IMPROVED CATALYSTS

Abstract: An improved catalyst for conversion of oxygen-­ containing aliphatics to hydrocarbons in a silica xerogel having a layer of an aluminium compound chemically bonded onto its surface, having a maximum pore diameter of 1.1 nm and having substantially only protons and/or transition metal cations as electrical charge balancing spe­ cies. The catalyst is very specific for the production of aromatics, if the reaction and calcination temperatures fall into given ranges. Certain catalysts show high selectivity for the production of toluene.

Description: "IMPROVED CATALYSTS" This invention concerns improved catalysts, more particularly it concerns improved catalysts of a synthetic zeolite type. Synthetic zeolite catalysts, such as those produced by Mobil under the designation ZSM-5, are known to convert methonol, synthesis gas and many oxygen-containing organic compounds into saturated and unsaturated lower hydrocarbons, offering the possibility of gasoline production. In our co-pending British Application No. 82/11371, Publication No. 2,100,710A, we have described a novel synthetic zeolite catalyst which comprises a highly porous amorphous silica xerogel having a layer of an amphoteric metal compound chemically bonded onto up to 90% of the available surface, the catalyst'having a maximum pore diameter of about 1.5 nm. The metal is preferably aluminium, thereby giving a synthetic catalyst having an active aluminosilicate layer which may exist in one or two major crystal planes. It is now thought that the aluminosilicate layer has free aluminium-derived cations associated therewith and that cationic species such as Al (OH) + may balance negatively charged 4- co-ordinate 2 aluminium bonded to the surface of the silica xerogel. This and other explanations contained herein are to be regarded as theoretical only and have no bearing on the scope of the present invention. The present invention provides a process for the'production of synthetic catalysts comprising the steps of: a) treating a dry highly porous amorphous silica xerogel with anhydrous hydrolysable compound of aluminium in an amount sufficient to cover up to 90% of the BET surface area of the silica with a monolayer of the compound and removing the solvent; b) causing the surface of the silica to react with the compound by heating to a temperature of from 3000C to 1200 C, to yield a material having a maximum pore diameter of about 1.1 nm; and c) treating the product material of step b) with an ammonium salt solution capable of exchanging labile cations for ammonium ions, washing the treated material with deionisedwater until no further ammonium cations can be detected, optionally ion exchanging to deposit transition metal cations on the surface, drying and calcining the material at a temperature not exceeding 12000C to yield the catalyst. The invention also provides a synthetic catalyst which comprises a highly porous amorphous silica xerogel having a layer of an aluminium compound chemically bonded onto the silica surface in an amount equivalent to a monolayer on up to 90% of the BET surface area of the silica, the catalyst having a maximum pore diameter of about 1.1 nm and having substantially only protons and/or transition metal cations as electrical charge balancing species on the surface of the layer, the reaction causing bonding of the layer having been carried out at a temperature of from 300 to 12000C and the catalyst having been calcined at a temperature not exceeding 12000C. Steps a) and b) are preferably carried out by a method derived from our British Published Application No. 2,100,710A, by treating the highly porous amorphous silica xerogel, having a suitable porosity, with a solution of the predetermined quantity of the hydrolysable compound of aluminium, removing the solvent to leave a layer of the compound on up to 90% of the available surface area, and causing the surface of the silica to react with the layer to chemically bond the aluminium to the surface of the silica. We have found that the temperature required in the reaction step b) is suitably 400 to 9000C, and that variations in this temperature can alter the catalytic properties of the final product. Preferably the reaction temperature is 450 to 5500C, especially about 5000C. Preferred catalysts have a deposition of aluminium compound corresponding to about 50% coverage. Preferably, the silica xerogel having the deposited layer is treated in step c) with a dilute aqueous solution of an ammonium salt such as ammonium nitrate. The material is conveniently treated packed in a column, through which the solution may be passed until analysis demonstrates that no further aluminium cations are found in the eluent. The solution is then displaced by deionised water, which is passed until no further trace of ammonium ion is detected; this is conveniently done by comparing the pH of the eluent with that of the deionised water feed. These treatments are conveniently done under ambient conditions of temperature and pressure, but may also be carried out below or above ambient. An ion-exchange step may be incorporated. Such ion-exchange steps have been described in the literature and can be carried out in manner known per se, suitably using a salt such as a nitrate. Preferred metals are lanthanum and rhodium. After washing, the catalyst material is dried, conveniently under -reduced pressure, and then calcined, preferably at a temperature of 300-9000C, more preferably 450-6000C, and suitably for 4. to 10 hours. The catalyst Of the invention is especially useful in the conversion of oxygen-containing aliphatics to hydrocarbons and water, such organics being preferably selected from alcohols and ethers and especially methanol. The catalyst may also be used, alone or in combination with, that is admixed with or directly subsequent to, a second catalyst, for the direct conversion of synthesis gas. Such a second catalyst may be a Fischer-Tropsch type catalyst such as a transition metal, for example iron, catalyst. Alternatively, the synthesis gas may be converted to methanol using a catalyst carrier impregnated with zinc and chromium or zinc and copper, or impregnated with a lanthanide metal such as ruthenium. For the conversion of methanol, the catalyst may be used in a conventional reactor, using fixed, moving or fluidised beds. Temperatures are preferably in the range 300 to 500 C, especially 350 to 450 C. The Liquid Hourly Space Velocity (LHSV) is preferably -l -1 from 0.1 to lh , more preferably 0.2 to 0.5 h . Under preferred con- ditions, the catalyst gives high conversion yields, approaching 100% per pass, and demonstrates an unusual and very high selectivity towards aromatics. This selectivity is materially and unexpectedly different from that observed using the untreated starting material catalyst, from that using the Na-form of the catalyst and from that found using Mobil's ZSM-5 catalyst. Thus, the invention also provides a process for the conversion of an oxygen-containing aliphatic compound into hydrocarbons, comprising passing the compound in vapour form, over the catalyst at a temperature of 250 to 5000C and at a LHSV of 0.1 to 1 h 1 The optimum reaction temperature of step b) and the calcination temperature of step c) are thought to be about 5000C and 5500C, respectively, for a catalyst for the conversion of oxygen-containing aliphatic compounds into hydrocarbons. We have also discovered a particularly unexpected activity of the catalysts of the invention. It is suggested in British Paten Specification No. 1,589,857 that crystalline zeolite catalysts catalyse the conversion of methanol with added water with selectivity to ethylene and propylene. This was not observed using the amorphous aluminosilicate catalysts of this invention, which yield a range of C1-C7 alkylbenzenes, but certain catalysts exhibited a very high selectivity to toluene. Acordingly, the present invention further provides a process for the production of toluene with high selectivity, comprising passing methanol with at least an equal weight of water over a catalyst according to the invention which has been calcined at a temperature not exceeding 6000C, preferably not exceeding 4500C, said catalysts having substantially only protons as electrical charge balancing species on the surface of the layer, at a reaction temperature of 290 to 6000C, preferably 300 to 4500C. The process reaction may be carried out using known forms of catalytic reactors, especially fluidised or fixed bed reactors. Suitable liquid hourly space velocities are in the range 0.1 to 5.0 h preferably 0.2 to about 1 h . The reaction is conveniently carried out at atmospheric pressure, but pressures above or below atmospheric may be used. The temperature of calcination of the catalysts which exhibit the high selectivity to toluene appears to be important, and is preferably less than 4500C, more preferably 300 to 3500C, although the other catalysts according to the invention are useful in the synthesis of a broader group of cyclic-hydrocarbons. The concentration of the water/methanol feedstock is preferably in the region 3:1 to 4:1 by weight. Under preferred conditions, the selectivity for toluene is in excess of 90%, with an overall conversion of methanol in the 30 to 50% range. The preparation of catalysts according to the invention and their use in catalytic processes will now be described by way of example only. EXAMPLE 1 A sample (loOg) of commercial silica xerogel was heated in an oven for 4 hours at 1200C to remove physically absorbed water. The dried xerogel was cooled in a desiccator and immersed in a 250 ml of a 33.87% w/v solution of aluminium sec-butoxide in dry hexane (an amount sufficient to cover 50% of the BET surface with a monolayer of the aluminium alkoxide after removal of the solvent) and the pressure reduced to allow liquid to enter the pores of the xerogel. After 12 hours, excess solution was decanted and the material transferred to a vacuum oven where it was dried. After soaking in deionised water for 16 hours to complete hydrolysis of the alkoxide and decanting the liquor, the material was dried in the vacuum oven. The material was heated at 500 C for 4 hours to complete reaction of the aluminium compound with the surface of-the xerogei. The product was desiglwat¯d "Catalyst A". A sample of Catalyst A was packed into a column and a O.1M aqueous solution of ammonium nitrate was pumped through the column. Samples of the eluent were tested periodically for the presence of aluminium by the addition of a few drops of 0.OlM sodium hydroxide solution; samples containing aluminium cation were characterised by the formation of a gelatinous precipitate. When no further aluminium could be detected in this way, the ammonium nitrate solution was replaced by deionised water and pumping continued until the pH of the eluent was identical with that of the feed water. The product was removed from the column, dried under reduced pressure and thereafter calcined at 50dOC for 6 hours. This was designated "Catalyst B". High resolution electron microscopy of Catalyst B showed-that it was composed of particles of 2-10 nm diameter having a strongly electron scattering surface layer Which was an integral part of the silica matrix. There was little fine microporosity but the gaps between the particles were approximately 1.0 nm. Degassed methanol was pumped by a positive displacement pump through a preheater packed with glass beads before the methanol vapour was passed into a tubular reactor packed with the catalyst on test. The tubular reactor was run at various temperatures, 300, 350, 400 and 4500C, and the preheater was maintained at 50C below the reaction temperature. The products emerging from the reaction tube were collected as a liquid fraction in an ice-cooled trap and a gaseous fraction in a gas reservoir. The products were analysed and the results are shown in Table 1 below. It will be observed from the results that using Catalyst B, -1 according to the invention, especially at a LHSV of 0.3 hr a very high specificity for aromatics is demonstrated. Similar tests were performed using a form of Catalyst B that had been calcined at 3250C, and a conversion of methanol to hydrocarbons of 19.1% was obtained at a bed temperature of 350 C. A form of Catalyst B, calcined at 700 C, converted methanol to hydrocarbons in a yield of 69% at a bed temperature of 350 C, with high selectivity to aromatics. The Na-form of Catalyst A, that is Catalyst A ion-exchanged with sodium was tested in the same apparatus and at a bed temperature of 4500C at a LHSV of 1.0 h 1 A conversion of less than 3% was observed; no aromatic hydrocarbons were detected in the products. TABLE 1 EMI8.1 Catalyst <SEP> ZSM-5(a) <SEP> Catalyst <SEP> A <SEP> Catalyst <SEP> B <tb> LHSV <SEP> (h-1) <SEP> 1.0 <SEP> 0.3 <SEP> 0.3 <SEP> 0.3 <SEP> 0.3 <SEP> 1.0 <SEP> 1.0 <tb> Temperature <SEP> ( C) <SEP> 370 <SEP> 350 <SEP> 450 <SEP> 950 <SEP> 450 <SEP> 350 <SEP> 450 <tb> Conversion <SEP> (wt <SEP> %) <SEP> 100 <SEP> 85 <SEP> 95 <SEP> 99.8 <SEP> 98.7 <SEP> 39.0 <SEP> 64.4 <tb> Product <SEP> distribution <SEP> (wt <SEP> %) <tb> Methanol <SEP> 1.0 <SEP> 2.40 <SEP> 11.20 <SEP> 0.03 <SEP> 7.70 <SEP> 3.70 <SEP> 8.60 <tb> Ethane <SEP> 0.6 <SEP> 9.10 <SEP> 16.90 <SEP> 0.50 <SEP> 3.20 <SEP> 0.20 <SEP> 0.90 <tb> Propane <SEP> 16.2 <SEP> 6.20 <SEP> 7.20 <SEP> 0.01 <SEP> 1.30 <SEP> 0.10 <SEP> 1.80 <tb> Butanes <SEP> 24.3 <SEP> 2.80 <SEP> 9.40 <SEP> 1.05 <SEP> 0.02 <SEP> 0.05 <SEP> 1.90 <tb> Pentanes <SEP> 9.1 <SEP> 1.10 <SEP> 3.00 <SEP> 0.02 <SEP> 0.02 <SEP> - <SEP> 0.10 <tb> C5+ <SEP> Alkanes <SEP> 4.3 <SEP> 4.40 <SEP> 7.50 <SEP> 0.12 <SEP> 0.03 <SEP> 0.10 <SEP> 0.02 <tb> Ethene <SEP> 0.5 <SEP> 7.60 <SEP> 10.40 <SEP> 0.01 <SEP> 5.00 <SEP> 0.10 <SEP> 1.20 <tb> Propene <SEP> 1.0 <SEP> 3.90 <SEP> 4.30 <SEP> 0.40 <SEP> 0.20 <SEP> - <SEP> 0.10 <tb> But-1-ene <SEP> 1.3 <SEP> - <SEP> - <SEP> 0.20 <SEP> 0.10 <SEP> - <SEP> Hexene <SEP> - <SEP> - <SEP> - <SEP> 0.02 <SEP> - <SEP> - <SEP> 0.10 <tb> Benzene <SEP> 1.7 <SEP> - <SEP> - <SEP> - <SEP> - <SEP> - <SEP> C7 <SEP> Alkylbenzene <SEP> 10.5 <SEP> 5.80 <SEP> 7.00 <SEP> 7.20 <SEP> 3.70 <SEP> 2.90 <SEP> 2.70 <tb> C8 <SEP> " <SEP> 18.0 <SEP> 8.90 <SEP> 5.10 <SEP> 5.40 <SEP> 4.70 <SEP> 1.10 <SEP> 2.70 <tb> C9 <SEP> " <SEP> 7.5 <SEP> 3.20 <SEP> 5.90 <SEP> 2.30 <SEP> 8.60 <SEP> 1.30 <SEP> 2.00 <tb> C10 <SEP> " <SEP> 3.3 <SEP> 10.80 <SEP> 1.50 <SEP> 31.30 <SEP> 27.60 <SEP> 2.10 <SEP> 3.80 <tb> C11 <SEP> " <SEP> 0.2 <SEP> 9.70 <SEP> 0.60 <SEP> 9.00 <SEP> 7.10 <SEP> 0.80 <SEP> 1.80 <tb> C12 <SEP> " <SEP> - <SEP> 9.90 <SEP> 0.60 <SEP> 15.00 <SEP> 6.40 <SEP> 1.50 <SEP> 0.80 <tb> C13 <SEP> " <SEP> - <SEP> 13.90 <SEP> 8.90 <SEP> 25.40 <SEP> 20.10 <SEP> 2.90 <SEP> 2.00 <tb> % <SEP> Aromatics <SEP> 41.5 <SEP> 62.9 <SEP> 28.6 <SEP> 97.6 <SEP> 81.4 <SEP> 73 <SEP> 52 <tb> NOTE: (a) Results published in J. Catal. 1977, 47. 249 EXAMPLE 2 A Catalyst B was prepared as described above, but was calcined at 3250C for 4 hours. Studies of the resulting catalyst showed that it consisted of collections of particles of 2-10 nm diameter having a strongly electronscattering surface layer which was an integral part of the silica matrix. There was little fine microporosity, but the gaps between particles were approximately 1.0 nm. Degassed methanol/water mixtures were pumped by a positive displacement pump through a preheater packed with glass beads before the methanol/water vapour was passed into the tubular reactor packed with the catalyst, at a liquid hourly space velocity of 1.0 h . The tubular reactor was run at various temperatures, 250, 300 350, 400 and 4500C, and the preheater was maintained at 50C below the reaction temperature. The products emerging from the reaction tube were collected as a liquid fraction in an ice-cooled trap and a very small gaseous fraction (insufficient for analysis) in a gas reservoir. The products were analysed and the results are shown in Table 2 below. TABLE 2 Water/Methanol wt. ratio 3:1 Bed temperature (OC) 250 300 350 400 450 Methanol conversion (wt Z) 3.2 47 49 41 27 Cycloalkanes (wt X) - 1.1 0.8 1.2 3.1 Toluene n - 93.5 95.7 92.5 90.0 C2 alkyl benzene - 3.9 2.5 4.3 6.0 C3 alkyl benzene - 1.5 0.9 1.9 0.9 The above-described procedure was repeated, except that the catalyst was calcined at 6000C for 4 hours, and the results are shown in Table 3 below. TABLE 3 Water/Methanol wt. ratio 3:1 Bed temperature (OC) 250 300 350 400 450 Methanol conversion (wt X) 0 22 32 48.1 50.2 Clycloalkanes (wt X) - 4.7 1.5 2.6 4.6 Toluene " - 42.1 41.8 32.0 15.8 C2 alkyl benzene n - 22.1 10.4 2.2 3.0 C3 alkyl benzene - 10.1 7.8 6.1 5.2 C4 alkyl benzene - 7.7 10.0 17.2 19.1 C5 alkyl benzene .. - 10.5 11.1 18.9 28.2 C6 alkyl benzene - 1.2 15.3 19.8 21.1 C7 alkyl benzene " - 1.2 2.0 1.1 3.0 It can be seen that although toluene is still a major product, the selectivity has been substantially reduced. The spread of products is broadly similar to that when pure methanol is used as fees'stock under the same conditions, instead of water/methanol. Instead of 3:1 water/methanol, a 1:2 water/methanol mixture was used, using the catalyst calcined at 6000C. The results are shown in Table 4 below from which it can be seen that there is no selectivity for toluene. TABLE 4 Water/Methanol wt. ratio 1:2 Bed temperature ( C) 200 250 300 350 400 450 Methanol conversion (wt %) 2.6 10.7 25.4 38.2 49.8 60.1 Clycloalkanes (wt %) 4.0 1.0 0.3 1.6 2.6 3.9 Toluene n 9.5 11.1 I1.0 8.2 6.9 9.9 C2 alkyl benzene n 16.5 16.2 14.8 13.7 10.8 12.0 C3 alkyl benzene n 19.7 20.9 19.7 17.2 16.1 14.8 C4 alkyl benzene " 22.0 19.7 18.1 17.0 17.0 16.9 C5 alkyl benzene " 21.0 21.6 19.8 23.2 26.8 22.1 C6 alkyl benzene " 4.9 8.2 15.2 17.9 19.7 18.2 C7 alkyl benzene " 2.4 1.3 1.1 1.2 1.2 2.3 Further tests using a pure methanol feed stock and using the catalyst calcined at 6000C showed a range of alkyl benzenes produced

Claims: PATENT CLAIMS: 1. A process for the production of synthetic catalysts, characterised in that it includes the steps of: a) treating a dry highly porous amorphous silica xerogel with an anhydrous hydrolysable compound of aluminium in an amount sufficient to cover up to 90% of the BET surface area of the silica with a monolayer of the compound and removing the solvent; ; b) causing the surface of the silica to react with the compound by heating to a temperature of from 300 C to 1200 C to yield a material having a maximum pore diameter of about 1.1 nm, and c) treating the product material of step b) with an ammonium salt solution capable of exchanging labile cations for ammonium ions, washing the treated material with deionosed water until no further ammonium cations can be detected, optionally ion exchanging to deposit transition metal cations on the surface, drying and calcining the material at a temperature not exceeding 1200 C. 2. A process according to claim 1, characterised in that the amount of aluminium compound in step a) is sufficient to cover approximately 50% of the BE-T surface area of the silica. 3. A process according to claim 1 or 2, characterised in that the reaction temperature of step b) is from 400 to 9000C. 4. A process according to claim 3, characterised in that the reaction temperature is 450 to 5500C. 5. A process according to any one of the preceding claims, characterised in that the calcining temperature of step c) is from 300 to 9000C. 6. A process according to claim 5,characterised in that the calcining temperature is from 450 to 6000C. 7. A synthetic catalyst comprising a highly porous amorphous silica xerogel having a layer of an aluminium compound in an amount equivalent to a monolayer covering up to 90% of the BET surface area of the silica, chemically bonded onto the surface thereof, said catalyst being characterised by a maximum pore diameter of about 1.1 nm and having substantially only protons and/or transition metal cations as electrical charge balancing species on the surface of the layer, and further characterised in that the reaction causing bonding of the layer having been carried out at a temperature from 300 to 1200 C and the catalyst having been calcined at a temperature not exceeding 12000C. 8. A catalyst according to claim 7, characterised in that the layer of aluminium compound is equivalent to a monolayer on about 50% of the BET surface area of the silica. 9. A catalyst according to claim 7 or 8, characterised that the reaction temperature was 400 to 9000C. 10. A catalyst according to claim 7, 8 or 9, characterised in that the calcination temperature was 300 to 9000C. 11. A process for the conversion of an oxygen-containing aliphatic compound into hydrocarbons, characterised in that the compound in vapour form is passed over a catalyst according to any one of claims 7 to 10, at a temperature of 250 to 500 C and at a LHSV of 0.1 to 1 h-1. 12. A process for the production of toluene, characterised in that methanol is passed with at least an equal weight of water over a catalyst according to any one of claims 7 to 10 and further characterised in that the catalyst has substantially only protons as electrical charge balancing species on the surface of the layer and the catalyst has been calcined at a temperature not exceeding 6000C, at a reaction temperature of 280 to 6000C.

Inventors: BARNES, DAVID IAN, RIEMER, PIERCE WILLIAM FOSTER, ROBINSON, JOSEPH GORDON
Applicants: COAL INDUSTRY (PATENTS) LIMITED
Application year: 1983
Main classification: B01J21
IPC codes: B01J37, B01J21, C07C1