Gallium-Tin-Platinum Catalyst for Butadiene Dehydrogenation
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Solution Overview
Problem
Current dehydrogenation technologies for producing 1,3-butadiene, such as the Catadiene and OXO-D processes, face issues with toxic chromium residues, high reaction volumes, environmental impact, and oxygen interference, leading to inefficiencies and safety concerns.
Innovation Solution
A catalytic composition comprising microspheroidal alumina modified with silica, gallium and/or gallium oxides, tin and/or tin oxides, and platinum in low quantities, supported on a fast-riser or fluid-bed reactor, which operates with low contact times and continuous regeneration, reducing reaction volumes and avoiding air-hydrocarbon mixing risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If Catadiene technology uses fixed adiabatic bed with chromium oxide catalyst, then dehydrogenation reaction can proceed, but toxic hexavalent chromium residues remain and environmental impact increases
Solution Approach 1:
The patent replaces chromium oxide catalyst with a catalyst system based on gallium, tin, and platinum metals supported on alumina. This fundamental change in catalyst composition eliminates toxic hexavalent chromium residues while maintaining dehydrogenation activity. The new catalyst system uses non-toxic alternative metals with different chemical properties to achieve the same transformation.
Solution Approach 2:
The invention employs a composite catalyst system combining multiple metals (gallium, tin, platinum) on an alumina support. This composite structure synergistically combines the dehydrogenation activity of noble metals with the promotional effects of gallium and tin, achieving high productivity without toxic chromium while stabilizing the catalyst structure through the support material.
2Device complexity
If Catadiene process operates in same reactor for both dehydrogenation and regeneration, then process integration is achieved, but safety risk increases due to potential mixing of air with hydrocarbon
Solution Approach 1:
The patent separates the dehydrogenation and regeneration operations into distinct functional zones or continuous flow arrangements where fresh feedstock is continuously introduced and product continuously removed. This spatial and temporal segmentation prevents mixing of air (used in regeneration) with hydrocarbon feedstock, eliminating the safety hazard while maintaining process integration benefits.
Solution Approach 2:
The invention introduces an intermediary barrier or control mechanism (such as staged injection, intermediate zones, or controlled flow arrangements) between the dehydrogenation and regeneration sections. This intermediary prevents direct contact between air and hydrocarbon streams while allowing heat and mass transfer necessary for process operation.
3Duration of action of stationary object
If OXO-D process uses oxidative dehydrogenation with air and vapor, then catalyst regeneration is not required, but selectivity to useful product decreases due to combustion products
Solution Approach 1:
The patent changes the chemical environment from oxidative (using air) to non-oxidative (using inert gas or vacuum). This parameter change in the gas composition eliminates oxygen that causes combustion reactions, thereby improving selectivity to 1,3-butadiene. The catalyst is designed to maintain activity under these non-oxidative conditions without requiring oxygen for regeneration.
Solution Approach 2:
The invention operates the dehydrogenation reaction in an inert atmosphere (nitrogen, argon, or vacuum) rather than oxidative conditions. This inert environment prevents combustion of hydrocarbons to CO2 and H2O, directing the reaction selectively toward 1,3-butadiene formation. The catalyst stability under inert conditions eliminates the need for periodic oxidative regeneration cycles.
4Temperature
If preheating ovens are used to heat feedstock before catalytic bed, then reaction temperature is achieved, but gaseous pollutants particularly NOx are generated
Solution Approach 1:
The patent replaces the mechanical/thermal preheating oven system with a catalytic or adiabatic heating approach. The feedstock is heated through the exothermic nature of the reaction itself or through contact with preheated catalyst/bed materials, eliminating the need for separate combustion-based preheating ovens that generate NOx emissions.
Solution Approach 2:
The invention uses an inert atmosphere (nitrogen or vacuum) during the heating and reaction process, preventing the combustion of hydrocarbons that would otherwise occur in oxygen-containing preheating ovens. This eliminates the formation of nitrogen oxides by removing the oxygen required for their formation, while still achieving the necessary reaction temperatures through alternative heating mechanisms.
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 solution achieves efficient dehydrogenation with reduced reaction volumes, eliminates toxic residue issues, and enhances safety by separating hydrocarbon and oxygen streams, thereby improving productivity and environmental sustainability.
Implementation Method 1
a catalytic composition comprising a microspheroidal alumina carrier modified with silica and an active component containing a mixture comprising Gallium and/or Gallium oxides, Tin and/or Tin oxides, a quantity ranging from 1 ppm to 500 ppm with respect to the total weight of the catalytic composition of platinum and/or platinum oxides, and oxides of alkaline and/or alkaline earth metals
Data Source
AI summary
The present invention relates to a catalytic composition which comprises microspheroidal alumina and an active component containing a mixture comprising Gallium and/or Gallium oxides, Tin and/or Tin oxides, a quantity ranging from 1 ppm to 500 ppm with respect to the total weight of the catalytic composition of platinum and/or platinum oxides, and oxides of alkaline and/or alkaline earth metals.