Nitrogen-Containing Carbon Catalyst for 1,2-Dichloroethane Cracking
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Solution Overview
Problem
Current catalysts for cracking 1,2-dichloroethane to produce chloroethylene suffer from high energy consumption, short service life, and difficulty in regeneration, leading to increased production costs and environmental pollution.
Innovation Solution
A catalyst comprising a nitrogen-containing carbon material supported on an inorganic porous carrier, prepared through a carbonization-nitridation process, which can be regenerated by calcination to extend its life and reduce energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high temperature thermal cracking is used to crack 1,2-dichloroethane, then the cracking reaction can proceed, but energy consumption is high and coking occurs frequently
Solution Approach 1:
A catalyst comprising nitrogen-containing carbon material supported on an inorganic porous carrier is introduced as an intermediary substance to facilitate the cracking reaction. The catalyst provides active sites for the reaction, enabling it to proceed at lower temperatures (250-350°C) while maintaining high conversion rates, thus reducing energy consumption without sacrificing productivity
Solution Approach 2:
The invention changes the temperature parameter from high temperature (500-600°C) to moderate temperature (250-350°C) by introducing a catalyst. This parameter change is achieved through the nitrogen-containing carbon material which provides catalytic activity, allowing the reaction to proceed efficiently at lower temperatures and thereby reducing energy consumption
2Productivity
If high temperature thermal cracking is used to crack 1,2-dichloroethane, then the cracking reaction can proceed, but coking particles block the cracking furnace and separation equipment
Solution Approach 1:
The catalyst acts as an intermediary that provides an alternative reaction pathway with lower activation energy. The inorganic porous carrier and nitrogen-containing carbon material work together to facilitate the reaction at milder conditions, preventing the formation of coking particles that would otherwise block equipment
Solution Approach 2:
The invention converts the harmful high-temperature condition that causes coking into a beneficial low-temperature catalytic process. The nitrogen-containing carbon material, which could potentially coke itself, is supported on an inorganic carrier that prevents deactivation, thereby converting what would be a harmful effect into a sustainable catalytic process
3Use of energy by moving object
If nitrogen-containing carbon catalyst is used to crack 1,2-dichloroethane, then reaction temperature is reduced and selectivity is improved, but the catalyst loses activity quickly
Solution Approach 1:
The invention creates a composite catalyst system where nitrogen-containing carbon material is supported on an inorganic porous carrier. The inorganic carrier provides structural stability and resistance to degradation, while the nitrogen-containing carbon provides catalytic activity. This composite structure allows the catalyst to maintain low reaction temperatures over extended periods without rapid deactivation
Solution Approach 2:
The inorganic porous carrier provides a high surface area support structure with controlled porosity. This porous structure allows for better heat and mass transfer, prevents agglomeration of the nitrogen-containing carbon species, and maintains catalyst activity over time by preventing deactivation mechanisms that occur in non-porous supports
4Productivity
If existing nitrogen-containing carbon catalyst is used, then conversion rate is improved, but the catalyst is expensive and difficult to regenerate
Solution Approach 1:
The invention enables easy regeneration of the catalyst by discarding accumulated carbon deposits through calcination in an oxidizing atmosphere. The inorganic porous carrier withstands the calcination process, allowing the catalyst to be regenerated multiple times. This recovering process restores catalyst activity at low cost, making the overall process economically viable
Solution Approach 2:
The invention uses inexpensive inorganic porous materials (such as silica, alumina, or zeolites) as carriers instead of expensive noble metal supports. The nitrogen-containing carbon species are deposited on these cheap carriers, creating a low-cost catalyst that maintains high conversion rates while being easy to manufacture and regenerate
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 significantly reduces reaction temperature and energy consumption, enhances selectivity and conversion rates, and allows for cost-effective, long-term industrial application with catalyst reuse.
Implementation Method 1
The nitrogen-containing carbon material supported on the inorganic porous carrier acts as a catalyst for the cracking of 1,2-dichloroethane, reducing the reaction temperature to 250-350°C and improving the conversion rate to 93%
Implementation Method 2
supporting an organic matter on an inorganic porous carrier and then performing a carbonization-nitridation process by pyrolysis in an atmosphere containing the nitrogen-containing compound
Implementation Method 3
calcinating the deactivated catalyst in an oxidizing atmosphere to remove all the carbonaceous portions on the surface
Data Source
Figure 1
AI summary
A catalyst for preparing chloroethylene by cracking 1,2-dichloroethane and a preparation and regeneration method thereof are disclosed in the present application. A catalyst for preparing chloroethylene by cracking 1,2-dichloroethane comprises a carrier and a nitrogen-containing carbon as an active component of the catalyst with the nitrogen-containing carbon being loaded on the carrier. The method for preparing the catalyst comprises the following steps: supporting an organic matter on an inorganic porous carrier and then performing a carbonization-nitridation process by pyrolysis in an atmosphere containing the nitrogen-containing compound. The method for regenerating the catalyst comprises the following steps: calcinating the catalyst with deactivated carbon deposit in an oxidizing atmosphere to remove all the carbonaceous portions on the surface, and repeating the above preparation process of the catalyst. The catalyst could reduce the reaction temperature, greatly reduce energy consumption, reduce the production cost, and improve the selectivity and conversion rate and is inexpensive and reproducible, and has a long service life in comparison with the existing thermal cracking technology.