ODH Process Mitigating CO2 and Acetylene via Mixed Metal Oxide Catalyst

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Oxidative dehydrogenation (ODH) processes face challenges such as lower conversion rates, selectivity issues, and the risk of thermal explosions due to the mixing of hydrocarbons with oxygen, which have limited their widespread commercial implementation, and they also produce carbon dioxide and acetic acid as by-products, requiring costly carbon dioxide management.

Innovation Solution

The introduction of a gas mixture of lower alkanes, oxygen, and carbon dioxide into ODH reactors, with the use of mixed metal oxide catalysts and heat dissipative particles, allows for controlled production of alkenes while mitigating carbon monoxide and acetylene formation, and adjusting steam levels to manage carbon dioxide output, thereby optimizing reaction conditions and reducing carbon dioxide production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If ODH process uses mixed metal oxide catalysts with oxygen and lower alkanes, then alkene production efficiency is improved, but carbon dioxide and acetic acid by-products are generated

Engineering Contradiction:

Improvealkene production efficiencyVSAvoidcarbon dioxide by-product

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful carbon dioxide by-product into a useful component by introducing it as a reactant. The mixed metal oxide catalyst facilitates the reaction where CO2 acts as an oxygen source for dehydrogenation, transforming the waste product into a beneficial reactant that improves alkene production while reducing net CO2 emissions

Inventive Principle:

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

Solution Approach 2:

The patent changes the chemical parameters of the reaction system by introducing carbon dioxide as a reactant rather than treating it solely as a by-product. This parameter change alters the reaction pathway, allowing CO2 to participate in the oxidative dehydrogenation process and reducing the formation of harmful by-products like acetic acid

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If ODH process mixes hydrocarbons with oxygen to achieve dehydrogenation, then alkene selectivity is improved, but risk of thermal explosion increases

Engineering Contradiction:

Improvealkene selectivityVSAvoidthermal explosion risk

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent introduces carbon dioxide as an intermediary substance that mediates between the hydrocarbon and oxygen. CO2 serves as a safer oxygen carrier compared to direct oxygen contact, reducing the thermal explosion risk while still enabling the oxidative dehydrogenation reaction to proceed with high alkene selectivity

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates a safer reaction environment by using carbon dioxide, which acts as an inert diluent that reduces the flammability of the hydrocarbon-oxygen mixture. This inert atmosphere approach maintains the necessary oxidation conditions for high selectivity while significantly reducing the risk of thermal explosions

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Productivity

If ODH process increases conversion rate, then productivity is improved, but selectivity to desired alkene decreases

Engineering Contradiction:

Improveconversion rateVSAvoidalkene selectivity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent changes the chemical parameters by introducing carbon dioxide as a reactant, which alters the reaction pathway and kinetics. This parameter change enables higher conversion rates while maintaining selectivity, as CO2 provides a controlled oxygen source that reduces over-oxidation to unwanted by-products like acetic acid

Inventive Principle:

Principle #35Parameter changes

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 approach enhances the selectivity and efficiency of ODH processes, reduces the risk of thermal explosions, and allows for carbon dioxide neutral or negative operations, minimizing the need for costly carbon dioxide flaring and improving the overall economic viability of ODH processes.

Implementation Method 1

In the presence of a catalyst and optionally an inert diluent

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

oxidative dehydrogenation (ODH) of lower alkanes into corresponding alkenes

Methodology Applied

Scientific EffectOxidation: Oxidation

Implementation Method 3

use of mixed metal oxide catalysts and heat dissipative particles

Methodology Applied

Scientific EffectHeat dissipation: Conduction (thermal)

Implementation Method 4

adjusting steam levels to manage carbon dioxide output

Methodology Applied

Scientific EffectDilution:

Data Source

PatentUS11447434B2Mitigating oxygen, carbon dioxide and/or acetylene output from an ODH process

Publication Date: 2022.09.20 NOVA CHEM (INT) SA

AI summary

A method of converting one or more alkanes to one or more alkenes that includes a) providing a first stream containing one or more alkanes and oxygen to an oxidative dehydrogenation reactor; b) converting at least a portion of the one or more alkanes to one or more alkenes in the oxidative dehydrogenation reactor to provide a second stream exiting the oxidative dehydrogenation reactor containing one or more alkanes, one or more alkenes, oxygen, carbon monoxide and optionally acetylene; and c) providing the second stream to a second reactor containing a catalyst that includes a group 11 metal to convert a least a portion of the carbon monoxide to carbon dioxide and reacting the acetylene.