Composite Zeolite Media for Ethane Dehydrogenation

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Solution Overview

Problem

Conventional methods for converting ethane (C2H6) to ethylene (C2H4) through steam cracking are energy-intensive and environmentally impactful, while alternative catalytic dehydrogenation processes face challenges with high energy demands, low single-pass conversion, and rapid catalyst deactivation.

Innovation Solution

A composite media comprising an aluminosilicate zeolite matrix with EDH catalysts like Fe, Zn, Pt, or Ga, supported on ZSM-5 or HZSM-5, which catalyzes non-oxidative ethane dehydrogenation, reducing energy requirements and extending catalyst lifespan.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional steam cracking processes are used to convert C2H6 to C2H4, then high conversion rates can be achieved, but high temperatures (≥850°C) are required resulting in high energy expenditures and environmental impacts

Engineering Contradiction:

ImproveC2H6 conversion rateVSAvoidthermal energy expenditure

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent changes the temperature parameter from conventional steam cracking (≥850°C) to catalytic dehydrogenation conditions (500-750°C), significantly reducing thermal energy expenditure while maintaining high C2H6 conversion rates through the use of catalytic materials

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the thermal cracking mechanism with a catalytic mechanism, substituting high-temperature thermal energy input with catalyst-mediated chemical reaction pathways that achieve the same conversion at lower temperatures

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Use of energy by moving object

If non-oxidative ethane dehydrogenation (EDH) is used, then energy demands are reduced compared to steam cracking, but single-pass conversion is limited by thermodynamic equilibrium

Engineering Contradiction:

Improveenergy demandVSAvoidsingle-pass conversion

Core Design Contradiction:

Use of energy by moving objectVSProductivity

Solution Approach 1:

The patent employs composite catalytic materials combining metal nanoparticles (Fe, Zn, Pt, or Ga) with zeolite supports (ZSM-5 or HZSM-5) to create a synergistic system that overcomes thermodynamic equilibrium limitations and achieves high single-pass conversion at reduced energy demands

Inventive Principle:

Principle #40Composite materials

3Use of energy by moving object

If conventional EDH catalysts are used, then energy demands are reduced, but rapid coking-induced deactivation occurs

Engineering Contradiction:

Improveenergy demandVSAvoidcatalyst lifespan

Core Design Contradiction:

Use of energy by moving objectVSDuration of action of stationary object

Solution Approach 1:

The patent utilizes porous zeolite materials (ZSM-5 or HZSM-5) with specific pore structures that prevent coke accumulation and maintain catalyst activity over extended periods, significantly extending catalyst lifespan while keeping energy demands low

Inventive Principle:

Principle #31Porous materials

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 solution achieves efficient ethane conversion to ethylene with high selectivity and stability, minimizing energy consumption and environmental impact, and maintaining catalytic activity over time.

Implementation Method 1

an EDH catalyst on one or more of an external surface of the aluminosilicate zeolite matrix and internal surfaces within pores of the aluminosilicate zeolite matrix. The EDH catalyst comprises one or more of Fe, Zn, Pt, Ga, alloys thereof, and oxides thereof

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS20230390748A1Ethane activation systems including a composite media and related reactor apparatuses

Publication Date: 2023.12.07 BATTELLE ENERGY ALLIANCE LLC

AI summary

A composite media for non-oxidative C2H6 dehydrogenation comprises an aluminosilicate zeolite matrix, and an EDH catalyst on one or more of an external surface of the aluminosilicate zeolite matrix and internal surfaces within pores of the aluminosilicate zeolite matrix. The EDH catalyst comprises one or more of Fe, Zn, Pt, Ga, alloys thereof, and oxides thereof. A C2H6 activation system, and a method of processing a C2H6-containing stream are also described.