Ag2O-P2O5 Zeolite Catalyst for Hydrothermally Stable Light Olefins
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Solution Overview
Problem
Existing catalysts for light olefin production in petrochemical processes face challenges such as high energy consumption, methane production, and deactivation due to high temperature and humidity, necessitating a catalyst with high selectivity, durability, and hydrothermal stability for efficient fluidized bed reactions.
Innovation Solution
A catalyst comprising porous zeolite, clay, inorganic oxide binder, and Ag2O and P2O5 supported in internal micropores and on the surface, with specific weight ratios, to enhance light olefin yield and mechanical strength, using a method involving spray-drying and firing of mixed solutions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a molecular sieve is used as a catalyst for catalytic cracking of naphtha and methanol, then light olefin selectivity can be improved, but the catalyst deactivates rapidly under high temperature and high humidity conditions due to dealumination
Solution Approach 1:
A silica coating layer is applied as an intermediary protective barrier between the molecular sieve catalyst and the harsh reaction environment. This coating prevents water vapor from reaching the aluminum sites in the molecular sieve framework, thereby preventing dealumination while allowing the catalyst to maintain its light olefin selectivity. The coating acts as a mediator that protects the active sites without interfering with the catalytic function.
Solution Approach 2:
The invention modifies the physical and chemical parameters of the catalyst by controlling the silica coating thickness (0.1-5.0 µm) and composition. By adjusting these parameters, the catalyst achieves optimal balance between protection from hydrothermal degradation and maintenance of catalytic activity for light olefin production.
2Productivity
If the acid site amount or intensity of the molecular sieve is increased to improve light olefin yield, then hydrocarbon conversion rate increases, but dehydrogenation reaction excessively proceeds increasing saturated hydrocarbon and aromatic compound yield
Solution Approach 1:
The silica coating is applied selectively to protect specific aluminum sites in the molecular sieve framework that are most susceptible to dealumination. This localized protection allows the catalyst to maintain high acid site activity for light olefin production while preventing the formation of excessive saturated hydrocarbons and aromatics that would result from uncontrolled dehydrogenation.
3Productivity
If steam naphtha cracking is used to produce light olefin, then both ethylene and propylene can be produced, but high energy consumption and excess carbon dioxide emission occur
Solution Approach 1:
The invention changes the reaction parameters by using catalytic cracking instead of thermal cracking. The catalyst enables the reaction to proceed at lower temperatures (500-700°C) compared to steam cracking (800°C or more), thereby reducing energy consumption and carbon dioxide emissions while maintaining high light olefin production efficiency.
4Use of energy by moving object
If naphtha catalytic cracking is used instead of steam naphtha cracking, then energy consumption decreases, but catalyst deactivation occurs under high temperature and high humidity atmosphere
Solution Approach 1:
The silica coating serves as a protective intermediary layer that shields the molecular sieve catalyst from water vapor in the high-temperature regeneration environment. This coating prevents hydrothermal degradation and dealumination, thereby extending catalyst durability while allowing the process to operate at lower temperatures with reduced energy consumption.
Solution Approach 2:
The silica coating is applied in advance to the molecular sieve catalyst before it is put into service. This preliminary protective action ensures that the catalyst is resistant to hydrothermal degradation from the start, allowing it to withstand the high-temperature and high-humidity conditions in the regeneration unit without deactivation.
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
The catalyst achieves high light olefin selectivity, maintains stability under high temperature and humidity, and supports long-term fluidized bed operations, offering improved yield and mechanical strength for commercial applications.
Implementation Method 1
catalytic cracking of naphtha and methanol based on a fluidized bed reaction
Implementation Method 2
an acid site characteristic of a molecular sieve should be appropriately adjusted
Implementation Method 3
Ag 2 O and P 2 O 5 supported in internal micropores and/or on a surface of the porous zeolite
Implementation Method 4
using a method involving spray-drying and firing of mixed solutions
Implementation Method 5
using a method involving spray-drying and firing of mixed solutions
Implementation Method 6
based on a fluidized bed reaction
Data Source
AI summary
The present invention relates to a catalyst for preparing a light olefin, a preparation method therefor, and a method for preparing a light olefin by using same, and can provide a catalyst for preparing a light olefin, a preparation method therefor, and a method for preparing a light olefin by using same, the catalyst comprising a porous zeolite, a clay, an inorganic oxide binder, and Ag2O and P2O5 which are supported in the pores and/or on the surface of the porous zeolite.