Boronated Zeolite Catalyst Preparation via Mild Hydrothermal Treatment
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Solution Overview
Problem
Conventional methods for producing boronated zeolite catalysts for catalytic cracking of hydrocarbons are limited by the need for multiple drying and calcination steps, which are energy-intensive and costly, reducing the economic viability of producing light olefins like ethylene and propylene.
Innovation Solution
A method involving the preparation of a boronated zeolite catalyst through a process that includes forming an initial slurry with water, a shape-selective zeolite, boric acid, and a weak acid, followed by hydrothermal treatment, pH adjustment, and subsequent drying and calcination, allowing for dealumination and boronation under mild conditions without additional drying and calcination steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to produce boronated zeolite catalysts with multiple drying and calcination steps, then the catalyst can be produced with adequate performance, but the production cost and energy consumption increase significantly
Solution Approach 1:
The patent combines multiple separate processing steps (drying and calcination) into a single integrated hydrothermal treatment step. The slurry is directly hydrothermally treated at 80-90°C for 12-48 hours, which simultaneously achieves moisture removal, boron incorporation, and catalyst activation, eliminating the need for separate drying and calcination operations and thereby reducing production cost and energy consumption
Solution Approach 2:
The patent changes the processing parameters from high-temperature calcination (typically 500-600°C) to mild hydrothermal treatment (80-90°C). This parameter change maintains catalyst performance while significantly reducing energy consumption and simplifying the manufacturing process
2Reliability
If multiple drying and calcination steps are implemented, then the boronated zeolite catalyst achieves proper structure and activity, but the production time and energy consumption increase
Solution Approach 1:
The patent replaces high-temperature calcination (500-600°C) with mild hydrothermal treatment (80-90°C), dramatically reducing the thermal energy input required while still achieving the necessary catalyst activation and boron incorporation
Solution Approach 2:
Multiple energy-intensive steps (drying and calcination) are merged into a single hydrothermal treatment step that operates at lower temperature, reducing cumulative energy consumption while maintaining catalyst activity
3Reliability
If conventional catalyst preparation methods are used, then the catalyst can be produced, but the complexity of the process increases with multiple drying and calcination steps
Solution Approach 1:
The patent merges multiple sequential operations (drying, then calcination) into a single hydrothermal treatment operation, simplifying the process flow and reducing the number of unit operations required while still producing catalysts with proper structure
Solution Approach 2:
The patent performs boron incorporation and catalyst activation simultaneously during the hydrothermal treatment step, rather than requiring separate preliminary drying and subsequent calcination steps, thereby simplifying the overall process
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 enhances the yield and selectivity of light olefins, such as ethylene and propylene, while reducing the economic costs associated with catalyst preparation, thereby improving the efficiency and economics of light olefin production.
Implementation Method 1
hydrothermally treating the initial slurry at a temperature of from 70° C. to 90° C. to produce a hydrothermally treated slurry comprising dealuminated zeolite particles
Implementation Method 2
after adjusting the pH to the intermediate pH, hydrothermally treating the basic slurry at a temperature of from 70° C. to 90° C. to produce a boronated zeolite slurry
Implementation Method 3
drying and calcining the boronated zeolite filtrate to produce the boronated zeolite catalyst
Data Source
AI summary
A method of making a boronated zeolite catalyst includes preparing an initial slurry comprising water, a shape selective zeolite, boric acid, and a weak acid selected from the group consisting of oxalic acid, citric acid, and oxalic acid and citric acid, hydrothermally treating the initial slurry at a temperature of from 70° C. to 90° C. to produce a hydrothermally treated slurry comprising dealuminated zeolite particles, adjusting the pH of the hydrothermally treated slurry to an intermediate pH of from 8 to 9 to produce a basic slurry, after adjusting the pH to the intermediate pH, hydrothermally treating the basic slurry at a temperature of from 70° C. to 90° C. to produce a boronated zeolite slurry, removing liquids from the boronated zeolite slurry to produce a boronated zeolite filtrate, and drying and calcining the boronated zeolite filtrate to produce the boronated zeolite catalyst.