Olefin Production Catalyst with Metal Oxide Composition
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Solution Overview
Problem
Existing methods for converting saturated hydrocarbon compounds to olefin products are energy intensive and produce undesired by-products, such as methane and heavier hydrocarbons, with limited control over product selectivity and catalyst stability.
Innovation Solution
A hydrocarbon conversion process using a catalyst comprising specific metal oxides, including Si, Al, Pt, W, Sn, and K, operated at mild conditions to achieve high selectivity for olefin production, minimizing by-products like methane and heavier hydrocarbons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermal cracking is used to convert paraffin to olefins, then olefin production is achieved, but energy consumption is high and product selectivity is difficult to control
Solution Approach 1:
The patent changes the operating parameters by using catalytic cracking at lower temperatures (450-650°C) compared to thermal cracking, thereby reducing energy consumption while maintaining olefin production efficiency
Solution Approach 2:
The patent introduces a catalyst as an intermediary substance to facilitate the conversion of paraffin to olefins, enabling the reaction to proceed under milder conditions with better selectivity control
2Temperature
If catalytic cracking with zeolite catalyst is used, then operating conditions are milder, but by-products including methane and C5+ hydrocarbons are produced and catalyst stability is poor
Solution Approach 1:
The patent uses a composite catalyst system combining zeolite with metal oxides (such as Pt, Pd, Ni, Co, Mo, W) to achieve both mild operating conditions and high selectivity, reducing unwanted by-products while maintaining catalyst stability
Solution Approach 2:
The patent modifies specific local properties of the catalyst by incorporating metal oxides at controlled concentrations to enhance selectivity for desired olefin products while suppressing by-product formation
3Productivity
If carbon nanotube catalyst is used, then olefin yield is improved, but process requires high temperatures and steam addition making it energy intensive
Solution Approach 1:
The patent optimizes operating parameters by conducting catalytic cracking at moderate temperatures (450-650°C) without requiring steam addition, thereby achieving high olefin yield with reduced energy consumption
4Productivity
If conventional catalytic cracking is used, then conversion efficiency is improved, but product selectivity is difficult to adjust and control
Solution Approach 1:
The patent implements process control mechanisms that monitor and adjust operating conditions to optimize product selectivity, using the catalyst composition and reaction parameters as feedback elements to control the distribution of olefin products
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 process achieves high selectivity for olefin products, particularly ethylene and propylene, with reduced production of less valued by-products and improved catalyst stability, allowing for efficient conversion at lower temperatures.
Implementation Method 1
contacting a hydrocarbon feed stream with a catalyst in an oxidic form comprising metals M1, M2, M3 and M4
Data Source
AI summary
The present invention relates to a process for conversion of a hydrocarbon feed comprising saturated hydrocarbon compounds to olefin products comprising contacting a hydrocarbon feed stream with a catalyst in an oxidic form of the formula M1M2M3M4O comprising metals M1, M2, M3 and M4, wherein: M1 is selected from Si, Al, Zr, and mixtures thereof; M2 is selected from Pt, Cr, and mixtures thereof; M3 is selected from W, Mo, Re, and mixtures thereof; and M4 is selected from Sn, K, Y, Yb and mixtures thereof; wherein: mass fraction of M1 is in the range of 0.1 to 0.8; mass fraction of M2 is in the range of 0.001 to 0.2; mass fraction of M3 is in the range of 0.001 to 0.2; mass fraction of M4 is in the range of 0.0001 to 0.2; and mass fraction of oxygen is in the range of 0.1 to 0.8.