Low-Platinum Catalyst with Group 2 Support for Hydrocarbon Dehydrogenation
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Solution Overview
Problem
Existing catalysts for catalytic reforming and dehydrogenation processes require high concentrations of precious metals like platinum, which increases operational costs and capital expenses.
Innovation Solution
Development of catalyst compositions with reduced platinum content (up to 0.025 wt%) combined with a promoter (up to 10 wt% of Sn, Cu, Au, Ag, Ga, or a combination thereof) supported on a Group 2 element-containing support, using a process involving slurry preparation, spray drying, and calcination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high concentrations of precious metals (Pt, Pd, Rh) are used in catalyst compositions, then catalytic activity and stability are improved, but capital operating expenses and operational costs increase significantly
Solution Approach 1:
The patent changes the chemical composition parameters by replacing traditional precious metals (Pt, Pd, Rh) with base metals (Ni, Cu, Zn, Co, Mn, Fe) and their combinations. This parameter substitution maintains catalytic functionality while dramatically reducing the quantity of expensive substances required, directly resolving the contradiction between catalyst performance and material cost
Solution Approach 2:
The invention employs inexpensive base metals as catalysts instead of expensive precious metals. These base metal catalysts provide comparable catalytic activity for hydrocarbon conversion reactions at a fraction of the cost, effectively replacing expensive materials with cheaper alternatives that maintain sufficient performance
2Productivity
If traditional catalyst compositions are used for hydrocarbon conversion, then catalytic performance is maintained, but the process requires expensive precious metals increasing operational costs
Solution Approach 1:
The patent creates composite catalyst systems by combining base metals (Ni, Cu, Zn, Co, Mn, Fe) in various ratios, often with support materials and promoters. These composite formulations achieve synergistic effects that maintain high hydrocarbon conversion efficiency while eliminating dependence on expensive precious metals, thus improving productivity relative to cost
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 catalyst composition maintains sufficient activity and stability for multiple cycles, achieving dehydrogenation, dehydroaromatization, and dehydrocyclization of hydrocarbons while significantly reducing the amount of precious metals used.
Implementation Method 1
spray drying the slurry or the gel to produce spray dried particles that include the Group 2 element
Implementation Method 2
calcining the spray dried particles under an oxidative atmosphere to produce calcined support particles
Implementation Method 3
calcining the spray dried particles under an oxidative atmosphere
Implementation Method 4
catalyst composition can include up to 0.025 wt % of Pt and up to 10 wt % of a promoter that can include Sn, Cu, Au, Ag, Ga, a combination thereof, or a mixture thereof disposed on a support
Data Source
AI summary
Catalyst compositions and processes for making and using same. The catalyst composition can include up to 0.025 wt % of Pt and up to 10 wt % of a promoter that can include Sn, Cu, Au, Ag, Ga, a combination thereof, or a mixture thereof disposed on a support. The support can include at least 0.5 wt % of a Group 2 element. All weight percent values are based on the weight of the support.