Process, reaction mixture and catalyst for the production of phosgene

Patent metadata

Field	Value
Publication number	US-2023192500-A1
Application number	US-202117925331-A
Country	US
Kind code	A1
Filing date	May 10, 2021
Priority date	May 20, 2020
Publication date	Jun 22, 2023
Grant date	—

Abstract

The invention relates to a process for the production of phosgene comprising a gas phase reaction of carbon monoxide and chlorine in the presence of a carbon catalyst in a multi-tubular reactor, wherein the carbon catalyst comprises an amount of mesopores having a pore diameter in the range of from 2 to 50 nm of at least 0.45 ml/g of the total pore volume and the use of a carbon catalyst comprising an amount of mesopores having a pore diameter in the range of from 2 to 50 nm of at least 0.45 ml/g of the total pore volume, for the production of phosgene and a reaction mixture for preparing phosgene, the mixture comprising a catalyst for preparing phosgene comprising a porous material comprising carbon, micropores and mesopores, wherein said micropores have a pore diameter of less than 2 nm and wherein said mesopores have a pore diameter in the range of from 2 to 50 nm, wherein the volume of the mesopores of the porous material is of at least 0.45 ml/g, and a gas stream G comprising carbon monoxide (CO) and chlorine (Cl2).

First claim

1 - 35 . (canceled)

36 . A Process for the production of phosgene comprising a gas phase reaction of carbon monoxide and chlorine in the presence of a carbon catalyst in a multi-tubular reactor, wherein the carbon catalyst comprises an amount of mesopores having a pore diameter in the range of from 2 to 50 nm of at least 0.45 ml/g of the total pore volume.

37 . The process according to claim 36 , wherein the volume fraction of the mesopores is at least 50% of the total pore volume.

38 . The process according to claim 36 , wherein the volume fraction, of the mesopores having a pore diameter from 2 to 50 nm, is in the range of from 50% to 90% of the total pore volume.

39 . The process according to claim 36 , wherein the total pore volume of the carbon catalyst is at least 0.5 ml/g measured by nitrogen adsorption.

40 . The process according to claim 36 , wherein the total pore volume of the carbon catalyst is in the range of from 0.5 ml/g to 2 ml/g measured by nitrogen adsorption.

41 . The process according to claim 36 , wherein the BET surface of the carbon catalyst is at least 500 m 2 /g.

42 . The process according to claim 36 , wherein the BET surface of the carbon catalyst is in the range of from 500 m 2 /g to 2500 m 2 /g.

43 . The process according to claim 36 , wherein the carbon catalyst is a pyrolyzed carbon aerogel.

44 . The process according to claim 43 , wherein the carbon catalyst is n activated pyrolyzed carbon aerogel.

45 . The process according to claim 36 , wherein the carbon catalyst has a total impurity content of elements having atomic numbers ranging from 11 to 92 as measured by total reflection x-ray fluorescence (TXRF) of less than 500 ppm.

46 . The process according to claim 36 , wherein the reaction takes place in a tube-bundle reactor with catalyst filled inside the tubes.

47 . The process according to claim 36 , wherein the cooling media on the shell side is liquid or a boiling liquid.

48 . The process according to claim 36 , wherein the feed stream has a stoichiometric ratio of carbon monoxide to chlorine of 0.0001 to 50 mol%.

49 . The process according to claim 36 , wherein the reaction takes place at a pressure of 1 to 10 bara.

50 . The process according to claim 36 , wherein the feed streams are supplied with an absolute pressure in the range of 0.5 to 20 bar.

51 . The process according to claim 36 , wherein the reaction is carried out at a surface load of 0.5 to 6 kg phosgene/m 2 s.

52 . The process according to claim 36 , wherein the contact tubes are passed by the at least one fluid heat carrier in separate cooling zones.

53 . The process according to claim 36 , wherein as a fluid heat carrier a liquid heat carrier is used.

54 . The process according to claim 36 , wherein it is used to produce directly or indirectly steam.

55 . Use of the carbon catalyst comprising an amount of mesopores having a pore diameter in the range of from 2 to 50 nm of at least 0.45 ml/g of the total pore volume, for the production of phosgene.

56 . A reaction mixture for preparing phosgene, the mixture comprising
(i) a catalyst for preparing phosgene comprising
a porous material comprising carbon, micropores and mesopores, wherein said micropores have a pore diameter of less than 2 nm and wherein said mesopores have a pore diameter in the range of from 2 to 50 nm,
wherein the volume of the mesopores of the porous material is of at least 0.45 ml/g; and
(ii) a gas stream G comprising carbon monoxide (CO) and chlorine (Cl 2 ).

57 . The reaction mixture of claim 56 , wherein the ratio of the volume of the mesopores of the porous material of the catalyst (i) relative to the volume of the micropores of the porous material of the catalyst (i) is of at least 1:1.

58 . The reaction mixture of claim 56 , wherein the total pore volume of the porous material of the catalyst (i) is in the range of from 0.5 to 2.25 ml/g.

59 . The reaction mixture of claim 56 , wherein less than or equal to 40% of the total pore volume of the porous material of the catalyst (i) resides in mesopores having a pore diameter of greater than 20 nm.

60 . The reaction mixture of claim 56 , wherein the volume of the mesopores of the porous material of the catalyst (i) is in the range of from 0.50 to 0.54 ml/g.

61 . The reaction mixture of claim 56 , wherein the volume of the micropores of the porous material of the catalyst (i) is of at most 0.7 ml/g.

62 . The reaction mixture of claim 56 , wherein the specific surface area of the porous material of the catalyst (i) induced by the mesopores is of in the range of from 70 to 250 m 2 /g,.

63 . The reaction mixture of claim 56 , wherein the porous material of the catalyst (i) is a pyrolyzed carbon aerogel, preferably an activated pyrolyzed carbon aero-gel.

64 . The reaction mixture of claim 56 , wherein from 99 to 100 weight-% of the porous material of the catalyst (i) consists of the carbon.

65 . The reaction mixture of claim 56 , wherein the porous material of the catalyst (i) has a total impurity content of elements having atomic numbers ranging from 11 to 92 as measured by total reflection x-ray fluorescence (TXRF) of less than 500 ppm.

66 . A catalyst for preparing phosgene comprising
a porous material comprising carbon, micropores and mesopores, wherein said mi-cropores have a pore diameter of less than 2 nm and wherein said mesopores have a pore diameter in the range of from 2 to 50 nm, wherein the volume of the mesopores of the porous material is in the range of from 0.50 to 0.54 ml/g and the ratio of the volume of the mesopores of the porous material relative to the total pore volume of the porous material is in the range of from 0.70: 1 to 0.75: 1, wherein from 99 to 100 weight-% of the porous material consist of carbon.

67 . The catalyst of claim 66 , wherein the volume of the mesopores of the porous material is in the range of from 0.51 to 0.53 ml/g, and the ratio of the volume of the mesopores of the porous material relative to the total pore volume of the porous material is in the range of from 0.72:1 to 0.74:1.

68 . A catalyst for preparing phosgene comprising
a porous material comprising carbon, micropores and mesopores, wherein said mi-cropores have a pore diameter of less than 2 nm and wherein said mesopores have a pore diameter in the range of from 2 to 50 nm, wherein the volume of the mesopores of the porous material is in the range of from 0.64 to 0.70 ml/g, and the ratio of the volume of the mesopores of the porous material rela-tive to the total pore volume of the porous material is in the range of from 0.72: 1 to 0.78: 1, wherein from 99 to 100 weight-% of the porous material consist of carbon.

69 . The catalyst of claim 68 , wherein the volume of the mesopores of the porous material is in the range of from 0.65 to 0.67 ml/g, and the ratio of the volume of the mesopores of the porous material relative to the total pore volume of the porous material, is in the range of from 0.73:1 to 0.76:1.

70 . The catalyst of claim 66 , wherein the total specific surface area of the porous material, measured preferably according to dual-isotherm NLDFT Advanced PSD technique, is of at least 600 m 2 /g.

Assignees

• Basf Se

Inventors

• Olbert Gerhard
• Kron Benjamin
• Gauer Jochen
• Ferbitz Jens
• Mattke Torsten
• Thiele Kai
• Van Den Abeel Peter
• Vandewalle Koenraad
• Bramnik Kirill
• Brandts Jim

Classifications

• B01J35/1061

  Operations & Transport · mapped topic

• B01J21/18

  Carbon · CPC title

• B01J35/04

  Operations & Transport · mapped topic

• B01J35/1042

  Operations & Transport · mapped topic

• B01J35/1028

  Operations & Transport · mapped topic