity, and stability due to uneven distribution and susceptibility to dropout or deactivation.

Innovation Solution

A supported composite particle material is developed with oxidized nickel and elements like palladium, platinum, ruthenium, gold, or silver, where the composite particles are localized within a specific range of the support, enhancing catalyst stability and activity by controlling their distribution and preventing adsorption of by-products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If nickel or nickel compounds are used as catalysts in chemical synthesis, then catalyst activity is improved, but target product selectivity deteriorates

Engineering Contradiction:

Improvecatalyst activityVSAvoidtarget product selectivity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by creating composite particles with specific spatial distribution of nickel and other metal elements (Pd, Pt, Ru, Au, or Ag) on the support surface. The localized arrangement of different metal components at specific positions within the composite particles enables selective catalysis for desired reactions while suppressing side reactions, thus improving both catalyst activity and target product selectivity simultaneously.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs composite materials by combining nickel with other metal elements (Pd, Pt, Ru, Au, or Ag) to form composite particles. This composite structure leverages the synergistic effects between different metals, where nickel provides high catalytic activity while the other metals enhance selectivity and stability, resolving the contradiction between activity and selectivity.

Inventive Principle:

Principle #40Composite materials

2Productivity

If nickel compounds are used as catalysts, then catalyst activity is improved, but catalyst stability deteriorates due to susceptibility to dropout or deactivation

Engineering Contradiction:

Improvecatalyst activityVSAvoidcatalyst stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies local quality by creating composite particles with specific spatial distribution of nickel and other metal elements (Pd, Pt, Ru, Au, or Ag) on the support surface. The localized arrangement of different metal components at specific positions within the composite particles enables selective catalysis for desired reactions while suppressing side reactions, thus improving both catalyst activity and target product selectivity simultaneously.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent employs composite materials by combining nickel with other metal elements (Pd, Pt, Ru, Au, or Ag) to form composite particles. This composite structure leverages the synergistic effects between different metals, where nickel provides high catalytic activity while the other metals enhance selectivity and stability, resolving the contradiction between activity and selectivity.

Inventive Principle:

Principle #40Composite materials

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 supported composite particle material maintains high reactivity over a long period by stabilizing the catalyst, preventing deactivation, and improving reaction activity and selectivity.

Implementation Method 1

composite particle formed of an oxidized nickel and X (wherein X represents at least one type of elements selected from the group consisting of palladium, platinum, ruthenium, gold and silver) which is supported onto a support as a catalyst in a reaction for forming carboxylic acid esters from aldehydes and alcohols

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

Ni functions as an oxygen activation site as a result of compounding Ni with a dissimilar metal element, and is thought to result in the formation of peroxo species serving as reactive species on the Ni

Methodology Applied

Scientific EffectOxidation: Oxidation

Implementation Method 3

Ni functions as an oxygen activation site as a result of compounding Ni with a dissimilar metal element, and is thought to result in the formation of peroxo species serving as reactive species on the Ni

Methodology Applied

Scientific EffectOxygen activation:

Data Source

PatentEP2500093B1Use of a supported composite particle material, production process of said material and process for producing compounds using supported composite particle material as catalyst for chemical synthesis

Publication Date: 2020.06.10 ASAHI KASEI KOGYO KABUSHIKI KAISHA

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AI summary

A supported composite particle material comprising a composite particle formed of an oxidized nickel and X, wherein X represents at least one of elements selected from the group consisting of palladium, platinum, ruthenium, gold, and silver; and a support on which the composite particle is supported, the supported composite particle material having a supported layer in which the composite particle is localized. Also disclosed is a process for producing said composite particle material and a process of using said composite particle material for producing a carboxylic acid ester.