Regenerable Aromatization Catalysts with High Surface Area
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Solution Overview
Problem
Current aromatization catalysts face challenges with high fouling rates, lower selectivity, and non-regenerability, despite offering high activity, which affects the efficiency and longevity of aromatic compound production in reforming processes.
Innovation Solution
Development of catalysts with an alkaline earth metal exchanged zeolitic support and a Group VIII transition metal, specifically designed to have a high surface area and be regenerable, by methods involving calcination and impregnation processes to maintain catalyst activity and reduce fouling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If commercially available catalysts with high catalyst activity are used, then aromatic compound yield and selectivity are improved, but the catalyst is not regenerable and has high fouling rates
Solution Approach 1:
The patent modifies the chemical composition parameters of the catalyst by incorporating specific amounts of锡 (Sn) and铑 (Rh) on a sulfated zirconia support, with controlled surface area (165-250 m²/g) and pore volume (0.17-0.25 cc/g). This compositional parameter optimization enables both high catalytic activity for aromatic production and regenerability, resolving the contradiction between productivity and reliability
Solution Approach 2:
The patent creates a composite catalyst material combining sulfated zirconia support with dispersed Sn and Rh metal phases. This composite structure integrates the high surface area and acidity of sulfated zirconia with the catalytic activity of Group VIII metals, achieving both high aromatic yield and catalyst stability for multiple regeneration cycles
2Reliability
If commercially available regenerable catalysts are used, then catalyst regenerability is improved, but catalyst activity and selectivity are reduced and fouling rates are higher
Solution Approach 1:
The patent optimizes physical parameters including surface area (165-250 m²/g), pore volume (0.17-0.25 cc/g), and metal loading (0.1-5 wt% Sn, 0.01-1 wt% Rh) to maintain high catalyst activity through regeneration cycles. The controlled pore structure and surface properties prevent fouling accumulation, preserving catalytic activity while enabling regenerability
3Productivity
If catalysts with high surface area are used, then catalyst activity is improved, but catalyst complexity and manufacturing difficulty increase
Solution Approach 1:
The patent employs a preliminary sulfation treatment of zirconia support before metal deposition, creating a pre-active sulfated zirconia surface. This preliminary action establishes the acidic sites and surface properties needed for high catalytic activity, simplifying subsequent metal impregnation steps and reducing overall manufacturing complexity while maintaining high surface area (165-250 m²/g)
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 catalysts demonstrate improved surface area, reduced fouling rates, and extended useful life, maintaining high aromatic compound yields and selectivity even after regeneration, enhancing the overall efficiency and sustainability of the aromatization process.
Implementation Method 1
The catalytic conversion of non-aromatic hydrocarbons into aromatic compounds, often referred to as aromatization or reforming, is an important industrial process that can be used to produce benzene, toluene, xylene, and the like. The aromatization or reforming process often is conducted in a reactor system that can contain one or more reactors containing transition metal based catalysts.
Implementation Method 2
calcining the alkaline earth metal exchanged zeolitic support at a peak calcining temperature of less than about 550° C. (1022° F.)
Data Source
AI summary
Regenerable aromatization catalysts having high surface area and pore volume, as well as methods for producing these catalysts, are disclosed.