Layered Catalyst Selective Hydrogenation Diolefins

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Solution Overview

Problem

Current catalysts for selectively hydrogenating diolefins are limited by reactivity, leading to polymerization and pressure drops, especially when using sulfided nickel catalysts, which require sulfur replenishment and removal, and existing processes struggle with high temperatures and diolefin instability.

Innovation Solution

A layered catalyst composition with an IUPAC Group 1-2 metal and an IUPAC Group 8-10 metal on a layered support, comprising a refractory inner core and a non-refractory outer layer, is used to selectively hydrogenate C5-C11 diolefins to C5-C11 monoolefins, eliminating the need for sulfided nickel and reducing sulfur handling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If sulfided nickel catalysts are used for selective hydrogenation, then diolefin conversion is improved, but sulfur loss to product occurs requiring replenishment and removal

Engineering Contradiction:

Improvediolefin conversionVSAvoidsulfur loss

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The patent removes sulfur from the catalyst system entirely by replacing sulfided nickel with a sulfur-free catalyst composition containing Group 8-10 metal on a layered oxide support, thereby eliminating sulfur loss to product while maintaining diolefin conversion capability

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the chemical composition parameters of the catalyst from sulfided nickel to Group 8-10 metal on layered oxide support, fundamentally altering the catalyst's chemical properties to achieve sulfur-free operation while preserving or improving catalytic activity

Inventive Principle:

Principle #35Parameter changes

2Productivity

If high temperatures are used to maintain catalyst activity, then reaction rate is improved, but polymerization of diolefins increases causing pressure drops

Engineering Contradiction:

Improvereaction rateVSAvoidpolymerization

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the catalyst's chemical composition to Group 8-10 metal on layered oxide support, which alters the reaction pathway and allows achieving high reaction rates at lower temperatures, thereby suppressing polymerization while maintaining productivity

Inventive Principle:

Principle #35Parameter changes

3Productivity

If active catalysts are used to rapidly convert diolefins, then conversion speed is improved, but excess heat generation occurs favoring gum formation

Engineering Contradiction:

Improveconversion speedVSAvoidheat generation

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent modifies the catalyst's chemical composition to Group 8-10 metal on layered oxide support, which changes the thermodynamic and kinetic parameters of the hydrogenation reaction, enabling faster conversion rates with reduced heat generation and improved temperature control

Inventive Principle:

Principle #35Parameter changes

4Device complexity

If fixed bed adiabatic reactors are used, then process simplicity is improved, but practical operating window is limited due to pressure drop problems

Engineering Contradiction:

Improveprocess simplicityVSAvoidoperating window

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The patent changes the catalyst composition to Group 8-10 metal on layered oxide support, which improves catalytic efficiency and reduces pressure drops, thereby expanding the practical operating window of fixed bed adiabatic reactors while maintaining process simplicity

Inventive Principle:

Principle #35Parameter changes

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 allows for higher space velocities and lower reaction temperatures, reducing reactor size and capital costs, while maintaining selectivity and minimizing the conversion of monoolefins to paraffins, thus improving process efficiency and stability.

Implementation Method 1

The layered catalyst composition comprises an IUPAC Group 1-2 metal and an IUPAC Group 8-10 metal on a layered composition support

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

The support comprises an inner core of an inorganic oxide, which is preferably a refractory inorganic oxide, such as, without limitation, cordierite

Methodology Applied

Scientific EffectThermal stability: Refractory Material

Implementation Method 3

an outer layer of a non-refractory inorganic oxide, such as, without limitation, gamma alumina

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS7816571B2Selective hydrogenation process using layered catalyst composition

Publication Date: 2010.10.19 UOP LLC

AI summary

The use of a layered catalyst composition to selectively hydrogenate C5-C11 diolefins in a hydrocarbon mixture to one or more respective C5-C11 monoolefins is disclosed. The layered catalyst comprises an inner core having a first inorganic oxide and an outer layer bonded to the inner core. The outer layer has a non-refractory second inorganic oxide with at least one Group 1-2 metal and at least one Group 8-10 metal dispersed thereon.