Mixed Metal Oxide Catalyst Termination for Alkane Dehydrogenation
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Solution Overview
Problem
Existing alkane oxidative dehydrogenation (ODH) and alkene oxidation processes using mixed metal oxide catalysts face challenges in maintaining catalyst activity and selectivity over subsequent reaction steps, often requiring temperature reduction and extended downtime for reactor cooling.
Innovation Solution
A process involving a mixed metal oxide catalyst with molybdenum, vanadium, niobium, and optionally tellurium, where the reaction is terminated by contacting the catalyst with a gas stream containing methane, an inert gas, or oxygen, maintaining or increasing catalyst activity and selectivity without the need for temperature reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the alkane ODH and/or alkene oxidation process is terminated by conventional methods, then the reaction is stopped, but the catalyst activity and selectivity deteriorate in subsequent processes requiring temperature reduction and extended cooling time
Solution Approach 1:
The patent applies preliminary action by introducing a specific gas stream composition (0-25 vol% alkane/alkene in methane, inert gas, or oxygen) before the catalyst deactivation becomes irreversible. This pre-emptive measure maintains the catalyst in an active state by preventing complete oxidation or sintering, thereby preserving catalyst performance for subsequent reactions without requiring extended cooling periods
Solution Approach 2:
The patent utilizes parameter changes by precisely controlling the composition of the termination gas stream, specifically maintaining alkane/alkene concentrations at 0-25 vol% rather than higher concentrations that would cause catalyst deactivation. This parameter optimization allows the catalyst to be terminated in a way that preserves its active sites and selectivity, eliminating the need for prolonged cooling and preparation time
2Productivity
If the temperature is reduced to terminate the reaction, then the reaction stops, but the productivity decreases due to extended cooling time before the next reaction step
Solution Approach 1:
The patent implements continuity of useful action by designing a termination process that maintains catalyst readiness for immediate reuse. The specific gas stream composition (0-25 vol% alkane/alkene in methane, inert gas, or oxygen) prevents catalyst deactivation, allowing the reactor to transition quickly between reaction cycles without extended cooling periods, thereby maintaining continuous productive operation
3Ease of operation
If the catalyst is used in subsequent processes without proper termination, then the process is simplified, but the catalyst activity and selectivity are not maintained
Solution Approach 1:
The patent applies self-service by designing a termination gas stream that inherently protects the catalyst without requiring additional protective measures or complex procedures. The gas composition (0-25 vol% alkane/alkene in methane, inert gas, or oxygen) automatically maintains catalyst activity and selectivity during termination, making the process both simple to operate and effective in preserving catalyst performance
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 method allows for quick termination of the alkane ODH or alkene oxidation process, maintaining or enhancing catalyst performance in subsequent steps without cooling the reactor, thus reducing downtime and maintaining or increasing activity and selectivity.
Implementation Method 1
Mixed metal oxide catalysts containing molybdenum (Mo), vanadium (V), niobium (Nb) and optionally tellurium (Te) as the metals, can be used as such oxydehydrogenation catalysts. Such catalysts may also be used in the direct oxidation of alkenes to carboxylic acids
Implementation Method 2
contacting a second gas stream comprising methane, an inert gas or oxygen or any combination of two or more of these with the catalyst, wherein the second gas stream comprises 0 to 25 vol. % of the alkane containing 2 to 6 carbon atoms and/or alkene containing 2 to 6 carbon atoms
Data Source
AI summary
The invention relates to a process of the oxidative dehydrogenation of an alkane containing 2 to 6 carbon atoms and/or the oxidation of an alkene containing 2 to 6 carbon atoms, comprising contacting a first gas stream comprising oxygen and the alkane containing 2 to 6 carbon atoms and/or the alkene containing 2 to 6 carbon atoms with a mixed metal oxide catalyst containing molybdenum, vanadium, niobium and optionally tellurium; followed by contacting a second gas stream comprising methane, an inert gas or oxygen or any combination of two or more of these with the catalyst, wherein the second gas stream comprises 0 to 25 vol. % of the alkane containing 2 to 6 carbon atoms and/or alkene containing 2 to 6 carbon atoms.