Fluidizable catalysts for oxidative dehydrogenation of hydrocarbons

Patent metadata

Field	Value
Publication number	US-9725381-B2
Application number	US-201514793440-A
Country	US
Kind code	B2
Filing date	Jul 7, 2015
Priority date	Jul 7, 2015
Publication date	Aug 8, 2017
Grant date	Aug 8, 2017

Abstract

Fluidizable catalysts for oxygen-free oxidative dehydrogenation of alkanes to corresponding olefins. The catalysts contain 10-20% (by weight per total catalyst weight) of one or more vanadium oxides as the catalytic material, which are mounted upon an alumina support that is modified with zirconia at alumina/zirconia ratios of 5:1 up to 1:2. Various methods of preparing and characterizing the fluidizable catalysts are also provided.

First claim

The invention claimed is:

1. A fluidizable catalyst comprising:
a zirconia-modified alumina support material; and
10-20% of one or more vanadium oxides by weight based on a total weight of the fluidizable catalyst, the one or more vanadium oxides being adsorbed onto the support material;
wherein the support material comprises an alumina/zirconia weight ratio of 1-5:1-3; and
wherein the fluidizable catalyst has an average particle size of 40-120 μm.

2. The fluidizable catalyst of claim 1 , wherein the one or more vanadium oxides are selected from the group consisting of V 2 O 5 , VO 2 , and V 2 O 3 .

3. The fluidizable catalyst of claim 2 , comprising at least 50% of V 2 O 5 based on total weight of the one or more vanadium oxides.

4. The fluidizable catalyst of claim 1 , wherein the alumina/zirconia weight ratio is 1-2:1.

5. The fluidizable catalyst of claim 1 , wherein the one or more vanadium oxides form a crystalline phase on the surface of the zirconia-modified alumina support material.

6. The fluidizable catalyst of claim 1 , having an apparent particle density of 1.5-3.5 g/cm 3 .

7. The fluidizable catalyst of claim 1 , having Class B powder properties in accordance with Geldart particle classification.

8. The fluidizable catalyst of claim 1 , wherein the zirconia present in the alumina/zirconia ratio depresses the surface acidity of the fluidizable catalyst.

9. The fluidizable catalyst of claim 1 , wherein the zirconia present in the alumina/zirconia ratio enhances the interaction between the one or more vanadium oxides and the support material.

10. The fluidizable catalyst of claim 1 , wherein the zirconia present in the alumina/zirconia ratio enhances the reducibility of the one or more vanadium oxides.

11. A process for converting an alkane to a corresponding olefin, comprising:
contacting an alkane feed stream with the fluidizable catalyst of claim 1 in an oxygen-free atmosphere at 525-675° C.

12. The process of claim 11 , wherein the alkane is selected from the group consisting of ethane, propane, n-butane and isobutane.

13. The process of claim 11 , wherein the fluidizable catalyst is present at an amount of 0.05-0.5 g/ml of the alkane feed stream.

14. The process of claim 11 , wherein the alkane is ethane and the process has an ethane conversion of 15-45%.

15. The process of claim 11 , wherein the alkane is ethane and the process has an ethylene selectivity of 75-90%.

16. A fluidizable catalyst, comprising:
a zirconia-modified alumina support material; and
10-20% of one or more vanadium oxides by weight based on a total weight of the fluidizable catalyst, the one or more vanadium oxides being adsorbed onto the support material;
wherein the support material comprises an aluminalzirconia weight ratio of 1-5:1-3; and
wherein the fluidizable catalyst is in the form of a plurality of particles and more than 75% of the particles have a particle size of 40-120 μm.

17. A process for converting an alkane to a corresponding olefin, comprising:
contacting an alkane feed stream with the fiuidizable catalyst of claim 16 in an oxygen-free atmosphere at 525-675° C.

18. A fluidizable catalyst, comprising:
a zirconia-modified alumina support material; and
10-20% of one or more vanadium oxides by weight based on a total weight of the fluidizable catalyst, the one or more vanadium oxides being adsorbed onto the support material;
wherein the support material comprises an alumina/zirconia weight ratio of 1-5:1-3; and
wherein the fluidizable catalyst has a BET surface area of 10-50 m 2 /g.

19. A process for converting an alkane to a corresponding olefin, comprising:
contacting an alkane feed stream with the fluidizable catalyst of claim 18 in an oxygen-free atmosphere at 525-675° C.

Assignees

• Univ King Fahd Pet & Minerals

Inventors

• Hossain Mohammad Mozahar
• Elbadawi Abdalwadood Hassan
• Ba-Shammakh Mohammed Saleh
• Razzak Shaikh Abdur

Classifications

• B01J35/32

  Bulk density · CPC title

• B01J2235/30

  Scanning electron microscopy; Transmission electron microscopy · CPC title

• B01J2235/15

  X-ray diffraction · CPC title

• B01J35/70

  characterised by their crystalline properties, e.g. semi-crystalline (catalysts comprising carbon B01J21/18; molecular sieves B01J29/00) · CPC title

• B01J35/80

  characterised by their amorphous structures · CPC title