Oxidized Hydrogenolysis Catalyst Activation Without Oxychlorination
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Solution Overview
Problem
Existing hydrogenolysis catalysts face high capital costs due to the use of noble metals like Ir and Pt, and conventional regeneration methods are complex and capital intensive, necessitating a cost-effective activation process.
Innovation Solution
A method involving contacting an oxidized catalyst with a hydrocarbon stream in the presence of hydrogen to form a hydrocarbon treated catalyst, followed by further treatment with hydrogen, modifies the catalyst's active site structure, enhancing its stability and activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional catalyst regeneration methods (burning carbon deposits in oxidative atmosphere followed by oxychlorination) are used, then catalyst activity is restored, but the process becomes complex and capital intensive
Solution Approach 1:
The invention extracts and eliminates the complex oxychlorination step from the conventional regeneration process. By using a simple hydrogen treatment to reduce oxidized metal sites and restore catalyst activity, the method removes the need for additional chlorinating agents, water, and complex process controls, while still achieving effective catalyst regeneration
Solution Approach 2:
The invention changes the chemical parameter of the treatment atmosphere from oxidative (oxygen-containing) to reductive (hydrogen-rich). This parameter change transforms the regeneration mechanism from oxidation-based carbon burn-off followed by chlorination to a direct hydrogen-based reduction process that restores active metal sites, simplifying the overall process
2Manufacturing precision
If noble metal catalysts (Ir or Pt) are used for hydrogenolysis, then ethane selectivity is improved (60-70%), but capital cost increases significantly
Solution Approach 1:
The invention changes the oxidation state parameter of the catalyst metal sites from oxidized to reduced form through hydrogen treatment. This parameter change restores the catalyst's hydrogenolysis activity and ethane selectivity, allowing spent or deactivated catalysts to be regenerated to their original performance levels without requiring replacement with new expensive noble metal catalysts
3Object-generated harmful factors
If catalyst is exposed to oxygen for regeneration, then carbon deposits are removed, but active site dispersion is compromised requiring additional oxychlorination steps
Solution Approach 1:
The invention converts the harmful effect of oxygen exposure (which oxidizes active metal sites and reduces dispersion) into a beneficial process by immediately following with hydrogen treatment. The hydrogen not only removes carbon deposits through hydrogasification but also reduces oxidized metal sites back to their active state, thereby restoring and maintaining active site dispersion without requiring additional oxychlorination steps
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 increases hydrocarbon conversion stability and extends catalyst life, reducing the need for frequent regeneration, while being more cost-effective than conventional methods.
Implementation Method 1
contacting an oxidized catalyst with a hydrocarbon containing stream in the presence of hydrogen (H2) to form a hydrocarbon treated catalyst
Implementation Method 2
The hydrocarbon treated catalyst can then be contacted with H2 to form an activated hydrogenolysis catalyst
Implementation Method 3
catalysts for hydrocarbon hydrogenolysis
Data Source
AI summary
Processes for activation of hydrogenolysis catalysts are described. A process can include contacting an oxidized catalyst with a butane containing stream in the presence of H2 to form a treated catalyst. The treated catalyst can then be contacted with H2 to form an activated hydrogenolysis catalyst. The source of the oxidized catalyst can be a fresh catalyst or deactivated catalyst that has been exposed to, for example, oxygen. Uses of the activated hydrogenolysis catalyst are also described.