Parallel Reactor Oxidative Dehydrogenation of Butene Isomers
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Solution Overview
Problem
Current methods for producing 1,3-butadiene, such as naphtha cracking and direct dehydrogenation of normal-butene, are inefficient and not suitable for commercialization due to high energy consumption and low yield, while oxidative dehydrogenation faces challenges with side reactions and catalyst activity differences for butene isomers.
Innovation Solution
A method using multi-component bismuth molybdate catalysts with different reaction activities for 1-butene and 2-butene isomers, where two catalysts are charged into parallel reactors to optimize the oxidative dehydrogenation of normal-butene, enhancing the yield and selectivity of 1,3-butadiene production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If naphtha cracking is used to produce 1,3-butadiene, then the production capacity is increased, but energy consumption increases substantially and other feedstock is produced in addition to 1,3-butadiene
Solution Approach 1:
The patent segments the butene isomers into different reaction streams by using parallel reactors with selective catalysts. One reactor processes 1-butene with a catalyst having high activity for 1-butene, while another reactor processes 2-butene with a catalyst having high activity for 2-butene. This segmentation allows exclusive production of 1,3-butadiene from each isomer stream, avoiding the need for naphtha cracking and reducing energy consumption.
2Productivity
If direct dehydrogenation of normal-butene is used, then 1,3-butadiene can be produced exclusively, but high-temperature and low-pressure conditions are required which are not suitable for commercial process
Solution Approach 1:
The patent changes the reaction parameters by using oxidative dehydrogenation instead of direct dehydrogenation. This chemical parameter change allows the reaction to proceed at lower temperatures (300-500°C) and higher pressures, making it suitable for commercial processes while still achieving exclusive 1,3-butadiene production through selective catalysts.
3Productivity
If oxidative dehydrogenation of normal-butene is used, then 1,3-butadiene can be produced at high yield with exothermic reaction, but side reactions such as complete oxidation occur
Solution Approach 1:
The patent applies local quality by using different catalysts with specific selectivities for different butene isomers in parallel reactors. The first catalyst has high activity for 1-butene and the second catalyst has high activity for 2-butene. This localized catalytic activity ensures that each isomer is converted selectively to 1,3-butadiene, minimizing side reactions and maximizing yield.
4Ease of manufacture
If pure bismuth molybdate catalyst is used for oxidative dehydrogenation, then the process is simple, but the yield of 1,3-butadiene is limited and not suitable for commercialization
Solution Approach 1:
The patent uses composite catalyst materials consisting of bismuth molybdate combined with other metal oxides (such as cobalt, iron, nickel, zinc, or manganese oxides) to enhance catalytic activity and selectivity. These composite catalysts maintain the simplicity of the manufacturing process while significantly improving the yield of 1,3-butadiene to levels suitable for commercialization.
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 achieves high yield and selectivity of 1,3-butadiene by exploiting the unique reactivity of each catalyst for specific butene isomers, improving the efficiency and commercial viability of the process.
Implementation Method 1
multi-component bismuth molybdate-based catalysts exhibiting different reaction activities to each of the normal-butene isomers (1-butene, trans-2-butene and cis-2-butene) being able to produce high value 1,3-butadiene
Implementation Method 2
oxidative dehydrogenation of normal-butene is a reaction in which normal-butene reacts with oxygen to produce 1,3-butadiene and water
Implementation Method 3
by passing continuously low-boiling point fraction contained mainly 1-butene obtained a distillation column from a C4 mixture containing normal-butene
Data Source
AI summary
Disclosed is a method for producing 1,3-butadiene through oxidative dehydrogenation of normal-butene using a parallel reactor in which catalysts are charged into fixed bed reactors and are not physically mixed. More specifically, disclosed is a method for efficiently producing 1,3-butadiene through oxidative dehydrogenation of normal-butene using the parallel reactor containing multi-component bismuth molybdate-based catalysts exhibiting different activities to oxidative dehydrogenation for normal-butene isomers (1-butene, trans-2-butene and cis-2-butene), and butene separated from a C4 mixture containing normal-butene and normal-butane, as a reactant.