Purification of unsaturated compounds

This application relates to a process for the reduction in carbonyl impurities in gaseous streams. A preferred embodiment relates to a process for the purification of unsaturated hydrocarbons from a gaseous mixture containing hydrocarbons, relatively non-condensable gases and carbonyl compounds as an impurity.
Unsaturated hydrocarbons are commercially produced by the catalytic dehydrogenation of more saturated hydrocarbons. For example, diolefins are produced in large quantities by the dehydrogenation of saturated hydrocarbons or olefins.
Improved processes for the preparation of unsaturated hydrocarbons such as butene. butadiene-1,3 isoprene and styrene are processes whereby hydrocarbons such as butane, butene, isopentenes or ethyl benzene are dehydrogenated at elevated temperatures in the presence of catalysts and oxygen and such processes are known as oxidative dehydrogenation processes. Superior results and yields of product are thereby obtained. However, the product streams contain not only the desired unsaturated hydrocarbon, but also various oxygenated compounds such as aldehydes and other carbonyl compounds. When air is used as the source of the oxygen, the effluent from the dehydrogenation reactor will contain large quantities of relatively non-condensable gases, such as nitrogen. The gaseous effluent may also contain varying amounts of steam. It is one of the principal objects of this invention to provide a process for the separation of the carbonyl and other oxygenated compounds from the gaseous stream containing hydrocarbons.
The oxygenated compounds are a serious contaminant in the unsaturated hydrocarbon product and must be essentially completely removed in order to have a product of suitable purity, e.g., a product having on the order of a few parts per million carbonyl compounds. The essentially complete removal of the oxygenated compound is quite difficult for several reasons. In the first place, the oxygenated compounds constitute only a very minor percentage of the gaseous stream to be purified. Normally the carbonyl compounds will constitute less than 5 mol percent of the gaseous stream to be purified and more usually may constitute such as less than or up to 2.5 mol percent of the gaseous stream. Generally the feed stream will contain at least about 10 ppm carbonyl compounds based on the other organic compounds such as the hydrocarbons. The oxygenated compounds are therefore quite difficult to remove because of their low concentrations in the gaseous stream. In addition, the oxygenated compounds may be difficult to separate from compounds such as hydrocarbons regardless of their relative concentration. Azeotropes may form between the oxygenated compounds and various hydrocarbons. For instance, an azeotrope is formed between acetaldehyde and butadiene-1,3. It is therefore an object of this invention to promote a process for the removal of carbonyl compounds from a gaseous stream containing only minute quantities of carbonyl compounds based on the total gaseous stream.
Prior processes have dealt with the separation of oxygenated compounds from oxidative dehydrogenation processes. In U.S. Pat. Nos. 3,308,201 and 3,336,414 oxygenated compounds are removed by scrubbing with an aqueous composition. These processes have the drawback that the carbonyl compounds are transferred to a scrubbing water and must still be disposed of such as by biodegradation. According to U.S. Pat. No. 3,557,238 the carbonyl compounds are condensed with the steam from the reactor effluent, revaporized and fed back to the dehydrogenation reactor. Therefore, one object of this invention is to provide a process for the destruction of carbonyl compounds. It is a further object to destroy the carbonyl compounds without significantly losing reactor product or significantly isomerizing any of the products. It is also an object to produce a catalyst which has long catalyst life and which has a reduced tendency to form coke. Another object is to provide a process which is particularly effective in destroying formaldehyde because formaldehyde is difficult to economically separate from aqueous compositions.
According to this invention is has been discovered that the elements and compounds thereof of Periodic Table* Groups 1a, 1b, 2a, 2b, 3b, 4b, 6b, 7b, 8 and mixtures catalyze the destruction of oxygenated compounds in vapor phase. Thus, it is possible to contact the reactor effluent directly with a catalyst bed and destroy oxygenated compounds.
*All references in this application are to the Periodic Table as found on page B-3 of the 51st. edition of the Handbook of Chemistry & Physics (1970-71 Chemical Rubber Publishing Company).
In general, atoms of metals of the Periodic Table Groups 1a, 1b, 2a, 2b, 3b, 4b, 6b, 7b, 8 and mixtures thereof are effective in the process of this invention. The atoms may be present such as in the form of the metal compounds such as oxides, salts or hydroxides. Many of these metals, salts and hydroxides may change during the preparation of the catalyst, during heating in a reactor prior to use in the process of this invention, or are converted to another form under the described reaction conditions, but such materials still function as an effective catalyst in the defined process to give carbonyl removal or destruction. For example, the metal may be present as the nitrates, nitriles, carbonates, hydroxides, acetates, sulfites, silicates, sulfides and the like. For instance, iron nitrate and iron sulfate may be converted at least to some extent to the corresponding oxides while being heated in a reactor to a reaction temperature of about 550.degree. C. Such salts of the defined metal groups, which are normally stable at the defined reaction temperatures may likewise be effective under the conditions of the described reaction. However, some metal compounds are more effective than other compounds of the same metal and, therefore, the compound giving the most effective results can be chosen. Preferably, catalysts solid under the conditions of carbonyl removal will be used. Preferably, the compound will exhibit some basicity e.g. as in the case of oxides, carbonates or hydroxides. It has been found that prior art compositions that are known as thermal or oxidative dehydrogenation catalysts or as hydrogenation catalysts have been effective to destroy carbonyl compounds according to this invention.
Examples of preferred catalysts are Mg, Ca, Sr, Ba, Ti, Zr, Cr, Mn, Cu, Zn, Pd, Pt, Co, Fe and mixtures thereof. In the Periodic Table Group 8 elements Fe and the platinum group metals are preferred with Fe being particularly preferred. The term mixtures thereof includes compounds thereof such as the ferrites. Useful compounds include, for example, beryllium oxide, magnesium acetate, magnesium bromide, magnesium oxide, magnesium iodide, calcium oxide, calcium acetate, calcium oxalate, calcium chloride, calcium bromide calcium iodide, calcium fluoride, calcium carbonate, strontium nitrate, strontium chloride, strontium oxide, strontium hydroxide, strontium carbonate, strontium bromide, barium oxide, barium chloride, barium hydroxide, barium sulfate, barium bromide, barium iodide, beryllium chloride, cupric bromide, cuprous chloride, cuprous oxide, cupric oxide, cuprous silicide, cuprous sulfide, cupric phosphate, silver oxide, zinc fluoride, zinc oxide, zinc ortho phosphate, zinc phosphide, zinc orthosilicate, zinc metasilicate, zinc sulfide, cadmium oxide, titanium dioxide, zirconium oxide, CrBr.sub.2, Cr.sub.2 O.sub.3, manganese dioxide, manganese disilicide, ferrous oxide, ferric oxide, Fe.sub.3 O.sub.4, thorium oxide, CeO.sub.2, rare earth compounds including mixtures such as didymium oxides, and the like and mixtures thereof. The platinum metal elements are the elements in the Fifth and Sixth Periods of Group 8 of the Periodic Table. These elements are ruthenium, rhodium, palladium, osmium, iridium, platinum. Preferred catalysts are platinum, palladium, compounds thereof, and mixtures of these. Suitable catalysts are such as palladium metal, palladium monoxide, platinum oxide(ous), platinum metal, platinum-rhodium alloys and the like. The elements of Groups 1a, 1b, 2a, 2b, 3b, 4b, 6b, 7b, 8 and mixtures are the main active constituents of the catalyst. Alkali metals may be preferably present in an amount up to 40 weight percent of the other metallic elements (calculated as the elements) but normally will range from about 0.5 to 30 weight percent. The preferred alkalis are potassium, sodium, rubidium, lithium and mixtures. Aluminum can be present in fairly large amounts but the exact function of aluminum is not known as aluminum by itself does not particularly catalyze the reaction. Non metals such as silica can be present. Oxides, hydroxides, or carbonates or compounds which are converted to these compounds under the conditions of reaction to destroy the carbonyl compounds are preferred. Ingredients or anions which suppress or deactivate the effect of the defined metal elements should be avoided.
Good results have been obtained with catalysts containing transition element(s) and/or 1a or 2a elements of the Periodic Table as the predominant metals.
A particularly preferred catalyst composition comprises at least one metal selected from the group consisting of the elements of Groups 8, 1b, 2b, 4b, 6b and 7b of the Periodic Table and at least one member selected from the group consisting of the elements of Groups 1a and 2a of the Periodic Table. Even more preferable, the catalyst comprises at least one metal selected from the group consisting of Cr, Mn, Fe, Cu, Zn and Zr and at least one element selected from the group of Li, Na, K, Rb, Mg, Ca, Sr and Ba. For example, a catalyst would include zinc ferrite in combination with barium oxide and Na.sub.2 CO.sub.3. A more preferred catalyst is one comprising at least one metal selected from the group consisting of the elements of Groups 8, 1b, 2b, 4b, 6b and 7b, at least one alkali metal of Group 1a and at least one alkaline earth metal of Group 2a. Within this more preferred composition a particular catalyst would comprise at least one metal selected from the group consisting of Cr, Mn, Fe, Cu, Zn and Zr, at least one alkali metal selected from the group consisting of Li, An, K and Rb and at least one alkaline earth metal selected from the group consisting of Mg, Ca, Sr and Ba.
In any of the catalysts described herein, the preferred Group 8, 1b, 2b, 6b or 7b metals are Cr, M. Fe, Cu, Zn and Zr. Similarly, the preferred alkali metals, Group 1a, are Li, Na, K and Rb and the preferred alkaline earth metals, Groups 2a, are Mg, Ca, Sr and Ba.
The following is offered as a proposed mechanism derived from the observation of the process and is not submitted as a limitation: The mechanism for the three component catalysts, i.e., metal, alkali metal and alkaline earth metal, is believed to be such that the metal and alkaline earth metal are the principal decarbonylation participants, the metal is a "catalyst" for the water gas reaction and the alkali metal is a promoter for the metal water gas "catalyst". In addition, these components can perform other functions and may have synergistic ramifications not presently known.
This system is not considered a likely oxidative dehydrogenation catalyst because of the presence of the alkali metal which has been observed to kill the effectiveness of some oxidative dehydrogenation catalyst for example, the water gas reaction is relevant to keeping the catalyst clean by removing the coke that forms from the decarbonylation. The water gas reaction is less important when there is oxygen present, however, in a typical use of the present invention, for example, where the present catalyst bed is immediately below or following an oxidative dehydrogenation, the reactant stream would be oxygen poor. Although oxygen could be injected, it probably would be best not to do so as explained hereinbelow.
Although the alkali metals are considered to be the principal promoter for the water gas "catalyst", the alkaline earth metals also have some capacity in this regard and can replace some or all of the alkali metal. This is particularly suitable where sufficient oxygen is present to aid in decoking the catalyst.
Particularly desirable and preferred catalysts according to the present invention comprise as the major atom by weight, the Group 1a, 2a, 2b, 3b, 4b, 7b and 8 elements described above.
Excellent catalysts are those which contain calcium as an ingredient such as CaO or more preferably calcium combined with aluminum and/or silicon such as calcium aluminate or calcium silicate. The use of cement is claimed in an application by Harold F. Christmann, Ser. No. 223,364, filed Feb. 3, 1972, U.S. Pat. No. 3,801,669, and entitled PURIFICATION OF HYDROCARBONS. Cements are combinations of calcium, aluminum and silica as main ingredients and may be prepared e.g. by the sintering of a mixture of calcium carbonate (as limestone) with an aluminum silicate. Cements are discussed on pages 684-696 volume 4 of Kirk-Othmer, Encyclopedia of Chemical Technology, 2nd. edition (1964) which disclosure is hereby incorporated by reference. Portland cements are classified by Types I, II, III, IV and V (ASTM C 150-63) and a preferred type according to the copending application is Type III. Typical cements would have by weight from about 15 or 20 percent silicon analyzed as SiO.sub.2, from about 2 to 6 or 8 percent aluminum analyzed as Al.sub.2 O.sub.3 (or up to about 45 percent for the high alumina cements, and from about 55 or 60 to 66 or 70 weight percent calcium analyzed as CaO, or down to about 30 percent CaO for the high alumina cements). The cements may also contain minor ingredients such as MgO and SO.sub.3. The specification for Type III Portland is that it have by weight a mixture of 5 percent MgO; when the 3CaO.multidot.Al.sub.2 O.sub.3 is 8 percent or less the SO.sub.3 should be at a maximum of 3.0 percent and when the 3CaO.multidot.Al.sub.2 O.sub.3 is more than 8 percent the SO.sub.3 should be 4.0 percent maximum; the loss on ignition is 3 percent maximum and the insoluble residue is 0.75 percent maximum.
A preferred type of catalyst is one which comprises iron and especially preferred are those that comprise iron as the major metal or cation component by weight. Excellent catalysts are those containing iron and at least one or more of alkali metals, especially K, Rb, or Na with K being preferred, and/or at least one alkaline earth metal such as Mg, Ba, Ca, Sr and mixtures thereof. Another preferred catalyst is Fe and Zn with or without the alkali metals. The iron and other compounds can be present as oxides or other compounds or may be present as e.g. hydroxides, carbonates nitrates, acetates, etc. One form is as ferrites such as magnesium ferrite, manganese ferrite, calcium ferrite, barium ferrite, strontium ferrite, zinc ferrite, magnesium chromium ferrite, zinc chromium ferrite, calcium zinc ferrite, mixtures thereof and the like. The ferrites may contain more than one metal as illustrated. Methods of preparing ferrites are disclosed e.g. in U.S. Pat. Nos. 3,284,536; 3,270,080; 3,303,235; 3,334,152; 3,342,890; 3,526,675 and so forth. Mixtures of iron oxide with other compounds such as oxides have given excellent results. Thus, iron can be combined as a compound or other combination such as a ferrite or as a mixture of compounds with at least one metal from the group of alkali metals such as Li, Na, K, Rb, alkaline earth metals such as Mg, Ca, Sr, Ba, Group 4b metals such as Ti, Group 6b metals such as Cr, Group 7b metals such as Mn, Group 8 metals such as Co, Group 1b metals such as Cu, Group 2b metals such as Zn. Additionally, e.g. Al, Si, P, Bi may be present. Examples of mixtures of iron oxide with other compounds may be found in U.S. Pat. Nos. 2,461,147 and 3,308,193.
The catalysts of this invention may be used as such or may be coated on catalyst carriers. Catalyst carriers are known in the art and include such compounds as alumina, silica, silicon carbide and so forth. Diluents may also be incorporated into the catalyst so long as the diluent does not prevent the catalyst from functioning. Preferably the carrier should be low surface and low acidity.
The gaseous mixture to be treated containing the carbonyl* compounds as an impurity may be obtained from a variety of sources. However, the invention is particularly suitable for the purification of gaseous effluents resulting from the oxidative dehydrogenation of organic compounds including hydrocarbons utilizing air or oxygen diluted with non-condensable diluents such as nitrogen or helium. Examples of oxidative dehydrogenation processes are disclosed, e.g. in U.S. Pat. Nos. 3,207,805; 3,284,536; 3,320,329; 3,342,890; and 3,476,824.
*All references to overall quantities of carbonyl compounds are determined by ASTM Method D-1089 and reported as acetaldehyde. The procedure is modified to exclude the analysis of acetals. Generally, the carbony compounds will have from 1 to 8 carbon atoms, e.g. from 1 to 6 carbon atoms when a C.sub.4 to C.sub.6 compound is being dehydrogenated, and will have from 1 to 2 carbonyl groups. Formaldehyde is included in this definition.
Organic compounds to be dehydrogenated may be acyclic, cycloaliphatic or alkyl aryl compounds of 3 or 4 to 9 carbon atoms, which contain at least two adjacent carbon atoms, each of which carbon atom has at least one hydrogen atom attached. Olefins, diolefins or compounds may be produced from more saturated compounds e.g. butadiene-1,3 may be produced from n-butane. A mixture of monoolefins and diolefins may also be produced such as a mixture of butadiene-1,3 and butenes from a feedstock of a mixture of n-butane and butene. Cyclohexane may be dehydrogenated to cyclohexene and/or benzene. Ethyl benzene or ethyl cyclohexane may be dehydrogenated to styrene. Good results may be obtained with an organic feed containing at least 50, such as at least 75 mol percent of an acyclic aliphatic hydrocarbon. Hydrocarbons of 4 to 5 carbon atoms having a straight chain of at least four carbon atoms, e.g., those having a single double bond have been used and preferred are the monoethylenically unsaturated compounds or mixtures of saturated and monoethylenically unsaturated compounds. Hydrocarbons having from 4 to 8 carbon atoms constitute a preferred feed with n-butane, n-butene, isopentane, isopentene, ethyl benzene and mixtures having given excellent results.
Oxygen will generally be supplied to the dehydrogenation zone in the range of about 0.20 mol of oxygen to 2.0 or 3.0 mols of oxygen per mol of hydrocarbon to be dehydrogenated. A preferred range for the oxygen is from about 0.3 to 1.50 mols of oxygen per mol of hydrocarbon to be dehydrogenated. Either air, oxygen or oxygen diluted with a diluent such as nitrogen, helium, and the like, may be utilized. The oxygen may be supplied in gaseous form or via a solid oxygen carrier such as in U.S. Pat. No. 3,420,911. Steam may be fed to the dehydrogenation zone in amounts such as from about 2 to 40 mols of steam per mol of hydrocarbon to be dehydrogenated. An advantageous range is from 2 to 20 mols of steam per mol of hydrocarbon.
The dehydrogenation reaction may be conducted in the absence of contact catalysts, but better results are obtained if the reaction is conducted in the presence of metal or metal compound catalysts. The dehydrogenation reactor may be a fixed or fluid bed reactor. Reactors conventionally used for the dehydrogenation of hydrocarbons to butadiene may be employed. The total pressure in the dehydrogenation zone may suitably be about atmospheric pressure. However, higher pressures or vacuum may be used. Pressures such as from about atmospheric (or below) up to about 100 to 200 p.s.i.g. may be employed. The dehydrogenation reaction will normally be conducted at a temperature at least about 250.degree. C. such as greater than about 300.degree. C. or 375.degree. C. and the maximum temperature in the reactor may be about 700.degree. C. or 800.degree. C. or perhaps higher such as 900.degree. C.
The effluent from the dehydrogenation zone will contain the impure unsaturated organic products, various impurities including oxygenated hydrocarbons, noncondensable* gases and perhaps some unconverted feed, oxygen and steam. If air is used as the source of oxygen, nitrogen will be present in relatively large quantities as a noncondensable gas. Steam may be present in an amount up to 96 mol percent of the total effluent, such as from about 5 to 96 percent. On a water free basis the organic phase including dehydrogenated product, any unreacted feed, oxygenated hydrocarbons, polymer and tar and precursors thereof and any organic decomposition products usually range from about 1 to 50 mol percent of the effluent and generally will be within the range of or about 3 to 30 mol percent of the effluent. Also on a water free basis the noncondensable gases, such as nitrogen or CO.sub.2, will usually be present in an amount of from or about 20 to 93 mol percent of the total effluent, but more often will be within the range of about 40 to 80 mol percent.
*The term "noncondensable" or "inert noncondensable" gases refers to those gases, other than hydrocarbons, such as nitrogen, CO.sub.2 and CO, which do not condense under the conditions encountered.
In those uses wherein the effluent stream passing over the decarbonylation catalyst is deficient in oxygen, particularly less than 1 mole percent of the reactor effluent, the water gas reaction becomes an important consideration and some steam becomes essential to the successful operation of the catalyst in a commercial manner. If the effluent stream is derived from an oxidative dehydrogenation steam will normally be a usual constituent of the effluent stream and in sufficient quantities, i.e., 3 to 30 mols of steam per mole of total organic compound (for example, unsaturated hydrocarbon and carbonyls).
The effluent gases leaving the dehydrogenation zone will generally be at a temperature of at least 400.degree. C. or 450.degree. C. with suitable ranges being between 450.degree. C. or 500.degree. C. and 800.degree. or 900.degree. C. depending upon the particular dehydrogenation process. According to the preferred embodiment of this invention the gases are fed directly into the catalyst bed for the destruction of oxygenated compounds or at least are fed to the catalyst bed prior to condensation of steam from the effluent gases. This catalyst bed may be incorporated into the same reactor chamber as the dehydrogenation bed, e.g., packing material may optionally be added between the dehydrogenation catalyst and the carbonyl destruction catalyst. Generally, the reactor effluent will not cool appreciably before the carbonyl destruction catalyst is encountered and, therefore, the temperature will be within the same ranges as for the reactor effluent. Optionally, prior to contacting with the carbonyl destruction catalyst the gaseous feed may be cooled or heated to give an optimum temperature for carbonyl destruction without adversely affecting the product. Also it is within the scope of the invention to remove portions or components of the reactor effluent prior to contacting with the catalyst. Normally the composition fed to the carbonyl destruction catalyst will contain at least 3 or 5 mols of uncondensed steam per mol of total organic compound such as hydrocarbon and may contain e.g. from 3 to 30 mols of steam. The reactor effluent will generally contain less than 5 mol percent free oxygen and may initially contain less than one mol percent of the reactor effluent. It is possible to add oxygen to the reactor effluent prior to contacting with the carbonyl destruction catalyst such as adding e.g. up to five mols of oxygen per mol of carbonyl compound but care should be exercised to avoid the explosive limits.
The presence of oxygen can be very detrimental in that the present decarbonylation catalysts tend to completely oxidize the unsaturated compound, e.g., hydrocarbon products. Hence, although oxygen can help keep the decarbonylation catalyst from coking, it may do so at the sacrifice of unsaturated product. For this reason, the present invention is carried out with less than 5 mol percent and preferably less than 1 mol percent free oxygen present in the feed passing over the present catalyst.
The gaseous composition to be fed to the carbonyl destruction catalyst zone will preferably comprise, exclusive of any water present, about or from 3.5 to 80 mol percent of unsaturated hydrocarbon, about or from 0.005 to 2.5 mol percent of carbonyl compounds, and about or from 20 to 93 mol percent of noncondensable gases (i.e. noncondensable under the conditions of contact with the catalyst) all based on the total mols of gaseous composition being fed to the catalyst.
Although the removal of any portion of the carbonyl compounds from a gaseous stream indicates the operativeness of the catalyst, preferred processes remove a predominant amount, i.e., at least 50 weight percent of the carbonyl originally present with destruction of only slight amounts of the hydrocarbons.
After the catalyst has been used for a period of time it may be regenerated such as by oxidation with air and/or with steam. Procedures for the regeneration of dehydrogenation catalysts to remove coke may be employed.
The following examples are only illustrative and are not intended to limit the invention. All percentages are by weight unless expressed otherwise.

EXAMPLES 1-23
A series of runs is made to illustrate the effect of a variety of materials including certain catalysts on the destruction of carbonyl compounds in an effluent stream containing unsaturated hydrocarbons. In each instance 25 cc of catalyst of 6 to 8 mesh (U.S. Standard) is employed in a one inch Vycor reactor. The reactor temperature is controlled within the range of 555.degree. to 575.degree. C. The feed to the reactor is a mixture of 6 ml/min. of liquid carbonyl mixture of 0.3% by weight of 50%--50% by weight mixture of formaldehyde and acetaldehyde which is vaporized by passing through a steam generator, 930 ml/min of gaseous nitrogen, and 575 ml/min of gaseous butadiene-1,3 with the gaseous volumes being calculated at 760 mm and 0.degree. C. In the runs in which CO.sub.2 is also added the carbonyl mixture is still fed at a rate of 6 ml per minute but the nitrogen is 720 ml/min, the butadiene-1,3 is 575 ml/min and the CO.sub.2 is 210 ml/min. In all of these feeds steam is present in an amount of 13 mols per mol of hydrocarbon. The contact time of the feed with the catalyst is about 0.05 seconds. The percent removal of carbonyl compounds is analyzed by the hydroxylamine .multidot. HCl method, calculated on feed and effluent as CH.sub.3 CHO (Reference Analytical Chem. Vol. 23, 1758). In the runs where a carrier is employed the percent carrier is the percent by weight based on the total weight of carrier and actives. The alumina carrier is an aluminum oxide carrier type AMC of 6 to 8 mesh (U.S. Standard). The ingredients in the catalyst are by weight percent. In some runs the catalyst is deliberately coated with coke to determine how well it performs under these adverse conditions which might be encountered on prolonged operation. The CO.sub.2 is added in some runs to simulate this adverse condition of the feed. Sampling is started after 30 minutes in order to give to catalyst a chance to equilibrate. The product is then collected for a period of 80 minutes and the collected sample is analyzed for percent carbonyl removal.
______________________________________ %Ex- Catalyst, Carrier, CO.sub.2 Carbonylample wt. % wt. % Present Removal______________________________________1 33.6 ZnO, 65 alumina No 14 1.4 Cu.sub.3 (PO.sub.4).sub.22 Quartz chips -- No 03 SAS 350 Al.sub.2 O.sub.3 No 04 35 calcium 65 alumina No 28 titanate5 14.4 ZnO, 65 alumina No 42 3.9 MnO.sub.2, 16.8 Cr.sub.2 O.sub.3.sup.16 50 Sr(OH).sub.2 50 alumina No 36.sup.27 50 Ca.sub.2 SiO.sub.4 -- No 87 50 calcium aluminate.sup.38 50 Ca.sub.2 SiO.sub.4 -- Yes 64 50 calcium aluminate (Pre- coked catalyst)9 38 2 CaO . SiO.sub.2, - 50 alumina No 94 7 calcium alumi- nate, 5 K.sub.2 CO.sub.310 " -- Yes 8611 69.5 MgO, 20.3 -- " 45 SiO.sub.2, 10 CaHPO.sub.412 Calcium aluminate -- " 7513 98 calcium alumi- -- " 80 nate, 2 CuO14 " -- " 43 (pre-coked)15 96 calcium alumi- -- " 80 nate, 2 CuO, 2 Cr.sub.2 O.sub.316 96 calcium alumi- -- " 43 nate, 2 CuO 2 Cr.sub.2 O.sub.3 (pre-coked) -17 15.9 Cr.sub.2 O.sub.3, 14.5 59.9 alumina " 59 calcium aluminate, 9.7 K.sub.2 CO.sub.318 21.4 calcium alumi- 59.8 alumina " 75 nate, 14.4 Ca.sub.2 SiO.sub.4 4.3 K.sub.2 CO.sub.319 21.4 calcium alumi- " " 53 nate, 14.5 Ca.sub.2 SiO.sub.4, 4.3 K.sub.2 CO.sub.3 (pre- coked)20 15.7 calcium alumi- 66.6 alumina " 75 nate, 12.92 ZnO, 4.8 K.sub.2 CO.sub.321 17.1 Ca Si.sub.2 O.sub.4, 59.8 alumina " 79 14.5 calcium alumi- nate, 4.3 Fe.sub.2 O.sub.3, 4.3 K.sub.2 CO.sub.322 " " " 64 (pre-coked)23 35 Ca.sub.3 (PO.sub.4).sub.2 65 alumina " 0 (catalyst coked)______________________________________ .sup.1 Catalyst of Example 5 prepared by precipitation from combining ZnSO.sub.4. 7H.sub.2 0+MnSO.sub.4. H.sub.2 O and (NH.sub.4).sub.2 CrO.sub.4 solutions. Calcined at 400.degree. C. for 4 hours. .sup.2 Repeat with CO.sub.2 gave 4% .sup.3 Calcium aluminate in all of the examples is Alcoa CA 25 having the empirical molar formula CaO . 2.5 Al.sub.2 O.sub.3.
EXAMPLES 24 to 30.
A series of runs is made feeding a vaporized mixture of 6 liquid ml per minute of 0.3% by weight mixture of 50% formaldehyde and 50% acetaldehyde and 1500 cc gaseous nitrogen per minute through a 25 cc catalyst bed of 6 to 8 mesh size. Runs are made from 4.2 to 8.2 minutes. The reactor is Vycor and the catalyst temperature is 540.degree. to 575.degree. C. Percentages are by weight.
______________________________________ Catalyst Carrier % CarbonylExample wt. % wt. % Removal______________________________________24 Quartz chips -- <125 CaO -- 8526 8 K.sub.2 CO.sub.3 92 silica gel 1927 23.3 ZnO, 74.8 Al.sub.2 O.sub.3 89 2.9 K.sub.2 CO.sub.328 CaCO.sub.3 -- 5029 TiO.sub.2 -- 5830 50 Ca.sub.2 SiO.sub.4 -- 91 50 calcium alumi- nate______________________________________
EXAMPLE 31
A run is made to determine the effect of the catalyst of this invention on unsaturated hydrocarbon products being fed to the catalyst for carbonyl removal. In order to be efficient the catalyst should not only be efficient in removing carbonyls but should not be destructive of the unsaturated products being fed to the carbonyl removal catalyst. For example, in the case of the oxidative dehydrogenation of butylenes to butadiene the effluent contains butadiene contaminated with carbonyl compounds and the effluent from this reaction can be fed to the catalyst for the removal of carbonyl compounds. The catalyst for the removal of the carbonyl compounds should selectively destroy carbonyl compounds but preferably does not destroy butadiene.
Butene-2 is oxidatively dehydrogenated to butadiene-1,3 by feeding a mixture of 15 mols of steam and 0.55 mols of oxygen (as air) per mol of butene-2 to an oxidative dehydrogenation reactor of one inch diameter. The liquid hourly space velocity is 1.5. The dehydrogenation effluent contains butadiene-1,3 in a mol percent conversion of 60.0 percent, mol percent selectivity of 92.8 percent and a mol percent yield of 55.7 percent of butadiene based on the butene-2 fed to the reactor. The temperature of the oxidative dehydrogenation effluent is 940.degree. F. The effluent is fed directly into a one inch long section containing 6-8 mesh alumina catalyst carrier (Type AMC) and fed directly into a one inch diameter stainless pipe which is the carbonyl removal catalyst chamber containing 50 cc of decarbonylation catalyst of 1/16.times.1/16 inch cylindrical pellets. The carbonyl removal catalyst consists by weight of 80% of (97% barium ferrite - 3% H.sub.3 PO.sub.4) and 20 percent K.sub.2 CO.sub.3. The decarbonylation catalyst section is encompassed by an electrical heater for temperature control. The temperature at the top of the decarbonylation catalyst section is 975.degree. F. and the temperature at the exit of the section is 1055.degree. F. The effluent from the carbonyl removal catalyst reactor is again analyzed for butadiene-1,3 and the butadiene product is calculated based on the butene-2 fed to the dehydrogenation reactor. Under these circumstances the overall conversion of butene-2 is 61.1 mol percent, the selectivity is 92.8 and the yield is 56.7 percent butadiene. The percent carbonyls removed are 77 percent, thus, illustrating that a high percentage of the carbonyls are removed and at the same time a high selectivity and yield of butadiene is still achieved after passing through the carbonyl removal section. Although there is an apparent increase in the yield, it is not urged that there was in fact any increase, since the apparent increase is within experimental error for the equipment, process and method of analysis. This data and that in Example 32 are considered to be representative merely of no substantial change in butadiene content of the steam after passage over the decarbonylation catalysts.
EXAMPLE 32.
Example 31 is repeated with the exception that the carbonyl removal catalyst is 80% (97.6% manganese ferrite - 2.4% H.sub.3 PO.sub.4) and 20% K.sub.2 CO.sub.3. The oxidative dehydrogenation effluent is at a temperature of 950.degree. F. and the temperature at the top of the decarbonylation section is 980.degree. F. and at the exit is 1040 .degree. F. The oxidative dehydrogenation effluent contains butadiene-1,3 equivalent to 59.5 mol percent conversion, 92.5 percent selectivity and 55 percent yield. The percent removal of the carbonyl compounds is 59 percent and the conversion, selectivity and yield after passing through the carbonyl removal section is 59.1, 94.1 and 55.6 mol percent.
EXAMPLES 33 to 88.
A series of runs using the apparatus and procedure described in Examples 1-23 is made feeding a mixture of:
______________________________________ ml/min______________________________________aldehyde solution (50/50 mixture of 6 HCHO and CH.sub.3 CHOnitrogen 720butadiene-1,3 575CO.sub.2 210______________________________________
25 cc of 6-8 mesh of the respective catalyst are employed. Examples 33 to 42, 73, 74 and 86 are the results of a sample taken for 40 minutes and the remaining examples are the results of an 80 minute sample and in all examples the catalyst is first run for 30 minutes for equilibration.
______________________________________Ex- %am- Catalyst Carrier Carbonylple Composition, wt. % wt. % Removal______________________________________33 97.9 Magnesium ferrite, 2 H.sub.3 PO.sub.4, 59 .02 Pd.sup.134 ZnO (Harshaw ZN 0401) 4935 8.9 Fe.sub.2 O.sub.3, 0.5 Cr.sub.2 O.sub.3 - SiO.sub.2 4 5.7 K.sub.2 CO.sub.336 Bi.sub.2 O.sub.3 + Fe.sub.2 O.sub.3 (1:1 mol ratio, 84 mixed)37 30 Fe.sub.2 O.sub.3.sup.1 70 alumina.sup.2 4638 25 Barium ferrite.sup.1 75 alumina 8939 59 Fe.sub.2 O.sub.3, 3 Cr.sub.2 O.sub.3 - 85 38 K.sub.2 CO.sub.3 (pre-coked)40 80 Barium ferrite - 93 2 K.sub.2 CO.sub.3.sup.141 " 80 (pre-coked)42 72.4 MgO, 18.4 Fe.sub.2 O.sub.3, 89 4.6 CuO, 4.6 K.sub.2 O.sup.14357 Fe.sub.2 O.sub.3, 15 calcium aluminate.sup.3 70 alumina 7944 14.4 Fe.sub.2 O.sub.3, 13.9 calcium alumi- 70.4 alumina 87 nate.sup.3, 9.5 K.sub.2 CO.sub.3, 4.1 ZnO 0.7 Cr.sub.2 O.sub.345 Girdler ICI - 35 -4 5346 77 Manganese ferrite - 72 3 H.sub.3 PO.sub.4 - 20K.sub.2 CO.sub.3.sup.147 97 Zinc ferrite - 3H.sub.3 PO.sub.4 impreg- 85 nated with Cr.sub.2 O.sub.3.sup.148 4 - 5% Pd on activated carbon 51 (Girdler T1484)49 ZnO, CuO (Girdler G-GGB) 3450 95 WO.sub.3 (Harshaw W-0602T) 1051 24.0 Fe.sub.2 O.sub.3, 15.4 K.sub.2 CO.sub.3, alumina 84 13.1 calcium aluminate 5.7 ZnO, 1.2 Cr.sub.2 O.sub.352 30 ZnCrFeO.sub.4.sup.1 (ferrite) 70 alumina 6, 41 (succes- sive run)53 30 CeO.sub.2.sup.1 70 alumina 4554 33 MgCrFeO.sub.4.sup.1 67 alumina 7255 33 ZnS.sup.1 67 alumina 7956 33 KFe O.sub.2.sup.1 67 alumina 687 33 Ba.sub.0.5 Zn.sub.0.5 Fe.sub.2 O.sub.4.sup.1,4 67 alumina 7558 33 Ca.sub.0.5 Zn.sub.0.5 Fe.sub.2 O.sub.4.sup.1,4 67 alumina 8059 Ca.sub.0.5 Zn.sub.0.5 Fe.sub.2 O.sub.4.sup.1,5 67 alumina 7360 ZnS.sup.1 7361 76 Fe.sub.2 O.sub.3, 19 MgO, 5 CaO.sup.1 remainder % 78 alumina62 33 Ba.sub.0.5 Zn.sub.0.5 Fe.sub.2 O.sub.4.sup.1,5 67 alumina 7963 CoO Girdler F301 6464 33 Nickel ferrite 67 alumina coked65 33 BiFeO.sub.3 67 alumina 2666 33 SrO . Fe.sub.2 O.sub.3 (1:1 mol ratio) 67 alumina 85 (non-calcined)67 50 ZrO.sub.2 50 alumina 7368 25.1 Fe.sub.2 O.sub.3, 19.4 ZrO.sub.2, remainder % 94 11.1 K.sub.2 CO.sub.3 alumina69 17.7 CaCO.sub.3, 21.8 ZrO.sub.2, " 76 9.9 K.sub.2 CO.sub.370 16.4 FeO, 28.1 ZrO.sub.2, 11.1 K.sub.2 CO.sub.3 " 6671 6.9 CaO, 19.5 Fe.sub.2 O.sub.3, 6.6 K.sub.2 CO.sub.3 " 8572 3.5 BaO, 22.1 Fe.sub.2 O.sub.3, 0.8 H.sub.3 PO.sub.4, remainder % 86 6.6 K.sub.2 CO.sub.3 alumina______________________________________ FOOTNOTES for Examples 33 to 72. .sup.1 Catalyst is prereduced with a mixture of steam and hydrogen for 3 hours at 560.degree. C. .sup.2 Alumina used in the series of runs is 6- 8 mesh (U.S. Standard) Type AMC. .sup.3 Alcoa CA25 calcium aluminate. .sup.4 Ferrite prepared at 750.degree. C. .sup.5 Ferrite prepared at 1000.degree. C.
__________________________________________________________________________ % Aldehyde DestructionExample Catalyst Composition, Wt % (successive samples) Remarks.sup.1__________________________________________________________________________73 30% CoO-Fe.sub.2 O.sub.3 /AMC (1:1 mole ratio, non-calcined) 87, 87 Acetone only74 30% CaFe.sub.2 O.sub.4 /AMC (1:1 mole ratio, calcined at 1000.degree. C.) 81, 80 Considerable acetone, little acetaldehyde75 33% SrFe.sub.2 O.sub.4 /AMC 79 Considerable acetone, some acetaldehyde76 25.1% Fe.sub.2 O.sub.3 -19.4% ZrO.sub.2 -11.1% K.sub.2 CO.sub.3 94MC Acetone > acetaldehyde 89 Acetone > acetaldehyde 91 Acetaldehyde >0 acetone 89 Acetaldehyde <acetone77 25.1% Fe.sub.2 O.sub.3 -19.4% ZrO.sub.2 -11.1% K.sub.2 CO.sub.3 83, 79, 92, 89 Acetaldehyde > acetone78 17.7% CaCO.sub.3 -21.8% ZrO.sub.2 -9.9% K.sub.2 CO.sub.3 /AMC 76, 77, 74 Acetaldehyde > acetone79 6.7% CaO-19.0% Fe.sub.2 O.sub.3 -0.8% H.sub.3 PO.sub.4 -6.6% K.sub.2 CO.sub.3 / 85, 82, 91 Considerable acetone, little AMC (CaO used in preparation) acetaldehyde80 Precoked 3.5 BaO-22.1 Fe.sub.2 O.sub.3 -0.8 H.sub.3 PO.sub.4 -6.6 K.sub.2 CO.sub.3 / 75 Acetaldehyde > acetone AMC (BaCO.sub.3 used in preparation)81 Above Ex. 80 regenerated with air 89 Acetone > acetaldehyde82 Aove Ex. 81 with 50 ml/min. O.sub.2 in stream 97 Small acetaldehyde + acetone Mole ratio aldehydes as CH.sub.3 CHO/O.sub.2 =5 Mole ratio Bd/O.sub.2 - .08 O.sub.2 - 0.5 mole % of total stream83 Above Ex. 82 with 34 ml/min. O.sub.2 in stream 88, 83 Acetone > acetaldehyde84 22 Fe.sub.2 O.sub.3 -9.3 K.sub.2 CO.sub.3 -0.7 Cr.sub.2 O.sub.3 - H.sub.3 PO.sub.4 /AMC 49, 35 Acetaldehyde > acetone Prereduced at 620.degree. C.85 Above Ex. 84 prereduced at 565.degree. C. 88, 89, 89 Acetaldehyde + trace of acetone86 Fe.sub.3 O.sub.4 -BaCO.sub.3 -10 K.sub.2 CO.sub.3 (40 92, 92 Little acetaldehyde, some acetone87 85 zinc ferrite - 15 K.sub.3 PO.sub.4 77 CH.sub.3 CHO. Trace acetone88 Same as Ex. 87 above, precoked 75 CH.sub.3 CHO. No__________________________________________________________________________ acetone .sup.1 Qualitative characterization of residual carbonyls, acetone is produced during the carbonyl destruction.
EXAMPLES 89-92.
These examples were carried out in the same equipment and by the same procedures as described above and demonstrate the wide applicability of the Group 1a alkali metal in the catalysts.
__________________________________________________________________________ % Aldehyde Removal.sup.(1) After Coking.sup.(2) After 1/2-Hr. After Another for 3-Hrs. then After 3 Hrs % Alkali Equilibration with 1/2-Hr. Equil. 1 Hr. Equil. w/ Equil. w/ Carbonate lostExample M.sub.2 CO.sub.3 Simultated stream with Stream Stream Stream during operations__________________________________________________________________________89 LiCO.sub.3 86 85 28 51 7.590 Na.sub.2 CO.sub.3 82 82 54 68 8.391 K.sub.2 CO.sub.3 92.sup.(3) 87 55 66 38.092 Rb.sub.2 CO.sub.3 89 87 58 51 38.0__________________________________________________________________________ .sup.(1) Catalyst: 27% (BaCO.sub.3 -Fe.sub.3 O.sub.4) + 3% M.sub.2 CO.sub.3 /AMC, Ba:Fe = 1:12, Temperature: 550.degree. C. .sup.(2) Coking effected with Bd (575 ml/min) and N.sub.2 (720 ml/min); n steam. .sup.(3) This run was conducted at a higher temperature than usual: 570.degree. C.

Number	Name	Date
3459824	Nelson et al.	Aug 1969
3476824	Woskow	Nov 1969
3801669	Christmann	Apr 1972

Purification of unsaturated compounds

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