Abstract

The design of hybrid pellet catalysts for dehydrogenation and metathesis of propane to olefins was investigated. Reaction kinetics and mathematical models of pellet catalysts in a reactor were developed and simulated using gPROMS. Three types of pellet catalysts including uniformly mixed, dehydrogenation-core (MDM) and dehydrogenation-shell (DMD) were compared with physically mixed pellet catalysts. A sensitivity analysis of operating conditions, ratios, types and sizes of pellet catalysts were performed to determine the optimal parameters offering a maximum alkene yield. The most suitable pellet catalyst type was DMD. Depending on operating conditions, the optimal DMD had a core metathesis diameter of between 0.28 and 3.43 mm, with spherical particles between 1 and 7 mm in diameter. The optimal DMD showed increased alkene yield up to 43%, while alkene selectivity improved by 25–35% from the base case. The amount of dehydrogenation catalysts reduced from the base case by approximately 59%.

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