Pentane Isomerization and Catalytic Activation for Olefin Production

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Solution Overview

Problem

Conventional processes for upgrading light alkanes to value-added products are not well-suited for hydrocarbon feed streams primarily comprising pentanes, such as isopentane and n-pentane, limiting the production of valuable transportation fuels and chemicals while producing excessive C1-C4 light paraffins.

Innovation Solution

A method involving isomerization of n-pentane to isopentane followed by catalytic activation in specific temperature and pressure conditions, using zeolite catalysts like ZSM-5, to maximize the conversion of hydrocarbons to olefins and aromatics, thereby minimizing the production of undesirable C1-C4 light hydrocarbons.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional processes are used to upgrade light alkanes, then the process is simple and well-established, but the production of valuable transportation fuels and chemicals is limited while excessive C1-C4 light paraffins are produced

Engineering Contradiction:

Improveproduction of valuable transportation fuels and chemicalsVSAvoidproduction of C1-C4 light paraffins

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical parameters by introducing specific catalysts (zeolites like ZSM-5) and controlling reaction conditions (temperature, pressure, residence time) to transform the reaction pathway. This converts the conventional cracking process into a selective oligomerization and aromatization process that produces liquid-range hydrocarbons instead of light paraffins, directly resolving the contradiction between valuable product production and harmful byproduct formation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses catalysts as intermediaries to mediate the transformation of light alkanes. Specifically, zeolite catalysts with controlled acidity and pore structure act as mediators that direct the reaction toward desired products (olefins, aromatics, liquid hydrocarbons) while suppressing unwanted pathways that produce C1-C4 light paraffins, thus resolving the technical contradiction

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If n-pentane is directly converted without isomerization, then the process steps are minimized, but the reactivity and conversion efficiency to desired products are reduced

Engineering Contradiction:

Improveconversion efficiency to olefins and aromaticsVSAvoidnumber of reaction zones and process steps

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent segments the conversion process into distinct functional zones: an isomerization zone that converts n-pentane to isopentane, and an activation zone that converts isopentane to olefins and aromatics. This segmentation allows each zone to be optimized for its specific function, with the isomerization zone maximizing isopentane production and the activation zone maximizing desired product formation, thereby resolving the contradiction between conversion efficiency and process complexity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies preliminary isomerization action before the main activation step. By pre-converting n-pentane to the more reactive isopentane isomer in the first zone, the subsequent activation zone achieves higher conversion efficiency and selectivity for desired products. This preliminary action resolves the contradiction by preparing the feedstock in advance to maximize subsequent reaction efficiency

Inventive Principle:

Principle #10Preliminary action

3Productivity

If activation temperature is increased to maximize conversion, then the conversion of hydrocarbons to olefins and aromatics is enhanced, but the production of C1-C4 light paraffins and coke increases

Engineering Contradiction:

Improveconversion of hydrocarbons to olefins and aromaticsVSAvoidproduction of C1-C4 light paraffins and coke

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent optimizes the activation temperature parameter to a specific range (500-650°C) that balances conversion efficiency with selectivity. Within this temperature window, the catalyst maintains high activity for producing olefins and aromatics while suppressing excessive cracking that leads to C1-C4 light paraffins and coke formation. This precise parameter control resolves the contradiction between conversion enhancement and harmful byproduct suppression

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite catalyst systems combining zeolites with different pore structures and acidity characteristics. This composite approach creates a synergistic effect where the catalyst composition is optimized to promote desired reactions (oligomerization, aromatization) while inhibiting unwanted pathways (excessive cracking, coking), thereby resolving the contradiction between high conversion and low harmful byproduct formation

Inventive Principle:

Principle #40Composite materials

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 enhances the yield of upgraded products suitable for liquid transportation fuels and value-added chemicals by optimizing the reactivity of pentane isomers, reducing the formation of C1-C4 light paraffins, and increasing the production of olefins and aromatics.

Implementation Method 1

contacting the hydrocarbon feed stream with one or more isomerization catalysts in a first reaction zone that is maintained at a temperature and a pressure that facilitates the isomerization of at least a portion of the n-pentane in the hydrocarbon feed stream to isopentane

Methodology Applied

Scientific EffectCatalytic isomerization: Catalysis

Implementation Method 2

contacting the isomerization effluent with an activation catalyst in a second reaction zone that is maintained at a temperature and pressure that facilitates at least one reaction selected from dehydrogenation, cracking and aromatization

Methodology Applied

Scientific EffectDehydrogenation: Catalysis

Implementation Method 3

Methodology Applied

Scientific EffectCracking: Catalysis

Implementation Method 4

Methodology Applied

Scientific EffectAromatization: Catalysis

Implementation Method 5

at least partially condensing the activation effluent to produce a liquid hydrocarbons fraction and a gaseous light hydrocarbons fraction

Methodology Applied

Scientific EffectCondensation: Condensation

Data Source

PatentUS10981847B2Isomerization and catalytic activation of pentane-enriched hydrocarbon mixtures

Publication Date: 2021.04.20 PHILLIPS 66 CO

AI summary

The present disclosure relates to processes that catalytically convert a hydrocarbon feed stream predominantly comprising both isopentane and n-pentane to yield upgraded hydrocarbon products that are suitable for use either as a blend component of liquid transportation fuels or as an intermediate in the production of other value-added chemicals. The hydrocarbon feed stream is isomerized in a first reaction zone to convert at least a portion of the n-pentane to isopentane, followed by catalytic-activation of the isomerization effluent in a second reaction zone with an activation catalyst to produce an activation effluent. The process increases the conversion of the hydrocarbon feed stream to olefins and aromatics, while minimizing the production of C1-C4 light paraffins. Certain embodiments provide for further upgrading of at least a portion of the activation effluent by either oligomerization or alkylation.