Dual catalyst processes and systems for propylene production

Patent metadata

Field	Value
Publication number	US-10919822-B2
Application number	US-201916390523-A
Country	US
Kind code	B2
Filing date	Apr 22, 2019
Priority date	Jan 20, 2017
Publication date	Feb 16, 2021
Grant date	Feb 16, 2021

Abstract

Processes and multiple-stage catalyst systems are disclosed for producing propylene from butene by at least partially metathesizing butene in a metathesizing reaction zone having a metathesis catalyst to form a metathesis reaction product and at least partially cracking the metathesis reaction product in a cracking reaction zone having a cracking catalyst to form a cracking reaction product that includes propylene. The metathesis catalyst may be a mesoporous silica-alumina catalyst support impregnated with metal oxide having a mesoporous silica-alumina catalyst support comprising from 5 weight percent to 50 weight percent alumina. The cracking catalyst may be a MFI structured silica-containing catalyst. The cracking reaction zone may be downstream of the metathesis reaction zone.

First claim

What is claimed is:

1. A multiple-stage catalyst system for producing propylene from butene, the multiple-stage catalyst system comprising a feed stream, a metathesis reaction zone and a cracking reaction zone directly downstream of the metathesis reaction zone, where:
the metathesis reaction zone comprises a metathesis catalyst comprising a mesoporous silica-alumina catalyst support impregnated with at least one metal oxide, the mesoporous silica-alumina catalyst support comprising from 5 weight percent to 50 weight percent alumina;
the cracking reaction zone comprises a cracking catalyst comprising an MFI structured silica-containing catalyst, where the MFI structured silica-containing catalyst directly cracks a metathesis product stream to form a cracking product stream comprising propylene; and
the feed stream to the multiple-stage catalyst system comprises from 20 wt. % to 60 wt. % of cis- or trans-2-butene, or both, from 10 wt. % to 20 wt. % of 1-butene, and from 5 wt. % to 20 wt. % n-butene.

2. The multiple-stage catalyst system of claim 1 where the mesoporous silica-alumina catalyst support impregnated with at least one metal oxide comprises from 1 weight percent to 30 weight percent tungsten oxide.

3. The multiple-stage catalyst system of claim 1 where the metathesis reaction zone and the cracking reaction zone are disposed within a single reactor.

4. The multiple-stage catalyst system of claim 1 where the volume ratio of the metathesis catalyst to the cracking catalyst is from 1:1 to 1:2.

5. The multiple-stage catalyst system of claim 1 where the mesoporous silica-alumina catalyst support comprises from 10 weight percent to 40 weight percent alumina.

6. The multiple-stage catalyst system of claim 1 where the metathesis catalyst includes a pore size distribution from 2.5 nm to 40 nm.

7. The multiple-stage catalyst system of claim 1 where the at least one metal oxide comprises one or more oxides of molybdenum, rhenium, tungsten, or combinations of these oxides.

8. The multiple-stage catalyst system of claim 1 where the at least one metal oxide of the mesoporous silica-alumina catalyst support impregnated with at least one metal oxide comprises tungsten oxide.

9. The multiple-stage catalyst system of claim 1 where the at least one metal oxide comprises tungsten oxide and the metathesis catalyst comprises from 5 weight percent to 20 weight percent tungsten oxide.

10. The multiple-stage catalyst system of claim 1 where the MFI structured silica-containing catalyst comprises alumina.

11. The multiple-stage catalyst system of claim 1 where the MFI structured silica-containing catalyst comprises less than 0.01 wt. % alumina.

12. The multiple-stage catalyst system of claim 1 where the MFI structured silica-containing catalyst comprises a total acidity from 0.001 mmol/g to 0.1 mmol/g.

13. The multiple-stage catalyst system of claim 1 where an acidity of the metathesis catalyst is from 0.001 mmol/g to 5 mmol/g.

14. The multiple-stage catalyst system of claim 1 in which the metathesis catalyst is disposed in a first reactor, the cracking catalyst is disposed in a second reactor downstream of the first reactor, and a direct conduit extends between the first reactor and second reactor so that the cracking catalyst directly cracks the metathesis product stream.

15. The multiple-stage catalyst system of claim 1 where the metathesis reaction zone is positioned directly against the cracking reaction zone.

16. A multiple-stage catalyst system for producing propylene from butene, the multiple-stage catalyst system comprising a metathesis reaction zone and a cracking reaction zone directly downstream of the metathesis reaction zone, where:
the metathesis reaction zone comprises a metathesis catalyst comprising a mesoporous silica-alumina catalyst support impregnated with at least one metal oxide, the mesoporous silica-alumina catalyst support comprising from 5 weight percent to 50 weight percent alumina;
the metathesis catalyst includes a relative pore volume per weight of the metathesis catalyst of at least 0.600 cm 3 /g; and
the cracking reaction zone comprises a cracking catalyst comprising an MFI structured silica-containing catalyst, where the MFI structured silica-containing catalyst directly cracks a metathesis product stream to form a cracking product stream comprising propylene.

17. The multiple-stage catalyst system of claim 16 in which the metathesis catalyst is disposed in a first reactor, the cracking catalyst is disposed in a second reactor downstream of the first reactor, and a direct conduit extends between the first reactor and second reactor so that the cracking catalyst directly cracks the metathesis product stream.

18. The multiple-stage catalyst system of claim 16 where the metathesis reaction zone is positioned directly against the cracking reaction zone.

19. The multiple-stage catalyst system of claim 16 further comprising a feed stream comprising butene.

20. The multiple-stage catalyst system of claim 19 where the butene comprises 2-butene.

Assignees

• Saudi Arabian Oil Co

Inventors

• Khokhar Munir D
• Alshafei Faisal H
• Sulais Noor A
• Shaikh Sohel K
• Abudawoud Raed H

Classifications

• B01J2235/15

  X-ray diffraction · CPC title

• B01J35/77

  Compounds characterised by their crystallite size · CPC title

• C07C2529/40

  of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11 · CPC title

• C07C2523/40

  of the platinum group metals · CPC title

• C07C2521/12

  Silica and alumina · CPC title