Catalyst system and process for preparing dimethyl ether

Patent metadata

Field	Value
Publication number	US-11529616-B2
Application number	US-201816956668-A
Country	US
Kind code	B2
Filing date	Dec 20, 2018
Priority date	Dec 20, 2017
Publication date	Dec 20, 2022
Grant date	Dec 20, 2022

Abstract

The invention relates to a catalyst system and process for preparing dimethyl ether from synthesis gas as well as the use of the catalyst system in this process.

First claim

The invention claimed is:

1. A catalyst system for a continuous synthesis gas-to-dimethyl ether process, comprising two spatially separated subsequent catalyst layers 1 and 2 in flow direction, the catalyst layers 1 and 2 having a volume ratio of from 9:1 to 1:9, catalyst layer 1 being formed of a packed bed of synthesis gas-to-methanol catalyst 1 particles or an admixture of catalyst 1 particles and inert 1 particles in a weight ratio of from 1:4 to 4:1, catalyst 1 particles comprising based on the total weight of catalyst 1 particles, which is 100 weight-%, 30 to 70 weight-% CuO, 10 to 30 weight-% ZnO, 10 to 30 weight-% Al 2 O 3 , the amount of ZrO 2 , if present, is in the range of from 0.5 to 5 weight-%, 0 to 7 weight-% of further additives, inert 1 particles comprising Al 2 O 3 ,
catalyst layer 2 being formed of a packed bed of an admixture of catalyst 1 particles and methanol-to-dimethyl ether catalyst 2 particles in a weight ratio of from 1:9 to 9:1, catalyst 2 particles being formed of an acidic aluminosilicate zeolite with a SiO2≥Al 2 O 3 molar ratio of from 10 to 1500:1 of framework type MFI, comprising based on the total weight of catalyst 2 particles, which is 100 weight-%, 10 to 90 weight-% of at least one binder material, selected from Al 2 O 3 , SiO2, TiO2 and ZrO2, and 0.01 to 20 weight-% of copper,
wherein the catalyst system is employed in one or more containments, which allow for the spatial separation of the subsequent catalyst layers 1 and 2, the containment having at least two sections in which the catalyst layers 1 and 2 are located, and the two sections being linked in a way that reactants can flow from catalyst layer 1 to catalyst layer 2.

2. The catalyst system according to claim 1 , wherein catalyst layer 2 directly follows catalyst layer 1 or is separated from it by a layer of inert particles.

3. The catalyst system according to claim 1 , wherein the catalyst 1 particles comprise, based on the total weight of catalyst 1 particles, which is 100 weight-%, 30 to 70 weight-% CuO, 10 to 30 weight-% ZnO, 10 to 30 weight-% Al 2 O 3 , 1 to 5 weight-% ZrO 2 , 0 to 7 weight-% of further additives.

4. The catalyst system according to claim 3 , wherein the further additives comprise 1-7 weight-% of a lubricant.

5. The catalyst system according to claim 1 , wherein the catalyst 2 particles comprise, based on the total weight of catalyst 2 particles, which is 100 weight-%, 30 to 80 weight-% of at least one acidic aluminosilicate of framework type MFI, 20 to 70 weight-% of at least one binder material selected from Al2O3, SiO2, TiO2 and ZrO2, and 0.01 to 20 weight-% copper.

6. The catalyst system according to claim 5 , wherein the catalyst 2 particles comprise ZSM-5 aluminosilicate, Al 2 O 3 as binder material and copper.

7. The catalyst system according to claim 1 , wherein catalyst layer 2 is formed of a packed bed of an admixture of catalyst 1 particles and catalyst 2 particles in a weight ratio of from 3:2 to 7:3.

8. The catalyst system according to claim 1 , wherein the catalyst 1 particles, catalyst 2 particles and inert 1 particles have each an average maximum particle diameter of from 0.5 to 5 mm.

9. The catalyst system according to claim 1 , wherein the catalyst system is located in one or more tubular reactors.

10. The catalyst system according claim 1 , wherein the catalyst layers 1 and 2 are present as packed beds and wherein the catalyst 1 particles, catalyst 2 particles and inert 1 particles are extrudates with an average maximum diameter of from 1 to 3.5 mm and a ratio of average length to average maximum diameter of from 0.5:1 to 10:1.

11. A process for producing dimethyl ether which comprises converting synthesis gas by contacting the synthesis gas with the catalyst system as claimed in claim 1 .

12. A process for preparing dimethyl ether from synthesis gas, comprising administering synthesis gas to catalyst layer 1 in a catalyst system as defined in claim 1 , and removing dimethyl ether-containing product gas from catalyst layer 2.

13. The process of claim 12 , wherein temperature in catalyst layers 1 and 2 are maintained within a temperature range of from 200 to 400° C.

14. The process of claim 13 , wherein catalyst layer 1 is maintained at a temperature within the range of from 260 to 280° C. and catalyst layer 2 is maintained at a temperature within the range of from 270 to 280° C.

Assignees

• Basf Se

Inventors

• Schuster Sabine
• Schwab Ekkehard
• Altwasser Stefan
• Kaiser Harry
• Schunk Stephan A
• Gaab Manuela

Classifications

• B01J29/46 Primary

  Iron group metals or copper · CPC title

• B01J37/0244 Primary

  Coatings comprising several layers · CPC title

• B01J37/0009

  Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst · CPC title

• C07C41/01

  Preparation of ethers · CPC title

• C07C2529/76

  Iron group metals or copper · CPC title