Catalyst Composition for Oxychlorination to Prevent Stickiness
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Solution Overview
Problem
Fluidized bed oxychlorination catalysts used in the production of 1,2-dichloroethane from ethylene are prone to 'catalyst sticking,' which leads to operational issues such as agglomeration and plugging, resulting in economic losses and reduced efficiency due to inappropriate operational conditions or catalyst properties.
Innovation Solution
A catalyst composition is developed using a high surface area alumina support with specific loadings of copper, alkali metals, alkaline earth metals, and manganese, deposited via an aqueous solution and dried to prevent stickiness, allowing for improved fluidization and resistance to operational upsets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional catalyst compositions are used for oxychlorination, then HCl conversion and 1,2-dichloroethane selectivity are achieved, but catalyst sticking occurs leading to agglomeration and plugging
Solution Approach 1:
The patent modifies the catalyst composition by introducing manganese chloride as a new component and adjusting the ratios of existing components (copper chloride, magnesium chloride, potassium chloride, cesium chloride). This parameter change in composition prevents catalyst sticking while maintaining high HCl conversion (99.5-99.8%) and 1,2-dichloroethane selectivity (96-97.5%), thereby resolving the contradiction between catalytic performance and stability.
Solution Approach 2:
The patent creates a composite catalyst material combining multiple metal chlorides (copper, magnesium, potassium, cesium, and manganese) on a high surface area support. This composite approach leverages the synergistic effects of different metals to prevent catalyst sticking and agglomeration while maintaining high catalytic activity for oxychlorination.
2Productivity
If catalyst activity is increased to improve productivity, then HCl conversion increases, but catalyst stickiness worsens
Solution Approach 1:
The patent achieves high HCl conversion (99.5-99.8%) while preventing catalyst stickiness by optimizing the compositional parameters of the catalyst. The specific combination of metal chlorides and their ratios creates a catalyst that maintains high productivity without the harmful effect of stickiness, even at the high conversion levels required for efficient oxychlorination.
3Productivity
If operational conditions are optimized for high conversion, then productivity increases, but catalyst stickiness becomes more pronounced
Solution Approach 1:
The patent develops a composite catalyst material with specific metal chloride combinations that maintains operational stability under high-conversion conditions. The multi-component formulation prevents agglomeration and plugging even when operating at high ethylene efficiency levels, thereby resolving the contradiction between productivity and operational stability.
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 catalyst composition enhances HCl conversion and 1,2-dichloroethane selectivity while maintaining stability and preventing catalyst stickiness, even at lower temperatures, thus improving operational efficiency and reducing economic losses.
Implementation Method 1
a catalyst for the oxychlorination of ethylene with HCl and oxygen (or an oxygen containing gas) to form 1,2-dichloroethane
Data Source
AI summary
This invention relates to a catalyst containing from about 2 up to about 8 % by wt. of copper, zero up to about 0.6 moles/kg of one or more alkali metal(s), from about 0.08 up about 0.85 moles/kg of one or more alkaline earth metals and from about 0.09 up to about 0.9 moles/kg of one or more transition metals selected from the group consisting of Mn, Re and mixtures thereof, where all the metals are impregnated in form of their chlorides or other water soluble salts on a fluidizable support with a BET surface area of from about 80 up to about 220 m2/g. A process for the oxychlorination of ethylene to form 1,2- dichloroethane using such a catalyst having good activity, good selectivity and low tendency to stickiness in fluidized bed oxychlorination reactions.