Composite Catalyst for Hydrocarbon Steam Cracking
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Solution Overview
Problem
Conventional catalysts for hydrocarbon steam cracking suffer from low thermal and mechanical stability at high temperatures, leading to reduced olefin yield and selectivity, as well as rapid loss of catalytic activity due to coke generation and evaporation during high-temperature reactions.
Innovation Solution
A composite catalyst is developed by sintering a mixture of oxide catalyst powder represented by CrZrjAkOx and carrier powder, or by impregnating the oxide catalyst on a carrier, using transition metals like Ti, Nb, Mo, V, Co, Ni, W, Fe, and rare earth metals, which enhances thermal/mechanical stability and catalytic activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts (potassium vanadate, alkali metal oxide) are used for hydrocarbon steam cracking, then olefin yield may be improved, but catalytic activity is lost rapidly at high temperature due to evaporation and low melting points
Solution Approach 1:
The patent uses composite materials by combining potassium vanadate catalyst with high-melting-point carrier materials (alumina, silica, zirconia). This composite structure allows the catalyst to maintain its olefin production capability while the carrier provides thermal stability and prevents evaporation at high temperatures, resolving the contradiction between productivity and reliability.
Solution Approach 2:
The high-melting-point carrier material acts as an intermediary that supports the potassium vanadate catalyst. The carrier mediates between the catalyst's need to remain stable at high temperatures and the requirement for catalytic activity, providing a stable framework that prevents catalyst evaporation while maintaining catalytic function.
2Productivity
If catalysts with low melting points are used to increase olefin yield, then catalytic activity is enhanced, but the catalyst components are easily evaporated and lost at high temperature
Solution Approach 1:
By creating a composite material where potassium vanadate is supported on high-melting-point carriers (alumina, silica, zirconia), the patent prevents catalyst component evaporation. The carrier material has a melting point significantly higher than the reaction temperature, anchoring the catalyst components and preventing their loss while maintaining catalytic activity for olefin production.
Solution Approach 2:
The patent applies local quality by having different materials perform different functions within the catalyst structure. The potassium vanadate provides catalytic activity in specific locations, while the high-melting-point carrier provides thermal stability and prevents evaporation in the high-temperature environment, allowing the catalyst to function effectively without component loss.
3Adaptability or versatility
If hybrid catalyst (molybdenum oxide, alumina, silica, silicalite, zirconium oxide) is used for low temperature reaction, then usability at low temperature is improved, but thermostability becomes very low at 700-800°C
Solution Approach 1:
The patent changes the temperature parameter by using a carrier system with extremely high melting point (alumina, silica, zirconia) that remains stable at hydrocarbon steam cracking temperatures (700-800°C). This allows the catalyst to maintain its structure and catalytic activity at the required high temperatures, unlike the hybrid catalyst which loses thermostability in this temperature range.
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 composite catalyst significantly increases light olefin yield and selectivity, maintains stability at high temperatures, and reduces inactivation rates by coke, effectively overcoming the limitations of conventional catalysts.
Implementation Method 1
a catalyst for hydrocarbon steam cracking which gives improved yield of light olefin and has thermal/mechanical stability at high temperature for the production of light olefin by hydrocarbon steam cracking
Implementation Method 2
a composite catalyst prepared by sintering the mixture of the oxide catalyst powder represented by CrZrjAkOx and carrier powder
Implementation Method 3
a composite catalyst having the structure where the oxide catalyst is impregnated on a carrier
Implementation Method 4
hydrocarbon steam cracking which is a major ingredient of natural gas or paraffin compounds such as naphtha and gas oil, at high temperature of at least 800° C. in the presence of water vapor
Data Source
AI summary
A catalyst for hydrocarbon steam cracking for the production of light olefin, a preparation method of the catalyst and a preparation method of olefin by using the same. More precisely, the present invention relates to a composite catalyst prepared by mixing the oxide catalyst powder represented by CrZrjAkOx (0.5≦j≦120, 0≦k≦50, A is a transition metal, x is the number satisfying the condition according to valences of Cr, Zr and A, and values of j and k) and carrier powder and sintering thereof, a composite catalyst wherein the oxide catalyst is impregnated on a carrier, and a method of preparing light olefin such as ethylene and propylene by hydrocarbon steam cracking in the presence of the composite catalyst. The composite catalyst of the present invention has excellent thermal/mechanical stability in the cracking process, and has less inactivation rate by coke and significantly increases light olefin yield.