Plasma Regeneration of Zeolite Catalyst for Acetylene Aromatization
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Solution Overview
Problem
Conventional methods for synthesizing aromatic compounds from acetylene using zeolite catalysts face challenges such as catalyst deactivation due to coke formation and excessive side reactions, leading to low yield and high energy consumption, making it difficult to commercialize the process.
Innovation Solution
A method involving plasma treatment at ambient temperature and pressure to selectively remove external and internal coke from the zeolite catalyst, allowing for repeated use and adjusting reaction speed to improve BTX selectivity and reduce reactant consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional thermal treatment is used to remove coke from zeolite catalyst, then coke removal efficiency is improved, but catalyst structure is damaged and micropores are destroyed
Solution Approach 1:
The patent replaces the conventional thermal treatment method (heat-based) with plasma treatment (electrical field-based). The plasma generated by applying a voltage at the kV level to a high voltage electrode removes coke through electrical discharge and reactive species, avoiding thermal damage to the zeolite catalyst structure while maintaining effective coke removal.
Solution Approach 2:
The patent changes the operating parameters from high temperature thermal treatment to ambient temperature plasma treatment. By applying voltage at the kV level instead of using high heat, the method achieves coke removal at milder conditions that preserve the catalyst's microporous structure and crystalline phase.
2Productivity
If high temperature aromatization is conducted to increase reaction speed, then productivity is improved, but side reactions increase and catalyst deactivation accelerates
Solution Approach 1:
The patent converts the harmful effect of coke formation into a beneficial regulatory mechanism. By allowing partial coke formation through plasma treatment and controlling its distribution, the method uses coke as a space-time distributor that regulates reaction speed and suppresses excessive side reactions, thereby improving selectivity while maintaining productivity.
Solution Approach 2:
The patent applies partial plasma treatment to remove only external coke while leaving internal coke partially intact. This partial removal strategy creates an optimal balance where sufficient active sites remain for high productivity, while residual internal coke acts as a buffer to control reaction rate and reduce harmful side reactions.
3Reliability
If complete coke removal is performed to restore catalyst activity, then catalyst activity is recovered, but additional coke formation occurs rapidly in subsequent reactions
Solution Approach 1:
The patent performs preliminary plasma treatment to remove external coke before the catalyst enters the reaction system. This preliminary action restores sufficient catalyst activity for high productivity, while the controlled presence of internal coke serves as a pre-established buffer that delays rapid coke formation during subsequent reactions, extending catalyst lifespan.
4Manufacturing precision
If plasma treatment is applied to remove external coke, then BTX selectivity is improved, but some internal coke remains that could affect activity
Solution Approach 1:
The patent applies local quality by differentiating between external and internal coke and treating them differently. External coke is removed by plasma treatment to improve BTX selectivity, while internal coke is partially preserved to maintain catalyst activity. This localized approach optimizes both selectivity and activity by creating different coke distributions in different regions of the catalyst system.
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 plasma-treated zeolite catalyst maintains stability and activity, delaying additional coke formation, reducing reactant waste, and enhancing BTX selectivity, enabling efficient and prolonged aromatic compound production.
Implementation Method 1
subjecting the zeolite catalyst deactivated by the coke formed in the aromatization of acetylene, to plasma treatment at ambient temperature and pressure so as to selectively remove the external cokes and partial internal coke
Data Source
AI summary
The present invention relates to a method of preparing an aromatic compound from acetylene, which includes synthesizing an aromatic compound from an acetylene-containing reactant gas in the presence of a zeolite catalyst for the aromatization of acetylene, and subjecting the zeolite catalyst deactivated by the coke formed in the aromatization of acetylene, to plasma treatment at ambient temperature and pressure so as to selectively remove the external cokes and partial internal coke, thereby regenerating the zeolite catalyst; a method of regenerating the zeolite catalyst used in the aromatization of acetylene by plasma treatment; and a regenerated zeolite catalyst for the aromatization of acetylene, prepared thereof.