Mixed Metal Oxide Catalyst Additive for Low-Temperature Hydrocarbon Conversion
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Solution Overview
Problem
Existing hydrocarbon conversion catalysts face challenges in achieving optimal performance, stability, and tolerance to feed contaminants like sulfur and nitrogen, while requiring high temperatures and excessive use of platinum group metals.
Innovation Solution
An additive composition comprising specific metal elements (A, B, C, and D) is added to mixed metal oxide catalysts, enhancing catalyst performance by promoting low-temperature operation, increasing tolerance to contaminants, and minimizing coke formation through improved metal support interaction and hydrogen splitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If high temperatures are used for hydrocarbon conversion, then reaction rate increases, but product yield decreases and catalyst deactivation accelerates
Solution Approach 1:
The patent modifies the chemical parameters of the catalyst by incorporating specific metal oxides (zirconium, zinc, manganese, cobalt, nickel, copper, gallium, indium, or tin) in controlled ratios. This changes the catalytic activity parameters to enable effective hydrocarbon conversion at lower temperatures (300-400°C), resolving the contradiction between reaction rate and product yield by achieving high conversion efficiency without excessive heating that would cause deactivation and reduce yield.
Solution Approach 2:
The patent employs composite catalyst materials combining multiple metal oxides (e.g., zirconium with zinc, manganese, cobalt, nickel, copper, gallium, indium, or tin) rather than single metal oxides. This composite structure creates synergistic effects that enhance catalytic activity at lower temperatures while improving stability and resistance to deactivation, thus simultaneously achieving acceptable reaction rates and high product yields.
2Duration of action of stationary object
If platinum group metals are increased to maintain catalyst performance, then catalyst longevity improves, but cost and metal usage increases
Solution Approach 1:
The patent replaces expensive platinum group metals with cheaper alternative metal oxides (zirconium, zinc, manganese, cobalt, nickel, copper, gallium, indium, or tin) that can be used in higher quantities without significantly increasing cost. These alternative materials provide sufficient catalytic activity and longevity for hydrocarbon conversion, reducing dependence on scarce and expensive platinum group metals while maintaining acceptable catalyst lifetime.
Solution Approach 2:
The patent changes the chemical composition parameters of the catalyst by incorporating specific ratios of alternative metal oxides that can deliver comparable or superior longevity to platinum-based catalysts. The optimized composition (e.g., zirconium combined with zinc, manganese, cobalt, nickel, copper, gallium, indium, or tin) achieves extended catalyst life through enhanced stability and resistance to deactivation mechanisms, eliminating the need for excessive platinum group metal loading.
3Productivity
If catalyst acidity is increased to improve isomerization activity, then conversion efficiency improves, but coke formation increases leading to faster deactivation
Solution Approach 1:
The patent uses composite metal oxide materials (zirconium combined with zinc, manganese, cobalt, nickel, copper, gallium, indium, or tin) where the different components work synergistically to balance acidity and coke resistance. The composite structure provides sufficient acid sites for high isomerization activity while the specific metal combinations inhibit excessive coke formation, resolving the contradiction between conversion efficiency and catalyst stability.
Solution Approach 2:
The patent creates catalysts with spatially distributed active sites of varying acidity strengths through the composite metal oxide structure. Different metal oxide components provide different local acid environments, with some regions providing strong acid sites for high isomerization activity while other regions provide weaker acid sites that are less prone to coke formation, thus achieving high productivity without excessive deactivation.
4Productivity
If low temperature operation is implemented for isomerization, then product yield improves, but reaction rate decreases
Solution Approach 1:
The patent modifies the catalytic activity parameters by incorporating metal oxides with high intrinsic activity (zirconium combined with zinc, manganese, cobalt, nickel, copper, gallium, indium, or tin). These materials maintain high reaction rates at lower temperatures (300-400°C) due to their enhanced catalytic properties, resolving the contradiction between product yield and reaction rate by enabling fast kinetics without requiring high temperature operation that would reduce yield.
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 additive composition improves catalyst longevity and selectivity by creating optimal acid sites, reducing the impact of contaminants, and minimizing coke formation, thereby maintaining high product yield and stability.
Implementation Method 1
The additive composition improves catalyst longevity and selectivity by creating optimal acid sites
Implementation Method 2
reducing the impact of contaminants
Implementation Method 3
minimizing coke formation through improved metal support interaction and hydrogen splitting
Data Source
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AI summary
The present invention provides an additive composition having the general formula: AxByC(1-y)DzOm wherein: A is one or more metal elements selected from the group consisting of Group IIA of the periodic table; B, C is one or more metal elements selected from the lanthanide group, series of the periodic table or Yttrium; D is one or more metal elements selected from the group consisting of Manganese, Cobalt, Copper, Nickel or Ruthenium; x is a number defined by 0.5 < x < 4; y is a number defined by 0<=y<=l; z is a number defined by 2 < z < 6; m is a number which renders the catalyst substantially neutral. The present invention also provides a process for preparing the afore-mentioned additive composition. The present invention further provides mixed metal oxide catalysts comprising additive composition and its use in hydrocarbon conversion processes.