Synthesis gas to hydrocarbon processes with neutral or negative carbon dioxide selectivity

Patent metadata

Field	Value
Publication number	US-12435012-B2
Application number	US-202017788144-A
Country	US
Kind code	B2
Filing date	Dec 2, 2020
Priority date	Dec 23, 2019
Publication date	Oct 7, 2025
Grant date	Oct 7, 2025

Abstract

A process for preparing C 2 to C 4 hydrocarbons includes introducing a feed stream into a reaction zone of a reactor, the feed stream comprising hydrogen gas and carbon monoxide. An additional stream is introduced into the reaction zone of the reactor, the additional stream comprising carbon dioxide. A combined stream that includes the feed stream and the additional stream is converted into a product stream comprising C 2 to C 4 hydrocarbons in the reaction zone in the presence of a hybrid catalyst. The hybrid catalyst includes a mixed metal oxide catalyst component, and a microporous catalyst component. The process operates at a gas hourly space velocity in excess of 2500 hr −1 and effectively yields a net carbon dioxide selectivity of less than 5.0% and a productivity of C 2 -C 4 hydrocarbons greater than 75 g hydrocarbons per kilogram of catalyst per hour.

First claim

The invention claimed is:

1. A process for preparing C 2 to C 4 hydrocarbons comprising:
introducing a feed stream comprising hydrogen gas and a carbon-containing gas comprising carbon monoxide into a reaction zone of a reactor;
introducing a second stream comprising carbon dioxide into the reaction zone of the reaction;
forming a combined stream from the feed and second stream;
converting the combined stream into a product stream comprising C 2 to C 4 hydrocarbons in the reaction zone in the presence of a hybrid catalyst, the hybrid catalyst comprising:
a mixed metal oxide catalyst component; and
a microporous catalyst component, wherein a gas hourly space velocity (GHSV) inside the reaction zone of at least 4200 hr −1 , a net CO 2 selectivity is less than 5.0%, and a C 2 to C 4 hydrocarbon productivity of at least 75 g hydrocarbon/kg catalyst per hour.

2. The process of claim 1 , wherein the second stream comprises up to 80.0 v % CO 2 .

3. The process of claim 1 , wherein the second stream consists of CO 2 .

4. The process of claim 1 , wherein the combined stream comprises greater than 6.3 v % CO 2 .

5. The process of claim 1 , wherein the combined stream comprises 50 v % to 80 v % hydrogen.

6. The process of claim 1 , wherein the combined stream comprises a carbon dioxide (CO 2 )/carbon monoxide (CO) volume ratio (CO 2 /CO) from 0.05 to 1.5 v/v.

7. The process of claim 1 , wherein the reaction zone operates at a temperature from 380° C. to 450° C.

8. The process of claim 1 , wherein the reaction zone operates at a pressure from 20 bar to 70 bar.

9. The process of claim 1 , wherein the GHSV is greater than 4800 hr −1 .

10. The process of claim 1 , wherein the mixed metal oxide catalyst component comprises ZrO 2 .

11. The process of claim 1 , wherein the mixed metal oxide catalyst component comprises ZrO 2 and Ga 2 O 3 .

12. The process of claim 1 , wherein the microporous catalyst component is a molecular sieve having 8-MR pore openings.

13. The process of claim 1 , wherein the microporous catalyst component is SAPO-34.

14. The process of claim 1 , wherein the net CO 2 selectivity is less than 1.0%.

15. The process of claim 1 , wherein the C 2 to C 4 hydrocarbons consist essentially of C 2 to C 4 olefins.

Assignees

• Dow Global Technologies Llc

Inventors

• Pollefeyt Glenn
• Nieskens Davy L S
• Kirilin Alexey
• Chojecki Adam
• Dewilde Joseph F
• Fish Barry B
• Malek Andrzej

Classifications

• C07C2523/08

  of gallium, indium or thallium · CPC title

• C07C2521/16

  Clays or other mineral silicates · CPC title

• C07C2521/06

  Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof · CPC title

• C07C1/046

  Numerical values of parameters · CPC title

• C07C1/043 Primary

  characterised by the composition · CPC title