Processes for improving the activity of hybrid catalysts

Patent metadata

Field	Value
Publication number	US-10703689-B2
Application number	US-201816483653-A
Country	US
Kind code	B2
Filing date	Feb 2, 2018
Priority date	Feb 6, 2017
Publication date	Jul 7, 2020
Grant date	Jul 7, 2020

Abstract

A process for converting a feed stream to C 2 to C 5 hydrocarbons includes introducing a feed stream of hydrogen and at least one carbon-containing component selected from CO, CO 2 , and mixtures thereof into a reaction zone at an initial reactor pressure and an initial reactor temperature. The feed stream is contacted to a hybrid catalyst positioned in the reaction zone, and the hybrid catalyst includes a methanol synthesis component and a solid microporous acid material. The pressure within the reaction zone is increased during the contacting of the feed stream to the hybrid catalyst from the initial reactor pressure to a final reactor pressure. A temperature within the reaction zone at any time during the contacting of the feed stream to the hybrid catalyst is within ±20° C. of the initial reactor temperature.

First claim

The invention claimed is:

1. A process for converting a feed stream to C 2 to C 5 hydrocarbons, comprising:
introducing a feed stream comprising hydrogen and at least one carbon-containing component selected from the group consisting of CO, CO 2 , and mixtures thereof into a reaction zone at an initial reactor pressure and an initial reactor temperature;
contacting the feed stream to a hybrid catalyst positioned in the reaction zone, wherein the hybrid catalyst comprises a methanol synthesis component and a solid microporous acid material; and
increasing a pressure within the reaction zone during the contacting of the feed stream to the hybrid catalyst from the initial reactor pressure to a final reactor pressure,
wherein a temperature within the reaction zone at any time during the contacting of the feed stream to the hybrid catalyst is within ±20° C. of the initial reactor temperature.

2. The process of claim 1 , wherein the final reactor pressure is at least 1 bar (0.1 MPa) greater than the initial reactor pressure.

3. The process of claim 1 , wherein the final reactor pressure and is from 1 bar (0.1 MPa) to 60 bar (6.0 MPa) greater than the initial reactor pressure.

4. The process of claim 1 , wherein the initial reactor pressure is from 15 bar (1.5 MPa) to 60 bar (6.0 MPa) and the final reactor pressure is from 16 bar (1.6 MPa) to 120 bar (12.0 MPa).

5. The process of claim 1 , wherein the initial reactor temperature is from 350° C. to 450° C.

6. The process of claim 1 , wherein a temperature within the reaction zone at any time during the contacting of the feed stream to the hybrid catalyst is within ±10° C. of the initial reactor temperature.

7. The process of claim 1 , wherein
the methanol synthesis component comprises one or more of Cu, Zn, Cr, and Al in any possible compositional combination and in either metallic or oxidic form, and
the solid microporous acid material is selected from molecular sieves having 8-MR access and having a framework type selected from the group consisting of framework types CHA, AEI, AFX, ERI, LTA, UFI, RTH, and combinations thereof, the framework types corresponding to the naming convention of the International Zeolite Association.

8. The process of claim 1 , wherein a flow rate of the feed stream is greater than 500 reciprocal hours (h −1 ).

9. The process of claim 1 , wherein the pressure within the reaction zone during the contacting of the feed stream to the hybrid catalyst is increased from the initial reactor pressure to the final reactor pressure at a plurality of intervals.

10. The process of claim 9 , wherein a duration of each of the plurality of intervals is at least 12 hours.

11. The process of claim 9 , wherein a pressure increase at each of the plurality of intervals is at least 1 bar (0.1 MPa).

12. The process of claim 9 , wherein a duration of each of the plurality of intervals is from 12 hours to 48 hours, and a pressure increase at each of the plurality of intervals is at least 1 bar (0.1 MPa).

13. The process of claim 1 , wherein the pressure within the reaction zone during the contacting of the feed stream to the hybrid catalyst is increased when a percentage yield of desired products reaches a predetermined threshold value.

14. The process of claim 13 , wherein a pressure within the reaction zone is increased by at least 1 bar (0.1 MPa) when the percentage yield of desired products reaches the predetermined threshold value.

15. The process of claim 13 , wherein a pressure within the reaction zone is increased by at least 5 bar (0.5 MPa) when the percentage yield of desired products reaches the predetermined threshold value.

Assignees

• Dow Global Technologies Llc

Inventors

• Nieskens Davy L S
• Sandikci Aysegul Ciftci
• Groenendijk Peter E
• Malek Andrzej

Classifications

• C07C2521/02

  Boron or aluminium; Oxides or hydroxides thereof · CPC title

• C07C1/047

  Processes in which one or more parameters are changed during the process; Starting-up of the process · CPC title

• C10G2300/4012

  Pressure · CPC title

• C07C2529/85

  Silicoaluminophosphates (SAPO compounds) · CPC title

• C10G2300/4006

  Temperature · CPC title