Nickel Single Atom Catalyst for Olefin Oligomerization

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Solution Overview

Problem

Conventional nickel-based oligomerization catalysts face deactivation issues due to acidic properties, leading to inefficient conversion and selectivity in oligomerizing light olefins, particularly C4 olefins, which are used in producing transportation fuels like aviation fuel and diesel oil.

Innovation Solution

A nickel-based catalyst is developed where nickel is supported as a single atom on an Al-mesoporous silicate with a controlled Si/Al atomic ratio, reducing acid sites and deactivation, achieved through ion exchange of Na-type Al-mesoporous silicate with nickel ions, allowing for improved long-term activity and separation efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional nickel-based catalysts with acidic properties are used, then oligomerization activity is initially high, but catalyst deactivation occurs rapidly

Engineering Contradiction:

Improveoligomerization activityVSAvoidcatalyst stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The harmful acidic properties are extracted and removed from the catalyst system by replacing conventional acidic supports with basic Al-mesoporous silicate supports, thereby eliminating the deactivation mechanism while preserving oligomerization activity

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The chemical nature of the support is changed from acidic to basic by using Al-mesoporous silicate with controlled Si/Al ratio, which fundamentally alters the interaction between nickel species and the support, preventing deactivation while maintaining catalytic activity

Inventive Principle:

Principle #35Parameter changes

2Productivity

If homogeneous catalysts are used, then oligomerization conversion is high, but separation and recycling become complicated

Engineering Contradiction:

Improveoligomerization conversionVSAvoidseparation process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

A solid Al-mesoporous silicate support acts as an intermediary carrier for nickel single atoms, enabling the catalyst to function as a heterogeneous system that maintains high conversion while allowing easy separation through filtration or decantation

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The catalyst is transformed from a homogeneous molecular complex to a heterogeneous solid-supported system, replacing the need for complex separation processes with simple physical separation methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If solid acid catalysts are used, then oligomerization of light olefins is effective, but environmental pollution and regeneration difficulties occur

Engineering Contradiction:

Improveoligomerization efficiencyVSAvoidenvironmental pollution

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

Instead of using conventional acidic catalysts, the invention inverts the approach by using a basic support material, thereby achieving the desired oligomerization reaction without the harmful environmental side effects associated with acid catalysts

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The basic properties of Al-mesoporous silicate, which might seem contrary to conventional catalyst design, are converted into a benefit by preventing catalyst deactivation and eliminating the need for regeneration, thereby reducing environmental impact

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Manufacturing precision

If nickel is supported on conventional supports, then dispersibility is achieved at low loading, but catalyst deactivation is inevitable due to acidic properties

Engineering Contradiction:

Improvenickel dispersibilityVSAvoidcatalyst stability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The support's chemical properties are changed from acidic to basic, which alters the interaction mechanism with nickel species, allowing high dispersibility at low loading while simultaneously preventing deactivation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

A composite catalyst system is created by combining nickel single atoms with Al-mesoporous silicate support, where the basic support material complements the nickel active sites to achieve both high dispersibility and long-term stability

Inventive Principle:

Principle #40Composite materials

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 effectively suppresses deactivation, enhances oligomerization activity, and improves yield and selectivity for C8+ olefins, such as C12 olefins, making it suitable for producing high-quality transportation fuels with reduced catalyst separation inefficiencies.

Implementation Method 1

ion exchanging the Na+ ions bound to the acid sites of the Na-type Al-mesoporous silicate with nickel ions

Methodology Applied

Scientific EffectIon exchange: Ion Exchange

Data Source

PatentUS20240326027A1Nickel-Based Oligomerization Catalysts and Method for Oligomerizing Light Olefins Using the Same

Publication Date: 2024.10.03 SK INNOVATION CO LTD

AI summary

In the present disclosure, a heterogeneous nickel-based oligomerization catalyst in which nickel in the form of single atom is loaded on an Al-mesoporous silicate support by ion exchange and a method for producing the same, and a method for oligomerizing light olefins, specifically C4 olefins using the catalyst are described.