Integrated Gas Turbine and C5 Conversion System
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Solution Overview
Problem
Current processes fail to efficiently convert acyclic C5 hydrocarbons to cyclic C5 compounds, particularly cyclopentadiene, due to low yields and excessive production of C4-cracked products, and suffer from catalyst deactivation and inability to use oxygen-containing gases for heat input without damaging the catalyst.
Innovation Solution
A process involving compressing an oxygen gas stream, oxidizing fuel to produce a hot gas stream, and contacting acyclic C5 hydrocarbon feedstock with a catalyst composition in parallel reactor tubes while transferring heat by convection from the hot gas stream, specifically using a turbine exhaust stream to produce cyclopentadiene with improved catalyst aging and reduced byproduct formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts (Pt/Sn on alumina) are used to dehydrogenate C5 hydrocarbons, then some conversion is achieved, but selectivity to cyclic C5 products is poor and yields are low
Solution Approach 1:
The patent employs a composite catalyst system comprising Pt/Sn on chlorided alumina combined with a zeolite component (such as ZSM-5 or other aluminosilicate zeolites). This composite structure integrates the dehydrogenation activity of Pt/Sn with the cyclization functionality of the zeolite, achieving both high conversion to cyclic C5 products and improved selectivity through synergistic catalytic effects.
2Productivity
If Pt supported on chlorided alumina catalysts are used to reform naphtha to aromatics, then dehydrogenation and cyclization of C6+ alkanes is effective, but conversion of acyclic C5 to cyclic C5 is low and catalyst deactivates within two hours
Solution Approach 1:
The patent combines Pt/Sn on chlorided alumina with zeolite to create a composite catalyst that maintains the cyclization activity of the alumina-supported component while the zeolite framework provides structural stability and resistance to deactivation. The zeolite's microporous structure prevents coke accumulation and maintains catalyst integrity over extended periods, resolving the short lifetime issue.
Solution Approach 2:
The zeolite component provides a porous framework that facilitates mass transfer and stabilizes the catalyst structure. The porous nature of the zeolite allows for continuous operation by managing heat and mass flow, preventing local hot spots and coke deposition that would otherwise cause rapid deactivation.
3Use of energy by moving object
If oxygen-containing gases are used for heat input to the reactor, then thermal energy is provided, but the catalyst is damaged
Solution Approach 1:
The patent introduces a heat transfer fluid (such as a separate circulating fluid or modified exhaust gas) as an intermediary to transfer thermal energy to the reactor. This intermediary carries heat away from the catalyst zone without allowing oxygen-containing gases to contact the catalyst directly, thus providing necessary thermal input while protecting the catalyst from oxidative damage.
Solution Approach 2:
The reactor system is segmented into distinct functional zones: a catalyst zone where the chemical reaction occurs and a separate heat transfer zone where thermal energy is applied. This spatial separation allows independent optimization of catalytic activity and thermal management, preventing oxygen exposure to the catalyst while maintaining adequate heat input for the endothermic reaction.
4Adaptability or versatility
If existing steam cracking facilities shift to lighter feeds, then production flexibility is improved, but cyclopentadiene production decreases while demand increases
Solution Approach 1:
The patent modifies the catalytic parameters and operating conditions to optimize cyclopentadiene production from lighter C5 feedstocks. By adjusting temperature, pressure, and catalyst composition (specifically the Pt/Sn/zeolite ratio and chlorination level), the process achieves high CPD yields from lighter feeds, reversing the negative impact of feedstock lightening while maintaining adaptability.
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 achieves high yield of cyclopentadiene with minimized C4-cracked products and extended catalyst activity by using the turbine exhaust stream for heat transfer, enabling efficient conversion of acyclic C5 hydrocarbons to cyclic C5 compounds while maintaining catalyst effectiveness.
Implementation Method 1
contacting the feedstock with catalyst composition in parallel reactor tubes
Implementation Method 2
transferring heat by convection from the hot gas stream to the outer surface of the reactor tube walls
Implementation Method 3
oxidizing fuel with the compressed gas stream to produce a hot gas stream
Implementation Method 4
burning fuel gas with the compressed gas stream in a turbine to produce turbine power
Data Source
AI summary
Disclosed is an integrated process and system to generate power and convert acyclic C5 feedstock to non-aromatic, cyclic C5 hydrocarbon. A combustion device, such as a turbine, and reactor tubes containing catalyst compound are disclosed. A process involving contacting acyclic C5 feedstock with catalyst composition and obtaining cyclic C5 hydrocarbon is also disclosed.