Mordenite Zeolite Catalyst for Heavy Aromatics Conversion
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Solution Overview
Problem
Current catalyst systems face challenges in efficiently converting heavy aromatics to lighter aromatic products, such as benzene and xylenes, particularly with C9+ aromatics, due to decoupling of dealkylation and transalkylation activities, leading to reduced aromatic ring loss and catalyst deactivation.
Innovation Solution
A single bed catalyst system comprising a medium pore first zeolite and a high activity meso-mordenite zeolite, combined with specific metals from Groups 10 and 11-15 of the IUPAC Periodic Table, enhances C9+ conversion and reduces aromatic ring loss, utilizing a catalyst composition with a mordenite zeolite synthesized from TEA or MTEA, and incorporating metals like platinum and copper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a stacked bed system with separate dealkylation and transalkylation catalysts is used, then dealkylation activity and transalkylation activity are improved, but device complexity increases
Solution Approach 1:
The patent combines dealkylation and transalkylation catalysts into a single blended catalyst system. The catalyst comprises a zeolite component (for transalkylation) and a metal component (for dealkylation) integrated in one catalyst bed, eliminating the need for separate stacked beds while maintaining both activities. This resolves the contradiction by merging multiple functions into a unified catalyst system.
2Device complexity
If conventional catalyst systems are used for C9+ aromatics conversion, then device complexity is maintained, but aromatic ring loss increases and catalyst deactivation occurs
Solution Approach 1:
The patent modifies catalyst parameters by incorporating specific metal components (such as Pt, Pd, Ni, Cu, Zn, Ga, In, or Sn) at controlled concentrations (0.01-5 wt%) into the zeolite structure. This changes the catalyst's chemical properties to reduce aromatic ring loss and prevent deactivation while maintaining structural simplicity. The metal-zeolite combination creates synergistic effects that improve reliability without increasing device complexity.
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 system effectively converts C8+ aromatic hydrocarbons to lighter aromatic products with improved efficiency and stability, maintaining high activity and minimizing ring loss, thereby optimizing the production of benzene, toluene, and xylenes.
Implementation Method 1
catalyst composition useful for converting heavy aromatics, specifically C8+ aromatics, to lighter aromatic products
Data Source
AI summary
Disclosed is a catalyst composition and its use in a process for the conversion of a feedstock containing C8+ aromatic hydrocarbons to produce light aromatic products, comprising benzene, toluene and xylene. The catalyst composition comprises a first zeolite having a constraint index of 3 to 12, a second zeolite comprising a mordenite zeolite synthesized from TEA or MTEA, at least one first metal of Group 10 of the IUPAC Periodic Table, and at least one second metal of Group 11 to 15 of the IUPAC Periodic Table, wherein said mordenite zeolite has a mesopore surface area of greater than 30 m2/g and said mordenite zeolite comprises agglomerates composed of primary crystallites, wherein said primary crystallites have an average primary crystal size as measured by TEM of less than 80 nm and an aspect ratio of less than 2.