Oxygen Transfer Agents for Oxidative Dehydrogenation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current olefin production processes, such as steam cracking, are energy-intensive and emit significant CO2 and NOx, necessitating more efficient and environmentally friendly methods for producing ethylene and propylene, which can be achieved through oxidative dehydrogenation (ODH) of hydrocarbons but require improved materials and reactor systems.
Innovation Solution
The use of a mixed oxide oxygen transfer agent with a cubic crystal lattice structure, capable of promoting ODH reactions, and a reactor system that facilitates the contact of hydrocarbons with oxygen, allowing for the oxidation and reduction of the oxygen transfer agent to enhance yield and reduce emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If steam cracking is used for olefin production, then high temperature process enables olefin synthesis, but energy consumption increases and CO2 emissions rise
Solution Approach 1:
The patent changes the reaction parameters from high-temperature endothermic steam cracking to lower-temperature exothermic oxidative dehydrogenation using oxygen transfer agents, achieving olefin production with reduced energy input and different thermal characteristics
Solution Approach 2:
The patent introduces oxygen transfer agents as intermediary substances that mediate the hydrocarbon conversion process, enabling selective oxidation to olefins through a catalytic cycle that avoids direct high-temperature cracking
2Productivity
If steam cracking is used for olefin production, then olefin synthesis is achieved, but CO2 and NOx emissions increase
Solution Approach 1:
The patent converts the harmful effect of oxygen (which would cause complete combustion and CO2 emissions) into a beneficial selective oxidation process by using oxygen transfer agents that provide controlled oxygen transfer, producing olefins and water instead of CO2 and NOx
Solution Approach 2:
The patent changes the oxidation state and reaction conditions to achieve selective oxidative dehydrogenation rather than complete combustion, controlling the oxygen involvement to produce desired olefins while minimizing harmful emissions
3Productivity
If platinum group metal catalysts are used for ODH, then catalytic activity is high, but material cost increases
Solution Approach 1:
The patent replaces expensive platinum group metal catalysts with cheaper oxygen transfer agents that can be regenerated, using materials such as metal oxides that are less costly and can be circulated through the process
Solution Approach 2:
The patent employs composite oxygen transfer agent materials combining different metal oxides and promoters to achieve catalytic activity comparable to platinum group metals at lower cost, utilizing synergistic effects of composite structures
4Productivity
If conventional ODH processes are used, then olefin production is achieved, but coke accumulation occurs and run length decreases
Solution Approach 1:
The patent changes the reaction conditions and catalyst characteristics to reduce coke formation, using oxygen transfer agents that promote selective oxidation over coking, thereby extending the operational run length between maintenance turnarounds
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
This approach increases the yield of unsaturated hydrocarbons to 70-80%, significantly reduces CO2 and NOx emissions, and allows for continuous operation with low coke accumulation, providing a more sustainable and efficient olefin production process.
Implementation Method 1
a process is provided comprising providing a saturated hydrocarbon to a reactor at least partially filled with an oxygen transfer agent according to the present invention, removing an effluent from the reactor containing the unsaturated hydrocarbon, and supplying oxygen to the oxygen transfer agent such that the oxygen transfer agent is oxidized
Implementation Method 2
the oxygen transfer agent is reduced by the reaction with hydrogen and/or hydrocarbons in the feed stream and reoxidized by reaction with oxygen
Implementation Method 3
ODH is a selective catalytic process that produces primarily ethylene and water as products
Implementation Method 4
ODH provides an opportunity to achieve some of the objectives to improve the efficiency of olefin production. While a significant amount of research has been done in ODH over the last 25 years, most reported processes involve highly exothermic catalytic reactions
Data Source
AI summary
A oxygen transfer agent useful for the oxidative dehydrogenation of saturated hydrocarbons includes at least one mixed oxide derived from manganese or compounds thereof, as well as a promoter, such as tungsten and/or phosphorus. The oxygen transfer agent may also include an alkali metal or compounds thereof, boron or compounds thereof, an oxide of an alkaline earth metal, and an oxide containing one or more of one or more of manganese, lithium, boron, and magnesium. A reactor is at least partially filled with the oxygen transfer agent in the form of a fixed or circulating bed and provides an unsaturated hydrocarbon product, such as ethylene and/or propylene. The oxygen transfer agent may be regenerated using oxygen.