Hybrid Catalyst for C2-C5 Paraffin Conversion
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Solution Overview
Problem
Existing synthetic processes for converting carbon-containing feed streams to C2 to C5 paraffins have low carbon conversion efficiency and catalyst stability, often resulting in significant conversion of feed carbon to CO2 or rapid catalyst deactivation.
Innovation Solution
A hybrid catalyst comprising a metal oxide catalyst component with copper, chromium, and zinc, combined with a microporous catalyst component having 8-MR pore openings, prepared by co-precipitation and calcination, is used to convert hydrogen and carbon-containing gases into C2 to C5 paraffins, achieving high carbon conversion and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional copper-zinc-aluminum or chromium-zinc-oxide based hybrid catalysts are used, then the catalyst can convert carbon-containing feed streams to C2 to C5 hydrocarbons, but the carbon conversion efficiency is low and much of the feed carbon exits as CO2 or unconverted
Solution Approach 1:
The patent employs a hybrid catalyst combining metal oxide catalyst component (containing copper, zinc, and aluminum oxides) with a microporous catalyst component (molecular sieve with 8-MR pore openings). This composite structure synergistically improves carbon conversion efficiency to C2-C5 hydrocarbons while minimizing CO2 formation, directly resolving the contradiction between productivity and substance loss.
2Reliability
If conventional hybrid catalysts are used for carbon conversion, then the process can produce C2 to C5 hydrocarbons, but the catalyst stability over time is poor and the catalyst rapidly loses its activity
Solution Approach 1:
The hybrid catalyst combines metal oxide catalyst component with microporous catalyst component, where the microporous molecular sieve provides structural stability and the metal oxide component maintains catalytic activity. This composite structure prevents rapid deactivation and maintains both stability and activity over extended operation periods.
Solution Approach 2:
The catalyst design assigns different functional properties to different components: the metal oxide catalyst component provides active sites for carbon conversion while the microporous molecular sieve component provides structural stability and shape selectivity. This local differentiation of properties enables the catalyst to simultaneously achieve high stability and sustained activity.
3Manufacturing precision
If the microporous catalyst component has 8-MR pore openings, then the catalyst achieves high selectivity for C2 to C5 hydrocarbons, but the catalyst preparation becomes more complex
Solution Approach 1:
The patent specifies using a microporous catalyst component with 8-MR pore openings (such as SAPO-34 molecular sieve) which provides shape selectivity for C2-C5 hydrocarbon production. The defined pore structure acts as a molecular sieve that selectively allows desired products to form and exit while preventing formation of larger or unwanted molecules, achieving high manufacturing precision in product selectivity.
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 hybrid catalyst achieves high cumulative productivity of C2 to C5 hydrocarbons with improved stability and activity, exceeding the performance of known copper-zinc-aluminum and chromium-zinc-oxide based hybrid catalysts by maintaining high conversion efficiency and stability over time.
Implementation Method 1
converting the feed stream into a product stream comprising C 2 to C 5 paraffins in the reaction zone in the presence of a hybrid catalyst
Implementation Method 2
calcining the precipitate at a temperature from 300 °C to 600 °C
Implementation Method 3
precipitating solids from a solution comprising copper salt, chromium salt, and zinc salt in a solvent to obtain a precipitate comprising copper, chromium and zinc
Data Source
AI summary
A process for preparing C2 to C5 paraffins includes introducing a feed stream comprising hydrogen gas and a carbon-containing gas into a reaction zone of a reactor, and converting the feed stream into a product stream comprising C2 to C5 paraffins in the reaction zone in the presence of a hybrid catalyst. The hybrid catalyst includes a metal oxide catalyst component and a microporous catalyst component. The metal oxide catalyst component satisfies: an atomic ratio of Cu/Zn from 0.01 to 3.00; an atomic ratio of Cr/Zn from 0.01 to 1.50; and percentage of (A1 + Cr) from greater than 0.0 at% to 50.0 at% based on a total amount of metal in the metal oxide catalyst component.