Modified Fluidized Dehydrogenation Catalysts for Light Olefin Yield
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Solution Overview
Problem
Conventional catalysts used for the dehydrogenation of alkanes in fluidized bed reactors suffer from reduced catalytic activity over time, affecting their ability to catalyze both alkane dehydrogenation and supplemental fuel combustion.
Innovation Solution
Modify partially deactivated catalysts by adding metals such as manganese, iron, chromium, or vanadium to restore catalytic activity for alkane dehydrogenation and supplemental fuel combustion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts are used for dehydrogenation of alkanes, then light olefin production is achieved, but catalytic activity decreases over time
Solution Approach 1:
The patent applies parameter changes by modifying the catalyst composition - specifically adding metals such as manganese, iron, chromium, or vanadium to the catalyst system. This chemical modification restores and enhances catalytic activity for both dehydrogenation and combustion functions, allowing the catalyst to maintain high productivity over extended periods without replacement
Solution Approach 2:
The patent employs composite materials by creating a modified catalyst that combines conventional catalyst components with additional metal elements (manganese, iron, chromium, or vanadium). This composite catalyst structure provides dual functionality - maintaining dehydrogenation activity for light olefin production while also enhancing combustion activity for heat generation - thereby resolving the contradiction between productivity and reliability
2Loss of substance
If catalyst is recycled to reduce waste, then material loss is reduced, but catalytic activity diminishes
Solution Approach 1:
The patent applies discarding and recovering by implementing a catalyst modification process that recovers and reuses deactivated catalysts. Instead of discarding spent catalysts, the process modifies them by adding active metals to restore their catalytic properties, thereby continuously reducing catalyst waste and maintaining high reliability performance
Solution Approach 2:
The modified catalyst system exhibits self-service characteristics by automatically regenerating its own activity through the combustion function. The catalyst can combust supplemental fuels and coke to generate heat, which helps maintain its catalytic properties and extend its operational life, reducing the need for external intervention or replacement
3Reliability
If catalyst modifies are added to restore activity, then dehydrogenation activity improves, but catalyst composition complexity increases
Solution Approach 1:
The patent applies parameter changes by systematically modifying the catalyst composition with specific metal elements (manganese, iron, chromium, or vanadium) in controlled amounts. This targeted chemical modification restores dehydrogenation activity while the modification process itself becomes a standardized procedure, managing complexity through systematic rather than random composition changes
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 modified catalysts enhance the dehydrogenation and combustion activities, allowing for the continued use of recycled catalysts, reducing waste and maintaining efficient light olefin production.
Implementation Method 1
light olefins may be formed by the catalytic dehydrogenation of alkanes in a fluidized bed reactor
Implementation Method 2
the catalyst is heated by exothermic combustion of at least a supplemental fuel
Implementation Method 3
the catalyst is heated by exothermic combustion of at least a supplemental fuel
Implementation Method 4
light olefins may be formed by the catalytic dehydrogenation of alkanes in a fluidized bed reactor
Data Source
AI summary
A method may include operating a dehydrogenation process whereby a hydrocarbon-containing feed is converted to light olefins, wherein the dehydrogenation process utilizes a fluidized process catalyst that circulates between a reactor and a combustor. The method may comprise withdrawing the process catalyst from the dehydrogenation process, modifying the process catalyst to form a modified catalyst, and adding the modified catalyst back to the dehydrogenation process. The process catalyst may include from 0.1 wt. % to 10 wt. % of one or more metals chosen from gallium, indium, thallium, or combinations thereof, from 1 ppmw to 1000 ppmw of one or more metals chosen from platinum, palladium, rhodium, iridium, ruthenium, osmium, or combinations thereof, and at least 85 wt. % support. Modifying the process catalyst may include adding one or more of manganese, iron, chromium, or vanadium.