Case Number 101025 - Macroporous Vandium Phosphorus-Oxide Catalysts

Contact: Geoffrey Pinski
Phone: 513-558-5696

Description:  Vanadium-phosphorus oxide catalysts are useful in the selective oxidation of lower alkanes (C2-C5). However, conventional synthesis methods for mixed metal oxides such as vanadium-phosphorus oxides, both wet chemistry and solid-state, offered very limited control over desirable structural and compositional properties, such as the phase, bulk and surface compositions, preferential exposure of active and selective surface planes, surface areas and pore architecture, all of which affect the catalytic activity of these materials.
A new method of preparation of macroporous vanadium phosphorous oxide catalysts has been developed which results in the production of macroporous catalysts with desirable structural, morphological, and composition properties for lower alkane oxidation.
The method as used in our laboratories produces material with unique and promising properties for the selective oxidation of lower alkanes, e.g.: ordered .2 - .4 micrometer pore architectures; unprecedentedly high surfaces areas (44 – 75 square meters per gram); and optimal surface composition for specific applications (e.g. P/V molar ration of 1.05 – 1.10 for n-butane oxidation to maleic anhydride)
The method affords the possibility to control and fine-tune structural, compositional, and morphological properties of vanadium phosphorus oxide catalysts for a variety of applications.
Cost savings should arise from use of catalysts prepared by this method by two mechanisms; first, enhanced activity should result in lower reaction temperatures, and hence reduced utility costs. Secondly, lower temperatures are expected to benefit the selective alkane oxidation over its combustion, resulting in higher product recovery and lower cost over conventional techniques.
The synthesis procedure for the novel catalysts is compatible with current commercial preparation methods.