Platinum Re-dispersion in CCR Reforming Catalysts
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Solution Overview
Problem
Current CCR reforming processes face challenges in effectively evaluating and controlling platinum re-dispersion in commercial halogenation zones, leading to poor catalyst performance due to platinum agglomeration, which affects activity, selectivity, and stability.
Innovation Solution
Developing methods and systems to evaluate and control oxychlorination conditions in small-scale reactors, allowing for the comparison and improvement of platinum re-dispersion in CCR catalysts by adjusting parameters such as chloride level, temperature, and oxygen content, simulating commercial halogenation zones to enhance catalyst performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If catalyst particles are cycled between reducing conditions in the reactor and oxidizing conditions in the regenerator to remove coke deposits, then catalyst activity is restored, but platinum atoms slowly agglomerate and catalyst performance degrades
Solution Approach 1:
The patent applies preliminary action by implementing a halogenation treatment step before the regenerator to pre-disperse platinum atoms and form protective halide complexes. This preliminary treatment prevents platinum agglomeration that would otherwise occur during the subsequent oxidation cycle in the regenerator, thereby maintaining catalyst performance while still enabling effective coke removal.
2Stability of the object's composition
If a halogenation zone is added to the regenerator to re-disperse platinum, then platinum dispersion is improved, but the complexity of the regeneration system increases
Solution Approach 1:
The patent merges the halogenation function into the existing regenerator system by integrating it as a treatment zone within the catalyst circulation loop. Rather than adding a completely separate halogenation unit, the system combines platinum re-dispersion and halogenation functions within the existing regeneration infrastructure, thereby improving platinum dispersion while minimizing increases in overall system complexity.
3Productivity
If oxychlorination conditions are controlled to optimize platinum re-dispersion, then catalyst selectivity and activity are improved, but the difficulty of detecting and measuring optimal conditions increases
Solution Approach 1:
The patent implements feedback control for oxychlorination conditions by monitoring catalyst performance parameters and adjusting halogenation zone conditions accordingly. This feedback mechanism enables the system to automatically optimize platinum re-dispersion and maintain optimal catalyst activity and selectivity, reducing the difficulty of detecting and measuring optimal conditions through real-time performance tracking and adaptive control.
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 enables the identification of optimal oxychlorination conditions for improved platinum dispersion, activity, and selectivity, allowing for the selection of the best catalysts for large-scale implementation and troubleshooting of inefficient commercial regenerator systems.
Implementation Method 1
contacting the catalyst particles with a halogen-containing gas to re-disperse the platinum group metals on the catalyst particles
Implementation Method 2
contacting the coke-containing catalyst at high temperature with an oxygen-containing gas to combust and to essentially convert the coke to carbon dioxide and water
Data Source
AI summary
Methods and systems for re-dispersing platinum on catalysts used in continuous catalyst regeneration reformer systems are disclosed. Some aspects of the disclosure provide, for example, methods of evaluating the platinum re-dispersion of a reforming catalyst in a small-scale reactor for use in a continuous catalyst regeneration reformer system and methods of improving the activity and selectivity of reforming catalysts for use in a continuous catalyst regeneration reformer system by selection of appropriate reaction parameters in a small-scale reactor for use in a continuous catalyst regeneration reformer system.