Synthesis Gas Poisoning Control to Suppress Catalyst Coking
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Solution Overview
Problem
Catalyst activity decreases over time due to hydrocarbon coating and coking, necessitating regeneration treatments that disrupt production and incur high costs, requiring a method to suppress catalyst deterioration.
Innovation Solution
Supplying a synthesis gas containing a controlled concentration of poisoning substances, such as ammonia or hydrogen sulfide, to the catalyst to delay catalyst deterioration, using a method and device that adjust and control the concentration of these substances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If regeneration treatment is performed to remove hydrocarbon coating and coking from the catalyst, then catalyst activity is restored, but production is disrupted and costs increase
Solution Approach 1:
The patent applies preliminary action by adding small amounts of poisoning substances (such as sulfur compounds or CO) to the synthesis gas before the catalyst becomes severely deactivated. This preventive measure maintains catalyst activity over extended periods by inhibiting wax deposition and coking before they occur, thereby avoiding the need for frequent shutdowns and regeneration treatments that would disrupt hydrocarbon production
Solution Approach 2:
The patent converts the harmful effect of poisoning substances into a beneficial outcome by utilizing controlled amounts of these substances to prevent catalyst deactivation. The poisoning substances, which would normally be considered harmful, are instead used to suppress unwanted side reactions and maintain catalyst performance, thereby sustaining continuous production without requiring shutdowns for regeneration
2Reliability
If regeneration treatment is performed to remove hydrocarbon coating and coking from the catalyst, then catalyst activity is restored, but treatment time and costs increase
Solution Approach 1:
The patent applies preliminary action by adding small amounts of poisoning substances (such as sulfur compounds or CO) to the synthesis gas before the catalyst becomes severely deactivated. This preventive measure maintains catalyst activity over extended periods by inhibiting wax deposition and coking before they occur, thereby avoiding the need for frequent shutdowns and regeneration treatments that would disrupt hydrocarbon production
Solution Approach 2:
The patent enables continuous operation of the Fischer-Tropsch synthesis process by preventing catalyst deactivation through controlled addition of poisoning substances. This eliminates the intermittent shutdowns required for regeneration treatments, maintaining continuous hydrocarbon production and eliminating time losses associated with stopping and restarting the process
3Reliability
If poisoning substances are added to synthesis gas to suppress catalyst deterioration, then catalyst activity is maintained, but gas composition control becomes more complex
Solution Approach 1:
The patent applies parameter changes by controlling the concentration of poisoning substances in the synthesis gas within specific ranges (e.g., sulfur compounds at 0.1-10 ppm, CO at 1-10%). By optimizing these concentration parameters, the system achieves effective catalyst protection while minimizing the complexity of control systems required. The controlled addition of small amounts of poisoning substances creates a balance between maintaining catalyst activity and managing gas composition
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 and device effectively suppress catalyst deterioration, maintaining catalyst activity and reducing the frequency of regeneration treatments, thereby enhancing production efficiency and reducing costs.
Implementation Method 1
supplying the synthesis gas to the catalyst as a gas containing a poisoning substance that is poisonous to the catalyst
Data Source
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AI summary
An object is to suppress deterioration in a catalyst capable of synthesizing a hydrocarbon from a synthesis gas containing carbon oxide. A supply method for supplying a synthesis gas containing hydrogen gas and carbon oxide gas to a catalyst capable of producing a hydrocarbon from the synthesis gas includes supplying the synthesis gas to the catalyst as a gas containing a poisoning substance that is poisonous to the catalyst. The concentration of the poisoning substance in the synthesis gas is set to more than 0 volppm and 1.0 volppm or less, preferably 0.01 volppm or more and 0.2 volppm or less, and more preferably 0.02 volppm or more and less than 0.1 volppm. The poisoning substance is a temporary poisoning substance which is at least one compound selected from the group consisting of NH3, HCN, PH3, NaCl, and KCl, or a permanent poisoning substance which is a compound including at least one of a compound containing S and HCl and is at least one compound selected from the group consisting of H2S, COS, HCl, and AsH3.