Gallium Oxide Catalyst for Alkane Dehydrogenation
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Solution Overview
Problem
Conventional gallium-based alkane dehydrogenation catalysts do not perform as well as chromium-based catalysts, posing environmental and health risks, thus necessitating the development of non-chromium-based catalysts with similar performance characteristics.
Innovation Solution
A catalyst comprising a support with an active layer of gallium oxide, aluminum oxide, cerium oxide, a Group 1 metal oxide, and a Group 8-11 metal oxide, formed through an impregnation process involving precursors, followed by drying and calcination, to enhance alkane conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chromium-based catalysts are used for alkane dehydrogenation, then high catalytic performance is achieved, but environmental and health hazards arise
Solution Approach 1:
The patent removes chromium from the catalyst composition and replaces it with gallium oxide as the active metal component. This extraction of the harmful chromium element while maintaining catalytic functionality through gallium oxide directly resolves the contradiction between achieving high catalytic performance and avoiding environmental/health hazards.
Solution Approach 2:
The patent changes the chemical composition parameters of the catalyst by substituting chromium with gallium oxide and adjusting the oxide ratios (gallium oxide: 1-10 wt%, aluminum oxide: 10-50 wt%, cerium oxide: 1-10 wt%). This parameter change enables the catalyst to achieve performance comparable to chromium-based systems while eliminating harmful chromium content.
2Object-affected harmful factors
If gallium-based catalysts are used instead of chromium-based catalysts, then environmental and health hazards are reduced, but catalytic performance deteriorates
Solution Approach 1:
The patent creates a composite catalyst material containing gallium oxide combined with aluminum oxide, cerium oxide, and Group 1 metal oxide. This composite approach enhances the catalytic performance of gallium-based material to levels comparable with chromium-based catalysts while maintaining environmental and health safety benefits.
Solution Approach 2:
The patent merges multiple oxide components (gallium oxide, aluminum oxide, cerium oxide, Group 1 metal oxide) into a single catalyst system. This combination synergistically improves the catalytic activity and stability of the gallium-based catalyst, resolving the performance deficiency when switching from chromium-based systems.
3Reliability
If a multi-component oxide active layer is formed through impregnation and calcination, then catalytic activity is enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent performs preliminary impregnation of the support with a solution containing multiple metal precursors (gallium, aluminum, cerium, Group 1 metal) before calcination. This preliminary action of depositing all components onto the support in one step simplifies the overall manufacturing process compared to sequential loading, while still achieving the complex multi-component active layer structure.
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 improved alkane conversion, comparable to chromium-based catalysts, while avoiding environmental and health hazards associated with chromium, thus providing a safer and effective alternative.
Implementation Method 1
contacting the impregnation solution with a catalyst support material to deposit gallium, aluminum, cerium, the Group 1 metal, and the Group 8-11 metal on the catalyst support material
Implementation Method 2
contacting the impregnation solution with a catalyst support material to deposit gallium, aluminum, cerium, the Group 1 metal, and the Group 8-11 metal on the catalyst support material
Implementation Method 3
calcining the dried impregnated support to form the alkane dehydrogenation catalyst
Implementation Method 4
contacting the alkane dehydrogenation catalyst with a feed including the alkane at a temperature of 450 to 800° C., or 500 to 750° C., to produce a product stream including an alkene
Data Source
AI summary
An alkane dehydrogenation catalyst including a support; and on the support. an active layer including gallium oxide, aluminum oxide, cerium oxide, a Group 1 metal oxide, and a Group 8-11 metal oxide. The catalyst composition of the examples comprises oxides of gallium, cerium, potassium, platinum and aluminium.