OXIDATIVE DEHYDROGENATION OF ALKANES TO ALKENES USING SULFUR AS AN OXIDANT
20210188741 · 2021-06-24
Inventors
- Tobin Jay Marks (Evanston, IL, US)
- Tracy L. Lohr (Houston, TX, US)
- Shanfu Liu (Chicago, IL, US)
- Allison Marie Arinaga (Bethesda, MD, US)
Cpc classification
Y02P20/52
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
C07C5/46
CHEMISTRY; METALLURGY
B01J27/049
PERFORMING OPERATIONS; TRANSPORTING
B01J21/10
PERFORMING OPERATIONS; TRANSPORTING
C07C5/46
CHEMISTRY; METALLURGY
B01J27/047
PERFORMING OPERATIONS; TRANSPORTING
B01J23/02
PERFORMING OPERATIONS; TRANSPORTING
International classification
C07C5/46
CHEMISTRY; METALLURGY
Abstract
The present disclosure provides a method for the oxidative dehydrogenation of an alkane, e.g., ethane, propane, etc. In embodiments, a method for oxidative dehydrogenation of an alkane comprises exposing a gas comprising an alkane having 2 or more carbons to elemental sulfur vapor at an elevated reaction temperature and for a period of time to convert the alkane to one or more products via oxidative dehydrogenation, the one or more products comprising a primary alkene.
Claims
1. A method for oxidative dehydrogenation of an alkane, the method comprising exposing a gas comprising an alkane having 2 or more carbons to elemental sulfur vapor at an elevated reaction temperature and for a period of time to convert the alkane to one or more products via oxidative dehydrogenation, the one or more products comprising a primary alkene.
2. The method of claim 1, wherein the exposure and conversion occur in the absence of a catalyst.
3. The method of claim 2, wherein the exposure and conversion occur in the absence of O.sub.2 and in the absence of an oxygen-containing compound in the gas.
4. The method of claim 1, wherein the exposure and conversion occur in the presence of a catalyst.
5. The method of claim 4, wherein the catalyst is formed by exposing a precatalyst to S.sub.2 and H.sub.2S at an elevated temperature and for an activation time.
6. The method of claim 5, further comprising forming the catalyst from the precatalyst, in situ, prior to exposure to the gas comprising the alkane.
7. The method of claim 5, wherein the elevated temperature in is the range of from 600° C. to 1000° C. and the activation time is in the range of from 1 to 10 hours.
8. The method of claim 4, wherein the exposure and conversion occur in the absence of O.sub.2 and in the absence of an oxygen-containing compound in the gas.
9. The method of claim 5, wherein the precatalyst is a supported transition metal oxide.
10. The method of claim 9, wherein the supported transition metal oxide is vanadium oxide on a metal oxide support.
11. The method of claim 10, wherein the metal oxide support is alumina.
12. The method of claim 5, wherein the catalyst is selected from compounds of formula M.sub.xO.sub.yS.sub.z wherein M is an alkali metal, an alkaline earth metal, or a transition metal, and wherein x>0, y≥0, and z≥0.
13. The method of claim 12, wherein M is vanadium and the catalyst is supported on a metal oxide support.
14. The method of claim 13, wherein the metal oxide support is alumina.
15. The method of claim 1, wherein the alkane is ethane.
16. The method of claim 1, wherein the alkane is propane.
17. The method of claim 16, wherein the exposure and conversion occur in the presence of a catalyst formed by exposing a precatalyst to S.sub.2 and H.sub.2S at an elevated temperature and for an activation time, and wherein the precatalyst is vanadium oxide on an alumina support.
18. The method of claim 1, wherein the alkane is ethane and the method is characterized by a conversion of ethane of at least 99% at 940° C., a selectivity of ethylene of at least 70% at 940° C., or both.
19. The method of claim 1, wherein the alkane is propane and the method is characterized by a selectivity of propylene of at least 80% at 550° C.
20. The method of claim 1, wherein the method is characterized by a conversion of the alkane, a selectivity of primary alkene, or both, that is constant after at least 60 hours at 940° C.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Illustrative embodiments of the present disclosure will hereafter be described with reference to the accompanying drawings.
[0008]
[0009]
[0010]
[0011]
[0012]
[0013]
[0014]
[0015]
DETAILED DESCRIPTION
[0016] In embodiments, a method for the oxidative dehydrogenation of an alkane comprises exposing a gas comprising an alkane to elemental sulfur vapor at an elevated reaction temperature to convert the alkane to one or more products via oxidative dehydrogenation. The gas comprising the alkane may also comprise one or more inert gases (e.g., helium, argon, etc.). By “elemental sulfur vapor” is meant a gas comprising S.sub.2, although the elemental sulfur vapor may comprise other sulfur allotropes. However, at least in embodiments, no other sulfur-containing compound is significantly present in the elemental sulfur vapor. Elemental sulfur vapor may be generated by heating solid sulfur (S.sub.8) as described in the Examples, below. By “elevated reaction temperature” it is meant greater than room temperature (20-25° C.). The specific temperature may be selected to provide a desired (e.g., maximum) conversion of the alkane and/or a desired (e.g., maximum) yield/selectivity of a particular product. Illustrative elevated reaction temperatures include at least 200° C., at least 400° C., at least 500° C., in the range of from 200° C. to 2500° C., from 400° C. to 2000° C., from 500° C. to 1500° C., or from 600° C. to 900° C.
[0017] The method may be used with a variety of alkanes to provide a primary alkene (among other possible products). By “primary alkene” it is meant the alkene corresponding to the same number of carbons as the reactant alkane. Another possible product is a primary alkyne (primary has an analogous meaning). Products having fewer numbers of carbons than the reactant alkane may be produced. In embodiments, the alkane has 2, 3, 4, 5, 6, 10, 14, or 18 carbons. In embodiments, the alkane is ethane. In embodiments, the alkane is propane. In embodiments, the alkane is not methane and the method does not involve use of methane.
[0018] Other conditions under which the alkane is exposed to sulfur include the weight hourly space velocity (WHSV) of the alkane, the ratio of sulfur:alkane and the pressure. Again, the specific values may be selected to provide a desired (e.g., maximum) conversion of the alkane and/or a desired (e.g., maximum) yield/selectivity of a particular product. Using ethane by way of example, the WHSV of the ethane may be in the range of from 0.00523 to 10.46 h.sup.−1, from 0.0523 h.sup.−1 to 2.616 h.sup.−1, or from 0.105 h.sup.−1 to 0.785 h.sup.−1. The sulfur:ethane ratio may be in the range of from 0 to 100, from 0.1 to 20, or from 0.1 to 5. The pressure may be in the range of from 0.01 psi to 200 psi, from 1 psi to 40 psi, from 2 psi to 5 psi, or from 2 psi to 4 psi. These ranges may also be used for other alkanes. Specific, illustrative values for propane as the alkane are provided in the Examples, below.
[0019] The exposure of the alkane to sulfur may take place entirely in the gas phase and in the absence of any catalyst. However, in embodiments, the exposure may take place in the presence of a catalyst. The catalyst may be one which is formed in situ, by exposing a precatalyst to a gas comprising S.sub.2 and H.sub.2S at an elevated temperature and for an activation time. The S.sub.2/H.sub.2S containing gas may also comprise other sulfur allotropes. However, at least in embodiments, no other sulfur-containing compound is present in the S.sub.2/H.sub.2S containing gas.
[0020] A variety of precatalysts may be used. Non-limiting, illustrative precatalysts include sulfides, oxides, oxysulfides of an alkali metal, e.g., Li.sub.2O; alkaline earth metal oxides, e.g., MgO; redox active transition metal oxides, e.g., Cr.sub.2O.sub.3, Fe.sub.3O.sub.4, Co.sub.2O.sub.3; and late transition metal oxides, e.g., ZnO. The metallic state of an alkali metal, an alkaline earth metal, and a transition metal may also be used. Noble metals (e.g., Pt, Pd, Ag, etc.) and their oxides, oxysulfides, and sulfides may be used. Combinations of different types of precatalysts may be used. The precatalysts may be in nanoparticle form, and optionally located on a high surface area support.
[0021] As noted above, the precatalyst may be a supported transition metal oxide. In embodiments, the transition metal oxide is vanadium oxide (VOx). In embodiments, the high surface area support is a metal oxide support. The metal oxide of such a support may have formula M.sub.xO.sub.y, where M is be a metal or metalloid from Groups 1-5 or 12-14 of the Periodic Table (e.g., MgO, La.sub.2O.sub.3, TiO.sub.2, Nb.sub.2O.sub.5, ZnO, Al.sub.2O.sub.3, or SiO.sub.2), and having a surface area between 50 and 1000 m.sup.2/g. In embodiments, the metal oxide is alumina (Al.sub.2O.sub.3). The amount of the transition metal oxide (e.g., vanadium oxide) on the support (e.g., alumina) may be selected to control the nature of active sites on the surface of the support. The VOx sites may consist of isolated, polymerized, or vanadium oxide sites. Illustrative amounts include those in a range of from 0.1 weight % to 10 weight %, from 0.5 weight % to 10 weight %, and from 0.1 weight % to 5 weight %.
[0022] The elevated temperature to generate the catalyst from the precatalyst may be those described above. The activation time may be in the range of from 10 minutes to 20 hours, from 1 hr to 10 hrs, or from 2 hrs to 6 hrs. The exposure of the precatalyst may involve heating to the elevated reaction temperature (the temperature at which the alkane is exposed to the elemental sulfur vapor) over the activation time.
[0023] Exposure of certain precatalysts to the gas comprising S.sub.2 and H.sub.2S at the elevated temperature and for the activation time provides catalysts comprising compounds of formula M.sub.xO.sub.yS.sub.z, wherein M is an alkali metal, an alkaline earth metal, or a transition metal and x>0, y≥0, and z≥0. In embodiments, M is a transition metal (e.g., V). As noted above, if the precatalyst is a supported precatalyst, the catalyst also comprises the high surface area support (e.g., alumina).
[0024] The alkane-containing gas and the elemental sulfur vapor may be considered to form a gaseous reactant mixture. If a precatalyst/catalyst is used, the gaseous reactant mixture may further comprise the S.sub.2/H.sub.2S from the activation of the precatalyst. However, at least in embodiments, the gases used to form the gaseous reactant mixture as well as the gaseous reactant mixture itself are free of O.sub.2 and any oxygen-containing compound (however, this does not preclude the use of an oxygen-containing solid catalyst, e.g., an oxide catalyst). Similarly, at least in embodiments, the gases used to form the gaseous reactant mixture as well as the gaseous reactant mixture itself are free of any other sulfur-containing compound (i.e., only S.sub.2 and optionally, a sulfur allotrope or H.sub.2S are present). By “free” it is meant that the amount is zero or sufficiently close to zero so as not to have a material effect on the oxidative dehydrogenation reaction.
[0025] The method may be carried out using a variety of reactor systems. A suitable reactor system is the plug-flow reactor system shown in
[0026] As further described in the Examples below, in at least in some embodiments, the method is able to achieve high values of alkane conversion. In embodiments, the alkane conversion is at least 80%, at least 85%, at least 90%, at least 95%, at least 99%, or about 100%. Alkane conversion is defined in the Examples, below. Similarly, at least in some embodiments, the method is able to achieve high selectivities, e.g., of a particular oxidative dehydrogenation product. By way of illustration, in embodiments, the method achieves a selectivity of a primary alkene or a primary alkyne of at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, or at least 90%. Product selectivity may be defined as provided in the Examples, below. In embodiments, the conversions and selectivities in this paragraph refer to the conversion of ethane (e.g., to ethylene) or the conversion of propane (e.g., to propylene and to ethylene).
[0027] The conversion/selectivities described above may refer to a particular set of conditions, a reaction temperature at any value or range of values disclosed herein, alkane WHSV at any value or range of values disclosed herein, sulfur:alkane ratio at any value or range of values disclosed herein, presence/absence of a catalyst, and a pressure at any value or range of values disclosed herein. The conversion/selectivities may refer to a specific combination of these parameters as used in the Examples, below.
[0028] At least in some embodiments, the dehydrogenation process exhibits high stability, i.e., the conversion and/or selectivity values are constant over a period of time. By “constant,” it is meant that the values do not change by more than ±10%. The period of time may be at least 100 hours.
EXAMPLES
Example 1
[0029] This Example demonstrates the oxidative dehydrogenation of ethane using sulfur (SODHE) in which ethane is selectively oxidized to ethylene by elemental sulfur at elevated temperature. SODHE uses ethane and sulfur vapor with an inert carrier gas as the feed, and produces ethylene, along with H.sub.2S, acetylene, CS.sub.2 and trace amounts of propane and propylene. The reaction is operated at 940° C. Fe.sub.3O.sub.4, Cr.sub.2O.sub.3, and MgO have been tested as precatalysts for this reaction. The active catalysts are generated in situ during a sulfurization process. Under reaction conditions, the conversion of ethane is 99%, and the selectivity and yield of ethylene is approximately 70%. The catalysts have been tested for stability and the performance does not change for 60 hours on stream. Optionally, similar ethylene yields, ethane conversion and ethylene selectivities are observed using the quartz reactor.
[0030] Materials and Methods
[0031] The Fe.sub.3O.sub.4 and Cr.sub.2O.sub.3 nanopowders were purchased from Alfa Aesar with a purity of ≥97%. The MgO nanopowder was purchased from Sigma Aldrich with a purity of ≥97%. Reactor measurements were carried out in a custom packed bed reactor. The experimental set-up is shown in
Results and Discussion
[0032] During preliminary experiments, the optimal operating temperature was determined for Fe.sub.3O.sub.4 MgO and Cr.sub.2O.sub.3 catalysts as well as the quartz control. These experiments were carried out at WHSV (weight hourly space velocity) of 0.628 h.sup.−1 and C.sub.2H.sub.6: S.sub.2 ratio=3.07. The conversion, selectivity, yield and mass balance are shown in
[0033] The conversion, selectivity, and yield are calculated based on the conservation of mass of carbon where C.sub.xH.sub.yS.sub.z is ethylene, acetylene or carbon disulfide:
[0034] As seen from the
Example 2
[0035] Experiments similar to those described above for Example 1 were conducted using propane as the reactant. The feed gas was propane and sulfur vapor, with a sulfur:propane ratio of 0.326 and a propane WHSV of 0.921 h.sup.−1. The precatalyst was Fe.sub.3O.sub.4 nanopowder (purchased from Alfa Aesar with a purity of ≥97%). The reaction temperature ranged from 650° C. to 950° C., although lower temperatures may be used, e.g., 400° C. The products of this reaction included methane, ethane, ethylene, acetylene and propylene. The results are shown in
[0036] As can be seen from
Example 3
[0037] Additional experiments similar to those described above for Example 2 were conducted, again, using propane as the reactant. The feed gas was propane and sulfur vapor, with a sulfur:propane ratio of 0.326 and a propane WHSV of 0.628 h.sup.−1. Various precatalysts (Cr.sub.2O.sub.3, w/S; MgO, w/S; ZrO.sub.2, w/S) were used, including blank controls (No frits, no S; Quartz sand, w/S; Quartz sand, No S; SiC, w/S.). The term “w/S” means with S.sub.2 which means that the precatalyst is exposed to S.sub.2/H.sub.2S and the reaction mixture is exposed to S.sub.2. The term “no S” means without S.sub.2 which means that the precatalyst is exposed to S.sub.2/H.sub.2S, but the reaction mixture is not exposed to S.sub.2. The conversion and selectivity results are shown in
[0038] The product distribution as a function of precatalysts and temperature are shown in
Example 4
[0039] Additional experiments similar to those described above for Example 3 were conducted, but using a sulfided V/Al.sub.2O.sub.3 catalyst. The sulfided V/Al.sub.2O.sub.3 catalyst was prepared from a precatalyst, vanadium oxide supported on alumina. The VOx supported on alumina precatalyst was prepared by incipient wetness impregnation. Aqueous NH.sub.4VO.sub.3 (>99%, Aldrich) was used as the vanadium oxide precursor. The solution was mixed with the alumina support, and the resulting mixture was dried overnight at 120° C. Then, the samples were calcined in air at 550° C. for 6 h. Prior to the SODHP reaction, the precatalyst, VOx/Al.sub.2O.sub.3, was heated to 600° C. and held for 4-6 h under a gas stream containing 0.28 wt % S.sub.2 and 0.33 wt % H.sub.2S.
[0040] The sulfided catalyst (1V/Al.sub.2O.sub.3, wherein “1” refers to 1.0 weight %) was then exposed to S.sub.2 and C.sub.3H.sub.8 to perform the catalytic SODHP reaction. The sulfur:propane ratio was 0.270, the propane WHSV was 31.7 min.sup.−1, and various temperatures were used, including 490° C. and 550° C. as shown in
[0041] In this Example, the precatalyst consists of VOx/Al.sub.2O.sub.3. Specifically, the support consists of the theta-alumina phase, as characterized by powder X-ray diffraction. For low weight loadings of vanadium (here 1.0 weight %), isolated VOx sites form on the surface of the alumina support. Higher weight loadings of vanadium may lead to polymerized VOx or crystalline V.sub.2O.sub.5 supported on alumina. After the sulfidation treatment, the alumina support likely retains its original oxide structure, as no aluminium sulfide is detected after treatment. The VOx sites may be sulfided to vanadium sulfide or oxysulfide sites. Currently, powder X-ray diffraction and X-ray photoelectron spectroscopy characterization suggest the formation of a vanadium sulfide supported on theta-alumina.
[0042] Propylene selectivity as a function of propane conversion is shown in
[0043] The word “illustrative” is used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “illustrative” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Further, for the purposes of this disclosure and unless otherwise specified, “a” or “an” means “one or more.”
[0044] The foregoing description of illustrative embodiments of the disclosure has been presented for purposes of illustration and of description. It is not intended to be exhaustive or to limit the disclosure to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principles of the invention and as practical applications of the disclosure to enable one skilled in the art to utilize the disclosure in various embodiments and with various modifications as suited to the particular use contemplated. It is intended that the scope of the disclosure be defined by the claims appended hereto and their equivalents.