US20080035524A1 - Microporous Amorphous Material, Preparation Method Thereof and Use of Same in the Catalytic Conversion of Organic Compounds - Google Patents

Microporous Amorphous Material, Preparation Method Thereof and Use of Same in the Catalytic Conversion of Organic Compounds Download PDF

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US20080035524A1
US20080035524A1 US11/547,805 US54780505A US2008035524A1 US 20080035524 A1 US20080035524 A1 US 20080035524A1 US 54780505 A US54780505 A US 54780505A US 2008035524 A1 US2008035524 A1 US 2008035524A1
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amorphous material
material according
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organic compounds
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Avelino Corma Canos
Maria Diaz Cabanas
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Consejo Superior de Investigaciones Cientificas CSIC
Universidad Politecnica de Valencia
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    • C01B39/46—Other types characterised by their X-ray diffraction pattern and their defined composition
    • C01B39/48—Other types characterised by their X-ray diffraction pattern and their defined composition using at least one organic template directing agent
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    • C07C2/54—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms by addition of unsaturated hydrocarbons to saturated hydrocarbons or to hydrocarbons containing a six-membered aromatic ring with no unsaturation outside the aromatic ring
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    • C10G11/00—Catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
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    • 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
    • C10G45/64—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 containing crystalline alumino-silicates, e.g. molecular sieves
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    • C10G47/02—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used
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Definitions

  • Zeolites are microporous crystalline materials formed by a crystal lattice of TO 4 tetrahedra which share all their vertices giving rise to a three-dimensional structure containing channels and/or cavities of molecular dimensions. They have variable composition, and T generally represents atoms with formal oxidation state of +3 or +4, such as for example Si, Ge, Ti, Al, B or Ga, among others.
  • each zeolite with a specific system of channels and cavities, gives rise to a characteristic X-ray diffraction pattern. So, the zeolites are differentiated among each other by their range of chemical composition and their X-ray diffraction pattern. Both characteristics (crystal structure and chemical composition) also determine the physico-chemical properties of each zeolite and its possible application in different industrial processes.
  • Amorphous micro- and mesoporous materials have been developed such as silicates, silicoaluminates and silicotitanates, among others, in an attempt to achieve molecular sieve properties, in other words very narrow pore distributions.
  • microporous materials when there existed a narrow distribution of pores, it was found that the materials could not be regarded as completely amorphous.
  • IR infrared
  • the present invention relates to a microporous amorphous material characterised in that it has a chemical composition in the calcined and anhydrous state which can be represented by the following empirical formula: x(M 1/n XO 2 ):y YO 2 :SiO 2 wherein:
  • X is preferably selected from among Al, Ga, B, Fe, Cr and a mixture of same
  • Y is preferably selected from among Ti, Ge, Sn, V and a mixture of same.
  • said microporous amorphous material is characterised in that it has a chemical composition in the calcined and anhydrous state which can be represented by the following empirical formula: x(M 1/n XO 2 ):y YO 2 :SiO 2 wherein:
  • the trivalent element or elements X are preferably selected from among Al, Ga, B, Fe, Cr and a mixture of same
  • Y is preferably selected from among Ti, Ge, Sn, V and a mixture of same
  • the inorganic cations which M can represent can be cited, for example, one or more alkaline, alkaline earth metals or mixtures of same.
  • the microporous amorphous material can have a composition which corresponds to the formula: x(M 1/n XO 2 ):SIO 2 wherein:
  • the microporous amorphous material has a composition in the calcined and anhydrous state which corresponds to the formula: y YO 2 :SiO 2 wherein:
  • the microporous amorphous material has a composition in the calcined and anhydrous state which corresponds to the formula: x(HXO 2 ):SiO 2 wherein:
  • the microporous amorphous material has a composition in the calcined and anhydrous state which corresponds to the formula SiO 2 .
  • microporous non-crystalline material of the present invention which we shall generically call MAS, has a pore distribution that is narrow and uniform in the micropore range.
  • Said microporous non-crystalline material is characterised in that its X-ray diffraction pattern does not display any diffraction peaks and its IR spectrum does not show bands developed in the range between 400 and 600 cm ⁇ 1 , such bands being characteristic of crystalline silicates, such as for example zeolites.
  • the present invention also relates to a method for synthesising a microporous amorphous material defined earlier, comprising at least:
  • reaction mixture comprising at least:
  • the method for synthesising a microporous amorphous material comprises:
  • reaction mixture comprising at least:
  • the method for synthesising a microporous amorphous material comprises:
  • reaction mixture comprising at least:
  • the method for synthesising a microporous amorphous material comprises:
  • reaction mixture comprising at least:
  • the method for synthesising a microporous amorphous material comprises:
  • reaction mixture comprising at least:
  • the reaction mixture has a composition, in terms of molar ratios of oxides, lying between the intervals:
  • the sources of SiO 2 can be mentioned, for example, tetraethylorthosilicate, colloidal silica and amorphous silica.
  • Al can be used; for example, aluminium alcoxides, aluminium oxides or aluminium salts can all be used as sources of aluminium.
  • the organic compound R is preferably in the form of hydroxide.
  • the organic cation in salt form (for example, a halide, preferably chloride, bromide or iodide).
  • the organic compound comprises one or more amine groups.
  • Said organic compound can also comprise one or more ammonium groups.
  • the organic compound is selected from among N(16)-methylsparteinium, 1,4-biscyclohexylpyrrolidiniumbutane hydroxide, 1,8-bisquinuclidiniumoctane hydroxide, 1,4-biscyclohexylpyrrolidiniumbutane hydroxide, hexamethonium hydroxide and tetraethylammonium hydroxide.
  • the heat treatment of the reaction mixture can be carried out statically or with stirring of the mixture.
  • the solid product is separated and dried.
  • the reaction mixture has a composition which accords with the empirical formula: a ROH:b M 1/n F:x X 2 O 3 :y YO 2 :SiO 2 :w H 2 O where X is one or more elements in an oxidation state +3, Y is one or more elements in an oxidation state +4, M is selected from among H + , one or more inorganic cations of charge +n and mixtures of same; and R is one or more organic compounds, and the values a, b, x, y and w are in the ranges:
  • the present invention also refers to a method of use of the microporous amorphous material defined earlier as a catalyst in a conversion process for organic compounds consisting of placing a feed in contact with a quantity of that catalyst.
  • Said process can be a process of catalytic cracking of organic compounds, preferably hydrocarbons.
  • the process is selected from among a hydrocracking process, gentle hydrocracking of hydrocarbons, gentle hydrocracking of functionalised hydrocarbons, gentle hydrocracking of hydrocarbons and functionalised hydrocarbons, hydroisomerisation of olefins, an isomerisation process of light paraffins, deparaffining, isodeparaffining and an alkylation process.
  • said alkylation can be selected from among alkylation of isoparaffins with olefins, alkylation of olefins with isoparaffins, alkylation of aromatics with olefins or alcohols, alkylation of substituted aromatics with olefins or alcohols, alkylation of thiophenic compounds with olefins or alcohols, alkylation of alkylthiophenic compounds with olefins or alcohols and alkylation of alkylbenzothiophenic compounds with olefins or alcohols.
  • said alkylation is the alkylation of benzene with propylene.
  • the microporous amorphous material can act as a catalyst in a process which is an acylation reaction of substituted aromatic compounds using acids, acid chlorides or organic acid anhydrides as acylating agents.
  • the process is a selective oxidation of organic compounds using an oxidising agent selected from among H 2 O 2 , organic peroxides and organic hydroperoxides.
  • the process is selected from among a Meerwein-Pondorf-Verley type oxidation reaction and a Baeyer-Villiger type oxidation reaction.
  • said microporous amorphous material can be used as a catalyst in a process of epoxidation of olefins, oxidation of alkanes, oxidation of alcohols and oxidation of organic compounds containing sulphur and which can produce sulphoxides and sulphones, using organic or inorganic hydroperoxides, such as for example, H 2 O 2 , tertbutylhydroperioxide, cumene hydroperoxide or molecular oxygen as oxidising agents and in ammoximation of ketones, and more specifically of cyclohexanone to cyclohexanone oxime with NH 3 and H 2 O 2 , or NH 3 and O 2 .
  • organic hydroperoxides such as for example, H 2 O 2 , tertbutylhydroperioxide, cumene hydroperoxide or molecular oxygen as oxidising agents and in ammoximation of ketones, and more specifically of cyclohexan
  • the microporous amorphous material of the present invention can be used as a catalyst in a Baeyer-Villiger type oxidation using H 2 O 2 as the oxidising agent.
  • FIG. 1 shows the X-ray diffraction diagram of a sample of the microporous amorphous material of the invention, prepared as per example 1, using N(16)-methylspartenium, and prior to calcining.
  • FIG. 2 shows the IR spectrum of a sample of the microporous amorphous material of the invention, known as MAS-1, prepared as per example 1, using N(16)-methylspartenium, and prior to calcining.
  • FIG. 3 shows the pore distribution of a sample of the microporous amorphous material of the invention, prepared as per example 1, using N(16)-methylspartenium, and calcined.
  • FIG. 4 shows the X-ray diffraction diagram of a sample of the microporous amorphous material of the invention, prepared as per example 2, using N(16)-methylspartenium, and prior to calcining.
  • FIG. 5 shows the X-ray diffraction diagram of a sample of the microporous amorphous material of the invention containing Ti, prepared as per example 3, using N(16)-methylspartenium, and without calcining.
  • FIG. 6 shows the X-ray diffraction diagram of a sample of the microporous amorphous material of the invention, pure silica MAS-1, and prepared as per example 4, using N(16)-methylspartenium, and without calcining.
  • FIG. 7 shows the X-ray diffraction diagram of a sample of the microporous amorphous material of the invention, prepared as per example 5, known as MAS-2, using 1,8-bisquinuclidiniumoctane hydroxide, and without calcining.
  • FIG. 8 shows the IR spectrum of a sample of the microporous amorphous material of the invention, prepared as per example 5, using 1,8-bisquinuclidiniumoctane hydroxide, and without calcining.
  • FIG. 9 shows the pore distribution of a sample of the microporous amorphous material of the invention, prepared as per example 5, using 1,8-bisquinuclidiniumoctane hydroxide, and calcined.
  • FIG. 10 shows the X-ray diffraction diagram of a sample of the microporous amorphous material of the invention, prepared as per example 6, using 1,8-bisquinuclidiniumoctane hydroxide, and without calcining.
  • FIG. 11 shows the X-ray diffraction diagram of a sample of the microporous amorphous material of the invention, prepared as per example 7, known as MAS-3, using 1,4-biscyclohexylpyrrolidiniumbutane hydroxide, and without calcining.
  • FIG. 12 shows the IR spectrum of a sample of the microporous amorphous material of the invention, prepared as per example 7, using 1,4-biscyclohexylpyrrolidiniumbutane hydroxide, and without calcining.
  • FIG. 13 shows the pore distribution of a sample of the microporous amorphous material of the invention, prepared as per example 7, using 1,4-biscyclohexylpyrrolidiniumbutane hydroxide, and calcined.
  • FIG. 14 shows the X-ray diffraction diagram of a sample of the microporous amorphous material of the invention, prepared as per example 8, using 1,4-biscyclohexylpyrrolidiniumbutane hydroxide, and without calcining.
  • FIG. 15 shows the X-ray diffraction diagram of a sample of the microporous amorphous material of the invention, prepared as per example 9, known as MAS-4, using hexamethonium hydroxide, and without calcining.
  • FIG. 16 shows the IR spectrum of a sample of the microporous amorphous material of the invention, prepared as per example 9, using hexamethonium hydroxide, and without calcining.
  • FIG. 17 shows the pore distribution of a sample of the microporous amorphous material of the invention, prepared as per example 9, using hexamethonium hydroxide, and calcined.
  • FIG. 18 shows the X-ray diffraction diagram of a sample of the microporous amorphous material of the invention, prepared as per example 10, known as MAS-5, using tetraethylammonium hydroxide, and without calcining.
  • FIG. 19 shows the IR spectrum of a sample of the microporous amorphous material of the invention, prepared as per example 10, using tetraethylammonium hydroxide, and without calcining.
  • FIG. 20 shows the X-ray diffraction diagram of a sample of the microporous amorphous material of the invention, prepared as per example 11, using tetraethylammonium hydroxide, and without calcining.
  • the gel is heated at 175° C. statically for 16 hours in steel autoclaves with an internal Teflon lining.
  • the solid obtained after filtering, washing with distilled water and drying at 100° C. is MAS1.
  • the X-ray diffraction pattern of the solid obtained, measured by the powder method using a fixed divergence grating and employing K a from Cu, is shown in FIG. 1 and the IR spectrum in FIG. 2 .
  • the material is calcined at 580° C. for 3 hours in an air stream in order to eliminate organic matter and the fluoride ions occluded in its interior.
  • the solid known as MAS-1 displays a specific surface area of 738 m 2 /g and a micropore volume of 0.28 cm 3 /g.
  • the pore diameter is 7.5 ⁇ and the pore distribution measured by Ar adsorption following the Hovartz-Kavazoe formalism is shown in FIG. 3 .
  • the gel is heated for 16 hours in steel autoclaves with an internal Teflon lining at 175° C. statically.
  • the solid obtained after filtering, washing with distilled water and drying at 100° C. is MAS-1.
  • the X-ray diffraction pattern of the solid obtained is shown in FIG. 4 .
  • the solid After calcining at 580° C. in an air stream for 3 hours, the solid, known as MAS-1, displays a specific surface area of 643 m 2 /g and a micropore volume of 0.24 cm 3 /g.
  • the gel is heated at 175° C. statically for 3 days in steel autoclaves with an internal Teflon lining.
  • the solid obtained after filtering, washing with distilled water and drying at 100° C. is Ti-MAS1.
  • the X-ray diffraction pattern of the solid obtained is shown in FIG. 5 .
  • the gel is heated for 7 days in steel autoclaves with an internal Teflon lining at 175° C. with stirring.
  • the solid obtained after filtering, washing with distilled water and drying at 100° C. is MAS-2.
  • the X-ray diffraction pattern of the solid obtained is shown in FIG. 7 and the IR spectrum in FIG. 8 .
  • the material is calcined at 580° C. for 3 hours in an air stream in order to eliminate organic matter and the fluoride ions occluded in its interior.
  • the solid known as MAS-2 displays a specific surface area of 388 m 2 /g and a micropore volume of 0.14 cm 3 /g.
  • the pore diameter is 6.0 ⁇ and the pore distribution measured by Ar adsorption following the Hovartz-Kavazoe formalism is shown in FIG. 3 .
  • the gel is heated for 3 days in steel autoclaves with an internal Teflon lining at 150° C. with stirring.
  • the solid obtained after filtering, washing with distilled water and drying at 100° C. is MAS-2.
  • the X-ray diffraction pattern of the solid obtained is shown in FIG. 10 .
  • the gel is heated at 175° C. with stirring for 5 days in steel autoclaves with an internal Teflon lining.
  • the solid obtained after filtering, washing with distilled water and drying at 100° C. is MAS-3.
  • the X-ray diffraction pattern of the solid obtained is shown in FIG. 11 and the IR spectrum in FIG. 12 .
  • the material is calcined at 580° C. for 3 hours in an air stream in order to eliminate organic matter and the fluoride ions occluded in its interior.
  • the solid known as MAS-1 displays a specific surface area of 418 m 2 /g and a micropore volume of 0.15 cm 3 /g.
  • the pore diameter is 6.2 ⁇ and the pore distribution measured by Ar adsorption following the Hovartz-Kavazoe formalism is shown in FIG. 13 .
  • the gel is heated for 4 days in steel autoclaves with an internal Teflon lining at 175° C. with stirring.
  • the solid obtained after filtering, washing with distilled water and drying at 100° C. is MAS-3.
  • the X-ray diffraction pattern of the solid obtained is shown in FIG. 14 .
  • the gel is heated for 5 days in steel autoclaves with an internal Teflon lining at 135° C. with stirring.
  • the solid obtained after filtering, washing with distilled water and drying at 100° C. is MAS-4.
  • the X-ray diffraction pattern of the solid obtained is shown in FIG. 15 and the IR spectrum in FIG. 16 .
  • the material is calcined at 580° C. for 3 hours in an air stream in order to eliminate organic matter and the fluoride ions occluded in its interior.
  • the solid known as MAS-4 displays a specific surface area of 348 m 2 /g and a micropore volume of 0.13 cm 3 /g.
  • the pore diameter is 5.5 ⁇ and the pore distribution measured by Ar adsorption following the Hovartz-Kavazoe formalism is shown in FIG. 17 .
  • tetraethylorthosilicate 19.9 g of tetraethylorthosilicate are added to 14.39 g of an aqueous solution of tetraethylammonium hydroxide (TEAOH) at 40% by weight and 3 g of water, and the mixture is stirred. A solution is then added containing 0.32 g of metallic aluminium (99.95%) previously dissolved in 9 g of TEAOH (40%). The mixture is left to evaporate with stirring until complete elimination of the ethanol coming from the hydrolysis of the TEOS plus the quantity of water necessary for reaching the final composition that is stated. Finally, 2.15 g of an aqueous solution of fluorhydric acid (48% of HF by weight) is added. The composition of the gel is: SiO 2 :0.062 Al 2 O 3 :0.665 ROH:0.54 HF:7 H 2 O where ROH is tetraethylammonium hydroxide.
  • TEAOH tetraethylammonium
  • the mixture obtained is introduced into an autoclave provided with an internal polytetrafluorethylene lining and is heated at 140° C. for 6 days in a stove provided with a rotation system. After that time, it is recovered by means of filtering, washed with water and then dried at 100° C, giving 27.9 g of solid per 100 g of gel.
  • the solid obtained is MAS-5 and its X-ray diffraction pattern of the solid obtained is shown in FIG. 18 and the IR spectrum in FIG. 19 .
  • the material is calcined at 580° C. for 3 hours in an air stream in order to eliminate organic matter and the fluoride ions occluded in its interior.
  • tetraethylorthosilicate 15.00 grams of tetraethylorthosilicate are hydrolysed in 16.36 grams of a solution of tetraethylammonium hydroxide (TEAOH) at 40% by weight and 3 g of water, and the mixture is stirred. The solution obtained is kept being stirred allowing all the alcohol formed in the hydrolysis and the surplus water to evaporate. Afterwards, 1.56 g of a solution of fluorhydric acid (50% of HF by weight) is then added and evaporation is continued until the mixture reaches a final composition: SiO 2 :0.54 ROH:0.54 HF:7 H 2 O where ROH is tetraethylammonium hydroxide.
  • TEAOH tetraethylammonium hydroxide
  • the gel is heated at 175° C. with stirring for 4 hours in steel autoclaves with an internal Teflon lining.
  • the solid obtained after filtering, washing with distilled water and drying at 100° C. is MAS-5 and its X-ray diffraction pattern is shown in FIG. 20 .
  • This example shows the catalytic activity of a bifunctional catalyst formed from an acid function (MAS, prepared as per example 2) and a hydrogenating-dehydrogenating function (Pt 1.0% by weight), introduced by impregnation starting from an aqueous solution of hexachloroplatinic acid, for the hydrocracking of n-hexadecane.
  • the reaction was carried out in a fixed bed continuous reactor at 270° C., pressure 40 bars, with a molar ratio of H 2 /hexadecane of 95 and a contact time (W/F) of 0.27 hours.
  • This example shows the catalytic activity of a bifunctional catalyst formed from an acid function (MAS, prepared as per example 2) and a hydrogenating function (Pt 1% by weight), introduced by impregnation starting from an aqueous solution of hexachloroplatinic acid, for the hydrocracking of a hydrotreated gasoil containing 10.6% by weight of hydrocarbons with a boiling point between 250° C. and 380° C., and 89.4% with boiling point above 380° C., and a sulphur content of 87 ppm.
  • This example shows the catalytic activity for catalytic cracking of an MAS material prepared according to example 2, in which n-decane is used as reagent.
  • the reaction conditions were: atmospheric pressure, weight ratio of catalyst/feed of 0.70, temperature of 500° C. and reaction time of 60 seconds. Under these conditions the conversion was 33%.
  • This example shows the catalytic activity for cracking of a vacuum gasoil, of the MAS material prepared as per example 2.
  • the reaction conditions were: atmospheric pressure, weight ratio of catalyst/feed of 0.65, reaction temperature of 500° C. and reaction time of 60 seconds.
  • the conversion was 60% by weight, with a yield to gases, gasoline, diesel and coke of 19.1, 23.2, 14.0 and 3.7%, respectively, the propylene/propane ratio in the gases being 4.9, for a propylene yield of 7%.

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US20110081416A1 (en) * 2008-04-28 2011-04-07 Formac Pharmaceuticals N.V. Ordered mesoporous silica material
US8900548B2 (en) 2011-10-12 2014-12-02 Exxonmobil Research And Engineering Company Synthesis of MSE-framework type molecular sieves
US8916130B2 (en) 2011-10-12 2014-12-23 Exxonmobil Research And Engineering Company Synthesis of MSE-framework type molecular sieves

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US20100194265A1 (en) 2007-07-09 2010-08-05 Katholieke Universiteit Leuven Light-emitting materials for electroluminescent devices
US8395008B2 (en) 2008-01-14 2013-03-12 Catalytic Distillation Technologies Process and catalyst for cracking of ethers and alcohols
US7682599B2 (en) * 2008-10-10 2010-03-23 Chevron U.S.A. Inc. Method for preparing NES-type zeolites using novel structure directing agents
US7648694B2 (en) * 2008-10-10 2010-01-19 Chevron U.S.A. Inc. Method for preparing SSZ-26/33 zeolites using novel structure directing agents
WO2010065128A1 (en) 2008-12-05 2010-06-10 Exxonmobil Research And Engineering Company Amorphous acidic materials, their synthesis and use
WO2012025624A1 (en) * 2010-08-27 2012-03-01 Formac Pharmaceuticals N.V. Processes for producing microporous silica materials
US10189717B2 (en) * 2016-09-01 2019-01-29 Chevron U.S.A. Inc. Synthesis of aluminosilicate zeolite SSZ-26 via interzeolite transformation

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