Aromatization Catalyst Reactivation via Metal Redispersion
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Solution Overview
Problem
Aromatization catalysts used in hydrocarbon conversion processes gradually lose activity due to contamination and carbonaceous material buildup, leading to reduced selectivity and conversion rates, necessitating effective reactivation methods to restore their performance without the need for frequent replacement.
Innovation Solution
A method involving the redispersion of metal on the catalyst support, followed by decoking to remove carbonaceous material, and subsequent treatment with halide-containing compositions, including fluoride, to reactivate the catalyst through thermal treatment, thereby restoring catalytic activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the catalyst is used continuously to produce aromatic compounds, then productivity is improved, but the catalyst activity decreases due to contamination and carbonaceous material buildup
Solution Approach 1:
The patent applies preliminary action by performing decoking and redispersion treatments on the spent catalyst before reactivation. The catalyst is first treated to remove carbonaceous material (decoking), then the metal is redispersed on the support, and finally the catalyst is reactivated by treatment with a reactivating composition. This sequence of preliminary treatments restores the catalyst's active sites and dispersions the metal uniformly, thereby recovering high catalytic activity and extending the catalyst's useful life.
2Reliability
If the spent catalyst is replaced with fresh catalyst, then catalyst activity is restored, but the cost of production increases
Solution Approach 1:
The patent applies the discarding and recovering principle by recovering the valuable metal components from the spent catalyst through decoking and redispersion processes. Instead of discarding the spent catalyst entirely, the method recovers the metal by removing carbonaceous deposits and redistributing the metal uniformly on the support, then reactivates the recovered catalyst. This recovery process eliminates the need for complete catalyst replacement, reducing material loss and production costs while maintaining high catalytic activity.
3Reliability
If the catalyst is treated with halide-containing compositions, then the catalyst is reactivated, but equipment corrosion may occur
Solution Approach 1:
The patent applies the intermediary principle by using a carefully controlled reactivating composition that contains halides as intermediaries to transfer to the catalyst. The reactivating composition serves as a mediator that delivers the necessary halide ions to the metal sites on the catalyst support, enabling reactivation without direct exposure of the equipment to highly corrosive halide environments. The controlled composition and treatment conditions allow catalyst reactivation while minimizing equipment corrosion.
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 method effectively increases the activity of spent aromatization catalysts to a level closer to that of fresh catalysts, extending their useful life and reducing the need for frequent replacement, while maintaining equipment compatibility and safety.
Implementation Method 1
redispersing the metal in the spent catalyst to produce a redispersed spent catalyst
Implementation Method 2
reducing the amount of carbonaceous material associated with the spent catalyst to produce a decoked spent catalyst
Implementation Method 3
contacting the decoked redispersed spent catalyst with a reactivating composition to produce a decoked redispersed reactivated spent catalyst
Implementation Method 4
thermally treating the redispersed, reactivated spent catalyst to produce a reactivated catalyst
Data Source
AI summary
A method of reactivating a spent catalyst comprising a metal and a catalyst support, the method comprising redispersing the metal in the spent catalyst to produce a redispersed spent catalyst, contacting the redispersed spent catalyst with a reactivating composition to produce a redispersed, reactivated spent catalyst, and thermally treating the redispersed, reactivated spent catalyst to produce a reactivated catalyst. A method comprising employing a fresh aromatization catalyst in one or more reaction zones for a time period sufficient to produce a spent catalyst, reducing the amount of carbonaceous material associated with the spent catalyst to produce a decoked spent catalyst, contacting the decoked spent catalyst with a redispersing composition to produce a decoked redispersed spent, contacting the decoked redispersed spent catalyst with a reactivating composition to produce a decoked redispersed reactivated spent catalyst, and thermally treating the decoked, reactivated spent catalyst to produce a reactivated catalyst.