Monocyclic Aromatic Compound Manufacturing Process
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Solution Overview
Problem
Existing industrial processes for converting oxygen-containing organic molecules to monocyclic aromatic compounds, such as BTX, suffer from premature catalyst deactivation due to coke formation and are inefficient, leading to reduced yield and catalyst longevity.
Innovation Solution
A process involving an aluminosilicate catalyst that contacts oxygen-containing organic molecules and in situ-generated hydrogen gas, with CO2 introduced to react and form additional monocyclic aromatic compounds, and the use of a weakly-coordinating compound like carbon monoxide to inhibit coke formation, extending catalyst life and increasing yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high temperatures are used to convert oxygen-containing organic molecules to BTX compounds, then conversion efficiency is improved, but catalyst deactivation due to coke formation worsens
Solution Approach 1:
Carbon monoxide is introduced as an intermediary substance that coordinates with the most acidic sites of the catalyst, preventing coke precursors from binding to these sites. This mediator approach allows high-temperature conversion to proceed while protecting the catalyst from deactivation by coke formation.
Solution Approach 2:
The process converts the harmful effect of coke formation into a beneficial outcome by using carbon monoxide to preferentially coordinate with acidic sites, thereby preventing coke deposition. The carbon monoxide acts as a protective agent that transforms the potential harm of high-temperature operation into extended catalyst life.
2Productivity
If conventional processes convert oxygen-containing organic molecules to BTX, then product is formed, but yield is reduced due to inefficient use of oxygen-containing molecules
Solution Approach 1:
The process makes the oxygen-containing organic molecules serve multiple functions: they are converted to BTX compounds while simultaneously generating hydrogen in situ that reacts with CO2 to produce additional BTX. This multi-functionality increases overall yield by utilizing all carbon atoms from the feedstock more effectively.
Solution Approach 2:
The system is self-sufficient by generating its own hydrogen reactant through the conversion of oxygen-containing molecules. The hydrogen produced in situ during BTX formation automatically reacts with introduced CO2 to create additional aromatic compounds, eliminating the need for external hydrogen supply.
3Productivity
If CO2 is introduced to react with in situ-generated hydrogen, then additional monocyclic aromatic compounds are produced, but process complexity increases
Solution Approach 1:
The process merges two reactions into one integrated system: the dehydroaromatization of oxygen-containing molecules to BTX and hydrogen, combined with the hydrogenation of CO2 to additional BTX using the in situ-generated hydrogen. This combining of functions occurs within a single reactor using one catalyst, avoiding the need for separate reaction stages.
Solution Approach 2:
The system generates its own hydrogen reactant through the first reaction, which then automatically serves the second reaction. The hydrogen produced during BTX formation from oxygen-containing molecules is immediately utilized to convert CO2 into additional aromatic compounds, creating a self-sustaining dual-function process.
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 process enhances the yield of monocyclic aromatic compounds by converting CO2 with hydrogen gas and using carbon monoxide to coordinate with catalyst sites, reducing coking and prolonging catalyst lifespan, while being compatible with high-water feed streams and utilizing waste CO2 from various sources.
Implementation Method 1
contacting an aluminosilicate catalyst with an oxygen-containing organic molecule in a reactor to produce the monocyclic aromatic compound and in situ-generated hydrogen gas
Implementation Method 2
allowing the CO2 to react with the in situ-generated hydrogen gas to form carbon monoxide
Implementation Method 3
the carbon monoxide coordinating with the most acidic sites of the catalyst to inhibit formation of the coke precursors
Implementation Method 4
the weakly-coordinating compound is a compound that reduces the H—O bond frequency of the aluminosilicate catalyst by about 1 to 300 cm-1 as measured by FT-IR
Data Source
AI summary
A process for manufacturing a monocyclic aromatic compound is disclosed. The process comprises contacting an aluminosilicate catalyst with an oxygen-containing organic molecule in a reactor to produce the monocyclic aromatic compound and in situ-generated hydrogen gas, and introducing CO2 into the reactor and allowing the CO2 to react with the in situ-generated hydrogen gas to form additional monocyclic aromatic compound.