Hydrogenolysis Catalyst Activation Using Butane and Hydrogen
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydrogenolysis catalysts face high capital costs due to the use of noble metals like Ir and Pt, and conventional regeneration methods are complex and costly, necessitating a need for a simpler and cost-effective activation process.
Innovation Solution
A method involving contacting an oxidized catalyst with a hydrocarbon stream in the presence of hydrogen to form a treated catalyst, followed by further treatment with hydrogen, which modifies the catalyst's active site structure, enhancing its stability and activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional regeneration methods (burning carbon deposits in oxidative atmosphere followed by oxychlorination) are used, then catalyst activity is restored, but the process becomes complex and capital intensive
Solution Approach 1:
The invention extracts and eliminates the complex oxychlorination step from the conventional regeneration process. By using a simple hydrogen reduction treatment instead of the multi-step oxidative atmosphere burning followed by oxychlorination, the patent removes unnecessary complexity while maintaining catalyst restoration effectiveness.
Solution Approach 2:
The invention replaces expensive, complex regeneration equipment and chemicals (oxychlorination agents) with a simple, inexpensive hydrogen reduction process. This disposable-like approach uses readily available hydrogen to restore catalyst activity without requiring complex regeneration systems.
2Manufacturing precision
If noble metals (Ir, Pt) are used in hydrogenolysis catalysts, then ethane selectivity is improved (60-70%), but capital cost increases significantly
Solution Approach 1:
The invention changes the chemical state and structure of the catalyst active sites through hydrogen reduction treatment. By modifying the oxidation state and surface properties of the catalyst particles, the process enhances ethane selectivity without requiring expensive noble metals, achieving high selectivity through parameter modification rather than material substitution.
Solution Approach 2:
The invention creates a composite catalyst system where metal particles are supported on a hydrogenolysis catalyst matrix. This composite structure, when treated with hydrogen reduction, produces active sites that achieve noble-metal-like selectivity at lower cost by combining multiple materials with complementary properties.
3Loss of substance
If catalyst is exposed to oxygen for regeneration, then carbon deposits are removed, but active site dispersion is compromised requiring additional oxychlorination
Solution Approach 1:
Instead of using oxidation to remove carbon deposits (conventional approach), the invention inverts the approach by using hydrogen reduction. This reverse methodology removes carbon deposits and restores active site dispersion simultaneously through reduction rather than oxidation, eliminating the need for subsequent oxychlorination to maintain dispersion.
Solution Approach 2:
The hydrogen reduction treatment performs multiple functions continuously: it removes carbon deposits, restores active site dispersion, and activates the catalyst all in one step. This continuous multi-functional action replaces the discontinuous conventional process of oxidation followed by separate oxychlorination to maintain dispersion.
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 process increases hydrocarbon conversion stability and extends catalyst life, reducing the need for frequent regeneration, while maintaining high ethane selectivity and minimizing byproduct formation.
Implementation Method 1
contacting an oxidized catalyst with a stream comprising butane in the presence of H2 to form a treated catalyst
Implementation Method 2
contacting the treated catalyst of step (a) with H2 to form an activated hydrogenolysis catalyst
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Processes for activation of hydrogenolysis catalysts are described. A process can include contacting an oxidized catalyst with a butane containing stream in the presence of H2 to form a treated catalyst. The treated catalyst can then be contacted with H2 to form an activated hydrogenolysis catalyst. The source of the oxidized catalyst can be a fresh catalyst or deactivated catalyst that has been exposed to, for example, oxygen. Uses of the activated hydrogenolysis catalyst are also described.