Extruded Isomerization Catalysts with Metal Silicate Clay Binder
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Solution Overview
Problem
The existing isomerization catalysts in tablet form are costly and time-consuming to manufacture, and they struggle to maintain isomerization activity after aging, while also facing challenges in withstanding the pressures and stresses within hydrocarbon flow systems.
Innovation Solution
An extruded catalyst comprising MgO, a metal silicate clay binder, and stabilizers such as ZrO2 and rare earth metals, which provides a high crush strength and maintains at least 50% of its fresh isomerization rate after aging at 650°C for 24 hours, allowing for efficient isomerization of 1-butene to 2-butene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If isomerization catalysts are provided in tablet form to maintain acceptable isomerization activity, then the catalyst can withstand pressures and stress during use, but the manufacture becomes costly and time consuming
Solution Approach 1:
The patent changes the physical form parameter from tablets to extrudates, and modifies compositional parameters by incorporating metal silicate clay binder (5-20 wt%) and stabilizers (1-20 wt%) to achieve both manufacturability and performance requirements
Solution Approach 2:
The patent creates a composite catalyst material combining MgO (70-90 wt%) with metal silicate clay binder and stabilizers, where the binder provides structural integrity for extrusion and the stabilizer maintains activity after aging, resolving the contradiction between ease of manufacture and reliability
2Strength
If tablets are formed to withstand crush strength requirements, then the catalyst can handle hydrocarbon flow pressure, but the formation of complex shapes becomes difficult or impossible
Solution Approach 1:
The patent adopts extrusion processing which allows dynamic shaping of catalysts into various geometries (round, triangular, square, rectangular, or other cross-sections), providing versatility in shape while maintaining structural integrity through the binder system
Solution Approach 2:
The patent changes the binder composition parameter to include metal silicate clay (5-20 wt%) which provides optimal binding strength and plasticity, enabling the formation of complex extruded shapes that can withstand crush strength requirements
3Reliability
If MgO is used for isomerization activity, then the catalyst performs the metathesis reaction, but the catalyst loses activity after aging at high temperature
Solution Approach 1:
The patent introduces a stabilizer (ZrO2, tetravalent rare earth metal, or trivalent rare earth metal at 1-20 wt%) as an intermediary component that protects the MgO active sites from deactivation during high-temperature aging, thereby maintaining isomerization activity over time
Solution Approach 2:
The patent creates a composite catalyst system where MgO (70-90 wt%) provides isomerization activity, metal silicate clay binder provides structural stability, and stabilizer (1-20 wt%) prevents activity loss during aging, achieving both high initial activity and long-term durability
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 extruded catalysts exhibit improved crush strength and sustained isomerization activity, offering a cost-effective and efficient alternative to traditional tablet forms, enabling the formation of complex geometries and maintaining performance over time.
Implementation Method 1
MgO accomplishes the isomerization of 1-butene to 2-butene
Implementation Method 2
MgO accomplishes the isomerization of 1-butene to 2-butene and adsorbs poisons in the feed stream such as H2O, CO2, oxygenates
Implementation Method 3
contacting said binder with said MgO or Mg(OH)2 under conditions effective to bind said binder to said MgO or Mg(OH)2
Data Source
Figure 1
AI summary
Extruded isomerization catalysts comprising MgO, a metal silicate clay binder and a stabilizer and methods of forming such isomerization catalysts are disclosed. Also disclosed are isomerization catalysts that exhibit a fresh isomerization rate and an aged isomerization rate that is at least 50% of the fresh isomerization rate. Embodiments of the isomerization catalysts disclosed herein include metal silicate clay binders that include a layered structure and metal silicate. The metal silicate clay binder may be present in an amount in the range from about 5 wt% to about 20 wt%. Exemplaiy stabilizers include one or more of Zr02, tetravalent rare earth metal and a trivalent rare earth metal. Stabilizers may be present in an amount up to about 40 \vt%. One or more improved properties, such as piece crush strength and isomerization performance, are exhibited by the catalyst article.