CN103124595A - 用于生物原料的加氢异构化催化剂 - Google Patents

用于生物原料的加氢异构化催化剂 Download PDF

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CN103124595A
CN103124595A CN2011800472204A CN201180047220A CN103124595A CN 103124595 A CN103124595 A CN 103124595A CN 2011800472204 A CN2011800472204 A CN 2011800472204A CN 201180047220 A CN201180047220 A CN 201180047220A CN 103124595 A CN103124595 A CN 103124595A
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catalyst
molecular sieve
oil
bio
matrix components
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CN103124595B (zh
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M·A·勒文施泰因
A·莫伊尼
I·佩特罗维克
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BASF SE
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    • Y02P30/20Technologies relating to oil refining and petrochemical industry using bio-feedstock

Abstract

提供用于加工生物基原料至生物柴油燃料内的加氢异构化催化剂。这些催化剂包含催化材料和基质组分。催化材料由具有预先装载的铂族金属的分子筛构成。将催化材料和基质组分一起加工以形成加氢异构化催化剂。制备这些加氢异构化催化剂的方法包括:合成分子筛;纯化分子筛;在没有基质组分下使分子筛与铂族金属缔合以在形成催化剂主体之前形成预先装载的分子筛;使预先装载的分子筛与基质组分混合以形成混合物;加工混合物以形成催化剂主体;以及干燥和煅烧催化剂主体以形成加氢异构化催化剂。这些加氢异构化催化剂可用于加工加氢脱氧的源于植物或动物的进料以生成生物燃料。

Description

用于生物原料的加氢异构化催化剂
相关申请的交叉引用
按照35U.S.C.§119(e)该申请要求2010年8月2日提交的美国专利申请号61/369,878的优先权的权益,其以引用方式全部在此并入。
技术领域
本发明通常属于用于由生物原料形成内燃机的燃料和润滑剂的催化剂。更具体而言,提供用于由加氢脱氧的源于植物的油或者动物脂形成柴油机燃料的加氢异构化催化剂。
背景技术
诸如源于植物和动物的油的生物原料提供可再生能源的来源。可将这些油加工以形成适合内燃机的燃料和润滑剂。通常,需要将油化学上重新安排以制备可在以及与例如汽油和柴油机中使用的燃料和/或润滑剂。这些方法通常提供第一氢化处理/加氢脱氧步骤以及第二异构化步骤,该第一氢化处理/加氢脱氧步骤分解生物原始材料的结构以形成直链烷烃,该第二异构化步骤重新安排直链烷烃至支链化合物内,该支链化合物提供合适性能性质,例如鲸蜡烷、浊点等。例如,美国专利号7,232,935(Jakkula)涉及制备生物起源的烃组分的方法,其中使用逆流原则来操作异构化步骤。
诸如铝硅酸盐沸石和SAPO类型的筛的分子筛通常与之前金属和基质/胶结剂一起使用以形成这类方法的催化剂。对开发这些催化剂有连续需求以得到高产量的所需燃料和/或润滑剂,同时具有所需性能性质。
发明概述
提供用于加工生物基原料至生物柴油燃料内的加氢异构化催化剂。这些催化剂包含催化材料和基质组分,其中催化材料包含分子筛,分子筛包含预先装载的铂族金属。将催化材料和基质组分一起加工以形成加氢异构化催化剂。
也提供加氢异构化催化剂,该加氢异构化催化剂包含通过以下步骤制备的用于加工生物基进料至生物燃料内,其包含预先装载的分子筛和基质组分:合成分子筛;纯化分子筛;在没有基质组分下使分子筛与铂族金属缔合以在形成催化剂主体之前形成预先装载的分子筛;使预先装载的分子筛与基质组分混合以形成混合物;加工混合物以形成催化剂主体;以及干燥和煅烧催化剂主体以形成加氢异构化催化剂。
其他方面提供制备生物燃料的方法,该方法包括:提供源于生物基进料的烷烃的来源;使加氢脱氧的生物基进料接触本发明的加氢异构化催化剂;以及生成生物燃料。生物基进料通常为源于植物或动物。示例性源于植物的油为芥花油、蓖麻油、椰子油、玉米油、棉籽油、大麻籽油、亚麻子油、芥子油、橄榄油、棕榈油、花生油、菜籽油、豆油、大豆油、向日葵油、及其组合。示例性源于动物的生物基进料包括动物脂、润滑脂、油类及其组合。
发明详述
提供用于加工生物基进料至生物柴油燃料内的加氢异构化催化剂。也提供制备和使用其的方法。这些催化剂包含催化材料和基质组分。催化材料由具有预先装载的铂族金属的分子筛构成。将催化材料和基质组分一起加工以形成加氢异构化催化剂。提到“预先装载的”是指在没有基质组分下以及在煅烧沸石和/或形成催化剂主体之前将分子筛浸渍或者使分子筛与铂族金属缔合。已经发现,在与基质组分混合以及形成催化剂主体之前诸如铂的铂族金属的预先装载导致高效加氢异构化催化剂,得到柴油机燃料的极好产量。如果需要,也可将铂族金属放置在基质上。
催化剂可包含全部铂族金属量,其是预先装载的铂族金属的量和基质基铂族金属的量的总和。在一个或多个实施方案中,将铂族金属在分子筛上浓缩。即,将全部存在于加氢异构化催化剂的大部分铂族金属与分子筛缔合。在一个实施方案中,使100重量%的铂族金属与分子筛缔合。在一个或多个实施方案中,使全部铂族金属的51至99重量%位于分子筛上以及使全部铂族金属的1至49重量%位于基质上。其他实施方案提供使99%、95%、90%、85%、80%、75%、70%、65%、60%、55%、或者甚至51重量%的铂族金属与分子筛缔合。
如本文所使用,分子筛是指具有不大于20A的孔尺寸的基本上均匀孔分布的材料。沸石是具有相当均匀孔尺寸的铝硅酸盐结晶材料,取决于沸石的类型和在沸石晶格中所包括的阳离子的类型和量,其通常直径为约3至10埃。SAPO类型分子筛是指共享四面体框架的角,其中大部分四面体位置均被铝和磷填充。SAPO类型分子筛的非限制性例子包括硅磷酸铝和金属-磷酸铝。具体非限制性例子包括SAPO-11和SAPO-41。
在具体的实施方案中,分子筛是一维孔沸石,其非限制性例子包括ZSM-12、ZSM-22、ZSM-23、ZSM-48、SAPO-11、和SAPO-41。
在另一实施方案中,催化剂进一步包含助催化剂,该助催化剂可清楚诸如碱金属的杂质。示例性碱金属包括镍、铜、铁、和锡。碱金属可以0.1至10.0重量%(或者0.1至5重量%、或者0.1至3重量%)范围的催化剂重量的量存在。
在一个或多个实施方案中,预先装载的铂族金属包含铂、钯、铑、钌、或其组合。详细的实施方案提供预先装载的铂族金属包含以0.1至2.0重量%范围的催化剂的量存在的铂。
基质、或胶结剂、组分是与预先装载的分子筛结合以形成催化材料的一种物质。基质组分可包含二氧化硅、氧化铝、或其组合。在详细的实施方案中,基质组分基于选自硅溶胶、羟基化氧化铝、煅烧氧化铝、磷酸铝、二氧化硅、及其组合的材料。羟基化氧化铝可选自:勃姆石、假勃姆石或凝胶状勃姆石、水铝石、新三水氧化铝、拜三水铝石、三水铝矿、具有添加至表面的羟基的氧化铝及其混合物。煅烧氧化铝可选自γ、δ、θ、κ、以及ρ氧化铝。
在一个或多个实施方案中,预先装载的分子筛以20-80重量%范围的加氢异构化催化剂的量存在以及基质组分以80-20重量%范围的加氢异构化催化剂的量存在。
在另一方面中,加氢异构化催化剂包含预先装载的分子筛和基质组分,其通过以下步骤制备以用于加工生物基进料至生物燃料内:合成分子筛;纯化分子筛;在没有基质组分下使分子筛与铂族金属缔合以在形成催化剂主体之前形成预先装载的分子筛;使预先装载的分子筛与基质组分混合以形成混合物;加工混合物以形成催化剂主体;以及干燥和煅烧催化剂主体以形成加氢异构化催化剂。
至于形成分子筛的合成步骤,提供含有所需框架成分的凝胶,其中预期也存在也称之为有机模板的有机结构导向剂。然后根据本领域已知方法来使所需分子筛结晶。为了形成铝硅酸盐沸石,使用具有有机结构导向剂的铝硅酸盐凝胶。例如,ZSM-23可由具有75:1至30:1范围的Si:Al比率的凝胶、以及有机结构导向剂形成。然后将所得晶体干燥。纯化步骤通常包括过滤和洗涤分子筛。
通过本领域已知方法可进行使分子筛与铂族金属缔合的步骤。例如,通过浸渍可使铂族金属与分子筛缔合。提到“浸渍”是指使用前述含有金属的溶液来浸透材料。在一些实施方案中,通过初期润湿来进行铂族金属的浸渍。在其他实施方案中,通过离子交换来进行浸渍,其中铂族金属与分子筛的阳离子进行离子交换。在又一其他实施方案中,通过初期润湿和离子交换来处理分子筛。通过在没有基质组分下以及在形成催化剂主体之前使用铂族金属浸渍分子筛,可将金属在分子筛上而不是分子筛和基质组分的混合物内浓缩。在一些实施方案中,然而,也期望提供具有铂族金属的基质组分,也使该铂族金属与基质组分缔合。在制备过程中根据需要可进行使用基质组分的该缔合。例如,可在某时间点之前将基质组分浸渍,例如在将其与预先装载的分子筛混合之前。另一选择是在已经煅烧催化剂主体之后使铂族金属与催化剂主体全部缔合(预先装载的分子筛和基质组分)。
在将预先装载的分子筛和基质组分混合之后,将混合物加工以形成催化剂主体。加工混合的优选方式是将它挤出通过成形孔口以形成挤出的催化剂主体、或者挤出物。可将其他催化剂主体形成至球体或者任意其他方便的构造内。
可在50-250℃范围的温度下干燥挤出物。可在350-700℃范围、优选400-550℃的温度下煅烧挤出物。
其他方面提供制备生物燃料的方法,该方法包括:提供氢化的源于植物的油;使氢化的源于植物的油接触本发明的加氢异构化催化剂;生成生物燃料。源于植物的油优选包含棕榈油。详细的实施方案提供生物燃料具有-15℃或更低的浊点。
在描述本发明的多个示例性实施方案之前,理解,本发明不限于示出在以下描述中结构或方法步骤的细节。本发明能够为其他实施方案以及以各种方式来实施或进行。
实施例
以下非限制性例子用于示出本发明的各种实施方案。
实施例1
如下制备在ZSM-23的分子筛上具有预先装载的铂组分的加氢异构化催化剂。
由含有吡咯烷作为有机结构导向剂的铝硅酸盐凝胶形成具有42的Si:Al比率的ZSM-23(MTT结构)分子筛。一旦结晶,通过过滤和洗涤来回收ZSM-23沸石。然后在100-110范围的温度下干燥。
为了预先装置铂,即在煅烧之前添加铂,然后使用含氨的铂“P”溶液将干燥的沸石浸渍,在周围条件下老化30分钟,并且在70-110℃范围的温度下干燥。然后在400-550℃范围的温度下将浸渍的沸石煅烧。承载煅烧的催化剂的铂约为0.5重量%。
实施例2
测试
将通过预先装载具有铂的沸石以及然后煅烧制备的实施例1的催化剂在压热器实验中测试以用于正十六烷的加氢异构化,其中观察到4.5小时转化为47%。作为对照,获得具有0.5重量%铂承载量的第一比对催化剂,通过煅烧沸石以去除模板以及然后使用铂浸渍来制备该第一比对催化剂。在相同测试条件下在4.5小时处第一比对催化剂提供35%转化。如此,实施例1的铂预先装载的ZSM-23催化剂提供n-十六烷转化的约35%增加。在300℃和在H2中450psig下、在1500rpm下振荡使用1.3重量%催化剂承载量来进行压热器实验。
实施例3
如下制备在ZSM-23分子筛和氧化铝的胶结剂上具有预先装载的铂组分的挤出的加氢异构化催化剂。
由含有吡咯烷作为有机结构导向剂的铝硅酸盐凝胶再次形成具有实施例1的42的Si:Al比率的ZSM-23(MTT结构)分子筛。一旦结晶,通过过滤和洗涤来回收ZSM-23沸石。然后在100-110℃范围的温度下干燥沸石。
为了预先装置铂,即在煅烧和挤出之前添加铂,然后使用含氨的铂“P”溶液将干燥的沸石浸渍,在周围条件下老化30分钟,并且在70-110℃范围的温度下干燥。将材料与氧化铝胶结剂(70重量%胶结剂以及30重量%预先装载的沸石)混合以及将其挤出以形成具有约1/16英寸直径和约1/8-3/8英寸长的催化剂挤出物。然后在400-550℃范围的温度下将挤出的材料干燥和煅烧。煅烧的催化剂的铂承载量为约0.5重量%。
实施例4
测试
在以下条件下将通过预先装载具有铂的沸石、使用氧化铝挤出、以及然后煅烧制备的实施例3的催化剂在使用n-十六烷作为原料的固定床反应器中试验:270-330℃的温度;450psig的压力;1hr-1的进料LHSV;以及以体积计的~310的H2/n-C16。作为对照,如下制备第二比对催化剂。由含有吡咯烷作为有机结构导向剂的铝硅酸盐凝胶形成具有48的Si:Al比率的ZSM-23分子筛。一旦结晶,通过过滤和洗涤来回收ZSM-23沸石。在100-110℃范围的温度下干燥沸石滤饼以及在550℃下煅烧6小时。然后通过使用氧化铝胶结剂挤出沸石以形成具有约1/16英寸直径和约1/8-3/8英寸长的挤出物、在400-550℃下煅烧挤出物以及然后使用铂"P"溶液的0.5重量%铂来浸渍挤出物来获得最终催化剂。在浸渍之后,在400-550℃范围的温度下将挤出物再次煅烧。如在表1中所示,在300℃下实施例3的催化剂具有显著更高活性,相对于在相同温度下第二比对催化剂的仅50%转化其得到91%转化。
实施例5
在另一例子中,根据在实施例3中催化剂的工序、具有约0.15wt.%的铂承载量来制备在未经煅烧的ZSM-23分子筛上具有预先装载的铂组分的挤出的加氢异构化催化剂。
实施例6
测试
将通过预先装载具有铂的未经煅烧的沸石、使用氧化铝挤出、以及然后煅烧制备的实施例5的催化剂在使用n-十六烷作为原料的固定床反应器中测试。测试条件与实施例4中相同。比较实施例4的第二比对催化剂以及实施例5的催化剂。如表1中所示,在300℃下实施例5的催化剂、即使具有远远更低的Pt承载量具有93%转化如与在相同温度下第二比对催化剂的仅50%转化相比的显著更高的活性。如表2所呈现,在实施例5中催化剂超过第二比对催化剂的另一性能优势是在-15℃的所需产品浊点下远远更低的裂化:12%比对27%。
实施例7
在又一例子中,如下制备在ZSM-23分子筛和氧化铝的胶结剂上具有预先装载的铂组分的挤出的加氢异构化催化剂。
由含有吡咯烷作为有机结构导向剂的铝硅酸盐凝胶来形成具有55的Si:Al比率的ZSM-23(MTT结构)分子筛。一旦结晶,通过过滤和洗涤来回收ZSM-23沸石。然后在100-110℃范围的温度下将沸石干燥。
为了预先装置铂,即在煅烧和挤出之前添加铂,然后使用含氨的铂“P”溶液将干燥的沸石浸渍,在周围条件下老化30分钟,并且在70-110℃范围的温度下干燥。将材料与氧化铝胶结剂(70重量%胶结剂以及30重量%预先装载的沸石)混合以及将其挤出以形成具有约1/16英寸直径和约1/8-3/8英寸长的催化剂挤出物。然后在400-550℃范围的温度下将挤出物干燥和煅烧。在催化剂中铂承载量为约0.15wt.%。
实施例8
测试
在如实施例4中相同测试条件下将通过具有铂的未经煅烧的沸石、使用氧化铝挤出、以及然后煅烧来制备的实施例7的催化剂在使用n-十六烷作为原料的固定床反应器中测试。比较第二比对催化剂以及实施例7。如表1中所示,在300XI下实施例7的催化剂、即使具有更高Si:Al比率以及远远更低的Pt承载量具有显著更高活性,得到78%转化比对在相同温度下第二比对催化剂仅50%转化。在-15℃的产品浊点下实施例7的催化剂也显示比第二比对催化剂远远更低的裂化(参见表2)。
表1:转化比对温度
Figure BDA00002985650900081
表2:裂化比对浊点
Figure BDA00002985650900091
实施例9
如下制备在ZSM-23的分子筛上具有不同量的预先装载的铂和镍组分的一系列加氢异构化催化剂。
由含有吡咯烷作为有机结构导向剂的铝硅酸盐凝胶来形成具有39的Si:Al比率的ZSM-23(MTT结构)。一旦结晶,通过过滤和洗涤来回收ZSM-23沸石。然后在100-110℃范围的温度下将沸石干燥。
为了预先装载铂和镍,即在煅烧之前添加铂和镍,然后使用含氨的铂“P”溶液将干燥的沸石浸渍,在周围条件下老化30分钟,并且在80-110℃范围的温度下干燥。在400℃的温度下将浸渍的沸石在空气中煅烧以及然后在400℃的温度下使用H2/N2的合成气体来还原,并且使用稀释空气来钝化。
实施例10
测试
如在实施例2中相同条件下将具有不同水平的镍和铂的实施例9的催化剂在n-十六烷的加氢异构化的压热器实验中测试。然后比较这些Ni-Pt催化剂以及根据实施例1制备的仅Pt催化剂。表3的测试结果显示:当镍含量增加时,则转化增加以及出现单分支,并且出现裂化降低。
表3:仅Pt催化剂比对Pt-Ni催化剂
Figure BDA00002985650900101
通过该说明书提及的“一个实施方案”、“某些实施方案”、“一个或多个实施方案”或者“实施方案”是指与实施方案相关描述的特定特征、结构、材料、或特征包括在本发明的至少一个实施方案中。因此,在该说明中各处措辞例如“在一个或多个实施方案中”、“在某些实施方案中”、“在一个实施方案中”或者“在实施方案中”的意思不一定是指本发明的相同实施方案。而且,在一个或多个实施方案中,可以任何合适的方式组合特定特征、结构、材料、或特征。
尽管参照特定实施方案已经描述本文中发明,但理解,这些实施方案仅为本发明的原则和应用的示意。在未违背本发明的精神和范围下可对本发明的方法和装置进行各种变更和改变,这对本领域技术人员而言显而易见。因此,旨在本发明包括涵盖在所附权利要求的范围内的变更和改变形式和它们的等同形式。

Claims (15)

1.一种用于加工生物基进料至生物柴油燃料内的加氢异构化催化剂,包含:
包含分子筛的催化材料,所述分子筛包含预先装载的铂族金属;以及
基质组分;
其中将所述催化材料和所述基质组分一起加工以形成所述加氢异构化催化剂。
2.权利要求1所述的催化剂,其中所述分子筛包含一维孔分子筛。
3.权利要求2所述的催化剂,其中所述一维孔分子筛选自:ZSM-12、ZSM-22、ZSM-23、ZSM-48、SAPO-11、和SAPO-41。
4.权利要求1所述的催化剂,进一步包含镍组分。
5.权利要求4所述的催化剂,其中所述镍以0.1至10.0重量%范围的所述催化剂的量存在。
6.权利要求1所述的催化剂,其中所述预先装载的铂族金属包含以0.1至2.0重量%范围的所述催化剂的量存在的铂。
7.权利要求1所述的催化剂,其中所述基质组分进一步包含选自铂、钯、铑、钌、或其组合的基质基铂族金属。
8.权利要求1所述的催化剂,其中所述基质组分包含二氧化硅、氧化铝、或其组合。
9.权利要求1所述的催化剂,其中所述基质组分基于选自硅溶胶、羟基化氧化铝、煅烧氧化铝、磷酸铝、二氧化硅、及其组合的材料。
10.权利要求1所述的催化剂,包含以20-80重量%范围的所述加氢异构化催化剂的量的所述预先装载的分子筛以及以80-20重量%范围的所述加氢异构化催化剂的量的所述基质组分。
11.一种通过以下步骤制备的用于加工生物基进料至生物燃料的加氢异构化催化剂的方法,所述加氢异构化催化剂包含预先装载的分子筛和基质组分:
合成分子筛;
纯化所述分子筛;
在没有所述基质组分下使所述分子筛与铂族金属缔合以在形成催化剂主体之前形成所述预先装载的分子筛;
使所述预先装载的分子筛与所述基质组分混合以形成混合物;
加工所述混合物以形成催化剂主体;以及
干燥和煅烧所述催化剂主体以形成所述加氢异构化催化剂。
12.权利要求11所述的方法,其中所述合成步骤包括混合铝硅酸盐凝胶和有机结构导向剂,使所述分子筛结晶,以及干燥所述分子筛。
13.一种用于制备生物燃料的方法,所述方法包括:
提供源于生物基进料的烷烃的来源;
使所述加氢脱氧的生物基进料接触权利要求1或14所述催化剂;以及
生成生物燃料。
14.权利要求13所述的方法,其中所述生物基进料包含源于植物的油,所述源于植物的油包括:芥花油、蓖麻油、椰子油、玉米油、棉籽油、大麻籽油、亚麻子油、芥子油、橄榄油、棕榈油、花生油、菜籽油、豆油、大豆油、向日葵油、或其组合。
15.权利要求13所述的方法,其中将所述生物基进料加氢脱氧。
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