Ethane Dehydrogenation Catalyst with Chlorine Intermediates
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Solution Overview
Problem
Current methods for producing ethylene, such as steam cracking, are inefficient due to frequent blockage of metal coils by coke fragments and high production costs, necessitating the development of alternative ethane dehydrogenation processes that can increase ethylene production efficiently.
Innovation Solution
A process involving a reactor with a catalyst comprising a redox agent, an alkali metal, and a rare earth element, reacting ethane with oxygen and a chlorine intermediate precursor to produce ethylene, unreacted ethane, carbon monoxide, and carbon dioxide, while minimizing deep oxidation reactions and maximizing ethylene selectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If steam cracking is used to produce ethylene, then ethylene can be produced from ethane, but metal coils are frequently blockage by coke fragments requiring periodic cleaning
Solution Approach 1:
The patent introduces oxygen as an intermediary substance that reacts with coke fragments to form carbon dioxide and water, preventing metal coil blockage. The oxygen acts as a mediator between the ethane feedstock and the cracking process, enabling continuous operation without periodic cleaning interruptions.
Solution Approach 2:
The patent changes the chemical environment by introducing oxygen and using a catalyst, transforming the cracking process from a purely thermal process to a controlled oxidative dehydrogenation process. This parameter change prevents coke formation and metal coil blockage while maintaining ethylene production.
2Productivity
If steam cracking uses expensive furnace technology, then ethylene production can be achieved, but production costs are high
Solution Approach 1:
The patent replaces the expensive furnace-based thermal cracking system with a catalytic oxidative dehydrogenation system. The catalyst enables the reaction to proceed at lower temperatures and with better selectivity, reducing energy consumption and production costs while maintaining ethylene yield.
Solution Approach 2:
The patent changes the reaction parameters by introducing oxygen and a catalyst, enabling the process to operate at lower temperatures with higher selectivity. This reduces the energy input required and eliminates the need for expensive furnace technology, thereby reducing production costs.
3Productivity
If oxidative dehydrogenation is used to increase ethylene production, then ethylene selectivity can be improved, but deep oxidation reactions may occur forming carbon dioxide
Solution Approach 1:
The patent optimizes reaction parameters including temperature, oxygen partial pressure, and catalyst composition to favor selective dehydrogenation over deep oxidation. By carefully controlling these parameters, the process achieves high ethylene selectivity while minimizing carbon dioxide formation.
Solution Approach 2:
The patent creates different local environments within the reactor by using a structured catalyst system that provides specific active sites for dehydrogenation versus oxidation. The catalyst composition and structure are designed to concentrate the desired reaction at specific locations while suppressing unwanted deep oxidation reactions.
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
This process enhances ethylene production by increasing ethylene selectivity and reducing carbon dioxide formation, thereby improving the efficiency and cost-effectiveness of ethylene production compared to traditional methods.
Implementation Method 1
wherein the catalyst comprises a redox agent, an alkali metal, and a rare earth element
Implementation Method 2
process for catalytic oxidative dehydrogenation of ethane to ethylene in the presence of chlorine intermediates
Data Source
AI summary
A process for producing ethylene comprising: (a) reacting a reactant mixture in a reactor to yield a product mixture, wherein the reactor comprises a catalyst, wherein the reactant mixture comprises ethane, oxygen, and a chlorine intermediate precursor, wherein the product mixture comprises ethylene, unreacted ethane, carbon monoxide, and carbon dioxide, wherein the catalyst comprises a redox agent, an alkali metal, and a rare earth element; and (b) recovering at least a portion of the ethylene from the product mixture. The reacting in step (a) further comprises (i) contacting at least a portion of the chlorine intermediate precursor with the catalyst to form a chlorinated catalyst; (ii) allowing at least a portion of the chlorinated catalyst to generate a chlorine intermediate; and (iii) allowing at least a portion of the reactant mixture to react via the chlorine intermediate.