Liquid Phase Catalyst Activation Water Removal
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Solution Overview
Problem
Existing liquid phase activation processes for catalysts used in the hydrogenation of aldehydes to alcohols suffer from high water concentration, leading to inefficient catalyst activity and increased aldehyde slip, while gas phase activation processes are costly and require additional equipment and downtime.
Innovation Solution
A liquid phase activation process is developed where the peak water concentration is maintained at less than 1.5 wt % by controlling the water concentration of the liquid feed stream, adjusting the rate of recovery of the liquid stream, and removing water produced within the reactor, resulting in a catalyst with increased activity comparable to gas phase activation processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If liquid phase activation process is used, then equipment complexity is reduced and operating costs are lowered, but water concentration increases leading to catalyst impairment and aldehyde slip
Solution Approach 1:
The patent extracts and removes water from the liquid phase activation system using a molecular sieve dryer. The liquid stream is passed through the molecular sieve which selectively adsorbs water molecules, separating water from the liquid phase and maintaining water concentration below 1.5 wt% during catalyst activation.
Solution Approach 2:
The patent changes the water concentration parameter in the liquid phase activation process by implementing continuous water removal. This parameter change transforms the activation process from high-water-concentration (harmful) to low-water-concentration (beneficial) conditions, achieving catalyst activity comparable to gas phase activation.
2Ease of manufacture
If liquid phase activation process is used, then capital costs are reduced, but catalyst activity decreases due to water and overheating
Solution Approach 1:
The patent converts the harmful effect of water (which normally causes catalyst impairment and reduced activity) into a beneficial outcome by implementing water removal. The molecular sieve dryer converts water from a harmful contaminant into a separated component, allowing the liquid phase activation to proceed with water concentration controlled below 1.5 wt%, thereby maintaining high catalyst activity.
Solution Approach 2:
The patent implements feedback control by monitoring water concentration in the liquid stream and adjusting the activation process accordingly. The molecular sieve dryer continuously removes water, and the system maintains water concentration within the target range (below 1.5 wt%) through this continuous monitoring and adjustment mechanism.
3Reliability
If gas phase activation process is used, then catalyst activity is improved, but equipment complexity increases due to compressors and heat exchangers
Solution Approach 1:
The patent introduces a molecular sieve dryer as an intermediary device in the liquid phase activation system. This intermediary component performs the water removal function that would otherwise require complex gas phase equipment, enabling the system to achieve gas-phase-like catalyst activity while maintaining the simplicity of liquid phase processing.
4Reliability
If gas phase activation process is used, then catalyst activity is improved, but operating costs increase
Solution Approach 1:
The patent employs a molecular sieve dryer, which is a relatively simple and cost-effective water removal device compared to gas phase activation equipment. The molecular sieve material can be regenerated and reused, providing an economical solution for water removal that maintains high catalyst activity without the high operating costs associated with gas phase compressors and heat exchangers.
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 achieves higher catalyst activity with reduced aldehyde slip, comparable to gas phase activation, while avoiding the drawbacks of liquid phase activation, such as excessive water and overheating, thereby improving the efficiency and commercial viability of the hydrogenation process.
Implementation Method 1
it is necessary to reduce the catalyst before it can be used to catalyse the desired reaction. This process of reducing the catalyst is generally known as an activation process
Implementation Method 2
The heat of reaction is generally removed by circulating the aldehyde in an excess of carrier gas... The heat of reaction is generally removed from the circulating gas or liquid by heat exchange
Implementation Method 3
removal of water produced within the reactor
Data Source
AI summary
The present invention relates to a process for the liquid phase activation of catalysts. Such activated catalysts have particular utility in hydrogenation of aldehydes to alcohols. As such, the present invention relates to a process for the hydrogenation of aldehydes to alcohols in the presence of a catalyst which has been activated in accordance with the first aspect of the present invention.