Shaped Dehydrogenation Catalyst for Stable Alkane Conversion
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Solution Overview
Problem
Existing dehydrogenation catalysts, such as those based on chromium, gallium, and platinum, face issues with environmental impact, high production costs, and a drop in alkane conversion during reaction and regeneration cycles due to Pt dispersion loss and sintering, while alternative methods like sol-gel synthesis generate volatile alcohols and are costly.
Innovation Solution
A shaped dehydrogenation catalyst is produced using a shaping method, combining group 13 and group 1 metal precursors with a catalyst support, followed by extrusion and calcination, avoiding impregnation and reducing volatile alcohol formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chromium-based catalysts are used for dehydrogenation, then catalytic activity is achieved, but environmental harm and disposal costs increase
Solution Approach 1:
The patent removes chromium from the catalyst composition entirely, extracting the harmful element while retaining the dehydrogenation function through alternative metals (Ga, Pt, or In combined with K, Cs, or Rb), thereby eliminating environmental harm while preserving catalytic activity
Solution Approach 2:
The patent replaces expensive and environmentally problematic chromium with more environmentally friendly alternative metal combinations that are easier to dispose of or regenerate, reducing long-term environmental liability and disposal costs
2Reliability
If Gallium and Platinum based catalysts are used, then alkane conversion ability is improved, but production cost increases
Solution Approach 1:
The patent uses small amounts of Ga or Pt (0.1-10 wt%) combined with alkaline earth metals to achieve effective catalysis, rather than requiring large quantities of expensive precious metals, thereby reducing production cost while maintaining alkane conversion ability
Solution Approach 2:
The patent creates composite catalyst systems combining Ga or Pt with alkaline earth metals (K, Cs, or Rb) on oxide supports, where the synergistic interaction between components enhances catalytic activity per unit of expensive metal, reducing overall production cost
3Manufacturing precision
If sol-gel method is used for catalyst synthesis, then catalyst can be formed with controlled composition, but volatile alcohol generation and production cost increase
Solution Approach 1:
The patent removes the sol-gel synthesis step entirely, extracting the process that generates volatile alcohols, and replaces it with direct impregnation or deposition methods that achieve sufficient composition control without harmful byproducts
Solution Approach 2:
The patent uses simpler, more direct synthesis methods (impregnation followed by drying and calcination) instead of complex sol-gel processes, reducing production cost and eliminating volatile alcohol generation while achieving adequate catalyst composition
4Duration of action of moving object
If Pt based catalysts undergo reaction and regeneration cycles, then catalyst can be reused, but alkane conversion drops due to Pt dispersion loss and sintering
Solution Approach 1:
The patent incorporates alkaline earth metals (K, Cs, or Rb) as structural promoters that preemptively prevent Pt sintering and dispersion loss during regeneration cycles, cushioning against the degradation that would otherwise occur during catalyst reuse
Solution Approach 2:
The patent creates composite structures where alkaline earth metals form stable phases with Pt or Ga that prevent sintering during regeneration, maintaining Pt dispersion and alkane conversion ability across multiple reaction-regeneration cycles
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 shaped catalyst exhibits higher alkane conversion and stability across multiple reaction-regeneration cycles, maintaining high conversion rates without significant drops, and is environmentally friendly by avoiding chromium and reducing volatile organic compound generation.
Implementation Method 1
combining a group 13 metal precursor, a group 1 metal precursor, and a catalyst support precursor to form a shapeable material
Implementation Method 2
the wet shaped material can be dried to form a dry shaped material
Implementation Method 3
the dry shaped material can be calcined to form the shaped dehydrogenation catalyst
Data Source
AI summary
Disclosed are shaped dehydrogenation catalysts, methods for making the catalysts, and methods for dehydrogenating a hydrocarbon using the catalyst. A method for making the shaped dehydrogenation catalyst can include combining a group 13 metal precursor and a group 1 metal precursor with a catalyst support precursor to form a shapeable material, shaping the shapeable material to form a wet shaped material, drying the wet shaped material to form a dry shaped material, and calcining the dry shaped material to form the shaped dehydrogenation catalyst.