Upstream Metal Alkyl Treatment for Hydrogenation Catalyst Protection
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Solution Overview
Problem
Aromatic hydrocarbons in hydrogenation reactors are deactivated by catalyst deactivation compounds, leading to reduced productivity and equipment fouling due to solid particulates and undesirable product formation.
Innovation Solution
Introduce a sacrificial metal alkyl compound upstream of the hydrogenation reactor to react with catalyst deactivation compounds, converting them into nonreactive compounds before they enter the reactor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If catalyst deactivation compounds are present in the aromatic feed stream, then the hydrogenation catalyst reacts with these compounds to form solid particulates, but this deactivates the catalyst and reduces productivity
Solution Approach 1:
The patent introduces a sacrificial metal alkyl compound into the aromatic feed stream upstream of the hydrogenation reactor, where it preliminarily reacts with catalyst deactivation compounds to form nonreactive solid products. This preliminary action prevents the deactivation compounds from reaching and deactivating the hydrogenation catalyst, thereby maintaining catalyst activity and productivity.
Solution Approach 2:
The sacrificial metal alkyl compound acts as an intermediary substance that mediates between the catalyst deactivation compounds and the hydrogenation catalyst. It reacts with the deactivation compounds to form solid particulates that are filtered out, preventing direct contact between the deactivation compounds and the catalyst, thus preserving catalyst performance.
2Productivity
If catalyst deactivation compounds react with the hydrogenation catalyst, then solid particulates are formed that deposit on reactor walls, but this causes equipment fouling and requires maintenance
Solution Approach 1:
The patent converts the harmful catalyst deactivation compounds into beneficial nonreactive solid products by introducing the sacrificial metal alkyl compound. These solid products are inert and can be easily filtered out, transforming the harmful deactivation process into a controlled solid formation process that prevents catalyst poisoning and reduces equipment fouling.
Solution Approach 2:
The patent extracts and removes the harmful catalyst deactivation compounds from the feed stream by reacting them with the sacrificial metal alkyl compound to form filterable solid particulates. These solids are then removed from the system through filtration, preventing deposition on reactor walls and equipment surfaces.
3Reliability
If the sacrificial metal alkyl compound is introduced upstream of the reactor, then catalyst deactivation is prevented, but the system complexity increases
Solution Approach 1:
The sacrificial metal alkyl compound serves multiple functions: it reacts with catalyst deactivation compounds to form nonreactive solids, prevents catalyst poisoning, and the resulting solid products can be filtered out to protect the hydrogenation catalyst. This multi-functional approach protects the catalyst system without requiring multiple separate protection mechanisms.
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
Enhances hydrogenation catalyst productivity and reduces equipment fouling by preventing catalyst deactivation and solid deposits, extending reaction run length and minimizing catalyst usage.
Implementation Method 1
reacting the sacrificial metal alkyl compound with the catalyst deactivation compound in the stream or equipment to form a nonreactive solid product
Implementation Method 2
a liquid cooling loop operable to receive a portion of a liquid reaction medium including liquid phase reaction components and solid particulates and to cool the portion of the liquid reaction medium
Implementation Method 3
reacting the aromatic compound with hydrogen in a presence of a homogeneous hydrogenation catalyst to form a cycloalkane compound
Data Source
AI summary
Compounds that can deactivate or poison a hydrogenation catalyst are converted to nonreactive compounds that are not reactive with the Group 10 metal(s) of the hydrogenation catalyst. Addition of a sacrificial metal alkyl compound upstream of the hydrogenation reactor produces the nonreactive compounds, which can include nonreactive solid products. In some cases, the nonreactive solid products are removed upstream of the hydrogenation reactor, while in other cases, the nonreactive solid products flow to the hydrogenation reactor and are removed in a cooling loop of the hydrogenation reactor.