Sulphided Catalyst for C3-C12 Oxygenate Conversion
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Solution Overview
Problem
Existing processes for converting C3-C12 oxygenates to middle distillate boiling products face challenges with catalyst deactivation due to coke formation and poisoning, limiting their operational duration and efficiency.
Innovation Solution
A process using a sulphided carbon-carbon coupling catalyst with a zeolite comprising 10-12 membered ring channels and a Silica to Alumina molar Ratio between 10 and 300, operated at high hydrogen pressure to extend catalyst stability and produce middle distillate boiling products with a smooth boiling curve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing processes are used for converting C3-C12 oxygenates to hydrocarbons, then conversion to liquid fuels is achieved, but catalyst deactivation due to coke formation and poisoning occurs, limiting operational duration
Solution Approach 1:
The patent changes the chemical environment parameters by introducing high hydrogen partial pressure (>1.0 MPa) and using a sulphided catalyst system, which fundamentally alters the reaction conditions to prevent coke formation and catalyst deactivation while maintaining high conversion efficiency
Solution Approach 2:
The patent introduces hydrogen as an intermediary substance that mediates between the oxygenate feed and the catalyst, preventing direct harmful interactions that lead to coke formation and catalyst poisoning, thereby extending catalyst life while maintaining productivity
2Duration of action of stationary object
If high hydrogen pressure is applied, then catalyst stability is extended, but energy consumption increases
Solution Approach 1:
The patent converts the potentially harmful high-pressure condition into a beneficial effect by using the high hydrogen pressure to suppress coke formation and catalyst deactivation, turning an energy-intensive parameter into a protective mechanism that extends catalyst life
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 allows for prolonged operation without substantial catalyst deactivation, achieving efficient conversion of C3-C12 oxygenates to middle distillate boiling products with improved stability and yield, suitable for biofuel production.
Implementation Method 1
contacting a feed, which feed comprises one or more C3-C12 oxygenates, with hydrogen at a hydrogen partial pressure of more than 1.0 MegaPascal in the presence of a sulphided carbon-carbon coupling catalyst
Implementation Method 2
The carbon-carbon coupling catalyst comprises equal to or more than 60 wt % of a zeolite and in the range from equal to or more than 0.1 wt % to equal to or less than 10 wt % of a hydrogenation metal
Data Source
AI summary
A process for converting one or more C3-C12 oxygenates comprising oxygenates comprising: contacting a feed, which feed comprises one or more C3-C12 oxygenates, with hydrogen at a hydrogen partial pressure of more than 1.0 Mega Pascal in the presence of a sulphided carbon-carbon coupling catalyst; wherein the carbon-carbon coupling catalyst comprises equal to or more than 60 wt % of a zeolite and in the range from equal to or more than 0.1 wt % to equal to or less than 10 wt % of a hydrogenation metal, based on the total weight of the carbon-carbon coupling catalyst; and wherein the zeolite comprises 10-membered and/or 12-membered ring channels and a Silica to Alumina molar Ratio (SAR) in the range from equal to or more than 10 to equal to or less than 300.