Alkylene Oxide Catalyst Control via Chloriding and Temperature
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Solution Overview
Problem
Conventional silver-based catalysts for alkylene oxide production exhibit low efficiency and selectivity, with efficiency curves being flat and insensitive to gas phase promoter concentrations, leading to complex process control and inefficiencies in maintaining desired alkylene oxide production rates.
Innovation Solution
A process is developed to adjust either the overall catalyst chloriding effectiveness or reaction temperature while maintaining the other constant to achieve and maintain a desired alkylene oxide production parameter, utilizing high efficiency silver catalysts with organic chloride gas phase promoters to optimize alkylene oxide production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional silver-based catalysts are used for alkylene oxide production, then the process is simpler to operate, but the catalyst efficiency and selectivity are low with flat efficiency curves that are insensitive to gas phase promoter concentrations
Solution Approach 1:
The patent applies parameter changes by introducing gas phase promoter concentrations as a controllable variable to shift the catalyst efficiency curve from flat to steep. By adjusting promoter concentration in the feed gas, the process can operate on the steep portion of the efficiency curve where small parameter changes produce large efficiency improvements, resolving the contradiction between achieving high reliability and maintaining operational simplicity.
2Reliability
If high efficiency silver catalysts with steep efficiency curves are used, then catalyst efficiency and selectivity improve significantly, but process control becomes more complex due to sensitivity to gas phase promoter concentrations
Solution Approach 1:
The patent implements feedback control by continuously monitoring promoter concentration and adjusting it to maintain operation on the steep portion of the efficiency curve. This feedback mechanism compensates for the heightened sensitivity of high efficiency catalysts, allowing the system to automatically correct deviations and maintain optimal performance without requiring complex manual intervention.
Solution Approach 2:
The patent applies dynamics by making the promoter concentration a dynamic variable that can be adjusted in real-time based on process conditions. This dynamic adjustment capability allows the system to adapt to changing conditions and maintain high efficiency operation, transforming the static catalyst system into a dynamically controllable process that resolves the ease of operation contradiction.
3Productivity
If gas phase promoter concentration is increased to enhance catalyst efficiency, then alkylene oxide production rate increases, but the complexity of maintaining optimal promoter levels increases
Solution Approach 1:
The patent applies self-service by designing a control system that automatically monitors and adjusts promoter concentration without external intervention. The system uses built-in sensors and control mechanisms to maintain optimal promoter levels, allowing the process to self-regulate and maintain high productivity while minimizing the operational complexity associated with promoter concentration management.
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 approach allows for efficient adjustment of alkylene oxide production parameters without significant deviation from initial operating conditions, enhancing catalyst performance and maintaining high efficiency across varying conditions.
Implementation Method 1
The production of alkylene oxides via catalytic epoxidation of olefins in the presence of oxygen using silver based catalysts is known
Implementation Method 2
Promoters refer to materials that enhance the performance of the catalysts by either increasing the rate towards the desired formation of alkylene oxide and/or suppressing the undesirable oxidation of olefin or alkylene oxide to carbon dioxide and water
Data Source
AI summary
An improved method of operating an alkylene oxide production process to achieve and maintain a desired alkylene oxide production parameter is shown and described. The method comprises adjusting one of an overall catalyst chloriding effectiveness parameter or reaction temperature to obtain the desired alkylene oxide production parameter.