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Applied Catalysis A, General (v.280, #1)
Preface to the Special Issue II “Industrial Catalytic Processes�
by Wolfgang F. Hölderich (pp. 1-1).
Research is an investment, not an expense by F. Peter Boer (pp. 3-15).
Commercial R&D, of which industrial catalysis is one branch, is typically a high-risk investment with a deferred payoff. It is mistaken to view it as a cost. And, as with other high-risk investments, returns can be extremely attractive.The value-creating potential for investment in industrial catalysis depends on two basic factors: technical opportunity and commercial opportunity. When both are aligned prospects are excellent. Three cases are discussed; olefin polymerization, where both types of opportunity coincided, fluid cracking where the commercial opportunities are real, but technical opportunities are limited, and selective catalytic reduction, which is rich in technical opportunities, but the market opportunity in the U.S. has so far been problematic.The financial tools for evaluating R&D investments have evolved well beyond basic discounted cash flow models. Better tools have been developed to value intellectual capital, including the quantitative assessment of the value added by R&D. The dissection of the elements of risk, and the application of real options theory are new features of the R&D landscape. Financing vehicles have also changed with a surge of venture capital and private equity funds. The analyst's toolbox has been enhanced by electronic spreadsheets, on-line databases, Monte Carlo software, the Internet, and the ubiquitous personal computer.
Keywords: Investment; Expense; R&D
New developments in hydrogenation catalysis particularly in synthesis of fine and intermediate chemicals by B. Chen; U. Dingerdissen; J.G.E. Krauter; H.G.J. Lansink Rotgerink; K. Möbus; D.J. Ostgard; P. Panster; T.H. Riermeier; S. Seebald; T. Tacke; H. Trauthwein (pp. 17-46).
Catalysis is a multidisciplinary science that serves a broad range of industries covering specialty, fine, intermediate, commodity and life science chemicals. Catalysts are commonly used for the hydrogenation of alkenes, alkynes, aromatics, aldehydes, ketones, esters, carboxylic acids, nitro groups, nitriles and imines. These materials may be in the form of bio-, homogeneous, heterogeneous and heterogenised homogeneous catalysts where each type has its own special properties that can be adjusted for their optimal use. Heterogeneous catalysts are commonly used in the form of powders for slurry and fluidized bed reactions or as formed bodies for fixed bed hydrogenations. The addition of promoters and adjustments in particle size and porosity allow these catalysts to be fine tuned for specific reactions. Homogeneous catalysts are also very flexible where the choice of active metal, ligands and reaction conditions can lead to highly selective hydrogenations. The separation problems associated with homogeneous catalysts have led to the development of heterogenised homogeneous catalysts via the fixation of the active complexes on organic or inorganic supports or via application in biphasic systems. While there have been some successes in this area, there still remains a considerable amount of work to be done. Biocatalysts are of particular interest for the formation of enantiopure compounds. New developments in cofactor regeneration and raised substrate tolerance help to implement enzymatic reduction reaction on industrial scale. Efficient reductases are still needed to broaden this technology for further applications. It is expected that the development of these catalysts will be accelerated through the use of high throughput screening and that the testing of catalyst libraries will allow for the rapid selection of both catalyst and conditions for targeted processes. Reactor technology will also change as continuous processes slowly replace the workhorse batch ones for the manufacture of large-scale chemicals. This paper provides an overview of the above-mentioned topics for the industrially relevant hydrogenations that have been brought on stream over the last 20 years, as well as, the upcoming processes that will set the future trends in chemical industry.
Keywords: Hydrogenation; Heterogeneous catalyst; Homogeneous catalyst; Heterogenised homogeneous catalyst; Biocatalytic hydrogenation
Recently developed catalytic processes with bimetallic catalysts by Takanori Miyake; Tetsuo Asakawa (pp. 47-53).
Catalytic processes recently industrialized and developed with bimetallic catalysts are overviewed. Especially Pd-based bimetallic catalysts such as Pd–Pb and Pd–Bi used for oxidative reactions are put focuses on.
Keywords: Bimetallic catalyst; Oxidative reaction; Palladium
Catalytic processes in vitamins synthesis and production by Werner Bonrath; Thomas Netscher (pp. 55-73).
Water- and fat-soluble vitamins are essential for human and animal nutrition. Several of them are produced in amounts of well above 1000t annually worldwide. In this highly competitive field, catalytic methods represent ideal tools to lower production costs, and consequently gain an economical advantage, by the application of environmentally benign processes. Examples of industrially important transformations given in this review are grouped by reaction types, e.g. hydrogenation, oxidation and various alkylation, rearrangement, cycloaddition, and esterification reactions.
Keywords: Catalysis; Environmentally benign processes; Fine chemicals; Organic synthesis; Selectivity
Technology development in nicotinate production by Roderick Chuck (pp. 75-82).
An overview is given of the developments in nicotinate technology over the past 10–15 years. In particular the developments of the areas of the starting materials, reaction technology and of the working-up to the final product are considered. Attention is paid both to niacin (nicotinic acid) and niacinamide (nicotinamide).
Keywords: Niacin; Nicotinic acid; Niacinamide; Nicotinamide; Nicotinate technology
New diol processes: 1,3-propanediol and 1,4-butanediol by T. Haas; B. Jaeger; R. Weber; S.F. Mitchell; C.F. King (pp. 83-88).
More than 1000t of polyester resins and fibers are produced every hour in the world. The highest fraction of this amount is contributed by the oldest polyester, polyethylene terephthalate (PET). This material is based on the diol ethylene glycol (EG). Beside ethylene glycol butanediol (BDO) gained increasing demand in the polyester business, especially because of the use of polybutylene terephthalate (PBT) in the automotive industry as an engineering plastic. In the last 5 years also 1,3-propanediol (PDO) joined its homologues as an interesting polyester raw material. This development was caused by the finding of unique properties of the corresponding polyester, polypropylene terephthalate (PPT) in fiber application. Because of the increasing new market demand for PPT and PBT new production technologies were developed for 1,3-propanediol and 1,4-butanediol. A review will be presented whereby the production of 1,3-propanediol via fermentation of glucose will be not considered.
Keywords: Polyesters; Resins; 1,3-Propandiol; 1,4-Butanediol; Polypropylene terephthalate; Polybutylene terepththalate
Industrial catalytic processes—phenol production by Robert J. Schmidt (pp. 89-103).
Significant improvements in the technology for the production of phenol have been made over the past decade. New catalysts and processes have been commercialized for the production of cumene via alkylation of benzene with propylene. Recent process design innovations have been commercialized for the cumene hydroperoxide route that remains the process of choice for the production of phenol. All of this effort has been directed at improving yield, process economics/costs, and process safety for the preparation of phenol as a key intermediate for the growing bis-phenol A and phenolic resins markets. A review of technology offerings by major licensors of these new processes is provided as well as a discussion of key process differences and recent advances.
Keywords: Alkylation; Benzene; Propylene; Cumene; Zeolites; Phenol; Cumene hydroperoxide; α-Methylstyrene
Quantum technology in catalysis by Xenophon Krokidis; Jan W. Andzelm; Niranjan Govind; V. Milman (pp. 105-113).
A detailed understanding of catalytic mechanisms and surface chemistry is critical to chemical processes. These mechanisms are typically controlled by the detailed structural, electronic, and thermo-chemical properties and interactions of molecules and materials.Computational techniques offer unique solutions in catalysis and surface chemistry, providing an in-depth knowledge of the reaction mechanisms and the role of the individual reaction components.Accelrys offers leading software solutions for modeling both homogeneous and heterogeneous processes, enabling scientists to characterize, optimize, and design complex systems.
Keywords: Computational techniques; Catalytic mechanisms; Surface chemistry