Hybrid Catalyst Pore Control for C2 to C3 Hydrocarbon Selectivity
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Solution Overview
Problem
Current hybrid catalyst processes for converting hydrogen and carbon-containing feed streams to C2 to C3 hydrocarbons result in a lower C2/C3 carbon molar ratio than desired, necessitating the development of processes that enhance this ratio while maintaining high productivity.
Innovation Solution
The use of a hybrid catalyst comprising a metal oxide catalyst component and a microporous catalyst component with 8-MR pore openings less than or equal to 5.1 Å and a cage defining ring size less than or equal to 7.45 Å, which increases the C2/C3 carbon molar ratio in the product stream to greater than or equal to 0.7.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If current hybrid catalyst processes are used, then productivity of C2 to C3 hydrocarbons is maintained, but C2/C3 carbon molar ratio in product is lower than desired
Solution Approach 1:
The patent changes the physical and chemical parameters of the microporous catalyst component by specifying precise pore opening sizes (less than or equal to 5.1 Å) and cage defining ring sizes (less than or equal to 7.45 Å). These parameter changes in the catalyst structure directly influence product distribution, achieving a C2/C3 carbon molar ratio greater than or equal to 0.7 while maintaining high productivity of C2 to C3 hydrocarbons.
Solution Approach 2:
The patent employs a composite catalyst system consisting of a metal oxide catalyst component combined with a microporous catalyst component. This composite material approach allows the synergistic interaction between the two components, where the metal oxide provides catalytic activity for hydrocarbon formation and the microporous component with specific pore dimensions controls product selectivity, thereby achieving both high productivity and improved C2/C3 ratio.
2Manufacturing precision
If microporous catalyst component with specific pore size is used, then C2/C3 carbon molar ratio increases, but catalyst activity may decrease
Solution Approach 1:
The composite catalyst system combines a metal oxide catalyst component with high catalytic activity with a microporous catalyst component that provides structural control. The metal oxide component ensures sufficient catalyst activity for converting feed stream to C2 to C3 hydrocarbons, while the microporous component with specific pore dimensions (≤5.1 Å) and cage defining ring size (≤7.45 Å) controls product distribution to achieve C2/C3 ratio ≥0.7, thus balancing activity and selectivity.
Solution Approach 2:
The microporous catalyst component exhibits local quality in its pore structure with specific pore opening sizes and cage defining ring sizes that are optimized for C2 hydrocarbon formation. This localized structural characteristic within the catalyst creates favorable environments for C2 product formation while the overall composite catalyst maintains high activity through the metal oxide component.
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 configuration achieves a C2/C3 carbon molar ratio greater than or equal to 1.0, enhancing the production of C2 hydrocarbons and maintaining catalyst activity for extended periods without regeneration.
Implementation Method 1
converting the feed stream into a product stream comprising C2 to C3 hydrocarbons in the reaction zone in the presence of a hybrid catalyst, the hybrid catalyst comprising a metal oxide catalyst component and a microporous catalyst component
Implementation Method 2
a microporous catalyst component comprising 8-membered ring (MR) pore openings having a size of less than or equal to 5.1 Å and a cage defining ring size less than or equal to 7.45 Å
Data Source
AI summary
A process for preparing C2 to C3 hydrocarbons may include introducing a feed stream including hydrogen gas and a carbon-containing gas comprising carbon monoxide, carbon dioxide, and mixtures thereof into a reaction zone of a reactor, and converting the feed stream into a product stream comprising C2 to C3 hydrocarbons in the reaction zone in the presence of a hybrid catalyst. The hybrid catalyst may include a metal oxide catalyst component and a microporous catalyst component comprising 8-MR pore openings less than or equal to 5.1 A and a cage defining ring size less than or equal to 7.45 A, where a C2/C3 carbon molar ratio of the product stream is greater than or equal to 0.7.