Hydrocarbon Dehydrocyclization with CO2 Methanation
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Solution Overview
Problem
Current processes for aromatizing non-aromatic hydrocarbons in the presence of CO2 face limitations due to molecular hydrogen production, leading to reduced aromatic hydrocarbon yield and catalyst deactivation, along with inefficiencies in energy use and reactor complexity.
Innovation Solution
The process involves catalytically converting CO2 to methane and water (CO2 methanation) using a combination of dehydrogenation and molecular sieve catalysts, which increases hydrogen consumption and provides heat for the endothermic aromatization reaction, enhancing aromatic hydrocarbon yield while minimizing catalyst coking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If molecular hydrogen is produced during hydrocarbon dehydrogenation, then aromatic hydrocarbon can be formed, but aromatic hydrocarbon yield is limited and catalyst deactivation increases
Solution Approach 1:
The patent converts the harmful effect of molecular hydrogen (which causes hydrogenolysis and coking) into a beneficial resource by introducing CO2 to react with H2 and form methane. This methanation reaction consumes the excess hydrogen that would otherwise cause catalyst deactivation, thereby extending catalyst life and maintaining activity while preserving aromatic hydrocarbon yield.
2Quantity of substance
If CO2 is separated from feed upstream of aromatization, then CO2 can be removed, but refrigeration equipment complexity and energy consumption increase
Solution Approach 1:
The patent merges the CO2 separation function with the aromatization reaction itself. Instead of using separate refrigeration equipment to remove CO2 upstream, the process allows CO2 to be present in the feed and reacts it in-situ during the aromatization step. This integration eliminates complex refrigeration equipment while achieving CO2 conversion and aromatic hydrocarbon production simultaneously.
3Productivity
If CO2 is separated downstream of aromatization, then aromatic hydrocarbon recovery can be improved, but the aromatics recovery system becomes bottlenecked
Solution Approach 1:
The patent converts CO2, which would otherwise be an inert gas interfering with the recovery system, into methane through the methanation reaction. This transformation removes CO2 from the recovery stream, eliminating the bottleneck effect and simplifying the aromatics recovery system while maintaining high aromatic hydrocarbon recovery efficiency.
4Productivity
If hydrogenolysis increases during simultaneous aromatization and RWGS, then aromatic hydrocarbon yield improves, but light saturated hydrocarbon byproduct increases and catalyst coking accelerates
Solution Approach 1:
The patent changes the chemical parameters of the system by introducing CO2 as a reactant that shifts the hydrogen utilization pathway. Instead of hydrogen reacting with hydrocarbons to form light saturated byproducts (hydrogenolysis), the CO2 reacts with H2 to form methane. This parameter change redirects the hydrogen consumption pathway, reducing light saturated hydrocarbon byproduct formation while maintaining aromatic hydrocarbon yield.
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 approach results in a more efficient and stable aromatization process with increased aromatic hydrocarbon yield and reduced catalyst deactivation, as the exothermic CO2 methanation reaction supports the endothermic aromatization process, maintaining reactor efficiency.
Implementation Method 1
catalytically converting CO2 to methane and water (CO2 methanation)
Implementation Method 2
the exothermic CO2 methanation reaction supports the endothermic aromatization process
Implementation Method 3
the endothermic aromatization reaction
Implementation Method 4
catalytically converting CO2 to methane and water
Data Source
AI summary
The invention relates to converting non-aromatic hydrocarbon in the presence of CO2 to produce aromatic hydrocarbon. CO2 methanation using molecular hydrogen produced during the aromatization increases aromatic hydrocarbon yield. The invention also relates to equipment and materials useful in such upgrading, to processes for carrying out such upgrading, and to the use of such processes for, e.g., natural gas upgrading.