Ceramic Membrane Recovery of Metallic Catalysts from Glycol Streams

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Solution Overview

Problem

Current methods for producing glycols from saccharide-containing feedstocks result in homogeneous catalysts being lost during the process, particularly in bleed streams, leading to environmental emissions and costly recovery processes.

Innovation Solution

A process utilizing a ceramic membrane with a selective layer of 0.5nm to 10nm pore size to separate metallic components from process streams, applying a pressure difference to create a permeate stream depleted in metallic components and a retentate stream enriched in them, allowing for the recovery and recycling of these components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If homogeneous catalysts are used in glycol production from saccharides, then catalytic activity is improved, but catalyst loss and environmental emissions worsen

Engineering Contradiction:

Improvecatalytic activityVSAvoidcatalyst loss and emissions

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent employs a ceramic membrane with controlled pore sizes (0.5nm to 10nm) to separate metallic catalyst components from the process stream. The porous structure allows selective passage of glycol products while retaining larger catalyst molecules, enabling catalyst recovery and reuse without compromising catalytic activity.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

Instead of discarding the bleed stream containing lost catalyst, the patent recovers metallic catalyst components through membrane filtration. The recovered catalyst in the retentate stream is recycled back to the reactor, reducing catalyst loss and environmental emissions while maintaining process efficiency.

Inventive Principle:

Principle #34Discarding and recovering

2Manufacturing precision

If distillation is used to separate glycols from process streams, then product purification is improved, but catalyst destruction and energy consumption worsen

Engineering Contradiction:

Improveproduct purificationVSAvoidenergy consumption and catalyst destruction

Core Design Contradiction:

Manufacturing precisionVSLoss of energy

Solution Approach 1:

The patent extracts the separation function from thermal distillation to a membrane filtration process. The ceramic membrane physically separates glycol products from catalysts and heavy hydrocarbons based on molecular size, eliminating the need for high-energy distillation and preventing catalyst destruction.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the thermal-mechanical distillation system with a mechanical membrane filtration system. This substitution uses physical size exclusion rather than thermal energy to achieve separation, significantly reducing energy consumption and preserving catalyst integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Quantity of substance

If bleed streams are flared to remove contaminants, then process stream purity is improved, but catalyst destruction and environmental harm worsen

Engineering Contradiction:

Improveprocess stream purityVSAvoidcatalyst destruction and emissions

Core Design Contradiction:

Quantity of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent recovers valuable metallic catalysts from what would otherwise be a waste bleed stream through membrane filtration. By separating catalysts before flaring, the system maintains process stream purity while preserving and recycling expensive catalyst materials, reducing both economic loss and environmental impact.

Inventive Principle:

Principle #34Discarding and recovering

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

Effectively recovers metallic catalysts from process streams, enabling their reuse and reducing environmental emissions by preventing the destruction of catalysts during flaring, thus enhancing process efficiency and sustainability.

Implementation Method 1

passing said process stream over a ceramic membrane comprising a selective layer with a pore size in the range of from at least 0.5nm to at most 10nm

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

a ceramic membrane comprising a selective layer with a pore size in the range of from at least 0.5nm to at most 10nm

Methodology Applied

Scientific EffectSize exclusion: Nanoporous Material

Implementation Method 3

applying a pressure difference across said ceramic membrane such that the pressure outside the ceramic membrane is at least 50kPa lower than the pressure inside the ceramic membrane

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Data Source

PatentEP3426373B1Process for recovering a metallic component

Publication Date: 2022.06.01 SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ BV

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AI summary

The invention provides a process for recovering a metallic component from a process stream, said process comprising passing said process stream over a ceramic membrane comprising a selective layer with a pore size in the range of from at least 0.5 nm to at most 10 nm; applying a pressure difference across said ceramic membrane such that the pressure outside the ceramic membrane is at least 50 kPa lower than the pressure inside the ceramic membrane; and, thus, providing a permeate stream which has passed through the ceramic membrane and which is depleted in the metallic component and a retentate stream enriched in the metallic component; wherein the process stream is derived from a process for the conversion of saccharide-containing feedstock into glycols.