Nickel-Silver Zeolite Catalyst for Butene Conversion
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Solution Overview
Problem
Current catalysts for petrochemical conversion, particularly in hydrocracking processes, face inefficiencies in converting larger olefins to smaller olefins like propylene and ethylene due to side reactions and reduced catalyst lifespan, leading to lower yields and increased coke formation.
Innovation Solution
A catalyst composition is developed by embedding nickel and silver oxides within a zeolitic material framework, formed through a process involving a slurry of zeolite, silica, and metal precursors, which enhances the cracking capabilities and reduces side reactions, thereby improving the conversion of butenes to propylene and ethylene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts are used for hydrocracking, then the catalyst can perform basic cracking functions, but the conversion efficiency of butenes to propylene and ethylene is low with increased side reactions and coke formation
Solution Approach 1:
The patent combines multiple metal oxides (nickel, silver, and optionally other metals) with zeolite support to create a composite catalyst system. This composite structure allows synergistic effects where nickel provides hydrogenation activity, silver enhances cracking selectivity, and zeolite provides structural stability and shape-selective pores, collectively improving conversion efficiency while reducing harmful side reactions and coke formation
Solution Approach 2:
The catalyst design incorporates specific metal oxides at controlled concentrations (nickel: 0.1-5 wt%, silver: 0.1-5 wt%) within the zeolite structure to create localized active sites with optimized properties. The metal oxides are dispersed throughout the zeolite framework, creating regions with enhanced catalytic activity for specific reactions while maintaining overall structural integrity and selectivity
2Duration of action of stationary object
If conventional catalysts are used, then the catalyst structure is simpler, but the catalyst lifespan is reduced due to faster deactivation
Solution Approach 1:
The multi-component composite catalyst (metal oxides on zeolite support) provides enhanced stability and resistance to deactivation mechanisms such as coking and sintering. The zeolite framework protects the metal oxide active sites, while the metal oxides promote reactions that reduce coke precursors, creating a synergistic system that extends catalyst lifespan despite the increased compositional complexity
Solution Approach 2:
The catalyst design converts potential harmful effects into beneficial ones: nickel oxide promotes hydrogenation of coke precursors, silver oxide enhances cracking selectivity to reduce heavy coke-forming species, and the zeolite structure provides shape selectivity to favor lighter products. These mechanisms transform what would be deactivation pathways into self-cleaning or protective effects, extending catalyst life
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 composition significantly increases the yield of propylene and ethylene from butene streams by efficiently hydrogenating double bonds and reducing coke formation, leading to improved catalytic activity and extended catalyst lifespan.
Implementation Method 1
drying and calcining the extrudate to form a dried and calcined extrudate
Implementation Method 2
efficiently hydrogenating double bonds and reducing coke formation
Implementation Method 3
improve the cracking capabilities of the catalyst. For example, the presence of the oxides of nickel and the oxides of silver in the catalyst compositions may improve the conversion of butenes to one or more smaller olefin products
Data Source
AI summary
According to embodiments, a method of producing a catalyst composition may include forming a slurry including an initial zeolite material, a surfactant, silica, and metal precursors, wherein the metal precursors contain a nickel-containing compound and a silver-containing compound, extruding the slurry to produce an extrudate, drying and calcining the extrudate to form a dried and calcined extrudate, hydrothermally treating the dried and calcined extrudate to form a hydrothermally-treated extrudate, and drying and calcining the hydrothermally-treated extrudate to produce the catalyst composition, wherein the catalyst composition includes zeolite, one or more oxides of nickel, and one or more oxides of silver.