Lower olefins producing catalyst and method for producing lower olefins using same

Patent metadata

Field	Value
Publication number	US-9382169-B2
Application number	US-201113333383-A
Country	US
Kind code	B2
Filing date	Dec 21, 2011
Priority date	Jun 22, 2009
Publication date	Jul 5, 2016
Grant date	Jul 5, 2016

Abstract

A lower olefin producing catalyst which has high olefin production efficiency and maintains its activity for a long period of time when lower olefins are produced from an oxygen-containing compound, which is a solid catalyst used in producing lower olefins from an oxygen-containing compound, includes a solid-state catalyst component containing an MFI-type zeolite, in which, at a position where the shortest distance to the outer surface is maximum among all positions inside a structure of the solid catalyst, the thickness defined as a distance twice the shortest distance from the point to the outer surface is in a range of from 0.1 to 2.0 mm, and a method for producing lower olefins.

First claim

The invention claimed is:

1. A lower olefin producing catalyst comprising:
a solid-state catalyst component comprising an MFI-type zeolite, the thickness of the catalyst being in a range of from 0.1 to 2.0 mm, where the thickness is defined as a distance twice the shortest distance from the outer surface to a position where the shortest distance to the outer surface is maximum among all positions inside a structure of the solid catalyst, and the compacted bulk density (CBD) of the catalyst being 800 kg/m 3 or less,
wherein the lower olefin producing catalyst is of a shape selected from the group consisting of honeycomb-shaped, three-leaf-shaped and four-leaf-shaped,
the solid-state catalyst component contains an alkaline-earth metal component in an amount of 0.3 to 10 parts by weight in terms of metal relative to 100 parts by weight of the MFI-type zeolite.

2. The lower olefin producing catalyst according to claim 1 , wherein the lower olefin producing catalyst is obtained by a process comprising shaping a mixture comprising the solid-state catalyst component comprising an MFI-type zeolite, and at least one binder selected from the group consisting of an oxide of aluminum, a hydroxide of aluminum, an oxide of silicon, a hydroxide of silicon and clay.

3. The lower olefin producing catalyst according to claim 2 , wherein the alkaline-earth metal is calcium.

4. The lower olefin producing catalyst according to claim 1 , wherein the lower olefin producing catalyst is honeycomb-shaped.

5. The lower olefin producing catalyst according to claim 1 , wherein the atomic ratio Si/Al in the zeolite framework of the MFI-type zeolite is in a range of from 10 to 2,000.

6. A method for producing a lower olefin producing catalyst comprising:
preparing a mixture by mixing/kneading a solid-state catalyst component comprising an MFI-type zeolite and at least one binder selected from the group consisting of an oxide of aluminum, a hydroxide of aluminum, an oxide of silicon, a hydroxide of silicon, and clay in the presence of a polar solvent; and
shaping the mixture and calcining the shaped mixture,
to obtain the catalyst having a thickness in a range of from 0.1 to 2.0 mm, where the thickness is defined as a distance twice the shortest distance from the outer surface to a position where the shortest distance to the outer surface is maximum among all positions inside a structure of the solid catalyst, and the catalyst having the compacted bulk density (CBD) of 800 kg/m 3 or less,
wherein the lower olefin producing catalyst is of a shape selected from the group consisting of honeycomb-shaped, three-leaf-shaped and four-leaf-shaped,
the solid-state catalyst component contains an alkaline-earth metal component in an amount of 0.3 to 10 parts by weight in terms of metal relative to 100 parts by weight of the MFI-type zeolite.

7. A method for producing lower olefins comprising:
contacting an oxygen-containing compound with the lower olefin producing catalyst according to claim 1 in a reactor into which the catalyst has been packed at 500° C. to 650° C. of outlet temperature under 0.12 MPa to 1.0 MPa of inlet pressure.

8. The method for producing lower olefins according to claim 7 , wherein the oxygen-containing compound comprises dimethyl ether and/or methanol.

9. The method for producing lower olefins according to claim 7 , wherein the catalyst packing density in the reactor is 800 kg/m 3 or less.

10. The method for producing lower olefins according to claim 8 , wherein the catalyst packing density in the reactor is 800 kg/m 3 or less.

11. The lower olefin producing catalyst according to claim 1 , wherein the alkaline-earth metal is calcium.

12. The lower olefin producing catalyst according to claim 1 , wherein the atomic ratio Si/Al in the zeolite framework of the MFI-type zeolite is in a range of 50 to 1,000.

13. The lower olefin producing catalyst according to claim 1 , wherein the compacted bulk density (CBD) of the catalyst is 729 kg/m 3 or less.

14. The lower olefin producing catalyst according to claim 1 , wherein the compacted bulk density (CBD) of the catalyst is 700 kg/m 3 or less.

15. The lower olefin producing catalyst according to claim 1 , wherein the compacted bulk density (CBD) of the catalyst is 650 kg/m 3 or less.

16. The lower olefin producing catalyst according to claim 1 , wherein the compacted bulk density (CBD) of the catalyst ranges from 200 to 650 kg/m 3 .

Assignees

• Okita Atsushi
• Honda Kazunori
• Inaki Chizu
• Takahashi Jumpei
• Yamaguchi Masashi
• Yoshikawa Yumiko
• Iwade Shinji
• Setoyama Tohru
• Jgc Corp
• Mitsubishi Chem Corp

Inventors

• Okita Atsushi
• Honda Kazunori
• Inaki Chizu
• Takahashi Jumpei
• Yamaguchi Masashi
• Yoshikawa Yumiko
• Iwade Shinji
• Setoyama Tohru

Classifications

• B01J2235/30

  Scanning electron microscopy; Transmission electron microscopy · CPC title

• B01J35/32

  Bulk density · CPC title

• B01J35/55

  Cylinders or rings · CPC title

• B01J35/56

  Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths · CPC title

• B01J35/50

  characterised by their shape or configuration · CPC title