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Catalyst formulation for methanol conversion catalysts

A technology of catalysts and catalyst particles, applied in the direction of catalyst activation/preparation, carbon compound catalysts, catalysts, etc., which can solve the problems of reducing the production capacity of conversion reactors and increasing operating costs

Pending Publication Date: 2021-10-26
EXXONMOBIL RESEARCHK & ENG CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

While catalyst regeneration can be at least partially effective in restoring catalyst activity, the need for frequent regeneration can increase operating costs and / or reduce throughput in the conversion reactor

Method used

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  • Catalyst formulation for methanol conversion catalysts
  • Catalyst formulation for methanol conversion catalysts
  • Catalyst formulation for methanol conversion catalysts

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0041] Example 1 - Addition of weak base during catalyst formulation: ZSM-48

[0042] In Example 1, various catalysts were tested in an isothermal fixed bed reactor where no recirculation was performed, but recirculation is possible and may be desirable as it can further extend the catalyst cycle time. This reactor configuration is illustrative and should not be considered limiting. In this example, pure methanol was used as the model feed, but co-feeds such as water, oxygenates, olefins, paraffins and aromatics are feasible and may even be desirable. For catalysts based on ZSM-48, test conditions included zeolite-based 2h -1 Weight Hourly Space Velocity (WHSV). In other words, the weight of the methanol feed is selected based on the weight of the zeolite in the catalyst rather than the total weight of the catalyst. Other conditions included a temperature of 450°C and a pressure of about 100 kPa-g. For catalysts based on ZSM-5, the conditions tested were WHSV (based on z...

Embodiment 2

[0049] Example 2 - Addition of weak base during catalyst formulation: ZSM-5

[0050] Additional characterization of the effect of adding a weak base (TEAOH) during catalyst formulation was done by using a binder comprising 65% by weight ZSM-5 and 35% by weight Catapal-200 alumina (specific surface area less than 100 m 2 / g) catalyst. The test conditions (as described above in Example 1) are believed to be representative of suitable conditions for the conversion of methanol to gasoline. Catalyst contact life was determined based on the time required for the concentration of unconverted methanol in the aqueous phase to reach 1%. Under the first test conditions, the catalyst formulated without the addition of TEAOH had a contact life of 4.8 days. Under the second test conditions, a catalyst formulated by adding 3.0 wt% of a weak base to alumina yielded a contact life of 5.1 days. Under the third test condition, the catalyst formulated by adding 3.0 wt% TEAOH to the combined ...

Embodiment approach 1

[0056] Embodiment 1. A process for converting an oxygenate feed using an oxygenate conversion catalyst comprising: an average reaction temperature of 230°C to 550°C, total pressure and 0.1hr -1 to 10.0hr -1 At a WHSV of , an oxygenate-containing feed is contacted with an oxygenate conversion catalyst comprising a zeolite and 1% by weight to 90% by weight of a binder to form a converted effluent with 250m 2 / g or less specific surface area, wherein the oxygenate conversion catalyst comprises a catalyst formulated during formulation using 1.5% to 5.0% by weight of a weak base in a mixture of zeolite and binder.

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Abstract

Methods are provided for formulation of catalysts with improved catalyst exposure lifetimes under oxygenate conversion conditions. In various additional aspects, methods are described for performing oxygenate conversion reactions using such catalysts with improved catalyst exposure lifetimes. The catalyst formulation methods can include formulation of oxygenate conversion catalysts with binders that are selected from binders having a surface area of roughly 250 m<2> / g or less, or 200 m<2> / g or less. In various aspects, during formulation, a weak base can be added to the zeotype crystals, to the binder material, or to the mixture of the zeotype and the binder. It has been unexpectedly discovered that addition of a weak base, so that the weak base is present in at least one component of the binder mixture prior to formulation, can result in longer catalyst exposure lifetimes under methanol conversion conditions.

Description

technical field [0001] The present invention relates to the growth and formulation of methanol conversion catalysts with improved catalyst life. Background technique [0002] Various industry processes are known for converting low boiling carbonaceous compounds into higher value products. For example, methanol-to-gasoline (MTG) is a commercial process for producing gasoline from methanol using a ZSM-5 catalyst. In the MTG process, methanol is first dehydrated to dimethyl ether. Methanol and / or dimethyl ether then react in a series of reactions leading to the formation of aromatics, paraffins and olefins. The resulting product consists of liquefied petroleum gas (LPG) and high-quality gasoline consisting of aromatics, paraffins and olefins. Typical MTG hydrocarbon products consist of 40% to 50% aromatics plus olefins and 50% to 60% paraffins. [0003] One difficulty with conventional methods of converting methanol to gasoline is that catalysts may have relatively short us...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): C10G3/00
CPCC10G3/49Y02P30/20Y02P30/40B01J21/04B01J29/703B01J37/0072C07C1/20C07C2529/70B01J2229/38B01J37/06
Inventor 布兰登·J·奥尼尔斯科特·J·韦格尔
Owner EXXONMOBIL RESEARCHK & ENG CO
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