Mo-TiO2 Catalyst for Ethane Dehydrogenation

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Solution Overview

Problem

Current methods for ethylene production from ethane, such as steam cracking and oxidative dehydrogenation, face challenges with low atom efficiency, high costs due to pure oxygen use, and catalyst deactivation, limiting their commercial viability.

Innovation Solution

A Mo-supported nanocrystalline TiO2 catalyst is developed for vapor phase dehydrogenation/oxidative dehydrogenation of ethane to ethylene, synthesized through a specific process involving titanium isopropoxide, MoCl3, and cetyltrimethylammonium bromide, allowing for high conversion and selectivity without deactivation over extended periods at atmospheric pressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If steam cracking is used to produce ethylene from ethane, then ethylene can be produced, but the process requires high energy input and achieves limited conversion (up to 60%) with maximum 80% selectivity

Engineering Contradiction:

Improveethylene production efficiencyVSAvoidenergy input for cracking

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent changes the reaction parameters by introducing oxidative dehydrogenation conditions with controlled oxygen partial pressure and using a specific catalyst system (MoS2 supported on nanocrystalline TiO2 with CeO2 promotion) to achieve high ethylene yield at lower temperatures compared to conventional steam cracking

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces an intermediary oxidizing environment that facilitates dehydrogenation while preventing excessive cracking. The controlled presence of oxygen acts as an intermediary that enables the reaction to proceed with better energy efficiency and selectivity

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If pure oxygen is used in oxidative dehydrogenation to achieve high conversion and selectivity, then ethylene production improves, but the process cost increases due to the need for gas separation towers

Engineering Contradiction:

Improveethylene conversion and selectivityVSAvoidprocess cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent applies partial oxidation by controlling the oxygen partial pressure to be sub-stoichiometric. This partial action of oxygen is sufficient to achieve high ethylene selectivity and conversion without requiring pure oxygen, thereby avoiding the need for costly gas separation towers while maintaining atom efficiency

Inventive Principle:

Principle #16Partial or excessive action

3Productivity

If conventional catalysts are used in oxidative dehydrogenation, then the reaction can proceed, but the catalyst deactivates rapidly due to metal leaching and poor stability

Engineering Contradiction:

Improvereaction activityVSAvoidcatalyst stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent employs a composite catalyst system where MoS2 is supported on nanocrystalline TiO2 and promoted with CeO2. This composite structure provides multiple benefits: the TiO2 support prevents metal leaching, CeO2 promotes redox cycles and stabilizes the active sites, and the nanocrystalline structure provides high surface area. Together, these composite materials achieve both high activity and long-term stability

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent uses nanocrystalline TiO2 with controlled porosity and surface area to provide a stable support structure for MoS2. The porous nanocrystalline structure allows for high dispersion of active sites while providing mechanical stability and resistance to deactivation over extended reaction periods

Inventive Principle:

Principle #31Porous materials

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 process achieves high ethane conversion (65-96%) and ethylene selectivity (88-100%) over 3-20 hours at 550-850°C, maintaining catalyst activity without deactivation, reducing production costs and by-product formation.

Implementation Method 1

A Mo-supported nanocrystalline TiO2 catalyst is developed for vapor phase dehydrogenation/oxidative dehydrogenation of ethane to ethylene

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

An improved process for the preparation of Mo supported nanocrystalline TiO2; the catalyst can effectively produce ethylene without any deactivation in a longer run

Methodology Applied

Scientific EffectHydrothermal synthesis:

Data Source

PatentUS9908101B2Catalyst for selective dehydrogenation / oxidative dehydrogenation reactions and process for the preparation thereof

Publication Date: 2018.03.06 COUNCIL OF SCI & IND RES

AI summary

The present invention provides a process and catalyst for the direct and selective conversion of ethane to ethylene. The process provides a direct single step vapor phase selective dehydrogenation/oxidative dehydrogenation of ethane to ethylene over Mo supported nanocrystalline TiO2. The process provides ethane conversion of 65-96% and selectivity of ethylene up to 100%. The process may be conducted in the presence or absence of oxygen.