Titanium-Modified Alumina Catalyst for Stable Oxychlorination
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Solution Overview
Problem
In the oxychlorination of ethylene, maintaining a stable oxygen content in tail gases is crucial for safety and control in industrial reactors, but existing catalysts struggle to consistently regulate oxygen levels, leading to operational challenges and inefficiencies.
Innovation Solution
A catalyst with copper deposited on alumina containing a specific range of titanium (0.03-15 g/kg) is used, along with additional active elements like magnesium and alkali metals, to maintain a stable oxygen profile in tail gases during the oxychlorination of ethylene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional catalysts (copper on alumina) are used for oxychlorination, then the catalytic activity is sufficient, but the oxygen content in tail gases becomes unstable
Solution Approach 1:
The invention changes the chemical composition parameter of the alumina support by introducing titanium at controlled concentrations (0.03-15 g/kg). This parameter modification transforms the catalyst's oxygen regulation capability while preserving its catalytic activity for ethylene oxychlorination.
Solution Approach 2:
The invention creates a composite catalyst system by combining copper active elements with titanium-modified alumina support. The composite structure integrates the catalytic function of copper with the oxygen-stabilizing property of titanium-containing alumina, achieving both high activity and stable oxygen content in tail gases.
2Reliability
If oxygen content in tail gases is not stabilized, then catalyst complexity remains simple, but safety and control of the industrial reactor are compromised
Solution Approach 1:
The invention modifies the alumina support composition by adding titanium within a specific concentration range (0.03-15 g/kg). This controlled parameter change enhances safety and control through stable oxygen profiling without requiring complex catalyst structures or additional system components.
3Reliability
If titanium is added to alumina to stabilize oxygen content, then oxygen profile stability improves, but manufacturing precision requirements increase
Solution Approach 1:
The invention defines a broad acceptable range for titanium content (0.03-15 g/kg, with preferred ranges of 0.05-5 g/kg and 0.1-1.5 g/kg). This parameter specification provides manufacturing flexibility while ensuring stable oxygen content in tail gases, balancing precision requirements with practical manufacturability.
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 ensures a constant oxygen and ethylene content in recycled gases, enhancing safety and control, reducing the need for continuous adjustments and minimizing corrosion and caking issues, thereby improving the efficiency and stability of the oxychlorination process.
Implementation Method 1
Gas phase reactions and in particular oxidation reactions generally make use of catalysts comprising active elements deposited on an inert support
Implementation Method 2
catalysts comprising active elements deposited on an inert support
Data Source
AI summary
The invention provides a catalyst containing active elements including copper deposited on alumina containing at least 0.03 g of titanium, expressed in metal form, per kg of alumina and use thereof in gas hase reactions, such as the oxychlorination of ethylene to 1,2-dichloroethane. This catalyst is suitable for maintaining a constant oxygen content in the tail gases and hence in the recycled gases. The invention further pertains to the use of an alumina containing at least 0.03g titanium, expressed in metal form, per Kg of alumina, as catalyst support and as catalyst diluent. In an example a catalyst containing CuCl2, MgCl2, KCl and LiCl deposited on alumina containing 1.13 g of titanium, expressed in metal form, per Kg of alumina was used for the oxychlorination of ethylene to 1,2-dichloroethane in a fluidized bed reactor.