Modified *BEA Zeolite Catalyst for Xylene Isomerization
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Solution Overview
Problem
Despite advances in xylene isomerization processes and catalysts, the industry seeks improved catalyst materials with enhanced isomerization rates for efficiently converting mixed xylenes into specific xylene components like para-xylene, ortho-xylene, and meta-xylene.
Innovation Solution
A xylene isomerization catalyst comprising post-framework modified *BEA zeolite material, where a portion of aluminum atoms in the zeolite framework is substituted with zirconium, hafnium, or titanium atoms, offering high isomerization activity and specific properties such as crystal lattice constants, surface area, and molar ratios, used in combination with other zeolite materials and inorganic oxides to enhance the production of preferred xylene isomers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional acidic catalyst systems are used for xylene isomerization, then the process is well-established and reliable, but the isomerization rate and productivity are insufficient to meet growing market demand
Solution Approach 1:
The patent modifies the catalyst's chemical composition parameters by substituting framework aluminum atoms with titanium, zirconium, and/or hafnium atoms. This changes the catalyst's acid strength and pore structure properties, thereby increasing the isomerization rate while maintaining reliable performance through controlled substitution levels (0.1-10 wt% metal content)
Solution Approach 2:
The patent creates a composite zeolite material combining multiple elements (aluminum, silicon, titanium, zirconium, and/or hafnium) within the zeolite framework. This composite structure integrates the benefits of conventional zeolite stability with enhanced isomerization activity from the metal substitutions, achieving both improved productivity and maintained reliability
2Productivity
If the demand for para-xylene continues to grow, then production capacity must be expanded, but existing catalyst materials reach their performance limits
Solution Approach 1:
The patent incorporates metal atoms (titanium, zirconium, and/or hafnium) into the zeolite framework during the catalyst synthesis stage rather than as a post-processing step. This preliminary incorporation ensures uniform distribution and stable integration, simplifying the overall manufacturing process while achieving enhanced production capacity
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 achieves effective isomerization of alkylated aromatics, particularly increasing the production of para-xylene from ortho- and meta-isomers, with improved isomerization rates and efficiency in xylene isomerization processes, addressing the need for enhanced catalyst performance.
Implementation Method 1
Ortho-xylene and meta-xylene are catalytically isomerized over an acidic catalyst, including zeolitic catalysts, to form para-xylenes. The xylene isomerization unit reestablishes an equilibrium distribution of xylene isomers by producing para-xylene from ortho- and meta-isomers.
Data Source
AI summary
The present invention relates to a catalyst for isomerization of alkylated aromatics such as mixed xylenes, using xylene isomerization catalyst particles including post-framework modified *BEA zeolite in which zirconium atoms and/or hafnium atoms, optionally in combination with titanium atoms, form a part of a framework of a beta-type zeolite.