SHORT DESCRIPTION
For chemical processing plants, this catalyst system produces olefins with record per-pass yields by integrating propane dehydrogenation and selective hydrogen combustion in one reactor.
*Principal Investigator
NU Tech ID: 2020-057
IP STATUS
Issued US Patent 12,311,343
DEVELOPMENT STAGE
TRL-4 - Prototype Validated in Lab: A laboratory-scale prototype has demonstrated integration of tandem catalytic functions with significant performance improvements.
BACKGROUND
Current dehydrogenation methods use either multiple reactors with complex layouts or catalysts that suffer from poor selectivity due to oxidation. Engineered solutions require expensive re-heaters and staged reactors, while catalytic methods often fail to overcome equilibrium limitations, driving the need for a simplified, efficient approach. ABSTRACT
The invention integrates a tandem catalyst design using atomic layer deposition to coat a platinum-alumina catalyst with indium oxide in a core-shell configuration. This spatially organized structure protects the propane dehydrogenation catalyst from oxidation while driving selective hydrogen combustion. The process shifts the equilibrium, achieving a record ~40% per-pass yield of propylene. Laboratory tests confirm catalyst stability and consistent selectivity across increased conversions. MARKET OPPORTUNITY
The global petrochemical market, valued at $623.8 billion in 2023, is under immense pressure to increase efficiency and reduce its significant energy footprint (Source: Fortune Business Insights, 2024). A critical segment within this industry is the refinery catalyst market, which was valued at $4.82 billion in 2023 and is driven by the constant need for process optimization (Source: Fortune Business Insights, 2024).
A primary operational bottleneck is the high cost and inefficiency of current dehydrogenation processes, which rely on complex, multi-reactor layouts with expensive re-heaters to manage high energy demands. Furthermore, conventional catalysts suffer from poor selectivity and deactivation due to coke buildup, leading to costly downtime. This technology directly addresses this multi-billion dollar unmet need by providing a simplified, highly efficient catalytic approach that overcomes equilibrium limitations, reduces capital expenditure, and minimizes energy consumption.
APPLICATIONS