Processes for efficient and sustained production of C2 to C4 olefins

Patent metadata

Field	Value
Publication number	US-12338194-B2
Application number	US-202017785740-A
Country	US
Kind code	B2
Filing date	Dec 14, 2020
Priority date	Dec 19, 2019
Publication date	Jun 24, 2025
Grant date	Jun 24, 2025

Abstract

A process for preparing C 2 to C 4 olefins includes introducing a feed stream of hydrogen gas and a carbon-containing gas into a reaction zone of a reactor and converting the feed stream into a product stream including C 2 to C 4 olefins in the reaction zone in the presence of a hybrid catalyst and in a non-oxidative atmosphere. The hybrid catalyst includes a metal oxide catalyst component comprising gallium oxide and zirconia, and a microporous catalyst component having an 8 membered ring structure. The process also includes periodically introducing an oxidative atmosphere into the reaction zone.

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;
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 and in a non-oxidative atmosphere, the hybrid catalyst comprising:
a metal oxide catalyst component comprising gallium oxide and zirconia; and
a microporous catalyst component comprising an 8 membered ring pore opening; and

periodically introducing an oxidative atmosphere into the reaction zone.

2. The process of claim 1 , wherein the oxidative atmosphere comprises from 0.1 vol % to 99.9 vol % oxygen.

3. The process of claim 1 , wherein the oxidative atmosphere comprises from 0.5 vol % to 3.0 vol % oxygen.

4. The process of claim 1 , wherein the balance of the oxidative atmosphere is inert gases.

5. The process of claim 1 , wherein the non-oxidative atmosphere comprises less than 0.1 vol % oxygen.

6. The process of claim 1 , wherein a frequency of periods where an oxidative atmosphere is introduced into a reaction zone is from 20 hours to 1000 hours.

7. The process of claim 1 , wherein a duration for which the oxidative atmosphere is introduced into the reaction zone is from 5 hours to 30 hours.

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

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

10. The process of claim 1 , wherein a temperature within the reaction zone while introducing the oxidative atmosphere is from ambient to 700° C.

11. The process of claim 1 , wherein a temperature within the reaction zone while introducing the oxidative atmosphere is from 300° C. to 550° C.

12. The process of claim 1 , wherein a pressure within the reaction zone while introducing the oxidative atmosphere is from 1 bar (100 kPa) to 50 bar (5,000 kPa).

13. The process of claim 1 , wherein a pressure within the reaction zone while introducing the oxidative atmosphere is from 10 bar (3,000 kPa) to 20 bar (4,000 kPa).

14. The process of claim 1 , wherein conversion conditions when the feed stream is introduced into the reaction zone comprise:
a temperature from 350° C. to 450° C.;
a pressure from 1 bar (100 kPa) to 70 bar (7,000 kPa); and
a gas hour space velocity (GHSV) from 1200 h −1 to 12000 h −1 .

15. The process of claim 1 , wherein loss of a C 2 to C 4 olefin selectivity measured after the hybrid catalyst has been on stream for 50 hours and measured after the hybrid catalyst has been on stream for 500 hours is less than 15 Cmol %.

16. The process of claim 1 , wherein
the oxidative atmosphere comprises from 0.5 vol % to 3.0 vol % oxygen,
a temperature within the reaction zone while introducing the oxidative atmosphere is from 300° C. to 550° C., and
a pressure within the reaction zone while introducing the oxidative atmosphere is from 10 bar (3,000 kPa) to 20 bar (4,000 kPa).

17. The process of claim 1 , wherein
the microporous catalyst component comprises SAPO-34, and
the metal oxide catalyst component comprises from 60.0 wt % to 90.0 wt % of the hybrid catalyst.

18. The process of claim 16 , wherein
the microporous catalyst component comprises SAPO-34, and
the metal oxide catalyst component comprises from 60.0 wt % to 90.0 wt % of the hybrid catalyst.

Assignees

• Dow Global Technologies Llc

Inventors

• Dewilde Joseph F
• Chojecki Adam
• Kirilin Alexey
• Tocha-Bielak Ewa A
• Yancey David F
• Pollefeyt Glenn
• Nieskens Davy L S
• Malek Andrzej

Classifications

• B01J35/613

  10-100 m2/g · CPC title

• B01J35/391

  Physical properties of the active metal ingredient · CPC title

• C07C2529/85

  Silicoaluminophosphates (SAPO compounds) · CPC title

• C07C2523/10

  of rare earths · CPC title

• C07C2523/08

  of gallium, indium or thallium · CPC title