Cu-Zn and MFI Zeolite Catalyst for LPG Synthesis
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Solution Overview
Problem
Conventional catalysts for synthesizing liquefied petroleum gas (LPG) face challenges in maintaining high yield, especially at low temperatures, as they tend to deactivate quickly at high temperatures, and produce low yields of propane when operated at lower temperatures.
Innovation Solution
A catalyst comprising a Cu—Zn-based material and an MFI-type zeolite catalytic material with specific mass ratios and supported with Pt and/or Pd, which allows for efficient synthesis of propane and butane even at low synthesis temperatures, maintaining stability and high yields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If synthesis is conducted at high temperature to enhance the yield of liquefied petroleum gas, then the yield of propane and butane is improved, but the mixed catalyst deactivates causing a decline in yield over time
Solution Approach 1:
The patent uses a composite catalyst system combining Cu-Zn-based catalyst with MFI-type zeolite supporting Pt. The Cu-Zn component promotes methanol synthesis while the MFI-type zeolite with Pt facilitates hydrocarbon formation and prevents catalyst deactivation. This composite structure allows high temperature operation (260-360°C) to achieve high LPG yield while maintaining catalyst stability and preventing the deactivation issues seen in conventional single-catalyst systems.
2Reliability
If synthesis is conducted at low temperature to suppress catalyst deactivation, then catalyst stability is improved, but the yield of liquefied petroleum gas becomes extremely low
Solution Approach 1:
The composite catalyst system enables low temperature synthesis (260-360°C) to achieve both high catalyst stability and high LPG yield. The Cu-Zn component maintains active methanol synthesis at low temperatures, while the MFI-type zeolite with Pt efficiently converts intermediates to hydrocarbons, overcoming the limitation of conventional catalysts that require high temperatures for adequate activity.
3Productivity
If conventional mixed catalysts are used to produce liquefied petroleum gas, then both propane and butane are produced, but propane yield is low and propane content in the product is insufficient
Solution Approach 1:
The MFI-type zeolite structure provides specific pore geometry and acid site distribution that selectively promotes propane formation. The zeolite's channel structure and active sites are optimized to favor C3 hydrocarbon formation over C4, enabling the catalyst to produce LPG with high propane content (70 vol% or more) while maintaining overall high yield of both propane and butane.
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 yields of propane and butane at low synthesis temperatures while preventing catalyst deactivation, ensuring stable long-term performance and suitable for use as a fuel even in cold climates.
Implementation Method 1
A catalyst for synthesizing liquefied petroleum gas including a Cu—Zn-based catalytic material and an MFI-type zeolite catalytic material supporting Pt
Data Source
AI summary
A catalyst for synthesizing liquefied petroleum gas according to the present invention includes: a Cu—Zn-based catalytic material; and an MFI-type zeolite catalytic material supporting Pt, in which a ratio (M1/(M1+M2)) of mass (M1) of the Cu—Zn-based catalytic material to total mass of the mass (M1) of the Cu—Zn-based catalytic material and mass (M2) of the MFI-type zeolite catalytic material is 0.30 or more and 0.95 or less.