Bi-metallic Catalyst for Aromatic Yield in Naphtha Reforming
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Solution Overview
Problem
Current methods for enhancing aromatic compound production from naphtha feedstreams are limited by the use of multiple catalysts, which increase costs and do not efficiently convert non-aromatic hydrocarbons to aromatics, particularly in the C6 to C8 range, essential for producing benzene, toluene, and xylenes.
Innovation Solution
A process involving a single catalyst system that includes passing a naphtha feedstream through a reformer, followed by fractionation and aromatics extraction, with a raffinate recycle to optimize conversion of non-aromatics to aromatics, utilizing a hydrotreater to remove sulfur and employing multiple reactor beds with interbed heating to enhance reaction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple catalysts are used to enhance aromatic compound production, then the aromatic content of gasoline is improved, but the production cost increases significantly
Solution Approach 1:
The patent combines multiple catalyst functions into a single bi-metallic catalyst containing both platinum and iridium. This single catalyst performs both dehydrogenation and cyclization reactions that previously required separate catalysts, thereby reducing the number of catalysts needed and lowering production costs while maintaining high aromatic content in the reformate stream.
Solution Approach 2:
The patent employs a bi-metallic catalyst composed of platinum and iridium metals supported on an acidic support material. This composite catalyst structure integrates the dehydrogenation activity of platinum with the cyclization capability of iridium, creating a synergistic system that achieves high aromatic conversion efficiency without requiring multiple separate catalyst beds, thus reducing overall manufacturing complexity and cost.
2Productivity
If multiple catalysts are used to convert non-aromatic hydrocarbons to aromatics, then the conversion efficiency is improved, but the device complexity increases
Solution Approach 1:
The patent merges the functions of multiple catalysts into a single bi-metallic catalyst system. Instead of using separate catalyst beds for dehydrogenation and cyclization, the invention uses one catalyst containing both platinum and iridium metals that perform both functions simultaneously, thereby simplifying the catalyst system architecture while maintaining high conversion efficiency of non-aromatic hydrocarbons to aromatics.
Solution Approach 2:
The bi-metallic catalyst exhibits multi-functionality by performing both dehydrogenation and cyclization reactions within a single catalyst system. This universal catalyst design eliminates the need for multiple specialized catalysts, reducing device complexity in terms of catalyst handling, regeneration, and system configuration while achieving comprehensive conversion of naphthenes and paraffins to aromatics.
3Ease of operation
If conventional reforming processes are used to produce aromatics, then the process is simple to operate, but the yield of C6 to C8 aromatics is limited
Solution Approach 1:
The patent changes the chemical composition parameters of the catalyst by introducing iridium in addition to platinum, and adjusts the metal-to-support ratio and particle size distribution. These parameter changes enhance the catalyst's ability to convert naphthenes and paraffins to aromatics, increasing the yield of C6 to C8 aromatics in the reformate stream while maintaining ease of operation through a single-catalyst system that does not require complex multi-catalyst 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 process significantly increases the yield of aromatics, particularly in the C6 to C8 range, achieving up to a 25% increase in benzene and 10% increase in toluene production while minimizing the formation of lesser desired by-products, thus improving the economic viability of aromatic compound production.
Implementation Method 1
passing the feedstream to a reformer, to create a reformate stream
Implementation Method 2
The reformate stream is passed to a first fractionation unit to create a light overhead stream comprising light gases and C4 or C5 and lighter hydrocarbons
Implementation Method 3
The reformate overhead stream is passed to an aromatics extraction unit, to recover a purified aromatics stream comprising C6 and C7 aromatics
Implementation Method 4
employing multiple reactor beds with interbed heating to enhance reaction efficiency
Implementation Method 5
employing multiple reactor beds with interbed heating to enhance reaction efficiency
Data Source
AI summary
A process for reforming a hydrocarbon stream is presented. The process involves splitting a naphtha feedstream to at least two feedstreams and passing each feedstream to separation reformers. The reformers are operated under different conditions to utilize the differences in the reaction properties of the different hydrocarbon components. The process utilizes a common catalyst, and common downstream processes for recovering the desired aromatic compounds generated.