Hydrocarbon and Carbon Dioxide Conversion Catalyst

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Solution Overview

Problem

Conventional methods for processing hydrocarbons and carbon dioxide either produce only olefins or syngas, or use a single hydrocarbon feed stream, failing to efficiently convert carbon dioxide while producing hydrogen gas, carbon monoxide, and olefins simultaneously.

Innovation Solution

A method involving a hydrocarbon mixture of propane, n-butane, and iso-butane combined with carbon dioxide, contacted with a catalyst comprising alkali or alkaline earth metal oxides, titanium oxide, and zirconium oxide in a reactor to produce a product mixture including hydrogen gas, carbon monoxide, and olefins, with a molar ratio of carbon dioxide to hydrocarbons optimized for efficient conversion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional methods use a single hydrocarbon feed stream, then the process is simple, but the product range is limited and carbon dioxide conversion efficiency is poor

Engineering Contradiction:

Improveproduct rangeVSAvoidprocess complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The catalyst system is designed to perform multiple functions simultaneously: it catalyzes the conversion of different hydrocarbon components (propane, n-butane, iso-butane) and carbon dioxide into multiple valuable products (olefins, hydrogen, carbon monoxide) in a single reactor, making the process versatile and adaptable to produce a range of chemicals

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines multiple hydrocarbon feed streams (propane, n-butane, iso-butane) with carbon dioxide in a single reactant mixture and processes them together in one reactor using a unified catalyst system, merging what would traditionally require separate processes into a single integrated operation

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If conventional methods produce only olefins or syngas separately, then each process is optimized for a single product, but the overall productivity and carbon dioxide utilization are insufficient

Engineering Contradiction:

Improveoverall production efficiencyVSAvoidcarbon dioxide conversion

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent converts carbon dioxide, a harmful greenhouse gas, into valuable chemical products (carbon monoxide and olefins) through catalytic reaction with hydrocarbons, transforming an environmental liability into an economic and environmental asset, thereby improving both productivity and carbon dioxide utilization

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If expensive metal catalysts are used, then catalytic activity is high, but the manufacturing cost increases

Engineering Contradiction:

Improvecatalytic activityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent employs a catalyst system based on inexpensive metal oxides (such as aluminum oxide, zinc oxide, calcium oxide) rather than expensive precious metals, using cost-effective materials that can be manufactured at lower cost while maintaining sufficient catalytic activity for the hydrocarbon and carbon dioxide conversion process

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The catalyst is formulated as a composite material containing multiple metal oxides (e.g., aluminum oxide, zinc oxide, calcium oxide) that work synergistically to provide the necessary catalytic functions for hydrocarbon cracking and carbon dioxide conversion, achieving reliable performance through material composition rather than relying on expensive single-metal catalysts

Inventive Principle:

Principle #40Composite materials

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 approach effectively converts carbon dioxide into valuable products like hydrogen gas, carbon monoxide, and olefins, enhancing the production of both olefins and syngas while mitigating carbon dioxide emissions, using a cost-effective catalyst that avoids expensive metals like platinum.

Implementation Method 1

contacting the reactant mixture with a catalyst in a reactor to produce a product mixture

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS20240368480A1Methods of processing hydrocarbons and carbon dioxide

Publication Date: 2024.11.07 SAUDI ARABIAN OIL CO

AI summary

A method for processing hydrocarbons and carbon dioxide may include combining a hydrocarbon mixture with carbon dioxide to produce a reactant mixture, which may include at least 95 mol. % of the combination of the hydrocarbon mixture and the carbon dioxide. The molar ratio of carbon dioxide to the hydrocarbon mixture in the reactant mixture may be from 0.01 to 100. The hydrocarbon mixture may include from 30 mol. % to 90 mol. % of propane, 5 mol. % to 50 mol. % of n-butane, and 5 mol. % to 50 mol. % of iso-butane. The method may also include contacting the reactant mixture with a catalyst in a reactor to produce a product mixture and passing the product mixture out of the reactor. The product mixture may include from 5 mol. % to 50 mol. % of one or more olefins, 1 mol. % to 25 mol. % of hydrogen gas, and 1 mol. % to 25 mol. % of carbon monoxide.