Use of a catalyst system in the production of 1,3-butadiene from ethanol in two stages
AssigneeSynthos S.A.
InventorsEwelina JANKOWIAK, Szymon SKOWRONEK, Magdalena SITKO
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Abstract
The invention relates to a process for the production of 1,3-butadiene from ethanol, the process comprising a first stage and a second stage. Furthermore, the invention relates to a catalyst system for use in the production of 1,3-butadiene from ethanol. Moreover, the invention relates to the use of the catalyst system for the production of 1,3-butadiene from a feed comprising ethanol, and a plant comprising the catalyst system.
Claims28
A process for the production of 1,3-butadiene, the process comprising the following stages
- i) a first stage contacting of a first stage feed comprising ethanol with a first stage catalyst,
- wherein the first stage catalyst comprises element MA1 and element MB1,
- MA1 is selected from the group consisting of zinc, copper, silver, gold, chromium, cerium, magnesium, platinum, palladium, cadmium, iron, manganese, ruthenium, cobalt, and nickel, and
- MB1 is selected from the group consisting of tantalum, zirconium, niobium, hafnium, titanium, and tin,
- to produce a first stage effluent comprising acetaldehyde and 1,3-butadiene,
- ii) a second stage contacting of a second stage feed with a second stage catalyst,
- the second stage feed comprising at least part of the first stage effluent, and the second stage feed comprising ethanol and acetaldehyde,
- wherein the second stage catalyst comprises element MB2, and
- MB2 is selected from the group consisting of tantalum, zirconium, niobium, hafnium, titanium, and tin,
- to produce a second stage effluent comprising 1,3-butadiene.
The process according to any of the preceding claims, wherein MA1 is selected from the group consisting of zinc, copper, silver, chromium, magnesium, and nickel, preferably wherein MA1 is zinc.
The process according to any of the preceding claims, wherein MA1 is present in an oxide form, preferably wherein the first stage catalyst comprises zinc oxide.
The process according to any of the preceding claims, wherein MB1 is selected from the group consisting of tantalum, zirconium, niobium, hafnium, preferably wherein MB1 is tantalum.
The process according to any of the preceding claims, wherein MB1 is present in an oxide form, preferably wherein the first stage catalyst comprises tantalum oxide.
The process according to any of the preceding claims, wherein the first stage catalyst comprises, based on the total weight of the first stage catalyst,
- a) zinc oxide in an amount of from 0.05 to 18 wt. %, preferably from 0.05 to 5 wt. %, more preferably from 0.05 to 1 wt. %, more preferably from 0.05 to 0.2 wt. %, most preferably about 0.1 wt. %, calculated as ZnO, and/or
- b) tantalum oxide in an amount of from 1 to 13 wt. %, preferably from 2 to 3 wt. %, more preferably about 2 wt. %, calculated as Ta2O5.
The process according to any of the preceding claims, wherein the first stage catalyst is a supported catalyst,
- preferably wherein the support is selected from the group consisting of ordered and non-ordered porous silica supports, aluminium oxide supports, aluminosilicate supports, clays, other porous oxide supports, and mixtures thereof,
- more preferably wherein the support is silica.
The process according to any of the preceding claims, wherein MB2 is selected from the group consisting of tantalum, zirconium, niobium, hafnium, preferably wherein MB2 is tantalum.
The process according to any of the preceding claims, wherein MB2 is present in an oxide form, preferably wherein the second stage catalyst comprises tantalum oxide.
The process according to any of the preceding claims, wherein the second stage catalyst is a supported catalyst,
- preferably wherein the support is selected from the group consisting of ordered and non-ordered porous silica supports, aluminium oxide supports, aluminosilicate supports, clays, other porous oxide supports and mixtures thereof,
- more preferably wherein the support is silica.
The process according to any of the preceding claims, wherein both the first and the second stage catalysts are supported catalysts.
The process according to any of the preceding claims, wherein the first stage catalyst comprises zinc and tantalum in a molar ratio of from 0.01 to 1, preferably from 0.1 to 0.7, more preferably from 0.1 to 0.2.
The process according to any of the preceding claims, wherein the first stage feed additionally comprises acetaldehyde,
- preferably wherein the acetaldehyde concentration is within a range of from 2 to 30 vol. %, more preferably from 5 to 20 vol. %, most preferably from 7 to 15 vol. %, each based on total volume of the first stage feed.
The process according to any of the preceding claims, wherein the first stage catalyst is produced or producible according to a method comprising:
- a) impregnating a first stage support comprising silica with a first stage catalyst precursor comprising an MA1 compound and an MB1 compound;
- b) drying the impregnated first stage support;
- and
- c) calcining the dried impregnated first stage support.
Catalyst system for use in the production of 1,3-butadiene from ethanol comprising
- i) a first stage catalyst comprising element MA1 and element MB1, wherein
- MA1 is selected from the group consisting of zinc, copper, silver, gold, chromium, cerium, magnesium, platinum, palladium, cadmium, iron, manganese, ruthenium, cobalt, and nickel, and
- MB1 is selected from the group consisting of tantalum, zirconium, niobium, hafnium, titanium, and tin, and
- ii) a second stage catalyst comprising element MB2, wherein
- MB2 is selected from the group consisting of tantalum, zirconium, niobium, hafnium, titanium, and tin.
The catalyst system according to any of the preceding claims, wherein the first stage catalyst comprises zinc and tantalum, and the second stage catalyst comprises tantalum.
The catalyst system according to any of the preceding claims, wherein the first stage catalyst comprises (each based on the total weight of the first stage catalyst)
- zinc oxide, preferably in an amount of from 0.05 to 18 wt. %, more preferably from 0.05 to 5 wt. %, more preferably from 0.05 to 1 wt. %, more preferably from 0.05 to 0.2 wt. %, most preferably about 0.1 wt. %, calculated as ZnO, and/or
- tantalum oxide, preferably in an amount of from 1 to 13 wt. %, more preferably from 2 to 3 wt. %, most preferably about 2 wt. %, calculated as Ta2O5.
Dependencies are inferred from the claim text.