Shaped Catalyst for Alkane Dehydrogenation via Binder Matrix
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Solution Overview
Problem
Existing catalysts for alkane oxidative dehydrogenation and alkene oxidation, such as those containing Mo, V, Nb, and Te, face challenges in achieving high mechanical strength and selectivity, particularly in processes involving alkanes and alkenes with 2 to 6 carbon atoms.
Innovation Solution
A process involving a mixed metal oxide catalyst with a binder having a surface area greater than 100 m2/g and a water loss of greater than 1 wt.% at 485°C, which is mixed with the catalyst, shaped by tableting, and then heated, resulting in a catalyst with enhanced mechanical strength and activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mixed metal oxide catalyst is mixed with ceria particles and support materials, then catalyst activity is improved, but mechanical strength deteriorates
Solution Approach 1:
A binder is introduced as an intermediary material to hold the catalyst particles and support materials together. The binder forms a matrix that binds the mixed metal oxide catalyst, ceria particles, and support materials, providing mechanical strength while maintaining catalyst activity. This resolves the contradiction by mediating between the loose powder mixture (high activity but low strength) and the need for a structurally sound catalyst pellet.
2Strength
If catalyst particles are mixed with binder and shaped by tableting, then mechanical strength is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent optimizes parameters including binder content (5-20 wt%), tableting pressure (50-200 MPa), and drying temperature (50-150°C) to achieve both mechanical strength and shape uniformity. By carefully controlling these parameters, the process produces catalyst pellets with consistent dimensions and mechanical properties, resolving the contradiction between strength enhancement and manufacturing precision.
3Reliability
If water loss upon heating is increased, then binder effectiveness is improved, but catalyst stability deteriorates
Solution Approach 1:
The binder undergoes controlled phase transitions through water loss upon heating (drying at 50-150°C and calcination at 200-500°C). This thermal treatment removes water and volatile components, transforming the binder from a wet, workable state to a stable, porous structure that provides mechanical strength without compromising catalyst stability. The controlled phase transition resolves the contradiction by enabling binder effectiveness while maintaining catalyst composition stability.
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 process yields a catalyst with improved mechanical strength and activity for alkane oxidative dehydrogenation and alkene oxidation, allowing for efficient conversion of alkanes and alkenes with 2 to 6 carbon atoms, while also enabling fine-tuning of volumetric activity levels by varying the binder content.
Implementation Method 1
a water loss upon heating at a temperature of 485° C. which is greater than 1 wt. %
Implementation Method 2
catalyst for alkane oxidative dehydrogenation (oxydehydrogenation; ODH) and/or alkene oxidation
Data Source
AI summary
The invention relates to a process for preparing a shaped catalyst for alkane oxidative dehydrogenation and/or alkene oxidation, which comprises: a) preparing a mixed metal oxide catalyst containing molybdenum, vanadium, niobium and optionally tellurium; b) mixing the catalyst obtained in step a), a binder and optionally water, wherein the binder has a surface area greater than 100 m2/g and a water loss upon heating at a temperature of 485° C. which is greater than 1 wt. %; c) shaping the mixture obtained in step b) to form a shaped catalyst by means of tableting; and d) subjecting the shaped catalyst obtained in step c) to an elevated temperature. Further, the invention relates to a catalyst obtainable by said process and to a process of alkane oxidative dehydrogenation and/or alkene oxidation wherein said catalyst is used.