Molten Salt Catalyst for Low-Temperature Hydrocarbon Cracking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for cracking carbon-containing feedstocks are energy-intensive and inefficient, requiring high temperatures and pressures, and struggle with processing waste plastics and bio-based materials due to the presence of heteroatoms and fillers, which limits the production of valuable olefinic and aromatic compounds.
Innovation Solution
A heterogeneous catalyst composition is developed, featuring a metal catalyst dispersed in a molten salt matrix of a eutectic mixture of alkali metal or alkaline earth metal carbonates or hydroxides, which allows for the cracking of carbon-containing feedstocks in the presence of an oxidant at lower temperatures and pressures, producing olefinic and aromatic compounds efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cracking methods are used to process carbon-containing feedstocks, then high temperatures and pressures are applied to break down the feedstock, but energy consumption increases and the process becomes inefficient
Solution Approach 1:
A molten salt catalyst serves as an intermediary substance that facilitates the cracking reaction between carbon-containing feedstocks and oxidants. The catalyst provides an alternative reaction pathway with lower activation energy, enabling the process to proceed at reduced temperatures and pressures while maintaining high cracking efficiency and productivity
Solution Approach 2:
The invention changes the physical and chemical parameters of the cracking process by introducing a molten salt catalyst that operates at lower temperatures and pressures compared to conventional methods. This parameter change reduces the energy input required while improving the overall cracking efficiency and product yield
2Productivity
If conventional cracking methods are used, then high temperatures are applied to achieve cracking, but the presence of heteroatoms and fillers in waste plastics and bio-based materials limits the production of valuable olefinic and aromatic compounds
Solution Approach 1:
The molten salt catalyst converts the harmful effect of heteroatoms and fillers into a benefit by providing a tolerant reaction environment that accommodates these impurities. Instead of being inhibited by heteroatoms and fillers as in conventional methods, the catalytic process utilizes the molten salt medium to facilitate reactions even in the presence of these contaminants, thereby improving the yield of olefinic and aromatic compounds from waste plastics and bio-based materials
Solution Approach 2:
The invention changes the chemical environment by introducing a molten salt catalyst system that operates under different chemical conditions compared to conventional cracking. This parameter change creates a reaction environment that is tolerant to heteroatoms and fillers, allowing the process to achieve high yields of valuable compounds even when processing contaminated feedstocks like waste plastics and bio-based materials
3Productivity
If a molten salt catalyst is used for oxycracking, then the process efficiency is improved, but the complexity of the catalyst composition increases
Solution Approach 1:
The molten salt catalyst system is designed to perform multiple functions simultaneously: it acts as a heat transfer medium, a reaction catalyst, and an impurity tolerance buffer. This multi-functionality allows the system to improve process efficiency across multiple parameters (reaction rate, product yield, impurity tolerance) while managing the complexity through a unified catalyst design that addresses several requirements at once
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 approach reduces energy consumption, tolerates acid impurities and fillers, and increases the yield of light olefins and aromatics, making it suitable for processing waste plastics and bio-based materials while maintaining thermal efficiency and product quality.
Implementation Method 1
a molten salt catalyst, and the present inventors have found that the molten salt catalyst can improve the process efficiency
Implementation Method 2
contacting in a reactor system a carbon-containing feedstock with at least one heterogeneous catalyst in the presence of an oxidant to generate olefinic and/or aromatic compounds
Implementation Method 3
the eutectic mixture is a mixture of alkali metal or alkaline earth metal carbonates or hydroxides having a melting point of less than about 750° C.
Implementation Method 4
a metal catalyst dispersed in a molten salt matrix comprising a eutectic mixture of alkali metal or alkaline earth metal carbonates or hydroxides
Data Source
AI summary
A catalyst composition includes a metal catalyst dispersed in a molten eutectic mixture of alkali metal or alkaline earth metal carbonates or hydroxides. A process for the catalytic cracking of hydrocarbons includes contacting in a reactor system a carbon-containing feedstock with at least one catalyst in the presence of oxygen to generate olefinic and/or aromatic compounds; and collecting the olefinic and/or aromatic compounds; wherein: the at least one catalyst includes a metal catalyst dispersed in a molten eutectic mixture of alkali metal or alkaline earth metal carbonates or hydroxides. A process for preparing the catalyst includes mixing metal catalyst precursors selected from transition metal compounds and rare-earth metal compounds and a eutectic mixture of alkali metal or alkaline earth metal carbonates or hydroxides and heating it. A use of the catalyst in the catalytic cracking process of hydrocarbons.