Acid/metal bifunctional catalyst produced by extrusion

Patent metadata

Field	Value
Publication number	US-11819818-B2
Application number	US-202016947704-A
Country	US
Kind code	B2
Filing date	Aug 13, 2020
Priority date	Aug 15, 2019
Publication date	Nov 21, 2023
Grant date	Nov 21, 2023

Abstract

A method of producing bifunctional catalysts by extrusion may include mixing an acid catalyst, a metal catalyst, optionally a binder, and a fluid to produce a dough; extruding the dough to form an extrudate; producing a powder from the extrudate; and calcining the powder to produce an acid/metal bifunctional catalyst. Such acid/metal bifunctional catalysts may be useful in, among other things, converting syngas to dimethyl ether in a single reactor.

First claim

The invention claimed is:

1. A method comprising:
mixing an acid catalyst, a metal catalyst, a binder, and a fluid to produce a dough, the acid catalyst comprising a zeolite, an ion exchanged zeolite, a molecular sieve, or a combination thereof, the metal catalyst comprising Cu, Zn, and Al;
extruding the dough to form an extrudate, the extruding being performed while heating the dough to a temperature within 20° C. of the boiling point of the fluid, the acid/metal bifunctional catalyst comprising 70 wt % to 80 wt % of the acid catalyst relative to a total weight of catalyst in the dough;
drying the extrudate;
producing a powder from the extrudate; and
calcining the powder to produce an acid/metal bifunctional catalyst.

2. The method claim 1 , wherein producing the powder from the extrudate comprises:
grinding the extrudate before or after drying, wherein the powder comprises 5 wt % or less of the fluid.

3. The method of claim 1 further comprising:
drying the powder.

4. The method of claim 1 , wherein the binder is selected from the group consisting of clay, theta-alumina, delta-alumina, alpha-alumina, silica, titania, zirconia, boric acid, carbon, and any combination thereof.

5. The method of claim 1 , wherein the binder is present at 10 wt % to 80 wt % relative to the total solids weight in the dough.

6. The method of claim 1 , wherein a weight ratio of the acid catalyst and the metal catalyst combined to the binder in the dough is about 10:1 to about 1:10.

7. The method of claim 1 , wherein the fluid is selected from the group consisting of: water, methanol, ethanol, and any combination thereof.

8. The method of claim 1 , wherein calcining is performed in air at 200° C. to 400° C.

9. The method of claim 1 , wherein the acid/metal bifunctional catalyst has an average diameter of 0.01 μm to 100 μm.

10. The method of claim 1 further comprising:
activating the acid/metal bifunctional catalyst in the presence hydrogen at 150° C. to 350° C.; and
reacting the activated acid/metal bifunctional catalyst with a feedstream comprising hydrogen and carbon monoxide.

11. The method of claim 10 , wherein reacting is at a temperature of about 200° C. to about 300° C., a pressure of about 20 bar to about 50 bar, and a gas hourly space velocity (GHSV) of about 1,000 hr −1 to about 8,000 hr −1 .

12. The method of claim 10 , wherein the reacting the activated acid/metal bifunctional catalyst with the feedstream is in the presence of steam.

Assignees

• Exxonmobil Technology & Engineering Company

Inventors

• Bai Chuansheng
• Dakka Jihad M
• Kamakoti Preeti
• Ramkrishnan Aruna
• Kovvali Anjaneya S
• Lee Anita S

Classifications

• B01J35/45

  Nanoparticles · CPC title

• B01J2235/10

  Infrared [IR] · CPC title

• B01J35/40

  characterised by dimensions, e.g. grain size (in a colloidal state B01J35/23; crystallite size B01J35/77) · CPC title

• B01J35/50

  characterised by their shape or configuration · CPC title

• B01J29/46 Primary

  Iron group metals or copper · CPC title