CON Zeolite Catalyst Aluminum Composition for Lower Olefin Production
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Solution Overview
Problem
Current zeolite catalysts used for producing lower olefins, such as propylene and butene, have limited catalyst life and efficiency, leading to reduced hydrocarbon production and increased ethylene by-product formation.
Innovation Solution
A CON zeolite catalyst with a specific aluminum composition and structure, characterized by a higher ratio of integrated intensity areas in the 57.5-70 ppm range and smaller primary particle diameter, is developed to enhance catalyst life and selectivity for lower olefins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional zeolite catalysts are used for producing lower olefins, then production efficiency is maintained initially, but catalyst life is limited and conversion rates deteriorate over time
Solution Approach 1:
The patent modifies the aluminum composition parameters within the zeolite catalyst framework, specifically controlling the Si/Al ratio and aluminum distribution. This parameter optimization enhances the catalyst's structural stability and resistance to deactivation, allowing it to maintain high conversion rates for lower olefin production over extended periods without significant activity loss
Solution Approach 2:
The invention creates a composite zeolite catalyst system with optimized aluminum-silicon framework structure. By carefully designing the composite nature of the zeolite with controlled aluminum content and distribution, the catalyst achieves improved mechanical strength, thermal stability, and resistance to coke formation, thereby extending operational life while maintaining productivity
2Reliability
If conventional zeolite catalysts are used, then initial selectivity for lower olefins is achieved, but ethylene by-product formation increases over time
Solution Approach 1:
The patent applies local quality by optimizing aluminum distribution at specific sites within the zeolite framework. By controlling where aluminum atoms are positioned relative to the pore structure and active sites, the catalyst maintains consistent selectivity for desired lower olefin products while suppressing unwanted ethylene by-product formation throughout its operational life
Solution Approach 2:
The invention adjusts critical parameters including Si/Al ratio, aluminum content, and framework composition to optimize the catalyst's selectivity profile. These parameter changes create a more stable active site environment that resists deactivation and maintains consistent product selectivity, reducing harmful by-product formation over time
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 improved zeolite catalyst maintains high conversion rates of raw materials over a longer period, stabilizing lower olefin production and reducing ethylene by-product formation, thus addressing the limitations of existing catalysts.
Implementation Method 1
a metathesis reaction using ethylene and 2-butene as raw materials, and a MTO (methanol to olefin) process using methanol and/or dimethyl ether as a raw material have been known
Data Source
AI summary
A CON zeolite satisfying the following (1) to (2): (1) The framework is CON as per the code specified by the International Zeolite Association (IZA); and (2) It contains silicon and aluminum, and the molar ratio of aluminum to silicon is 0.04 or more.