Supported Tantalum Catalyst for 1,3-Butadiene Activity and Yield
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Solution Overview
Problem
Existing catalysts for producing 1,3-butadiene from ethanol and acetaldehyde do not achieve high activity and yield, necessitating the development of catalysts with improved selectivity and productivity.
Innovation Solution
A supported catalyst comprising 0.1 to 10 wt.% tantalum (Ta2O5), 5 to 60 ppm aluminium, and 35 to 75 ppm sodium, along with specific support materials and reaction conditions, enhances the catalyst's activity and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts are used for producing 1,3-butadiene from ethanol and acetaldehyde, then the basic catalytic function is achieved, but the activity and yield are insufficient
Solution Approach 1:
The patent applies parameter changes by precisely controlling the sodium content (35-75 ppm) and aluminium content (5-60 ppm) in the catalyst system. These specific concentration ranges optimize the catalytic activity and yield of 1,3-butadiene, transforming the catalyst performance through quantitative compositional adjustments rather than qualitative changes.
Solution Approach 2:
The patent employs composite materials by combining silica support with controlled amounts of sodium and aluminium impurities to create a multifunctional catalyst system. This composite structure integrates the support material with active components that work synergistically to enhance both activity and yield, resolving the contradiction between basic function and optimized performance.
2Productivity
If ultra-pure silica support is used, then the selectivity is maintained, but the activity and overall production efficiency are reduced
Solution Approach 1:
The patent converts the traditionally harmful effect of sodium and aluminium impurities (which were considered contaminants reducing selectivity) into a beneficial factor. By intentionally introducing controlled amounts of these impurities (35-75 ppm sodium, 5-60 ppm aluminium), the catalyst achieves enhanced activity and production efficiency while maintaining selectivity, thus converting what was previously seen as a negative into a positive attribute.
Solution Approach 2:
The patent applies parameter changes by redefining the acceptable ranges of sodium and aluminium content from trace contaminants to optimized compositional parameters. This quantitative adjustment transforms the catalyst's interaction with reactants, improving production efficiency without sacrificing selectivity to 1,3-butadiene.
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 higher activity and yield of 1,3-butadiene, maintaining selectivity comparable to ultra-pure silica supports while increasing overall production efficiency.
Implementation Method 1
The conversion of ethanol, obtainable e.g. from biomass, to 1,3-butadiene may be performed in two ways reported in the literature: as one-step process (Lebedev process) and as two-step process (Ostromislensky process)... In the second step, conversion of the mixture of ethanol and acetaldehyde to 1,3-butadiene over, for example, a silica-supported tantalum catalyst takes place
Data Source
AI summary
The present invention relates to a supported catalyst comprising a support and 0.1 to 10 wt. % of tantalum, calculated as Ta2O5 and based on the total weight of the catalyst, wherein the supported catalyst further comprises 5 to 60 ppm of aluminium and 35 to 75 ppm of sodium, based on the total weight of the catalyst, respectively. Moreover, the invention relates to a catalyst reaction tube for the production of 1,3-butadiene comprising at least one packing of the supported catalyst as defined herein, to a reactor for the production of 1,3-butadiene comprising one or more of the catalyst reaction tubes as defined herein, and to a plant for the production of 1,3-butadiene comprising one or more of the reactors as defined herein. The invention also relates to a process for the production of 1,3-butadiene as defined herein and to a process for the production of the supported catalyst as defined herein. Finally, the present invention relates to the use of the supported catalyst as defined herein for the production of 1,3-butadiene from a feed comprising ethanol and acetaldehyde and to the use of sodium in an amount in a range of from 35 to 75 ppm in a supported catalyst for the production of 1,3-butadiene from a feed comprising ethanol and acetaldehyde for increasing the yield of 1,3-butadiene.