Agglomerated Oxidative Dehydrogenation Catalyst Strength
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Solution Overview
Problem
Existing oxidative dehydrogenation catalysts for ethane to ethylene conversion lack sufficient strength to prevent attrition and do not effectively utilize Nb2O5 as a binder or support, limiting activity and selectivity.
Innovation Solution
Development of agglomerated catalysts comprising 10-95% of a catalyst active phase (Mo1.0V0.12-0.49Te0.6-0.16Nb0.15-0.20Od) with 5-90% Nb2O5 and optional non-antagonistic binders, extruded into specific shapes with controlled pore distribution and crush strength, using Nb2O5 hydrate as a binder to enhance catalyst activity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional catalyst formulations are used, then the catalyst can perform oxidative dehydrogenation, but the catalyst particles lack sufficient strength and suffer from attrition during use
Solution Approach 1:
The patent employs a composite catalyst formulation combining Mo-V-Te-Nb mixed oxide active phase with Nb2O5 binder in an agglomerated structure. This composite approach integrates the catalytic function with mechanical strength provision, where Nb2O5 serves dual role as binder and structural component, creating particles that resist attrition while maintaining catalytic activity.
2Strength
If Nb2O5 is used as a binder at higher levels to improve strength, then catalyst particle strength increases, but the activity in terms of temperature for 25% conversion deteriorates
Solution Approach 1:
The patent optimizes the Nb2O5 binder content to a specific range (5-90 wt%, preferably 10-50 wt%) to balance mechanical strength and catalytic activity. By precisely controlling the binder concentration and the agglomeration process parameters, the formulation achieves sufficient particle strength while maintaining low temperature activity for 25% conversion.
Solution Approach 2:
The agglomerated structure creates local regions with different compositions and properties. The external surface and internal pores have different Nb2O5 concentrations and pore characteristics, allowing the outer layers to provide strength while inner regions maintain high catalytic activity and accessibility.
3Ease of manufacture
If incipient wetness impregnation is used to prepare supported catalyst, then catalyst can be deposited on support, but the method requires precise control of solvent type and volume to minimally wet the support
Solution Approach 1:
The patent extracts the catalyst from solution form and transforms it into an agglomerated solid formulation. This eliminates the need for liquid impregnation processes and their associated solvent control requirements, simplifying the manufacturing process while achieving complete catalyst utilization.
Solution Approach 2:
The catalyst active phase, binder, and pore structure are merged into a single agglomerated particle formulation rather than being separate components requiring sequential processing. This integration simplifies manufacturing by eliminating multiple steps like impregnation, drying, and calcination that are required for supported catalysts.
4Manufacturing precision
If agglomeration method is used with wider binder to catalyst ratios, then enhanced control over pore volume and size is achieved, but the formulation complexity increases
Solution Approach 1:
The agglomeration process enables precise control of pore volume (0.02-0.20 cm³/g) and pore size distribution through adjustment of binder-to-catalyst ratios and processing parameters. The Nb2O5 binder content and agglomeration conditions are optimized to achieve target pore characteristics that enhance catalyst performance.
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 agglomerated catalysts demonstrate improved activity and selectivity in oxidative dehydrogenation of ethane, maintaining high selectivity while reducing the temperature for 25% conversion, and exhibit enhanced crush strength and stability, overcoming attrition issues.
Implementation Method 1
Nb2O5 hydrate is useful as a binder for the catalyst particles
Implementation Method 2
agglomerated oxidative dehydrogenation catalysts to convert paraffins, for example C2-4, or for example ethane, to the corresponding alkene
Data Source
AI summary
Oxidative dehydrogenation catalysts for converting lower paraffins to alkenes such as ethane to ethylene when prepared as an agglomeration, for example extruded with supports comprising slurries of Nb2O5.