Pt-Ga-Sn-Al Catalyst for Acyclic C5 to Cyclopentadiene Conversion
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Solution Overview
Problem
Current processes fail to efficiently convert acyclic C5 hydrocarbons to cyclic C5 compounds, particularly cyclopentadiene, with high yield and selectivity, due to catalyst deactivation and excessive production of C4 cracked products, and lack effective methods for on-purpose CPD production from acyclic C5 feedstocks.
Innovation Solution
A process involving a furnace with parallel reactor tubes containing a catalyst composition, where an inverse temperature profile is maintained, and a rejuvenation gas with hydrogen is used to remove coke material, allowing for continuous conversion of acyclic C5 hydrocarbons to cyclic C5 hydrocarbons, including cyclopentadiene, while minimizing byproduct formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If Pt/Sn/alumina or Pt-Sn/aluminate catalysts are used for dehydrogenation, then conversion of n-pentane is achieved, but selectivity and yield to cyclic C5 products are poor
Solution Approach 1:
The patent changes the catalyst composition parameters by incorporating Ga (gallium) into the Pt-Sn-alumina system to create Pt-Ga-Sn-Al catalysts. This compositional parameter change transforms the catalyst's function to achieve both high conversion and high selectivity to cyclic C5 products, resolving the contradiction between productivity and manufacturing precision.
2Productivity
If Pt supported on chlorided alumina catalysts are used for reforming, then dehydrogenation and cyclization of C6 and higher alkanes is effective, but conversion of acyclic C5 to cyclic C5 is low and catalyst deactivates within two hours
Solution Approach 1:
The patent modifies the catalyst composition by adding Ga to the Pt-Sn-Al system, creating Pt-Ga-Sn-Al catalysts with enhanced stability. This parameter change allows the catalyst to maintain both high dehydrogenation/cyclization activity and prolonged stability, resolving the contradiction between productivity and reliability.
Solution Approach 2:
The patent creates a composite catalyst system combining Pt, Ga, Sn, and Al components. This composite material approach synergistically integrates multiple elements to achieve both high activity for dehydrogenation/cyclization and improved long-term stability, resolving the contradiction between productivity and reliability.
3Productivity
If conventional catalysts are used, then some conversion occurs, but catalyst deactivation due to coke formation limits continuous operation
Solution Approach 1:
The patent changes the catalyst composition parameters by incorporating Ga into Pt-Sn-Al to create Pt-Ga-Sn-Al catalysts with enhanced resistance to coke formation. This parameter modification allows the catalyst to maintain high conversion rates while extending operational lifetime, resolving the contradiction between productivity and duration of action.
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 catalyst stability and efficiency, achieving high conversion rates and selectivity to cyclic C5 products, reducing catalyst deactivation and byproduct formation, and enabling commercial-scale production of cyclopentadiene from acyclic C5 feedstocks.
Implementation Method 1
a furnace comprising parallel reactor tube(s), the reactor tubes containing catalyst composition
Implementation Method 2
contacting the feedstock with the catalyst composition; obtaining a reactor effluent comprising cyclic C5 hydrocarbon
Implementation Method 3
contacting the rejuvenation gas with the catalyst composition to remove at least a portion of coke material on the catalyst composition
Data Source
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AI summary
Disclosed is a process and system to convert acyclic C5 feedstock to non-aromatic, cyclic C5 hydrocarbon. A furnace and reactor tubes comprising a catalyst compound are disclosed. A process involving contacting acyclic C5 feedstock with catalyst composition and obtaining cyclic C5 hydrocarbon is also disclosed.