Aromatization Catalyst with Halide-Bound Zeolite Support
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Solution Overview
Problem
The existing methods for preparing aromatization catalysts face challenges in achieving high selectivity and conversion rates, and the movement of catalyst particles during loading and operation leads to the formation of fines, which are abrasive and can plug reactor equipment.
Innovation Solution
A catalyst comprising a zeolite support, a Group VIII metal, and at least two halides bound to the zeolite support or the Group VIII metal, with a specific method of preparation involving calcination, fluorination, washing, and metal impregnation to enhance the catalyst's crush strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If catalyst particles are moved during loading and operation, then catalyst can be loaded and operated, but catalyst fines are generated which are abrasive and can plug equipment
Solution Approach 1:
The catalyst undergoes preliminary action during preparation by forming a binder coating on the catalyst particles before they are loaded into the reactor. This binder coating is applied in advance to prevent particle breakage during subsequent handling and operation, thereby reducing fines generation while maintaining ease of catalyst loading
2Strength
If catalyst crush strength is increased to reduce fines, then equipment plugging is minimized, but catalyst preparation complexity increases
Solution Approach 1:
The catalyst preparation employs composite materials by combining the catalyst particles with a binder material to form a composite structure. This composite catalyst particle achieves enhanced crush strength and reduced fines generation while the preparation process remains integrated and does not require separate complex preparation steps beyond the initial binder coating application
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 described catalyst exhibits improved selectivity and conversion rates, with increased crush strength reducing the formation of fines and minimizing equipment plugging issues, thus enhancing the efficiency and durability of the aromatization process.
Implementation Method 1
The catalytic conversion of hydrocarbons into aromatic compounds, referred to as aromatization, is an important industrial process
Implementation Method 2
Aromatization reactions may include the dehydrogenation, isomerization, and hydrocracking of hydrocarbons
Data Source
AI summary
Catalysts and method of preparing the catalysts are disclosed. One of the catalysts includes a zeolite support, a Group VIII metal on the zeolite support, and at least two halides bound to the zeolite support, to the Group VIII metal, or to both, and can have an average crush strength greater than 11.25 lb based on at least two samples of pellets of the catalyst measured in accordance with ASTM D4179.