U.S. patent application number 10/861214 was filed with the patent office on 2004-11-04 for process and catalyst for production of formaldehyde from dimethyl ether.
This patent application is currently assigned to Regents of the University of California. Invention is credited to Iglesia, Enrique, Liu, Haichao.
Application Number | 20040220429 10/861214 |
Document ID | / |
Family ID | 27752903 |
Filed Date | 2004-11-04 |
United States Patent
Application |
20040220429 |
Kind Code |
A1 |
Liu, Haichao ; et
al. |
November 4, 2004 |
Process and catalyst for production of formaldehyde from dimethyl
ether
Abstract
Dimethyl ether is converted to formaldehyde using a supported
catalyst comprising molybdenum and/or vanadium oxides. The surface
density of the oxide(s) ranges from greater than that for the
isolated monomeric oxides upwards, so long as there is a
substantial absence of bulk crystalline molybdenum and/or vanadium
oxide(s). Conversion and selectivity to formaldehyde are improved
as compared to data reported for known catalysts. Also disclosed is
a supported catalyst comprising molybdenum and/or vanadium oxides
wherein the support comprises one or more reducible metal oxides,
preferably a layer or layers of one or more reducible metal oxides
disposed on the surface of a particulate alumina or zirconia
support.
Inventors: |
Liu, Haichao; (Beijing,
CN) ; Iglesia, Enrique; (Moraga, CA) |
Correspondence
Address: |
TOWNSEND AND TOWNSEND AND CREW, LLP
TWO EMBARCADERO CENTER
EIGHTH FLOOR
SAN FRANCISCO
CA
94111-3834
US
|
Assignee: |
Regents of the University of
California
Berkeley
CA
|
Family ID: |
27752903 |
Appl. No.: |
10/861214 |
Filed: |
June 3, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10861214 |
Jun 3, 2004 |
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10371908 |
Feb 20, 2003 |
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6781018 |
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10861214 |
Jun 3, 2004 |
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10081047 |
Feb 20, 2002 |
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Current U.S.
Class: |
568/465 |
Current CPC
Class: |
B01J 37/0201 20130101;
C07C 45/32 20130101; B01J 35/0046 20130101; B01J 23/28 20130101;
B01J 23/22 20130101; C07C 45/37 20130101; C07C 45/32 20130101; C07C
47/04 20130101; C07C 45/37 20130101; C07C 47/04 20130101 |
Class at
Publication: |
568/465 |
International
Class: |
C07C 045/37 |
Claims
1-59. (canceled).
60. A catalyst comprising molybdenum oxide, vanadium oxide, or a
mixture of molybdenum oxide and vanadium oxide supported on a
support comprising one or more layers comprised of a reducible
metal oxide or a mixture of reducible metal oxides, the reducible
oxide layer or layers being disposed on a particulate alumina or
zirconia support, in which the surface density of the molybdenum
and/or vanadium oxide or oxides on the support is greater than that
for the respective monomeric isolated oxide or oxides, and the
catalyst is characterized by a substantial absence of bulk
crystalline molybdenum and/or vanadium oxides.
61. A catalyst according to claim 60 in which the reducible metal
oxides are selected from reducible oxides of tin, iron, cerium,
manganese, cobalt, nickel, chromium, rhenium, titanium, silver and
copper, and mixtures thereof.
62. A catalyst according to claim 60 in which the reducible metal
oxide is selected from oxides of tin, iron, cerium, and mixtures
thereof.
63. A catalyst according to claim 60 in which the reducible metal
oxide comprises stannic oxide.
64. A catalyst according to claim 60 in which the surface density
of the molybdenum and/or vanadium oxide on the support is from
about 50% of the surface density of a monolayer of the oxide or
oxides to about 300% of the surface density of a monolayer of the
oxide or oxides.
65. A catalyst according to claim 60 in which the surface density
of the molybdenum and/or vanadium oxide or oxides on the support is
approximately that of a monolayer of the oxide or oxides at the
surface of the support.
66. A catalyst according to claim 60 comprising molybdenum oxide
supported on a layer of stannic oxide that is disposed on a
particulate alumina support, and in which the surface density of
the molybdenum-oxide is from about 1.5 to about 20 Mo/nm.sup.2.
67. A catalyst according to claim 60 comprising molybdenum oxide
supported on a layer of stannic oxide that is disposed on a
particulate alumina support, and in which the surface density of
the molybdenum oxide is approximately that of a monolayer of the
oxide or oxides at the surface of the support.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part of application Ser. No.
10/081,047 filed Feb. 20, 2002.
FIELD AND BACKGROUND OF THE INVENTION
[0002] This invention relates to a process for production of
formaldehyde, and optionally also methyl formate as a co-product,
by oxidation of dimethyl ether (DME), and to catalysts for use in
the process, including catalysts that are novel per se. In
addition, this invention relates to the use of such novel catalysts
in other processes.
[0003] Formaldehyde is widely used as an intermediate or basic
building block in the commercial synthesis of many chemicals.
Because of the existence of large reserves of methane worldwide it
has been considered desirable for some time to develop processes to
convert methane to more valuable chemicals. One such effort has
been in the area of direct conversion of methane to formaldehyde
via selective oxidation. However, this has not been particularly
successful. Up to now, all such processes have resulted in low
yields due to the tendency of the formaldehyde so produced being
further oxidized to carbon oxides under the severe reaction
conditions required for methane oxidation.
[0004] Instead, formaldehyde is commercially produced from methane
indirectly, for instance, by first converting the methane to
synthesis gas (CO and H.sub.2), then reacting that to form
methanol, and finally oxidizing the methanol to produce
formaldehyde. The oxidation of methanol to formaldehyde has been
extensively studied, and is the dominant process today for
formaldehyde synthesis, typically using silver- or
iron/molybdenum-based catalysts.
[0005] Another possible route to formaldehyde involves the
oxidation of dimethyl ether (CH.sub.3OCH.sub.3) via cleavage of the
C--O--C linkages. This process, however, has not been widely
studied.
[0006] Dimethyl ether is a generally environmentally benign
molecule. Its physical properties resemble those of LPG (liquefied
petroleum gases), and dimethyl ether thus can be transported within
existing and developing LPG infrastructures. Like methanol,
dimethyl ether can be produced from synthesis gas. These
characteristics give it the potential to be a new, clean
alternative fuel. This potential is expected to lead to the
production of substantially larger quantities of dimethyl ether
than in the past, thus making it available for use as an
intermediate in production of other chemicals, including
formaldehyde.
[0007] Several patents disclose processes for producing
formaldehyde from dimethyl ether using various catalysts. U.S. Pat.
No. 2,075,100 describes such a process using a number of
comparatively mild oxidation catalysts including platinum wire or
foil, palladium black, and metals such as gold, silver, and copper.
Vanadium pentoxide and iron, chromium and uranium sesqui-oxides are
termed "very suitable". U.S. Pat. No. 3,655,771 describes using
catalysts containing tungsten oxide, alone or optionally with no
more than 10% of an additive. The additives mentioned include
bismuth, selenium, molybdenum, vanadium, phosphorus and boron
oxides, as well as phosphoric acid, ammonium phosphate and ammonium
chloride.
[0008] More recently, U.S. Pat. No. 4,435,602 describes a process
for production of formaldehyde from dimethyl ether using naturally
occurring manganese nodules as a catalyst. U.S. Pat. No. 4,439,624
describes such a process using an intimate mixture of bismuth,
molybdenum and copper oxides, preferably prepared by
coprecipitation. U.S. Pat. No. 4,442,307 describes such a process
using an intimate mixture of bismuth, molybdenum and iron oxides,
similarly prepared. U.S. Pat. No. 6,256,528 describes oxidation of
dimethyl ether with a catalyst containing metallic silver to
produce a mixture of products including formaldehyde, light
alkanes, carbon oxides and water. Information in these patents
indicates that formaldehyde was produced with reasonable yields,
but that overoxidation of that product to carbon oxides occurred to
an undesirable degree.
[0009] As described above, it would be advantageous to provide a
process and associated process technology for production of
formaldehyde from dimethyl ether with good conversion and good
selectivity to formaldehyde. Preferably such a process could be
operated without the occurrence of substantial direct oxidation of
dimethyl ether to carbon oxides or further oxidation of product
formaldehyde to carbon oxides, thus improving the chemical and
energy efficiency of the process.
BRIEF SUMMARY OF THE INVENTION
[0010] In brief, in one aspect, this invention comprises a process
for the production of formaldehyde by oxidation of dimethyl ether
in the presence of a supported catalyst comprising molybdenum
oxide, vanadium oxide or a mixture of molybdenum and vanadium
oxides. The support is one that substantially does not react with
the molybdenum or vanadium oxide to form unreducible mixed
oxide(s). Preferred supports comprise alumina, zirconia, stannic
oxide, titania, silica, ferric oxide, ceric oxide, other reducible
metal oxides, and mixtures and combinations thereof.
[0011] In one preferred embodiment this invention comprises such a
process in which the molybdenum and/or vanadium oxides are
dispersed on the surface of the support, the surface density of the
oxide or oxides on the support is greater than that for the
isolated monomeric oxide or oxides, and in which the catalyst is
characterized by a substantial absence of bulk crystalline
molybdenum and/or vanadium oxides.
[0012] Most preferably the surface density of the molybdenum and/or
vanadium oxide or oxides on the support is approximately that of a
monolayer of the oxide or oxides at the surface of the support.
[0013] In another preferred embodiment, the catalyst comprises one
or more reducible metal oxides. More preferably in this embodiment,
the catalyst comprises a layer of the reducible metal oxide or
oxides, most preferably stannic oxide, on a particulate support
(preferably alumina and/or zirconia) with the molybdenum and/or
vanadium oxide or oxides being present as an upper layer or layers
on the layer of reducible metal oxide(s) layer. In this embodiment,
preferably the surface density of the molybdenum and/or vanadium
oxide or oxides on the support is greater than that for the
isolated monomeric oxide or oxides, and the catalyst is
characterized by a substantial absence of bulk crystalline
molybdenum and/or vanadium oxides. Most preferably the surface
density of the molybdenum and/or vanadium oxide or oxides on the
support is approximately that of a monolayer of the oxide or oxides
at the surface of the support.
[0014] Catalysts of the above type in which the catalyst comprises
one or more reducible metal oxides, particularly stannic oxide, and
more particularly in which the molybdenum and/or vanadium oxide is
supported on a layer or layers of reducible metal oxide or oxides,
with the oxide layer or layers being disposed on a particulate
alumina and/or zirconia, are novel and form another feature of this
invention.
[0015] Yet another aspect of this invention is the use of the novel
catalysts just described to catalyze other processes, particularly
oxidation of methanol to formaldehyde, oxidative dehydrogenation of
alkanes, and oxidation of alkenes.
DETAILED DESCRIPTION OF THE INVENTION
[0016] In brief, a primary aspect of this invention comprises a
process for the production of formaldehyde by oxidation of dimethyl
ether in the presence of a supported catalyst comprising molybdenum
oxide, vanadium oxide or a mixture of molybdenum and vanadium
oxides. Preferably the oxides are supported on alumina
(Al.sub.2O.sub.3) and/or zirconia (ZrO.sub.2), and more preferably
on such a support that also includes one or more reducible metal
oxides, as described herein. Preferably, the molybdenum and/or
vanadium oxides are dispersed on the surface of the support, the
surface density of the oxide or oxides on the support is greater
than that for the isolated monomeric oxide or oxides, and the
catalyst is characterized by a substantial absence of bulk
crystalline molybdenum or vanadium oxides. More preferably the
molybdenum and//or vanadium oxides are dispersed on a layer or
layers of a reducible oxide or oxides that is further supported on
alumina, titania, silica or zirconia (if zirconia is not used as
the above-mentioned layer).
[0017] Catalysts of this type that comprise molybdenum or vanadium
oxides supported on alumina or zirconia are described in several
prior publications, for catalyzing the oxidative dehydrogenation of
propane to propene. These include Chen, et al., in "Studies in
Surface Science and Catalysis", Vol. 136, pp. 507-512, J. J.
Spivey, E. Iglesia and T. M. Fleisch, Ed. (Elsevier Science, B. V.,
2001); Chen et al., J. Catalysis 189, 421 (2000), Khodakov et al.,
J. Catalysis 177, 343 (1998), Chen et al., J. Catalysis 198, 232
(2001) and Chen et al., J. Phys. Chem. B2011, 105, 646 (2001).
These publications are hereby incorporated herein by reference.
However, these publications do not disclose catalysts containing
stannic oxide, titania, silica, or other supports, and do not
discuss the usefulness or potential usefulness of the disclosed
catalysts for reactions such as the production of formaldehyde from
dimethyl ether.
[0018] In the catalysts of this invention, the molybdenum and/or
vanadium oxide is distributed on the surface of the support
material in what is known as "small domain" distribution. The
surface density of the oxide catalyst on the support (measured in
units of Mo or V metal atoms per nm.sup.2) is chosen so as to be
greater than the surface density of the respective isolated
monomeric oxide or oxides, but the catalyst overall is
characterized by a substantial absence of bulk crystalline
molybdenum and/or vanadium oxides (corresponding to the oxide or
oxides used in preparing the catalyst). By "bulk crystalline
oxides" is meant oxide(s) having a clear X-ray diffraction pattern.
The crystallinity can be determined by X-ray diffraction based on
the peak intensity ratio between one of the peaks of the supported
metal oxide and one of the peaks of the support employed after
calibration with a mixture of known amounts of the metal oxide and
the support. By "substantial absence" is meant that the supported
catalyst contains less than about 5% of bulk crystalline molybdenum
and/or vanadium oxide(s).
[0019] Surface densities of the catalysts in this invention are
given in terms of nominal surface density. This value is calculated
based on the elemental analysis of the molybdenum and/or vanadium
oxide and on the surface area of the support, i.e., by dividing the
number of metal atoms of the catalytic metal (Mo or V) in a given
mass of sample by the surface area of the support (calculated from
N.sub.2 absorption at its normal boiling point using the
Brunauer-Emmett-Teller, or BET, equation). Where the metal oxide
does not appreciably interact with the support to form a complex
(as described below), this calculated surface density fairly
closely conforms to the actual surface density of the metal atoms
on the surface of the support. However, where an appreciable amount
of a complex is formed between the metal oxide and the support, the
(nominal) surface density represents what that value would be were
a complex not formed.
[0020] The surface density of the catalyst affects the catalyst
efficiency. At one extreme, catalysts of this type with relatively
isolated oxide species, for example monomolybdate or monovanadate
species, have relatively few active sites on the support surface.
These catalysts tend to retain their oxygen and thus provide rather
low reaction rates for the oxidation of dimethyl ether to
formaldehyde. At the other extreme, catalysts having bulk crystals
may possibly provide reasonable reaction rates per unit surface
area. However, they also lack efficiency in the utilization of the
oxide catalyst because a substantial amount of the oxide is located
within the crystals and is thus not available for catalyzing the
reaction. Bulk MoO.sub.3 crystals also tend to be nonselective in
their functioning, and can cause overreaction to produce carbon
oxides rather than the desired products formaldehyde and methyl
formate.
[0021] It has been found that the most preferred catalysts for this
reaction tend to have a surface density of approximately a
monolayer of catalyst on the support. The monolayer surface density
depends primarily on the oxide chosen. For molybdenum oxide, the
monolayer surface density is .about.5.0 Mo atoms per square
nanometer of support (Xie et al, Adv. Catal., 37, 1 (1990)). For
vanadium oxide, this value is approximately 7.5 V atoms per square
nanometer (Centi, Appl. Catal. A, 147, 267 (1996)). The term
"monolayer" as used herein is meant to refer to these approximate
surface densities. If the catalyst is uniformly dispersed on the
support, satisfactory results are obtainable with a preferred
surface density of from approximately 50-300% of the monolayer
capacity values for alumina supports, and approximately 50-400% of
these values for zirconia supports. Overall, a preferred range of
surface densities is from about 50 to about 300% of the monolayer
capacity, for both molybdenum and vanadium oxides, for all supports
usable in this invention.
[0022] The molybdenum or vanadium oxide may be present as the oxide
per se, represented by the general formulas MoO.sub.x and VO.sub.y,
where x and y represent general values for oxygen in such
molecules. For MoO.sub.x, the oxide generally comprises about three
oxygen atoms per molybdenum atom; i.e., the general form of the
oxide may be represented as MoO.sub.3, or molybdenum trioxide. For
VO.sub.y, the oxide generally comprises about five oxygen atoms per
two vanadium atoms, represented by the general formula
V.sub.2O.sub.5, or vanadium pentoxide. However, in a given case the
oxide may have an oxygen-to-metal atomic ratio that is not
necessarily exactly 3:1 for molybdenum oxides or 5:2 for vanadium
oxides. Likewise, oxides used as a component of the support may be
represented by more general formulas such as SnO.sub.x, FeO.sub.x
and CeO.sub.x where the oxides generally comprise about 2, 1.5 and
2 oxygen atoms per metallic atom, respectively. However, in a given
case, such oxide may have an oxygen-to-metal atomic ratio that is
not exactly these values.
[0023] In addition, the molybdenum or vanadium oxides may form one
or more complexes or compounds with the support. These complexes
usually also will be an oxide such as polymolybdates and/or
polyvanadates. Such molybdenum complexes may have general formulas
such as ZrMo.sub.2O.sub.8. Vanadium complexes would generally be
represented by the formula M.sub.2xV.sub.2yO.sub.(nx+5y) where M is
the cationic ion of the support and n is the oxidation state of M,
e.g., ZrV.sub.2O.sub.7. In any case, such complexes of molybdenum
and vanadium oxides with the support are considered to be within
the definition of the oxide catalysts to which this invention
pertains.
[0024] For instance, with molybdenum oxide supported on zirconia,
as seen in examples below, where the Mo surface density is below
6.4 Mo/nm.sup.2 the ZrO.sub.2 surface is covered predominantly by
two-dimensional polymolybdates (irrespective of the temperature of
preparation), and the MoO.sub.x domain size increases with
increasing the Mo surface density. At Mo surface densities above
6.4 Mo/nm.sup.2, increase in the Mo surface density leads to the
preferential formation of MoO.sub.3 or ZrMo.sub.2O.sub.8
crystallites on the ZrO.sub.2 surface after treatment in air at 723
and 773 K or at 873 K, respectively. This makes a fraction of the
Mo active centers inaccessible to dimethyl ether reactions and
thus, as described below, leads to a monotonic decrease in the
primary dimethyl ether reaction rates with increasing Mo surface
density (>6.4 Mo/nm.sup.2).
[0025] For such samples where the surface density was greater than
6.4 Mo/nm.sup.2, the areal dimethyl ether reaction rates (per
surface area) and primary selectivities approached constant values
as the Mo surface density increased. This indicates that the
MoO.sub.3 or ZrMo.sub.2O.sub.8 domains at the ZrO.sub.2 surface do
not change in their local structure or surface properties, while
their domain size grows with increasing the Mo surface density. The
surface density of 6.4 Mo/nm.sup.2 exceeds the theoretical
polymolybdate monolayer, which is about 5.0 Mo/nm.sup.2
Nevertheless, the catalyst sample with a surface density of 6.4
Mo/nm.sup.2 exhibited the highest dimethyl ether reaction rates
among the zirconia-supported molybdenum catalyst samples. This
appears to be a compromise between reactivity and accessibility of
the MoO.sub.x sites. The samples having a ZrMo.sub.2O.sub.8
structure possess a higher reactivity compared to the samples
having polymolybdates and MoO.sub.3 crystallines at a given Mo
surface density, which is believed to be a result of the higher
reducibility of the ZrMo.sub.2O.sub.8 species. The reducibility of
the MoO.sub.x domains (characterized by a H.sub.2
temperature-programmed reduction method) was found also to be
dependent on the domain size and structures of the MoO.sub.x
species. The larger MoO.sub.x domains undergo faster reduction
compared to the smaller ones, and ZrMo.sub.2O.sub.8 domains are
more reducible than two-dimensional polymolybdate and MoO.sub.3
domains at a given Mo surface density, reflecting the difference in
the ability of these species to delocalize charge.
[0026] The support may be selected among commonly used supports for
such oxide catalysts, including mixtures of such supports, provided
it allows or favors the formation of a monolayer of molybdenum
and/or vanadium oxide on the surface of the support and otherwise
is suitable for use in the production of formaldehyde from dimethyl
ether. Some properties may make certain supports unsuitable for use
in the process of this invention. For instance, supports that will
react with the molybdenum and/or vanadium oxide to form any
significant amounts of unreducible mixed bulk oxides, i.e. oxides
that would undergo substantial formation of oxygen vacancies at
temperatures below about 300-400.degree. C., would in general not
be suitable for use in this process. One commonly used catalyst
support, magnesium oxide, for example, was tested for suitability
in this process and was found unsuitable. Supports that could cause
undesired combustion of products to form carbon oxides under the
operating conditions of this process, or that contain acid sites
that could cause formation of excessive amounts of methanol under
the conditions of this process also would not be suitable for use
in this invention.
[0027] The catalyst preferably contains molybdenum or vanadium
oxide, but may contain a combination of the two. When both oxides
are present in the catalyst, one may be present as a layer of oxide
on the support, preferably close to a monolayer, and the other
present as a layer on top of the first oxide layer. Catalysts of
this invention thus may comprise a layer, preferably approximately
a monolayer, of one of molybdenum or vanadium oxide on a layer,
preferably approximately a monolayer, of the other, on a support
such as alumina or zirconia. The support may optionally further
comprise a reducible metal oxide as described below.
[0028] Preferred supports include alumina, zirconia, titania,
silica, and reducible metal oxides such as stannic oxide, ferric
oxide, ceric oxide, and mixtures or other combinations of two or
more of these oxides. Particularly preferred are alumina, zirconia
and stannic oxide, arid mixtures or other combinations of two or
all three of them. Most preferred is a catalyst comprising alumina,
titania, zirconia or silica modified by the incorporation of a
layer or layers of a reducible oxide such as zirconia, stannic
oxide, ferric oxide or ceric oxide deposited thereon. The supports
that are suitable for use in this process may be used in any of
their available forms, including forms that as of the present time
might not yet have been developed, or may have been developed but
have not yet been commercialized. Both high and low surface area
supports may be used, including materials known by the acronym MCM
(standing for Mobil Compositions of Matter), e.g., MCM-41. These
are recently developed mesoporous materials (often comprising
silica) and are described in Kresge, et al., (Nature, 359, 710
(1992)) and by Corma (Chem. Rev., 97, 2373 (1997)). High surface
area supports of various physical types are preferred for use in
the invention from the point of view of efficiency in that they may
produce greater amounts of product per unit mass of overall
catalyst.
[0029] Reducible metal oxides suitable for inclusion in the
catalysts of this invention are those in which at least a fraction
of the metal cations undergo a one- or two-electron reduction
during contact with a reactant such as hydrogen, dimethyl ether,
methanol, alkanes or alkenes at typical temperatures of catalytic
oxidation reactions, whether or not such metal oxides function as
catalyst for the reaction in question. The fraction of the
reducible metal oxide that undergoes such reduction need not be
large, as the effect of the reducible metal oxide is continuous.
Such reducible metal oxides include reducible oxides of tin, iron,
cerium, manganese, cobalt, nickel, chromium, rhenium, titanium,
silver and copper, and mixtures thereof. Of these, oxides of tin
(e.g., stannic oxide), iron (e.g., ferric oxide) and cerium (e.g.,
ceric oxide) are preferred, with stannic oxide being most preferred
for such catalysts of this invention.
[0030] Novel catalysts of this invention include those in which the
support comprises a layer of a reducible metal oxide disposed on a
particulate alumina and/or zirconia (except where zirconia is used
as the above-mentioned layer), or a layer of zirconia disposed on a
particulate alumina, particularly those in which the layer of or
zirconia has a surface density close to that of a monolayer of that
substance. Exemplary catalysts may comprise molybdenum and/or
vanadium oxide on a near-monolayer of stannic oxide disposed on a
particulate (preferably high surface area) alumina. Novel catalysts
of this invention also include those in which the reducible metal
oxide or oxides is incorporated into the support.
[0031] Without intending to be bound by an explanation, it is
believer that the reducible metal oxides aid in catalyst
performance by decreasing the temperature required for the
reduction of some of the molybdenum and/or vanadium atoms from
their highest oxidation state.
[0032] The novel catalysts of this invention that contain reducible
metal oxides also are suitable as catalysts for other reactions and
processes, including but not limited to oxidation of methanol to
produce formaldehyde, oxidative dehydrogenation of alkanes, and
oxidation of alkenes.
[0033] The catalysts of the invention are prepared by typical
means, for instance by impregnation, particularly incipient wetness
impregnation, of the support with an aqueous solution containing
molybdenum and/or vanadium, e.g. using a salt such as an ammonium
molybdate or vanadate, for instance, ammonium di- or heptamolybdate
or ammonium metavanadate. The preparation is carried out so as to
disperse the molybdenum and/or vanadium oxide over the surface of
the support and the amounts are chosen so as to achieve a desired
surface density. Where the catalyst also comprises a reducible
metal oxide, for instance as a layer on a particulate support, the
reducible metal oxide may be first deposited on the particulate
support, for instance by impregnation such as incipient wetness
impregnation. Then the molybdenum and/or vanadium oxide is
deposited on the support in a second step, e.g. a second
impregnation. Preparation of such catalysts by incipient wetness
impregnation is described in the Chen et al. and Khodakov et al.
publications mentioned above.
[0034] Catalysts of this invention may alternatively be prepared by
other means such as chemical vapor deposition of layers,
precipitation, sol-gel methods and the like. Reducible metal oxides
may be incorporated into the catalysts either before or after the
incorporation of the molybdenum and/or vanadium oxides.
[0035] The primary products of the reaction are formaldehyde and
methyl formate. Production of methyl formate can be increased if
desired, by decreasing the surface density of metal oxide or
choosing a specific support such as stannic oxide and/or zirconia,
or it may be decreased (which is generally preferred since
formaldehyde is typically the preferred product) by providing a
catalyst having a surface density close to the value for a
monolayer of catalyst, which, as will be shown below, generally has
the highest selectivity to formaldehyde of the catalysts of the
invention. However, production of methyl formate is to be expected
in such a process, and is not especially detrimental as methyl
formate has uses of its own as a chemical intermediate and can
readily be separated from the reaction products and forwarded to
other process units for such uses.
[0036] Methanol is also produced in processes of this type, but it
dehydrates relatively readily to re-form dimethyl ether. The
methanol produced can be recovered and recycled. Alternatively,
methanol produced by this reaction may be forwarded to another
unit, either for production of further formaldehyde using a typical
catalyst for that process, or for other uses as a chemical
intermediate. Methanol formation therefore can be essentially
disregarded in calculating selectivity of the dimethyl ether to
formaldehyde.
[0037] The feed to the process may include, in addition to dimethyl
ether, mixtures of dimethyl ether and methanol, provided that
dimethyl ether is the major component of such mixtures. The
oxidizing agent may be air, oxygen-enriched air, or even pure
oxygen (though this is likely to be unnecessarily costly).
[0038] The process of this invention may be run in equipment
ranging in size from microreactors (e.g. microchannel reactors) to
full-sized commercial process equipment. A commercial installation
will include typical process expedients such as recycle streams,
for efficient use of reactants and reaction products, and may be
integrated with process units for production of dimethyl ether or
for production of products from formaldehyde.
[0039] As compared with data in patents mentioned above, the
process of this invention exhibits both improved conversions of
dimethyl ether as well as improved selectivity to formaldehyde, and
can achieve these results at lower temperatures. The process of
this invention may be operated in general at temperatures of from
about 150 to about 400.degree. C., preferably from about 180 to
about 350.degree. C., most preferably from about 150 to about
320.degree. C. Operating pressures are about 0.1-100 atm,
preferably about 1-20 atm. Residence time generally ranges from
about 1 to about 60 seconds.
EXAMPLES
[0040] The following are representative examples of this invention.
These examples are provided by way of illustration only and not by
way of limitation. Those of skill will readily recognize a variety
of noncritical parameters that could be changed or modified to
yield essentially similar results.
Example 1
Production of Formaldehyde from Dimethyl Ether using Molybdenum
Catalysts Supported on Alumina, Zirconia and Stannic Oxide
[0041] Supported MoO.sub.x catalysts were prepared by incipient
wetness impregnation of ZrO(OH).sub.2, SnO.sub.2, or
Al.sub.2O.sub.3, respectively, with aqueous
(NH.sub.4).sub.2Mo.sub.2O.sub.8 (99%, Aldrich) solutions (13-15).
ZrO(OH).sub.2 was prepared by hydrolysis of aqueous zirconyl
chloride solutions (>98%, Aldrich) using NH.sub.4OH (14.8 N),
followed by drying in ambient air at 393 K overnight. SnO.sub.2 was
prepared by hydrolysis of tin (IV) chloride pentahydrate (98%, Alfa
Aesar) with NH.sub.4OH (14.8 N), followed by treatment in flowing
dry air at 773 K for 3 h. A commercial source of
.gamma.-Al.sub.2O.sub.3 (Degussa A G) was used without further
treatment. All samples were dried after impregnation at 373 K in
ambient air and then treated in flowing dry air at 773 K for 3 h.
Bulk MoO.sub.3 powders were prepared by decomposition of
(NH.sub.4).sub.2Mo.sub.2O.sub.8 (99%, Aldrich) in flowing dry air
at 773 K for 3 h.
[0042] Dimethyl ether reactions were carried out in a fixed-bed
quartz microreactor using catalysts (0.3 g) diluted with quartz
powder (1 g) in order to prevent local high temperatures caused by
the exothermic nature of the reaction. The reactant mixture
consisted of 80 kPa DME and 18 kPa O.sub.2, and 2 kPa N.sub.2 was
used as an internal standard. Reactants and products were analyzed
by on-line gas chromatography (Hewlett-Packard 6890 GC) using flame
ionization and thermal conductivity detectors and methyl-silicone
capillary and Porapak.RTM. Q packed columns.
[0043] Table 1 shows catalytic results obtained at 513 K on
MoO.sub.x domains supported on Al.sub.2O.sub.3, ZrO.sub.2 and
SnO.sub.2 with similar Mo surface densities (6.4-7.0
Mo-atoms/nm.sup.2), alone and compared with results reported in
previous patents. Rates and selectivities (in all tables) were
measured as a function of DME conversion, which was changed by
varying the reactant residence time. DME conversion rates and
formaldehyde selectivities were extrapolated to zero reactant
residence time in order to obtain primary DME conversion rates and
selectivities. DME conversion rates and selectivities are reported
in two forms in the results shown in Table 1. One approach
considers CH.sub.3OH as a DME conversion product; the other
approach reports rates and selectivities on a CH.sub.3OH-free
basis, which seems appropriate in view of the reversible nature of
DME conversion to methanol and the pathways available for the
ultimate conversion of both CH.sub.3OH and DME to HCHO.
[0044] Primary reaction rates (normalized by catalyst mass) were
much higher on the three catalysts of the invention than on
catalysts previously reported in the patents, even at the lower
temperatures used here. Rates were higher on SnO2 and ZrO.sub.2
supports than on Al.sub.2O.sub.3, but the primary formaldehyde
selectivity (CH.sub.3OH-free) was almost 100% on
MoO.sub.x/Al.sub.2O.sub.3. Pure supports showed very low DME
conversion rates. A MoO.sub.3 sample with relatively low surface
area gave a low DME conversion rate (per gram), but its areal rate
resembled those on MoO.sub.x/Al.sub.2O.sub.3 and was 2-6 times
lower than on MoO.sub.x supported on ZrO.sub.2 and SnO.sub.2. Thus,
DME conversion appears to require small MoO.sub.x domains with much
greater accessibility to reactants than those available in bulk
MoO.sub.3 samples. Formaldehyde was not detected on MoO.sub.3 at
513 K, because of the low DME conversions attained. At higher
temperatures (593 K), the primary HCHO selectivity was 52.9% (on a
CH.sub.3OH-free basis) on bulk MoO.sub.3. MoO.sub.x/Al.sub.2O.sub.3
was the most selective catalyst for DME conversion to HCHO. Its
primary HCHO selectivity was 79.1% (98.1%, CH.sub.3OH-free basis)
and CO and CO.sub.2 (CO.sub.x) were not detected as primary
products.
[0045] Included in these tests was a catalyst similarly prepared
comprising molybdenum oxide supported on magnesium oxide. MgO was
prepared by contacting MgO (>98%, Aldrich) with deionized water
at 355-365 K for 4 h, followed by treatment in flowing dry air at
773 K for 8 h. As seen from Table 1, however, MoO.sub.x domains
supported on MgO did not give detectable DME conversion rates,
apparently as a result of the formation of mixed metal oxides,
which are unable to undergo reduction-oxidation cycles required for
catalytic DME conversion turnovers at these temperatures. This
support thus appears unsuitable for use with the catalysts in this
process.
1TABLE 1 DME oxidation rates and selectivities on supported
MoO.sub.x catalysts at 513 K (80.0 kPa, 18 kPa O.sub.2 and 2 kPa
N.sub.2), on bulk MoO.sub.3, on pure supports, and on previously
reported catalysts. DIMETHYL ETHER DME DME Mo Conversion Conversion
Conversion Catalyst Surface surface Temper- Rate.sup.d Rate.sup.d
Rate.sup.d (MoO.sub.3 area density ature (mmol/ (mol/g-atom
(10.sup.-5 Selectivity (%).sup.d wt %) (m.sup.2/g) (Mo/nm.sup.2)
(K) g.sub.-cat-h) Mo-h) mol/m.sup.2-h) CH.sub.3OH HCHO MF.sup.a
DMM.sup.b CO.sub.x.sup.c Reference MoO.sub.3/ZrO.sub.2 136.3 6.4
513 17.6 12.2 12.9 22.6 53.4 16.8 0.3 6.9 This study (20.7%) (13.6)
(9.4) (69.0) (21.7) (0.4) (8.9) MoO.sub.3/SnO.sub.2 46.5 6.5 513
18.4 36.5 39.6 13.1 67.3 9.6 0 9.8 This study (7.2%) (16.0) (31.7)
(77.6) (11.1) (0) (11.3) MoO.sub.3/Al.sub.2O.sub.3 90.0 7.0 513 5.8
5.7 6.6 19.7 79.9 1.6 0 0 This study (15.0%) (4.7) (4.6) (98.1)
(1.9) (0) (0) MoO.sub.3/MgO 171.2 5.8 513 not detected not detected
-- -- -- -- -- -- This study (24.0%) ZrO.sub.2 106.4 -- 513 not
detected -- -- -- -- -- -- -- This study SnO.sub.2 48.8 -- 513 0.6
-- 1.2 29.7 0 0 0 70.3 This study Al.sub.2O.sub.3 110 -- 513 0.2 --
0.2 82.9 0 0 0 17.1 This study MoO.sub.3 3.3 -- 513 0.2 -- 6.1 6.0
0 0 0 94.0 This study .sup.eAg -- -- 887 10.5 -- -- -- 45.8 0 0
30.7 10 .sup.fBi--Mo-- -- -- 773 3.1 -- -- 0 46.0 0 0 54.0 7
FeO.sub.x .sup.gBi--Mo-- -- -- 773 2.9 -- -- 0 43.0 0 0 55.0 8
CuO.sub.x .sup.hMn nodules .about.230 -- 623 1.7 -- 0.7 -- 49.0 --
-- -- 9 .sup.aMF: Methyl formate; .sup.bDMM: dimethoxymethane;
.sup.cCO.sub.x: CO + CO.sub.2; .sup.dThe data in parentheses are
reported on a CH.sub.3OH-free basis by excluding CH.sub.3OH as a
reaction product in view of its reactivity in formaldehyde
synthesis and its tendency to dehydrate to re-form
CH.sub.3OCH.sub.3. .sup.efrom U.S. Pat. No. 6,265,528; Reactants:
59.9 kPa DME, 8.5 kPa O.sub.2, 31.6 kPa N.sub.2. .sup.ffrom U.S.
Pat. No. 4,442,307; Reactants: 5.0 kPa DME, 20.0 kPa O.sub.2, 75.0
kPa N.sub.2. .sup.gfrom U.S. Pat. No. 4,439,624; reactants same as
(f); .sup.hfrom U.S. Pat. No. 4,435,602; reactants same as (f).
Example 2
Additional Tests with Molybdenum Oxide Catalysts Supported on
Alumina
[0046] A parallel study showed that the catalytic properties of
these MoO.sub.x domains depend sensitively on their size and local
structure, which were varied by changing the Mo surface density on
Al.sub.2O.sub.3 (1.6-11.3 Mo/nm.sup.2) and ZrO.sub.2 (2.2-30.6
Mo/nm.sup.2). Primary DME reaction rates increased from 2.3 to 5.7
mol/g-atom Mo-h as the Mo surface density increased from 1.6 to 7.0
Mo/nm.sup.2 on Al.sub.2O.sub.3 (Table 2). These rates increased
from 0.6 to 12.2 mol/g-atom Mo-h as the Mo surface density
increased from 2.2 to 6.4 Mo/nm.sup.2 on ZrO.sub.2. On both
ZrO.sub.2 and Al.sub.2O.sub.3, DME conversion rates per Mo reached
maximum values at surface densities of 6-7 Mo/nm.sup.2. Results are
reported in Table 2.
[0047] X-Ray diffraction and Raman, UV-visible, and X-ray
absorption spectroscopies did not detect MoO.sub.3 crystallites in
samples with surface densities below 7 Mo/nm.sup.2. In this Mo
surface density range, most, if not all, MoO.sub.x species are
accessible at surfaces and the DME conversion rates per Mo atom are
equivalent to rates per exposed MoO.sub.x moiety (i.e. turnover
rates). Therefore, the higher reaction rates attained with
increasing surface density reflect a higher reactivity of exposed
MoO.sub.x as the size and dimensionality of MoO.sub.x domains
increases with increasing Mo surface density. The larger domains
formed at higher MoO.sub.x surface densities (detected by
measurements of their absorption edge energy in the UV-visible
spectra) appear to undergo the redox cycles required for DME
conversion to HCHO with greater ease than isolated monomolybdate
species or smaller two-dimensional polymolybdate domains.
[0048] This interpretation is consistent with the observed decrease
in the temperature required for H.sub.2 reduction of Mo.sup.6+ to
Mo.sup.4+ in these samples. Ultimately, DME conversion rates (per
Mo) decreased at even higher Mo surface densities (>10
Mo/nm.sup.2), because the incipient formation of three-dimensional
MoO.sub.3 clusters leads to increasingly inaccessible MoO.sub.x
species.
[0049] Primary formaldehyde selectivities also increased
monotonically with increasing Mo surface density; they reached
79.1% (98.1% on a CH.sub.3OH-free basis) on
MoO.sub.x/Al.sub.2O.sub.3 at 11.3 Mo/nm.sup.2. Methanol
selectivities decreased as the Al.sub.2O.sub.3 support was covered
with MoO.sub.x species, and the primary formaldehyde selectivity
concurrently increased with increasing Mo surface density. Methyl
formate and CO.sub.x primary selectivities were very low on all
Al.sub.2O.sub.3-supported MoO.sub.x samples. On
Al.sub.2O.sub.3-supported samples with surface densities of 1.6 to
11.3 Mo/nm.sup.2, the CH.sub.3OH-free primary HCHO selectivity was
95.2-98.1% (Table 2).
2TABLE 2 Effects of surface density of MoO.sub.x/Al.sub.2O.sub.3
catalysts on primary DME reaction rates and primary products at 513
K (80.0 kPa, 18 kPa O.sub.2 and 2 kPa N.sub.2). MoO.sub.3 loading
Mo surface density Rate.sup.d Rate.sup.d Selectivity (%).sup.d
(MoO.sub.3 wt %) (Mo/nm.sup.2) (mol/g-atom Mo-h) (10.sup.-5
mol/m.sup.2-h) CH.sub.3OH HCHO MF.sup.a DMM.sup.b CO.sub.x.sup.c
4.0% 1.6 2.3 0.6 34.1 62.8 2.5 0 0.8 .sup. (1.5).sup.d .sup.
(0.4).sup.d (95.2) (3.7) (0) (1.2) 8.0% 3.4 3.9 2.2 27.0 70.5 2.4 0
0.2 (2.8) (1.6) (96.5) (3.2) (0) (0.3) 10.0% 4.5 5.2 4.0 22.1 76.3
1.5 0 0.1 (4.1) (3.1) (97.9) (1.9) (0) (0.1) 15.0% 7.0 5.7 6.6 19.5
79.1 1.6 0 0 (4.6) (5.3) (98.1) (1.9) (0) (0) 20.0% 11.3 3.8 7.1
19.4 79.0 1.6 0.1 0 (3.1) (5.7) (98.0) (1.9) (0.1) (0) .sup.aMF:
Methyl formate; .sup.bDMM: dimethoxymethane; .sup.cCO.sub.x: CO +
CO.sub.2; .sup.dThe data in parentheses are reported on a
CH.sub.3OH-free basis by excluding CH.sub.3OH as a reaction product
in view of its reactivity in formaldehyde synthesis and its
tendency to dehydrate to re-form CH.sub.3OCH.sub.3.
Example 3
Effect of Temperature on Reaction Rates and Primary Products
[0050] Table 3 shows results of a study comparing reaction rates
and selectivity at temperatures of 473-533 K (200-250.degree. C.).
The catalyst used contained 15 wt. % MoO.sub.3 on alumina with a
surface density of 7.0 Mo/nm.sup.2. As the temperature was
increased from 473 to 533 K, the reaction rate increased
significantly, and selectivity to formaldehyde (as opposed to
methyl formate) also increased significantly.
3TABLE 3 Effects of temperature on primary DME reaction rates and
primary products on MoO.sub.x/Al.sub.2O.sub.3 catalyst (15 wt. %
MoO.sub.3; 7.0 Mo/nm.sup.2) (80.0 kPa, 18 kPa O.sub.2 and 2 kPa
N.sub.2). Rate.sup.d (mol/ Selectivity (%).sup.d Temperature g-atom
Mo-h) CH.sub.3OH HCHO MF.sup.a DMM.sup.b CO.sub.x.sup.c 473 1.3
24.2 69.2 4.2 0.2 2.1 (1.0) (91.2) (5.5) (0.3) (2.8) 493 2.9 23.8
73.1 2.0 0 1.2 (2.2) (95.9) (2.6) (0) (1.6) 513 5.7 19.5 79.1 1.6 0
0 (4.6) (98.1) (1.9) (0) (0) 533 12.9 17.3 81.0 1.8 0 0 (10.7)
(97.9) (2.1) (0) (0) .sup.aMF: Methyl formate; .sup.bDMM:
dimethoxymethane; .sup.cCO.sub.x: CO + CO.sub.2; .sup.dThe data in
parentheses are reported on a CH.sub.3OH-free basis by excluding
CH.sub.3OH as a reaction product in view of its reactivity in
formaldehyde synthesis and its tendency to dehydrate to re-form
CH.sub.3OCH.sub.3.
Example 4
Further Experiments with Molybdenum Oxide Catalysts Supported on
Zirconia
[0051] A series of molybdenum oxide catalysts supported on
zirconia, having a range of surface densities and prepared by
calcining at two different temperatures was used to catalyze the
production of formaldehyde from dimethyl ether.
[0052] The catalysts were prepared by incipient wetness
impregnation of precipitated zirconium oxyhydroxide (ZrO(OH).sub.2)
with an aqueous solution of ammonium dimolybdate
[(NH.sub.4).sub.2Mo.sub.2O.sub.8] (99%, Aldrich). Zirconium
oxyhydroxide (ZrO(OH).sub.2) was prepared by precipitation of a
zirconyl chloride solution (98%, Aldrich) at a constant pH of 10 by
controlling the rate of addition of ammonium hydroxide solution
(29.8%, Fisher Sci.). After precipitation, the solids were washed
with mildly basic ammonium hydroxide solution (pH.about.6) until
the effluent showed no chloride ions tested by a silver nitrate
solution. The resulting solids were dried in air overnight at 393 K
(120.degree. C.). The dried solids were impregnated with an aqueous
solution of ammonium dimolybdate at room temperature. The Mo.sup.6+
concentrations in the solution were varied in order to get desired
Mo content in the final catalysts. After impregnation, samples were
dried in air at 393 K and treated in dry air at 723, 773 or 873 K
(450, 500 and 600.degree. C.) for 3 h.
[0053] The catalysts were systematically characterized by means of
powder X-ray diffraction (XRD), diffuse reflectance UV-visible,
Raman, and X-ray absorption (XANES/XAFS) spectroscopies. Surface
areas were measured by N2 physisorption using standard multipoint
BET method. Mo surface density is expressed as the number of Mo
atoms per square nanometer BET surface area (Mo/nm.sup.2). The
catalysts so prepared are listed in Table 4.
4TABLE 4 Surface areas and Mo surface density for
MoO.sub.x/ZrO.sub.2 catalysts treated at 723, 773 and 873 K. 723 K
773 K 873 K MoO.sub.3 Loading Surface area Mo surface density
Surface area Mo surface density Surface area Mo surface Sample (wt.
%) (m.sup.2/g) (Mo/nm.sup.2) (m.sup.2/g) (Mo/nm.sup.2) (m.sup.2/g)
density (Mo/nm.sup.2) 1MoO.sub.x/ZrO.sub.2 1.0% 118.8 0.3 105.6 0.4
85.6 0.5 6MoO.sub.x/ZrO.sub.2 5.7% 130.0 1.8 110.3 2.2 97.1 2.5
11MoO.sub.x/ZrO.sub.2 11.0% 145.9 3.2 132.6 3.5 103.4 4.5
21MoO.sub.x/ZrO.sub.2 20.7% 153.7 5.6 136.3 6.4 102.7 8.4
29MoO.sub.x/ZrO.sub.2 29.3% 114.0 10.7 96.9 12.6 64.6 20.0
37MoO.sub.x/ZrO.sub.2 37.0% 99.6 15.5 73.9 20.9 49.3 31.4
44MoO.sub.x/ZrO.sub.2 44% 83.5 22.0 60.2 30.6 36.7 50.1
[0054] Tables 5 and 6 show the results using catalysts so prepared
and calcined at 773 K and 873 K, respectively. Both catalysts
demonstrated very good dimethyl ether conversion rates and
selectivity, with better performance being exhibited in general by
the catalyst that had been calcined at 873 K.
5TABLE 5 Effects of surface density of MoO.sub.x/ZrO.sub.2
catalysts (calcined at 773 K) on primary DME reaction rates and
primary products at 513 K (80.0 kPa, 18 kPa O.sub.2 and 2 kPa
N.sub.2). MoO.sub.3 loading Mo surface density Rate.sup.d
Rate.sup.d Selectivity (%).sup.d (MoO.sub.3 wt. %) (Mo/nm.sup.2)
(mol/g-atom Mo-h) (10.sup.-5 mol/m.sup.2-h) CH.sub.3OH HCHO
MF.sup.a DMM.sup.b CO.sub.x.sup.c 11.0% 3.5 8.5 4.9 24.0 32.3 30.0
0 13.7 (6.5) (3.7) (42.5) (39.5) (0) (18.1) 20.7% 6.4 12.2 12.9
22.6 53.4 16.8 0.3 6.9 (9.4) (10.0) (68.9) (21.7) (0.4) (8.9) 29.3%
12.6 4.1 8.6 22.3 62.9 8.4 0.2 6.4 (3.2) (6.7) (80.8) (10.7) (0.2)
(8.2) 37.0% 20.9 3.2 11.1 23.0 66.9 7.6 0.1 2.4 (2.5) (8.6) (86.9)
(9.8) (0.1) (3.1) 44.0% 30.6 2.0 10.4 22.4 68.6 5.0 0 4.0 (1.6)
(8.1) (88.4) (6.5) (0) (5.1) .sup.aMF: Methyl formate; .sup.bDMM:
dimethoxymethane; .sup.cCO.sub.x: CO + CO.sub.2; .sup.dThe data in
parentheses are reported on a CH.sub.3OH-free basis by excluding
CH.sub.3OH as a reaction product in view of its reactivity in
formaldehyde synthesis and its tendency to dehydrate to re-form
CH.sub.3OCH.sub.3.
[0055]
6TABLE 6 Effects of surface density of MoO.sub.x/ZrO.sub.2
catalysts (calcined at 873 K) on primary DME reaction rates and
primary products at 513 K (80.0 kPa, 18 kPa O.sub.2 and 2 kPa
N.sub.2). MoO.sub.3 loading Mo surface density Rate.sup.d
Rate.sup.d Selectivity (%).sup.d (MoO.sub.3 wt. %) (Mo/nm.sup.2)
(mol/g-atom Mo-h) (10.sup.-5 mol/m.sup.2-h) CH.sub.3OH HCHO
MF.sup.a DMM.sup.b CO.sub.x.sup.c 11.0% 4.5 23.0 17.0 24.9 46.0
23.5 0.4 5.2 (17.3) (13.0) (61.2) (31.3) (0.5) (7.0) 20.7% 8.4 46.5
51.7 23.7 60.1 11.5 0.8 4.0 (35.5) (39.5) (78.6) (15.1) (1.1) (5.2)
29.3% 20.0 19.0 60.0 24.1 59.6 12.2 0.9 3.2 (14.4) (45.5) (78.5)
(16.1) (1.2) (4.2) 37.0% 31.4 11.7 61.1 24.9 58.3 12.6 1.1 3.0
(8.8) (45.9) (77.7) (16.8) (1.5) (4.0) 44.0% 50.1 7.4 61.3 27.8
60.1 10.4 0.9 1.3 (5.3) (44.3) (82.7) (14.4) (1.2) (3.8) .sup.aMF:
Methyl formate; .sup.bDMM: dimethoxymethane; .sup.cCO.sub.x: CO +
CO.sub.2; .sup.dThe data in parentheses are reported on a
CH.sub.3OH-free basis by excluding CH.sub.3OH as a reaction product
in view of its reactivity in formaldehyde synthesis and its
tendency to dehydrate to re-form CH.sub.3OCH.sub.3.
[0056] In other work, the effect of partial pressures on the
reaction was investigated on the 44 MoO.sub.x/ZrO.sub.2 catalyst
(50.1 Mo/nm.sup.2). The reaction rates nearly increased linearly as
the DME partial pressure increased from 10 to 40 kPa, and then
approached the constant values above 60 kPa. The primary
selectivities to methyl formate and dimethoxymethane were almost
independent of the DME partial pressure. The primary selectivity to
CO.sub.x decreased from 6.0% to the constant value of 1.5% while
the selectivity to HCHO increased from 78.3 to 82.7% with
increasing the DME pressure from 10 to 40 kPa.
Example 5
Preparation and Use of Supported Vanadium Pentoxide Catalysts
[0057] The catalysts were prepared by incipient wetness
impregnation of .gamma.-Al.sub.2O.sub.3 (Degussa A G) with an
aqueous solution of ammonium metavanadate [NH.sub.4NO.sub.3] (99%,
Aldrich) and oxalic acid (Mallinckrodt, analytical grade;
NH.sub.4/NO.sub.3/oxalic acid=0.5 M) (the addition of oxalic acid
improves the dissolution of NH.sub.4NO.sub.3 in water). The
V.sup.5+ concentrations in the solution were varied in order to get
desired V content in the final catalysts. After impregnation,
samples were dried in air at 393 K and treated in dry air at 773 K
(500.degree. C.) for 3 h.
[0058] On VO.sub.x/Al.sub.2O.sub.3 (8.0 V/nm .sup.2) the
CH.sub.3OH-free primary HCHO selectivity was 99.6% at 513 K and the
primary DME reaction rate was 6.8 mol/g-atom V-h. Results are shown
in Table 7.
7TABLE 7 Primary DME reaction rates and primary products on
VO.sub.x dispersed on different supports at 240.degree. C. (80.0
kPa, 18 kPa O.sub.2 and 2 kPa N.sub.2). Catalyst V surface density
Rate.sup.a Rate.sup.a Selectivity (%) (V.sub.2O.sub.5 wt. %)
(V/nm.sup.2) (mol/g-atom V-h) (10.sup.-5 mol/m.sup.2-h) CH.sub.3OH
HCHO MF.sup.b DMM.sup.c CO.sub.x.sup.d VO.sub.x/Al.sub.2O.sub.3 8.0
8.0 6.7 14.72 84.96 0.26 0 0 (10.0%) (6.8) (5.6) (99.61) (0.3)
VO.sub.x/ZrO.sub.2 6.2 13.1 8.5 5.2 37.9 9.2 0 47.7 (15%) (12.4)
(8.1) (40.0) (9.7) (50.3) VO.sub.x/MgO 5.5 1.8 1.0 11.0 0 0 0 89.0
(20.0%) .sup.aThe data in the parentheses are reported on a
CH.sub.3OH-free basis by excluding CH.sub.3OH as a reaction product
in view of its reactivity in formaldehyde synthesis and its
tendency to dehydrogenate to re-from CH.sub.3OCH.sub.3; .sup.bMF:
methyl formate; .sup.cDMM: dimethoxymethane; .sup.dCO.sub.x: CO +
CO.sub.2.
Example 6
Use of Mixed Oxide Catalysts
[0059] Similarly, experiments were conducted using a catalyst
containing molybdenum oxide on a support of alumina modified by
stannic oxide, cerium oxide and ferric oxide.
[0060] SnO.sub.x and ZrO.sub.x-modified Al.sub.2O.sub.3 supports
(SnO.sub.x/Al.sub.2O.sub.3 and ZrO.sub.x/Al.sub.2O.sub.3) were
prepared by incipient wetness impregnation of Al.sub.2O.sub.3
(Degussa A G, .about.100 m.sup.2/g or 180 m.sup.2/g) with
isobutanol solutions of Sn(i-C.sub.4H.sub.9O).sub.4 and
Zr(i-C.sub.4H.sub.9O).sub.4 (Aldrich, 99.8%), respectively at 289 K
under dry N.sub.2 atmosphere for 5 h, followed by drying at 393 K
overnight and then treating in flowing dry air (Airgas, zero grade)
at 673 K for 3 h. CeO.sub.x and FeO.sub.x-modified Al.sub.2O.sub.3
supports (CeO.sub.x/Al.sub.2O.sub.3 and FeO.sub.x/Al.sub.2O.sub.3)
were prepared by incipient wetness impregnation of Al.sub.2O.sub.3
(Degussa A G, 100 m.sup.2/g) with aqueous solutions of
Ce(NO.sub.3).sub.4 (Aldrich, 99.99%) and Fe(NO.sub.3).sub.3
(Aldrich, 99.9%), respectively at 289 K for 5 h, followed by drying
at 393 K overnight and then treating in flowing dry air (Airgas,
zero grade) at 673 K for 3 h. SnO.sub.2 was prepared by hydrolysis
of tin (IV) chloride pentahydrate (98%, Alfa Aesar) at a pH of
.about.7 using NH.sub.4OH (14.8 N, Fisher Scientific). The
precipitates were washed with deionized water until the effluent
was free of chloride ions. The resulting solids were treated in
flowing dry air (Airgas, zero grade) at 773 K for 3 h. Supported
MoO.sub.x catalysts were prepared by incipient wetness impregnation
method using aqueous (NH.sub.4).sub.6Mo.sub.7O.sub.2- 4 (Aldrich,
99%) solutions. Supported VO.sub.x catalysts were also prepared by
incipient wetness impregnation method using an aqueous solution of
ammonium metavanadate [NH.sub.4NO.sub.3] (Aldrich, 99%) and oxalic
acid (Mallinckrodt, analytical grade; NH.sub.4NO.sub.3/oxalic
acid=0.5 M). All samples were dried at 393 K in ambient air after
impregnation and then treated in flowing dry air (Airgas, zero
grade) at 773 K for 3 h. The Mo or V surface density for all
supported samples is reported as Mo/nm.sup.2 or V/nm.sup.2, based
on the Mo or V content and the BET surface area for each
sample.
[0061] The catalysts retained the good selectivity of the
molybdenum oxide/alumina catalysts but had higher activity. Results
are reported in Tables 8 and 9. Table 10 shows results using
vanadium oxide catalysts on alumina and on stannic oxide/alumina.
As shown in Table 10, the DME conversion rates using
VO.sub.x/SnO.sub.x/Al.sub.2O.sub.3 (5.5 Sn/nm2) were about 2.4
times than the rates on VO.sub.x/Al.sub.2O.sub.3 at 513K.
8TABLE 8 Primary DME conversion rates and product selectivities for
MoO.sub.x domains supported on Al.sub.2O.sub.3 modified with
SnO.sub.x at different surface densities (1.5-11.2 Sn/nm.sup.2) and
also on unmodified Al.sub.2O.sub.3 and SnO.sub.2 (.about.7.0
Mo/nm.sup.2; 513 K; 80.0 kPa DME, 18 kPa O.sub.2 and 2 kPa
N.sub.2). Support (MoO.sub.3 Sn surface density .sup.aDME
conversion rate .sup.aPrimary selectivity (%) wt %) (Sn/nm.sup.2)
(mol/g-atom Mo-h) HCHO .sup.bMF .sup.cDMM .sup.dCO.sub.x
Al.sub.2O.sub.3 0 4.6 98.1 1.9 0 0 (15.0%) MoO.sub.x/SnO.sub.2 --
36.4 70.4 12.5 0 17.2 (5.9%) SnO.sub.x/Al.sub.2O.sub.3 1.5 5.4 97.2
2.8 0 0 (15.0%:) SnO.sub.x/Al.sub.2O.sub.3 2.8 7.1 98.0 2.0 0 0
(15.0%) SnO.sub.x/Al.sub.2O.sub.3 5.5 12.2 97.7 2.3 0 0 (15.0%)
SnO.sub.x/Al.sub.2O.sub.3 11.2 12.9 97.6 2.4 0 0 (13.6%) .sup.aThe
data are reported on a CH.sub.3OH-free basis by excluding
CH.sub.3OH as a reaction product in view of its reactivity in
formaldehyde synthesis and its tendency to dehydrate to re-form
CH.sub.3OCH.sub.3. .sup.bMF: Methyl formate; .sup.cDMM:
dimethoxymethane; .sup.dCO.sub.x: CO + CO.sub.2.
[0062]
9TABLE 9 Primary DME conversion rates and product selectivities for
MoO.sub.x domains supported on unmodified Al.sub.2O.sub.3, and on
Al.sub.2O.sub.3 modified with near-single monolayer SnO.sub.x,
ZrO.sub.x, CeO.sub.x, and FeO.sub.x (513 K; 80.0 kPa DME, 18 kPa
O.sub.2 and 2 kPa N.sub.2). Catalyst Mo surface density .sup.aDME
conversion rate .sup.aPrimary selectivity (%) (MoO.sub.3 wt %)
(Mo/nm.sup.2) (mol/g-atom Mo-h) HCHO .sup.bMF .sup.cDMM
.sup.dCO.sub.x MoO.sub.x/Al.sub.2O.sub.3 7.0 4.6 98.1 1.9 0 0
(15.0%) MoO.sub.x/SnO.sub.x/Al.sub.2O.sub.3 7.1 12.2 97.7 2.3 0 0
(15.0%) MoO.sub.x/ZrO.sub.x/Al.sub.2O- .sub.3 6.8 8.7 98.6 1.4 0 0
(15.0%) MoO.sub.x/CeO.sub.x/Al.s- ub.2O.sub.3 6.6 6.8 98.8 1.2 0 0
(13.4%) MoO.sub.x/FeO.sub.x/Al.sub.2O.sub.3 6.7 6.2 99.7 0.3 0 0
(14.1%) .sup.aThe data are reported on a CH.sub.3OH-free basis by
excluding CH.sub.3OH as a reaction product in view of its
reactivity in formaldehyde synthesis and its tendency to dehydrate
to re-form CH.sub.3OCH.sub.3. .sup.bMF: Methyl formate; .sup.cDMM:
dimethoxymethane; .sup.dCO.sub.x: CO + CO.sub.2.
[0063]
10TABLE 10 Primary DME conversion rates and product selectivities
on VO.sub.x domains at near-single monolayer V surface density
supported on unmodified and SnO.sub.x-modified Al.sub.2O.sub.3 (5.5
Sn/nm.sup.2) (513 K; 80.0 kPa DME, 18 kPa O.sub.2 and 2 kPa
N.sub.2). Catalyst Mo surface density .sup.aDME Conversion Rate
.sup.aPrimary selectivity (%) (MoO.sub.3 wt %) (Mo/nm.sup.2)
(mol/g-atom Mo-h) HCHO .sup.bMF .sup.cDMM .sup.dCO.sub.x
VO.sub.x/Al.sub.2O.sub.3 8.0 6.8 99.6 0.4 0 (10.0%)
VO.sub.x/SnO.sub.x/Al.sub.2O.sub.3 7.9 16.3 97.7 2.3 0 (10.1%)
.sup.aThe data are reported on a CH.sub.3OH-free basis by excluding
CH.sub.3OH as a reaction product in view of its reactivity in
formaldehyde synthesis and its tendency to dehydrate to re-form
CH.sub.3OCH.sub.3. .sup.bMF: Methyl formate; .sup.cDMM:
dimethoxymethane; .sup.dCO.sub.x: CO + CO.sub.2.
[0064] Tables 11 and 12 show the effects of BET surface area of the
MoO.sub.x and VO.sub.x catalysts on the primary DME conversion
rates and product selectivities at 513 K. The rates normalized by
the mass of the catalysts were proportional to their surface areas,
while the rates normalized by Mo or V atoms and the HCHO
selectivities were essentially independent of the surface area of
the catalysts.
[0065] For example, on MoO.sub.x/Al.sub.2O.sub.3(B), the DME
conversion rate per gram catalyst increased from 4.7 mmol/g-cat-h
to 9.4 mmol/g-cat-h, i.e., by a factor of two as the surface area
increased from 90.0 m.sup.2/g for MoO.sub.x/Al.sub.2O.sub.3(A) to
174.9 m.sup.2/g. The rate per Mo atom (4.7 vs. 5.1 mmol/g-atom
Mo-h) and the primary HCHO selectivity (98.1% vs. 96.0%) values
remained essentially unchanged, reflecting no change in the
catalytic properties of the active MoO.sub.x sites with changing
the surface area of the samples.
11TABLE 11 Surface area effects on primary DME conversion rates and
product selectivities for MoO.sub.x domains at near one monolayer
surface density supported on unmodified and SnO.sub.x-modified
Al.sub.2O.sub.3 (.about.5.5 Sn/nm.sup.2) (513 K; 80.0 kPa DME, 18
kPa O.sub.2 and 2 kPa N.sub.2). BET surface Mo surface .sup.aDME
conversion .sup.aDME conversion .sup.aPrimary HCHO selectivity area
density rate rate (%) Support (m.sup.2/g-cat) (Mo/nm.sup.2)
(mmol/g-cat-h) (mol/g-atom Mo-h) HCHO .sup.bMF .sup.cDMM
.sup.dCO.sub.x Al.sub.2O.sub.3 (A) 90.0 7.0 4.7 4.6 98.1 1.9 0 0
(15.0%) Al.sub.2O.sub.3 (B) 174.7 6.4 9.4 5.1 95.9 3.1 0 0 (26.8%)
SnO.sub.2/Al.sub.2O.sub.3 (A) 87.9 7.1 12.6 12.1 97.7 2.3 0 0
(15.0%) SnO.sub.2/Al.sub.2O.sub.3 (B) 150.3 6.4 18.4 11.4 98.2 1.8
0 0 (22.9%) .sup.aThe data are reported on a CH.sub.3OH-free basis
by excluding CH.sub.3OH as a reaction product in view of its
reactivity in formaldehyde synthesis and its tendency to dehydrate
to re-form CH.sub.3OCH.sub.3. .sup.bMF: Methyl formate; .sup.cDMM:
dimethoxymethane; .sup.dCO.sub.x: CO + CO.sub.2.
[0066]
12TABLE 12 Surface area effects on primary DME conversion rates and
product selectivities for VO.sub.x domains at near one monolayer
surface density supported on unmodified and SnO.sub.x-modified
Al.sub.2O.sub.3 (.about.5.5 Sn/nm.sup.2) (513 K; 80.0 kPa DME, 18
kPa O.sub.2 and 2 kPa N.sub.2). BET surface V surface .sup.aDME
conversion .sup.aDME conversion .sup.aPrimary HCHO selectivity
Support area density rate rate (%) (V.sub.2O.sub.5%)
(m.sup.2/g-cat) (V/nm.sup.2) (mmol/g-cat-h) (mol/g-atom V-h) HCHO
.sup.bMF .sup.cDMM .sup.dCO.sub.x Al.sub.2O.sub.3 (A) 83.0 8.0 6.7
6.8 99.6 0.4 0 0 (10.0%) Al.sub.2O.sub.3 (B) 195.9 7.8 13.5 5.9
97.1 2.9 0 0 (23.2%) SnO.sub.2/Al.sub.2O.sub.3 (A) 84.3 7.9 16.2
16.3 97.7 2.3 0 0 (10.1%) SnO.sub.2/Al.sub.2O.sub.3 (B) 149.2 7.5
25.3 15.3 98.0 2.0 0 0 (16.8%) .sup.aThe data are reported on a
CH.sub.3OH-free basis by excluding CH.sub.3OH as a reaction product
in view of its reactivity in formaldehyde synthesis and its
tendency to dehydrate to re-form CH.sub.3OCH.sub.3. .sup.bMF:
Methyl formate; .sup.cDMM: dimethoxymethane; .sup.dCO.sub.x: CO +
CO.sub.2.
[0067] All publications and patent applications cited in this
specification are herein incorporated by reference as if each
individual publication or patent application were specifically and
individually indicated to be incorporated by reference.
[0068] Although the foregoing invention has been described in some
detail by way of illustration and example for purposes of clarity
of understanding, it will be readily apparent to those of ordinary
skill in the art in light of the teachings of this invention that
certain changes and modifications may be made thereto without
departing from the spirit or scope of the appended claims.
* * * * *