Mixed Oxide Comprising Oxygen, Phosphorous, Tungsten and at Least One Metal from the Groups 8 to 11 of the Periodic Table of the Elements

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This patent describes a new class of mixed oxides containing oxygen, phosphorus, tungsten, and at least one metal from Groups 8 to 11 of the periodic table (such as ruthenium, rhodium, palladium, platinum, silver, or gold). These mixed oxides are predominantly amorphous (40-100% by weight) and are produced using an efficient solution combustion synthesis method. The invention demonstrates that these materials are highly effective as catalysts, especially for the selective partial oxidation of hydrocarbons (like n-butane or propane) to produce valuable chemicals such as maleic anhydride, acrolein, and acrylic acid.

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• Selective catalytic oxidation of hydrocarbons (e.g., converting n-butane to maleic anhydride, or propane/propylene to acrolein or acrylic acid) in petrochemical industry.
• Replacement for vanadium-based catalysts, especially in processes where vanadium usage is restricted or undesirable.
• Used in industrial reactors as fixed-bed catalyst forms (e.g., tablets or extrudates) for large-scale chemical production.
• Possible use in the controlled oxidation of various hydrocarbon feedstocks, including alkanes, alkenes, and aromatics.
• Facilitating greener chemical processes by improving yield and selectivity in oxidation reactions.

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• Higher selectivity and activity for producing value-added products like maleic anhydride compared to traditional catalysts.
• Can be formulated without vanadium or molybdenum, reducing toxicity and regulatory concerns.
• Simple and potentially cost-effective catalyst preparation via solution combustion synthesis.
• Good performance at moderate temperatures (350-450°C), suitable for industrial processes.
• Structural and compositional flexibility for catalyst optimization.
• Predominantly amorphous nature may provide enhanced catalytic properties and greater resistance to deactivation.
• Facilitates greener chemistry by reducing total combustion to CO/CO2 and maximizing desired product yield.

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Patent Abstract

The invention relates to a mixed oxide comprising oxygen, phosphorous, tungsten, at least one metal M1 from the groups 8 to 11 of the periodic table of the elements, wherein the molar ratio of tungsten to M1, W:M1, is in the range from greater than 0:1 to less than 6:1, and wherein 40 to 100 wt% of the mixed oxide is x-ray amorphous.