Composite Catalyst for Olefin Metathesis and Cracking
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Solution Overview
Problem
Current propene production methods, such as steam cracking and Fluid Catalytic Cracking (FCC) units, face challenges in meeting rapid demand due to inefficiencies and high costs associated with separate catalysts used in metathesis, isomerization, and cracking reactions, leading to segregation and reduced reactor efficiency.
Innovation Solution
Development of multi-functional composite catalysts that combine zeolite particles and catalytically active compounds, such as tungsten oxide, within a catalyst support material, allowing for uniform distribution and simultaneous performance of multiple reactions like metathesis and cracking without the need for separate catalyst zones or inert spacers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate catalysts are used for metathesis, isomerization, and cracking reactions, then each reaction can be optimized with dedicated catalysts, but the system complexity increases and capital costs rise due to separate reactor zones or inert spacers
Solution Approach 1:
The patent combines multiple separate catalysts (metathesis catalyst, isomerization catalyst, and cracking catalyst) into a single composite catalyst particle. This merging eliminates the need for separate reactor zones, inert spacers, and multiple catalyst charging operations, thereby reducing system complexity and capital costs while maintaining the ability to perform all three reactions simultaneously with optimized catalyst functionalities
Solution Approach 2:
The composite catalyst is designed to perform multiple functions within a single particle structure. Different catalyst components are incorporated to provide metathesis, isomerization, and cracking activities simultaneously, allowing one catalyst system to replace multiple specialized catalyst systems and simplify the overall reactor design
2Device complexity
If physical catalyst mixtures of different solid particulate catalyst materials are used, then costs are reduced and dead zones are eliminated, but the catalysts gradually segregate in the reactor over time due to settling
Solution Approach 1:
Instead of using a physical mixture of separate catalyst particles that can segregate, the patent merges multiple catalyst components into a single integrated composite catalyst particle. This structural integration prevents segregation and settling issues because there is only one catalyst material in the reactor, eliminating the stability problem while maintaining system simplicity
Solution Approach 2:
The patent employs composite catalyst materials where different catalyst components are combined within a single particle structure. This composite approach allows multiple catalytic functionalities to coexist in a stable, non-segregating manner, as the different catalyst materials are structurally integrated rather than physically mixed
3Reliability
If separate catalysts are charged to separate reactors or separated with inert spacers, then each catalyst can perform its specific function, but the initial capital cost substantially increases
Solution Approach 1:
The patent merges multiple catalyst functions into a single composite catalyst that can be charged to a single reactor, eliminating the need for multiple reactors or complex catalyst separation structures. This significantly reduces capital costs for reactor vessels, installation, and maintenance while preserving all necessary catalytic functionalities through the integrated composite structure
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 catalysts enhance propene production efficiency by eliminating segregation issues and reducing capital costs, maintaining reactor efficiency over time, and enabling a single catalyst to perform multiple reactions, thus addressing the limitations of traditional methods.
Implementation Method 1
a catalytically active compound deposited on the surfaces of the catalyst support material, the zeolite particles, or both
Implementation Method 2
production of propene from a butene-containing stream, such as a Raffinate stream or other butene-containing stream, can be accomplished through metathesis of the butene to propene
Implementation Method 3
metathesis, isomerization, and cracking in order to increase the overall yield and propene selectivity of the reaction system
Data Source
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AI summary
Composite catalysts includes zeolite particles at least partially embedded in a catalyst support material and at least one catalytically active compound deposited on the outer surfaces and pore surfaces of the catalyst support material, zeolite particles, or both. A method of making the composite catalysts may include preparing a catalyst precursor mixture that includes the zeolite, catalyst support material, triblock copolymer surfactant, and the catalytically active compound precursor and spray drying the catalyst precursor mixture. The composite catalysts may be used as a single catalyst for conducting olefin metathesis and cracking reactions. A method for producing propene may include contacting a butene-containing feed with the composite catalysts.