Composite Catalyst for Propene Production
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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 the increasing demand for propene due to high costs and inefficiencies associated with separate catalysts in reactor systems, which lead to segregation and reduced reactor efficiency.
Innovation Solution
Development of multi-functional composite catalysts that combine different catalytic functionalities into a single particle, using a catalyst support material like fumed silica or alumina with preformed catalyst materials and catalytically active compounds, allowing for simultaneous isomerization, metathesis, and cracking reactions without the need for separate catalyst zones or spacer materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate catalysts are used for cracking, metathesis, and isomerization reactions, then each reaction can be conducted with optimized catalyst performance, but the device complexity increases and capital cost substantially increases due to separate reactor vessels
Solution Approach 1:
The patent combines multiple separate catalysts (cracking catalyst, metathesis catalyst, and isomerization catalyst) into a single composite catalyst particle. This merging eliminates the need for separate reactor vessels and reduces device complexity while maintaining all required catalytic functionalities within one integrated catalyst structure.
Solution Approach 2:
The composite catalyst particle is designed to perform multiple catalytic functions simultaneously - cracking, metathesis, and isomerization reactions - within a single catalyst structure. This multi-functionality eliminates the need for separate specialized reactors for each reaction type, reducing overall system complexity.
2Stability of the object's composition
If separate catalysts are separated with inert spacers in a single reactor, then catalyst segregation is prevented, but dead volumes are created that reduce reactor efficiency
Solution Approach 1:
Instead of using inert spacers to separate catalysts, the patent merges all catalyst types into a single composite particle structure. This eliminates dead volumes created by spacers while maintaining intimate contact between different catalytic components, thereby preserving reactor efficiency.
Solution Approach 2:
The composite catalyst structure nests multiple catalyst types within a single particle matrix. Different catalysts are distributed throughout the particle structure, allowing them to work together without physical separation, eliminating dead zones while maintaining functional integrity.
3Productivity
If physical catalyst mixtures of solid particulate catalyst materials are used, then costs are reduced and dead zones are eliminated, but the separate catalysts gradually segregate in the reactor over time due to settling
Solution Approach 1:
The patent merges multiple catalyst types into a single composite particle rather than using a physical mixture of separate particles. This integration prevents gravitational settling and segregation because all catalyst components move together as one unified particle, maintaining mixture homogeneity over time.
Solution Approach 2:
The invention creates a composite catalyst material where different catalyst types are integrated into a single composite structure. This composite formulation ensures that all catalytic components remain together during reactor operation, preventing the segregation that occurs with physical mixtures of separate solid particles.
4Reliability
If multiple separate reactors are used for different catalytic reactions, then each reaction can be optimized independently, but the initial capital cost of the reaction system substantially increases
Solution Approach 1:
The patent merges the functionality of multiple separate reactors into a single reactor vessel by using a composite catalyst that performs all required reactions. This consolidation dramatically reduces capital costs while maintaining the ability to optimize each catalytic function within the integrated catalyst structure.
Solution Approach 2:
The composite catalyst provides universal functionality for multiple reactions (cracking, metathesis, isomerization) within a single catalyst particle, allowing all reactions to occur in one reactor. This eliminates the need for multiple expensive reactor vessels while preserving reaction optimization capabilities.
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 dead zones in reactors, reducing capital costs, and maintaining performance over time by preventing catalyst segregation, thus addressing the limitations of conventional systems.
Implementation Method 1
at least one catalytically active compound supported by the catalyst support, the preformed catalyst material, or both
Implementation Method 2
drying the aerosolized catalyst precursor mixture to produce a plurality of composite catalyst particles
Data Source
AI summary
A multi-functional composite catalyst includes a catalyst support material, a preformed catalyst material at least partially secured in the catalyst support, and at least one catalytically active compound supported by the catalyst support, the preformed catalyst material, or both. The catalyst support material may include fumed silica, alumina, fumed alumina, fumed titania, or combinations of these. A catalytic activity of the catalytically active compound may be different than a catalytic activity of the preformed catalyst material. The composite catalyst may be catalyst for producing propene from 2-butene and may include a zeolite as the preformed catalyst material and a metal oxide, such as tungsten oxide, as the catalytically active material. A method of making the composite catalyst may include aerosolizing a catalyst precursor mixture that includes a preformed catalyst material, catalyst support precursor, and catalytically active compound precursor, and drying the aerosolized catalyst precursor mixture.