Group 8-10 Catalyst for Propane Dehydrogenation
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Solution Overview
Problem
Existing propane dehydrogenation processes using alumina supported chromia catalysts achieve high propylene yields but require low pressures, which limits process efficiency.
Innovation Solution
Development of catalyst compositions featuring 0.001 wt % to 6 wt % of a Group 8-10 element disposed on a support containing Al and at least 0.5 wt % of a Group 2 element, with minimal or no silicon content, to enhance propylene yield at higher pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If alumina supported chromia catalyst is used to achieve high propylene yield, then propylene yield is improved, but operating pressure must be reduced to low pressure conditions
Solution Approach 1:
The patent modifies the catalyst composition parameters by incorporating Group 8-10 elements (Fe, Co, Ni, Ru, Pd, Os, Ir, Pt) at specific weight percentages (0.001-6 wt%) combined with Al and Group 2 elements (Mg, Ca, Sr, Ba) at at least 0.5 wt%, while controlling Si content. This compositional parameter change enables the catalyst to maintain high propylene yield (≥52%) and selectivity (≥75%) at higher operating pressures (≥20 kPa), resolving the contradiction between productivity and pressure requirements
Solution Approach 2:
The patent creates a composite catalyst material combining multiple metal elements (Group 8-10 elements with Al and Group 2 elements) on a support structure. This composite approach leverages synergistic effects between different metal components to achieve both high propylene yield and compatibility with higher pressure operating conditions, eliminating the need to operate at low pressures
2Productivity
If low pressure operation is used to maintain high propylene yield, then propylene selectivity is improved, but process efficiency is reduced
Solution Approach 1:
The catalyst composition is modified by incorporating specific metal elements (Group 8-10 elements at 0.001-6 wt% and Group 2 elements at ≥0.5 wt%) to change the catalytic properties. This enables the system to achieve high propylene yield (≥52%) and selectivity (≥75%) at higher pressures, thereby reducing energy loss associated with low-pressure operation and improving overall process efficiency
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 new catalyst compositions maintain high propylene yields and selectivity over multiple cycles without the need for low operating pressures, thereby improving the efficiency of the dehydrogenation process.
Implementation Method 1
catalyst compositions and processes for making and using same... catalyst composition can include 0.001 wt % to 6 wt % of a Group 8-10 element disposed on a support... to effect one or more of dehydrogenation, dehydroaromatization, and dehydrocyclization of at least a portion of the hydrocarbon-containing feed
Implementation Method 2
The support can include Al and at least 0.5 wt % of a Group 2 element, based on the weight of the support... calcining the spray dried particles under an oxidative atmosphere to produce calcined support particles
Implementation Method 3
calcining the spray dried particles under an oxidative atmosphere to produce calcined support particles
Data Source
AI summary
Catalyst compositions and processes for making and using same. The catalyst composition can include 0.001 wt % to 6 wt % of a Group 8-10 element disposed on a support, based on the weight of the support. The support can include Al and at least 0.5 wt % of a Group 2 element, based on the weight of the support. The catalyst composition can be free of Si or can contain <0.5 wt % of Si, based on the weight of the support.