Zeolite Catalyst Metal Oxide Dispersion via Dual-Solvent Pre-wetting

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Solution Overview

Problem

Existing catalyst compositions for aromatizing hydrocarbons have low metal oxide dispersion within zeolite supports, leading to reduced conversion rates and yields of aromatic compounds due to external aggregates and poor metal oxide distribution.

Innovation Solution

A dual-solvent technique is employed, where a zeolite support is pre-wetted with a hydrocarbon solvent and combined with a polar solvent containing a metal salt, followed by drying and calcination to form a catalyst composition with increased metal oxide dispersion across the zeolite surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If existing impregnation techniques (thermal spreading, single-solvent impregnation, wet impregnation) are used to deposit metal oxide on catalyst support, then the catalyst can be produced with simpler processes, but the metal oxide dispersion is low and external aggregates form, reducing conversion rate and aromatic yield

Engineering Contradiction:

Improvemetal oxide dispersionVSAvoidaromatic yield

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The zeolite support is pre-wetted with a hydrocarbon solvent before metal salt impregnation. This preliminary action ensures the pores are filled with a solvent that matches the metal salt solution's polarity, preventing metal oxide aggregation during subsequent drying and calcination steps, thereby improving dispersion and aromatic yield

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the polarity parameter of the solvent system by using a dual-solvent approach: first a hydrocarbon solvent (non-polar) to pre-wet the zeolite, then a polar solvent containing metal salt. This parameter change optimizes metal oxide distribution throughout the pores, preventing aggregate formation and improving both dispersion and catalytic performance

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If metal oxide is deposited on the outer surface of the catalyst support, then the deposition process is simpler and faster, but large aggregates form and conversion rate decreases

Engineering Contradiction:

Improvedeposition process simplicityVSAvoidmetal oxide distribution

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent utilizes the porous structure of the zeolite support by pre-wetting it with hydrocarbon solvent to ensure complete pore penetration. The dual-solvent system enables metal salt to be distributed throughout the pore network rather than just on the outer surface, achieving uniform dispersion while maintaining manufacturing simplicity

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The hydrocarbon solvent acts as an intermediary substance that facilitates uniform metal oxide distribution. By pre-wetting the zeolite pores with this solvent, it creates a favorable environment for subsequent metal salt impregnation, ensuring uniform distribution without complex deposition procedures

Inventive Principle:

Principle #24Intermediary (Mediator)

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 method enhances the yield of aromatic hydrocarbon compounds by improving metal oxide distribution, leading to higher conversion rates and increased production of valuable aromatic products compared to traditional impregnation techniques.

Implementation Method 1

combining the zeolite support with a hydrocarbon solvent to form a zeolite mixture, where the hydrocarbon solvent pre-wets the pores of the zeolite support

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

combining a polar solvent comprising a metal salt with the zeolite support to form an impregnated zeolite support

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 3

drying the impregnated zeolite support

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 4

calcining the impregnated zeolite support to convert the metal salt to the metal oxide

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Data Source

PatentUS11439991B2Catalyst compositions for aromatizing hydrocarbons and processes for producing aromatic compounds using the catalyst compositions

Publication Date: 2022.09.13 SAUDI ARABIAN OIL CO

AI summary

Processes for aromatizing hydrocarbons include contacting the hydrocarbons with a catalyst composition comprising a metal oxide dispersed on a surface of a zeolite support, where contacting the hydrocarbons with the catalyst composition causes at least a portion of the hydrocarbons to undergo a chemical reaction to form aromatic hydrocarbons. The catalyst composition is prepared by a synthesis process that includes combining the zeolite support with a hydrocarbon solvent to form a zeolite mixture, where the hydrocarbon solvent pre-wets the pores of the zeolite support. The synthesis process further includes combining a polar solvent comprising a metal salt with the zeolite mixture to form an impregnated zeolite support. The synthesis process also includes drying the impregnated zeolite support and calcining the impregnated zeolite support to convert the metal salt to the metal oxide, thereby forming the catalyst composition.