PROCESS FOR THE PREPARATION OF ORGANIC COMPOUNDS FROM SYNTHESIS GAS

Abstract: Process for the preparation of organic compounds from synthesis gas by passing said gas in at least one reaction zone through fluid-permeable holders containing catalyst particles which holders are stacked in the reaction zone(s).

Description: PROCESS FOR THE PREPARATION OF ORGANIC COMPOUNDS FROM SYNTHESIS- GAS The invention relates to a process for the preparation of organic compounds from synthesis gas. In this method of preparation, in which synthesis gas is led continuously or discontinuously through a catalyst bed, it is often desirable to employ as small catalyst particles as possible in order to improve the yield per unit weight of catalyst. It is not, however, possible to reduce the particle size of the catalyst indefinitely, since the pressure drop in a catalyst bed in the direction of flow of the synthesis gas is greater as the catalyst particles are smaller. The greater pressure drop often cancels out the advantage ensuing from the-employment of smaller particles. It has now been found that the drawbacks connected with the employment of smaller catalyst particles can largely be overcome by employing catalyst particles packed in stacked catalyst holders permeable to fluid (i.e. gas and liquid). The invention therefore relates to a process for the preparation of organic compounds from synthesis gas wherein said gas is passed in at least one reaction zone through fluid-permeable holders containing catalyst particles which holders are stacked in the reaction zone(s). The process according to the invention causes only a relatively small pressure drop while the yield per unit weight of catalyst remains almost the same as that obtained by employing similar catalyst particles without said holders; in addition mass transport limitations arising from the employment of larger catalyst particles are largely eliminated. Moreover, heat transfer is improved. The process according to the invention can be carried out continuously or discontinuously; preferably a continuous process is employed. The particle size of the catalyst is preferably between 0.1 and 1.5 mm and more preferably between 0.25 and 1.0 mm, always based bun the largest diameter of each particle. The catalyst holder can in principle have any shape. Preferably, the height and width of the catalyst holder do not differ by more than 50% from the length; in particular, the catalyst holder has a regular shape, for example substantially cylindrical or spherical. Substantially spherical catalyst holders are the most preferred. The diameter of the catalyst holder is advantageously between 2 and 10 mm and-in particular between 4 and 8 mm,- always based on the largest diameter of each holder. The catalyst holder suitably consists of a continuous network of material which, under the conditions under which the synthesis gas is contacted with the catalyst, is inert. Preferably, the catalyst holder consists of a closed network of aluminium or stainless steel. Advantageously 20-95% and preferably 40-90% of the surface area of the holder consists of a permeable area. The permeable area is formed by a plurality of openings in e.g. a network, which openings have a diameter of 0.05 to 0.7 mm and in particular of 0.1 to 0.5 mm, the diameter of course always being chosen such that the catalyst particles in the catalyst holder cannot pass through the openings in the catalyst holder. At least 50%, preferably at least 80% and in particular the entire volume of the reaction zone is occupied by the stacked catalyst holders forming interstices, the interstices between the stacked catalyst holders preferably occupying between 20 and 50%-of the volume in the reaction zone. The process according to the invention is in principle suitable for any conversion of synthesis gas into organic compounds. In such a conversion, the synthesis gas is passed at a particular temperature and pressure and with a particular space velocity through a catalyst bed containing a particular catalyst packed in the above-described catalyst holders. The choice of catalyst, temperature, pressure and space velocity depends on the desired product. The process according to the invention is particularly suitable for the preparation of hydrocarbons and/or oxygencontaining hydrocarbon derivatives, such as methanol, from synthesis gas. If the process according to the invention is carried out for the preparation of methanol, catalysts known in the art for converting synthesis gas into methanol should be employed as catalyst, e.g. a catalyst containing zinc together with chromium. If the process according to the invention is carried out for the preparation of hydrocarbons, Fischer-Tropsch catalysts known in the art, which contain Fe, Co, Ru and/or Ni, can be employed. The present invention is suitable for the preparation of middle distillates. In this context "middle distillates" are understood to be hydrocarbon mixtures whose boiling range corresponds substantially to that of the kerosine and gas oil fractions, which are obtained in the classical atmospheric distillation of crude petroleum. The middle distillate range extends substantially from about 150 to 360 "C. Middle distillates can be prepared in one or two stages. They are prepared in one stage by passing the synthesis gas over a Fischer-Tropsch catalyst with one ore more promotors and a carrier material. The products which can be prepared with these catalysts generally contain a very wide molecular weight distribution and, in addition to branched and non-branched paraffins, often contain considerable quantities of olefins and oxygen-containing organic compounds. The products obtained often contain only a small proportion of middle distillates. Besides the yield, the product characteristics of the gas oil obtained leave much to be desired as a consequence of the presence of the previously mentioned olefins and oxygen-containing organic compounds. That is why the two-stage method of preparation is preferably used, in which in a first step a class of Fischer-Tropsch catalysts is used, which catalysts have the property that they give a product containing only very small amounts of olefins and oxygen-containing organic compounds and consisting almost exclusively of non-branched paraffins, a large proportion of which boil above the middle distillate range, and in which in a second stage the high-boiling part of the product obtained in the first stage is converted by hydrocracking into middle distillates. As feedstock for the hydrocracking, at least that part of the product is chosen whose initial boiling point lies above the final boiling point of the heaviest middle distillate desired as end product. The hydrocracking, which is characterized by a low hydrogen consumption, gives middle distillates with a substantially better pour point than those obtained from the direct conversion of a H2/CO mixture according to the Fischer-Tropsch method. The process according to the invention is advantageously employed in the first stage of this two-stage method of preparation. The Fischer-Tropsch catalysts used in the first stage of the two-stage method of preparation preferably contain silica, alumina or silica-alumina as carrier material, and cobalt together with zirconium, titanium and/or- chromium as catalytically active metals, preferably in such quantities that 3-60 parts by weight cobalt and 0.1-100 parts by weight zirconium, titanium and/or chromium are present per 100 parts by weight carrier material. The catalysts are advantageously prepared by kneading and/or impregnating the metals in question onto the carrier material. Before being used, the cobalt catalysts are preferably activated. This activating can be suitably carried out by contacting the catalyst at a temperature of between 200 and 350 OC with hydrogen or a hydrogen-containing gas. The conversion of synthesis gas into middle distillates is preferably carried out at a temperature of 125-350 OC and in particular of 175-275 OC and a pressure of 5-100 bar and in particular of 10-75 bar. The E2- and CO-containing feedstock, which is converted into middle distillates with the aid of the above-mentioned catalysts, preferably has an H2/CO mol. ratio of 1.0-2.5 and in particular of 1.5-2.25. Although in the preparation of middle distillates from thev product obtained via the synthesis catalyst, that part of the product whose initial boiling point lies above the final boiling point of the heaviest middle distillate desired as end product can be used as feedstock for the hydrocracking, use is preferably made for this purpose of the total C9+ fraction and in particular of the total C5+ fraction of the product of the first stage, since it has been observed that under the influence of the catalytic hydrogen treatment, the quality of the gasoline, kerosine and gas oil fractions contained therein is improved. The hydrocracking is carried out by contacting the fraction to be treated, at elevated temperature and pressure and in the presence of hydrogen, with a catalyst containing one or more noble metals from Group VIII on a carrier. As hydrocracking catalyst, a catalyst is preferably employed which contains 0.1-2 wt% and in particular 0.2-1 wtZ of one or more noble metals from Group VIII on a carrier. Preferred catalysts are those which contain platinum or palladium as noble metal from Group VIII and silica-alumina as carrier. The hydrocracking is preferably carried out at a temperature of 200-400 OC and in particular of 250-350 "C and at a pressure of 5-100 bar and in particular of 10-75 bar. If the reaction product prepared via the synthesis catalyst still contains sufficient unconverted hydrogen for carrying out the hydrocracking, both steps can be carried out in "series flow". In that case, the C8- fraction or the C4- fraction is not separated after the first stage, but only after the second stage. As is known, carrying out a multi-stage process in series flow means that the total reaction product from a given stage, without components being removed from it or added to it, is used as feedstock for the following stage, which is carried out substantially at the same pressure as the previous stage. The invention will now be illustrated with the aid of the following Examples of which only Example 3 relates to the process according to the invention. Comparative Example I Synthesis gas (molar ratio H2 : : CO = 2) was contacted at 230 C and 20 bar and at a space velocity of 900- 1 (STP)/I catalyst/hour with 8 kg catalyst (9 parts by weight cobalt and 6 parts by weight zirconium per 100 parts by weight Si02 as carrier) in a reactor with a volume of 13 1. The catalyst consisted of catalyst particles with a diameter of 0.38 mm. Comparative Example 2 Example 1 was repeated, except that the diameter of the catalyst particles was now 2.4 mm. Example 3 Example 1 was repeated, except that the catalyst particles were packed in catalyst holders. The catalyst holders were spherical, had a diameter of 6 mm and consisted of a network of stainless steel with openings of 0.3 mm and a permeable area of 75% of the network area. The reactor was, except for the interstices, entirely filled with catalyst holders. The quantity of catalyst was 5.2 kg. In these 3 Examples the yield (expressed as kg Cl+.kg catalyst-1 .h-1) the selectivity (the part of the C1+ fraction that belonged to the C3+ fraction) and the pressure drop were determined. The results are given in Table 1 below. Table 1 Example 1 2 3 diameter of catalyst particles 0.38 mm 2.4 mm 0.38 mm catalyst holder - - + yield 123 52 120 selectivity (C3+/C1+) 87 67 83 pressure drop (bar) 10 0.25 0.04

Claims: CLAIMS 1. Process for the preparation of organic compounds from synthesis gas wherein said gas is passed in at least one reaction zone through fluid-permeable holders containing catalyst particles which holders are stacked in the reaction zone(s). 2. Process according to claim 1 wherein the catalyst particles have a diameter lying between 0.1 and 1.5 mm. 3. Process according to claim 1 or 2 wherein the catalyst holders have a width and height not differing by more than 50% from the length. 4. Process according to any of the preceding claims wherein the catalyst holders are substantially cylindrical or spherical 5. Process according to any of the preceding claims wherein the catalyst holders have a diameter lying between 2 and 10 mm. 6. Process according to any of the preceding claims wherein the interstices between the stacked catalyst holders occupy between 20 and 50% of the volume in the reaction zone. 7. Process according to any of the preceding claims wherein the catalyst holders consist of a continuous network of material which is inert under the conditions under which the synthesis gas is contacted with the catalyst. 8. Process according to claim 7 wherein the catalyst holders consist of a closed network of aluminium or stainless steel. 9. Process according to any of the preceding claims wherein between 20 and 95% of the surface area of the holders consists of permeable area. 10. Process according to any of the preceding claims wherein the holders are provided with openings having a diameter lying between 0.1 and 0.5 mm. 11. Process substantially as described hereinbefore with reference to Example 3. CXRHO4

Inventors: VAN DER BURGT, MAARTEN JOHANNES
Applicants: SHELL INTERNATIONALE RESEARCH MAATSCHAPPIJ B.V.
Application year: 1986
Main classification: C07C1
IPC codes: C07B61, C07C1, C07C29, C10G2, C07C67, B01J8, B01J35, C10G3, C07C27