Hydrocarbon Soluble Organometallic Catalyst Synthesis at Low Temperature
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Solution Overview
Problem
Existing methods for synthesizing organometallic catalysts for hydrocracking heavy oils require high temperatures, leading to energy-intensive and costly processes, making them unsuitable for large-scale, economically viable operations.
Innovation Solution
A process for synthesizing hydrocarbon soluble transition metal catalysts at lower temperatures (40°C) using a mixture of transition metal salts, carboxylate salts, water, and organic solvents, specifically employing iron salts with 2-ethyl hexyl carboxylate and tridecanoate, to produce catalysts suitable for hydrocracking heavy oils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional high-temperature synthesis methods are used to prepare organometallic catalysts, then the catalysts can be effectively produced, but the energy consumption increases significantly making the process costly and unsuitable for large-scale operations
Solution Approach 1:
The patent changes the temperature parameter from conventional high temperatures (typically >100°C) to room temperature (20-25°C), dramatically reducing energy consumption while maintaining catalyst synthesis effectiveness. This parameter change resolves the contradiction between catalyst reliability and energy consumption by finding an optimal temperature point that satisfies both requirements.
Solution Approach 2:
The patent introduces organic solvents (such as toluene, xylene, or dichloromethane) as intermediaries to facilitate the metathesis reaction between metal salts and carboxylic acid salts at room temperature. These solvents act as mediators that enable the reaction to proceed effectively without requiring high thermal energy input, thus resolving the energy consumption issue while maintaining catalyst quality.
2Reliability
If high-temperature synthesis is employed to ensure catalyst quality, then the catalysts are effective for hydrocracking, but the process cost increases due to energy requirements
Solution Approach 1:
The patent changes the synthesis temperature parameter to room temperature, which directly reduces energy costs and makes the manufacturing process more economical. This parameter modification maintains catalyst quality through optimized solvent selection and reaction conditions, thereby resolving the contradiction between catalyst quality and manufacturing cost.
Solution Approach 2:
The patent uses readily available, inexpensive organic solvents and common metal salts (such as iron(III) nitrate, cobalt(II) nitrate, nickel(II) nitrate) as reactants. These cheap, easily obtainable materials reduce raw material costs and simplify the manufacturing process, making large-scale catalyst production economically viable while maintaining effective catalyst quality.
3Productivity
If conventional synthesis methods are used, then catalysts can be produced, but the process is energy-intensive and not economically viable for large-scale operations
Solution Approach 1:
The patent changes the temperature parameter to room temperature, which reduces energy intensity and enables scalable production. The optimized room-temperature protocol with appropriate solvents ensures high-yield catalyst synthesis that can be easily scaled up for large-scale operations without proportionally increasing energy consumption, thus resolving the contradiction between productivity and energy intensity.
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 yields of catalysts at reduced energy consumption, enabling their use in large-scale hydrocracking operations while maintaining their solubility and effectiveness in converting heavy oils into lighter fractions.
Implementation Method 1
The process involves reacting a transition metal salt of Formula M-S, wherein M is a transition metal and S is a ligand selected from the group consisting of nitrate, sulfate, chloride, sulfite, and nitrite; with at least one carboxylate salt selected from the group consisting of salts of R1(COOH)c and salts of R2(COOH)d
Data Source
AI summary
The instant disclosure provides a process for synthesis of compound of Formula: wherein Mz+ is a transition metal ion and X and Y are carboxylate anions. The catalysts are hydrocarbon soluble and the process for their preparation, as disclosed herein, constitutes an elegant method for the preparation of such catalysts.