Reconstituted Pt-Ga Catalyst Activity Retention
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Solution Overview
Problem
Dehydrogenation catalysts containing Group 10 elements, such as platinum, undergo deactivation during use, leading to frequent and costly replacement, as existing methods for reactivation are inefficient and economically undesirable.
Innovation Solution
A process involving impregnation of a partially deactivated Pt-Ga/Al2O3 catalyst with a platinum salt solution followed by calcination at temperatures ranging from 400°C to 1000°C, resulting in a reconstituted catalyst with enhanced platinum retention and activity comparable to fresh catalysts, without replacing modifier components or support materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If dehydrogenation catalyst is used continuously, then production continues, but catalyst activity decreases and deactivation occurs
Solution Approach 1:
The patent recovers and reuses the platinum metal from deactivated catalyst through a fluidized bed reconstitution process. The spent catalyst is treated with a platinum salt solution that deposits additional platinum onto the catalyst support, recovering the valuable metal and restoring catalytic activity without discarding the entire catalyst system.
Solution Approach 2:
The patent changes the physical and chemical parameters of the catalyst by controlling the reconstitution conditions including temperature (400-1000°C), platinum salt concentration, and treatment time. These parameter changes restore the catalyst's active sites and maintain productivity while preventing deactivation.
2Reliability
If fresh catalyst is replaced frequently, then catalyst activity is maintained, but cost increases
Solution Approach 1:
Instead of discarding deactivated catalyst containing expensive platinum, the patent recovers the platinum through reconstitution treatment. The fluidized bed process with platinum salt solution retrieves and redistributes the platinum metal, preventing loss and reducing the need for frequent catalyst replacement.
Solution Approach 2:
The catalyst performs self-service by undergoing in-situ reconstitution within the fluidized bed reactor. The platinum salt treatment and thermal processing restore the catalyst's own active sites and structure, enabling it to maintain activity without external replacement, thereby preventing platinum loss.
3Reliability
If catalyst reconstitution is performed, then platinum retention is improved, but process complexity increases
Solution Approach 1:
The patent merges the reconstitution process with the existing fluidized bed reactor system. The platinum salt treatment and thermal processing are integrated into the same equipment used for catalytic dehydrogenation, eliminating the need for separate reconstitution equipment and reducing overall process complexity while improving platinum retention.
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 reconstituted catalyst exhibits improved platinum retention and delayed deactivation, maintaining or exceeding the activity of fresh catalysts, allowing for extended use without the need for frequent replacement, thus reducing costs and maintaining process efficiency.
Implementation Method 1
The noble metal salt of a weak acid is reduced to the noble metal under hydrogenation conditions
Implementation Method 2
calcining the impregnated dehydrogenation catalyst at a temperature ranging from 400° C. to 1000° C.
Data Source
AI summary
A process for dehydrogenating alkane or alkylaromatic compounds comprising contacting the given compound and a dehydrogenation catalyst in a fluidized bed. The dehydrogenation catalyst is prepared from an at least partially deactivated platinum/gallium catalyst on an alumina-based support that is reconstituted by impregnating it with a platinum salt solution, then calcining it at a temperature from 400° C. to 1000° C., under conditions such that it has a platinum content ranging from 1 to 500 ppm, based on weight of catalyst; a gallium content ranging from 0.2 to 2.0 wt %; and a platinum to gallium ratio ranging from 1:20,000 to 1:4. It also has a Pt retention that is equal to or greater than that of a fresh catalyst being used in a same or similar catalytic process.