Classifications

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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
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • B01J29/40—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
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  • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
  • B01J21/02—Boron or aluminium; Oxides or hydroxides thereof
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  • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
  • B01J21/02—Boron or aluminium; Oxides or hydroxides thereof
  • B01J21/04—Alumina
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  • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
  • B01J21/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
  • B01J21/08—Silica
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  • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
  • B01J21/16—Clays or other mineral silicates
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  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J27/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
  • B01J27/14—Phosphorus; Compounds thereof
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  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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  • B01J27/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
  • B01J27/14—Phosphorus; Compounds thereof
  • B01J27/16—Phosphorus; Compounds thereof containing oxygen, i.e. acids, anhydrides and their derivates with N, S, B or halogens without carriers or on carriers based on C, Si, Al or Zr; also salts of Si, Al and Zr
• • 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
  • B01J29/00—Catalysts comprising molecular sieves
• • 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
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/049—Pillared clays
• • 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
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • B01J29/08—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
  • B01J29/084—Y-type faujasite
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  • B01J35/00—Catalysts, in general, characterised by their form or physical properties
  • B01J35/19—Catalysts containing parts with different compositions
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  • B01J35/00—Catalysts, in general, characterised by their form or physical properties
  • B01J35/40—Catalysts, in general, characterised by their form or physical properties characterised by dimensions, e.g. grain size
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  • B01J35/00—Catalysts, in general, characterised by their form or physical properties
  • B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
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  • B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
  • B01J35/61—Surface area
  • B01J35/613—10-100 m2/g
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B01J35/00—Catalysts, in general, characterised by their form or physical properties
  • B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
  • B01J35/61—Surface area
  • B01J35/615—100-500 m2/g
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  • B01J35/00—Catalysts, in general, characterised by their form or physical properties
  • B01J35/70—Catalysts, in general, characterised by their form or physical properties characterised by their crystalline properties, e.g. semi-crystalline
• • B—PERFORMING OPERATIONS; TRANSPORTING
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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
  • B01J37/0045—Drying a slurry, e.g. spray drying
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/04—Mixing
• • B—PERFORMING OPERATIONS; TRANSPORTING
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  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/08—Heat treatment
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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  • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
  • B01J37/12—Oxidising
  • B01J37/14—Oxidising with gases containing free oxygen
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C4/00—Preparation of hydrocarbons from hydrocarbons containing a larger number of carbon atoms
  • C07C4/02—Preparation of hydrocarbons from hydrocarbons containing a larger number of carbon atoms by cracking a single hydrocarbon or a mixture of individually defined hydrocarbons or a normally gaseous hydrocarbon fraction
  • C07C4/06—Catalytic processes
• • 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
  • B01J2235/00—Indexing scheme associated with group B01J35/00, related to the analysis techniques used to determine the catalysts form or properties
  • B01J2235/15—X-ray diffraction
• • 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
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/10—Feedstock materials
  • C10G2300/1037—Hydrocarbon fractions
  • C10G2300/1044—Heavy gasoline or naphtha having a boiling range of about 100 - 180 °C
• • 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
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/40—Characteristics of the process deviating from typical ways of processing
  • C10G2300/4018—Spatial velocity, e.g. LHSV, WHSV
• • 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
  • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
  • C10G2300/40—Characteristics of the process deviating from typical ways of processing
  • C10G2300/4081—Recycling aspects
• • 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
  • C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
  • C10G2400/20—C2-C4 olefins
• • 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
  • Y02P20/52—Improvements relating to the production of bulk chemicals using catalysts, e.g. selective catalysts

Definitions

• the present invention relates to a solid acid catalyst and a process for producing light olefins from hydrocarbon feeds using the same. More particularly, the present invention pertains to a solid acid catalyst, which exhibits excellent selectivity to light olefins at a low temperature in comparison with any conventional techniques including steam cracking process, and a process of selectively producing light olefins from hy ⁇ drocarbon feeds (typically, full range naphthas) using the same.
• Olefins particularly, light olefins, such as ethylene or propylene
• the light olefins are produced by conducting thermal cracking of naphthas in the presence of steam, i.e., steam cracking.
• steam cracking Various modifications of the steam cracking technology have been attempted so as to cope with reaction conditions such as high temperature and reduction of retention time, and to optimize energy efficiency.
• reaction conditions such as high temperature and reduction of retention time
• the steam cracking process has consumed about 40 % of the energy used in the total petrochemical industry.
• light olefin compounds may be produced through a FCC (fluid catalytic cracking) process.
• the FCC process is a catalytic cracking technology using a catalyst in the form of fine particle which behave like a fluid when they are aerated with steam, and is extensively known in the art.
• a DCC (deep catalytic cracking) technology is known as a process in which the FCC process is modified to improve the yield of olefins (mainly, propylene) instead of gasoline.
• the FCC process employs oils, such as vacuum residues, atmospheric residues, or gas oils, which are heavier than the full range naphthas desirably intended as feeds in the present invention.
• Japanese Patent Laid-Open No. Hei. 6-192135 discloses a catalytic cracking process (reaction conditions: a reaction temperature of 620-750°C and a WHSV of 1-200 h "1 ) for producing ethylene and propylene from light naphthas containing C 2-12 paraffins (having a density of 0.683 g/cc; and a composition containing 42.7 wt% n- paraffins, 36.1 wt% i-paraffins, 0.1 wt% olefins, 14.0 wt% naphthenes, and 7.1 wt% aromatics; and the paraffins being composed of 0.1 wt% C3, 5.2 wt% C4, 18.7 wt% C5, 19.0 wt% C6, 15.2 wt% C7, 13.5 wt% C8, 6.1 wt% C9, 0.1 wt% ClO, and 0.1 wt% Cl 1) in the presence of HZ
• the conversion efficiency is about 93.6 wt% and the total amount of ethylene+propylene generated is 44.9 wt% under reaction conditions of 680°C and a WHSV of 25 h "1 .
• HZSM-5 or HZSM-11 is used in a catalytic cracking reaction without being pelletized, and steam or inert gas is not introduced during the reaction, thus there is a possibility that the catalyst may be readily deactivated even though the initial activity is excellent. In this regard, an additional technology is required to shape the catalyst.
• Japanese Patent Laid-Open No. Hei. 6-199707 reports a catalytic cracking process for producing ethylene and propylene as main products from light naphthas having C paraffins.
• the zeolite is used in the catalytic cracking reaction without being pelletized, and steam or inert gas is not employed during the reaction, thus there is a possibility that the catalyst may be readily deactivated even though the initial activity is excellent.
• the used catalyst is zeolite (e.g., zeolite having a structure, such as MFT, MEL, MTW, TON, MTT, FER, or MFS, and being ex ⁇ emplified by ZSM-21, ZSM-38, or ZSM-48) which has pores of about 7 A and a ratio of silica/alumina of 200 or more.
• zeolite e.g., zeolite having a structure, such as MFT, MEL, MTW, TON, MTT, FER, or MFS, and being ex ⁇ emplified by ZSM-21, ZSM-38, or ZSM-48
• ZSM-21, ZSM-38, or ZSM-48 zeolite which has pores of about 7 A and a ratio of silica/alumina of 200 or more.
• U.S. Patent No. 6,566,293 discloses a catalyst useful to produce light olefins.
• HZSM-5 zeolite in which at least 10 wt% P O is contained, and Y zeolite as main components (10-40 wt%) are mixed with silica (0-25 wt%) and amorphous alumina (about 10 wt%), pelletized through spray drying, and are sintered at 300-1000°C to produce the catalyst.
• U.S. Patent No. 6,521,563 discloses a method of producing a SAPO molecular sieve which contains 4-20 mol% Si, 40-55 mol% Al, and 30-50 mol% P and has an AEL structure, and its application to a catalyst for naphtha catalytic cracking.
• WO 02/10313 A2 pertains to single component and mixed catalyst compositions which are used to selectively produce light olefins through steam cracking of hy ⁇ drocarbons, such as n-hexane or n-octane, and discloses an extrudated catalyst which comprises oxides of Al, Si and Cr, optionally oxides of alkaline metal (Na, K, Li or the like), and a binder (bentonite) and a method of producing the same.
• hy ⁇ drocarbons such as n-hexane or n-octane
• the composition of catalyst as aforementioned contains 50-95 wt% SiO , 3-30 wt% Al 0 , 2-10 wt% Cr O , 0-18 wt% alkaline metal oxides, and 10-30 wt% binder.
• U.S. Patent No. 6,342,153 and Korean Patent Laid-Open No. 2003-0055172 d isclose a method of producing a pillared clay catalyst, which is useful to thermal cracking of heavy oils, and the use of the same.
• This technology involves a production of porous material through pillaring by use of the layered compound.
• the method of producing the catalyst according to this technology is as follows, (i) Kaolin and HZSM-5 are modified with a rare earth metal ion and an alkaline earth metal ion, re ⁇ spectively and a pelletized catalyst is prepared using a spray dryer, (ii) Separately, polymeric cationic aluminum hydroxide complexes are prepared, (iii) The palletized catalyst produced in step (i) is pillared by use of the complexes of step (ii) at an ap ⁇ basementte pH to produce the catalyst.
• the composition of the catalyst contains 30-75 wt% layered compound, 0-30 wt% HZSM-5 having a pentasil structure or Y-type zeolite, 10-40 wt% inorganic binder (oxides of Al, Si and/or Zr modified with polyethylene glycol), and 1-10 wt% modifying component (polyethylene glycol, and Mg, Al, K, P or Sn).
• U.S. Patent No. 6,211,104 discloses a preparation method of catalyst applicable to a thermal cracking process for the production of light olefins, in which the pH of slurry consisting of 10-70 wt% layered compound (Kaolin), 5-85 wt% inorganic metal oxides (amorphous silica-alumina, alumina, silica, or pseudo-boehmite), and 1-50 wt% zeolite (0-25 wt% Y zeolite, and 75-100 wt% high silica zeolite with a pentasil structure which contains P and Al, P and Mg, or P and Ca) is controlled to 2-4, agitation is conducted at 20-80°C, pelletization is carried out using spray drying, and sintering is carried out at 450-650°C.
• Kaolin 10-70 wt% layered compound
• inorganic metal oxides amorphous silica-alumina, alumina, silica,
• the high silica zeolite comprises 2-8 wt% P and 0.3-3 wt% Al, Mg or Ca based on the weight of zeolite selected from the group consisting of ZSM-5, ZSM-8, and ZSM-Il having a SiO /Al O molar ratio of 15-60.
• the Y zeolite refers to high silica Y zeolite in which 14 wt% or less rare earth metal oxides are included.
• WO 01/04785 discloses a production of light olefins and aromatics in which a catalyst containing ZSM-5 and/or ZSM-11 zeolite comes into contact with C4+ naphthas (boiling point: 27-221°C).
• the catalyst is produced from raw material which comprises 5-75 wt% ZSM-5 and/or ZSM-11 zeolite having a SiO /Al O ratio below 70, 20 wt% or less inorganic oxides (silica or clay), and 0.5-10 wt% P.
• WO 03/064039 Al pertains to a mixed catalyst for DCC (deep catalytic cracking) of n-hexane, n-octane, and light naphthas, which is useful for the selective production of light olefins such as ethylene, propylene, and BTX.
• the mixed catalyst comprises crystalline microporous silicate (for example, pentasil-type silicate) and mesoporous silica-alumina or ZrO , and Al O , MoO , LaO , CeO , a mixture
• WO 01/81280 Al discloses a method of producing ethylene and propylene.
• a zeolite (TON, MTT) catalyst which has a pore size index of 23-25, no one- dimensional channels cross-linked with each other, and a diameter of 4.4-4.5 A, comes into contact with one or more C4-C9 olefins (e.g., a mixture of butane and butene) and is heated.
• C4-C9 olefins e.g., a mixture of butane and butene
• a fixed bed reaction is conducted under conditions of a temperature of 450-750°C, pressure of 0.5-10 atm, and a WHSV of 0.5-1000 h "1 .
• WO 01/04237 A2 discloses a production of light olefins, in which hydrocarbons containing at least 50 wt% C4-C7 aliphatic hydrocarbons are used as feeds and come into contact with ZSM-5 and/or ZSM-11 having a SiO /Al O ratio over 300 and to 2 2 3 containing P.
• the catalyst used in this prior art comprises 5-75 wt% zeolite, 25-95 wt% matrix such as silica, alumina and clay, and 0.5-10 wt% P.
• the reaction conditions include a temperature of 510-704°C, a pressure of 0.1-8 bar, a ratio of catalyst/feed of 0.1-10 (weight ratio), and a space velocity of 1-20 h "1 .
• the total amount of ethylene and propylene generated is 20 wt% of total products, and a ratio of propylene/ethylene is at least 3.
• U.S. Patent No. 5,171,921 discloses a method for selectively producing C2-C5 olefins.
• C3-C20 hydrocarbons which is a mixture of paraffins and olefins
• WHSV 10-1000 h "1
• a pelletized catalyst which comprises 10-25 wt% ZSM-5 containing 1-3 wt% P and having a Si/Al ratio of 20-60, and a binder such as silica, Kaolin, and bentonite.
• U.S. Patent No. 5,232,675 and Korean Patent Application No. 1996-7000207 disclose a method of producing a pentasil-type high silica zeolite catalyst in which RE O is 0.01-0.30, Na O is 0.4-1.0 and a ratio of SiO /Al O is 20-60. According to this
• HZSM-5 having a MFl structure or HZSM-5 modified with P as a main component is physically mixed with an inorganic oxide binder to prepare a pelletized catalyst.
• ZSM-5 participates in the catalytic cracking, and the binder physically mixed therewith does not show the catalytic activity.
• it is required to control a relative amount of the main component of the catalyst or artificially introduce a component serving as micropores or mesopores, depending on the compositional characteristics of naphthas (for example, when the naphthas become heavy).
• pillared layered material is added with HZSM-5 and Y-zeolite, and then an inorganic oxide binder and an additive are introduced thereto.
• the main component of the catalyst is zeolite having a pore size of 5-6 A and a three dimensional structure, which is represented by HZSM-5.
• the catalyst has a drawback in that much time is taken due to the complexity of the synthesis procedures, and reproducibility is poor when the catalyst is commercially produced.
• heavy oils vacuum residues, atmospheric residues, gas oils and the like
• light oils containing a predetermined content of olefins are typically used as feeds. If heavy oils are used as the feed, undesirably, the yield of light olefins is low. On the other hand, if light oils are used as the feed, a desired yield of light olefins is plausible only when the oils contain the specific olefin content or more.
• the present inventors have developed a novel porous solid acid catalyst which exhibits various advantages in comparison with the conventional HZSM-5 zeolite-based catalyst and an excellent conversion performance of hydrocarbons fraction (represented by full range naphthas, especially the full range naphthas having C hydrocarbons) into light olefins (e.g., ethylene and propylene), and which can be prepared in the simple procedure.
• hydrocarbons fraction represented by full range naphthas, especially the full range naphthas having C hydrocarbons
• light olefins e.g., ethylene and propylene
• the present invention is based on the unexpected finding that a porous material, which is prepared through (i) a pillaring reaction and (ii) a solid state reaction of a raw material mixture having specific components and compositional ratio, has properties (e.g., crystalline structure) that are apparently different from those of the raw mixture, and that if it is employed as a catalyst for producing light olefins from the hydrocarbons fraction, high yield and selectivity can be attained.
• properties e.g., crystalline structure
• an object of the present invention is to provide a solid acid catalyst showing selective conversion performance of hydrocarbons fraction into light olefins.
• Another object of the present invention is to provide a method of preparing a solid acid catalyst for producing light olefins, which is advantageous in that commercial preparation is readily achieved due to simplicity of synthetic procedure.
• Still another object of the present invention is to provide a process of producing light olefins from hydrocarbons fraction in the presence of the aforesaid solid acid catalyst.
• a porous solid acid catalyst for producing light olefins which comprises a product of (i) pillaring reaction and (ii) solid state reaction through heat treatment of a raw material mixture, and has a crystalline structure represented by an XRD pattern in Table 1.
• the raw material mixture comprises 42.0-60.0 wt% HZSM-5 having Si/Al molar ratio of 15-300, 12.0-38.0 wt% layered compound, 1.0-20.0 wt% Al O , 1.0-4.0 wt% P O , 10.0-15.0 wt% SiO , and 0.5-2.5 wt% B O based on an oxide form.
• a preparation method of a porous solid acid catalyst for producing light olefins which comprises:
• a process for producing light olefins which comprises:
• a porous solid acid catalyst according to the present invention has a crystalline structure which is converted by pillaring and solid state reactions and is quite different from structures of components constituting a raw material, particularly HZSM-5 and a layered compound.
• a raw material particularly HZSM-5 and a layered compound.
• the reactions involved in the preparation of the catalyst are simple, the price of raw materials for the catalyst is relatively less expensive, and it is possible to assure sufficient catalytic activity required to produce light olefins, even at a temperature lower than a reaction temperature required in the conventional steam cracking process.
• the present invention enables to use of relatively low-priced full range naphthas as feed for the production of light olefins.
• FTG. 1 illustrates XRD patterns of a layered compound (Kaolin; 1) and HZSM-5 (2) which are raw materials used to produce a catalyst according to the present invention, a pelletized catalyst before heat treatment (3), a pelletized catalyst after heat treatment (Example 2; 4), and ZSM-5 cited from JCPDS card No. 45-0133 (5), respectively;
• FIG. 2 schematically illustrates a system for measuring performances of catalysts prepared in accordance with Examples and Comparative Examples.
• FIG. 3 illustrates XRD patterns of a layered compound (Kaolin; 1), a pelletized catalyst prepared through heat treatment of HZSM-5 according to Comparative Example 8 (2), a pelletized catalyst prepared according to Comparative Example 3 (3), a pelletized catalyst prepared according to Comparative Example 1 (4), a pelletized catalyst prepared according to Comparative Example 6 (5), and a pelletized catalyst prepared according to Comparative Example 4 (6), respectively.
• Kaolin layered compound
• a catalytically active component i.e., HZSM-5 of a raw material mixture containing 42.0-60.0 wt% HZSM-5 having a Si/Al molar ratio of 15-300, 12.0-38.0 wt% lay ⁇ >ered comp r ound, ' 1.0-20.0 wt% Al 2 O 3 , 1.0-4.0 wt% P 2 O 5 , 10.0-15.0 wt% SiO 2 , and 0.5-2.5 wt% B O based on an oxide form, is subjected to a solid state reaction in conjunction with a pillared layered compound, and is converted into a porous material having properties (crystalline structure) that are completely different from an original form thereof.
• HZSM-5 a catalytically active component of a raw material mixture containing 42.0-60.0 wt% HZSM-5 having a Si/Al molar ratio of 15-300, 12.0-38.0 wt% lay ⁇ >ered comp r ound,
• a description of the catalyst according to the present invention is not limited to a specific theory. However, it is supposed that, when the raw mixture containing HZSM- 5 and the pillared layered compound is pelletized and heat treated under specific conditions, metal oxide pillars are firmly formed between layers of the layered compound, thus porosity is developed and a solid state reaction occurs between particles, thereby the catalyst has properties (particularly, X-ray diffraction structure) that are demonstrably different from those of components constituting the raw material, particularly the main component (i.e., HZSM-5).
• the porous solid acid catalyst according to the present invention after being subjected to the solid state reaction, has the XRD pattern shown in the following Table 1, and is also different in crystalline structure from each of HZSM-5, the layered compound and a physical mixture thereof used in the raw material mixture. Furthermore, a specific surface area of the resulting catalyst is preferably 200-400 D/g, and more preferably 200-300 D/g.
• the catalyst is prepared as follows: the pillaring of a layered compound in the raw mixture having the specific composition; the shaping of the pillaring-subjected raw mixture; and the solid state reaction of the pelletized catalyst under heat treatment conditions sufficient to achieve the crystalline structure having the XRD pattern as set forth above.
• An exemplified method is explained in detail, below.
• An aqueous pillaring-binding solution in which an aluminum compound as source of alumina (Al O ) and a phosphorus compound as source of phosphorus pentoxide (P O ) are controlled in the predetermined ratio, is prepared.
• the aluminum compound acts as a pillaring agent to form pillar structures between layers of the layered compound which is one of the raw materials described later.
• the phosphorus compound functions to smoothly combine HZSM-5 (as a main component) with the layered compound (as an auxiliary component).
• a molar ratio of Al O /P O is preferably controlled in the range of about 0.7-1.4, and more preferably on the order of 1.0 as a factor affecting the strength of the catalyst to be pelletized. It is preferred that they are mixed with each other in water (e.g., distilled water) under stirring to result in a homogeneous aqueous solution. Optionally, it is preferred to allow the resultant solution to stand at room temperature for about 10-15 hours to achieve aging of the aqueous pillaring-binding solution.
• the aluminum compound (as the source of Al O ) is typically in the form of aluminum salt, for example Al(NO ) D9HO, Al (SO ) D 18HO, AlCl D6HO, or a mixture thereof.
• the phosphorus compound (as the source of P O ) is typically phosphoric acid or a salt thereof, and is exemplified H PO , (NH ) HPO 4 , or a mixture thereof.
• H 3 PO 4 is most p *referable.
• HZSM-5 a layered compound and a silicon compound is admixed with each other in water (preferably, distilled water) to give a slurry. It is preferable that mixing be conducted for about 5-10 hours to prepare the homogeneous mixture. It is also preferable that a solid content in the slurry be controlled within a range from 20.0 to 60.0 wt%.
• HZSM-5 depending on the distribution and concentration of solid acid, it is chosen among ones ranging within about 15-300 and preferably about 25-80 in Si/Al molar ratio.
• the general properties thereof are well known in the art.
• the specific surface area is about 350-430 D/g and the pore size is about 5-6 A.
• a layered compound either natural layered compounds or chemically synthesized layered compounds can be used.
• Kaolin bentonite, saponite, or a mixture thereof is used with preference. Kaolin is most preferably used in the present invention.
• a source of silica used as an auxiliary binder is not specifically limited, and any silicon compounds (e.g., Ludox silica sol AS-40, Ludox silica sol HS- 40, Ludox silica sol HS-30 or a mixture thereof) known in the art may be used. Ludox silica sol AS-40 is most preferable.
• boron compound which is the source of boron oxide (B O ), preferably a boric acid aqueous solution (for example, having a concentration of about 5.0-10.0 wt%), is added thereto in order to prepare the homogeneous slurry.
• B O boron oxide
• the boron oxide is inserted into defect sites of HZSM-5 and the layered compound during the subsequent solid state reaction so as to appropriately control the acidic sites of the final catalyst.
• the mixing is preferably conducted for a time sufficient to cause a pillaring reaction. More preferably, the mixing is conducted with agitation (particularly, vigorous agitation) for about 10-15 hours.
• the time point when the boric acid solution is added is not specifically limited, but it is preferable that such addition is performed while the solution being mixed with the slurry.
• the pillaring reaction occurs between the layers of the layered compound by the aluminum compound contained in the aqueous pillaring-binding solution, and it is preferable to conduct agitation so that the pillaring reaction occurs sufficiently, as described above.
• Schematic description of the pillaring reaction is disclosed in U.S. Patent Nos. 6,342,153 and 5,614,453, which are incorporated for reference herein.
• the aqueous slurry prepared in step (3) is pelletized to form a catalyst having a predetermined shape.
• fine spheres having a uniform size for example, about 50-80 D
• the properties of the respective components (such as HZSM-5 and the layered compound) constituting the raw mixture are physically mixed with each other in the pelletized catalyst.
• the pelletized catalyst is subjected to a solid state reaction under heat treatment so as to have the above-mentioned XRD pattern, resulting in a structure that is different from those of the components constituting the raw material.
• the respective sources of alumina, silica, phosphorus pentoxide and boron oxide are converted into oxide forms thereof, any impurities are removed, the porosity is increased to optimize the performance of the catalyst, and the physical strength of the pelletized catalyst is improved.
• a preferred aspect of the heat treatment consists of two steps, and the steps are as follows.
• the first heat treatment step is conducted in an inert atmosphere (for example, a nitrogen atmosphere) at a temperature of about 450-600°C, and preferably about 500°C, and a preferred heat treatment time is about 3-5 hours.
• an inert atmosphere for example, a nitrogen atmosphere
• the impurities contained in pores of a porous molecular sieve are removed to develop pores, and the distances between the particles is so close that an formation of metal oxide pillars between the layers of layered pillared compound and a binding reaction between HZSM-5 and the layered compound are efficiently carried out in the subsequent second heat treatment step.
• the second heat treatment step is conducted in the presence of oxygen (preferably, in an air atmosphere) at a temperature of about 550-700°C, and preferably about 650°C, and a preferred heat treatment time is about 3-5 hours.
• oxygen preferably, in an air atmosphere
• a preferred heat treatment time is about 3-5 hours.
• the temperature of the second heat treatment is higher than that of the first heat treatment preferably by about 50-200°C, more preferably by about 100-150°C.
• the pillaring of the layered compound in the pelletized catalyst subjected to the first heat treatment step is completed in the second heat treatment step, and thus the oxide pillars are firmly formed between the layers, resulting in conversion into the porous material.
• the boron component used as the additive is inserted into the defect sites of HZSM-5 and the layered compound so as to appropriately control acidic sites of the pelletized catalyst, and the inorganic binder and other components are sintered so as to assure high physical strength.
• HZSM-5 acts as a seed to convert the structure of the pillared layered compound into a zeolite-like crystalline structure.
• the resulting product is a porous material whose properties (e.g., an XRD pattern) are not identical to those of HZSM-5 as the raw material.
• (1) and (2) respectively denote the layered compound (Kaolin) and HZSM-5 zeolite used as the raw materials.
• (3) denotes a sample which is prepared by mixing the raw materials having the predetermined composition and shaping the resulting mixture by use of spray drying, and in which properties of (1) and (2) are physically mixed with each other.
• the raw material for producing the catalyst should be adjusted to have the composition comprising 42.0-60.0 wt% HZSM-5 having Si/Al molar ratio of 15-300, 12.0-38.0 wt% layered compound, 1.0-20.0 wt% Al O , 1.0-4.0 wt% P O , 10.0-15.0 wt% SiO , and 0.5-2.5 wt% B O based on an
• 6,211,104 discloses a preparation method of a pelletized catalyst which comprises 10-70 wt% layered compound, 5-85 wt% inorganic oxide, and 1-50 wt% zeolite (HZSM-5), it cannot be considered to relate to the creation of a novel crystalline structure, unlike the present invention.
• the porous material is useful as a catalyst for selective production of light olefins from hydrocarbons fraction, preferably full range naphthas, more preferably full range naphthas having C hydrocarbons.
• hydrocarbons fraction preferably full range naphthas, more preferably full range naphthas having C hydrocarbons.
• the feasible type of reaction to be involved therein will be catalytic cracking reaction.
• the full range naphthas are different from costly light naphthas used in a steam cracking process for the production of light olef i ns, a raw material containing olefins used in the conventional catalytic cracking processes, and C ⁇ heavy oils which have been generally used in the FCC process.
• the full range naphthas are preferably employed as a feed in the economic standpoint, even though the use of other hydrocarbon fractions is possible.
• the various advantages obtained from the use of full range naphthas are owing to the excellent catalytic performance of the catalyst as provided by the present invention.
• the full range naphtha refers to a hydrocarbons fraction containing C
• 2-12 hydrocarbons directly obtained from a crude oil refining process and comprises paraff i ns (n-paraffins and i-paraffins), naphthenes, aromatic compounds, and the like. In some cases, a certain amount of olefins may be further present therein.
• the paraffin-content in the full range naphthas is high, the full range naphthas have a light characteristic, while when the paraffin-content is low, the full range naphthas have a heavy characteristic.
• the full range naphthas which have the total paraffin (i.e., n-paraffins and i-paraffins) content of preferably 60-90 wt%, more preferably 60-80 wt%, and most preferably 60-70 wt% may be used depending on yield, economic efficiency and the like.
• olefins may be contained in an amount of 20 wt% or less, preferably 10 wt% or less, and more preferably 5 wt% or less.
• Table 2 unit: wt%).
• the feed to be used may be a mixture of the full range naphthas and C 4 5 hydrocarbons recycled after light olefins and heavy products are separated from an effluent of the reaction zone.
• At least one reactor may be provided in the reaction zone.
• the type of reactor is not specifically limited, but a fixed bed reactor or a fluidized bed reactor may be used with preference.
• the feed is subjected to a conversion reaction (e.g., catalytic cracking) in the presence of the catalyst of the present invention within the reactor, and are thus converted into light olefins.
• a conversion reaction e.g., catalytic cracking
• the reaction performance significantly depends on a reaction temperature, a space velocity, and a weight ratio of hydrocarbons (e.g., naphtha)/steam.
• hydrocarbons e.g., naphtha
• the reaction temperature is about 500-750°C, preferably about 600-700°C, and more preferably about 610-680°C.
• the weight ratio of hydrocarbons / steam is about 0.01-10, preferably about 0.1-2.0, and more preferably about 0.3-1.0.
• the space velocity is about 0.1-20 h “1 , preferably about 0.3-10 h “ , and more preferably about 0.5-4 h " .
• a weight ratio of catalyst/ hydrocarbons is about 1-50, preferably about 5-30, and more preferably about 10-20, and a retention time of hy ⁇ drocarbons is about 0.1-600 sec, preferably about 0.5-120 sec, and more preferably about 1-20 sec.
• the amount of light olefins (i.e., the sum of ethylene and propylene) in the effluent of the reaction zone is preferably about 40 wt% or more, more preferably about 45 wt% or more, and most preferably about 47 wt% or more.
• a weight ratio of ethylene/propylene is about 0.5-1.5.
• a pelletized catalyst was produced from the slurry by use of a spray drier (MH-8 manufactured by ME HYUN Engineering Co., Ltd.) (such that particle sizes ranged from 50 D to 80 D). Subsequently, the pelletized catalyst was subjected to first heat treatment in a nitrogen atmosphere at 500°C for 3 hours, and then second heat treatment in an air atmosphere at 650°C for 3 hours to produce a catalyst. A BET specific surface area of the resulting catalyst was measured, and found to be about 200 D/g.
• the composition of raw material used is shown in the following Table 3.
• Example 1 The procedure of Example 1 was repeated to produce a catalyst, with the exception that the composition of raw material was changed as shown in the following Table 3.
• the particle size was about 50-80 D, and the BET specific surface area was about 270
• a catalyst was prepared in the same procedure as in Example 2, and the present example was conducted in order to evaluate the effect according to the type of full range naphthas. [90]
• Kaolin Aldrich Co., Ltd. was subjected to first heat treatment in a nitrogen atmosphere at 500°C for 3 hours, and then second heat treatment in an air atmosphere at 650°C for 3 hours to produce a catalyst.
• a BET specific surface area was about 20
• a pelletized catalyst was produced from the slurry using a spray drier (MH-8 manufactured by ME HYUN Engineering Co., Ltd.) (such that particle sizes ranged from 50 D to 80 D). Subsequently, the pelletized catalyst was subjected to first heat treatment in a nitrogen atmosphere at 500°C for 3 hours, and then second heat treatment in an air atmosphere at 650°C for 3 hours to produce a catalyst. A BET specific surface area of the resulting catalyst was measured, and found to be about 50 D/g.
• the composition of raw material used is shown in the following Table 3.
• a pelletized catalyst was produced from the slurry by use of a spray drier (MH-8 manufactured by ME HYUN Engineering Co., Ltd.) (such that particle sizes ranged from 50 D to 80 D). Subsequently, the pelletized catalyst was subjected to first heat treatment in a nitrogen atmosphere at 500°C for 3 hours, and then second heat treatment in an air atmosphere at 650°C for 3 hours to produce a catalyst. A BET specific surface area of the resulting catalyst was measured, and found to be about 150 D/g.
• the composition of raw material used is shown in the following Table 3.
• HZSM-5 Zeolyst International Inc.
• Kaolin Aldrich Co., Ltd.
• 22.6 g of Ludox silica sol AS-40 were added thereto.
• 20 g of solution (1) prepared in Example 1 and 16.5 g of 9.1 wt% boric acid solution were added thereto, and agitated again for 5 hours to give a homogeneous slurry.
• a pelletized catalyst was produced from the slurry by use of a spray drier (MH-8 manufactured by ME HYUN En ⁇ gineering Co., Ltd.) (such that particle sizes ranged from 50 D to 80 D). Subsequently, the pelletized catalyst was subjected to first heat treatment in a nitrogen atmosphere at 500°C for 3 hours, and then second heat treatment in an air atmosphere at 650°C for 3 hours to produce a catalyst. A BET specific surface area of the resulting catalyst was measured, and found to be about 150 D/g.
• the composition of raw material used is shown in the following Table 3.
• HZSM-5 Zeolyst International Inc.
• Kaolin Aldrich Co., Ltd.
• a pelletized catalyst was produced from the slurry by use of a spray drier (MH-8 manufactured by ME HYUN Engineering Co., Ltd.) (such that particle sizes ranged from 50 D to 80 D).
• the pelletized catalyst was subjected to first heat treatment in a nitrogen atmosphere at 500°C for 3 hours, and then second heat treatment in an air atmosphere at 650°C for 3 hours to produce a catalyst.
• a BET specific surface area of the resulting catalyst was measured, and found to be about 240 D/g.
• the composition of raw material used is shown in the following Table 3.
• a pelletized catalyst was produced from the slurry by use of a spray drier (MH-8 manufactured by ME HYUN En ⁇ gineering Co., Ltd.) (such that particle sizes ranged from 50 D to 80 D). Subsequently, the pelletized catalyst was subjected to first heat treatment in a nitrogen atmosphere at 500°C for 3 hours, and then second heat treatment in an air atmosphere at 650°C for 3 hours to produce a catalyst. A BET specific surface area of the resulting catalyst was measured, and found to be about 80 D/g.
• the composition of raw material used is shown in the following Table 3.
• a pelletized catalyst was produced from the slurry by use of a spray drier (MH-8 manufactured by ME HYUN En ⁇ gineering Co., Ltd.) (such that particle sizes ranged from 50 D to 80 D). Subsequently, the pelletized catalyst was subjected to first heat treatment in a nitrogen atmosphere at 500°C for 3 hours, and then second heat treatment in an air atmosphere at 650°C for 3 hours to produce a catalyst. A BET specific surface area of the resulting catalyst was measured, and found to be about 80 D/g.
• the composition of raw material used is shown in the following Table 3.
• HZSM-5 (Zeolyst International Inc.) having Si/Al molar ratio of 25 and a specific surface area of 400 D/g was subjected to first heat treatment in a nitrogen atmosphere at 500°C for 3 hours, and then second heat treatment in an air atmosphere at 650°C for 3 hours to produce a catalyst.
• a BET specific surface area was about 400 D/g after the heat treatment.
• FIG. 3 illustrates XRD patterns of (1) a layered compound (Kaolin), (2) a pelletized catalyst produced according to Comparative Example 8, (3) a catalyst produced according to Comparative Example 3, (4) a catalyst produced according to Comparative Example 1, (5) a catalyst produced according to Comparative Example 6, and (6) a pelletized catalyst produced according to Comparative Example 4.
• the layered compound (1) is converted into an amorphous type (4) due to thermal instability of a structure thereof during a heat treatment process unlike HZSM-5 (2).
• the pelletized catalyst produced from the raw material exclusive of a specific component in comparison with the present invention as shown in Comparative Example 3 (3) has an XRD pattern that is similar to that of ZSM-5.
• the pelletized catalyst which deviates from the present invention in the compositional range of the raw material, has the XRD pattern in which ZSM-5 and an amorphous layered compound having a destroyed structure are mixed with each other (6), and shows a pattern lacking crystallinity of the catalyst, or incorporation of third components.
• the raw material contains an excessive amount of specific component such as Al O (5), third components generated by a solid state reaction of components other than a main component at high temperatures, co-exist within the resulting catalyst.
• a system for measuring activity of the catalyst comprised a naphtha feeding device
• a water feeding device 3 fixed bed reactors 5, 5', and an activity evaluation device as shown in FlG. 2, and were organically connected to each other.
• naphthas which are specified in Table 2 were used as a feed.
• Naphthas and water which were fed using liquid injection pumps were mixed with each other while they passed through a preheater (not shown) at 300°C, mixed with He and N which are supplied through helium feeders 2, 2' and nitrogen feeders 1, Y at 6 D/min and 3 D/min, respectively, and then fed into the fixed bed reactors 5, 5'.
• the amounts and rates of gases were controlled using flow controllers (not shown).
• Each of the fixed bed reactors comprised an internal reactor and an external reactor.
• the external reactor was an Inconel reactor and had a length of 38 D and an external diameter of 4.6 D, while the internal reactor was made of stainless steel and had a length of 20 D and an external diameter of 0.5 inches.
• the internal temperature of the reactor was indicated through temperature output units 7, 7', and reaction conditions were controlled using PID controllers 8, 8' (NP200 manufactured by Hanyoung Electronic Co., Ltd.).
• catalysts of Examples are different from those of Comparative Examples in catalytic activities. That is to say, the catalysts of Examples 1 and 2 have high conversion efficiency of about 64-72 wt% and simultaneously a total amount of ethylene and propylene of about 41-47 wt%, which means high selectivity (a weight ratio of ethylene/propylene is about 1.1-1.5).
• the catalysts of Comparative Examples 1-3 and 5 which use the same feeds as in Examples 1 and 2, have conversion efficiency of about 46-60 wt% and a total amount of ethylene and propylene of 25-37 wt%.
• the catalysts of Comparative Examples 4, 6, and 7, which include all of the components constituting the raw material of the present invention but have the compositional ratios deviating from that of the present invention have conversion efficiency of about 49-54 wt% and a total amount of ethylene and propylene of about 31-35 wt%.
• Example 3 which uses lighter full range naphthas as the feeds, has better conversion and selectivity to light olefins than those of Example 2.
• both Examples 2 and 3 show results that are higher than the desired level.
• the present catalyst enables to employ full range naphthas, which are heavier than light naphthas used in the conventional steam cracking process, the present light olefin preparation is sufficiently competitive in terms of economic efficiency of the commercial process.
• the catalyst consisting of only HZSM-5 is used (Comparative
• Example 8 the conversion is about 67 wt% and the total amount of ethylene and propylene is 43 wt%. This result can be considered to be similar to those of Examples 1 and 2, but since it is impossible to produce the pelletized catalyst using only HZSM- 5, it is difficult to apply in practice.

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