Silicate-Modified Silica Catalyst for C5 Conversion
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Solution Overview
Problem
Current processes fail to efficiently convert acyclic C5 feedstocks into cyclic C5 compounds like cyclopentadiene with high yield and selectivity, leading to excessive production of light byproducts and catalyst deactivation, which limits the production of valuable polymers and chemicals.
Innovation Solution
A catalyst composition featuring a Group 10 metal, such as platinum, supported on silica modified with a Group 1 alkali metal silicate and/or a Group 2 alkaline earth metal silicate, is used under specific conditions to convert acyclic C5 feedstocks into cyclic C5 compounds with improved carbon selectivity and reduced byproduct formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If Pt/Sn supported on alumina or Zn/Ca aluminate catalysts are used for dehydrogenation, then conversion of C5 feedstock is achieved, but selectivity to cyclic C5 products is poor and yield is low
Solution Approach 1:
The patent changes the catalyst support material from alumina to silica, and modifies the silica with alkali metal silicates or alkaline earth metal silicates. This parameter change in the catalyst composition achieves both high conversion of n-pentane and high selectivity to cyclic C5 products, resolving the contradiction between productivity and manufacturing precision.
Solution Approach 2:
The patent uses a composite catalyst system consisting of Pt-Sn alloy particles supported on silica that is modified with alkali metal silicates or alkaline earth metal silicates. This composite material structure combines the dehydrogenation activity of Pt-Sn with the cyclization promotion of silicate-modified silica, achieving both high conversion and high selectivity to cyclic C5 products.
2Manufacturing precision
If Pt on chlorided alumina catalysts are used for cyclization, then dehydrogenation and cyclization of C6+ species occurs, but conversion of acyclic C5 to cyclic C5 is low and catalyst deactivates rapidly
Solution Approach 1:
The patent changes the support material from chlorided alumina to silica modified with alkali metal silicates or alkaline earth metal silicates. This parameter change eliminates the rapid deactivation observed with chlorided alumina while maintaining cyclization capability, achieving both manufacturing precision and reliability for C5 conversion.
Solution Approach 2:
The patent avoids using chlorided alumina catalysts that have short operational life due to rapid deactivation. By transitioning to silicate-modified silica supported Pt-Sn catalysts, the system achieves long-term stable operation, effectively replacing short-living catalysts with durable ones for continuous production.
3Productivity
If conventional catalysts are used, then light byproducts (C4-) are produced, but carbon selectivity to cyclic C5 is reduced
Solution Approach 1:
The patent changes the catalyst composition to Pt-Sn on silicate-modified silica, which alters the reaction pathway to favor cyclization over cracking. This parameter change achieves high carbon selectivity to cyclic C5 products (exceeding 80%) while maintaining high conversion rates, resolving the contradiction between productivity and substance loss.
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 achieves high conversion rates of acyclic C5 feedstocks to cyclic C5 compounds, such as cyclopentadiene, with enhanced carbon selectivity and prolonged catalyst stability, reducing the production of undesirable light byproducts and increasing the yield of valuable cyclic C5 products.
Implementation Method 1
contacting said feedstock and, optionally, hydrogen under acyclic C5 conversion conditions in the presence of a catalyst composition to form said product
Data Source
AI summary
Disclosed is a process for the conversion of acyclic C5 feedstock to a product comprising cyclic C5 compounds, such as for example, cyclopentadiene, and catalyst compositions for use in such process. The process comprising the steps of contacting said feedstock and, optionally, hydrogen under acyclic C5 conversion conditions in the presence of a catalyst composition to form said product. The catalyst composition comprises a Group 10 metal, and, optionally, a Group 11 metal, on a catalyst support with a Group 1 alkali metal silicate and/or a Group 2 alkaline earth metal silicate.