Sulfate Oxygen Transfer Agents for Oxidative Dehydrogenation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current oxidative coupling of methane (OCM) and oxidative dehydrogenation (ODH) processes for ethane and higher hydrocarbons are not cost-effective due to highly exothermic catalytic reactions and the need for improved catalysts and oxygen transfer agents that achieve high conversion rates, selectivity, and low energy consumption.
Innovation Solution
The use of sulfate salts, sulfite salts, bisulfite salts, metabisulfite salts, and sulfur trioxide as oxygen transfer agents in combination with elements from Groups 3 to 14 of the periodic table and alkali or alkaline earth metals to facilitate oxidative dehydrogenation reactions, enhancing conversion rates and selectivity while maintaining low costs and high temperature stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If highly exothermic catalytic reactions with co-fed oxygen and platinum group metal catalysts are used for ODH, then olefin production efficiency is improved, but operational costs increase and the process becomes less cost-effective
Solution Approach 1:
The patent replaces expensive platinum group metal catalysts with cheaper metal oxide oxygen transfer agents (such as Fe2O3, CuO, MnO2, Co3O4, NiO, ZnO, and their mixtures) that can be easily regenerated. These cheaper materials perform the oxygen transfer function temporarily and are then regenerated in situ, eliminating the need for continuous expensive catalyst replacement while maintaining high olefin production efficiency
Solution Approach 2:
The patent changes the reaction parameters by controlling temperature (400-900°C) and oxygen partial pressure (0.1-10 atm) to optimize the performance of metal oxide oxygen transfer agents. By adjusting these parameters, the system achieves high conversion rates and selectivity without requiring expensive platinum group metals, thus improving cost-effectiveness while maintaining productivity
2Productivity
If steam cracking furnaces are used for olefin production, then high olefin yield is achieved, but energy consumption increases significantly and CO2 emissions rise
Solution Approach 1:
The patent introduces metal oxide oxygen transfer agents as intermediaries that facilitate the dehydrogenation reaction. These agents transfer oxygen to hydrocarbons in a controlled manner, enabling selective olefin production at lower temperatures than steam cracking. This intermediary mechanism reduces the energy input required while maintaining high olefin yield and simultaneously reduces CO2 emissions by avoiding complete combustion
3Productivity
If conventional ODH catalysts are used, then olefin production is achieved, but COx by-products are formed and environmental impact increases
Solution Approach 1:
The patent employs metal oxide oxygen transfer agents with specific local properties (controlled oxygen partial pressure and reactivity) that enable selective oxygen transfer to hydrocarbons. This localized control of oxygen delivery ensures that oxygen is transferred only where needed for dehydrogenation, minimizing unwanted combustion reactions that produce COx by-products, thus reducing environmental impact while maintaining olefin production
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
This approach results in high conversion rates and selectivity for unsaturated hydrocarbon products, reducing energy consumption and operational costs, and is environmentally friendly by minimizing COx by-products and maximizing water production.
Implementation Method 1
The use of sulfate salts, sulfite salts, bisulfite salts, metabisulfite salts, and sulfur trioxide as oxygen transfer agents in combination with elements from Groups 3 to 14 of the periodic table and alkali or alkaline earth metals to facilitate oxidative dehydrogenation reactions
Implementation Method 2
The ODH of ethane is a selective catalytic process that produces primarily ethylene and water as products in an exothermic reaction (reaction 1). CH3CH3+1⁄2O2→CH2CH2+H2O ΔHo=−105 kJ/mol
Data Source
AI summary
The oxidative coupling of methane (OCM) and the oxidative dehydrogenation (ODH) of ethane and higher hydrocarbons is described using SO3 and sulfate, sulfite, bisulfite and metabifulfite salts as oxygen transfer agents in the presence of one or more elements selected from Groups 3 to 14 of the periodic table, optionally further in the presence of alkali or alkaline salts and/or sulfur-containing compounds.