Olefins Production Catalyst Additive for Sustained Combustion Activity
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Solution Overview
Problem
The combustion activity of catalysts in fluidized catalytic dehydrogenation (FCDh) processes decreases faster than dehydrogenation activity, necessitating excessive fresh catalyst addition, thereby increasing economic costs.
Innovation Solution
A catalyst system combined with a combustion additive, containing platinum and optionally gallium, is used to maintain sufficient combustion activity in the catalyst-processing portion without significant cost increase, by introducing the additive when combustion gases exceed a certain flammability limit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If catalyst is relied upon to provide combustion activity in the catalyst-processing portion, then combustion activity is maintained, but fresh catalyst must be added at a rate greater than necessary to maintain dehydrogenation activity, greatly increasing economic cost
Solution Approach 1:
A combustion additive is introduced as an intermediary substance that specifically enhances combustion activity in the catalyst-processing portion. The additive contains platinum and optionally gallium, which act as combustion promoters without interfering with dehydrogenation activity. This mediator allows the system to maintain combustion activity while using less fresh catalyst overall.
Solution Approach 2:
The combustion additive is applied locally to the catalyst in the catalyst-processing portion where combustion activity is needed, rather than uniformly across all catalyst functions. This localized enhancement ensures that combustion activity is maintained specifically where required without unnecessarily increasing catalyst quantity or cost throughout the entire system.
2Quantity of substance
If combustion additive is introduced to maintain combustion activity, then fresh catalyst addition is reduced, but additive must be introduced at specific conditions (when hydrocarbons exceed 5% of LFL)
Solution Approach 1:
The system incorporates feedback control by monitoring hydrocarbon concentrations in the combustion gas and only introducing the combustion additive when hydrocarbons exceed 5% of the lower flammability limit (LFL). This feedback mechanism ensures additive introduction is timed optimally to maintain combustion activity while avoiding unnecessary additive addition, thereby reducing overall costs and simplifying operational decision-making.
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 sustains combustion activity efficiently, reducing the need for excessive fresh catalyst addition and maintaining economic viability.
Implementation Method 1
contacting a hydrocarbon-containing feed with a catalyst in a reactor portion of a reactor system to form an olefin-containing effluent
Implementation Method 2
introducing a combustion additive to the reactor system when the combustion gas comprises one or more hydrocarbons in an amount greater than 5 percent (%) of a lower flammability limit (LFL) of the combustion gas
Data Source
AI summary
According to one or more embodiments of the present disclosure, a method for producing olefins includes contacting a hydrocarbon-containing feed with a catalyst in a reactor portion of a reactor system to form an olefin-containing effluent, separating at least a portion of the olefin-containing effluent from the catalyst, passing the catalyst to a catalyst-processing portion of the reactor system and processing the catalyst to produce a processed catalyst and a combustion gas, passing the processed catalyst from the catalyst-processing portion to the reactor portion, and introducing a combustion additive to the reactor system when the combustion gas comprises one or more hydrocarbons in an amount greater than 5% of an LFL of the combustion gas at a temperature and pressure of the catalyst processing portion. The catalyst may include from 1 ppmw to 150 ppmw platinum. The combustion additive may include from 150 ppmw to 1,000 ppmw platinum.