Silicon-Aluminum Molecular Sieve Catalyst for Low-Temperature DCE Pyrolysis

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Solution Overview

Problem

Existing catalysts for the pyrolysis of 1,2-dichloroethane (DCE) to produce vinyl chloride (VC) suffer from high reaction temperatures, high energy consumption, and issues with coking and carbon deposition, limiting their industrial applicability.

Innovation Solution

A silicon-aluminum molecular sieve-based catalyst with specific silicon-aluminum ratios and optional metal ion modifications, combined with a matrix, is used for pyrolysis, along with a method of extrusion and roasting to enhance activity and selectivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If thermal pyrolysis is used at high temperature (500°C) to improve 1,2-DCE conversion rate, then conversion rate is improved, but energy consumption increases and coking/carbon deposition occurs

Engineering Contradiction:

Improve1,2-DCE conversion rateVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent changes the temperature parameter from 500°C to 260-350°C through catalyst introduction, fundamentally altering the reaction conditions to achieve both high conversion and low energy consumption

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

A silicon-aluminum molecular sieve catalyst acts as an intermediary substance to facilitate the pyrolysis reaction at lower temperatures, mediating between the reactant and product while reducing energy requirements

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If thermal pyrolysis at high temperature is used to improve conversion rate, then conversion rate is improved, but coking and carbon deposition occur requiring periodic shutdown

Engineering Contradiction:

Improve1,2-DCE conversion rateVSAvoidcontinuous operation capability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The temperature parameter is reduced from 500°C to 260-350°C, which fundamentally prevents coking and carbon deposition mechanisms that occur at higher temperatures, enabling continuous operation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the thermal pyrolysis mechanism with a catalytic pyrolysis mechanism, substituting heat-driven decomposition with catalyst-mediated decomposition that occurs at milder conditions

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Temperature

If existing catalysts are used to reduce pyrolysis temperature, then temperature is reduced, but catalyst activity is insufficient and life is short

Engineering Contradiction:

Improvepyrolysis temperatureVSAvoidcatalyst activity

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The patent employs a composite catalyst system consisting of silicon-aluminum molecular sieve with specific SiO2/Al2O3 ratio (2-10), combining the structural benefits of molecular sieve with optimized composition for enhanced activity and stability

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The catalyst structure is optimized with specific silicon-aluminum ratio to create local active sites with appropriate acidity and porosity, enhancing catalytic activity at the molecular level while maintaining overall structural stability

Inventive Principle:

Principle #3Local quality

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 high 1,2-DCE conversion rates of up to 95% and VCM selectivity of 98%, reducing pyrolysis temperatures from 450-500°C to 260-350°C, minimizing coking, and allowing for catalyst regeneration.

Implementation Method 1

a catalyst for pyrolysis of 1,2-dichloroethane (1,2-DCE) to prepare vinyl chloride monomer (VCM)... a catalyst for pyrolysis of 1,2-DCE to prepare VCM includes a silicon-aluminum molecular sieve... catalytic pyrolysis of 1,2-DCE to prepare VCM

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

thermal pyrolysis is adopted for the pyrolysis of 1,2-DCE to prepare VCM... pyrolysis of 1,2-DCE to prepare VCM... pyrolysis of 1,2-DCE to prepare VCM

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Data Source

PatentUS12502660B2Catalyst for pyrolysis of 1,2-dichloroethane (DCE) to prepare vinyl chloride (VC) and preparation method, use, and regeneration method thereof

Publication Date: 2025.12.23 DALIAN INSTITUTE OF CHEMICAL PHYSICS CHINESE ACADEMY OF SCIENCES

AI summary

A catalyst for pyrolysis of 1,2-dichloroethane (1,2-DCE) to prepare vinyl chloride monomer (VCM), a preparation method, a use, and a regeneration method thereof are provided. The catalyst for pyrolysis of 1,2-DCE to prepare VCM includes a silicon-aluminum molecular sieve. The catalyst for pyrolysis of 1,2-DCE to prepare VCM has high reaction activity and excellent selectivity and solves the problem that the pyrolysis of 1,2-DCE to prepare VCM in the prior art involves high reaction temperature and large energy consumption and is prone to coking and carbon deposition.