Integrated carboxylic acid production from synthesis gas

Patent metadata

Field	Value
Publication number	US-2024010596-A1
Application number	US-202118253605-A
Country	US
Kind code	A1
Filing date	Nov 17, 2021
Priority date	Dec 1, 2020
Publication date	Jan 11, 2024
Grant date	—

Abstract

A process for preparing C2 to C4 carboxylic acids from synthesis gas includes introducing a feed stream comprising hydrogen gas and a carbon-containing gas comprising carbon monoxide into a reaction zone of a first reactor, converting the feed stream into an intermediate stream comprising C2 to C4 hydrocarbons in the reaction zone in the presence of a first catalyst, wherein the intermediate stream further comprises carbon dioxide and wherein the first catalyst is a composite catalyst comprising a metal oxide catalyst component and a microporous catalyst component, and converting the intermediate stream into a product stream comprising C2 to C4 carboxylic acids in the presence of a second catalyst in a second reactor. The second reactor can be configured for olefin oxidation or paraffin oxidation.

First claim

1 . A process comprising:
introducing a feed stream comprising hydrogen gas and a carbon-containing gas comprising carbon monoxide and carbon dioxide into a reaction zone of a first reactor;
converting the feed stream into an intermediate stream comprising C 2 to C 4 hydrocarbons in the reaction zone in the presence of a first catalyst, wherein the intermediate stream further comprises carbon dioxide and wherein the first catalyst is a composite catalyst comprising a metal oxide catalyst component and a microporous catalyst component; and
converting the intermediate stream into a product stream comprising C 2 to C 4 carboxylic acids in the presence of a second catalyst in a second reactor.

2 . The process of claim 1 , wherein the intermediate stream comprising C 2 to C 4 hydrocarbons comprises C 2 to C 4 olefins, C 2 to C 4 paraffins, carbon dioxide, and unreacted carbon monoxide and hydrogen.

3 . The process of claim 2 , wherein the second reactor converts the C 2 to C 4 olefins in the intermediate stream to C 2 to C 4 carboxylic acids.

4 . The process of claim 3 , further comprising separating the C 2 to C 4 carboxylic acids and C 2 to C 4 paraffins from the product stream and recycling carbon dioxide and carbon monoxide to the feed stream.

5 . The process of claim 1 , wherein the metal oxide catalyst component comprises gallium oxide, zinc oxide, chromium oxide, zirconium oxide, or combinations thereof.

6 . The process of claim 5 , wherein the metal oxide catalyst component comprises gallium oxide and phase pure zirconium oxide.

7 . The process of claim 2 , wherein the second reactor converts the C 2 to C 4 paraffins in the intermediate stream to the product stream comprising C 2 to C 4 carboxylic acids.

8 . The process of claim 7 , further comprising separating the C 2 to C 4 carboxylic acids from the product stream and recycling carbon dioxide, carbon monoxide, and unreacted C 2 to C 4 paraffins to the feed stream.

9 . The process of claim 1 , wherein the metal oxide catalyst component comprises gallium oxide.

10 . The process of claim 1 , wherein unreacted hydrogen is removed from the intermediate stream prior to converting the intermediate stream into the product stream.

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

12 . The process of claim 1 , wherein the microporous catalyst component is a molecular sieve having a Chabazite (CHA) framework.

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

14 . The process of claim 1 , wherein the microporous catalyst component comprises SSZ-13.

Assignees

• Rohm & Haas

Inventors

• Dewilde Joseph F
• Limbach Kirk W
• Chakrabarti Reetam

Classifications

• C07C51/225 Primary

  of paraffin waxes · CPC title

• C07C51/64

  Separation; Purification; Stabilisation; Use of additives · CPC title

• C07C2521/06

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

• C07C2523/08

  of gallium, indium or thallium · CPC title

• C07C2529/85

  Silicoaluminophosphates (SAPO compounds) · CPC title