Production of products from natural resources

Patent metadata

Field	Value
Publication number	US-2019023640-A1
Application number	US-201816141501-A
Country	US
Kind code	A1
Filing date	Sep 25, 2018
Priority date	Apr 24, 2013
Publication date	Jan 24, 2019
Grant date	—

Abstract

The method disclosed herein relates to two stage catalytic processes for converting syngas to acetic acid, acrylic acid and/or propylene. More specifically, the method described and claimed herein relate to a method of producing acrylic acid and acetic acid comprising the steps of: a) providing a feedstream comprising syngas; b) contacting the feedstream with a first catalyst to produce a first product stream comprising C 2 -C 3 olefins and/or C 2 -C 3 paraffins; and c) contacting the first product stream with oxygen gas and a second catalyst, thereby producing a second product stream comprising acrylic acid and acetic acid, wherein there is no step for separating the components of the first product stream before the first product stream is contacted with the second catalyst.

First claim

1 . A method of producing acrylic acid and acetic acid comprising the steps of:
a) providing a feedstream comprising syngas; b) a step consisting of contacting the feedstream with a first catalyst to produce a first product stream comprising C 2 -C 3 olefins and/or C 2 -C 3 paraffins; and c) contacting the first product stream with oxygen gas and a second catalyst, thereby producing a second product stream comprising acrylic acid and acetic acid,  wherein there is no step for separating the components of the first product stream before the first product stream is contacted with the second catalyst.

2 . The method of claim 1 , wherein the method further comprises separating the acetic acid and the acrylic acid.

3 . The method of claim 1 , wherein the first catalyst comprises a mixed metal oxide represented by the formula
Co a2 Mn b2 La z2 P y2 M2 d2 O f2 , wherein a2 is 1; wherein b2 is from 0.8 to 1.2; wherein z2 is greater than 0 to 0.5; wherein y2 is greater than 0 to 0.5; wherein M2 comprises an alkali metal, alkaline earth metal, or transition metal, or a mixture thereof, wherein d2 is greater than 0 to 0.5; and wherein f2 is a number determined by the valence requirements of elements of the other elements present in the catalyst.

4 . The method of claim 3 , wherein the M2 comprises Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Ti, or Zr, or a mixture thereof.

5 . The method of claim 3 , wherein the first catalyst comprises a binder.

6 . The method of claim 5 , wherein the binder is selected from the group consisting of silica, alumina, titania, zirconia, carbon and zeolite, or a mixture thereof.

7 . The method of claim 1 , wherein the first product stream comprises at least 30% C 2 -C 3 olefins and/or C 2 -C 3 paraffins.

8 . The method of claim 1 , wherein the first product stream comprises at least 40% C 2 -C 3 olefins and/or C 2 -C 3 paraffins.

9 . The method of claim 1 , wherein the first product stream comprises at least 50% C 2 -C 3 olefins and/or C 2 -C 3 paraffins.

10 . The method of claim 1 , wherein the first product stream does not comprise C 1 -C 5 alcohols.

11 . The method of claim 1 , wherein the second catalyst comprises
Mo a3 V b3 Ga c3 Pd d3 Nb c3 Z f3 , wherein a1 is 1, wherein b3 is from 0.01 to 0.9, wherein c3 is greater than 0 to 0.2, wherein d3 is from 0.0000001 to 0.2, wherein e3 is greater than 0 to 0.2, wherein Z comprises La, Te, Ge, Zn, Si, In, or W, or a mixture thereof, wherein f3 is greater than 0 to 0 . 5 .

12 . The method of claim 11 , wherein Z comprises Te.

13 . The method of claim 12 , wherein the second catalyst comprises a support material.

14 . The method of claim 13 , wherein the support material comprises Al 2 O 3 , SiO 2 , CeO 2 , TiO 2 , ZrO 2 , acetate-SiO 2 , low surface area TiO 2 , high surface area TiO 2 , acetate-Al 2 O 3 , acetate-ZrO 2 , actetate-CeO 2 , AlPO 4 , SiC, silicon-carbide, Mo-carbide, aluminumsilicate, a zeolite, or a molecular sieve, or a mixture thereof.

15 . The method of claim 13 , wherein the support material is neutral or oxidative.

16 . The method of claim 13 , wherein the support material comprises additional components M s and X s ,
wherein M s is a metal comprising B, La, Mn, Sb, Ti, Zr, La, Fe, Cs, Au, or Ce; and wherein X s is optionally present and is an alkaline metal comprising Na, K, Mg, or Ca.

17 . The method of claim 16 , wherein the support material comprises Al 2 O 3 , SiO 2 , TiO 2 , CeO 2 , AlPO 4 , ZrO 2 , SiC, Mo-carbide, aluminumsilicate, a zeolite, or a molecular sieve, or a mixture thereof.

18 . The method of claim 17 , wherein the second catalyst is at least 20% more effective in oxidizing propane to acrylic acid than a base second catalyst.

19 . The method of claim 1 , wherein step b) is performed in a first vessel and step c) is performed in a second vessel.

20 . The method of claim 1 , wherein providing syngas comprises producing syngas from coal, biomass, or natural gas.

Assignees

• Saudi Basic Ind Corp

Inventors

• Karim Khalid
• Ahmed Labeeb Chaudhary

Classifications

• C07C2523/889

  Manganese, technetium or rhenium · CPC title

• C07C2527/187

  with manganese, technetium or rhenium · CPC title

• C07C51/215 Primary

  of saturated hydrocarbyl groups · CPC title

• C07C51/225 Primary

  of paraffin waxes · CPC title

• C07C1/0485

  Set-up of reactors or accessories; Multi-step processes · CPC title