Acid/metal bifunctional catalysts produced by slurry methods

Patent metadata

Field	Value
Publication number	US-2021046462-A1
Application number	US-202016993219-A
Country	US
Kind code	A1
Filing date	Aug 13, 2020
Priority date	Aug 15, 2019
Publication date	Feb 18, 2021
Grant date	—

Abstract

A method of producing a acid/metal bifunctional catalyst may include: mixing an acid catalyst, a metal catalyst, and a fluid to produce a slurry, wherein the acid catalyst is present at 50 wt % or less relative to a total catalyst weight in the slurry; heating the slurry; producing a powder from the slurry; and calcining the powder to produce the acid/metal bifunctional catalyst. Such acid/metal bifunctional catalyst would be useful in the direct conversion of syngas to dimethyl ether as well as other reactions.

First claim

The invention claimed is:

1 . A method comprising:
mixing an acid catalyst, a metal catalyst, and a fluid to produce a slurry, wherein the acid catalyst is present at 50 wt % or less relative to a total catalyst weight in the slurry; heating the slurry; drying the slurry produce a dried slurry; producing a powder from the dried slurry; and calcining the powder to produce an acid/metal bifunctional catalyst.

2 . The method claim 1 , wherein producing the powder from the dried slurry comprises:
grinding the dried slurry to produce a powder, wherein the powder comprises 5 wt % or less of the fluid.

3 . The method of claim 1 , wherein mixing is maintained during heating.

4 . The method of claim 1 , wherein mixing is performed for 30 minutes to 3 hours.

5 . The method of claim 1 , wherein heating is to a temperature within 20° C. of a boiling point of the fluid.

6 . The method of claim 1 , wherein the acid catalyst is selected from the group consisting of a zeolite, an ion exchanged zeolite, a molecular sieve, a metal oxide, and any combination thereof.

7 . The method of claim 1 , wherein the metal catalyst is a M1/M2/Al catalyst, wherein M1 is selected from the group consisting of Cu, Cr, Ag, Au, Ru, Rh, Pd, Re, Os, Ir, Pt, and any combination thereof, wherein M2 is selected from the group consisting of Ti, V, Cr, Mn, Fe, Co, Ni, Zn, a rare earth metal, a La series metal, a Y series metal, and any combination thereof, and wherein M1 and M2 are different.

8 . The method of claim 1 , wherein the acid catalyst is present at 10 wt % to 50 wt % relative to the total catalyst weight in the slurry.

9 . The method of claim 1 , wherein the acid catalyst is present at 15 wt % to 35 wt % relative to the total catalyst weight in the slurry.

10 . The method of claim 1 , wherein the acid catalyst has a larger average diameter than the metal catalyst.

11 . The method of claim 1 , wherein the fluid is selected from the group consisting of: water, methanol, ethanol, alcohols of C1 to C10, oxygenates, and any combination thereof.

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

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

14 . The method of claim 1 , wherein the acid/metal bifunctional catalyst has a N 2 BET surface area according to ASTM D3663-03 (2015) of about 75 m 2 /g to about 200 m 2 /g.

15 . The method of claim 1 , wherein the acid/metal bifunctional catalyst has an average pore volume of about 0.1 mL/g to about 1.2 mL/g.

16 . The method of claim 1 , wherein the acid/metal bifunctional catalyst has an average pore size according to ASTM D4641-17 of about 7 nm to about 17 nm.

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

18 . The method of claim 17 , 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 .

19 . The method of claim 17 , wherein the reacting the activated acid/metal bifunctional catalyst with the feedstream is in the presence of steam.

20 . The method of claim 17 , wherein reacting the activated acid/metal bifunctional catalyst with the feedstream has a selectivity to producing methanol of 25% to 60%.

21 . The method of claim 17 , wherein reacting the activated acid/metal bifunctional catalyst with the feedstream has a selectivity to producing dimethyl ether of 20% to 55%.

22 . A method comprising:
activating an acid/metal bifunctional catalyst in the presence of hydrogen at 150° C. to 350° C., wherein the acid/metal bifunctional catalyst has an average diameter of 0.01 μm to 100 μm and comprises an acid catalyst component and a metal catalyst component, wherein the acid catalyst component is selected from the group consisting of a zeolite, an ion exchanged zeolite, a molecular sieve, a metal oxide, and any combination thereof, wherein the metal catalyst component is a M1/M2/Al catalyst, wherein M1 is selected from the group consisting of Cu, Cr, Ag, Au, Ru, Rh, Pd, Re, Os, Ir, Pt, and any combination thereof, wherein M2 is selected from the group consisting of Ti, V, Cr, Mn, Fe, Co, Ni, Zn, a rare earth metal, a La series metal, a Y series metal, and any combination thereof, and wherein M1 and M2 are different, and the acid catalyst component is present at 50 wt % or less relative to the acid/metal bifunctional catalyst; and reacting the activated acid/metal bifunctional catalyst with a feedstream comprising hydrogen and carbon monoxide.

Assignees

• Exxonmobil Res & Eng Co

Inventors

• Bai Chuansheng
• CUNNINGHAM Majosefina
• Daaka Jihad M
• Kamakoti Preeti
• Ramkrishnan Aruna
• Kovvali Anjaneya S
• Lee Anita S

Classifications

• C07C43/043

  Dimethyl ether · CPC title

• C07C31/04

  Methanol · CPC title

• C07C29/154

  containing copper, silver, gold, or compounds thereof · CPC title

• B01J2235/10

  Infrared [IR] · CPC title

• B01J2235/15

  X-ray diffraction · CPC title