Metal-Supported Catalyst Regeneration for Light Alkane Dehydrogenation
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Solution Overview
Problem
Current light alkane dehydrogenation processes face challenges such as rapid coke deposition, catalyst deactivation, environmental pollution from chromium compounds, and high catalyst costs, while single-atom catalysts suffer from complex preparation and regeneration difficulties.
Innovation Solution
A method involving treatment of metal-supported catalysts with ammonia or nitrogen-containing organic compounds to form a CN layer, improving catalyst stability and activity, and a regeneration process to remove deactivating substances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If Cr-base catalyst with alumina support is used for dehydrogenation, then catalyst cost is reduced and alkane conversion is increased, but catalyst lifetime is shortened due to rapid coke deposition and frequent regeneration is required
Solution Approach 1:
The patent changes the chemical composition parameters of the catalyst by introducing specific promoters (Fe, Co, Ni, Cu, Mn, Zn, Al) in controlled amounts alongside the Cr base catalyst. This parameter modification optimizes the balance between catalytic activity for alkane conversion and resistance to coke deposition, extending catalyst lifetime while maintaining high productivity.
Solution Approach 2:
The patent creates a composite catalyst system combining Cr base catalyst with multiple metal promoters (Fe, Co, Ni, Cu, Mn, Zn, Al) and alumina support. This composite structure synergistically improves both alkane conversion capability and coke resistance, resolving the contradiction between high productivity and long catalyst lifetime.
2Ease of manufacture
If Cr-base catalyst is used for dehydrogenation, then catalyst cost is reduced, but environmental pollution increases due to chromium toxicity
Solution Approach 1:
The patent modifies the catalyst composition by adjusting Cr content and introducing alternative metal promoters (Fe, Co, Ni, Cu, Mn, Zn, Al) that can partially or fully compensate for Cr functionality. This parameter change reduces Cr toxicity while maintaining catalytic performance, lowering environmental pollution risk without significantly increasing cost.
Solution Approach 2:
The patent replaces expensive and toxic Cr base catalyst with cheaper, less toxic alternative metal catalysts (Fe, Co, Ni, Cu, Mn, Zn, Al) that can achieve similar or better performance. This substitution eliminates chromium pollution while maintaining cost-effectiveness.
3Productivity
If single-atom catalyst is used for dehydrogenation, then atomic utilization rate is increased and cost is reduced, but preparation process becomes complex and regeneration becomes difficult
Solution Approach 1:
The patent optimizes the metal content parameters and promoter ratios in the catalyst formulation to achieve high atomic utilization similar to single-atom catalysts, while using conventional preparation methods. This parameter optimization maintains high productivity without the complexity of single-atom synthesis procedures.
Solution Approach 2:
The patent introduces specific promoter metals (Fe, Co, Ni, Cu, Mn, Zn, Al) as intermediaries that facilitate the formation of highly active catalytic sites with high atomic utilization. These promoters act as mediators between the base metal and the catalytic function, achieving single-atom-like efficiency through conventional preparation methods.
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 method enhances catalyst conversion and selectivity, simplifies preparation, and ensures long-term stability, making it suitable for industrial applications.
Implementation Method 1
The catalytic dehydrogenation of Catofin process is carried out in fixed bed reactor
Implementation Method 2
treating metal supported catalyst with ammonia or nitrogen-containing organic, the metal supported catalyst is a Ma-Mb-Mc metal supported catalyst
Data Source
AI summary
The present invention relates to a method for preparing, activating and regenerating a metal supported catalyst, comprising: treating a Ma-Mb-Mc metal supported catalyst at 10-700° C. by using an ammonia or nitrogen-containing organic matter, wherein the Ma metal is an active metal selected from one or more of a noble metal atom or a transition metal, the support is a common industrial porous catalyst, and the Ma metal is dispersed on the support in a state of single atomic site. According to the Ma-Mb-Mc metal supported noble metal/zinc catalyst treated by the method of the present invention, the direct dehydrogenation conversion rate and selectivity of catalyzing light alkanes are remarkably improved; the method for preparing the catalyst is simple in process, the catalytic activity after regeneration is still kept, and the catalyst can be industrially produced on a large scale.