Tungsten Fluorine Bond Catalyst for Propylene Metathesis
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Solution Overview
Problem
Current propylene production methods, such as steam cracking and other conventional processes, fail to meet the growing demand for propylene due to insufficient yields and high capital costs, necessitating the development of cost-effective methods to increase propylene production from both refinery hydrocarbons and non-petroleum based feeds.
Innovation Solution
A catalyst comprising a tungsten metal compound with a tungsten-fluorine bond dispersed on a refractory oxide support, specifically tungsten-fluorine compounds like WR4F, WOFR3, or W(NR′)FR3, chemically bonded to the support, is used for the metathesis of olefins to enhance propylene production from ethylene and butylene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If steam cracking is used for propylene production, then ethylene and propylene can be produced from hydrocarbon feedstocks, but the yield of propylene is insufficient to satisfy worldwide demand
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition and structure of the catalyst. Specifically, it uses tungsten compounds with controlled oxidation states (W(VI), W(V), W(IV)) and specific ligand environments (alkoxides, amides, carbenes) to optimize the metathesis reaction for propylene production. The catalyst system includes tungsten compounds dispersed on supports like silica or alumina, with controlled surface area and pore structure parameters to enhance propylene yield from C4 olefins and other hydrocarbon feedstocks.
2Productivity
If dedicated propylene production routes like paraffin dehydrogenation are used, then propylene production capacity can be increased, but capital cost increases significantly
Solution Approach 1:
The patent applies universality by developing a catalyst system that can process multiple types of hydrocarbon feedstocks (C4 olefins, naphtha, gas oil, biomass-derived feedstocks) through the same metathesis reaction mechanism. This multi-functional catalyst enables propylene production from diverse feedstocks using a single catalytic system, avoiding the need for separate dedicated production routes for each feedstock type and thereby reducing overall capital costs while maintaining high propylene production capacity.
3Productivity
If conventional catalysts are used for olefin metathesis, then the reaction can proceed, but selectivity and conversion rates are insufficient to address the demand-supply gap
Solution Approach 1:
The patent applies local quality by creating highly specific active sites on the catalyst surface with precise electronic and steric properties. The tungsten compounds are designed with specific ligand environments (alkoxide, amide, carbene ligands) and oxidation states that create localized regions of high catalytic activity and selectivity. The catalyst support is engineered with controlled surface area, pore size distribution, and surface chemistry to provide optimal local environments for propylene formation, thereby achieving high selectivity and conversion rates that address the demand-supply gap.
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 significantly increases propylene yields by effectively converting ethylene and butylene into propylene, achieving high selectivity and conversion rates, thereby addressing the demand-supply gap and reducing production costs.
Implementation Method 1
A catalyst comprising a tungsten metal compound with a tungsten-fluorine bond dispersed on a refractory oxide support is used for the metathesis of olefins to enhance propylene production from ethylene and butylene
Data Source
AI summary
A catalyst for the metathesis of olefins in general and specifically for the production of propylene from ethylene and butylene has been developed. The catalyst comprises a tungsten metal compound, which contains at least one tungsten-fluoro bond, dispersed or grafted onto a support. A specific example of the catalyst is the compound WOF(CH2CMe3)3 grafted onto a silica support.