Effect of direct ultrasound synthesis via a sesquihydrate route on bismuth-promoted vanadyl pyrophosphate catalysts

A series of 1, 3, and 5% Bi-doped vanadium phosphate catalyst catalysts were prepared via sesquihydrate route using direct ultrasound method and were denoted as VPSB1, VPSB3, and VPSB5, respectively. These catalysts were synthesized solely using a direct ultrasound technique and calcined in a n-butane/air mixture. This study showed that catalyst synthesis time can be drastically reduced to only 2 hr compared to conventional 32–48 hr. All Bi-doped catalysts exhibited a well-crystallized (VO)₂P₂O₇ phase. In addition, two V⁵⁺ phases, that is, β-VOPO₄ and α_II-VOPO₄, were observed leading to an increase in the average oxidation state of vanadium. All catalysts showed V2p_3/2 at approx. 517 eV, giving the vanadium oxidation state at approx. 4.3–4.6. Field-emission scanning electron microscopy micrographs showed the secondary structure consisting of thin and small plate-like crystal clusters due to the cavitation effect of ultrasound waves. VPSB5 showed the highest amount of oxygen species removed associated with the V⁵⁺ and V⁴⁺ species in temperature-programmed reduction in H₂ analyses. TheX-ray absorption near edge structure (XANES) measurement showed the occurrence of vanadium oxide reductions in hydrogen gas flow, indicating the presence of V⁴⁺ and V⁵⁺ species. Higher average valence states of V⁵⁺, indicating more V⁵⁺ phases, were present. The addition of bismuth has increased the activity and selectivity to maleic anhydride.