Propylene Production via Balanced Catalyst Ratios
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Solution Overview
Problem
Current methods for producing propylene are energy intensive and involve significant side reactions, requiring high heat and a high weight ratio of isomerization catalyst to disproportionation catalyst, which reduces efficiency and increases costs.
Innovation Solution
A catalyst composition with a weight ratio of isomerization catalyst to disproportionation catalyst ranging from 10:1 to 1:10, using transition metal oxides like WO3 on solid supports, such as alumina or silica, at temperatures between 500°F to 650°F, to efficiently convert butene and ethylene into propylene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high heat (650°F) and high weight ratio of isomerization catalyst to disproportionation catalyst are used, then propylene production is achieved, but energy consumption increases and side reactions occur
Solution Approach 1:
The patent changes the temperature parameter from conventional high heat (650°F) to a lower range (400-650°F), and modifies the catalyst weight ratio parameter from high isomerization catalyst content to a balanced ratio (1:1 to 10:1), thereby reducing energy consumption while maintaining propylene production efficiency
Solution Approach 2:
The patent employs a composite catalyst system combining both isomerization catalyst and disproportionation catalyst in specific weight ratios, creating a synergistic effect that improves propylene production while reducing the need for excessive heat input and minimizing side reactions
2Productivity
If high weight ratio of isomerization catalyst to disproportionation catalyst is used, then propylene production is maintained, but device complexity and cost increase
Solution Approach 1:
The patent optimizes the catalyst composition parameter by establishing a specific weight ratio range (1:1 to 10:1) between isomerization and disproportionation catalysts, simplifying the catalyst system design while maintaining high propylene production efficiency
Solution Approach 2:
The catalyst composition is designed to perform multiple functions simultaneously - both isomerization and disproportionation reactions occur effectively in the same reactor system, reducing the need for separate catalyst beds or complex multi-stage processes
3Productivity
If conventional disproportionation catalyst (WO3 on SiO2) and isomerization catalyst (MgO) are used separately, then propylene is produced, but side reactions consume propylene and produce higher olefins
Solution Approach 1:
The patent merges the isomerization catalyst and disproportionation catalyst into a single combined catalyst system with optimized weight ratios, allowing both reactions to occur synergistically in one reactor, thereby preventing propylene consumption in unwanted side reactions that produce higher olefins
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 method achieves a butene conversion percentage of greater than 55% and propylene selectivity of over 85%, reducing energy consumption and increasing propylene yield while minimizing side reactions.
Implementation Method 1
MgO is one type of isomerization catalyst that has been used
Implementation Method 2
Olefin metatheses, which are also known as disproportionation, are reversible reactions in which double bonds of, for example, ethylene and 2-butene (B2) are broken and then reformed as propylene
Data Source
AI summary
The present disclosure relates to chemical catalysts and methods that may be used for the production and/or interconversion of olefins. In some embodiments, methods for producing propylene from ethylene and butene comprising, (a) obtaining a catalyst composition comprising an isomerization catalyst and a disproportionation catalyst, wherein the weight ratio of the isomerization catalyst to the disproportionation catalyst is from 10:1 to 1:10; and (b) reacting butene with ethylene at a temperature from about 500° F. (260° C.) to about 650° F. (350° C.) in the presence of the catalyst composition under conditions sufficient to produce propylene are provided.