SBIR Phase I: Intensification of propylene oxide manufacture via solid-catalyst design

SBIR 第一阶段：通过固体催化剂设计强化环氧丙烷生产

• 批准号: 1746827
• 负责人: Alexander Okrut
• 金额: $ 22.5万
• 依托单位: Berkeley Materials Solutions
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2018
• 资助国家: 美国
• 起止时间: 2018-01-01 至 2019-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1746827&HistoricalAwards=false
• 关键词: SBIR; Phase; Intensification; propylene; oxide

This Small Business Innovation Research Phase I project aims to develop a delaminated zeolite-based catalyst to facilitate more economical and environmentally friendly propylene-oxide (PO) production. PO is a commodity chemical with a $5.6B/year market. The two current pain points for PO producers are (i) that the currently used industrial catalyst lacks long-term stability under the harsh conditions at the tail-end of the PO synthesis reactor, and (ii) as a result of catalyst deficiency, that the process to manufacture PO consumes an extra $140M of raw materials per year, separate from the problem in (i) above. Berkeley Materials Solutions developed a catalyst for the tail-end of the PO synthesis reactor that nearly eliminates both of these problems. The catalyst allows for nearly 100% conversion of all raw material into PO, which leads to $145 M/year of additional revenue for PO producers, corresponding to a revenue increase of 8.6%. This increased revenue comes at no additional cost since it is a drop-in replacement. In addition, there are significant energy efficiency improvements associated with recovering the currently lost raw material in the PO synthesis process, which amounts to a CO2 footprint of ~740 kilo tons of CO2 per year worldwide.The intellectual merit of this project will be represented by the development of a generalizable crystalline catalyst platform to replace existing amorphous catalysts. Technical hurdles that will be addressed in the proposal are (i) the successful delamination of a layered zeolite precursor using a swelling method and sonication, (ii) establishing a sonication-free scalable delamination method for layered zeolite precursors, and (iii) the insertion of catalytically active heteroatom sites into the delaminates frameworks. If successful, this will enable the economical production of these zeolite catalysts for application in the PO synthesis reactor under flow conditions. The targeted scales even during Phase I activities are large enough to enable testing in collaboration with industrial partners who manufacture propylene oxide at large scales. These test results will be used to optimize the prototype catalyst. The results from Phase I activities will help to uncover other possible opportunities to use delaminated zeolites as highly efficient catalysts for chemical manufacturing.

这个小型企业创新研究阶段I项目旨在开发一种基于沸石的分层催化剂，以促进更经济和环保的丙烯 - 氧化物（PO）生产。 PO是一种商品化学品，市场为5.6 b/年。 PO生产商的当前两个疼痛点是（i），当前使用的工业催化剂在PO合成反应器的尾端的恶劣条件下缺乏长期稳定性，并且（ii）由于催化剂缺乏，生产PO的过程每年消耗额外的1.4亿美元原料，与上述（I）中的问题分开。 伯克利材料解决方案开发了PO合成反应器尾端的催化剂，该末端几乎消除了这两个问题。该催化剂允许将所有原材料转换为PO，这使PO生产商的额外收入为145 m/年，相当于收入增长8.6％。由于这是一个替代品，因此收入增加的收入无需额外费用。 此外，在PO合成过程中恢复当前丢失的原材料的能源效率提高了，每年在全球范围内，二氧化碳占地面积约为740千吨二氧化碳。该项目的智力优点将由可替代现有的Amorphous Amorphous catalysts的开发来代表。提案中将解决的技术障碍是（i）使用肿胀方法和超声处理成功地分层的沸石前体，（ii）为分层的沸石前体者建立无超声的可扩展分层方法，（iii）（iii）催化活跃的杂型杂型杂型杂片的插入式插入到Delamaines serformess fromports。如果成功，这将使这些沸石催化剂的经济生产能够在流动条件下应用于PO合成反应堆。即使在I期活动中，目标量表也足够大，可以与在大尺度上生产氧化丙烷的工业伙伴合作进行测试。这些测试结果将用于优化原型催化剂。 I期活动的结果将有助于发现其他可能的机会使用分层的沸石作为化学制造的高效催化剂。

项目成果

Understanding the role of Zn2+ in surfactant-free layered silicate delamination: Exfoliation of magadiite

• DOI: 10.1016/j.micromeso.2019.03.048
• 发表时间: 2019-07
• 期刊: Microporous and Mesoporous Materials
• 影响因子: 5.2
• 作者: A. Okrut;Nicolás A. Grosso‐Giordano;Christian Schöttle;S. Zones;Alexander Katz

SSZ-70 borosilicate delamination without sonication: effect of framework topology on olefin epoxidation catalysis.

• DOI: 10.1039/c8dt03044h
• 发表时间: 2018-10
• 期刊: Dalton transactions
• 影响因子: 4
• 作者: A. Okrut;M. Aigner;Christian Schöttle;Nicolás A. Grosso‐Giordano;Son-Jong Hwang;X. Ouyang;S. Zones;Alexander Katz