Foamed Catalyst Selective Hydrogenation
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Solution Overview
Problem
Current processes for the selective hydrogenation of polyunsaturated compounds in hydrocarbon feedstocks do not achieve optimal catalytic performance in terms of activity and selectivity, particularly when using conventional catalyst supports.
Innovation Solution
A process utilizing a catalyst with an active phase based on metals from Group VIII supported on a ceramic or metal foam with specific geometric surface area and pore diameter, which reduces the amount of active phase needed and improves selectivity in the hydrogenation of polyunsaturated compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional catalyst supports are used for selective hydrogenation, then the catalytic activity can be maintained at acceptable levels, but the selectivity towards desired products is insufficient
Solution Approach 1:
The patent employs foam supports with controlled pore structures (characterized by PPI, pore diameter, geometric surface area, and porosity) to enhance both selectivity and activity. The porous structure provides optimized mass transfer and active phase distribution, resolving the contradiction between selectivity and catalytic activity.
Solution Approach 2:
The invention uses composite foam supports combining ceramic or metal materials with specific geometric structures. These composite materials integrate the mechanical strength of ceramics/metals with the optimized pore architecture, enabling simultaneous improvement of selectivity and catalytic performance.
2Productivity
If the amount of active phase is increased to improve conversion, then the conversion rate increases, but the reactor volume and process complexity increase
Solution Approach 1:
The patent optimizes physical parameters of the foam support (PPI, pore diameter, geometric surface area, porosity) to maximize the efficiency of the active phase. By changing these structural parameters, the invention achieves high conversion rates with reduced active phase loading, thereby minimizing reactor volume while maintaining productivity.
Solution Approach 2:
The high geometric surface area of the foam support (resulting from optimized pore structure) provides extensive surface area for active phase dispersion. This allows achieving high conversion rates with lower amounts of active phase, reducing the required reactor volume while maintaining high productivity.
3Reliability
If foam supports with high geometric surface area are used to reduce active phase amount, then the selectivity improves, but the manufacturing complexity increases
Solution Approach 1:
The patent employs foam supports with controlled pore structures (characterized by PPI, pore diameter, geometric surface area, and porosity) to enhance both selectivity and activity. The porous structure provides optimized mass transfer and active phase distribution, resolving the contradiction between selectivity and catalytic activity.
Solution Approach 2:
The invention uses composite foam supports combining ceramic or metal materials with specific geometric structures. These composite materials integrate the mechanical strength of ceramics/metals with the optimized pore architecture, enabling simultaneous improvement of selectivity and catalytic performance.
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 process achieves improved catalytic performance by reducing the reactor volume and enhancing selectivity towards desired products, while maintaining high conversion rates of polyunsaturated compounds.
Implementation Method 1
Method for selective hydrogenation using a foamed catalyst... in the presence of a catalyst provided in the form of a metal or ceramic foam
Data Source
AI summary
The present invention relates to a method for the selective hydrogenation of polyunsaturated compounds containing at least two carbon atoms per molecule in the presence of a catalyst comprising an active phase made from at least one group VIII metal and a support in the form of a ceramic or metal foam, the catalyst having a geometric surface area of between 1000 and 7000 m2/m3 and a pore diameter of between 0.2 and 1.5 mm.