Catalysts comprising a zirconia and gallium oxide component for production of C2 to C4 olefins

Patent metadata

Field	Value
Publication number	US-11986799-B2
Application number	US-201917417846-A
Country	US
Kind code	B2
Filing date	Dec 16, 2019
Priority date	Dec 28, 2018
Publication date	May 21, 2024
Grant date	May 21, 2024

Abstract

A process for preparing C 2 to C 4 olefins includes introducing a feed stream comprising hydrogen gas and a carbon-containing gas selected from carbon monoxide, carbon dioxide, and mixtures thereof into a reaction zone of a reactor. The feed stream is converted into a product stream including C 2 to C 4 olefins in the reaction zone in the presence of the hybrid catalyst. The hybrid catalyst includes a metal oxide catalyst component comprising gallium oxide and phase pure zirconia, and a microporous catalyst component.

First claim

The invention claimed is:

1. A process for preparing C 2 to C 4 olefins comprising:
introducing a feed stream comprising hydrogen gas and a carbon-containing gas selected from the group consisting of carbon monoxide, carbon dioxide, and mixtures thereof into a reaction zone of a reactor; and
converting the feed stream into a product stream comprising C 2 to C 4 olefins in the reaction zone in the presence of a hybrid catalyst, the hybrid catalyst comprising:
a metal oxide catalyst component comprising gallium oxide and phase pure zirconia; and
a microporous catalyst component.

2. The process of claim 1 , wherein the phase pure zirconia comprises crystalline phase pure zirconia.

3. The process of claim 1 , wherein the phase pure zirconia comprises monoclinic phase pure zirconia.

4. The process of claim 1 , wherein the phase pure zirconia has a BET surface area that is greater than or equal to 40 m 2 /g.

5. The process of claim 1 , wherein the phase pure zirconia has a BET surface area that is greater than or equal to 100 m 2 /g.

6. The process of claim 1 , wherein the metal oxide catalyst component comprises from greater than 0.0 g gallium per 100 g phase pure zirconia to 30.0 g gallium per 100 g of phase pure zirconia.

7. The process of claim 1 , wherein the metal oxide catalyst component comprises from greater than 0.0 g gallium per 100 g phase pure zirconia to 15.0 g gallium per 100 g of phase pure zirconia.

8. The process of claim 1 , wherein microporous catalyst component comprises an 8 membered ring structure.

9. The process of claim 1 , wherein the microporous catalyst component comprises SAPO-34.

10. The process of claim 1 , wherein the metal oxide catalyst component comprises from 1.0 wt % to 99.0 wt % of the hybrid catalyst.

11. The process of claim 1 , wherein the metal oxide catalyst component comprises from 60.0 wt % to 90.0 wt % of the hybrid catalyst.

12. The process of claim 1 , wherein a temperature within the reaction zone during the converting is from 350° C. to 450° C.

13. The process of claim 1 , wherein a pressure within the reaction zone during the converting is at least 1 bar (100 kPa).

14. The process of claim 1 , wherein a GHSV within the reaction zone during the converting is from 1,200/h to 12,000/h.

15. The process of claim 1 , wherein the metal oxide catalyst component is formed by an impregnation method.

16. The process of claim 1 , wherein:
the phase pure zirconia comprises crystalline phase pure zirconia;
the metal oxide catalyst component comprises from greater than 0.0 g gallium per 100 g phase pure zirconia to 30.0 g gallium per 100 g of phase pure zirconia; and
the microporous catalyst component comprises SAPO-34.

17. The process of claim 1 , wherein:
a temperature within the reaction zone during the converting is from 350° C. to 450° C.;
a pressure within the reaction zone during the converting is at least 1 bar (100 kPa); and
a GHSV within the reaction zone during the converting is from 1,200/h to 12,000/h.

18. The process of claim 1 , wherein the phase pure zirconia is a support for the gallium oxide.

Assignees

• Dow Global Technologies Llc
• Dow Global Tech Lllc

Inventors

• Chojecki Adam
• Kirilin Alexey
• Malek Andrzej
• Dewilde Joseph F
• Santos Castro Vera P
• Yancey David F
• Andrews Kyle C

Classifications

• B01J23/08 Primary

  of gallium, indium or thallium · CPC title

• B01J23/002

  Mixed oxides other than spinels, e.g. perovskite · CPC title

• B01J29/85

  Silicoaluminophosphates [SAPO compounds] · CPC title

• B01J35/19

  Catalysts containing parts with different compositions · CPC title

• B01J35/612

  less than 10 m2/g · CPC title