The synthesis of maleic anhydride: study of a new process and improvement of the industrial catalyst

Maleic anhydride is an important chemical intermediate mainly produced by the selective oxidation of n-butane, an industrial process catalyzed by vanadyl pyrophosphate-based materials, (VO)2P2O7. The first topic was investigated in collaboration with a company specialized in the production of organic anhydrides (Polynt SpA), with the aim of improving the performance of the process for the selective oxidation of n-butane to maleic anhydride, comparing the behavior of an industrial vanadyl pyrophosphate catalysts when utilized either in the industrial plant or in lab-scale reactor. The study was focused on how the catalyst characteristics and reactivity are affected by the reaction conditions and how the addition of a dopant can enhance the catalytic performance. Moreover, the ageing of the catalyst was studied, in order to correlate the deactivation process with the modifications occurring in the catalyst. The second topic was produced within the Seventh Framework (FP7) European Project “EuroBioRef”. The study was focused on a new route for the synthesis of maleic anhydride starting from an alternative reactant produced by fermentation of biomass:“bio-1-butanol”. In this field, the different possible catalytic configurations were investigated: the process was divided into two main reactions, the dehydration of 1-butanol to butenes and the selective oxidation of butenes to maleic anhydride. The features needed to catalyze the two steps were analyzed and different materials were proposed as catalysts, namely Keggin-type polyoxometalates, VOPO4∙2H2O and (VO)2P2O7. The reactivity of 1-butanol was tested under different conditions, in order to optimize the performance and understand the nature of the interaction between the alcohol and the catalyst surface. Then, the key intermediates in the mechanism of 1-butanol oxidehydration to MA were studied, with the aim of understanding the possible reaction mechanism. Lastly, the reactivity of the chemically sourced 1-butanol was compared with that one of different types of bio-butanols produced by biomass fermentation.

Deidrogenazione ossidativa del n-butano catalizzata da ossidi metallici difettivi

The oxidative dehydrogenation (ODH) of n-butane is a promising way to synthetize butenes and 1,3-butadiene, currently produced by steam cracking or direct dehydrogenation of n-butane. The addition of oxygen as a reagent leads to the formation of water, a very stable by-product, which makes the process exothermic.In this work, the ODH of n- butane was investigate to selectively obtain butenes and 1,3-butadiene. Four catalysts based on metal oxides (V2O5, La2O3, CeO2 and TiO2) were mixed with Mg metallic powder and reduced at 650 °C for 5 h in 5% H2/Ar atmosphere, with the purpose of creating oxygen vacancies in the crystal lattice of the oxides. Subsequently, the effect of the Mg concentration, and thus the oxygen vacancies concentration, was studied. The titanium oxide-based catalysts were the most active, in terms of butane conversion and selectivity to butenes and 1,3 butadiene. Overall, this study shows that the formation of oxygen vacancies on metal oxides can be influenced by the addition of metallic Mg during the synthesis. In the case of TiO2, this leads to an increase on the activity compared to the untreated sample.