WO2013129614A1 - C2酸素化物合成用の触媒、c2酸素化物の製造装置及びc2酸素化物の製造方法 - Google Patents
C2酸素化物合成用の触媒、c2酸素化物の製造装置及びc2酸素化物の製造方法 Download PDFInfo
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- WO2013129614A1 WO2013129614A1 PCT/JP2013/055532 JP2013055532W WO2013129614A1 WO 2013129614 A1 WO2013129614 A1 WO 2013129614A1 JP 2013055532 W JP2013055532 W JP 2013055532W WO 2013129614 A1 WO2013129614 A1 WO 2013129614A1
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- WO
- WIPO (PCT)
- Prior art keywords
- oxygenate
- catalyst
- ethanol
- oxygenates
- mixed gas
- Prior art date
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Definitions
- the present invention relates to a catalyst for synthesizing C2 oxygenates, an apparatus for producing C2 oxygenates, and a method for producing C2 oxygenates.
- This application is filed on February 28, 2012, Japanese Patent Application No. 2012-041775 filed in Japan, July 27, 2012, Japanese Patent Application No. 2012-167725 filed in Japan, and August 22, 2012. Furthermore, priority is claimed based on Japanese Patent Application No. 2012-183389 filed in Japan, the contents of which are incorporated herein.
- Bioethanol is being popularized as an alternative fuel for petroleum.
- Bioethanol is mainly produced by saccharification and fermentation of sugarcane and corn.
- woody and herbaceous biomass also referred to as cellulose biomass
- cellulose biomass woody and herbaceous biomass
- waste wood and unused parts of crops such as rice straw that do not compete with food and feed
- saccharification methods there are concentrated sulfuric acid saccharification method, dilute sulfuric acid / enzymatic saccharification method, hydrothermal saccharification method and the like, but many problems still remain to produce bioethanol at low cost.
- a mixed gas of hydrogen and carbon monoxide can be obtained from resources other than petroleum such as natural gas and coal
- the method for synthesizing C2 oxygenates such as ethanol, acetaldehyde, and acetic acid from the mixed gas is dependent on petroleum. It is being researched as a technology to get rid of.
- a method for obtaining a C2 oxygenate from a mixed gas of hydrogen and carbon monoxide for example, a method in which a mixed gas is brought into contact with a catalyst in which rhodium and an alkali metal are supported on a silica gel carrier is known (for example, Patent Documents 1 and 2).
- CO conversion is the percentage of the number of moles of CO consumed in the number of moles of CO in the mixed gas.
- Selectivity is the percentage of the number of moles of CO consumed in the gas mixture occupied by the number of moles of C converted to a specific oxygenate. For example, according to the following formula ( ⁇ ), the selectivity for ethanol as the C2 oxygenate is 100 mol%.
- the selectivity for ethanol as a C2 oxygenate is 50 mol%, and the selectivity for acetaldehyde as a C2 oxygenate is also 50 mol%.
- the selectivity for the C2 oxygenate is 100 mol%.
- Space-time yield of C2 oxygenate is the synthesis amount of C2 oxygenate per unit time (g / L-catalyst / h) per unit volume of catalyst, and the CO conversion rate and the C2 oxygenate selectivity Is proportional to the product of For this reason, a catalyst in which either one of the CO conversion rate and the C2 oxygenate selectivity is remarkably lowered cannot increase the space-time yield of the C2 oxygenate. Moreover, even if the selectivity of C2 oxygenates could be increased, the CO conversion could not be sufficiently increased. For this reason, the conventional method for producing C2 oxygenates using a catalyst for synthesizing C2 oxygenates cannot sufficiently increase the space-time yield of C2 oxygenates.
- the present invention increases the ratio of ethanol in the product C2 oxygenate, provides a catalyst for C2 oxygenate synthesis that can efficiently synthesize ethanol, and increases the space-time yield of C2 oxygenate.
- An object is to provide a catalyst for the synthesis of C2 oxygenates.
- the present invention relates to the following.
- a catalyst for synthesizing C2 oxygenates in which a hydrogenation active metal is supported on a porous carrier and C2 oxygenates are synthesized from a mixed gas containing hydrogen and carbon monoxide
- the porous carrier is a catalyst for synthesizing C2 oxygenates having an average pore diameter of 0.1 to 20 nm.
- the catalyst for synthesizing C2 oxygenates according to (1) wherein the average pore diameter is 0.1 to 8 nm.
- the catalyst for synthesizing C2 oxygenates according to (1) wherein the average pore diameter is 2 to 20 nm.
- the hydrogenation active metal is an alkali metal and a periodic table.
- the hydrogenation active metal is an alkali metal, and the supported amount of the hydrogenation active metal is 0.125 to 10 parts by mass with respect to 100 parts by mass of the porous carrier.
- the hydrogenated active metal is an element belonging to Group 7 of the periodic table, and the supported amount of the hydrogenated active metal is 0.25 to 10 mass with respect to 100 parts by mass of the porous carrier.
- the amount of the auxiliary active metal supported is 1 to 10 parts by mass with respect to 100 parts by mass of the porous carrier.
- the C2 oxygenate means a molecule having 2 carbon atoms, such as acetic acid, ethanol, and acetaldehyde, which is composed of carbon atoms, hydrogen atoms, and oxygen atoms.
- the catalyst for synthesizing the C2 oxygenate according to the present invention increases the ratio of ethanol in the product C2 oxygenate and / or increases the space-time yield of the C2 oxygenate, thereby increasing the C2 oxygenate, and thus ethanol. It can be synthesized efficiently.
- the catalyst for synthesizing C2 oxygenate according to the present invention (hereinafter sometimes simply referred to as catalyst) is a catalyst for synthesizing C2 oxygenate from a mixed gas containing hydrogen and carbon monoxide, and has a hydrogenation activity on a porous carrier. This is a so-called supported catalyst in which a metal is supported.
- the material of the porous carrier is not particularly limited, and examples thereof include silica, zirconia, titania, magnesia, etc. Among them, silica is preferable because various products having different specific surface areas and pore diameters can be procured on the market.
- the size of the porous carrier is not particularly limited.
- a silica porous carrier having a particle size of 0.5 to 5000 ⁇ m is preferable.
- the particle size of the porous carrier is adjusted by sieving.
- the porous carrier preferably has a narrowest particle size distribution.
- the total pore volume (total pore volume) in the porous carrier is not particularly limited, but is preferably 0.01 to 1.0 mL / g, more preferably 0.1 to 0.8 mL / g, 0 More preferably, it is 3 to 0.7 mL / g.
- the total pore volume is less than the above lower limit, the specific surface area of the porous carrier is insufficient, and the amount of the hydrogenation active metal and the auxiliary metal described below (hereinafter sometimes referred to as catalyst metal) is insufficient. Thus, the CO conversion rate may decrease.
- the total pore volume is a value measured by a water titration method.
- the water titration method is a method in which water molecules are adsorbed on the surface of a porous carrier and the pore distribution is measured from the condensation of the molecules.
- the “CO conversion rate” means the percentage of the number of moles of CO consumed in the number of moles of CO in the mixed gas.
- Selectivity is the percentage of the number of moles of CO consumed in the gas mixture occupied by the number of moles of C converted to a specific C2 oxygenate. For example, according to the following formula ( ⁇ ), the selectivity for ethanol as the C2 oxygenate is 100 mol%. On the other hand, according to the following formula ( ⁇ ), the selectivity for ethanol as a C2 oxygenate is 50 mol%, and the selectivity for acetaldehyde as a C2 oxygenate is also 50 mol%.
- the average pore diameter of the porous carrier is 0.1 to 20 nm, but from the viewpoint of the selectivity of C2 oxygenate, preferably ethanol, 0.1 to 8 nm is preferable, More preferably, the thickness is 0.1 to 5 nm, and still more preferably 1 to 4 nm.
- the average pore diameter is less than the lower limit, the amount of catalyst metal supported is reduced, and the CO conversion rate is lowered. If the average pore diameter exceeds the above upper limit value, the diffusion rate of the mixed gas becomes too fast, the contact time between the catalyst metal and the mixed gas becomes insufficient, and the selectivity for C2 oxygenates and hence ethanol is lowered. .
- the average pore diameter of the porous carrier is preferably 2 to 20 nm, more preferably more than 5 nm and less than 14 nm, and further preferably more than 5 nm and less than 10 nm.
- the average pore diameter When the average pore diameter is less than the lower limit, the amount of catalyst metal supported is reduced, and the CO conversion rate is lowered. If the average pore diameter exceeds the above upper limit, the diffusion rate of the mixed gas becomes too fast, the contact time between the catalyst metal and the mixed gas becomes insufficient, and the selectivity of C2 oxygenate, preferably ethanol is low. Become. That is, when the average pore diameter is within the above range, the contact time between the catalyst metal and the mixed gas becomes a time suitable for increasing the space-time yield of C2 oxygenates, and C2 oxygenates are synthesized more efficiently. it can.
- the “space-time yield of C2 oxygenate” is a value when it is assumed that the C2 oxygenate has been completely converted to ethanol by a conventionally known hydrogen reduction treatment (for example, catalytic hydrogen reduction). means.
- the average pore diameter is not more than the above upper limit, the specific surface area of the porous carrier is sufficiently large, the heat transfer efficiency to the catalyst is increased, and the C2 oxygenate can be synthesized more efficiently.
- the average pore diameter is a value measured by the following method. When the average pore diameter is 0.1 nm or more and less than 10 nm, it is calculated from the total pore volume and the BET specific surface area.
- the average pore diameter is 10 nm or more, it is measured by a mercury porosimetry porosimeter.
- the total pore volume is a value measured by a water titration method
- the BET specific surface area is a value calculated from the amount of adsorption and the pressure at that time using nitrogen as an adsorption gas.
- mercury intrusion method mercury is pressurized and pressed into the pores of the porous carrier, and the average pore diameter is calculated from the pressure and the amount of mercury inserted.
- the mode diameter of the pore diameter of the porous carrier is preferably from 0.1 to 8 nm, more preferably from 0.1 to 5 nm, still more preferably from 1 to 4 nm, from the viewpoint of the selectivity of C2 oxygenate, preferably ethanol. It is. Further, from the viewpoint of space-time yield of C2 oxygenate, preferably ethanol, the mode diameter of the pore diameter of the porous carrier is preferably 2 to 20 nm, more preferably more than 5 nm and less than 14 nm, further preferably more than 5 nm and more than 10 nm. It is as follows.
- the specific surface area of the porous carrier is not particularly limited, but for example, 1 to 1000 m 2 / g is preferable, 450 to 1000 m 2 / g is more preferable, 300 to 800 m 2 / g is more preferable, and 400 to 700 m 2 / g. Is particularly preferable, and 500 to 700 m 2 / g is particularly preferable. If the specific surface area is not less than the above lower limit value, the amount of catalyst metal supported is sufficient, and the CO conversion rate is further increased. In addition, if the specific surface area is not less than the above lower limit, C2 oxygenates can be synthesized more efficiently.
- the specific surface area is a BET specific surface area measured by a BET gas adsorption method using nitrogen as an adsorption gas.
- the product of the total pore volume and the specific surface area of the porous carrier is preferably 1 to 1000 mL ⁇ m 2 / g 2 . 100 to 500 mL ⁇ m 2 / g 2 is more preferable. If it is more than the said lower limit, the load of catalyst metal will become sufficient and CO conversion rate will increase more. If it is below the said upper limit, the diffusion rate of mixed gas becomes more suitable, and the selectivity of C2 oxygenate, Preferably ethanol increases more. That is, if it is in the said range, the space-time yield of C2 oxygenate can be raised more.
- volume / area / diameter ratio The value represented by (total pore volume) / (specific surface area ⁇ average pore diameter) in the porous carrier (hereinafter sometimes referred to as volume / area / diameter ratio) is preferably from 0.1 to 1, 2 to 0.5 is more preferable. If it is at least the above lower limit, the porosity of the porous carrier becomes sufficient and the CO conversion is further increased, and if it is not more than the above upper limit, the diffusion rate of the mixed gas becomes more appropriate and C2 oxygen The selectivity of the compound can be further increased. That is, if the volume / area / diameter ratio is within the above range, the space-time yield of C2 oxygenates can be further increased.
- the volume / area / diameter ratio in a porous carrier having a total pore volume of 0.61 mL / g, a specific surface area of 430 m 2 / g, and an average pore diameter of 5.7 nm can be obtained by the following equation (i).
- any metal conventionally known as a metal capable of synthesizing C2 oxygenates from a mixed gas may be used.
- alkali metals such as lithium and sodium; manganese, rhenium, etc .; Elements belonging to the group; elements such as ruthenium, etc. belonging to group 8 of the periodic table; cobalt, rhodium, etc., elements belonging to group 9 of the periodic table; nickel, palladium, etc., elements belonging to group 10 of the periodic table, etc. It is done.
- These hydrogenation active metals may be used individually by 1 type, and may be used in combination of 2 or more type.
- the hydrogenation active metal from the viewpoint of further increasing the CO conversion rate and the selectivity of ethanol, a combination of rhodium, manganese, and lithium, a combination of ruthenium, rhenium, and sodium, rhodium, ruthenium, and alkali are used. A combination of a metal and another hydrogenation active metal is preferred.
- the amount of the hydrogenation active metal supported in the catalyst is determined in consideration of the type of the hydrogenation active metal, the material of the porous carrier, and the like.
- the supported amount of the hydrogenation active metal is preferably 0.001 to 30 parts by mass, more preferably 0.125 to 10 parts by mass with respect to 100 parts by mass of the porous carrier. If the amount is less than the lower limit, the amount of the hydrogenated active metal supported may be too small and the CO conversion rate may be reduced. If the amount exceeds the upper limit value, the hydrogenated active metal cannot be uniformly and highly dispersed, and the CO conversion rate is decreased. In addition, the selectivity of C2 oxygenates and the space-time yield of C2 oxygenates may be reduced.
- the supported amount of the hydrogenation active metal is preferably 0.001 to 30 parts by mass with respect to 100 parts by mass of the porous carrier, 0.25 More preferable is 10 parts by mass. If the amount is less than the lower limit, the amount of the hydrogenated active metal supported may be too small and the CO conversion rate may be reduced. If the amount exceeds the upper limit value, the hydrogenated active metal cannot be uniformly and highly dispersed, and the CO conversion rate is decreased. In addition, the selectivity of C2 oxygenates and the space-time yield of C2 oxygenates may be reduced.
- the supported amount of the hydrogenation active metal is preferably 0.1 to 30 parts by mass with respect to 100 parts by mass of the porous carrier. 1 to 10 parts by mass is more preferable. If the amount is less than the lower limit, the amount of the hydrogenated active metal supported may be too small and the CO conversion rate may be reduced. If the amount exceeds the upper limit value, the hydrogenated active metal cannot be uniformly and highly dispersed, and the CO conversion rate is decreased. In addition, the selectivity of C2 oxygenates and the space-time yield of C2 oxygenates may be reduced.
- the supported amount of the hydrogenation active metal is determined in consideration of the composition, the type of the porous carrier, etc., for example, if the porous carrier is silica. For example, 0.05 to 30 parts by mass is preferable with respect to 100 parts by mass of the porous carrier, and 1 to 10 parts by mass is more preferable. If the amount is less than the lower limit value, the CO conversion rate may decrease. If the value exceeds the upper limit value, the hydrogenated active metal cannot be uniformly and highly dispersed, and the CO conversion rate, the selectivity of the C2 oxygenate, and the C2 oxygenate value may be reduced. The space-time yield of can be reduced.
- the supported state of the hydrogenation active metal in the catalyst is not particularly limited, and for example, a powdered metal may be supported on the porous support, or may be supported on the porous support in the form of a metal element.
- a state of being supported on a porous carrier in the form of a metal element is preferable. If the porous carrier is supported in the form of a metal element, the contact area with the mixed gas is increased, and the CO conversion rate and the selectivity of ethanol in the C2 oxygenate can be further increased.
- an auxiliary metal may be supported on the catalyst.
- the co-active metal include one or more selected from titanium, vanadium, chromium, boron, magnesium, lanthanoids, and elements belonging to Group 13 of the periodic table. Among these, for example, titanium, magnesium, vanadium, and the like. Is preferred. Titanium is preferable from the viewpoint of increasing the space-time yield of C2 oxygenates. Since the catalyst supports these co-active metals, the CO conversion rate, the selectivity of ethanol in the C2 oxygenate, or the space time yield of the C2 oxygenate can be further increased.
- the loading amount of the promoter metal in the catalyst is determined in consideration of the type of promoter metal, the type of hydrogenation active metal, and the like. For example, 0.01 to 20 parts by weight with respect to 100 parts by weight of the porous carrier. Preferably, 1 to 10 parts by mass is more preferable. If the amount is less than the above lower limit value, the loading amount of the promoter metal is too small, and it is difficult to further improve the CO conversion rate and the selectivity of C2 oxygenates such as ethanol, and the space-time yield of C2 oxygenates such as ethanol. It is difficult to make further improvements.
- the surface of the porous carrier is excessively coated with the promoter metal, and it is difficult to improve the CO conversion rate and the selectivity of C2 oxygenates such as ethanol. For example, it is difficult to further improve the space-time yield of ethanol.
- the supporting state of the promoter metal in the catalyst is not particularly limited.
- a powdery metal may be supported on the porous support, or may be supported on the porous support in the form of a metal element.
- the state may be sufficient, and among these, the state of being supported on the porous carrier in the form of a metal element is preferable. If it is supported on the porous carrier in the form of a metal element, the contact area with the mixed gas increases, and the CO conversion rate, the C2 oxygenate such as ethanol selectivity, and the C2 oxygenate such as ethanol space time. The yield can be further increased.
- the amount of the catalyst metal supported is determined in consideration of the type and composition of the catalyst metal, the material of the porous carrier, and the like. For example, 0.05 to 30 parts by mass is preferable with respect to 100 parts by mass of the porous carrier. 10 parts by mass is more preferable. If the amount is less than the above lower limit value, the amount of catalyst metal supported is too small, and it is difficult to improve the CO conversion rate, the selectivity of ethanol, and the space-time yield of C2 oxygenates such as ethanol. Therefore, it is difficult to further improve the CO conversion rate, the selectivity of C2 oxygenates such as ethanol, and the space-time yield of C2 oxygenates such as ethanol.
- a catalyst containing rhodium, manganese and an alkali metal is preferable, and a catalyst containing rhodium, manganese, an alkali metal and a promoter metal is more preferable.
- a C2 oxygenate such as ethanol can be synthesized more efficiently, and further, the catalytic activity can be maintained for a long time.
- a catalyst containing rhodium, manganese, and lithium is preferable.
- a catalyst containing rhodium, manganese, lithium, and magnesium, or rhodium, manganese, lithium, and titanium The catalyst is preferred.
- Catalyst containing rhodium, manganese, alkali metal and promoter metal preferably a catalyst containing rhodium, manganese, lithium and magnesium, or rhodium, manganese, lithium and titanium
- a composition represented by the following formula (I) is preferable.
- A rhodium
- B manganese
- C represents an alkali metal such as lithium
- D represents an auxiliary metal such as magnesium or titanium
- a is preferably 0.053 to 0.98. If the amount is less than the lower limit, the rhodium content is too small, and the synthesis efficiency of the C2 oxygenate may not be sufficiently increased. If the amount exceeds the upper limit, the content of other metals is too small.
- b is preferably 0.0006 to 0.67. If the content is less than the lower limit, the content of manganese is too small, and the synthesis efficiency of C2 oxygenates may not be sufficiently increased. If the content exceeds the upper limit, the content of other metals is too small. There is a possibility that the synthesis efficiency of C2 oxygenates may not be sufficiently increased.
- c is preferably 0.00056 to 0.51. If it is less than the above lower limit, the content of alkali metal is too small and the synthesis efficiency of C2 oxygenates may not be sufficiently increased, and if it exceeds the above upper limit, the content of other metals becomes too small.
- the synthesis efficiency of C2 oxygenates may not be sufficiently increased.
- d is preferably 0.0026 to 0.94. If the amount is less than the above lower limit, the content of the co-active metal may be too small and the synthesis efficiency of the C2 oxygenate may not be sufficiently increased. If the amount exceeds the above upper limit, the content of other metals is too small. Therefore, the synthesis efficiency of C2 oxygenates may not be sufficiently increased.
- the catalyst of the present invention is produced according to a conventionally known method for producing a supported catalyst.
- the method for producing the catalyst include an impregnation method and an ion exchange method, and the impregnation method is preferable.
- the impregnation method By using the impregnation method, the catalyst obtained is dispersed more uniformly in the catalytic metal, the contact efficiency with the mixed gas is further increased, the CO conversion rate and the selectivity of C2 oxygenate such as ethanol, and further C2 The space time yield of oxygenates such as ethanol can be further increased.
- Catalyst metal raw materials used for catalyst preparation include oxides, chlorides, sulfides, nitrates, carbonates and other inorganic salts, oxalates, acetylacetonate salts, dimethylglyoxime salts, ethylenediamineacetate, etc.
- catalyst metal compounds such as organic salts or chelate compounds, carbonyl compounds, cyclopentadienyl compounds, ammine complexes, alkoxide compounds, alkyl compounds, and the like conventionally used for preparing metal catalysts, Chloride or sulfide is preferred.
- the hydrogenated active metal and, if necessary, the starting compound of the auxiliary metal are dissolved in a solvent such as water, methanol, ethanol, tetrahydrofuran, dioxane, hexane, benzene, toluene, and the resulting solution (impregnating solution) is dissolved.
- the impregnating liquid is adhered to the porous carrier, for example, by immersing the porous carrier.
- the solvent is evaporated to form a catalyst.
- the mass ratio of each catalyst metal in the impregnation liquid is the mass ratio of each catalyst metal supported on the catalyst. For this reason, the mass ratio of each catalyst metal in the catalyst can be easily controlled by producing the catalyst by the impregnation method.
- a method of impregnating the impregnating liquid into the porous carrier a method of impregnating the carrier with a solution in which all raw material compounds are dissolved (simultaneous method), a solution in which each raw material compound is separately dissolved is prepared, and sequentially applied to the carrier. Examples include a method of impregnating each solution (sequential method).
- a primary support in which a porous carrier is impregnated with a solution (primary impregnation liquid) containing an auxiliary metal (primary impregnation step) and dried to support the auxiliary metal on the porous carrier.
- a solution containing a hydrogenation active metal secondary impregnation liquid is impregnated in the primary support (secondary impregnation step) and dried (secondary support step).
- the catalyst becomes a catalyst in which the catalyst metal is more highly dispersed, and the CO conversion rate and C2
- the selectivity of oxygenates such as ethanol, and the space time yield of C2 oxygenates such as ethanol can be further increased.
- Examples of the primary supporting step include a method of drying a porous carrier impregnated with the primary impregnating liquid (primary drying operation), and heating and firing it at an arbitrary temperature (primary baking operation).
- the drying method in the primary drying operation is not particularly limited, and examples thereof include a method of heating the porous carrier impregnated with the primary impregnation liquid at an arbitrary temperature.
- the heating temperature in the primary drying operation may be a temperature at which the solvent of the primary impregnation liquid can be evaporated, and is 80 to 120 ° C. if the solvent is water.
- the heating temperature in the primary firing operation is, for example, 300 to 600 ° C.
- Examples of the secondary supporting step include a method of drying the primary support impregnated with the secondary impregnating liquid (secondary drying operation), and further heating and baking at an arbitrary temperature (secondary baking operation).
- the drying method in the secondary drying operation is not particularly limited, and examples thereof include a method of heating the primary carrier impregnated with the secondary impregnation liquid at an arbitrary temperature.
- the heating temperature in the secondary drying operation may be a temperature at which the solvent of the secondary impregnation solution can be evaporated, and is 80 to 120 ° C. if the solvent is water.
- the heating temperature in the secondary firing operation is, for example, 300 to 600 ° C.
- the catalyst prepared by the above-described method is usually subjected to reduction treatment to be activated and used for the synthesis of C2 oxygenate.
- reduction treatment a method of bringing a catalyst into contact with a gas containing hydrogen is simple and preferable.
- the treatment temperature is such that the hydrogenation active metal is reduced, for example, 100 ° C. or more, preferably 200 to 600 ° C. for rhodium.
- hydrogen reduction may be performed while gradually or stepwise increasing the temperature from a low temperature.
- the catalyst may be subjected to a reduction treatment in the presence of carbon monoxide and water, or in the presence of a reducing agent such as hydrazine, a borohydride compound, or an aluminum hydride compound.
- a reducing agent such as hydrazine, a borohydride compound, or an aluminum hydride compound.
- the heating time in the reduction treatment is preferably 1 to 10 hours, and more preferably 2 to 5 hours. If it is less than the lower limit, the reduction of the catalyst metal becomes insufficient, and the CO conversion rate, the selectivity of C2 oxygenates such as ethanol, and the space-time yield of C2 oxygenates such as ethanol may be lowered.
- An apparatus for producing a C2 oxygenate of the present invention (hereinafter sometimes referred to simply as a production apparatus) is produced from a reaction tube filled with the catalyst of the present invention, a supply means for supplying a mixed gas into the reaction tube, and the reaction tube. And a discharging means for discharging the object.
- FIG. 1 is a schematic diagram showing a manufacturing apparatus 10 according to an embodiment of the present invention.
- the production apparatus 10 includes a reaction tube 1 filled with a catalyst to form a reaction bed 2, a supply tube 3 connected to the reaction tube 1, a discharge tube 4 connected to the reaction tube 1, and a reaction tube 1.
- the temperature control part 5 connected and the pressure control part 6 provided in the discharge pipe 4 are provided.
- the reaction tube 1 is preferably made of a material inert to the raw material gas and the synthesized C2 oxygenate, and preferably has a shape capable of withstanding heating at about 100 to 500 ° C. or pressurization at about 10 MPa.
- An example of the reaction tube 1 is a substantially cylindrical member made of stainless steel.
- the supply pipe 3 is a supply means for supplying the mixed gas into the reaction tube 1 and includes, for example, a pipe made of stainless steel or the like.
- the discharge pipe 4 is a discharge means for discharging the synthesis gas (product) containing the C2 oxygenated product synthesized in the reaction bed 2 and includes, for example, a pipe made of stainless steel or the like.
- the temperature control part 5 should just be what can make the reaction bed 2 in the reaction tube 1 arbitrary temperature, for example, an electric furnace etc. are mentioned.
- the pressure control part 6 should just be what can make the pressure in the reaction tube 1 arbitrary pressure, for example, a well-known pressure valve etc. are mentioned.
- the manufacturing apparatus 10 may include a known device such as a gas flow rate control unit that adjusts a gas flow rate such as mass flow.
- Method for producing C2 oxygenate In the method for producing a C2 oxygenate according to the present invention, a mixed gas is brought into contact with a catalyst. An example of the method for producing the C2 oxygenated product of the present invention will be described using the production apparatus of FIG. First, the inside of the reaction tube 1 is set to an arbitrary temperature and an arbitrary pressure, and the mixed gas 20 is caused to flow into the reaction tube 1 from the supply tube 3.
- the mixed gas 20 is not particularly limited as long as it contains hydrogen and carbon monoxide.
- the mixed gas 20 may be prepared from natural gas or coal, biomass gas obtained by gasifying biomass, or the like. It may be.
- the biomass gas can be obtained by a conventionally known method such as heating the pulverized biomass in the presence of water vapor (for example, 800 to 1000 ° C.).
- the mixed gas 20 is removed for the purpose of removing impurities such as tar, sulfur, nitrogen, chlorine and moisture before supplying the mixed gas 20 into the reaction tube 1. May be subjected to gas purification treatment.
- the gas purification treatment for example, various methods known in the technical field such as a wet method and a dry method can be adopted.
- wet methods include sodium hydroxide method, ammonia absorption method, lime / gypsum method, magnesium hydroxide method, and dry methods include activated carbon adsorption method such as pressure swing adsorption (PSA) method, electron beam method, etc. Is mentioned.
- PSA pressure swing adsorption
- the mixed gas 20 is mainly composed of hydrogen and carbon monoxide, that is, the total of hydrogen and carbon monoxide in the mixed gas 20 is preferably 50% by volume or more, and 80% by volume or more. More preferably, it is more preferable that it is 90 volume% or more, and 100 volume% may be sufficient.
- the volume ratio represented by hydrogen / carbon monoxide in the mixed gas 20 (hereinafter sometimes referred to as H 2 / CO ratio) is preferably 1/5 to 5/1, more preferably 1/2 to 3/1. Further, 1/1 to 2.5 / 1 is more preferable.
- the mixed gas 20 may contain methane, ethane, ethylene, nitrogen, carbon dioxide, water, etc. in addition to hydrogen and carbon monoxide.
- the temperature (reaction temperature) at which the mixed gas 20 is brought into contact with the catalyst is preferably 150 to 450 ° C., more preferably 200 to 400 ° C., and further preferably 250 to 350 ° C. . If it is more than the said lower limit, the speed
- the pressure (reaction pressure) when the mixed gas 20 is brought into contact with the catalyst is preferably 0.5 to 10 MPa, more preferably 1 to 7.5 MPa, and further preferably 2 to 5 MPa. preferable. If it is more than the said lower limit, the speed
- the inflowing mixed gas 20 flows while in contact with the catalyst in the reaction bed 2, and a part thereof becomes C2 oxygenated product. While the mixed gas 20 flows through the reaction bed 2, for example, a C2 oxygenate is generated by a catalytic reaction represented by the following formulas (1) to (5).
- a catalytic reaction represented by the formula (5) proceeds, and acetic acid or acetaldehyde produced by the catalytic reaction of the formulas (1) to (2) is converted to the formulas (3) to (4).
- the synthesis gas 22 is not particularly limited as long as it contains a C2 oxygenate, preferably ethanol.
- a C2 oxygenate preferably ethanol.
- Products other than ethanol for example, acetic acid, acetaldehyde, etc., C2 oxygenates excluding ethanol, ethyl acetate, methyl acetate, formic acid, etc.
- Oxygenates such as esters such as methyl; hydrocarbons such as methane).
- the selectivity for the C2 oxygenate is preferably 60 mol% or more, and more preferably 80 mol% or more.
- the content of the C2 oxygenate in the oxygenate in the synthesis gas 22 is not particularly limited, but is preferably 60 mol% or more, and more preferably 80 mol% or more. If it is more than the said lower limit, the production amount of C2 oxygenate can be raised more.
- the ethanol content in the C2 oxygenate in the synthesis gas 22 is not particularly limited, but is preferably 55 mol% or more, and more preferably 70 mol% or more. If it is more than the said lower limit, the process of removing products other than ethanol or converting products other than ethanol into ethanol can be simplified.
- the space-time yield of the C2 oxygenates is preferably 650 (g / L-catalyst / h) to 180 (g / L-catalyst / h).
- the space-time yield is within these ranges, the C2 oxygenate can be synthesized with high efficiency.
- the ethanol selectivity in the C2 oxygenate is preferably 96 mol% to 35 mol%. When the ethanol selectivity is at least the lower limit, there is an advantage that separation and purification are facilitated.
- the supply speed of the mixed gas 20 is preferably, for example, a space velocity of the mixed gas in the reaction bed 2 (a value obtained by dividing the gas supply amount per unit time by the catalyst amount (volume conversion)) in terms of the standard state, preferably 10 to 100000 L / L-catalyst / h, more preferably 1000 to 50000 L / L-catalyst / h, still more preferably 3000 to 20000 L / L-catalyst / h.
- the space velocity is appropriately adjusted in consideration of the reaction pressure, the reaction temperature, and the composition of the mixed gas that is a raw material.
- the synthesis gas 22 discharged from the discharge pipe 4 may be treated with a gas-liquid separator or the like to separate the unreacted mixed gas 20 and the C2 oxygenate.
- the mixed gas is brought into contact with the reaction bed 2 of the fixed bed.
- the catalyst may be in a form other than the fixed bed, such as a fluidized bed or a moving bed, and the mixed gas may be brought into contact therewith.
- the obtained C2 oxygenate may be separated for each necessary component by distillation or the like.
- the ethanolification step include a method in which a C2 oxygenate containing acetaldehyde, acetic acid and the like is brought into contact with a hydrogenation catalyst and converted to ethanol.
- the hydrogenation catalyst a catalyst known in the art can be used, and copper, copper-zinc, copper-chromium, copper-zinc-chromium, iron, rhodium-iron, rhodium-molybdenum, palladium, palladium- Examples thereof include iron, palladium-molybdenum, iridium-iron, rhodium-iridium-iron, iridium-molybdenum, rhenium-zinc, platinum, nickel, cobalt, ruthenium, rhodium oxide, palladium oxide, platinum oxide, and ruthenium oxide.
- These hydrogenation catalysts may be supported catalysts supported on a porous support similar to the support used in the catalyst of the present invention.
- supported catalysts include copper, copper-zinc, copper-chromium or copper- A copper-based catalyst in which zinc-chromium is supported on a silica-based carrier is preferable.
- a simultaneous method or a sequential method may be used as in the catalyst of the present invention.
- the selectivity of ethanol in the C2 oxygenate is increased, or the C2 oxygenate, preferably ethanol is efficiently produced by increasing the space time yield of the C2 oxygenate.
- the production amount of C2 oxygenates can be increased by increasing the space-time yield of C2 oxygenates.
- the average pore diameter of the porous carrier is 0.1 to 8 nm
- the speed at which the mixed gas enters and leaches into the pores is relatively slow. That is, the time during which the mixed gas stays in the pores becomes long, and the contact time between the catalytic metal supported in the pores and the mixed gas becomes relatively long.
- the contact time between the mixed gas and the catalytic metal is suitable for the catalytic reactions of the above formulas (3) to (5), particularly the catalytic reaction of the formula (5). Can be synthesized efficiently.
- the average pore diameter of the porous carrier is less than 2 nm, the speed at which the mixed gas enters the pores and the speed at which the mixed gas leaches out from the pores are relatively slow.
- the contact time between the mixed gas that has entered the pores and the catalytic metal is sufficient to be converted into C2 oxygenate, but the frequency at which the mixed gas enters or leaches out of the pores. Becomes smaller and the CO conversion cannot be increased.
- the average pore diameter is less than 2 nm, the space-time yield of C2 oxygenates cannot be increased.
- the average pore diameter is more than 20 nm, the mixed gas enters or exits from the pores too quickly.
- the contact time between the mixed gas that has entered the pores and the catalytic metal is such that the mixed gas is converted to C2 oxygenate. It will be insufficient. For this reason, when the average pore diameter exceeds 20 nm, the selectivity of C2 oxygenates becomes small, and the space-time yield of C2 oxygenates cannot be increased. Therefore, if the average pore diameter of the porous carrier is 2 to 20 nm, it is considered that the time for which the mixed gas stays in the pores can be set to a time suitable for increasing the space-time yield of C2 oxygenates.
- Example 1-1 0.58 mL of an aqueous solution (primary impregnation solution) containing 0.049 g of titanium lactate ammonium salt (Ti (OH) 2 [OCH (CH 3 ) COO ⁇ ] 2 (NH 4 + ) 2 ) was added to a porous carrier (material: silica , Particle diameter: 1.18-2.36 mm, average pore diameter: 1.9 nm, total pore volume: 0.29 mL / g, specific surface area: 620 m 2 / g) (Primary impregnation step). This was dried at 110 ° C. for 3 hours (primary drying operation), and further fired at 400 ° C.
- aqueous solution primary impregnation solution
- a porous carrier material: silica , Particle diameter: 1.18-2.36 mm, average pore diameter: 1.9 n
- Rhodium chloride trihydrate (RhCl 3 .3H 2 O) 0.154 g, manganese chloride dihydrate (MnCl 2 .2H 2 O) 0.087 g, lithium chloride monohydrate (LiCl ⁇ H 2 O) ) 0.6 mL of an aqueous solution containing 0.01 g (secondary impregnation liquid) is dropped onto the primary carrier to be impregnated (secondary impregnation step), dried at 110 ° C. for 3 hours (secondary drying operation), and The catalyst was obtained by calcining at 400 ° C. for 4.5 hours (secondary calcining operation, secondary supporting step).
- Example 1-2 A catalyst was obtained in the same manner as in Example 1-1 except that the primary impregnation step and the primary support step were not performed.
- Example 1-3 In the primary impregnation step, 1.22 mL of an aqueous solution (primary impregnation solution) containing 0.049 g of titanium lactate ammonium salt was added to a porous carrier (material: silica, particle size: 1.18 to 2.36 mm, average pore diameter: 5. 7 nm, total pore volume: 0.61 mL / g, specific surface area: 430 m 2 / g) A catalyst was obtained in the same manner as in Example 1-1 except that it was dropped and impregnated.
- aqueous solution primary impregnation solution
- titanium lactate ammonium salt titanium lactate ammonium salt
- Example 1-4 A catalyst was obtained in the same manner as in Example 1-3 except that the primary impregnation step and the primary support step were not performed.
- Example 1-5 2.16 mL of an aqueous solution (primary impregnation solution) containing 0.123 g of titanium lactate ammonium salt was added to a porous carrier (material: silica, particle diameter: 0.7 to 2.0 mm, average pore diameter: 13.7 nm, all fine Pore volume: 1.08 mL / g, specific surface area: 315 m 2 / g) was dropped into 2.0 g and impregnated (primary impregnation step). This was dried at 110 ° C. for 3 hours (primary drying operation), and further fired at 400 ° C. for 4.5 hours to obtain a primary support (primary firing operation, primary support step).
- a porous carrier material: silica, particle diameter: 0.7 to 2.0 mm, average pore diameter: 13.7 nm, all fine Pore volume: 1.08 mL / g, specific surface area: 315 m 2 / g
- Example 1-6 A catalyst was obtained in the same manner as in Example 1-5 except that the primary impregnation step and the primary support step were not performed.
- Example 1--7 0.58 mL of an aqueous solution (primary impregnation solution) containing 0.123 g of titanium lactate ammonium salt was added to a porous carrier (material: silica, particle size: 1.18 to 2.36 mm, average pore diameter: 1.9 nm, all fine) Pore volume: 0.29 mL / g, specific surface area: 620 m 2 / g) primary impregnation step in which 2.0 g was dropped and impregnated; and 0.154 g of rhodium chloride trihydrate and manganese chloride dihydrate Except for the secondary impregnation step in which 2.16 mL of an aqueous solution (secondary impregnation solution) containing 032 g and 0.005 g of lithium chloride monohydrate was dropped and impregnated on the primary support, the same procedure as in Example 1-1 was performed.
- a porous carrier material: silica, particle size: 1.18 to 2.36 mm, average pore diameter:
- the catalyst was obtained.
- Catalyst / h was passed through the reaction bed at 2 MPa to produce synthesis gas containing C2 oxygenates.
- the mixed gas was passed through the reaction bed for 3 hours, and the resultant synthesis gas was recovered and analyzed by gas chromatography.
- Examples 1-1 to 1-7 to which the present invention is applied The selectivity of ethanol was 12.3 mol% or more, and the ratio of ethanol in the C2 oxygenate was 22.6 mol% or more.
- the selectivity of ethanol is 23.0 mol% or more, and the ratio of ethanol in the C2 oxygenate was 39.1 mol% or more.
- Examples 1-1 and 1-3 carrying a promoter metal were carried out.
- Examples 1-5 and 1-6 using a porous carrier having an average pore diameter of more than 8 nm, compared with Examples 1-1 to 1-4, ethanol selectivity and ethanol in C2 oxygenated product
- the selectivity for C2 oxygenates was 50 mol% or more
- the space-time yield of C2 oxygenates was 200 (g / L-catalyst / h) or more.
- Example 2 A synthesis gas containing C2 oxygenate was produced in the same manner as in Example 1-1, except that the catalyst obtained in Example 1-1 was used and the reaction temperatures in Table 2 were used, and selection of each product was performed. The rate (mol%) was calculated. The obtained results are shown in Table 2 and FIG. In Table 2 and FIG. 2, the ratio of ethanol in the C2 oxygenate was calculated as the content of ethanol in the total amount of ethanol, acetaldehyde and acetic acid (ie, the total amount of C2 oxygenate) in the product.
- FIG. 2 is a graph in which the horizontal axis represents the reaction temperature and the vertical axis represents the ratio (mol%) of ethanol in the C2 oxygenate. As shown in Table 2 and FIG. 2, in this example, the ratio of ethanol in the C2 oxygenate was 90 mol% or more between the reaction temperatures of 272 to 305 ° C.
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Abstract
Description
本願は、2012年2月28日に、日本に出願された特願2012-041775号、2012年7月27日に、日本に出願された特願2012-167725号、及び2012年8月22日に、日本に出願された特願2012-183389号に基づき優先権を主張し、その内容をここに援用する。
セルロース系バイオマスを原料とし、従来のエタノール発酵法を用いてバイオエタノールを製造するためには、セルロースを糖化させる必要がある。糖化方法としては、濃硫酸糖化法、希硫酸・酵素糖化法、水熱糖化法等があるが、安価にバイオエタノールを製造するためにはいまだ多くの課題が残されている。
さらに、水素と一酸化炭素との混合ガスは、天然ガス、石炭等の石油以外の資源からも得られるため、混合ガスからエタノール、アセトアルデヒド、酢酸等のC2酸素化物を合成する方法は、石油依存を脱却する技術として研究されている。
水素と一酸化炭素との混合ガスからC2酸素化物を得る方法としては、例えば、ロジウム及びアルカリ金属をシリカゲルの担体に担持させた触媒に、混合ガスを接触させる方法が知られている(例えば、特許文献1~2)。
「CO転化率」は、混合ガス中のCOのモル数の内、消費されたCOのモル数が占める百分率である。
「選択率」は、混合ガス中の消費されたCOのモル数のうち、特定の酸素化物へ変換されたCのモル数が占める百分率である。例えば、下記(α)式によれば、C2酸素化物であるエタノールの選択率は100モル%である。一方、下記(β)式によれば、C2酸素化物であるエタノールの選択率は50モル%であり、C2酸素化物であるアセトアルデヒドの選択率も50モル%である。加えて、(α)式及び(β)式において、C2酸素化物の選択率は100モル%である。
7H2+4CO→C2H5OH+CH3CHO+2H2O ・・・(β)
また、C2酸素化物の選択率を高められても、CO転化率を十分に高められなかった。このため、従来のC2酸素化物合成用の触媒を用いたC2酸素化物の製造方法では、C2酸素化物の空時収量を十分に高められなかった。
そこで、本発明は、生成物であるC2酸素化物中のエタノールの比率を高めて、エタノールを効率的に合成できるC2酸素化物合成用の触媒の提供およびC2酸素化物の空時収量を高めることのできるC2酸素化物合成用の触媒の提供を目的とする。
(1)多孔質担体に水素化活性金属が担持され、水素と一酸化炭素とを含む混合ガスからC2酸素化物を合成するC2酸素化物合成用の触媒において、
前記多孔質担体は、平均細孔直径が0.1~20nmである、C2酸素化物合成用の触媒。
(2)前記平均細孔直径が、0.1~8nmである、(1)に記載のC2酸素化物合成用の触媒。
(3)前記多孔質担体の細孔直径のモード径が、0.1~8nmである、(1)に記載のC2酸素化物合成用の触媒。
(4)前記平均細孔直径が、2~20nmである、(1)に記載のC2酸素化物合成用の触媒。
(5)前記多孔質担体の細孔直径のモード径が、2~20nmである、(1)に記載のC2酸素化物合成用の触媒
(6)前記水素化活性金属は、アルカリ金属及び周期表の第7~10族に属する元素からなる群から選択される1種以上である(2)又は(3)に記載のC2酸素化物合成用の触媒。
(7)前記水素化活性金属は、アルカリ金属及び周期表の第7~10族に属する元素からなる群から選択される1種以上である(4)又は(5)に記載のC2酸素化物合成用の触媒。
(8)前記C2酸素化物が、エタノール、アセトアルデヒド及び酢酸からなる群から選択される少なくとも1つである(1)~(7)のいずれか1つに記載のC2酸素化物合成用の触媒。
(9)前記C2酸素化物合成用の触媒が、ロジウムと、マンガンと、リチウムとを含有する触媒である(1)~(8)のいずれか1つに記載のC2酸素化物合成用の触媒。
(10)前記C2酸素化物合成用の触媒が、さらに、チタン又はマグネシウムを含有する(1)~(9)のいずれか1つに記載のC2酸素化物合成用の触媒。
(11)前記多孔質担体の比表面積が、400~700m2/gである(1)~(10)のいずれか1つに記載のC2酸素化物合成用の触媒。
(12)前記多孔質担体における(全細孔容積)/(比表面積×平均細孔直径)で表される値が、0.2~0.5である(1)~(11)のいずれか1つに記載のC2酸素化物合成用の触媒。
(13)前記水素化活性金属がアルカリ金属であり、かつ、前記水素化活性金属の担持量が、前記多孔質担体100質量部に対して、0.125~10質量部である(1)~(12)のいずれか1つに記載のC2酸素化物合成用の触媒。
(14)前記水素化活性金属が周期表の第7族に属する元素であり、かつ、前記水素化活性金属の担持量が、前記多孔質担体100質量部に対して、0.25~10質量部である(1)~(13)のいずれか1つに記載のC2酸素化物合成用の触媒。
(15)前記助活性金属の担持量が、前記多孔質担体100質量部に対して、1~10質量部である(1)~(14)のいずれか1つに記載のC2酸素化物合成用の触媒。
(16)(1)~(15)のいずれか1つに記載のC2酸素化物合成用の触媒が充填された反応管と、前記混合ガスを前記反応管に供給する供給手段と、前記反応管から生成物を排出する排出手段とを備えるC2酸素化物の製造装置。
(17)(1)~(15)のいずれか1つに記載のC2酸素化物合成用の触媒に、水素と一酸化炭素とを含む混合ガスを接触させてC2酸素化物を得ることと特徴とするC2酸素化物の製造方法。
(18)前記C2酸素化物の空時収量が650(g/L-触媒/h)~180(g/L-触媒/h)である、(17)に記載のC2酸素化物の製造方法。
(19)前記C2酸素化物中のエタノールの選択率が、96モル%~35モル%である、(17)に記載のC2酸素化物の製造方法。
本発明のC2酸素化物合成用の触媒(以下、単に触媒ということがある)は、水素と一酸化炭素とを含む混合ガスからC2酸素化物を合成する触媒であり、多孔質担体に水素化活性金属が担持された、いわゆる担持触媒である。
加えて、多孔質担体は、粒子径分布ができるだけ狭いものが好ましい。
全細孔容積は、水滴定法により測定される値である。水滴定法とは、多孔質担体の表面に水分子を吸着させ、分子の凝縮から細孔分布を測定する方法である。
「選択率」とは、混合ガス中の消費されたCOのモル数のうち、特定のC2酸素化物へ変換されたCのモル数が占める百分率である。例えば、下記(α)式によれば、C2酸素化物であるエタノールの選択率は100モル%である。一方、下記(β)式によれば、C2酸素化物であるエタノールの選択率は50モル%であり、C2酸素化物であるアセトアルデヒドの選択率も50モル%である。
7H2+4CO→C2H5OH+CH3CHO+2H2O ・・・(β)
より好ましくは0.1~5nm、さらに好ましくは1~4nmである。平均細孔直径が上記下限値未満では、触媒金属の担持量が少なくなって、CO転化率が低下する。平均細孔直径が上記上限値超では、混合ガスの拡散速度が速くなりすぎて、触媒金属と混合ガスとの接触時間が不十分となって、C2酸素化物、ひいてはエタノールの選択率が低くなる。加えて、平均細孔直径が上記上限値以下であれば、多孔質担体の比表面積が十分に大きくなって触媒への伝熱効率が高まり、C2酸素化物をより効率的に合成できる。このため、平均細孔直径が上記上限値以下であれば、より効率的にC2酸素化物、ひいてはエタノールを合成できる。
また、C2酸素化物の空時収量の観点からは、多孔質担体の平均細孔直径は、2~20nmが好ましく、より好ましくは5nm超14nm未満、さらに好ましくは5nm超10nm以下である。平均細孔直径が上記下限値未満では、触媒金属の担持量が少なくなって、CO転化率が低下する。平均細孔直径が上記上限値超では、混合ガスの拡散速度が速くなりすぎて、触媒金属と混合ガスとの接触時間が不十分となって、C2酸素化物、好ましくはエタノールの選択率が低くなる。即ち、平均細孔直径が上記範囲内であれば、触媒金属と混合ガスとの接触時間が、C2酸素化物の空時収量を高めるのに適した時間となり、C2酸素化物をより効率的に合成できる。
本明細書において、「C2酸素化物の空時収量」とは、C2酸素化物が、従来公知の水素還元処理(例えば、接触水素還元等)によって、すべてエタノールに変換されたと仮定した場合の値を意味する。
加えて、平均細孔直径が上記上限値以下であれば、多孔質担体の比表面積が十分に大きくなって触媒への伝熱効率が高まり、C2酸素化物をより効率的に合成できる。平均細孔直径は、以下の手法で測定される値である。平均細孔直径が0.1nm以上10nm未満の場合、全細孔容積とBET比表面積とから算出される。平均細孔直径が10nm以上の場合、水銀圧入法ポロシメーターにより測定される。
ここで、全細孔容積は、水滴定法により測定される値であり、BET比表面積は、窒素を吸着ガスとし、その吸着量とその時の圧力から算出される値である。
水銀圧入法は、水銀を加圧して多孔質担体の細孔に圧入させ、その圧力と圧入された水銀量から平均細孔直径を算出するものである。
比表面積が上記上限値以下であれば、混合ガスの拡散速度がより適切になって、エタノールの選択率がより高まる。
比表面積は、窒素を吸着ガスとし、BET式ガス吸着法により測定されるBET比表面積である。
上記上限値以下であれば、混合ガスの拡散速度がより適切になって、C2酸素化物、好ましくはエタノールの選択率がより高まる。すなわち、上記範囲内であれば、C2酸素化物の空時収量をより高められる。
例えば、全細孔容積0.61mL/g、比表面積430m2/g、平均細孔直径5.7nmの多孔質担体における容積/面積・直径比は、下記(i)式により求められる。
これらの水素化活性金属は、1種単独で用いられてもよいし、2種以上が組み合わされて用いられてもよい。例えば、水素化活性金属としては、CO転化率やエタノールの選択率をより高める観点から、ロジウム、マンガン及びリチウムを組み合わせたものや、ルテニウム、レニウム及びナトリウムを組み合わせたもの等、ロジウム又はルテニウムとアルカリ金属とその他の水素化活性金属とを組み合わせたものが好ましい。
水素化活性金属としてアルカリ金属を用いる場合、水素化活性金属の担持量は、多孔質担体100質量部に対して0.001~30質量部が好ましく、0.125~10質量部がより好ましい。上記下限値未満では、水素化活性金属の担持量が少なすぎてCO転化率が低下するおそれがあり、上記上限値超では、水素化活性金属を均一かつ高分散状態にできず、CO転化率やC2酸素化物の選択率、さらには、C2酸素化物の空時収量が低下するおそれがある。
水素化活性金属として、周期表の第7族に属する元素を用いる場合、水素化活性金属の担持量は、多孔質担体100質量部に対して0.001~30質量部が好ましく、0.25~10質量部がより好ましい。上記下限値未満では、水素化活性金属の担持量が少なすぎてCO転化率が低下するおそれがあり、上記上限値超では、水素化活性金属を均一かつ高分散状態にできず、CO転化率やC2酸素化物の選択率、さらには、C2酸素化物の空時収量が低下するおそれがある。
水素化活性金属として、周期表の第8族~第10族に属する元素を用いる場合、水素化活性金属の担持量は、多孔質担体100質量部に対して0.1~30質量部が好ましく、1~10質量部がより好ましい。上記下限値未満では、水素化活性金属の担持量が少なすぎてCO転化率が低下するおそれがあり、上記上限値超では、水素化活性金属を均一かつ高分散状態にできず、CO転化率やC2酸素化物の選択率、さらには、C2酸素化物の空時収量が低下するおそれがある。
助活性金属としては、例えば、チタン、バナジウム、クロム、ホウ素、マグネシウム、ランタノイド及び周期表の第13族に属する元素から選択される1種以上が挙げられ、中でも、例えば、チタン、マグネシウム、バナジウム等が好ましい。C2酸素化物の空時収量を高める観点からは、チタンが好ましい。触媒は、これらの助活性金属が担持されていることで、CO転化率やC2酸素化物中のエタノールの選択率、又は、C2酸素化物の空時収量をより高めることができる。
金属元素の形態で多孔質担体に担持された状態であれば、混合ガスとの接触面積が大きくなり、CO転化率、C2酸素化物、例えばエタノールの選択率やC2酸素化物、例えばエタノールの空時収量をより高められる。
ロジウムと、マンガンと、アルカリ金属とを含有する触媒の中でも、ロジウムと、マンガンと、リチウムとを含有する触媒が好ましい。
ロジウムと、マンガンと、アルカリ金属と、助活性金属とを有する触媒のうち、ロジウムと、マンガンと、リチウムと、マグネシウムとを含有する触媒、又はロジウムと、マンガンと、リチウムと、チタンとを含有する触媒が好ましい。
ロジウムと、マンガンと、アルカリ金属と、助活性金属とを含有する触媒、好ましくは、ロジウムと、マンガンと、リチウムと、マグネシウムとを含有する触媒、又は、ロジウムと、マンガンと、リチウムと、チタンとを含有する触媒としては、下記(I)式で表される組成が好ましい。
aA・bB・cC・dD ・・・・(I)
(I)式中、Aはロジウムを表し、Bはマンガンを表し、Cは例えばリチウム等のアルカリ金属を表し、Dは例えばマグネシウム又はチタン等の助活性金属を表し、a、b、c及びdはモル分率を表し、a+b+c+d=1である。
(I)式中のaは、0.053~0.98が好ましい。上記下限値未満であるとロジウムの含有量が少なすぎて、C2酸素化物の合成効率が十分に高まらないおそれがあり、上記上限値超であると他の金属の含有量が少なくなりすぎて、C2酸素化物の合成効率が十分に高まらないおそれがある。
(I)式中のbは、0.0006~0.67が好ましい。上記下限値未満であるとマンガンの含有量が少なすぎて、C2酸素化物の合成効率が十分に高まらないおそれがあり、上記上限値超であると他の金属の含有量が少なくなりすぎて、C2酸素化物の合成効率が十分に高まらないおそれがある。
(I)式中のcは、0.00056~0.51が好ましい。上記下限値未満であるとアルカリ金属の含有量が少なすぎて、C2酸素化物の合成効率が十分に高まらないおそれがあり、上記上限値超であると他の金属の含有量が少なくなりすぎて、C2酸素化物の合成効率が十分に高まらないおそれがある。
(I)式中のdは、0.0026~0.94が好ましい。上記下限値未満であると助活性金属の含有量が少なすぎて、C2酸素化物の合成効率が十分に高まらないおそれがあり、上記上限値超であると他の金属の含有量が少なくなりすぎて、C2酸素化物の合成効率が十分に高まらないおそれがある。
触媒の調製に用いられる触媒金属の原料化合物としては、酸化物、塩化物、硫化物、硝酸塩、炭酸塩等の無機塩、シュウ酸塩、アセチルアセトナート塩、ジメチルグリオキシム塩、エチレンジアミン酢酸塩等の有機塩又はキレート化合物、カルボニル化合物、シクロペンタジエニル化合物、アンミン錯体、アルコキシド化合物、アルキル化合物等、触媒金属の化合物として、従来、金属触媒を調製する際に用いられるものが挙げられ、中でも、塩化物又は硫化物が好ましい。
一次乾燥操作における乾燥方法は特に限定されず、例えば、一次含浸液が含浸された多孔質担体を任意の温度で加熱する方法が挙げられる。一次乾燥操作における加熱温度は、一次含浸液の溶媒を蒸発できる温度であればよく、溶媒が水であれば、80~120℃とされる。一次焼成操作における加熱温度は、例えば、300~600℃とされる。一次焼成操作を行うことで、助活性金属の原料化合物に含まれていた成分の内、触媒反応に寄与しない成分を十分に揮散し、触媒活性をより高められる。
二次乾燥操作における乾燥方法は特に限定されず、例えば、二次含浸液が含浸された一次担持体を任意の温度で加熱する方法が挙げられる。二次乾燥操作における加熱温度は、二次含浸液の溶媒を蒸発できる温度であればよく、溶媒が水であれば、80~120℃とされる。二次焼成操作における加熱温度は、例えば、300~600℃とされる。二次焼成操作を行うことで、水素化活性金属の原料化合物に含まれていた成分の内、触媒反応に寄与しない成分を十分に揮散し、触媒活性をより高められる。
還元処理における加熱時間は、例えば、1~10時間が好ましく、2~5時間がより好ましい。上記下限値未満では、触媒金属の還元が不十分となり、CO転化率やC2酸素化物、例えばエタノールの選択率、さらには、C2酸素化物、例えばエタノールの空時収量が低くなるおそれがある。上記上限値超では、触媒金属が凝集し、CO転化率やC2酸素化物、例えばエタノールの選択率、さらには、C2酸素化物の空時収量、例えばエタノールの空時収量が低くなったり、還元処理におけるエネルギーが過剰になり経済的な不利益が生じたりするおそれがある。
本発明のC2酸素化物の製造装置(以下、単に製造装置ということがある)は、本発明の触媒が充填された反応管と、混合ガスを反応管内に供給する供給手段と、反応管から生成物を排出する排出手段とを備えるものである。
反応管1としては、例えば、ステンレス製の略円筒形の部材が挙げられる。
供給管3は、混合ガスを反応管1内に供給する供給手段であり、例えば、ステンレス製等の配管が挙げられる。
排出管4は、反応床2で合成されたC2酸素化物を含む合成ガス(生成物)を排出する排出手段であり、例えば、ステンレス製等の配管が挙げられる。
温度制御部5は、反応管1内の反応床2を任意の温度にできるものであればよく、例えば、電気炉等が挙げられる。
圧力制御部6は、反応管1内の圧力を任意の圧力にできるものであればよく、例えば、公知の圧力弁等が挙げられる。
また、製造装置10は、マスフロー等、ガスの流量を調整するガス流量制御部等の周知の機器を備えていてもよい。
本発明のC2酸素化物の製造方法は、混合ガスを触媒に接触させるものである。本発明のC2酸素化物の製造方法の一例について、図1の製造装置を用いて説明する。
まず、反応管1内を任意の温度及び任意の圧力とし、混合ガス20を供給管3から反応管1内に流入させる。
混合ガス20として、バイオマスガスを用いる場合、混合ガス20を反応管1内に供給する前に、タール分、硫黄分、窒素分、塩素分、水分等の不純物を除去する目的で、混合ガス20にガス精製処理を施してもよい。ガス精製処理としては、例えば、湿式法、乾式法等、当該技術分野で知られる各方式を採用できる。湿式法としては、水酸化ナトリウム法、アンモニア吸収法、石灰・石膏法、水酸化マグネシウム法等が挙げられ、乾式法としては、圧力スイング吸着(PSA)法等の活性炭吸着法、電子ビーム法等が挙げられる。
混合ガス20における水素/一酸化炭素で表される体積比(以下、H2/CO比ということがある)は、1/5~5/1が好ましく、1/2~3/1がより好ましく、1/1~2.5/1がさらに好ましい。上記範囲内であれば、CO転化率、C2酸素化物、好ましくはエタノールの選択率、さらには、C2酸素化物、好ましくはエタノールの空時収量をより高められる。
なお、混合ガス20は、水素及び一酸化炭素の他に、メタン、エタン、エチレン、窒素、二酸化炭素、水等を含んでいてもよい。
混合ガス20は、反応床2を流通する間、例えば、下記(1)~(5)式で表される触媒反応によりC2酸素化物を生成する。本発明においては、主に、(5)式で表される触媒反応が進行すると共に、(1)~(2)式の触媒反応により生成された酢酸又はアセトアルデヒドが(3)~(4)式で表される触媒反応によりエタノールとなる。
2H2+2CO→CH3COOH・・・(1)
3H2+2CO→CH3CHO+H2O ・・・(2)
2H2+CH3COOH→CH3CH2OH+H2O ・・・(3)
H2+CH3CHO→CH3CH2OH ・・・(4)
4H2+2CO→CH3CH2OH+H2O ・・・(5)
合成ガス22において、C2酸素化物の選択率は60モル%以上が好ましく、80モル%以上がより好ましい。C2酸素化物の選択率が上記下限値以上であれば、C2酸素化物の生成量をより高められる。
合成ガス22中の酸素化物におけるC2酸素化物の含有量は、特に限定されないが、60モル%以上が好ましく、80モル%以上がより好ましい。上記下限値以上であれば、C2酸素化物の生成量をより高められる。
合成ガス22中のC2酸素化物におけるエタノール含有量は、特に限定されないが、55モル%以上が好ましく、70モル%以上がより好ましい。上記下限値以上であれば、エタノール以外の生成物を除去したり、エタノール以外の生成物をエタノールに変換したりする工程の簡略化が図れる。
また、本発明に係るC2酸素化物の製造方法においては、前記C2酸素化物中のエタノールの選択率が96モル%~35モル%であることが好ましい。エタノールの選択率が、下限値以上であることにより、分離精製が容易になるという利点がある。
また、本発明では、エタノール以外の生成物を水素化してエタノールに変換する工程(エタノール化工程)を設けてもよい。エタノール化工程としては、例えば、アセトアルデヒド、酢酸等を含むC2酸素化物を水素化触媒に接触させてエタノールに変換する方法が挙げられる。
ここで、水素化触媒としては、当該技術分野で知られる触媒が使用でき、銅、銅-亜鉛、銅-クロム、銅-亜鉛-クロム、鉄、ロジウム-鉄、ロジウム-モリブデン、パラジウム、パラジウム-鉄、パラジウム-モリブデン、イリジウム-鉄、ロジウム-イリジウム-鉄、イリジウム-モリブデン、レニウム-亜鉛、白金、ニッケル、コバルト、ルテニウム、酸化ロジウム、酸化パラジウム、酸化白金、酸化ルテニウム等が挙げられる。これらの水素化触媒は、本発明の触媒に用いられる担体と同様の多孔質担体に担持させた担持触媒であってもよく、担持触媒としては、銅、銅-亜鉛、銅-クロム又は銅-亜鉛-クロムをシリカ系担体に担持させた銅系触媒が好適である。担持触媒である水素化触媒の製造方法としては、本発明の触媒と同様に同時法又は逐次法が挙げられる。
平均細孔直径が20nm超では、混合ガスが細孔内に浸入し又は細孔内から浸出する速度が速くなりすぎる。混合ガスが細孔内に浸入し又は細孔内から浸出する頻度は高まるものの、細孔内に浸入した混合ガスと触媒金属との接触時間は、混合ガスがC2酸素化物に転換されるには不十分なものとなる。このため、平均細孔直径が20nm超では、C2酸素化物の選択率が小さくなり、C2酸素化物の空時収量を高められない。
従って、多孔質担体の平均細孔径が2~20nmであれば、混合ガスが細孔内に滞留する時間をC2酸素化物の空時収量を高めるのに適した時間にできると考えられる。
チタンラクテートアンモニウム塩(Ti(OH)2[OCH(CH3)COO-]2(NH4 +)2)0.049gを含む水溶液(一次含浸液)0.58mLを、多孔質担体(材質:シリカ、粒子径:1.18~2.36mm、平均細孔直径:1.9nm、全細孔容積:0.29mL/g、比表面積:620m2/g)2.0gに滴下して含浸させた(一次含浸工程)。これを110℃にて3時間乾燥し(一次乾燥操作)、さらに400℃にて4.5時間焼成して一次担持体とした(一次焼成操作,以上、一次担持工程)。塩化ロジウム三水和物(RhCl3・3H2O)0.154gと、塩化マンガン二水和物(MnCl2・2H2O)0.087gと、塩化リチウム一水和物(LiCl・H2O)0.01gとを含む水溶液(二次含浸液)0.6mLを一次担持体に滴下して含浸させ(二次含浸工程)、110℃にて3時間乾燥し(二次乾燥操作)、さらに400℃にて4.5時間焼成して触媒を得た(二次焼成操作,以上、二次担持工程)。一次含浸液と二次含浸液との合計において、水素化活性金属のモル比は、ロジウム:マンガン=1:0.75、ロジウム:リチウム=1:0.275、マンガン:リチウム=1:0.667である。
一次含浸工程及び一次担持工程を行わなかった以外は、実施例1-1と同様にして触媒を得た。二次含浸液において、水素化活性金属のモル比は、ロジウム:マンガン=1:0.75、ロジウム:リチウム=1:0.275、マンガン:リチウム=1:0.667である。
一次含浸工程において、チタンラクテートアンモニウム塩0.049gを含む水溶液(一次含浸液)1.22mLを多孔質担体(材質:シリカ、粒子径:1.18~2.36mm、平均細孔直径:5.7nm、全細孔容積:0.61mL/g、比表面積:430m2/g)2.0gに滴下し、含浸させた以外は、実施例1-1と同様にして触媒を得た。一次含浸液と二次含浸液との合計において、水素化活性金属のモル比は、ロジウム:マンガン=1:0.75、ロジウム:リチウム=1:0.275、マンガン:リチウム=1:0.667である。
一次含浸工程及び一次担持工程を行わなかった以外は、実施例1-3と同様にして触媒を得た。二次含浸液において、水素化活性金属のモル比は、ロジウム:マンガン=1:0.75、ロジウム:リチウム=1:0.275、マンガン:リチウム=1:0.667である。
チタンラクテートアンモニウム塩0.123gを含む水溶液(一次含浸液)2.16mLを、多孔質担体(材質:シリカ、粒子径:0.7~2.0mm、平均細孔直径:13.7nm、全細孔容積:1.08mL/g、比表面積:315m2/g)2.0gに滴下して含浸させた(一次含浸工程)。これを110℃にて3時間乾燥し(一次乾燥操作)、さらに400℃にて4.5時間焼成して一次担持体とした(一次焼成操作,以上、一次担持工程)。塩化ロジウム三水和物0.154gと、塩化マンガン二水和物0.032gと、塩化リチウム一水和物0.005gとを含む水溶液(二次含浸液)2.16mLを一次担持体に滴下して含浸させ(二次含浸工程)、110℃にて3時間乾燥し(二次乾燥操作)、さらに400℃にて4.5時間焼成して触媒を得た(二次焼成操作,以上、二次担持工程)。一次含浸液と二次含浸液との合計において、水素化活性金属のモル比は、ロジウム:マンガン=1:0.275、ロジウム:リチウム=1:0.138、マンガン:リチウム=1:0.5である。
一次含浸工程及び一次担持工程を行わなかった以外は、実施例1-5と同様にして触媒を得た。二次含浸液において、水素化活性金属のモル比は、ロジウム:マンガン=1:0.75、ロジウム:リチウム=1:0.275、マンガン:リチウム=1:0.667である。
チタンラクテートアンモニウム塩0.123gを含む水溶液(一次含浸液)0.58mLを、多孔質担体(材質:シリカ、粒子径:1.18~2.36mm、平均細孔直径:1.9nm、全細孔容積:0.29mL/g、比表面積:620m2/g)2.0gに滴下して含浸させた一次含浸工程、及び塩化ロジウム三水和物0.154gと塩化マンガン二水和物0.032gと塩化リチウム一水和物0.005gとを含む水溶液(二次含浸液)2.16mLを一次担持体に滴下して含浸させた二次含浸工程以外は、実施例1-1と同様にして触媒を得た。二次含浸液において、水素化活性金属のモル比は、ロジウム:マンガン=1:0.75、ロジウム:リチウム=1:0.275、マンガン:リチウム=1:0.667である。
一次含浸工程において、チタンラクテートアンモニウム塩0.123gを含む水溶液(一次含浸液)1.96mLを多孔質担体(材質:シリカ、粒子径:1.18~2.36mm、平均細孔直径:31.1nm、全細孔容積:0.98mL/g、比表面積:107m2/g)2.0gに滴下し、含浸させた以外は、実施例1-1と同様にして触媒を得た。
一次含浸液と二次含浸液との合計において、水素化活性金属のモル比は、ロジウム:マンガン=1:0.75、ロジウム:リチウム=1:0.275、マンガン:リチウム=1:0.667である。
実施例1-1~1-7、比較例1-1の触媒0.5gを直径0.5インチ(1.27cm)、長さ10インチ(25.4cm)のステンレス製の円筒型の反応管に充填して反応床を形成した。反応床に、常圧で水素-窒素ガス(H2/N2=1/2)を30mL/分で流通させながら、320℃で2.5時間加熱し、触媒に還元処理を施した。
次いで、反応床を250℃とした後、反応床を表1中の反応温度とし、混合ガス(H2/CO比=2/1)を空間速度8400L/L-触媒/h、又は12000L/L-触媒/h、2MPaで反応床に流通させて、C2酸素化物を含む合成ガスの製造を行った。
混合ガスを反応床に3時間流通させ、得られた合成ガスを回収し、ガスクロマトグラフィーにより分析した。
得られたデータからCO転化率(モル%)、C2酸素化物の選択率(モル%)、各生成物の選択率(モル%)、C2酸素化物の空時収量(g/L-触媒/h)を算出し、これらの結果を表1に示す。C2酸素化物の空時収量は、得られたC2酸素化物の全てを、従来公知の水素還元処理(例えば、接触水素還元等)に付し、エタノールに変換したと仮定した場合の値である。また、表中、C2酸素化物中のエタノールの比率は、生成物におけるエタノール、アセトアルデヒド及び酢酸の合計量(即ち、C2酸素化物の総量)中のエタノールの含有量として算出した。
エタノールの選択率が、12.3モル%以上であり、C2酸素化物中のエタノールの比率が、22.6モル%以上であった。
なかでも、平均細孔直径が8nm未満の実施例1-1~1-4、及び1-7においては、エタノールの選択率が23.0モル%以上であり、C2酸素化物中のエタノールの比率が39.1モル%以上であった。加えて、実施例1-1と実施例1-2との比較、実施例1-3と実施例1-4との比較において、助活性金属を担持させた実施例1-1、1-3は、それぞれ実施例1-2、1-4に比べてエタノール選択率及びC2酸素化物中のエタノールの比率が高まっていた。
また、平均細孔直径が8nm超の多孔質担体を用いた実施例1-5、1-6では、実施例1-1~1-4に比べて、エタノール選択率及びC2酸素化物中のエタノールの比率は劣るものの、C2酸素化物の選択率はいずれも50モル%以上であり、かつ、C2酸素化物の空時収量も200(g/L-触媒/h)以上であった。
一方、比較例1-1においては、エタノールの選択率が15.8モル%以下であり、C2酸素化物中のエタノールの比率が29.9モル%以下であり、また、C2酸素化物の空時収量は122.5(g/L-触媒/h)であった。
これらの結果から、本発明を適用することで、混合ガスからエタノールを効率的に合成できることが判った。
実施例1-1で得られた触媒を用い、表2中の反応温度とした以外は、実施例1-1と同様にしてC2酸素化物を含む合成ガスの製造を行い、各生成物の選択率(モル%)を算出した。得られた結果を表2、図2に示す。表2及び図2中、C2酸素化物中のエタノールの比率は、生成物におけるエタノール、アセトアルデヒド及び酢酸の合計量(即ち、C2酸素化物の総量)中のエタノールの含有量として算出した。
表2、図2に示すように、本実施例は、反応温度272~305℃の間でC2酸素化物中のエタノールの比率を90モル%以上にできた。
2 反応床
3 供給管
4 排出管
5 温度制御部
6 圧力制御部
10製造装置
20混合ガス
22合成ガス
Claims (6)
- 多孔質担体に水素化活性金属が担持され、水素と一酸化炭素とを含む混合ガスからC2酸素化物を合成するC2酸素化物合成用の触媒において、
前記多孔質担体は、平均細孔直径が0.1~20nmである、C2酸素化物合成用の触媒。 - 前記平均細孔直径が、0.1~8nmである、請求項1に記載のC2酸素化物合成用の触媒。
- 前記平均細孔直径が、2~20nmである、請求項1に記載のC2酸素化物合成用の触媒。
- 前記水素化活性金属は、アルカリ金属、周期表の第7~10族に属する元素からなる群から選択される1種以上であることを特徴とする請求項1~3のいずれか1項に記載のC2酸素化物合成用の触媒。
- 請求項1~4のいずれか1項に記載のC2酸素化物合成用の触媒が充填された反応管と、前記混合ガスを前記反応管内に供給する供給手段と、前記反応管から生成物を排出する排出手段とを備えることを特徴とするC2酸素化物の製造装置。
- 請求項1~4のいずれか1項に記載のC2酸素化物合成用の触媒に、水素と一酸化炭素とを含む混合ガスを接触させてC2酸素化物を得ることを特徴とするC2酸素化物の製造方法。
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CA2847233A1 (en) | 2013-09-06 |
US20140194541A1 (en) | 2014-07-10 |
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EP2821136A1 (en) | 2015-01-07 |
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