Mixed Oxide Comprising Nb, V, and P Suitable as Catalyst for Partial Oxidation of Hydrocarbons

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This patent describes a novel mixed oxide catalyst comprising niobium (Nb), vanadium (V), phosphorus (P), and oxygen (O), with a specific ratio of Nb to (Nb+V), and featuring a crystalline NbOPO4 phase along with a crystalline alpha(II) VOPO4 phase. The invention also provides efficient preparation methods (including solution combustion and hydrothermal approaches) and demonstrates the catalyst's strong performance for the selective partial oxidation of hydrocarbons, particularly propane to propylene and n-butane to maleic anhydride.

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• Catalyst for selective partial oxidation of hydrocarbons such as propane and n-butane in industrial processes.
• Production of valuable chemicals like propylene from propane and maleic anhydride from n-butane.
• Integration into chemical reactors (e.g., fixed-bed reactors) for large-scale petrochemical manufacturing.
• Use in processes that aim to improve selectivity and yield of oxygenated products from hydrocarbon feedstocks.
• Potential application in the development of environmentally friendly processes due to higher selectivity and efficiency.

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• Provides high selectivity towards target oxygenates (like maleic anhydride and propylene), reducing side products and waste.
• Demonstrates high catalytic activity and conversion rates, improving process efficiency.
• Can be prepared with flexible methods that may reduce synthesis time and cost.
• Robust and adaptable catalyst structure allows tuning for different hydrocarbon feeds or process needs.
• Reduces reliance on traditional catalysts such as vanadyl pyrophosphate, offering an alternative with improved performance characteristics.
• Supports industrial scalability with options for supporting the catalyst on common materials (e.g., silica).

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Patent Abstract

A mixed oxide comprising Nb, V, P, and O, exhibiting a molar ratio of Nb to the sum of Nb and V, Nb:(Nb+V), of equal to or greater than 0.091:1, comprising a crystalline NbOPO4 phase, and comprising a crystalline alpha(ll) VOPO4 phase in an amount in the range of from equal to or greater than 50 weight-%, based on the sum of the weight of Nb calculated as NbOPO4 and of V calculated as VOPO4, determined as disclosed herein.