Advancements in Supported Liquid-Phase Catalyst Systems for Sustainable Industrial Hydroformylation

In light of contemporary environmental challenges and the essential need for sustainable industrial practices, optimizing chemical processes to reduce energy consumption, resource usage, and operational costs has become crucial. The process industry is increasingly focusing on advancing sustainable development goals by improving efficiency and minimizing the environmental impact of production methods. This dissertation addresses these challenges by exploring the development and optimization of supported liquid-phase (SLP) catalysts for the hydroformylation reaction of 1-butene, a key process in producing valuable aldehydes.
The dissertation is structured into five distinct parts:

Part I introduces the core concepts of catalysis with a particular emphasis on supported liquid-phase catalysis and the hydroformylation reaction. It outlines the fundamental principles behind this catalytic process and details the specifications of the catalysts employed in this study. This part also defines the research framework and presents the primary objectives of the PhD project.

Part II highlights the importance of characterization techniques for assessing catalyst properties. A pilot-test unit designed for preliminary screening of catalyst performance, including selectivity, activity, and stability, is described to bridge laboratory findings with industrial applications. It also outlines the experimental procedures for conducting reactions in the mini-pilot plant at DTU and the methodologies used for catalyst synthesis.

Part III delves into the study of SLP materials and their application in the hydroformylation reaction. It investigates various support structures for SLP catalysts and their impact on the continuous flow hydroformylation process. The research explores the optimization of liquid-phase compositions and reaction parameters to enhance catalyst performance, considering both technical and economic aspects. Detailed characterization of catalytic materials is also provided, focusing on liquid distribution within porous supports to achieve optimal catalytic performance. Techniques such as electron microscopy (SEM-EDX), nuclear magnetic spectroscopy (¹H T₂/CPMG NMR), and X-ray scattering (SAXS) are employed to assess the effectiveness of the liquid distribution. Additionally, the sensitivity of catalyst ligands to water, which affects catalyst lifetime and performance, is evaluated.