Polynuclear Vanadyl Pyrophosphate

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This patent describes a new class of polynary vanadyl pyrophosphate compounds, including those with the general formula (VO)a(M1-bVb)2(P2O7)c, where M is selected from a variety of metals (such as Fe, Cr, Ti, etc.). The invention includes the preparation methods for these compounds and their use as heterogeneous catalysts, specifically for gas phase oxidation of hydrocarbons with at least four carbon atoms. One key representative compound is (VO)Fe2(P2O7)2. These catalysts are particularly useful in the production of maleic anhydride from n-butane and other hydrocarbons.

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• Industrial production of maleic anhydride from n-butane or other C4 hydrocarbons via gas phase oxidation.
• Catalysts in chemical processes involving partial oxidation or ammoxidation of hydrocarbons.
• Modification or enhancement of existing vanadyl pyrophosphate-based catalysts for improved performance in hydrocarbon oxidation.
• Production of intermediates or fine chemicals requiring selective oxidation reactions.
• Use in packed bed or fluidized bed reactors for continuous chemical manufacturing.

BenefitsContent extracted from patent full text and abstract with AI.

• Provides new catalyst compositions with potentially improved activity and selectivity for gas phase oxidation reactions.
• Enables more efficient production of maleic anhydride, a key industrial chemical.
• Reduces the formation of undesired side-products by increasing catalyst selectivity.
• Allows for the customization of catalyst properties by varying the metal component (M) in the framework.
• Can be manufactured using scalable, industrially relevant processes (e.g., spray drying, calcination).
• Potential for longer catalyst lifetime due to improved structural and compositional robustness.

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Patent Abstract

The invention relates to a novel polynary vanadyl pyrophosphate of general formula (VO)a(M1-bVb)2(P2O7)c (I), wherein M represents one or more metals selected from the group including Ti, Zr, Hf, Cr, Fe, Co, Ni, Ru, Rh, Pd, Cu, Zn, B, Al, Ga and In, a has a value of 0.5 to 1.5, b has a value of 0 to 0.9, c has a value of 1.5 to 2.5, said novel compound having a crystal structure and being characterized by defined diffraction reflexes in powder X-ray diffraction. A preferred representative is (VO)Fe2(P2O7)2. The vanadyl pyrophosphates are suitable as gas phase oxidation catalysts, e.g. for producing maleic anhydride from a hydrocarbon with at least four carbon atoms.