Improving the synthesis of Zn-Ta-TUD-1 for the Lebedev process using the Design of Experiments methodology

[Display omitted] •Zinc-tantalum on mesoporous silica TUD-1 catalyst showed remarkable activity in the conversion of ethanol to butadiene.•Plackett-Burman design identified key synthesis parameters for high productivity.•TUD-1 synthesis parameters compromised between surface area and pore diameter.•Response Surface Methodology identified high performing catalyst composition. The synthesis method of a zinc-tantalum catalyst supported on three-dimensional mesoporous silica with high specific surface area was studied. Its activity in the conversion of ethanol to butadiene was optimized using the Design of Experiment approach. A Plackett-Burman screening design identified the important preparation parameters, notably the ratio of Zn to Ta. It was subsequently optimized using the Response Surface Methodology, affording a highly active catalyst.