Hydrocarbon Conversion Catalyst System for Olefin Selectivity
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Solution Overview
Problem
Current methods for producing light olefins from saturated paraffins are energy-intensive and face challenges in product selectivity and yield, with side reactions such as hydrogenation and cracking reducing the efficiency of olefin production.
Innovation Solution
A hydrocarbon conversion catalyst system comprising a dehydrogenation active metal on a solid support and a transition metal on an inorganic support, specifically using platinum or its alloys with aluminum oxide and silicon dioxide or zeolite, enhances the selectivity and yield of olefins by minimizing side reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermal cracking is used to convert saturated paraffins to olefins, then olefin production is achieved, but energy consumption is high and product selectivity is difficult to control
Solution Approach 1:
The patent replaces thermal cracking (mechanical/thermal process) with catalytic dehydrogenation using metal catalysts (platinum, palladium, iridium, chromium) on solid supports. This substitution enables the reaction to proceed at lower temperatures with better selectivity, directly resolving the contradiction between productivity and energy consumption.
Solution Approach 2:
The patent changes the reaction parameters by using catalytic dehydrogenation instead of thermal cracking, operating at lower temperatures (200-500°C) compared to thermal cracking. This parameter change maintains high olefin production while significantly reducing energy consumption.
2Productivity
If dehydrogenation is used to convert saturated paraffins to olefins, then olefin yield is improved, but side reactions such as hydrogenation and cracking occur reducing efficiency
Solution Approach 1:
The patent uses different metal catalysts with specific dehydrogenation activities (platinum, palladium, iridium, chromium) on solid supports to create localized catalytic sites that favor dehydrogenation. This local quality control minimizes side reactions like hydrogenation and cracking, resolving the contradiction between olefin yield and harmful side reactions.
Solution Approach 2:
The patent addresses the harmful effect of hydrogen produced during dehydrogenation by introducing a metathesis catalyst (tungsten, molybdenum, rhenium, vanadium) that converts the hydrogen into useful olefin products through metathesis reactions. This transforms the harmful hydrogen into a beneficial component, resolving the contradiction between olefin yield and side reactions.
3Temperature
If conventional catalytic materials are used for hydrocarbon cracking, then cracking occurs at less severe conditions, but product selectivity is difficult to adjust and control
Solution Approach 1:
The patent changes the catalyst composition parameters by using specific metals (platinum, palladium, iridium, chromium) on solid supports combined with metathesis catalysts (tungsten, molybdenum, rhenium, vanadium). This parameter change enables operation at moderate temperatures while achieving high product selectivity, resolving the contradiction between operating conditions and product selectivity.
Solution Approach 2:
The patent employs composite catalyst systems combining dehydrogenation catalysts (metal on solid support) with metathesis catalysts (transition metals). This composite material approach enables simultaneous control of dehydrogenation and metathesis reactions, achieving high selectivity for desired olefin products while operating at less severe conditions.
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 catalyst system significantly increases the selectivity of olefin production, achieving up to 60 wt% total olefins selectivity, improving the economic viability and yield of light olefin production compared to existing technologies.
Implementation Method 1
a first composition comprising a dehydrogenation active metal on a solid support
Implementation Method 2
a second composition comprising a transition metal on an inorganic support
Data Source
AI summary
The present invention relates to a hydrocarbon conversion catalyst system comprising: a first composition comprising a dehydrogenation active metal on a solid support; and a second composition comprising a transition metal on an inorganic support and a hydrocarbon conversion process utilizing the hydrocarbon conversion catalyst system.