Aerosol Catalyst Synthesis for Propylene Conversion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for synthesizing metathesis and isomerization catalysts, such as wet impregnation or grafting, are limited in accessibility and control of catalyst properties, which hinders efficient conversion of Raffinate-2 and Raffinate-3 streams to propylene.
Innovation Solution
Aerosol processing is used to synthesize metathesis and isomerization catalysts by forming a catalyst precursor mixture without surfactants, aerosolizing, drying, and reacting it to distribute oxometallate or metal oxide within silica or alumina supports, enabling better control over catalyst properties and accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wet impregnation or grafting techniques are used to insert metal oxide into support material, then catalyst synthesis is achieved, but the entire particle volume is not accessible for metal oxide insertion and control of catalyst properties is limited
Solution Approach 1:
The patent replaces conventional wet impregnation mechanical processes with aerosol processing technology. The aerosolization system generates fine droplets that penetrate the entire particle volume, enabling uniform metal oxide distribution throughout the support material rather than just surface-level impregnation. This substitution of the delivery mechanism resolves the contradiction by achieving both complete particle volume accessibility and precise property control.
Solution Approach 2:
The patent changes the physical state and delivery parameters of the metal oxide precursor from liquid slurry (wet impregnation) to aerosolized droplets. This parameter change enables the precursor to reach throughout the entire particle volume while maintaining controlled concentration and distribution. The aerosol processing parameters (droplet size, concentration, flow rate) provide precise control over the final catalyst properties.
2Productivity
If conventional synthesis methods are used, then catalyst production is achieved, but conversion efficiency of Raffinate-2 and Raffinate-3 streams to propylene is insufficient
Solution Approach 1:
The patent applies local quality by ensuring uniform distribution of metal oxide throughout the entire particle volume of the catalyst. Rather than having heterogeneous distribution with concentrated metal oxide only on the surface or in specific regions, the aerosol processing creates consistent local composition throughout the catalyst particle. This uniform local quality translates to consistent and reliable catalytic performance across the entire catalyst bed, improving both productivity and reliability.
3Reliability
If wet impregnation techniques are used, then catalyst synthesis is achieved, but selectivity and activity of the metathesis catalyst are limited
Solution Approach 1:
The aerosol processing system serves multiple functions simultaneously: it delivers metal oxide precursor, controls distribution uniformity, adjusts concentration precision, and enables complete particle volume penetration. This multi-functional approach achieves high selectivity and activity through superior metal oxide distribution while maintaining ease of manufacture through a single integrated processing step that replaces multiple conventional operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances the conversion of 2-butene to propylene, offering improved selectivity and activity compared to conventional methods, and allows for independent control of metathesis and isomerization functionalities.
Implementation Method 1
aerosolizing the catalyst precursor mixture
Implementation Method 2
drying the aerosolized catalyst precursor mixture
Implementation Method 3
reacting the dried catalyst precursor to yield the metathesis and isomerization catalyst
Data Source
AI summary
Embodiments of a method of synthesizing a metathesis and isomerization catalyst or metathesis catalyst or isomerization catalyst comprises forming a catalyst precursor solution comprising a diluent and a catalyst precursor where the catalyst precursor comprises at least one of a silica precursor and an alumina precursor for the isomerization catalyst and additionally an oxometallate precursor or metal oxide precursor for the metathesis catalyst or the metathesis and isomerization catalyst, where the catalyst precursor solution is absent a surfactant; aerosolizing the catalyst precursor solution; drying the aerosolized catalyst precursor mixture to form a dried catalyst precursor; and reacting the dried catalyst precursor to yield the metathesis and isomerization catalyst or the metathesis catalyst or the isomerization catalyst, the metathesis and isomerization catalyst comprising a silica and alumina support with an oxometallate or a metal oxide distributed within the silica and alumina support.