Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
  • B01J37/0027—Powdering
  • B01J37/0045—Drying a slurry, e.g. spray drying
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  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
  • B01J23/002—Mixed oxides other than spinels, e.g. perovskite
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  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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  • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
  • B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
  • B01J23/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
  • B01J23/84—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36 with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
  • B01J23/889—Manganese, technetium or rhenium
  • B01J23/8898—Manganese, technetium or rhenium containing also molybdenum
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  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
  • B01J37/0027—Powdering
  • B01J37/0036—Grinding
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  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/02—Impregnation, coating or precipitation
  • B01J37/03—Precipitation; Co-precipitation
  • B01J37/031—Precipitation
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  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/02—Impregnation, coating or precipitation
  • B01J37/03—Precipitation; Co-precipitation
  • B01J37/031—Precipitation
  • B01J37/035—Precipitation on carriers
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  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/08—Heat treatment
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J38/00—Regeneration or reactivation of catalysts, in general
  • B01J38/04—Gas or vapour treating; Treating by using liquids vaporisable upon contacting spent catalyst
  • B01J38/12—Treating with free oxygen-containing gas
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2/00—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms
  • C07C2/02—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms by addition between unsaturated hydrocarbons
  • C07C2/04—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms by addition between unsaturated hydrocarbons by oligomerisation of well-defined unsaturated hydrocarbons without ring formation
  • C07C2/06—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms by addition between unsaturated hydrocarbons by oligomerisation of well-defined unsaturated hydrocarbons without ring formation of alkenes, i.e. acyclic hydrocarbons having only one carbon-to-carbon double bond
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C5/00—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms
  • C07C5/32—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by dehydrogenation with formation of free hydrogen
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C5/00—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms
  • C07C5/42—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by dehydrogenation with a hydrogen acceptor
  • C07C5/48—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by dehydrogenation with a hydrogen acceptor with oxygen as an acceptor
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G35/00—Reforming naphtha
  • C10G35/04—Catalytic reforming
  • C10G35/06—Catalytic reforming characterised by the catalyst used
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
  • C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
  • C10G45/58—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins
  • C10G45/60—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins characterised by the catalyst used
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2523/00—Constitutive chemical elements of heterogeneous catalysts
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J38/00—Regeneration or reactivation of catalysts, in general
  • B01J38/04—Gas or vapour treating; Treating by using liquids vaporisable upon contacting spent catalyst
  • B01J38/12—Treating with free oxygen-containing gas
  • B01J38/14—Treating with free oxygen-containing gas with control of oxygen content in oxidation gas
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2521/00—Catalysts comprising the elements, oxides or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium or hafnium
  • C07C2521/02—Boron or aluminium; Oxides or hydroxides thereof
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2521/00—Catalysts comprising the elements, oxides or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium or hafnium
  • C07C2521/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
  • C07C2523/02—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the alkali- or alkaline earth metals or beryllium
  • C07C2523/04—Alkali metals
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
  • C07C2523/16—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
  • C07C2523/24—Chromium, molybdenum or tungsten
  • C07C2523/26—Chromium
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
  • C07C2523/16—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
  • C07C2523/24—Chromium, molybdenum or tungsten
  • C07C2523/28—Molybdenum
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
  • C07C2523/16—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
  • C07C2523/32—Manganese, technetium or rhenium
  • C07C2523/34—Manganese
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
  • C07C2523/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the iron group metals or copper
  • C07C2523/74—Iron group metals
  • C07C2523/745—Iron
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
  • C07C2523/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the iron group metals or copper
  • C07C2523/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups C07C2523/02 - C07C2523/36
  • C07C2523/84—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups C07C2523/02 - C07C2523/36 with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
  • C07C2523/843—Arsenic, antimony or bismuth
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P20/00—Technologies relating to chemical industry
  • Y02P20/50—Improvements relating to the production of bulk chemicals
  • Y02P20/584—Recycling of catalysts

Definitions

• the invention relates to a catalyst and a process for the oxidative dehydrogenation of n-butenes to butadiene.
• Butadiene is an important basic chemical and is used, for example, for the production of synthetic rubbers (butadiene homopolymers, styrene-butadiene rubber or nitrile rubbers).
• thermoplastic terpolymers acrylonitrile-butadiene-styrene copolymers
• Butadiene is further converted to sulfolane, chloroprene and 1, 4-hexamethylenediamine (over 1, 4-dichlorobutene and adiponitrile).
• sulfolane sulfolane
• chloroprene 1, 4-hexamethylenediamine
• 4-dichlorobutene and adiponitrile By dimerization of butadiene, vinylcyclohexene can also be produced, which can be dehydrogenated to styrene.
• Butadiene can be prepared by thermal cracking (steam cracking) of saturated hydrocarbons, usually starting from naphtha as the raw material. Steam cracking of naphtha produces a hydrocarbon mixture of methane, ethane, ethene, acetylene, propane, propene, propyne, allenes, butanes, butenes, butadiene, butynes, methylalls, Cs and higher hydrocarbons.
• Butadiene can also be obtained by oxidative dehydrogenation of n-butenes (1-butene and / or 2-butene).
• n-butenes 1,3-butene and / or 2-butene
• any n-butenes containing mixture can be used.
• a fraction containing n-butenes (1-butene and / or 2-butene) as a main component and obtained from the C 4 fraction of a naphtha cracker by separating butadiene and isobutene can be used.
• gas mixtures which comprise 1-butene, cis-2-butene, trans-2-butene or mixtures thereof and which have been obtained by dimerization of ethylene can also be used as starting gas.
• n-butenes containing gas mixtures obtained by catalytic fluid cracking (FCC) can be used as the starting gas.
• Gas mixtures containing n-butenes, which are used as the starting gas in the oxidative dehydrogenation of n-butenes to butadiene, can also be prepared by non-oxidative dehydrogenation of n-butane-containing gas mixtures.
• WO2009 / 124945 discloses a shell catalyst for the oxidative dehydrogenation of 1-butene and / or 2-butene to butadiene, which is obtainable from a catalyst precursor comprising
• X 2 Si and / or Al
• X 3 Li, Na, K, Cs and / or Rb,
• y a number determined by the valency and frequency of elements other than oxygen, assuming charge neutrality
• WO 2010/137595 discloses a multimetal oxide catalyst for the oxidative dehydrogenation of alkenes to dienes comprising at least molybdenum, bismuth and cobalt, of the general formula
• X is at least one element selected from the group consisting of magnesium
• Y is at least one element from the group consisting of sodium (Na), potassium (K), rubidium (Rb), cesium (Cs) and thallium (Tl).
• Z is at least one element selected from the group consisting of boron (B), phosphorus (P), arsenic (As) and tungsten (W).
• a catalyst of the composition
• EP 1 005 908 A2 describes multimetal oxide catalysts for the production of acrolein from propene, which comprise a Ni- and Cr-free mixed metal oxide and may be present in the form of chippings, moldings or coated catalysts.
• the multimetal oxide has the formula Moi2Bi a X 1 bFe c X 2 dX 3 eOy, where
• X1 Co and / or Ni, preferably Co,
• y corresponds to the amount of the number which, assuming charge neutrality, results from the weights and the stoichiometric coefficients of the remaining elements.
• Multimetal oxide catalysts for the oxidative dehydrogenation of alkenes to dienes have the problem that they contain toxic or carcinogenic substances and therefore their use in industrial production poses a threat to these toxins.
• the element chromium is known to have a high toxicity.
• oxides of chromium in the oxidation state + VI are to be avoided because of their carcinogenic effect.
• the maximum chromium content of the catalyst disclosed in WO2009 / 124945 is low, some portion may be present in this oxidation state.
• nickel oxide is a carcinogenic substance, which should be avoided.
• the object of the invention is to provide a multimetal oxide catalyst for the oxidative dehydrogenation of n-butenes to butadiene, which contains no chromium as a doping element and yet is characterized by a high activity and selectivity.
• the object is achieved by a catalyst comprising a catalytically active, molybdenum and at least one further metal-containing multimetal oxide of the general formula (I),
• X 1 Si and / or Al
• X 2 Li, Na, K, Cs and / or Rb;
• a 0.1 to 5, preferably 0.3 to 1.5;
• b 0 to 2, preferably 0 to 1;
• c 2 to 10, preferably 3 to 10;
• d 0.5 to 10, preferably 1 to 7;
• e 0 to 24, preferably 0.1 to 2;
• f 0 to 1, preferably 0.01 to 0.5;
• x a number determined by the valency and frequency of the elements other than oxygen in (I). It has been found that the replacement of chromium by manganese as doping element leads to a catalyst with comparable activity and selectivity. Unlike chromium, manganese oxides are not classified as carcinogenic.
• X 1 is silicon. In another preferred embodiment, X 2 is potassium.
• the multimetal has the formula Moi2Bio, 6Co 7 Fe 3 Mno, 5Ko, o8Sii.6 or Moi2Bio.6Co 7 Fe 3 Sii.6 on.
• the catalyst according to the invention may be a solid material catalyst or a shell catalyst. If it is a shell catalyst, it has a carrier body (a) and a shell (b) containing the catalytically active, molybdenum and at least one further metal-containing multimetal oxide of the general formula (I).
• Support materials suitable for shell catalysts are e.g. porous or preferably non-porous aluminum oxides, silicon dioxide, zirconium dioxide, silicon carbide or silicates such as magnesium or aluminum silicate (for example C 220 steatite from CeramTec).
• the materials of the carrier bodies are chemically inert.
• the support materials may be porous or non-porous.
• the carrier material is preferably non-porous (total volume of the pores based on the volume of the carrier body preferably ⁇ 1% by volume).
• substantially nonporous, surface-rough, spherical steatite supports for example C 220 Steatite from CeramTec
• spherical steatite supports for example C 220 Steatite from CeramTec
• the diameter is 1 to 8 mm, preferably 2 to 6 mm, particularly preferably 2 to 3 or 4 to 5 mm.
• cylinders made of chemically inert carrier material as a support body whose length is 2 to 10 mm and whose outer diameter is 4 to 10 mm.
• the wall thickness is usually 1 to 4 mm.
• annular support body Preferably to be used annular support body have a length of 2 to 6 mm, an outer diameter of 4 to 8 mm and a wall thickness of 1 to 2 mm.
• the layer thickness of the shell (b) of a molybdenum and at least one further metal-containing multimetal oxide composition is usually at 5 to 1000 ⁇ . Preference is given to 10 to 800 ⁇ , more preferably 50 to 600 ⁇ and most preferably 80 to 500 ⁇ .
• the coated catalyst is prepared by applying a layer of molybdenum and at least one further metal-containing multimetal oxide to the carrier by means of a binder, drying and calcining the coated carrier.
• the preparation of the coated catalyst comprises steps (i) to (vi): (i) preparing a molybdenum and at least one further metal-containing multi-metal oxide precursor composition,
• the production of a full-material catalyst generally comprises steps (i) to (iii).
• finely divided, molybdenum-containing and at least one further metal-containing multimetal oxides are basically obtainable by forming an intimate dry mixture of starting compounds of the elemental constituents of the catalytically active oxide composition and thermally treating the intimate dry mixture at a temperature of from 150 to 650 ° C.
• step (i) To prepare the finely divided multimetal oxide compositions (step (i)), starting from known starting compounds of the elemental constituents of the desired multimetal oxide composition in the respective stoichiometric ratio is started, and from these produces a very intimate, preferably finely divided dry mixture, which is then subjected to the thermal treatment (calcination).
• the sources can either already be oxides, or those compounds which can be converted into oxides by heating, at least in the presence of oxygen.
• suitable starting compounds are, in particular, halides, nitrates, formates, oxalates, acetates, carbonates or hydroxides.
• Suitable starting compounds of molybdenum are also its oxo compounds (molybdate) or the acids derived therefrom.
• Suitable starting compounds of Bi, Fe and Co are in particular their nitrates.
• Suitable starting compounds of manganese are in particular nitrates and acetates
• the intimate mixing of the starting compounds can in principle be carried out in dry form or in the form of aqueous solutions or suspensions.
• an aqueous suspension may be prepared by combining a solution containing at least molybdenum and an aqueous solution containing the remaining metals. Alkali metals or alkaline earth metals can be present in both solutions.
• a precipitation is carried out, which leads to the formation of a suspension.
• the temperature of the precipitation may be higher than room temperature, preferably from 30 ° C to 95 ° C, and more preferably from 35 ° C to 80 ° C.
• the suspension may then be aged at elevated temperature for a period of time.
• the aging period is generally between 0 and 24 hours, preferably between 0 and 12 hours, and more preferably between 0 and 8 hours.
• the temperature of aging is generally between 20 ° C and 99 ° C, preferably between 30 ° C and 90 ° C, and more preferably between 35 ° C and 80 ° C.
• the pH of the mixed solutions or suspension is generally between pH 1 and pH 12, preferably between pH 2 and pH 11 and more preferably between pH 3 and pH 10. Removal of the water produces a solid which is an intimate mixture represents the added metal components.
• the drying step may be generally carried out by evaporation, spray drying or freeze drying or the like. Preferably, the drying is carried out by spray drying.
• the suspension is sprayed at elevated temperature with a spray head whose temperature is generally at 120 ° C to 350 ° C, and collected the dried product at a temperature of> 60 ° C.
• the residual moisture, determined by drying the spray powder at 120 ° C, is generally less than 20 wt .-%, preferably less than 15 wt.% And particularly preferably less than 12 wt .-%.
• the spray powder is transferred in a further step in a shaped body (step (ii)).
• shaping aids e.g. Water, boron trifluoride or graphite into consideration.
• Preferred lubricant is graphite.
• the calcination of the catalyst precursor shaped body is usually carried out at temperatures exceeding 350 ° C. Normally, however, the temperature of 650 ° C is not exceeded during the thermal treatment. According to the invention is advantageous in Under the thermal treatment, the temperature of 600 ° C, preferably the temperature of 550 ° C and more preferably the temperature of 500 ° C is not exceeded. Furthermore, in the process according to the invention in the context of the thermal treatment of the catalyst precursor molded body preferably the temperature of 380 ° C, advantageously the temperature of 400 ° C, with particular advantage the temperature of 420 ° C and most preferably the temperature of 440 ° C exceeded. In this case, the thermal treatment can also be divided into several sections in their time sequence.
• a thermal treatment at a temperature of 150 to 350 ° C, preferably from 220 to 280 ° C, and then a thermal treatment at a temperature of 400 to 600 ° C, preferably from 430 to 550 ° C are performed.
• the thermal treatment of the catalyst precursor body takes several hours (usually more than 5 h) to complete. Often, the total duration of the thermal treatment extends to more than 10 hours. Treatment times of 45 hours and 35 hours are usually not exceeded within the scope of the thermal treatment of the catalyst precursor molding. Often the total treatment time is less than 30 h.
• 500 ° C are not exceeded in the thermal treatment of the Katalysatorfor headphonesrform stresses and the treatment time in the temperature window of> 400 ° C extends to 5 to 30 h.
• the calcination of the catalyst precursor moldings can be carried out both under inert gas and under an oxidative atmosphere, e.g. Air (mixture of inert gas and oxygen) and also under reducing atmosphere (for example mixture of inert gas, NH 3, CO and / or H 2 or methane).
• an oxidative atmosphere e.g. Air (mixture of inert gas and oxygen) and also under reducing atmosphere (for example mixture of inert gas, NH 3, CO and / or H 2 or methane).
• the thermal treatment can also be carried out under vacuum.
• the thermal treatment of the catalyst precursor moldings in a variety of furnace types such. heated Um Kunststoffsch, Hordenöfen, rotary kilns, belt calciner or shaft furnaces are performed.
• the thermal treatment of the catalyst precursor shaped bodies preferably takes place in a belt calcination device, as recommended by DE-A 10046957 and WO 02/24620.
• the thermal treatment of the catalyst precursor moldings below 350 ° C usually pursues the thermal decomposition of the sources of elemental constituents of the desired catalyst contained in the catalyst precursor moldings. Often, in the process according to the invention, this decomposition phase takes place during the heating to temperatures ⁇ 350.degree.
• the catalytically active oxide composition obtained after calcination is then used to prepare a coated catalyst, e.g.
• the fineness of the catalytically active oxide material applied to the surface of the carrier body becomes a matter of course hereby (step (iv), which is then applied to the outer surface of the carrier body by means of a liquid binder (step (v)) adapted to the desired shell thickness.
• Suitable support materials for the preparation of coated catalysts are porous or preferably nonporous aluminas, silica, zirconium dioxide, silicon carbide or silicates such as Magnesium or aluminum silicate (eg steatite of type C 220 from CeramTec).
• the materials of the carrier bodies are chemically inert.
• the support materials may be porous or non-porous.
• the carrier material is preferably non-porous (total volume of the pores, based on the volume of the carrier body, preferably -i 1% by volume).
• Preferred hollow cylinders as support bodies have a length of 2 to 10 mm and an outer diameter of 4 to 10 mm.
• the wall thickness is moreover preferably 1 to 4 mm.
• Particularly preferred annular carrier bodies have a length of 2 to
• the layer thickness D of a molybdenum and at least one further metal containing Muletetalloxidmasse is usually from 5 to 1000 ⁇ . Preferred are 10 to 800 ⁇ , more preferably 50 to 600 ⁇ and most preferably 80 to 500 ⁇ .
• the application of the molybdenum and at least one further metal-containing multimetal oxide to the surface of the carrier body can be carried out according to the methods described in the prior art, for example as described in US-A 2006/0205978 and EP-A 0 714 700.
• the finely divided masses are applied to the surface of the carrier body with the aid of a liquid binder.
• a liquid binder e.g. Water, an organic solvent or a solution of an organic substance (e.g., an organic solvent) in water or in an organic solvent.
• the liquid binder used is particularly advantageously a solution consisting of 20 to 95% by weight of water and 5 to 80% by weight of an organic compound.
• the organic fraction of the abovementioned liquid binders is preferably from 10 to 50% by weight and more preferably from 10 to 30% by weight.
• the boiling point or sublimation point of such organic binders or binder fractions at atmospheric pressure is very preferably at the same time below the highest calcination temperature used in the preparation of the molybdenum-containing finely divided multimetal oxide. Usually, this highest calcination temperature is ⁇ 600 ° C, often ⁇ 500 ° C.
• organic binders mono- or polyhydric organic alcohols such as ethylene glycol, 1, 4-butanediol, 1, 6-hexanediol or glycerol, mono- or polyvalent organic carboxylic acids such as propionic acid, oxalic acid, malonic acid, glutaric acid or maleic acid, amino alcohols such as ethanolamine or diethanolamine and mono- or polyvalent organic amides such as formamide.
• Monosaccharides and oligosaccharides such as glucose, fructose, sucrose and / or lactose are suitable as organic binder promoters which are soluble in water, in an organic liquid or in a mixture of water and an organic liquid.
• liquid binders are solutions which consist of 20 to 95% by weight of water and 5 to 80% by weight of glycerol.
• the glycerol content in these aqueous solutions is from 5 to 50% by weight and more preferably from 8 to 35% by weight.
• step (v)) can be carried out in such a way that disperse the finely divided mass of molybdenum-containing multimetal in the liquid binder dispersed and spraying the resulting suspension to moving and optionally hot carrier body, as described in DE-A 1642921, DE-A 2106796 and DE-A 2626887.
• moving and optionally hot carrier body as described in DE-A 1642921, DE-A 2106796 and DE-A 2626887.
• pore-forming agents such as malonic acid, melamine, nonylphenolethoxylate, stearic acid, glucose, starch, fumaric acid and succinic acid may be added to the finely divided multimetal oxide to be supported on the support to produce a suitable pore structure of the catalyst and to improve its mass transfer properties.
• the carrier body is first moistened with the liquid binder, and subsequently the finely divided mass of multimetal oxide is applied to the surface of the carrier body moistened with the binder by rolling the moistened carrier body in the finely divided mass.
• the process described above is preferably repeated several times, d. H. the base-coated carrier body is moistened again and then coated by contact with dry finely divided mass.
• the carrier bodies to be coated are filled into a preferably tilted rotary container (for example a turntable or coating pan) which rotates (the angle of inclination is generally 30 to 90 °).
• the temperatures necessary to effect the removal of the coupling agent are below the highest calcination temperature of the catalyst, generally between 200 ° C and 600 ° C.
• the catalyst is heated to 240 ° C to 500 ° C, and more preferably to temperatures between 260 ° C and 400 ° C.
• the time to remove the primer may be several hours.
• the catalyst is generally heated at said temperature for between 0.5 and 24 hours to remove the coupling agent.
• the time is between 1, 5 and 8 hours and more preferred between 2 and 6 hours.
• a flow around the catalyst with a gas can accelerate the removal of the adhesion promoter.
• the gas is preferably air or nitrogen and more preferably air.
• the removal of the adhesion promoter can be carried out, for example, in a gas-flowed oven or in a suitable drying apparatus, for example a belt dryer.
• Oxidative dehydrogenation (oxydehydrogenation, ODH)
• an oxidative dehydrogenation of n-butenes to butadiene is carried out by mixing a n-butenes containing starting gas mixture with an oxygen-containing gas and optionally additional inert gas or steam and in a fixed bed reactor at a temperature of 220 to 490 ° C with is brought into contact with the catalyst of the invention arranged in a fixed catalyst bed.
• the reaction temperature of the oxydehydrogenation is generally controlled by a heat exchange medium located around the reaction tubes. As such liquid heat exchange agents come z. B.
• the temperature of the heat exchange medium is between 220 to 490 ° C and preferably between 300 to 450 ° C and more preferably between 350 and 420 ° C.
• the temperature in certain sections of the interior of the reactor during the reaction may be higher than that of the heat exchange medium, and a so-called hotspot is formed.
• the location and height of the hotspot is determined by the reaction conditions, but it may also be regulated by the dilution ratio of the catalyst layer or the flow rate of mixed gas.
• the difference between hotspot temperature and the temperature of the heat exchange medium is generally between 1 -150 ° C, preferably between 10-100 ° C and more preferably between 20-80 ° C.
• the temperature at the end of the catalyst bed is generally between 0-100 ° C, preferably between 0.1-50 ° C, more preferably between 1 -25 ° C above the temperature of the heat exchange medium.
• the oxydehydrogenation can be carried out in all fixed-bed reactors known from the prior art, such as, for example, in the hearth furnace, in the fixed bed tube or tubular reactor or in the plate heat exchanger reactor. A tube bundle reactor is preferred.
• the catalyst layer configured in the reactor may consist of a single layer or of two or more layers. These layers may be pure catalyst or diluted with a material that does not react with the source gas or components of the product gas of the reaction. Furthermore, the catalyst layers may consist of solid material or supported shell catalysts.
• the starting gas pure n-butenes (1-butene and / or cis- / trans-2-butene), but also a butene-containing gas mixture can be used. Such can be obtained, for example, by non-oxidative dehydrogenation of n-butane.
• n-butenes (1-butene and / or 2-butene) as a main component and obtained from the C 4 fraction of naphtha cracking by separating butadiene and isobutene
• gas mixtures which comprise pure 1-butene, cis-2-butene, trans-2-butene or mixtures thereof and which have been obtained by dimerization of ethylene can also be used as starting gas.
• n-butenes containing gas mixtures obtained by catalytic fluid cracking (FCC) can be used as the starting gas.
• the starting gas mixture containing n-butenes is obtained by non-oxidative dehydrogenation of n-butane.
• a non-oxidative catalytic dehydrogenation with the oxidative dehydrogenation of the n-butenes formed, a high yield of butadiene, based on n-butane used, can be obtained.
• a gas mixture is obtained which, in addition to butadiene 1-butene, 2-butene and unreacted n-butane, contains minor constituents.
• Common secondary constituents are hydrogen, water vapor, nitrogen, CO and CO2, methane, ethane, ethene, propane and propene.
• the composition of the gas mixture leaving the first hydrogenation zone can vary greatly depending on the mode of operation of the dehydrogenation.
• the product gas mixture has a comparatively high content of water vapor and carbon oxides.
• the product gas mixture of the non-oxidative dehydrogenation has a comparatively high content of hydrogen.
• the product gas stream of the non-oxidative n-butane dehydrogenation typically contains 0.1 to 15% by volume of butadiene, 1 to 15% by volume of 1-butene, 1 to 25% by volume of 2-butene (cis / trans) 2-butene), 20 to 70% by volume of n-butane, 1 to 70% by volume of steam, 0 to 10% by volume of low-boiling hydrocarbons (methane, ethane, ethene, propane and propene), 0, 1 to 40% by volume of hydrogen, 0 to 70% by volume of nitrogen and 0 to 5% by volume of carbon oxides.
• the product gas stream of the non-oxidative dehydrogenation can be fed to the oxidative dehydrogenation without further workup.
• any impurities may be present in a range in which the effect of the present invention is not inhibited.
• n-butenes (1-butene and cis- / trans-2-butene)
• impurities saturated and unsaturated, branched and unbranched hydrocarbons such.
• methane, ethane, ethene, acetylene, propane, propene, propyne, n-butane, isobutane, isobutene, n-pentane and dienes such as 1, 2-butadiene may be mentioned.
• the amounts of impurities are generally 70% or less, preferably 30% or less, more preferably 10% or less, and most preferably 1% or less.
• the concentration of linear monoolefins having 4 or more carbon atoms (n-butenes and higher homologs) in the starting gas is not particularly limited; it is generally 35.0-99.99 vol.%, preferably 71. 0-99.0 vol.%, and more preferably 75.0-95.0 vol.%.
• a gas mixture is required which has a molar oxygen: n-butenes ratio of at least 0.5. Preference is given to operating at an oxygen: n-butenes ratio of 0.55 to 10.
• the starting material gas can be mixed with oxygen or an oxygen-containing gas, for example air, and optionally additional inert gas or water vapor.
• the resulting oxygen-containing gas mixture is then fed to the oxydehydrogenation.
• the molecular oxygen-containing gas is a gas which generally comprises more than 10% by volume, preferably more than 15% by volume and more preferably more than 20% by volume of molecular oxygen, and specifically, this is preferably air.
• the upper limit of the content of molecular oxygen is generally 50% by volume or less, preferably 30% by volume or less, and more preferably 25% by volume or less.
• any inert gases may be present in a range in which the effect of the present invention is not inhibited.
• Possible inert gases include nitrogen, argon, neon, helium, CO, CO2 and water.
• the amount of inert gases for nitrogen is generally 90% by volume or less, preferably 85% by volume or less, and more preferably 80% by volume or less. In the case of components other than nitrogen, it is generally 10% by volume or less, preferably 1% by volume or less. If this amount becomes too large, it becomes increasingly difficult to supply the reaction with the required oxygen.
• inert gases such as nitrogen and also water (as water vapor) may also be present together with the mixed gas of the starting gas and the gas containing molecular oxygen.
• Nitrogen is present to adjust the oxygen concentration and to prevent the formation of an explosive gas mixture, the same applies to water vapor.
• Water vapor is also present to control the coking of the catalyst and to dissipate the heat of reaction.
• water (as water vapor) and nitrogen are mixed into the mixed gas and introduced into the reactor.
• steam is introduced into the reactor, it is preferable to introduce a content of 0.2-5.0 (parts by volume), preferably 0.5-4, and more preferably 0.8-2.5, based on the introduction amount of the above-mentioned starting gas.
• a content of 0.1-8.0 (parts by volume), preferably 0.5-5.0, and more preferably 0.8-3.0, based on the introduction amount of the above-mentioned starting gas initiated.
• the content of the starting gas containing the hydrocarbons in the mixed gas is generally 4.0% by volume or more, preferably 6.0% by volume or more, and still more preferably 8.0% by volume or more.
• the upper limit is 20 vol% or less, preferably 16.0 vol% or less, and more preferably 13.0 vol% or less.
• the residence time in the reactor in the present invention is not particularly limited, but the lower limit is generally 0.3 s or more, preferably 0.7 s or more, and still more preferably 1.0 s or more.
• the upper limit is 5.0 seconds or less, preferably 3.5 seconds or less, and more preferably 2.5 seconds or less.
• the ratio of flow rate of mixed gas, based on the amount of catalyst inside the reactor, is 500-8000 hr.sup.- 1 , preferably 800-4000 hr.sup.- 1 and even more preferably 1200-3500.r.sup.- 1 .
• the catalyst load on butenes is generally 0.1 -5.0 hl -1 , preferably 0.2-3.0 hr 1, and more preferably 0.25, in stable operation -1, 0 hl -1
• the volume and mass of the catalyst are based on the complete catalyst consisting of support and active mass Regeneration of the multimetal oxide catalyst
• a regeneration step is performed between every two production cycles.
• the regeneration step is preferably carried out before the constant temperature loss of conversion is greater than 25%.
• the regeneration step is carried out by passing a sour-containing regeneration gas mixture at a temperature of 200 to 450 ° C. over the fixed catalyst bed, whereby the carbon deposited on the multimetal oxide catalyst is burned off.
• the oxygen-containing regeneration gas mixture used in the regeneration step generally contains an oxygen-containing gas and additional inert gases, water vapor and / or hydrocarbons. In general, it contains 0.5 to 22% by volume, preferably 1 to 20% by volume and in particular 2 to 18% by volume of oxygen.
• the product gas stream leaving the oxidative dehydrogenation generally contains unreacted n-butane and isobutane, 2-butene and water vapor.
• the product gas stream leaving the oxidative dehydrogenation generally contains carbon monoxide, carbon dioxide, oxygen, nitrogen, methane, ethane, ethene, propane and propene, optionally hydrogen and oxygen-containing hydrocarbons, so-called oxygenates.
• it contains only small amounts of 1-butene and isobutene.
• the product gas stream leaving the oxidative dehydrogenation may be 1 to 40% by volume butadiene, 20 to 80% by volume n-butane, 0 to 5% by volume iso-butane, 0.5 to 40% by volume 2-butene, 0 to 5% by volume of 1-butene, 0 to 70% by volume of steam, 0 to 10% by volume of low-boiling hydrocarbons (methane, ethane, ethene, propane and propene), 0 to 40% by volume of hydrogen, 0 to 30% by volume. -% oxygen, 0 to 70% by volume of nitrogen, 0 to 10% by volume of carbon oxides and 0 to 10% by volume of oxygenates.
• Oxygenates may include, for example, formaldehyde, furan, acetic acid, maleic anhydride, formic acid, methacrolein, methacrylic acid, crotonaldehyde, croton acid, propionic acid, acrylic acid, methyl vinyl ketone, styrene, benzaldehyde, benzoic acid, phthalic anhydride, fluorenone, anthraquinone and butyraldehyde.
• the product gas stream at the reactor exit is characterized by a temperature near the temperature at the end of the catalyst bed.
• the product gas stream is then brought to a temperature of 150-400 ° C, preferably 160-300 ° C, more preferably 170-250 ° C. It is possible to isolate the conduit through which the product gas stream flows to maintain the temperature in the desired range, but use of a heat exchanger is preferred. This heat exchanger system is optional, as long as the temperature of the product gas can be kept at the desired level with this system.
• heat exchangers there may be mentioned spiral heat exchangers, plate heat exchangers, double tube heat exchangers, multi-tube heat exchangers, boiler spiral heat exchangers, shell-shell heat exchangers, liquid-liquid contact heat exchangers, air heat exchangers, direct-contact heat exchangers and finned tube heat exchangers. Because, while the temperature of the product gas is adjusted to the desired temperature, a portion of the high-boiling by-products contained in the product gas may precipitate, therefore, the heat exchanger system should preferably have two or more heat exchangers.
• the two or more intended heat exchangers may be arranged in parallel.
• the product gas is supplied to one or more, but not all, heat exchangers, and after a certain period of operation, these heat exchangers are replaced by other heat exchangers.
• the cooling can be continued, part of the heat of reaction can be recovered, and in parallel, the high-boiling by-products deposited in one of the heat exchangers can be removed.
• a solvent as long as it is capable of dissolving the high-boiling by-products, can be used without restriction, and as examples, an aromatic hydrocarbon solvent such as, for example, can be used.
• an aromatic hydrocarbon solvent such as, for example, can be used.
• toluene, xylene, etc. and an alkaline aqueous solvent such as the aqueous solution of sodium hydroxide can be used.
• a process step can be used to remove residual oxygen from the product gas stream.
• the residual oxygen can have a disturbing effect insofar as it can cause butadiene peroxide formation in downstream process steps and can act as an initiator for polymerization reactions.
• Unstabilized 1,3-butadiene can form dangerous butadiene peroxides in the presence of oxygen.
• the peroxides are viscous liquids. Their density is higher than that of butadiene. Moreover, since they are only slightly soluble in liquid 1,3-butadiene, they settle on the bottoms of storage containers. Despite their relatively low chemical reactivity, the peroxides are very unstable compounds that can spontaneously decompose at temperatures between 85 and 110 ° C. A special danger exists in the high
• the oxygen removal is carried out immediately after the oxidative dehydrogenation.
• a catalytic combustion stage is carried out for this purpose, in which oxygen is reacted with hydrogen added in this stage in the presence of a catalyst. As a result, a reduction in the oxygen content is achieved down to a few traces.
• the product gas of the 02 removal stage is now brought to an identical temperature level as described for the area behind the ODH reactor.
• the cooling of the compressed gas is carried out with heat exchangers, which may for example be designed as a tube bundle, spiral or plate heat exchanger.
• the dissipated heat is preferably used for heat integration in the process.
• a large part of the high-boiling secondary components and the water can be separated from the product gas stream by cooling.
• This separation is preferably carried out in a quench.
• This quench can consist of one or more stages.
• a method is used in which the product gas is brought directly into contact with the cooling medium and thereby cooled.
• the cooling medium is not particularly limited, but preferably, water or an alkaline aqueous solution is used.
• a gas stream is obtained in which n-butane, 1-butene, 2-butenes, butadiene, optionally oxygen, hydrogen, water vapor, small amounts of methane, ethane, ethene, propane and propene, isobutane, carbon oxides and inert gases remain , Furthermore, traces of high-boiling components can remain in this product gas stream, which were not quantitatively separated in the quench.
• the product gas stream from the quench is compressed in at least one first compression stage and subsequently cooled, with at least one condensate stream comprising water condensing out and a gas stream containing n-butane, 1-butene, 2-butenes, butadiene, optionally hydrogen, water vapor, in small amounts Methane, ethane, ethene, propane and propene, iso-butane, carbon oxides and inert gases, optionally oxygen and hydrogen remains.
• the compression can be done in one or more stages. Overall, a pressure in the range of 1, 0 to 4.0 bar (absolute) is compressed to a pressure in the range of 3.5 to 20 bar (absolute).
• the condensate stream can therefore also comprise a plurality of streams in the case of multistage compression.
• the condensate stream is generally at least 80 wt .-%, preferably at least 90 wt .-% of water and also contains minor amounts of low boilers, C4 hydrocarbons, oxygenates and carbon oxides.
• Suitable compressors are, for example, turbo, rotary piston and reciprocating compressors. The compressors can be driven, for example, with an electric motor, an expander or a gas or steam turbine. Typical compression ratios (outlet pressure: inlet pressure) per compressor stage are between 1, 5 and 3.0, depending on the design.
• the cooling of the compressed gas takes place with heat exchangers, which are used, for example, as a tube bundle, spiral or plate heat exchanger can be performed.
• coolant cooling water or heat transfer oils are used in the heat exchangers.
• air cooling is preferably used using blowers.
• the butadiene, butene, butane, inert gases and optionally carbon oxides, oxygen, hydrogen and low-boiling hydrocarbons (methane, ethane, ethene, propane, propene) and small amounts of oxygenates containing stream is fed as output stream of further treatment.
• the separation of the low-boiling secondary constituents from the product gas stream can be carried out by customary separation processes such as distillation, rectification, membrane process, absorption or adsorption.
• the product gas mixture can be passed through a membrane which is usually designed as a tube and which is permeable only to molecular hydrogen.
• the thus separated molecular hydrogen can, if necessary, at least partially used in a hydrogenation or else be supplied to another utilization, for example, be used for generating electrical energy in fuel cells.
• the carbon dioxide contained in the product gas stream can be separated by CO2 gas scrubbing.
• the carbon dioxide gas scrubber may be preceded by a separate combustion stage in which carbon monoxide is selectively oxidized to carbon dioxide.
• the non-condensable or low-boiling gas constituents such as hydrogen, oxygen, carbon oxides, the low-boiling hydrocarbons (methane, ethane, ethene, propane, propene) and inert gas such as optionally nitrogen in an absorption / desorption cycle means separated from a high-boiling absorbent, wherein a C4 product gas stream is obtained, which consists essentially of the C4 hydrocarbons.
• the C4 product gas stream consists of at least 80% by volume, preferably at least 90% by volume, more preferably at least 95% by volume, of the C4 hydrocarbons, essentially n-butane, 2-butene and butadiene.
• the product gas stream after prior removal of water is contacted with an inert absorbent and the C4 hydrocarbons are absorbed in the inert absorbent, wherein C4 hydrocarbons laden absorbent and the other gas constituents containing exhaust gas are obtained.
• the C4 hydrocarbons are released from the absorbent again.
• the absorption stage can be carried out in any suitable absorption column known to the person skilled in the art. Absorption can be accomplished by simply passing the product gas stream through the absorbent. But it can also be in columns or in Rotational absorbers take place. It can be used in cocurrent, countercurrent or cross flow. Preferably, the absorption is carried out in countercurrent. Suitable absorption columns are z. B. tray columns with bell, centrifugal and / or sieve tray, columns with structured packings, eg. B. Sheet metal packings with a specific surface area of 100 to 1000 m 2 / m 3 as Mellapak® 250 Y, and packed columns.
• an absorption column is fed in the lower region of the butadiene, butene, butane, and / or nitrogen and optionally oxygen, hydrogen and / or carbon dioxide-containing material stream.
• the solvent and optionally water-containing material stream is abandoned.
• Inert absorbent used in the absorption stage are generally high-boiling non-polar solvents in which the C4-hydrocarbon mixture to be separated has a significantly higher solubility than the other gas constituents to be separated off.
• Suitable absorbents are relatively nonpolar organic solvents, for example aliphatic Cs to Cis alkanes, or aromatic hydrocarbons, such as the paraffin-derived middle oil fractions, toluene or bulky groups, or mixtures of these solvents, such as 1,2-dimethyl phthalate may be added.
• Suitable absorbers are also esters of benzoic acid and phthalic acid with straight-chain d-Cs-alkanols, as well as so-called heat transfer oils, such as biphenyl and diphenyl ether, their chlorinated derivatives and triaryl alkenes.
• a suitable absorbent is a overall mixture of biphenyl and diphenyl ether, preferably in the azeotropic composition, for example the commercially available Diphyl ®. Often, this solvent mixture contains di-methyl phthalate in an amount of 0.1 to 25 wt .-%.
• Suitable absorbents are octanes, nonanes, decanes, undecanes, dodecanes, tridecanes, tetradecanes, pentadecanes, hexadecanes, heptadecanes and octadecanes, or fractions obtained from refinery streams containing as main components said linear alkanes.
• the solvent used for the absorption is an alkane mixture such as tetradecane (technical C14-C17 cut).
• an offgas stream is withdrawn, which is essentially inert gas, carbon oxides, optionally butane, butenes, such as 2-butenes and butadiene, optionally oxygen, hydrogen and low-boiling hydrocarbons (for example methane, ethane, ethene, propane, propene) and contains water vapor.
• This stream can be partially fed to the ODH reactor or 02 removal reactor.
• the inlet flow of the ODH reactor can be adjusted to the desired C4 hydrocarbon content.
• the loaded with C4 hydrocarbons solvent stream is passed into a desorption column. All column internals known to those skilled in the art are suitable for this purpose.
• the desorption step is carried out by relaxation and / or heating of the loaded solvent.
• the preferred process variant is the addition of stripping steam and / or the supply of live steam in the bottom of the desorber. That of C 4 -
• Hydrocarbon-depleted solvents may be fed as a mixture together with the condensed vapor (water) to a phase separation, so that the water is separated from the solvent. All apparatuses known to the person skilled in the art are suitable for this purpose. It is also possible to use the water separated from the solvent to generate the stripping vapor.
• the absorbent regenerated in the desorption stage is returned to the absorption stage.
• the separation is generally not completely complete, so that in the C 4 -Shgasstrom - depending on the type of separation - still small amounts or even traces of other gas components, in particular the heavy boiling hydrocarbons, may be present.
• the volume flow reduction also caused by the separation relieves the subsequent process steps.
• the C 4 product gas stream consisting essentially of n-butane, butenes, such as 2-butenes and butadiene generally contains from 20 to 80% by volume of butadiene, from 20 to 80% by volume of n-butane, from 0 to 10% by volume. % 1 -butene, and 0 to 50% by volume of 2-butenes, the total amount being 100% by volume. Furthermore, small amounts of iso-butane may be included.
• the C 4 product gas stream may then be separated by an extractive distillation into a stream consisting essentially of n-butane and 2-butene and a stream consisting of butadiene.
• the stream consisting essentially of n-butane and 2-butene can be completely or partially recycled to the C 4 feed of the ODH reactor. Since the butene isomers of this recycle stream consist essentially of 2-butenes and these 2-butenes are generally dehydrogenated oxidatively slower to butadiene than 1-butene, this recycle stream may undergo a catalytic isomerization process prior to delivery to the ODH reactor. In this catalytic process, the isomer distribution can be adjusted according to the isomer distribution present in the thermodynamic equilibrium.
• the extractive distillation may, for example, as described in "petroleum and coal - natural gas - petrochemistry", Volume 34 (8), pages 343 to 346 or “Ullmann's Encyclopedia of Industrial Chemistry", Volume 9, 4th edition 1975, pages 1 to 18, be performed.
• the C 4 - product gas stream with an extractant preferably an N-methylpyrrolidone
• the extraction zone is generally carried out in the form of a wash column which contains trays, fillers or packings as internals. This generally has 30 to 70 theoretical plates on, so that a sufficiently good release effect is achieved.
• the wash column has a backwash zone in the column head. This backwash zone is used to recover the extractant contained in the gas phase by means of a liquid hydrocarbon reflux, to which the top fraction is condensed beforehand.
• the mass ratio extractant to C4 product gas stream in the feed of the extraction zone is generally from 10: 1 to 20: 1.
• the extractive distillation is preferably carried out at a bottom temperature in the range from 100 to 250 ° C., in particular at a temperature in the range from 110 to 210 ° C., a top temperature in the range from 10 to 100 ° C., in particular in the range from 20 to 70 ° C. ° C and a pressure in the range of 1 to 15 bar, in particular operated in the range of 3 to 8 bar.
• the extractive distillation column preferably has from 5 to 70 theoretical plates.
• Suitable extractants are butyrolactone, nitriles such as acetonitrile, propionitrile, methoxypropionitrile, ketones such as acetone, furfural, N-alkyl-substituted lower aliphatic acid amides such as dimethylformamide, diethylformamide, dimethylacetamide, diethylacetamide, N-formylmorpholine, N-alkyl-substituted cyclic acid amides (lactams) such as N Alkylpyrrolidones, especially N-methylpyrrolidone (NMP).
• NMP N-methylpyrrolidone
• alkyl-substituted lower aliphatic acid amides or N-alkyl substituted cyclic acid amides are used.
• Particularly advantageous are dimethylformamide, acetonitrile, furfural and in particular NMP.
• Particularly suitable is NMP, preferably in aqueous solution, preferably with 0 to 20 wt .-% water, particularly preferably with 7 to 10 wt .-% water, in particular with 8.3 wt .-% water.
• the overhead product stream of the extractive distillation column contains essentially butane and butenes and in small amounts of butadiene and is taken off in gaseous or liquid form.
• the stream consisting essentially of n-butane and 2-butene contains 50 to 100% by volume of n-butane, 0 to 50% by volume of 2-butene and 0 to 3% by volume of further constituents such as isobutane, isobutene, propane , Propene and Cs + hydrocarbons.
• a stream containing the extractant, water, butadiene and in small amounts butene and butane is obtained, which is fed to a distillation column. In this will be recovered overhead or as a side take butadiene.
• an extractant and water-containing stream is obtained, wherein the composition of the extractant and water-containing stream corresponds to the composition as it is added to the extraction.
• the extractant and water-containing stream is preferably returned to the extractive distillation.
• the extraction solution is transferred to a desorption zone, wherein the butadiene is desorbed from the extraction solution.
• the desorption zone may, for example, be in the form of a wash column containing 2 to 30, preferably 5 to 20 theoretical stages and, where appropriate, if a backwash zone with, for example, 4 theoretical stages. This backwash zone is used to recover the extractant contained in the gas phase by means of a liquid hydrocarbon reflux, to which the top fraction is condensed beforehand.
• internals packings trays or packing are provided.
• the distillation is preferably carried out at a bottom temperature in the range from 100 to 300.degree. C., in particular in the range from 150 to 200.degree. C. and a top temperature in the range from 0 to 70.degree. C., in particular in the range from 10 to 50.degree.
• the pressure in the distillation column is preferably in the range of 1 to 10 bar. In general, in the desorption zone, reduced pressure and / or elevated temperature prevails over the extraction zone.
• the product stream obtained at the top of the column generally contains 90 to 100% by volume of butadiene, 0 to 10% by volume of 2-butene and 0 to 10% by volume of n-butane and isobutane.
• a further distillation according to the prior art can be carried out.
• Solution A 3200 g of water were placed in a 10 l stainless steel pot. While stirring by means of a
• Anchor stirrer 4.8 g of a KOH solution (33 wt .-% KOH) was added to the initially introduced water. The solution was heated to 60 ° C. Then, 1066 g of an ammonium heptamolybdate solution (( ⁇ 4) 6 ⁇ 7 ⁇ 24 * 4 H2O, 54% by weight of Mo) were added in portions over a period of 10 minutes. The suspension obtained was stirred for a further 10 minutes.
• the solution B was pumped to solution A by means of a peristaltic pump within 15 min. During the addition and then by means of an intensive mixer (Ultra-Turrax) was stirred. Thereafter, 98.22 g of a silica suspension (Ludox, 49 wt .-% Si0 2 ) were added and stirring was continued for 5 minutes.
• the suspension obtained was spray-dried in a spray tower from NIRO (spray head No. FOA1, rotational speed 25,000 rpm) over a period of 1.5 h. The original temperature was kept at 60 ° C.
• the gas inlet temperature of the spray tower was 340 ° C, the gas outlet temperature 130 ° C.
• the resulting powder was mixed with 1 wt .-% graphite, compacted twice with 9 bar pressing pressure and comminuted through a sieve with a mesh size of 0.8 mm.
• the split was again mixed with 2% by weight of graphite and the mixture was pressed with a Kilian S100 tablet press into rings 5 ⁇ 3 ⁇ 2 mm (outside diameter ⁇ length ⁇ inside diameter).
• the catalyst precursor obtained was calcined in batches (1000 g) in a convection oven from Heraeus, DE (type K, 750/2 S, internal volume 55 l). The following program was used for this:
• a catalyst is prepared according to Example B (p.28) of DE 10 2007 004 961 A1.
• the catalyst has the stoichiometry Moi2Co7Fe3Bio.6Ko.o8Sii, 60 x .
• Example 3 (comparison)
• the original temperature was kept at 60 ° C.
• the gas inlet temperature of the spray tower was 300 ° C, the gas outlet temperature 1 10 ° C.
• the powder obtained had a particle size (d 50) of less than 40 ⁇ m.
• the resulting powder was mixed with 1 wt .-% graphite, compacted twice with 9 bar pressing pressure and comminuted through a sieve with a mesh size of 0.8 mm.
• the split was again mixed with 2% by weight of graphite and the mixture was pressed with a Kilian S100 tablet press into rings 5 ⁇ 3 ⁇ 2 mm (outside diameter ⁇ length ⁇ inside diameter).
• the catalyst precursor obtained was calcined in batches (500 g) in a convection oven from Heraeus, DE (type K, 750/2 S, internal volume 55 l). The following program was used for this: - Heat up to 130 ° C in 72 minutes, hold for 72 minutes
• the screening reactor was a salt bath reactor having a length of 120 cm and an inside diameter of 14.9 mm and a thermowell having an outside diameter of 3.17 mm.
• the thermowell contained a multiple thermocouple with 7 measuring points.
• the bottom 4 measuring points had a distance of 10 cm and the top 4 measuring points a distance of 5 cm.
• Butane and raffinate II or 1-butene were dosed liquid at about 10 bar by a coriolis flow meter, mixed in a static mixer and then relaxed in a heated evaporator section and evaporated. This gas was then mixed with nitrogen and passed in a preheater with a steatite. Water was metered in liquid and evaporated in an evaporator coil in an air stream. The air / steam mixture was combined at the bottom of the preheater with the N2 / raffinate-II / butane mixture. The completely mixed reactant gas was then fed to the reactor, whereby an analysis stream for the online GC measurement can be deducted.
• an analysis stream is also withdrawn, which can be analyzed by online GC measurement or by an IR analyzer on the volume fraction of CO and CO2.
• a pressure control valve follows behind the branch of the analysis line, which adjusts the pressure level of the reactor.
• a 6 cm long bed was filled consisting of 16 g steatite spheres with a diameter of 3.5 - 4.5 mm.
• 44 g of the catalyst from Example 1 were thoroughly mixed with 88 g of steatite rings of the same geometry and filled into the reactor (146 ml bulk volume, 88 cm bed height).
• the catalyst bed was followed by a 7 cm long feed consisting of 16 g of steatite balls with a diameter of 3.5-4.5 mm.
• the reactor was operated at 100 to 250 NL / h of a reaction gas of composition 8% 1-butene, 2% butane, 12% oxygen, 10% water, 68% nitrogen at a salt bath temperature of 330 ° C for 50 hours.
• the product gases were analyzed by GC.
• the turnover and selectivity data are listed in Tables 1 and 2.
• the catalysts of Examples 1 to 3 were used for the reaction of butene to butadiene in the dehydrogenation reactor.
• 60 g of the 5 ⁇ 3 ⁇ 2 mm rings (outer diameter ⁇ length ⁇ inner diameter) were mixed with 60 g of steatite rings of the same geometry. They were activated by heating in a mixture of oxygen, nitrogen and water vapor (10/80/10) at 400 ° C overnight.
• the gas velocity was varied to change the conversion (100 NL / h to 250 NL / h).
• the salt bath temperature was controlled so that a maximum of about 95% conversion was achieved.
• the temperatures at which the conversion was about 90% are shown in Table 1.
• Table 1 Activities of the tested catalysts from Examples 1 to 3
• the sales and selectivity data are listed in Table 2.
• the selectivities are compared at about 90% conversion. With a butene conversion of about 90%, all catalysts have the same selectivity for butadiene within the scattering of the measured values. The catalysts thus differ only in their activity (see temperatures for 90% conversion in Table 1).

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