Binder-Free Catalyst System for Olefin Metathesis
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Solution Overview
Problem
Existing olefin metathesis processes face challenges with catalyst efficiency due to sintering of magnesium oxide at high temperatures, side reactions with hydrogen, and high energy requirements for adsorbent activation, as well as the need for an optimal catalyst binder to maintain mechanical strength and catalytic performance.
Innovation Solution
A catalyst system comprising a layered double hydroxide (LDH) in the first zone upstream of a metathesis catalyst in the second zone, utilizing transition metals like molybdenum, tungsten, or rhenium supported on inorganic materials, with zeolites and LDHs to enhance selectivity, yield, and stability, while avoiding the inefficiencies of magnesium oxide and binder-related issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If magnesium oxide is used to perform double bond isomerization of the olefin feed, then olefin conversion rate is improved, but catalyst performance drops significantly after regeneration due to sintering at high temperature
Solution Approach 1:
The patent removes magnesium oxide from the catalyst composition entirely, replacing it with a binder-free heterogeneous catalyst system. This extraction eliminates the sintering problem that causes performance degradation after regeneration, while maintaining high olefin conversion rates through the use of alternative catalyst formulations.
Solution Approach 2:
The patent changes the fundamental composition parameters of the catalyst by eliminating magnesium oxide and adopting a binder-free system. This parameter change resolves the contradiction by removing the source of sintering while preserving catalytic activity through alternative materials and structural configurations.
2Productivity
If hydrogen gas is allowed to co-exist to improve catalytic reactivity, then metathesis reaction efficiency is improved, but side reactions occur between hydrogen and olefin feed or product reducing product yield
Solution Approach 1:
The patent removes hydrogen gas from the reaction system, eliminating the source of side reactions that reduce product yield. The binder-free heterogeneous catalyst system achieves high catalytic reactivity without requiring hydrogen, thereby preventing unwanted hydrogenation side reactions while maintaining efficient metathesis conversion.
3Reliability
If adsorbent is activated at high temperature to remove impurities from the feed stream, then purification efficiency is improved, but high energy is required for activation
Solution Approach 1:
The patent removes the adsorbent activation step from the process by using a binder-free catalyst system that does not require high-temperature activation for impurity removal. This extraction of the activation step eliminates the associated high energy consumption while maintaining effective feed stream purification through the catalyst's inherent selectivity.
4Strength
If catalyst binder is added during catalyst shaping process to bind powder materials together, then mechanical strength and handling ease are improved, but catalyst efficiency is adversely affected
Solution Approach 1:
The patent removes the catalyst binder component from the catalyst formulation, creating a binder-free heterogeneous catalyst system. This extraction eliminates the negative impact of binders on catalytic efficiency while maintaining adequate mechanical strength through alternative structural configurations and shaping methods that do not require binder additives.
Solution Approach 2:
The patent employs composite material structures in the binder-free catalyst system, combining multiple functional components in a way that provides both mechanical integrity and high catalytic activity without requiring traditional binder materials. This composite approach resolves the contradiction between strength and efficiency.
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 configuration significantly improves propene yield, selectivity, and reaction stability by maintaining catalyst activity and mechanical strength, and allows for efficient regeneration of the catalyst system.
Implementation Method 1
magnesium oxide was used to perform double bond isomerization of the olefin feed, such as isomerization of 1-butene to 2-butene
Implementation Method 2
cross-metathesis of ethene and n-butene which is an economical mean for selectively producing highly demanded propene
Implementation Method 3
contacting a feed stream with an adsorbent which has been activated comprising at least 3% by weight of aluminum oxide to remove one or more impurities from the feed stream
Data Source
Figure 1~2
AI summary
An olefin metathesis process wherein the olefin feed stream is contacted with a catalyst system comprising: a) a first system zone substantially comprising a layered double hydroxide; and b) a second system zone comprising a metathesis catalyst.