Catalyst for selective hydrogenation of acetylene and method for producing same
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Solution Overview
Problem
Existing catalysts for acetylene hydrogenation suffer from low reactivity, rapid deactivation due to carbon deposition and side reactions, leading to reduced ethylene yield and shortened catalyst lifespan, particularly at high temperatures.
Innovation Solution
A catalyst comprising palladium nanoparticles dispersed on a molten crystalline silicon oxide support, such as cristobalite, with controlled surface area and palladium content, suppresses side reactions and maximizes ethylene production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sulfide catalysts or copper-based catalysts are used at low temperature, then the catalyst cost is reduced, but the reactivity is low and polymerization reaction is fast causing catalyst deactivation
Solution Approach 1:
The patent changes the temperature parameter from low temperature (below 300°C) to high temperature (500-1000°C) operation, enabling the use of palladium catalysts that maintain high reactivity and selectivity at elevated temperatures, avoiding the deactivation issues of sulfide catalysts while achieving superior performance
Solution Approach 2:
The patent uses a composite catalyst system combining palladium metal particles with a specific support material (silica-alumina or silica-magnesia with controlled acidity), creating a composite structure that enhances both reactivity and stability, resolving the contradiction between cost-effective catalysts and high performance
2Productivity
If reaction temperature is raised to increase acetylene conversion, then more acetylene is converted to ethylene, but the fraction of conversion from ethylene to ethane also increases reducing selectivity
Solution Approach 1:
The patent identifies an optimal temperature window (500-1000°C) where the reaction kinetics favor acetylene hydrogenation while suppressing ethylene hydrogenation, achieving both high conversion and high selectivity simultaneously through precise temperature parameter control
Solution Approach 2:
The patent introduces a specific support material as an intermediary between the palladium catalyst and reactants, where the controlled acidity of the support moderates the reaction pathway, enhancing acetylene activation while protecting ethylene from further hydrogenation
3Productivity
If noble metal palladium is used as catalyst, then reactivity and selectivity are improved, but catalyst cost increases
Solution Approach 1:
The patent applies local quality by concentrating the expensive palladium in highly active nanoscale particles (1-10 nm diameter) dispersed on the support, maximizing the utilization efficiency of palladium at critical active sites while minimizing the overall palladium loading to reduce cost
Solution Approach 2:
The patent employs porous support materials with specific surface area and pore structure to disperse palladium particles effectively, increasing the surface area to volume ratio and maximizing the exposure of active sites, thereby achieving high reactivity with minimal palladium content
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 catalyst achieves high ethylene yield and minimizes coke generation, extending catalyst life by maintaining high selectivity and reaction rate across various temperatures.
Implementation Method 1
palladium nanoparticles dispersed and supported on the catalyst support
Implementation Method 2
selective hydrogenation of acetylene
Implementation Method 3
a method of dispersing a catalyst component using a support is used
Implementation Method 4
When 1 mole of acetylene is hydrogenated to produce 1 mole of ethylene, more than 40 kcal of reaction heat is generated
Data Source
AI summary
The present invention relates to a catalyst for selective hydrogenation of acetylene and a preparation method thereof. More specifically, the catalyst and preparation method maximize the catalytic reaction rate at various reaction temperatures and suppress side reactions to minimize the generation of green oil and cokes and to improve the deactivation rate of a catalyst when preparing ethylene from acetylene. Thus, the catalyst and the preparation method provide a high conversion rate of acetylene and a high ethylene production yield.