Micro-Mesoporous Catalyst for Low-Temperature Oxidative Dehydrogenation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current commercial technologies for producing light olefins like ethylene and propylene face challenges due to catalyst deactivation at high temperatures in non-oxidative dehydrogenation and poor product selectivity in oxidative dehydrogenation, leading to inefficient and energy-intensive processes.
Innovation Solution
A heterogeneous catalyst composition comprising a metal catalyst chemically-interacted with a micro-mesoporous aluminosilicate support, which is prepared by heating a catalyst precursor mixture to 390° C. to 750° C., enabling oxidative dehydrogenation of hydrocarbons to produce olefinic compounds with improved activity and selectivity at lower temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If non-oxidative dehydrogenation is used to produce light olefins, then product selectivity is improved, but catalyst deactivates at high operating temperatures requiring frequent regeneration
Solution Approach 1:
The patent changes the operating temperature parameter from high temperature (>500°C) to low temperature (400-750°C) range, and introduces oxidative dehydrogenation with controlled oxygen concentration (0.1-10% O2) to enable continuous operation without catalyst deactivation while maintaining product selectivity
Solution Approach 2:
The patent introduces oxygen as an intermediary substance that mediates the dehydrogenation reaction by removing hydrogen as water, preventing catalyst deactivation and enabling continuous operation. The oxygen acts as a mediator that allows the reaction to proceed at lower temperatures without compromising selectivity
2Productivity
If oxidative dehydrogenation is used to remove coke deposits, then continuous operation is enabled, but poor product selectivity limits olefin yields
Solution Approach 1:
The patent optimizes oxygen concentration parameter to 0.1-10% O2 in the feedstock, which is sufficient to remove coke deposits and enable continuous operation but not high enough to cause excessive oxidation of the olefin product, thereby maintaining good selectivity
Solution Approach 2:
The patent applies partial oxidation by using controlled, limited amounts of oxygen (0.1-10%) that is sufficient for coke removal and hydrogen abstraction but insufficient for complete combustion or excessive olefin oxidation, achieving the right balance for continuous operation with good selectivity
3Productivity
If catalyst activity is increased to improve reaction rate, then productivity is improved, but catalyst deactivates faster at high temperatures
Solution Approach 1:
The patent changes the temperature parameter from high temperature (>500°C) to low temperature (400-750°C) operating range, which maintains high catalyst activity and reaction rate while preventing thermal deactivation and extending catalyst lifetime
4Productivity
If high temperature operation is used to improve reaction rate, then productivity is improved, but energy consumption increases
Solution Approach 1:
The patent changes the temperature parameter from high temperature (>500°C) to low temperature (400-750°C) range, which reduces energy consumption while maintaining acceptable reaction rates through the use of oxidative dehydrogenation and controlled oxygen concentration
Solution Approach 2:
The patent introduces oxygen as an intermediary that mediates the reaction, allowing hydrogen removal without requiring high temperatures. The oxygen facilitates the reaction at lower temperatures by providing an alternative pathway that reduces the energy barrier
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 superior activity over time and enhances olefin yield by operating at lower temperatures, reducing energy consumption and catalyst degradation.
Implementation Method 1
a heterogeneous catalyst composition comprising a metal catalyst chemically-interacted with a micro-mesoporous aluminosilicate support
Implementation Method 2
catalytic oxidative dehydrogenation of hydrocarbons to produce olefinic compounds
Implementation Method 3
heating the catalyst precursor mixture to a temperature of from 390° C. to 750° C. to form the heterogeneous catalyst composition
Data Source
AI summary
The present disclosure relates to a heterogeneous catalyst composition comprising a metal catalyst chemically interacted with a micro-mesoporous aluminosilicate support. A process for catalytic oxidative dehydrogenation of hydrocarbons may include contacting, in a reactor system, a hydrocarbon-containing feedstock with the heterogeneous catalyst composition to generate olefinic compounds. A process for preparing a heterogeneous catalyst composition may include combining a micro-mesoporous aluminosilicate support with a metal catalyst precursor to form a catalyst precursor mixture, and heating the catalyst precursor mixture to a temperature of about 390° C. to about 750° C. to form a heterogeneous catalyst composition.