Composite Catalyst for Aromatization Coke Resistance
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Solution Overview
Problem
Conventional aromatization processes face inefficiencies due to the refractory nature of methane and ethane, leading to decreased aromatic hydrocarbon yield and catalyst deactivation, requiring frequent regeneration and resulting in high selectivity to catalyst coke.
Innovation Solution
Development of catalytically active materials comprising a molecular sieve component and a dehydrogenation component, with the molecular sieve present in ≥80 wt. % and the dehydrogenation component including elements from Groups 3 to 15, designed for use in fixed-bed processes to enhance resistance to deactivation and reduce coke selectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional aromatization catalysts are used, then aromatic hydrocarbon conversion can be achieved, but catalyst deactivation occurs frequently due to coke accumulation
Solution Approach 1:
The patent employs a composite catalyst system comprising a molecular sieve component (≥80 wt.%) and a dehydrogenation component (Groups 3-15 elements). This composite structure combines the shape-selective properties of molecular sieves with the dehydrogenation activity of metal elements, creating a synergistic effect that reduces coke formation while maintaining high aromatic hydrocarbon yield and extending catalyst life without frequent regeneration.
2Duration of action of stationary object
If conventional aromatization processes are operated long-term, then continuous production is achieved, but aromatic hydrocarbon yield decreases due to coke accumulation
Solution Approach 1:
The patent converts the harmful effect of coke accumulation into a beneficial outcome by designing a catalyst system that inherently resists coking. The molecular sieve component (≥80 wt.%) with its specific pore structure and the dehydrogenation component (Groups 3-15 elements) work together to promote aromatic hydrocarbon formation while minimizing coke precursors, allowing long-term operation (extended time-on-stream) without significant yield degradation.
3Productivity
If frequent catalyst regeneration is performed, then aromatic hydrocarbon yield is maintained, but process efficiency decreases and coke selectivity increases
Solution Approach 1:
The patent applies preliminary action by designing the catalyst with inherent anti-coking properties built into its structure before operation begins. The molecular sieve component (≥80 wt.%) and dehydrogenation component (Groups 3-15 elements) are configured to promote favorable reaction pathways that minimize coke formation from the outset, eliminating the need for frequent regeneration and reducing energy consumption while maintaining high aromatic hydrocarbon yield throughout the catalyst's operational life.
Data Source
AI summary
The invention relates to catalytic aromatization, e.g., for the conversion of non-aromatic hydrocarbon to higher-value aromatic hydrocarbon, to catalysts useful for such aromatization, to methods for making such catalysts, and to systems and apparatus for carrying out aromatization in the presence of the catalyst.