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 molecular sieve catalyst composition is formulated by combining an over-flocculated molecular sieve with a phosphorous compound, such as phosphoric acid, and optionally a non-over flocculated molecular sieve, to enhance attrition resistance and reduce slurry viscosity, thereby improving process operability and reducing catalyst requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If molecular sieve catalyst compositions are used in conversion processes, then conversion efficiency of oxygenates to light olefins is improved, but attrition rates increase causing particle breakdown
Solution Approach 1:
The patent combines molecular sieve particles with a matrix material (such as alumina, silica, or other porous materials) to form a composite catalyst composition. The matrix material provides structural support and reduces particle breakdown, while the molecular sieve maintains its catalytic activity for converting oxygenates to light olefins. This composite structure resolves the contradiction by preserving conversion efficiency while improving attrition resistance.
2Productivity
If molecular sieve particles are used in catalytic conversion, then conversion performance is improved, but slurry viscosity increases affecting process operability
Solution Approach 1:
The patent modifies the local properties of the catalyst composition by incorporating a matrix material with specific physical characteristics (porosity, particle size, surface area) that are optimized to reduce slurry viscosity. The matrix material creates a more open structure that allows better fluid flow, thereby improving ease of operation while maintaining the molecular sieve's conversion performance through localized catalytic sites.
3Productivity
If molecular sieve catalyst compositions are used, then light olefin production is improved, but catalyst durability decreases due to particle breakdown
Solution Approach 1:
The patent incorporates a matrix material that acts as a protective framework before the molecular sieve particles are subjected to mechanical stress in the reactor. This pre-established structural support cushions the molecular sieve particles against attrition and particle breakdown, thereby extending catalyst durability while maintaining light olefin production capability.
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 composition exhibits improved attrition performance and lower slurry viscosity, leading to increased durability and reduced operating costs, with enhanced conversion efficiency of oxygenates to light olefins like ethylene and propylene.
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 phosphorous compound, such as phosphoric acid
Data Source
AI summary
A catalyst composition that comprises an over flocculated molecular sieve and 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 a phosphorous compound and, optionally, a non-over flocculated molecular sieve.