Zeolite Lanthanide Catalyst for Alkylation

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Solution Overview

Problem

Conventional alkylation processes in industrial scales face challenges with the use of toxic and corrosive substances, requiring complex corrosion prevention and catalyst separation, and solid catalysts often lack sufficient activity and selectivity for efficient industrial application.

Innovation Solution

A catalyst comprising an inorganic structural material with ion-exchange ability, such as zeolite, supported with a metal ion of valency 2 or more, allowing for easy separation and recycling through filtration, enhancing activity and selectivity for alkylaromatic hydrocarbon production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional liquid acid catalysts (sulfuric acid, hydrogen fluoride, aluminum chloride) are used for alkylation, then high reaction activity is achieved, but the process requires complex corrosion prevention measures and catalyst separation procedures

Engineering Contradiction:
Improvereaction activityVSAvoidprocess complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The patent uses a solid acid catalyst as an intermediary substance that provides the necessary catalytic activity while avoiding the harmful properties of liquid acids. The solid catalyst acts as a mediator between reactants and products, enabling high reaction activity without requiring corrosion prevention systems or complex separation procedures. This resolves the contradiction by decoupling the catalytic function from the harmful properties of conventional liquid acid catalysts.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention changes the physical state parameter of the catalyst from liquid to solid form. This parameter change fundamentally alters the process characteristics: solid catalysts can be easily separated from reaction mixtures by filtration or decantation, eliminating the need for complex separation equipment and procedures. The solid state also eliminates corrosion issues inherent with liquid acid catalysts, thereby reducing device complexity while maintaining catalytic activity.

Inventive Principle:
Principle #35Parameter changes

2Ease of operation

If solid catalysts are used to simplify separation and collection, then ease of operation is improved, but the activity and selectivity are insufficient for industrial application

Engineering Contradiction:
Improvecatalyst separationVSAvoidreaction activity
Core Design Contradiction:
Ease of operationVSProductivity

Solution Approach 1:

The patent employs composite solid catalyst materials that combine multiple functional components to achieve both ease of operation and high productivity. The composite structure integrates active catalytic sites with appropriate support materials, enabling the catalyst to maintain high activity and selectivity while preserving the solid state advantages for easy separation. This resolves the contradiction by creating a material that simultaneously provides catalytic performance and operational simplicity.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The invention applies local quality enhancement by concentrating catalytic active sites on specific regions or phases of the solid catalyst structure. This ensures that the portions of the catalyst that contact reactants have optimal activity and selectivity, while the overall solid structure maintains ease of separation. The localized optimization of catalytic properties resolves the contradiction between activity and ease of operation.

Inventive Principle:
Principle #3Local quality

3Productivity

If highly toxic chemical substances are used for alkylation reactions, then reaction activity is maintained, but safety and environmental risks increase significantly

Engineering Contradiction:
Improvereaction activityVSAvoidtoxicity
Core Design Contradiction:
ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful property of liquid acid catalysts into a beneficial solid catalyst system. By transforming the catalyst phase from liquid to solid, the invention eliminates toxicity and corrosion hazards while retaining catalytic functionality. The solid catalyst provides the necessary reaction activity without the harmful side effects, effectively converting a harmful process into a safe one while maintaining productivity.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention employs solid catalysts that can be easily separated and potentially regenerated or disposed of without environmental contamination. Unlike liquid acid catalysts that require complex neutralization and disposal procedures, the solid catalyst can be filtered out and handled as a non-toxic material, significantly reducing environmental and safety risks while maintaining reaction efficiency.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

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 achieves industrially suitable activity and selectivity, enabling high-yield and high-selectivity production of alkylaromatic hydrocarbons while simplifying catalyst separation and recycling processes.

Implementation Method 1

an inorganic structural material having an ion-exchange ability and a metal ion having a valency of 2 or more, the metal ion being supported on the inorganic structural material

Methodology Applied
Scientific EffectIon exchange: Ion Exchange

Data Source

PatentUS8772529B2Catalyst for alkylation and process for producing alkylaromatic hydrocarbon compound using the catalyst
Publication Date: 2014.07.08 UBE CORPORATION
  • US8772529B2 patent drawing
  • US8772529B2 patent drawing
  • US8772529B2 patent drawing

AI summary

A catalyst for alkylation contains an inorganic structural material having an ion-exchange ability and a metal ion having a valency of 2 or more. The metal ion is supported on the inorganic structural material. The inorganic structural material is preferably a zeolite. The metal ion is preferably a lanthanide metal. The catalyst for alkylation imparts industrially satisfiable activity and selectivity and can be readily separated, collected and recycled. Furthermore, the process for producing an alkylaromatic hydrocarbon compound includes reacting an aromatic hydrocarbon compound and a compound having an unsaturated bond in the presence of the catalyst for alkylation.