Metallosilicate Catalyst for Acyclic C5 to Cyclopentadiene Conversion
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Solution Overview
Problem
The rising demand for cyclopentadiene, a crucial raw material in various chemical products, is not met due to supply limitations, particularly in steam cracking processes, which produce it as a minor byproduct, necessitating the optimization of catalyst formulations for efficient conversion of acyclic C5 feedstocks to cyclic C5 compounds.
Innovation Solution
A formulated catalyst composition comprising a microporous crystalline metallosilicate with a constraint index less than or equal to 12, a Group 10 metal, and optional metals from Groups 8, 9, or 11, along with an alkali or alkaline earth metal, and a binder like silica or titania, is used to convert acyclic C5 feedstocks to cyclic C5 compounds in fluidized or moving bed reactors, minimizing the use of clay and alumina to maintain catalyst integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If steam cracking is used to produce cyclopentadiene, then cyclopentadiene is obtained as a byproduct, but the production volume is limited and costs are high
Solution Approach 1:
The invention changes the chemical reaction parameters by using a specific catalyst system (metallosilicate with constraint index ≤12 combined with Group 10 metal) to transform the conversion process of C5 feedstock, shifting from steam cracking where CPD is a minor byproduct to a selective catalytic process where CPD becomes the primary product, thereby dramatically increasing production volume
Solution Approach 2:
The invention employs a composite catalyst formulation combining microporous crystalline metallosilicate (with specific framework types like MWW, MFI, LTL, MOR, BEA, TON, MTW, MTT, FER, MRE, MFS, MEL, DDR, EUO, or FAU) and Group 10 metal (Ni, Pd, or Pt), optionally with Group 11 metals (Cu, Ag, Au), creating a synergistic catalytic system that achieves high CPD selectivity and productivity
2Productivity
If conventional catalyst formulations are used for C5 conversion, then the process is simpler, but the yield and selectivity of cyclic C5 compounds are lower
Solution Approach 1:
The invention optimizes specific catalyst parameters including the constraint index of metallosilicate (≤12), the selection of microporous framework types, and the combination with Group 10 and Group 11 metals, transforming a simple catalyst into a highly selective catalytic system that achieves superior cyclic C5 compound yield and selectivity
Solution Approach 2:
The invention creates a composite catalyst system by combining microporous crystalline metallosilicate with Group 10 metal (Ni, Pd, Pt) and optionally Group 11 metals (Cu, Ag, Au), where the synergistic interaction between components enhances catalytic activity and selectivity for cyclic C5 compound production
3Reliability
If clay and alumina are used as binders in catalyst composition, then the catalyst structure is simpler, but the catalyst integrity and performance are compromised
Solution Approach 1:
The invention extracts and eliminates clay and alumina from the binder composition, replacing them with alternative binder materials that maintain or improve catalyst integrity and performance, thereby resolving the contradiction between structural simplicity and functional reliability
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
This approach significantly enhances the yield and selectivity of cyclic C5 compounds, such as cyclopentadiene, while reducing the production of light byproducts, thus addressing supply limitations and cost issues associated with traditional steam cracking methods.
Implementation Method 1
contacting a feedstock with a formulated catalyst composition under acyclic C5 conversion conditions effective to convert at least part of the acyclic C5 feedstock to produce an effluent comprising one or more cyclic C5 compounds
Data Source
AI summary
Disclosed is a process for the conversion of acyclic C5 feedstock to a product comprising cyclic C5 compounds, including cyclopentadiene, and formulated catalyst compositions for use in such process. The process comprises contacting the feedstock and, optionally, hydrogen under acyclic C5 conversion conditions in the presence of a catalyst composition to form the product. The catalyst composition comprises a microporous crystalline metallosilicate, a Group 10 metal or compound thereof, a binder, optionally, a metal selected from the group consisting of rare earth metals, metals of Groups 8, 9, or 11, mixtures or combinations thereof, or a compound thereof, in combination with a Group 1 alkali metal or a compound thereof and/or a Group 2 alkaline earth metal or a compound thereof.