Catalyst for the oxychlorination of ethylene to 1, 2-dichloroethane

Patent metadata

Field	Value
Publication number	US-9248434-B2
Application number	US-201314072057-A
Country	US
Kind code	B2
Filing date	Nov 5, 2013
Priority date	Nov 6, 2012
Publication date	Feb 2, 2016
Grant date	Feb 2, 2016

Abstract

This invention relates to a catalyst containing from about 2 up to about 8% by wt. of copper, zero up to about 0.6 moles/kg of one or more alkali metal(s), from about 0.08 up about 0.85 moles/kg of one or more alkaline earth metals and from about 0.09 up to about 0.9 moles/kg of one or more transition metals selected from the group consisting of Mn, Re and mixtures thereof, where all the metals are impregnated in form of their chlorides or other water soluble salts on a fluidizable support with a BET surface area of from about 80 up to about 220 m 2 /g. A process for the oxychlorination of ethylene to form 1,2-dichloroethane using such a catalyst having good activity, good selectivity and low tendency to stickiness in fluidized bed oxychlorination reactions.

First claim

What is claimed is:

1. A catalyst composition comprising:
a support having deposited thereon catalytically active metals comprising:
(i) from about 2 to about 8% by weight of copper as metal,
(ii) from about 0.1 to about 0.6 moles/kg of one or more alkali metals as metal,
(iii) from about 0.08 to about 0.85 moles/kg of one or more alkaline earth metals as metal, and
(iv) from about 0.09 to about 0.9 moles/kg of one or more transition metals as metal, the one or more transition metals comprising Mn, Re, or mixtures thereof, and

wherein amounts of each of the catalytically active metals are based upon a total weight of the catalyst composition,
wherein all of the catalytically active metals are impregnated in forms of their chlorides or other water soluble salts on the support,
wherein the support is a fluidizable support having a BET surface of from about 80 up to about 220 m 2 /g,
and
wherein the catalyst composition is free of rare earth metals.

2. The catalyst composition according to claim 1 , wherein:
the copper is present from about 3% to about 6% by weight as metal,
the one or more alkali metals are present from about 0.1 to about 0.4 moles/kg as metal,
the one or more alkaline earth metals are present from about 0.2 to about 0.75 moles/kg as metal, and
the one or more transition metals are present from about 0.09 to about 0.4 moles/kg as metal.

3. The catalyst composition of claim 1 wherein the support is an alumina support.

4. The catalyst composition of claim 1 wherein the one or more alkali metals comprise at least one metal selected from the group consisting of potassium, lithium, sodium, rubidium, and cesium.

5. The catalyst composition of claim 1 wherein the one or more alkali metals comprise potassium.

6. The catalyst composition of claim 1 wherein the one or more alkaline earth metals comprise magnesium.

7. The catalyst composition of claim 1 wherein the one or more transition metals comprise manganese.

8. A catalyst composition comprising a support having deposited thereon catalytically active metals, the catalytically active metals comprising:
(i) from about 2 to about 8% by weight of copper as metal,
(ii) from about 0.1 to about 2% by weight of potassium as metal,
(iii) from about 0.2 to about 2.0% by weight of magnesium as metal, and
(iv) from about 0.5 to about 5.0% by weight of manganese as metal, and
wherein amounts of each of the catalytically active metals are based upon a total weight of the catalyst composition,
wherein all the catalytically active metals are impregnated in forms of their chlorides or other water soluble salts on the support,
wherein the support is a fluidizable support having a BET surface of from about 80 up to about 220 m 2 /g, and
wherein the catalyst composition is free of rare earth metals.

9. A process of oxychlorination of ethylene to produce 1,2-dichloroethane, the process comprising:
contacting a mixture of ethylene, oxygen, or oxygen containing gas and hydrogen chloride with a catalyst in a reaction zone, and
recovering 1,2-dichloroethane from effluents of the reaction zone, wherein said catalyst comprises:
a support having deposited thereon catalytically active metals comprising:
(i) from about 2% to about 8% by weight of copper as metal,
(ii) from about 0.1 to about 0.6 moles/kg of one or more alkali metals as metal,
(iii) from about 0.08 to about 0.85 moles/kg of one or more alkaline earth metals as metal, and
(iv) from about 0.09 to about 0.9 moles/kg of one or more transition metals selected from the group consisting of Mn, Re and mixtures thereof,

wherein amounts of all of the catalytically active metals are based upon a total weight of the catalyst composition, wherein all the catalytically active metals are impregnated in forms of their chlorides or other water soluble salts on the support, wherein the support is a fluidizable support having a BET surface area of from about 80 up to about 220 m 2 /g, and wherein the catalyst composition is free of rare earth metals.

10. The process of claim 9 wherein:
the copper is present from about 3% to about 6% by weight as metal,
the one or more alkali metals are present from about 0.1 to about 0.4 moles/kg as metal,
the one or more alkaline earth metals are present from about 0.2 to about 0.75 moles/kg as metal, and
the one or more transition metals are present from about 0.09 to about 0.4 moles/kg as metal.

11. The process of claim 9 wherein the metals are deposited on a fluidizable alumina support.

12. The process of claim 9 wherein the alkali metal is at least one metal selected from the group consisting of potassium, lithium, sodium, rubidium, and cesium.

13. The process of claim 12 wherein the one or more alkali metals comprise potassium.

14. The process of claim 9 wherein the one or more alkaline earth metals comprise magnesium.

15. The process of claim 9 wherein the one or more transition metals comprise manganese.

16. A process of oxychlorination of ethylene to produce 1,2-dichloroethane, the process comprising:
contacting a mixture of ethylene, oxygen, or oxygen containing gas and hydrogen chloride with a catalyst in a reaction zone, and
recovering 1,2-dichloroethane from effluents of the reaction zone, wherein said catalyst comprises:
a support having deposited thereon catalytically active metals comprising:
(i) from about 2 to about 8% by weight of copper as metal,
(ii) from about 0.1 to about 2% by weight of potassium as metal,
(iii) from about 0.2 to about 2.0% by weight of magnesium as metal, and
(iv) from about 0.5 to about 5.0% by weight of manganese as metal,

wherein amounts of all of the catalytically active metals are based upon a total weight of the catalyst composition, wherein all the catalytically active metals are impregnated in forms of their chlorides or other water soluble salts on the support, wherein the support is a fluidizable support having a BET surface area of from about 80 up to about 220 m 2 /g, and wherein the catalyst composition is free of rare earth metals.

17. The process of claim 9 further characterized in that:
the ratio of ethylene to HCl employed ranges from about 1.0 to about 2.0 moles of ethylene for every 2.0 moles of HCl, and
the ratio of oxygen to HCl employed ranges from about 0.5 to about 0.9 mole of oxygen for every 2.0 moles of HCl.

18. The process of claim 9 wherein the reactants are passed over the catalyst in a once through process.

19. The process of claim 9 wherein the unreacted ethylene is recycled through the reaction zone.

Assignees

• Basf Corp

Inventors

• Tompers Rolf
• Kramer Keith

Classifications

• B01J23/8892 Primary

  Manganese · CPC title

• B01J23/8896

  Rhenium · CPC title

• B01J37/08

  Heat treatment {(B01J37/0009, B01J37/0018 take precedence)} · CPC title

• B01J35/023

  Operations & Transport · mapped topic

• B01J21/04

  Alumina · CPC title