Cerium Carbonate Hydroxide Dehydrogenation Catalyst Pellets
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Solution Overview
Problem
Conventional dehydrogenation catalysts used in the production of styrene, particularly those with high cerium content, face challenges in achieving sufficient physical strength for industrial-scale use, leading to pulverization and decreased catalytic performance due to the use of cerium carbonate hydroxide being limited and not effectively utilized for improving physical strength.
Innovation Solution
The use of cerium carbonate hydroxide as a cerium source in combination with iron oxide and potassium oxide, along with additional cerium compounds and promoters, to produce dehydrogenation catalyst pellets with improved physical strength through a process involving wet kneading, extrusion molding, and calcination, ensuring the catalyst maintains high performance and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high cerium-containing dehydrogenation catalyst is produced using cerium carbonate hydroxide as cerium source, then catalytic performance (ethylbenzene conversion rate and styrene yield) is improved, but physical strength of catalyst pellets becomes too low for industrial scale use
Solution Approach 1:
The invention uses a composite material approach by combining cerium carbonate hydroxide with iron oxide and potassium oxide in specific proportions (CeO2: 5-35 wt%, Fe2O3: 35-85 wt%, K2O: 5-30 wt%). This composite composition achieves both high catalytic performance and sufficient physical strength (crash strength ≥ 20 N/mm, abrasion strength ≤ 5%) for industrial application, resolving the contradiction between catalytic activity and mechanical durability.
2Strength
If cement binding agents are added to improve physical strength of catalyst pellets, then crash strength increases, but catalytic activity deteriorates considerably
Solution Approach 1:
The invention changes the compositional parameters by using cerium carbonate hydroxide instead of conventional cerium carbonate, and by optimizing the ratio of CeO2 (5-35 wt%), Fe2O3 (35-85 wt%), and K2O (5-30 wt%). This parameter optimization achieves physical strength comparable to cement-bound catalysts (crash strength ≥ 20 N/mm) while maintaining high catalytic activity without the need for cement binding agents that would poison the catalyst.
3Ease of manufacture
If cerium carbonate hydroxide is used as cerium source, then handling ease and cost are improved, but physical strength of catalyst pellets becomes insufficient
Solution Approach 1:
The invention creates a composite material system where cerium carbonate hydroxide is combined with iron oxide and potassium oxide in specific proportions. This composite approach allows the use of easily handled cerium carbonate hydroxide while achieving sufficient physical strength through the synergistic combination of materials, eliminating the need for additional binding agents.
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 resulting dehydrogenation catalyst pellets exhibit significantly enhanced physical strength, with crash strength doubled and abrasion strength improved, making them suitable for industrial use while maintaining catalytic performance comparable to conventional catalysts.
Implementation Method 1
a dehydrogenation catalyst having improved physical strength, process for producing the catalyst and dehydrogenation method thereof, in a catalyst used in a production of vinyl aromatic compounds, mainly styrene monomer, by dehydrogenating alkyl aromatic compounds, mainly ethylbenzene
Implementation Method 2
A dehydrogenation reaction of ethylbenzene is an endothermic reaction accompanied by a volume expansion as shown in the formula below. C6H5-C2H5 → C6H5-C2H3 + H2 + 30 kcal/mol
Implementation Method 3
As the reaction is carried out at the high temperature of 550 - 650 °C, steam can be utilized as a heat source for heating ethylbenzene
Data Source
AI summary
A high cerium-containing dehydrogenation catalyst of alkyl aromatic compounds used in industrial scale, comprising iron oxide and potassium oxide, having improved physical strength of catalytic pellets, and a method for producing the catalyst, and the dehydrogenation method using the catalyst are disclosed. In producing high cerium-containing pellets by using a dehydrogenation catalyst comprising iron oxide and potassium oxide, cerium carbon hydroxide or a mixture of cerium carbon hydroxide and other cerium compounds is used as a cerium source to produce catalytic pellets having improved physical strength.