Hydrocarbon Catalyst Regeneration via Hydrogen Peroxide
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Solution Overview
Problem
Existing methods for regenerating spent catalysts used in hydrocarbon treatment processes are hindered by the use of toxic additives and the release of carbon monoxide, which complicates industrial-scale reuse and environmental safety.
Innovation Solution
A two-stage process involving controlled combustion of coke at temperatures between 350°C to 550°C, followed by the deposition of specific additives on the catalyst surface, which are easy to use and non-toxic, to restore catalyst activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional regeneration processes are used to restore catalyst activity, then catalyst activity is improved, but toxic additives must be used and carbon monoxide is released
Solution Approach 1:
The invention changes the chemical parameters of the regeneration process by using an aqueous hydrogen peroxide solution instead of traditional organic additives and oxygen-based combustion. This parameter change eliminates toxic emissions while restoring catalyst activity, as hydrogen peroxide decomposes into water and oxygen, leaving no harmful residues.
Solution Approach 2:
The invention uses hydrogen peroxide as a disposable reagent that decomposes completely during the regeneration process. The hydrogen peroxide solution is applied, performs its oxidizing function to remove coke deposits, and then decomposes into harmless water and oxygen, eliminating the need for toxic additive management and carbon monoxide handling.
2Reliability
If rejuvenation processes with organic additives are applied, then catalyst activity is restored to new catalyst levels, but toxic substances are introduced and carbon monoxide is released
Solution Approach 1:
The invention fundamentally changes the chemical nature of the rejuvenation process by replacing organic additives with an aqueous hydrogen peroxide solution. This parameter change transforms the reaction products from carbon monoxide and other hydrocarbon decomposition products into water and oxygen, eliminating harmful emissions while maintaining catalyst activity restoration.
Solution Approach 2:
The invention converts the harmful effect of coke deposits into a beneficial oxidation reaction. By using hydrogen peroxide as the oxidizing agent, the coke is converted into carbon dioxide and water through controlled oxidation, rather than producing carbon monoxide through incomplete combustion or requiring toxic organic additives for removal.
3Ease of manufacture
If combustion of coke is performed at elevated temperatures, then catalyst surface is cleaned, but catalyst structure may be damaged
Solution Approach 1:
The invention replaces the thermal-mechanical combustion process with a chemical oxidation process using hydrogen peroxide. Instead of relying on high-temperature combustion that mechanically and thermally stresses the catalyst structure, the hydrogen peroxide solution chemically oxidizes and removes coke deposits at lower temperatures, preserving catalyst structure integrity.
Solution Approach 2:
The invention changes the temperature parameter of the regeneration process by using hydrogen peroxide oxidation, which effectively removes coke at lower temperatures compared to traditional combustion methods. This parameter change prevents thermal damage to the catalyst support structure and active metal sites while achieving complete coke removal.
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 effectively rejuvenates catalysts to a higher activity level than previous methods, while significantly reducing or eliminating carbon monoxide emissions, ensuring safer and more efficient catalyst reuse.
Implementation Method 1
combustion of coke, by heating the catalyst to an elevated temperature in the presence of an oxygen-containing gas
Implementation Method 2
combustion of coke, by heating the catalyst to an elevated temperature in the presence of an oxygen-containing gas
Implementation Method 3
a second step of depositing, on the surface of the catalyst, one or more additive(s)
Data Source
Figure 1
AI summary
The present invention relates to a process for regenerating a catalyst containing at least one metal from group VIII and at least one metal from group VIB deposited on a refractory oxide support, comprising: - at least a first step of heat treatment of the catalyst, in the presence of oxygen and at a temperature ranging from 350°C to 550°C; - at least a second step of deposition, on the surface of the catalyst, of one or more additive(s) of formula (I):