Over Flocculated Molecular Sieve Catalyst Attrition Resistance
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Solution Overview
Problem
Current molecular sieve catalyst compositions face challenges with high attrition rates and increased slurry viscosity, which affect their durability and efficiency in hydrocarbon conversion processes, particularly in the production of light olefins from oxygenates.
Innovation Solution
A method of formulating a molecular sieve catalyst composition by combining an over flocculated molecular sieve with a binder, optionally a matrix material, and a phosphorous compound, followed by milling the catalyst slurry to improve attrition resistance and reduce viscosity, thereby enhancing the catalyst's performance in converting oxygenates to olefins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If molecular sieve catalyst compositions are used in conversion processes, then olefin production is achieved, but attrition resistance is poor and slurry viscosity is high
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical properties of the molecular sieve catalyst composition. Specifically, it changes the particle size distribution, surface area, and chemical composition parameters to optimize both attrition resistance and slurry viscosity. The invention adjusts these parameters to achieve a balance where the catalyst maintains structural integrity during operation while forming a workable slurry for handling and application.
Solution Approach 2:
The patent employs composite materials by combining molecular sieve particles with binders and matrix materials to create a catalyst composition that exhibits improved mechanical strength and reduced viscosity. The composite structure integrates the catalytic activity of the molecular sieve with the structural support and binding properties of the matrix material, resulting in a material that simultaneously achieves better attrition resistance and ease of manufacture.
2Productivity
If molecular sieve particles are used in conversion processes, then catalytic activity is achieved, but particle breakdown into fines occurs
Solution Approach 1:
The patent applies beforehand cushioning by pre-strengthening the molecular sieve particles through controlled synthesis and size reduction processes before they are used in the conversion process. The invention creates a particle size distribution and structural configuration that provides internal reinforcement, cushioning against mechanical stress and preventing premature breakdown into fines during catalytic operation.
Solution Approach 2:
The patent uses composite materials by forming a multi-component catalyst composition where the molecular sieve particles are embedded in a matrix material and bound together with binders. This composite structure provides mechanical reinforcement to the individual particles, preventing their breakdown into fines while maintaining their catalytic activity for olefin production.
3Reliability
If catalyst composition particles undergo physical breakdown, then attrition occurs, but more catalyst material is required
Solution Approach 1:
The patent applies parameter changes by optimizing the physical and chemical parameters of the catalyst composition to enhance durability. Specifically, it adjusts particle size, surface area, and compositional ratios to create a catalyst that resists attrition and maintains its structural integrity over time, thereby reducing the quantity of catalyst material needed and improving the economic viability of the process.
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 approach results in a catalyst composition with improved attrition resistance and lower slurry viscosity, leading to increased durability and efficiency in converting oxygenates to light olefins, such as ethylene and propylene, with reduced catalyst consumption and operational costs.
Implementation Method 1
an oxygenate, typically mostly methanol, is converted into primarily ethylene and/or propylene in the presence of a molecular sieve
Implementation Method 2
Molecular sieves, such as zeolites or zeolite-type molecular sieves, carbons and oxides, are porous solids having pores of different sizes that selectively adsorb molecules that can enter the pores, and exclude other molecules that are too large
Implementation Method 3
combining an over flocculated molecular sieve with a binder, optionally a matrix material, and a phosphorous compound, followed by milling the catalyst slurry
Data Source
AI summary
A catalyst composition that comprises an over flocculated molecular sieve and optionally, a phosphorous compound and, optionally, a non-over flocculated molecular sieve. A method of preparing a catalyst composition that comprises mixing an over flocculated molecular sieve and optionally, a phosphorous compound and, optionally, a non-over flocculated molecular sieve.