Layered Zinc Ferrite Catalyst for Coke-Resistant Butadiene Production
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Solution Overview
Problem
Existing oxidative dehydrogenation catalysts for producing 1,3-butadiene suffer from low yield and selectivity due to coke deposition, which deactivates the catalyst over time, and there is a need for a more stable and efficient process.
Innovation Solution
A catalyst for oxidative dehydrogenation comprising a carrier with a first coating layer of metal oxide and a second coating layer of zinc ferrite-based catalyst, where the metal oxide includes Ce, K, Mg, or La, to suppress coke deposition and enhance catalyst activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional zinc ferrite-based catalyst is used for oxidative dehydrogenation, then the catalyst can perform the reaction, but coke deposition occurs leading to decreased activity and lower butadiene yield over time
Solution Approach 1:
The patent applies composite materials by combining zinc ferrite catalyst with metal oxide (Ce, K, Mg, La) on a carrier to create a multi-component catalyst system. This composite structure suppresses coke deposition while maintaining catalytic activity, thereby improving both butadiene yield and long-term catalyst stability compared to traditional single-component zinc ferrite catalysts
Solution Approach 2:
The patent implements local quality by creating a multi-layer catalyst structure where different components perform specific functions: the metal oxide layer suppresses coke formation, while the zinc ferrite layer provides catalytic activity. This spatial differentiation of functions within the catalyst structure optimizes both productivity and reliability
2Quantity of substance
If multiple batches of catalyst are prepared to satisfy target amount, then sufficient catalyst quantity is obtained, but reactivity varies among batches leading to inconsistent product yield
Solution Approach 1:
The patent applies segmentation by dividing the catalyst preparation into distinct functional layers: a metal oxide layer for coke suppression and a zinc ferrite layer for catalysis. This layered approach standardizes the preparation process, ensuring consistent reactivity across different production batches while maintaining the required catalyst quantity
Solution Approach 2:
The patent utilizes parameter changes by optimizing the composition ratios of metal oxide to zinc ferrite and controlling preparation conditions such as coating thickness and heat treatment parameters. These standardized parameter controls ensure that catalyst batches produced at different times maintain consistent reactivity and performance
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 proposed catalyst achieves higher butadiene yield and stability by reducing coke formation, leading to improved long-term performance compared to traditional zinc ferrite-based catalysts.
Implementation Method 1
a first coating layer provided on the carrier and comprising a metal oxide... to suppress a phenomenon in which coke is deposited on the catalyst
Implementation Method 2
a second coating layer provided on the first coating layer and comprising a zinc ferrite-based catalyst... the oxidative dehydrogenation reaction of butene is a reaction in which butene and oxygen react with each other in the presence of a metal oxide catalyst to manufacture 1,3-butadiene and water
Implementation Method 3
performing a first heat treatment process; and forming a second coating layer by coating the first coating layer with a second solution comprising a zinc ferrite-based catalyst, and then performing a second heat treatment process
Data Source
AI summary
A catalyst for an oxidative dehydrogenation reaction that includes a carrier; a first coating layer provided on the carrier and including a metal oxide; and a second coating layer provided on the first coating layer and including a zinc ferrite-based catalyst, in which the metal oxide includes one or more metals selected from among Ce, K, Mg, La and Y.