Boron Nitride Catalysts for Oxidative Dehydrogenation Selectivity

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Solution Overview

Problem

Current methods for oxidative dehydrogenation of C3-C5 alkanes to produce C3-C5 olefins are energy-intensive, lead to catalyst deactivation due to coke formation, and result in low olefin selectivity due to unwanted side-reactions, limiting their industrial scalability.

Innovation Solution

The use of boron or nitride-containing catalysts that catalyze oxidative dehydrogenation reactions, increasing selectivity to desired olefins while reducing the production of CO and CO2 byproducts, and maintaining catalyst stability over extended periods without the need for regeneration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional steam cracking or catalytic dehydrogenation is used to produce C3-C4 olefins, then olefin production can be achieved, but the process becomes energy-intensive and requires high temperatures leading to catalyst deactivation and continuous regeneration

Engineering Contradiction:

Improveolefin production capacityVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The invention changes the reaction conditions from high-temperature conventional dehydrogenation to lower-temperature oxidative dehydrogenation by introducing oxygen as a reactant. This parameter change transforms the endothermic dehydrogenation reaction into an exothermic oxidative dehydrogenation reaction, reducing energy consumption and eliminating the need for continuous catalyst regeneration while maintaining high olefin production capacity

Inventive Principle:

Principle #35Parameter changes

2Productivity

If high temperature conditions are used for dehydrogenation, then dehydrogenation reaction can proceed, but catalyst deactivation due to coke formation occurs

Engineering Contradiction:

Improvedehydrogenation reaction rateVSAvoidcatalyst stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The invention converts the harmful effect of oxygen (which can cause over-oxidation and catalyst deactivation) into a beneficial effect by using it as a reactant in the oxidative dehydrogenation reaction. The oxygen participates in the reaction to form water instead of causing coke formation, thereby improving catalyst stability while maintaining reaction productivity at lower temperatures

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Use of energy by moving object

If oxidative dehydrogenation is used to improve energy efficiency, then reaction can proceed at lower temperatures, but unwanted side-reactions occur leading to low olefin selectivity

Engineering Contradiction:

Improveenergy consumptionVSAvoidolefin selectivity

Core Design Contradiction:

Use of energy by moving objectVSManufacturing precision

Solution Approach 1:

The invention applies local quality by designing a catalyst with specific active sites that are selective for the desired oxidative dehydrogenation reaction. The catalyst composition and structure are optimized to create localized active sites that favor olefin formation while suppressing over-oxidation side reactions, thereby achieving high olefin selectivity at lower temperatures with improved energy efficiency

Inventive Principle:

Principle #3Local quality

4Reliability

If continuous catalyst regeneration is implemented to maintain catalyst activity, then catalyst stability can be preserved, but process complexity and production costs increase

Engineering Contradiction:

Improvecatalyst activityVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention enables the catalyst to self-regenerate by designing the oxidative dehydrogenation reaction conditions where oxygen selectively removes coke deposits from the catalyst surface during normal operation. This self-cleaning mechanism eliminates the need for separate regeneration systems and continuous catalyst regeneration operations, simplifying the overall process while maintaining catalyst activity and reliability

Inventive Principle:

Principle #25Self-service

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 boron or nitride catalysts achieve high selectivity (up to 77% propene selectivity) at lower temperatures, with negligible COx formation and prolonged catalyst stability, making the process more energy-efficient and cost-effective for industrial applications.

Implementation Method 1

Heterogeneous catalysts for the oxidative dehydrogenation of alkanes or oxidative coupling of methane

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

Oxidative dehydrogenation (ODH), the catalytic dehydrogenation of feedstock alkanes in the presence of oxygen

Methodology Applied

Scientific EffectOxidation: Oxidation

Data Source

PatentEP3347332B1Heterogeneous catalysts for the oxidative dehydrogenation of alkanes or oxidative coupling of methane

Publication Date: 2022.04.27 WISCONSIN ALUMNI RES FOUND

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AI summary

Improved methods of oxidative dehydrogenation (ODH) of short chain alkanes or ethylbenzene to the corresponding olefins, and improved methods of oxidative coupling of methane (OCM) to ethylene and/or ethane, are disclosed. The disclosed methods use boron- or nitride-containing catalysts, and result in improved selectivity and/or byproduct profiles than methods using conventional ODH or OCM catalysts.