Solid Acid Catalyst with Strong Lewis Sites for Stable Hydrocracking
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Solution Overview
Problem
Existing hydrocracking catalysts for non-aromatic hydrocarbons suffer from low conversion rates and high side reactions due to insufficient interaction with hydrocarbon molecules.
Innovation Solution
A solid acid catalyst is developed with super strong Lewis acid sites formed by etching a metal oxide carrier with an acidic pH buffer, followed by loading a modifying metal component, and calcining under an inert or reducing atmosphere to create uniformly distributed coordination-unsaturated metal ion sites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydrocracking catalysts are used, then the catalyst structure is simple and easy to manufacture, but the conversion rate of non-aromatic hydrocarbons is low and side reactions are high
Solution Approach 1:
The patent introduces modifying metal components (such as Pt, Pd, Ni, or Co) at specific locations on the catalyst surface, creating local areas with enhanced Lewis acid strength and different catalytic properties. This allows the catalyst to have zones optimized for hydrocracking activity while other zones minimize side reactions, directly resolving the contradiction between conversion rate and side reactions.
Solution Approach 2:
The patent creates a composite catalyst system by combining metal oxide carriers (such as Al2O3, SiO2, or TiO2) with modifying metal components. This composite structure integrates the support material's basic catalytic activity with the modifying metals' enhanced Lewis acid sites, achieving both high conversion rate and reduced side reactions through synergistic effects.
2Productivity
If the Lewis acid strength is increased to improve conversion rate, then the conversion rate of non-aromatic hydrocarbons increases, but the interaction with hydrocarbon molecules becomes too strong causing deactivation
Solution Approach 1:
The patent optimizes the Lewis acid strength by carefully controlling the type and amount of modifying metal components (0.1-5 wt%), as well as the calcination temperature (300-600°C) and atmosphere. This parameter optimization ensures the catalyst has sufficient activity for high conversion while maintaining stability and preventing deactivation through excessive strong interactions.
Solution Approach 2:
The patent introduces a controlled amount of modifying metal components that provide partial enhancement of Lewis acid sites rather than complete saturation. This partial action approach achieves the necessary conversion rate improvement while avoiding the excessive strength that would lead to catalyst deactivation, maintaining a balance between activity and 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 catalyst enhances the conversion rate of non-aromatic hydrocarbons while reducing side reactions through the synergistic effect of strong Lewis acid sites and metal components, facilitating stable hydrocracking operations.
Implementation Method 1
etching a metal oxide carrier with an acidic pH buffer having a pH value of 1-5, to obtain a carrier precursor
Implementation Method 2
loading the modifying metal component onto the carrier obtained in step 2), optionally drying, and calcining
Implementation Method 3
calcining under an inert or reducing atmosphere to create uniformly distributed coordination-unsaturated metal ion sites
Implementation Method 4
Lewis acid sites on the surface of a metal oxide with unsaturated-coordination are potential Lewis acid sites... capable of accepting electrons
Data Source
AI summary
A solid acid catalyst, and preparation and use thereof are provided. The catalyst contains a metal oxide carrier and at least one modifying metal component. When the catalyst is characterized by solid nuclear magnetic resonance with trimethylphosphine as the probe molecule, it exhibits a spectral peak in the range of −5 to −20 ppm. The catalyst can be used for hydrocracking reaction of non-aromatic hydrocarbons.