Chromium Dehydrogenation Catalyst for Methane-Fired Olefin Heating
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Solution Overview
Problem
Conventional catalysts used for light olefin production suffer from low methane combustion activity, leading to insufficient heating of the catalyst and safety risks due to un-combusted methane exceeding flammability limits.
Innovation Solution
A catalyst composition comprising gallium, indium, thallium, platinum, palladium, rhodium, iridium, ruthenium, osmium, and chromium, supported on a substrate, enhances methane combustion activity, allowing for efficient heating and safe operation by cycling the catalyst between a reactor and a combustor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional catalysts are used for dehydrogenation, then the catalyst can maintain structural stability, but the methane combustion activity is insufficient leading to inadequate heating and safety risks
Solution Approach 1:
The patent applies composite materials by combining chromium with traditional dehydrogenation catalyst components (such as gallium, platinum, or zeolites). This composite catalyst structure enables dual functionality: maintaining dehydrogenation activity while adding methane combustion capability. The chromium component specifically promotes methane combustion to heat the catalyst, resolving the contradiction between safety requirements and combustion activity.
Solution Approach 2:
The patent modifies catalyst composition parameters by introducing chromium at specific concentrations (0.1-10 wt%) to enhance methane combustion activity. This parameter change transforms the catalyst's energy utilization characteristics, enabling it to effectively combust methane for self-heating while maintaining structural stability and dehydrogenation function.
2Temperature
If supplemental fuel is combusted to heat the catalyst, then the reactor temperature can be maintained, but un-combusted methane may exceed flammability limits creating safety hazards
Solution Approach 1:
The chromium-modified catalyst performs self-service by utilizing the combustion of supplemental methane fuel to heat itself, eliminating the need for external heating systems. The catalyst's enhanced methane combustion activity ensures complete combustion of supplemental fuel, converting it into useful thermal energy for maintaining reactor temperature while preventing un-combusted methane accumulation and associated safety hazards.
Solution Approach 2:
The chromium component acts as a promoter that accelerates the oxidation combustion of methane. This enhanced oxidation capability ensures complete combustion of supplemental fuel at lower temperatures, converting methane efficiently into heat while minimizing un-combusted methane emissions that could exceed flammability limits.
3Productivity
If conventional catalysts are used, then the dehydrogenation reaction can proceed, but the methane combustion efficiency is too low to provide sufficient heat
Solution Approach 1:
The chromium-modified catalyst achieves multi-functionality by simultaneously performing dehydrogenation and methane combustion functions. This universal catalyst design allows it to produce light olefins through dehydrogenation while also combusting supplemental methane fuel to generate the necessary thermal energy, eliminating the need for separate heating systems and improving overall process efficiency.
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 improves methane combustion, ensuring adequate reactor temperature and reducing safety hazards, thereby enhancing the efficiency and safety of light olefin production processes.
Implementation Method 1
the catalyst is heated by exothermic combustion of at least a supplemental fuel
Implementation Method 2
combustion of methane
Implementation Method 3
light olefins may be formed by the catalytic dehydrogenation of alkanes
Implementation Method 4
catalytic dehydrogenation
Data Source
AI summary
A method may include contacting a hydrocarbon-containing feed with a catalyst in a reactor to form an olefin-containing effluent, then at least partially separating the olefin-containing effluent from the catalyst. Passing the catalyst to a combustor and heating the catalyst by combusting a supplemental fuel. The supplemental fuel includes methane in an amount greater than or equal to 1 mol. %. Passing the catalyst from the combustor to the reactor, such that at least a portion of the catalyst continuously cycles between the reactor and the combustor. The catalyst includes from 0.1 wt. % to 10 wt. % of one or more metals chosen from gallium, indium, thallium or combinations thereof, from 5 ppmw to 1000 ppmw of one or more metals chosen from platinum, palladium, rhodium, iridium, ruthenium, osmium, or combinations thereof, from 100 ppmw to 30000 ppmw of chromium, and at least 85 wt. % support.