Catalytic System for Industrial Chemical Manufacture

Oxidation reactions, which use air or oxygen, are used in the manufacture of a wide range of chemicals. The enhancement of oxidation selectivity represents one of the largest opportunities for improving energy efficiency in the chemical industry. One of the most important chemicals (sulfuric acid) uses high-temperature catalytic oxidation as a critical step in its production. For conventional catalysts, the oxidation temperature is about 750°F. At this temperature the oxidation reaction is equilibrium limited, which lowers the overall yield of the process and increases the emissions of sulfur. A new catalyst that operates at lower temperature could shift the equilibrium to produce more products, increasing the overall yield and energy efficiency of the process and decreasing the emissions of acid rain precursors. This project will continue the development of a novel catalyst that can carry out this critical oxidation at a temperature near 600°F, with the same level of activity. In addition, the oxidation reaction no longer will be equilibrium limited, and the overall yield (and therefore process efficiency) will be improved. Because the new catalyst will be designed as a drop-in replacement in existing catalytic reactors, no new process equipment would be required. Phase I will formulate several catalysts by varying the loadings of the active components and the preparation methods. The catalysts then will be tested at laboratory scale using synthetic feedstocks. The catalysts will be fully characterized, in order to relate structure and chemical composition to catalyst activity and selectivity. Using these data, a preliminary economic analysis will be performed. In Phase II, the process will be scaled-up from the laboratory to the bench scale, and a slipstream test will be performed. Commercial Applications and other Benefits as described by the awardee: The low temperature catalyst would serve as a replacement to existing catalysts in the production of sulfuric acid and other chemicals. Compared with existing commercial catalysts, the new catalyst offers a reduction of emissions and, potentially, a 25% increase in plant capacity.