Multiple-Stage Catalyst System for Propene Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The demand for propene has exceeded its supply, as existing production processes, such as steam cracking and fluid catalytic cracking, cannot keep pace with the increasing demand for polypropylene, propylene oxide, and acrylic acid, and current metathesis processes are inefficient in producing propene from butene.
Innovation Solution
A multiple-stage catalyst system comprising an isomerization catalyst (magnesium oxide, MgO), a metathesis catalyst (mesoporous silica supported with metal oxide), and a cracking catalyst (zeolite) is used to convert butene into propene through isomerization, metathesis, and cracking reactions, optimizing the yield of propene and ethylene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If steam cracking or fluid catalytic cracking is used for propene production, then existing infrastructure can be utilized, but the processes cannot respond adequately to rapid increase in propene demand
Solution Approach 1:
The patent changes the chemical reaction parameters by introducing a metathesis reaction process with specific catalysts (molybdenum oxide or tungsten oxide on silica support) to convert butene to propene, enabling the system to adapt to increased propene demand without relying on traditional steam cracking or FCC processes
2Productivity
If traditional metathesis processes are used for propene production, then propene can be produced from butene, but the processes are inefficient
Solution Approach 1:
The patent uses composite catalyst materials consisting of molybdenum oxide or tungsten oxide supported on silica with specific surface area and pore volume characteristics, creating a highly efficient catalytic system that dramatically improves propene production efficiency from butene compared to traditional metathesis processes
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 system significantly enhances the yield of propene and ethylene, improving the efficiency of propene production without requiring externally added ethylene, while minimizing the production of undesirable by-products like isobutene, thus addressing the supply-demand imbalance.
Implementation Method 1
at least partially isomerizing butene with an isomerization catalyst to form an isomerization reaction product
Implementation Method 2
at least partially metathesizing the isomerization reaction product with a metathesis catalyst to form a metathesis reaction product
Implementation Method 3
at least partially cracking the metathesis reaction with a cracking catalyst to form a cracking reaction product that comprises propene
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Processes and multiple-stage catalyst systems are disclosed for producing propene by at least partially isomerizing butene in an isomerization reaction zone having an isomerization catalyst to form an isomerization reaction product, at least partially metathesizing the isomerization reaction product in a metathesis reaction zone having a metathesis catalyst to form a metathesis reaction product, and at least partially cracking the metathesis reaction product in a cracking reaction zone having a cracking catalyst. The isomerization catalyst may be MgO, and the metathesis catalyst may be a mesoporous silica catalyst support impregnated with a metal oxide. The metathesis reaction zone may be downstream of the isomerization reaction zone, and the cracking reaction zone may be downstream of the metathesis reaction zone.