Spent FCC Catalyst Composition for Propane Dehydrogenation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional propane dehydrogenation processes require high temperatures, leading to decreased propylene selectivity and catalyst deactivation, and existing catalysts are costly and difficult to dispose of due to stringent environmental regulations, necessitating the development of a cost-effective and efficient method for converting alkanes to alkenes using spent catalysts from Fluid Catalytic Cracking (FCC) processes.
Innovation Solution
A catalyst composition utilizing spent catalysts from FCC processes, calcined and modified with metal oxides from transition groups VB, VIB, VIII, and Lanthanide series, and optionally alkali metals, which can be used for both non-oxidative and oxidative propane dehydrogenation in the presence of CO2, involving steps such as calcination, grinding, and impregnation with metals like Vanadium and Nickel to enhance propylene yield and selectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high temperatures are used for propane dehydrogenation to achieve economically viable conversions, then conversion is improved, but propylene selectivity decreases and catalyst deactivation accelerates
Solution Approach 1:
The patent changes the temperature parameter by introducing oxidative dehydrogenation at lower temperatures (400-500°C) compared to conventional non-oxidative dehydrogenation (600-700°C). This parameter change allows achieving viable conversions while maintaining propylene selectivity and reducing catalyst deactivation rates.
Solution Approach 2:
The patent uses composite catalyst materials combining transition metal oxides (Cr, V, Fe) with specific supports (alumina, silica) and promoters (Sn, Zn, alkaline earth metals). These composite materials enhance catalytic activity and selectivity at lower temperatures, resolving the contradiction between conversion and selectivity.
2Reliability
If conventional alumina supported noble metal catalysts are used for propane dehydrogenation, then catalytic activity is improved, but cost increases and disposal becomes difficult due to environmental regulations
Solution Approach 1:
The patent replaces expensive noble metal catalysts (Pt, Pd, Rh) with cheaper transition metal oxides (Cr, V, Fe) that can be more easily disposed of or recycled. These alternative catalysts achieve comparable catalytic activity while being more environmentally friendly and cost-effective.
Solution Approach 2:
The patent changes the catalyst composition parameters by using non-noble metals with specific oxide forms and support materials. This parameter change maintains catalytic performance while eliminating the need for expensive noble metals and simplifying disposal according to environmental regulations.
3Use of energy by moving object
If oxidative dehydrogenation is used to perform dehydrogenation at lower temperatures, then energy consumption is reduced, but excess oxidation may occur in the presence of O2
Solution Approach 1:
The patent changes the oxidant parameter by using CO2 instead of O2 as the oxygen source in oxidative dehydrogenation. This parameter change allows proceeding at lower temperatures while preventing excess oxidation reactions, as CO2 provides controlled oxygen transfer without the harshness of molecular oxygen.
Solution Approach 2:
The patent introduces CO2 as an intermediary oxygen carrier that mediates the oxidation process. CO2 acts as a gentle oxidant that transfers oxygen in a controlled manner, enabling low-temperature dehydrogenation while avoiding the harmful effects of direct O2 oxidation.
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 method achieves efficient conversion of alkanes to alkenes with propylene selectivity ranging from 25-90% and conversion of light paraffins between 15-55%, while effectively reusing spent catalysts, thus reducing waste and operational costs.
Implementation Method 1
A catalyst composition for conversion of alkanes to alkenes and method of preparation thereof
Implementation Method 2
calcining the spent catalyst to remove coke and/or any other volatile material
Implementation Method 3
Oxidative dehydrogenation refers to a chemical reaction, wherein oxygen reacts with a hydrocarbon molecule to remove one or more hydrogen atoms from the hydrocarbon
Data Source
AI summary
The present invention relates to preparation of catalyst for production of olefinic hydrocarbons by dehydrogenation of their corresponding paraffins, particularly propylene from propane, comprising a metal oxide or combination of metal oxides utilizing spent catalyst from Fluid Catalytic Cracking (FCC)/Resid Fluid Catalytic Cracking (RFCC) processes. The metal oxides are possibly from transition metal group, particularly from groups VB, VIB, VIII, and Lanthanide series, and at least one metal from alkali group. The catalyst support used is spent catalyst or modified spent catalyst or combination thereof. The said catalyst can be used for both non-oxidative Propane Dehydrogenation (PDH) and Oxidative Propane Dehydrogenation (OPDH) process in the presence of CO2.