Mesoporous Carbon Copper Catalyst Resists Sintering
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Solution Overview
Problem
Existing catalysts for dehydrogenating C2 to C12 chain alkyl compounds, such as isobutane, face challenges including high costs due to the use of toxic metals like Cr or expensive metals like Pt, and suffer from low isobutane conversion and rapid activity decay, especially under elevated temperatures.
Innovation Solution
A mesoporous carbon-supported copper-based catalyst with auxiliary elements like SnO2, Li2O, or K2O is developed, which improves isobutane conversion and selectivity to isobutene while maintaining stability over a long period and resisting sintering and coke deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Cr based catalyst or Pt based catalyst is used for isobutane dehydrogenation, then catalytic activity is achieved, but cost increases and environmental pollution occurs
Solution Approach 1:
The patent replaces expensive and toxic precious metals (Pt, Cr) with inexpensive copper-based catalysts supported on mesoporous carbon. The copper catalyst achieves comparable catalytic activity for isobutane dehydrogenation without the environmental pollution and high cost associated with traditional catalysts, effectively using cheap materials to replace expensive ones.
Solution Approach 2:
The patent introduces auxiliary elements (alkali metals like K, Na, Li; alkaline earth metals like Ca, Sr, Ba; or rare earth elements) to modify the copper catalyst's properties. These parameter changes enhance the catalyst's activity, selectivity, and stability, allowing copper to achieve performance levels previously only attainable with precious metals.
2Productivity
If reaction temperature is elevated to increase isobutane conversion, then conversion level improves, but catalyst sintering and deactivation occur
Solution Approach 1:
The patent modifies the catalyst's physical and chemical parameters by incorporating auxiliary elements that enhance thermal stability. These modifications allow the copper catalyst to maintain its structural integrity and catalytic activity at elevated temperatures (500-700°C), preventing sintering and deactivation while achieving high isobutane conversion.
Solution Approach 2:
The patent creates a composite catalyst system combining copper with auxiliary elements and mesoporous carbon support. This composite structure provides thermal stability and resistance to sintering, enabling the catalyst to operate effectively at high temperatures without degradation, thus resolving the contradiction between conversion and stability.
3Productivity
If traditional catalysts are used for dehydrogenation, then initial activity is achieved, but activity decays rapidly over time
Solution Approach 1:
The patent adjusts the catalyst's chemical composition by adding auxiliary elements that enhance long-term stability. These parameter modifications prevent rapid activity decay by improving resistance to coke deposition and maintaining active sites over extended operation periods, achieving both high initial activity and sustained performance.
Solution Approach 2:
The patent utilizes mesoporous carbon as a support material with controlled pore structure. The porous architecture provides high surface area for catalyst dispersion, facilitates mass transport, and enhances stability against deactivation. This porous structure allows the catalyst to maintain activity over long periods while achieving high initial dehydrogenation rates.
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 mesoporous carbon-supported copper-based catalyst achieves high isobutane conversion (up to 75%) and isobutene selectivity (up to 98%) with stable activity, reducing production costs and energy consumption, and exhibits improved high-temperature resistance.
Implementation Method 1
A mesoporous carbon-supported copper-based catalyst with auxiliary elements like SnO2, Li2O, or K2O is developed, which improves isobutane conversion and selectivity to isobutene
Implementation Method 2
The mesoporous carbon-supported copper-based catalyst... exhibits improved high-temperature resistance
Data Source
AI summary
This invention relates to a mesoporous carbon supported copper based catalyst comprising mesoporous carbon, a copper component and an auxiliary element supported on said mesoporous carbon, production and use thereof. The catalyst is cheap in cost, friendly to the environment, and satisfactory in high temperature resistance to sintering, with a highly improved and a relatively stable catalytic activity.