Bifunctional Copper-Iron Catalyst for Olefin Hydrogenation and CO Shift
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Solution Overview
Problem
Current industrial processes, such as the Fischer-Tropsch process, face challenges in utilizing off-gas streams due to the presence of olefins and carbon monoxide, which hinder further reactions and require separate catalysts and different reaction conditions for hydrogenation and shift reactions, leading to increased costs and reduced conversion yields.
Innovation Solution
A bi-functional catalyst comprising copper, stabilizer oxides, and multiple-valence metals, allowing for simultaneous hydrogenation of olefins and shift reaction of carbon monoxide under similar reaction conditions, reducing the need for separate processes and minimizing the formation of methane or methanol, thus enhancing stability and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate catalysts are used for hydrogenation and shift reactions, then each reaction can be optimized, but device complexity and operational costs increase
Solution Approach 1:
The patent combines two separate catalysts (Cu-based for hydrogenation and Fe-based for shift reaction) into a single bifunctional catalyst material that performs both hydrogenation of olefins and water-gas shift reaction simultaneously. This merging eliminates the need for separate catalyst systems while maintaining the functional capabilities of both individual catalysts.
Solution Approach 2:
The catalyst material is designed with multi-functionality, incorporating copper particles for hydrogenation activity and iron oxide phases for water-gas shift activity within a single catalyst structure. This universal catalyst can perform multiple reactions (olefin hydrogenation and CO shift) under the same operational conditions, replacing what previously required separate specialized catalysts.
2Reliability
If separate processes are used for hydrogenation and shift reaction, then reaction conditions can be optimized for each, but loss of time and increased operational costs occur
Solution Approach 1:
The patent merges two sequential processes (hydrogenation followed by shift reaction) into a single simultaneous process using one catalyst material. This eliminates the time loss associated with performing reactions sequentially in separate units while maintaining optimized reaction conditions for both transformations.
Solution Approach 2:
The bifunctional catalyst enables continuous processing where olefin hydrogenation and CO shift reactions occur simultaneously in the same reactor stream. This continuous action eliminates idle time between sequential processes and maintains steady-state operation with optimized conditions for both reactions occurring concurrently.
3Productivity
If conventional catalysts are used, then hydrogenation and shift reactions can proceed, but formation of methane and methanol increases operational costs
Solution Approach 1:
The patent modifies the catalyst composition parameters by incorporating specific iron oxide phases (Fe2O3, Fe3O4) alongside copper particles, creating a bifunctional material that changes the reaction pathway. This parameter change in catalyst composition selectively promotes desired hydrogenation and shift reactions while suppressing unwanted side reactions that produce methane and methanol.
Solution Approach 2:
The invention uses a composite catalyst material combining copper particles with iron oxide phases in a specific structural arrangement. This composite structure provides distinct active sites for hydrogenation and water-gas shift reactions while the synergistic interaction between components suppresses harmful side reactions, improving selectivity and reducing methane and methanol formation.
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 catalyst achieves high selectivity and catalytic activity for both hydrogenation and shift reactions, maintaining or improving conversion yields while being insensitive to temperature, steam/gas ratio, and space velocity changes, thereby reducing operational and capital costs.
Implementation Method 1
the method comprising reacting an olefin with hydrogen in contact with a catalyst material of the disclosure
Implementation Method 2
the method comprising reacting carbon monoxide with water in contact with a catalyst material of the disclosure
Data Source
AI summary
The disclosure provides catalyst materials useful for hydrogenating olefins and shifting carbon monoxide and methods for using such catalyst materials. In one aspect, the disclosure provides catalyst materials including (a) copper, present in the range of about 20 weight % to about 80 weight %; (b) one or more stabilizer oxides stable under reducing conditions, each stabilizer oxide being a transition metal oxide or a metalloid oxide, the one or more stabilizer oxides being present in a total amount in the range of about 20 weight % to about 70 weight %; and (c) one or more multiple-valence metals, each multiple-valence metal being present in a positive oxidation state, the one or more multiple-valence metals are present in the range of about 0.1 weight % to about 40 weight %, all on an oxide basis.