Production of products from natural resources

Patent metadata

Field	Value
Publication number	US-10112883-B2
Application number	US-201414786010-A
Country	US
Kind code	B2
Filing date	Apr 22, 2014
Priority date	Apr 24, 2013
Publication date	Oct 30, 2018
Grant date	Oct 30, 2018

Abstract

The method disclosed herein relates to two stage catalytic processes for converting syngas to acetic acid, acrylic acid and/or propylene. More specifically, the method described and claimed herein relate to a method of producing acrylic acid and acetic acid comprising the steps of: a) providing a feedstream comprising syngas; b) contacting the feedstream with a first catalyst to produce a first product stream comprising C2-C3 olefins and/or C2-C3 paraffins; and c) contacting the first product stream with oxygen gas and a second catalyst, thereby producing a second product stream comprising acrylic acid and acetic acid, wherein there is no step for separating the components of the first product stream before the first product stream is contacted with the second catalyst.

First claim

What is claimed is:

1. A method of producing acrylic acid and acetic acid comprising the steps of:
a) providing a feedstream comprising syngas;
b) a step consisting of contacting the feedstream with a first catalyst to produce a first product stream comprising C2-C3 olefins and/or C2-C3 paraffins; and
c) contacting the first product stream with oxygen gas and a second catalyst, thereby producing a second product stream comprising acrylic acid and acetic acid,
wherein there is no step for separating the components of the first product stream before the first product stream is contacted with the second catalyst,

wherein the first catalyst is a catalyst composition comprising cobalt; manganese; hydrophilic silica; and at least one element comprising lanthanum, phosphorus, Fe, Zr, or Zn, wherein the relative molar ratios of the elements comprised in said composition are represented by the formula
Co a1 Mn b1 Si z1 X y1 M1 d1 O f1 ,

wherein a1 is 1;
wherein b1 is from 0.8 to 1.2;
wherein Si is in the form of a hydrophilic silica;
wherein z1 is from 0.1 to 1;
wherein X is La, P, Fe, Zr, or Zn, or a mixture thereof;
wherein y1 is greater than 0 to 0.005;
wherein M1 is one or more elements selected from the group consisting of alkali metal, alkaline earth metal and transition metal,
wherein d1 is 0 to 0.005; and
wherein f1 is a number determined by the valence requirements of elements of the other elements present in the catalyst.

2. The method of claim 1 , wherein the method further comprises separating the acetic acid and the acrylic acid.

3. The method of claim 1 , wherein M1 comprises Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Ti, or Zr, or a mixture thereof.

4. The method of claim 1 , wherein X is La and P.

5. The method of claim 1 , wherein X is one element and is Fe, Zr, or Zn.

6. The method of claim 1 , wherein the hydrophilic silica has a specific surface area from 200 m 2 /g to 400 m 2 /g.

7. The method of claim 1 , wherein the hydrophilic silica has a pH of 3.7-4.7.

8. The method of claim 1 , wherein the first product stream comprises at least 50 mole % C2-C3 olefins and/or C2-C3 paraffins.

9. The method of claim 1 , wherein the first product stream does not comprise C1-05 alcohols.

10. The method of claim 1 , wherein the second catalyst comprises
Mo a3 V b3 Ga c3 Pd d3 Nb e3 Z f3 ,
wherein the a3, b3, c3, d3, e3, and f3 are relative molar ratios in the second catalyst,
wherein a3 is 1,
wherein b3 is from 0.01 to 0.9,
wherein c3 is greater than 0 to 0.2,
wherein d3 is from 0.0000001 to 0.2,
wherein e3 is greater than 0 to 0.2,
wherein Z comprises La, Te, Ge, Zn, Si, In, or W, or a mixture thereof, and
wherein f3 is greater than 0 to 0.5.

11. The method of claim 10 , wherein Z comprises Te.

12. The method of claim 10 , wherein the second catalyst comprises a support material.

13. The method of claim 12 , wherein the support material comprises Al 2 O 3 , SiO 2 , CeO 2 , TiO 2 , ZrO 2 , acetate-SiO 2 , low surface area TiO 2 , high surface area TiO 2 , acetate-Al 2 O 3 , acetate-ZrO 2 , acetate-CeO 2 , AlPO 4 , SiC, silicon-carbide, Mo-carbide, aluminumsilicate, a zeolite, or a molecular sieve, or a mixture thereof.

14. The method of claim 12 , wherein the support material is neutral or oxidative.

15. The method of claim 12 , wherein the support material comprises additional components M s and Xs,
wherein Ms is a metal comprising B, La, Mn, Sb, Ti, Zr, La, Fe, Cs, Au, or Ce; and
wherein Xs is optionally present and is an alkaline metal comprising Na, K, Mg, or Ca.

16. The method of claim 15 , wherein the support material comprises Al 2 O 3 , SiO 2 , TiO 2 , CeO 2 , AlPO 4 , ZrO 2 , SiC, Mo-carbide, aluminumsilicate, a zeolite, or a molecular sieve, or a mixture thereof.

17. The method of claim 15 , wherein Ms comprises La, Zr, Ce, or Cs.

18. The method of claim 16 , wherein Ms comprises La.

19. The method of claim 1 , wherein the method consists of steps a)-c).

Assignees

• Saudi Basic Ind Corp

Inventors

• Karim Khalid
• Ahmed Labeeb Chaudhary

Classifications

• C07C51/252

  of propene, butenes, acrolein or methacrolein · CPC title

• C07C2527/187

  with manganese, technetium or rhenium · CPC title

• C07C2523/889

  Manganese, technetium or rhenium · CPC title

• B01J27/187

  with manganese, technetium or rhenium · CPC title

• C07C51/215 Primary

  of saturated hydrocarbyl groups · CPC title