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Vanadium-phosphorus oxide catalysts are useful in the selective oxidation of lower alkanes (C2-C5). However, conventional synthesis methods for mixed metal oxides such as vanadium-phosphorus oxides, both wet chemistry and solid-state, offer very limited control over desirable structural and compositional properties, such as the phase, bulk and surface compositions, preferential exposure of active and selective surface planes, surface areas and pore architecture, all of which affect the catalytic properties of these materials.
A new method of preparation of nanoporous vanadium phosphorous oxide catalysts has been developed which results in the production of nanoporous catalysts with desirable structural, morphological, and composition properties for lower alkane oxidation.
The method as used in our laboratories produces materials with unique and promising properties for the selective oxidation of lower alkanes, e.g.: ordered 3 – 30 nm ordered and tunable straight, one-dimensional cylindrical pores or three-dimensional pores of cubic symmetry; high surfaces areas (20 – 800 square meters per gram); and optimal surface composition for specific applications (e.g. P/V molar ration of 1.05 – 1.10 for n-butane oxidation to maleic anhydride and other oxidation and acid-base catalyzed reactions).
The catalysts have improved thermal stability compared to catalysts prepared according to conventional techniques.