U.S. patent application number 11/253897 was filed with the patent office on 2006-03-09 for method for producing dimethyl ether.
This patent application is currently assigned to JFE HOLDINGS, INC.. Invention is credited to Kaoru Fujimoto, Masatsugu Mizuguchi, Takashi Ogawa, Yotaro Ohno, Masami Ono, Tsutomu Shikada.
Application Number | 20060052647 11/253897 |
Document ID | / |
Family ID | 33033371 |
Filed Date | 2006-03-09 |
United States Patent
Application |
20060052647 |
Kind Code |
A1 |
Shikada; Tsutomu ; et
al. |
March 9, 2006 |
Method for producing dimethyl ether
Abstract
A method for producing dimethyl ether comprising forming a
slurry by introducing a catalyst for producing dimethyl ether into
a solvent and introducing a mixed gas comprising carbon monoxide
and hydrogen into the slurry.
Inventors: |
Shikada; Tsutomu; (Fukuyama,
JP) ; Ohno; Yotaro; (Tokyo, JP) ; Ogawa;
Takashi; (Yokohama, JP) ; Mizuguchi; Masatsugu;
(Kunitachi, JP) ; Ono; Masami; (Yokohama, JP)
; Fujimoto; Kaoru; (Tokyo, JP) |
Correspondence
Address: |
FRISHAUF, HOLTZ, GOODMAN & CHICK, PC
220 Fifth Avenue
16TH Floor
NEW YORK
NY
10001-7708
US
|
Assignee: |
JFE HOLDINGS, INC.
Tokyo
JP
|
Family ID: |
33033371 |
Appl. No.: |
11/253897 |
Filed: |
October 19, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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|
10938226 |
Sep 9, 2004 |
|
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|
11253897 |
Oct 19, 2005 |
|
|
|
10341478 |
Jan 13, 2003 |
6800665 |
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10938226 |
Sep 9, 2004 |
|
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|
09587153 |
Jun 2, 2000 |
6562306 |
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10341478 |
Jan 13, 2003 |
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08847347 |
Apr 24, 1997 |
6147125 |
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09587153 |
Jun 2, 2000 |
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Current U.S.
Class: |
568/671 ;
502/307 |
Current CPC
Class: |
C01B 3/16 20130101; C07C
41/01 20130101; B01J 23/26 20130101; B01J 23/80 20130101; B01J
37/038 20130101; C07C 43/043 20130101; B01J 37/0225 20130101; C07C
41/01 20130101; B01J 35/023 20130101; B01J 23/72 20130101; Y02P
20/52 20151101; B01J 21/04 20130101 |
Class at
Publication: |
568/671 ;
502/307 |
International
Class: |
C07C 41/02 20060101
C07C041/02; B01J 23/00 20060101 B01J023/00 |
Foreign Application Data
Date |
Code |
Application Number |
May 13, 1996 |
JP |
8-117243 |
May 20, 1996 |
JP |
8-124780 |
May 21, 1996 |
JP |
8-125370 |
May 22, 1996 |
JP |
8-126669 |
Dec 19, 1996 |
JP |
8-339758 |
Claims
1. A method for producing dimethyl ether comprising: (i) providing
a catalyst for producing dimethyl ether, the catalyst being
produced by a method comprising forming a layer comprising a
methanol synthesis catalyst which comprises copper oxide, zinc
oxide and alumina, around alumina particles, the alumina particles
having an average size of 200 .mu.m or less, wherein the methanol
synthesis catalyst layer formed around said alumina particles is in
an amount of 0.05 to 5 parts by weight to 1 part by weight of the
alumina, wherein the layer is produced by a method comprising: (a)
forming a slurry by introducing the alumina particles into an
aqueous solution containing a metallic salt of one or more active
elements of the methanol synthesis catalyst; (b) heating the slurry
at a temperature of 50 to 90.degree. C. to provide a heated slurry;
(c) neutralizing the heated slurry with a base solution, whereby
the one or more active elements of the methanol synthesis catalyst
form deposits on the alumina particles; (d) allowing the slurry to
stand for a sufficient time or subjecting the slurry to a mild
agitation for aging to sufficiently develop the deposits; and (e)
washing the layer with an acidic aqueous solution; (ii) forming a
slurry by introducing the catalyst into a solvent; and (iii)
introducing a mixed gas comprising carbon monoxide and hydrogen
into the slurry.
2. The method of claim 1, wherein the mixed gas further comprises
carbon dioxide.
3. The method of claim 2, wherein the mixed gas further comprises
water vapor.
4. A method for producing dimethyl ether comprising: (a) providing
a catalyst for producing dimethyl ether, the catalyst comprising:
alumina particles having pores; and deposits which exist inside the
pores, the deposits comprising copper oxide, zinc oxide and
alumina; (b) forming a slurry by introducing the catalyst into a
solvent; and (c) introducing a mixed gas comprising carbo monoxide
and hydrogen into the slurry.
5. The catalyst of claim 4, wherein a weight ratio of the copper
oxide, the zinc oxide and the alumina is 1:005 to 20:0 to 2.
6. A method for producing dimethyl ether comprising: (a) providing
a catalyst for producing dimethyl ether, the catalyst comprising: a
methanol synthesis catalyst; a methanol dehydration catalyst; and a
binder for integrating the methanol synthesis catalyst and the
methanol dehydration catalyst; (b) forming a slurry by introducing
the catalyst into a solvent; and (c) introducing a mixed gas
comprising carbon monoxide and hydrogen into the slurry.
7. The method of claim 6, wherein the methanol synthesis catalyst
comprises copper oxide, zinc oxide and optionally alumina.
8. The method of claim 7, wherein the methanol synthesis catalyst
has a weight ratio of the copper oxide:the zinc oxide:the alumina
of 1:005 to 20:0 to 2.
9. The method of claim 6, wherein the methanol synthesis catalyst
comprises zinc oxide, chromium oxide and optionally alumina.
10. The method of claim 9, wherein the methanol synthesis catalyst
has a weight ratio of the zinc oxide:the chromium oxide:the alumina
of 1:0.1 to 10:0 to 2.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Divisional application of application
Ser. No. 10/938,226 filed Sep. 9, 2004, which is a Divisional
application of application Ser. No. 10/341,478 filed Jan. 13, 2003
(U.S. Pat. No. 6,800,665), which is a Continuation application of
application Ser. No. 09/587,153 filed Jun. 2, 2000 (U.S. Pat. No.
6,562,306), which is a Divisional application of application Ser.
No. 08/847,347 filed Apr. 24, 1997 (U.S. Pat. No. 6,147,125).
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a catalyst for dimethyl
ether, a method for producing the catalyst, and a method for
producing dimethyl ether by using the catalyst
[0004] 2. Description of the Related Arts
[0005] There are several known methods for manufacturing dimethyl
ether starting from a mixed gas of carbon monoxide, carbon dioxide,
and hydrogen under the presence of a catalyst suspended in a
solvent
[0006] For example, JP-A-2-9833 (the term "JP-A-" referred to
herein signifies "Unexamined Japanese patent publications"),
JP-A-3-181435, JP-A-3-52835, JP-A-4-264046, WO 93/10069 disclose
methods for manufacturing dimethyl ether or a mixture of dimethyl
ether and methanol through the contact of a synthesis gas with a
mixture of a methanol synthesis catalyst and a methanol dehydration
catalyst suspended in an inert liquid.
[0007] The method disclosed in JP-A-2-9833 is a method of direct
synthesis of dimethyl ether from a synthesis gas, which method
comprises the step of contacting a synthesis gas consisting of
hydrogen, carbon monoxide and carbon dioxide with a solid catalyst,
or reacting the synthesis gas react under the presence of the solid
catalyst to conduct catalytic synthesis of dimethyl ether from the
synthesis gas, wherein the synthesis gas undergoes catalytic action
under the presence of the solid catalyst system, and wherein the
solid catalyst is a single catalyst or a mixture of plurality of
catalysts which are suspended in a liquid medium in a three-phase
(slurry phase) reactor system, and wherein the three-phase reactor
system comprises at least a single three-phase reactor.
[0008] The method disclosed in JP-A-3-181435 is a method for
manufacturing dimethyl ether from a mixed gas of carbon monoxide
and hydrogen, or a mixed gas of carbon monoxide and hydrogen and
further containing carbon dioxide and/or water vapor, wherein a
catalyst is used in a slurry form by suspension thereof in a
solvent.
[0009] The method disclosed in JP-A-3-52835 is a method of dimethyl
ether synthesis characterized in that a synthesis gas is reacted
under the presence of a solid methanol synthesis catalyst to
produce methanol, and that the produced methanol is reacted under
the presence of a solid dehydration catalyst to produce dimethyl
ether. According to the method, dimethyl ether is synthesized from
a synthesis gas consisting of hydrogen, carbon monoxide, and carbon
dioxide. That is, the synthesis gas is contacted with a solid
catalyst system comprising a methanol-synthesizing ingredient and a
dehydrating (ether-forming) ingredient, wherein the solid catalyst
system is a single catalyst or a mixture of plurality of catalysts
in a three-phase (liquid phase) reactor, system, and wherein the
reactor system is controlled to keep the minimum effective methanol
rate to at least a level of 1.0 g-mole of methanol per 1 kg of
catalyst per hour.
[0010] The method disclosed in WO 93/10069 is a method for
manufacturing dimethyl ether from a mixed gas containing carbon
monoxide and either or both of water and water vapor, or from a
mixed gas containing carbon monoxide and either or both of water
and water vapor and further containing carbon dioxide, wherein a
catalyst is used in a form of solvent slurry, which catalyst is
prepared by pulverizing a mixed catalyst containing at least zinc
oxide and, copper oxide or chromium oxide, and aluminum oxide, by
adhering these ingredients together under pressure, and by
pulverizing them again to suspend in the solvent.
[0011] On the other hand, dimethyl ether is synthesized generally
in a fixed bed system. There is a known catalyst for a fixed bed
system, which catalyst is prepared by depositing a methanol
synthesis catalyst onto a support of metallic oxide such as
alumina, then by calcining them together. (JP-A-2-280386)
[0012] The methods for manufacturing dimethyl ether disclosed in
JP-A-2-9833, JP-A-3-52835, JP-A-4-264046, and JP-A-3-181435,
however, raise problems such that the two kinds of or three kinds
of catalysts suspended in a solvent separate from each other in the
reactor owing to the difference in specific gravity among the
methanol synthesis catalyst, the methanol dehydration catalyst, and
the water gas shift catalyst, which induces a distribution in
catalyst concentration or deposition of one of these catalysts,
thus significantly degrading the use efficiency of the
catalysts.
[0013] The catalyst disclosed in WO 93/10069 is prepared by
integrating the above-described three kinds of catalysts by means
of a mechanical method. These types of catalysts also raise a
problem, that during a period of use in a slurry state, the
catalyst particles separate from each other to induce a
distribution in catalyst concentration and catalyst deposition.
SUMMARY OF THE INVENTION
[0014] It is an object of the present invention to provide a
catalyst suitable for producing dimethyl ether at a high yield and
a method for producing the catalyst, and to provide a method for
producing dimethyl ether at a high space time yield.
[0015] To attain the object, the present invention provides a first
catalyst suitable for producing dimethyl ether, the catalyst
comprising:
[0016] alumina particles having an average size of 200 .mu.m or
less;
[0017] a layer comprising a methanol synthesis catalyst, the layer
being formed around each of the alumina particles; and
[0018] the methanol synthesis catalyst having a weight ratio of
0.05 to 5 to a weight of the alumina particles.
[0019] In the first catalyst, the average size of the alumina
particles is preferably 1 to 100 .mu.m. The average size of 1 to 50
.mu.m is more preferable.
[0020] The methanol synthesis catalyst may comprise copper oxide,
zinc oxide and alumina. It is desirable that a weight ratio of the
copper oxide:the zinc oxide:the alumina is 1:0.05 to 20:0 to 2. The
methanol synthesis catalyst may comprise zinc oxide, chromium oxide
and alumina. It is desirable that a weight ratio of the zinc
oxide:the chromium oxide:the alumina being 1:0.1 to 10:0 to 2.
[0021] The first catalyst suitable for producing dimethyl ether is
produced by the following method comprising the steps of:
[0022] forming a layer comprising a methanol synthesis catalyst
around each of alumina particles; and
[0023] washing the alumina particles, around which the layer was
formed, with an acid aqueous solution.
[0024] The forming of the layer may comprise:
[0025] forming a slurry by introducing the alumina particles into
an aqueous solution containing a metallic salt of active element of
the methanol synthesis catalyst;
[0026] heating the slurry; and
[0027] neutralizing the heated slurry with a base solution, thereby
the active element of the methanol synthesis catalyst being
deposited around each of the alumina particles.
[0028] The deposition of the active element of the methanol
synthesis catalyst is preferably carried out at a temperature of 50
to 90.degree. C.
[0029] Dimethyl ether is produced by using the first catalyst. A
method for producing dimethyl ether comprising the steps of:
[0030] providing the first catalyst suitable for producing dimethyl
ether, the catalyst;
[0031] forming a slurry by introducing the catalyst into a solvent;
and
[0032] introducing a mixed gas comprising carbon monoxide and
hydrogen into the slurry.
[0033] The present invention provides a second catalyst suitable
for producing dimethyl ether, the catalyst comprising.
[0034] alumina particles having pores;
[0035] deposits which exist inside the pores; and
[0036] the deposits comprising copper oxide, zinc oxide, and
alumina.
[0037] It is preferable that the alumina particles have an average
size of 200 .mu.m or less. A weight ratio of the copper oxide:the
zinc oxide:the alumina is preferably 1:0.05 to 20:0 to 2.
[0038] The second catalyst suitable for producing dimethyl ether is
produced by the method comprising the steps of:
[0039] (a) introducing an alumina having pores into an aqueous
solution containing a copper salt, a zinc salt and an aluminum salt
for impregnating the pores with the aqueous solution;
[0040] (b) vaporizing the aqueous solution on a surface of the
alumina;
[0041] (c) contacting the alumina subjected to the step (b) with a
solution containing a deposition agent for hydrolyzing the copper
salt, the zinc salt and the aluminum salt to copper hydroxide, zinc
hydroxide and aluminum hydroxide and for depositing the copper
hydroxide, the zinc hydroxide and the aluminum hydroxide within the
pores of the alumina;
[0042] (d) washing the alumina subjected to the step (c); and
[0043] (e) calcining the washed alumina.
[0044] Dimethyl ether is produced by using the second catalyst. A
method for producing dimethyl ether comprising the steps of:
[0045] providing the second catalyst suitable for producing
dimethyl ether;
[0046] forming a slurry by introducing the catalyst into a solvent;
and
[0047] introducing a mixed gas comprising carbon monoxide and
hydrogen into the slurry.
[0048] The present invention provides a third catalyst suitable for
producing dimethyl ether, the catalyst comprising:
[0049] a methanol synthesis catalyst;
[0050] a methanol dehydration catalyst; and
[0051] a binder for integrating the methanol synthesis catalyst and
the methanol dehydration catalyst.
[0052] The methanol synthesis catalyst may comprise copper oxide,
zinc oxide and alumina. A weight ratio of the copper oxide:the zinc
oxide:the alumina is preferably 1:0.05 to 20:0 to 2. Also, the
methanol synthesis catalyst may comprise zinc oxide, chromium oxide
and alumina. A weight ratio of the zinc oxide:the chromium
oxide:the alumina is preferably 1:0.1 to 10:0 to 2. The methanol
dehydration catalyst may be at least one selected from the group
consisting of .gamma.-alumina, silica-alumina and zeolite. The
third catalyst may further comprise a water gas shift catalyst. The
water gas shift catalyst may comprise iron oxide and chromium
oxide. The binder may be alumina sol or clay.
[0053] Dimethyl ether is produced by using the third catalyst. A
method for producing dimethyl ether comprising the steps of:
[0054] providing the third catalyst suitable for producing dimethyl
ether,
[0055] forming a slurry by introducing the catalyst into a solvent;
and
[0056] introducing a mixed gas comprising carbon monoxide and
hydrogen into the slurry.
[0057] Further, the present invention provides a method for
producing a catalyst suitable for producing dimethyl ether, the
method comprising the steps of:
[0058] (a) preparing a methanol synthesis catalyst, a methanol
dehydration catalyst, a water gas shift catalyst and a solvent;
[0059] (b) calculating an A value regarding to the methanol
synthesis catalyst, the methanol dehydration catalyst and the water
gas shift catalyst using an average particle size of the catalyst,
a particle density of the catalyst and a density of the solvent,
the A value being defined by the following equation:
A=D.sup.2(P-S), where D denotes the average particle size of the
catalyst, (cm), [0060] P denotes the particle density of the
catalyst, (g/cm.sup.3), and [0061] S denotes the density of the
solvent, (g/cm.sup.3),
[0062] (c) controlling at least one of the group consisting of the
average particle size of the catalyst, the particle density of the
catalyst and the density of the solvent to maintain differences in
the A values within .+-.1.times.10.sup.-6 g/cm among the methanol
synthesis catalyst, the methanol dehydration catalyst, and the
water gas shift catalyst;
[0063] (d) after the step (c), suspending the methanol synthesis
catalyst, the methanol dehydration catalyst, and the water gas
shift catalyst in the solvent.
[0064] Furthermore, dimethyl ether can be produced by the method
comprising the steps of:
[0065] providing a mixed gas containing carbon monoxide and at
least one selected from the group of hydrogen and water vapor;
[0066] contacting the mixed gas with a first catalyst consisting
essentially of a methanol synthesis catalyst, a dehydration
catalyst and a water gas shift catalyst; and
[0067] contacting the mixed gas, which contacted with the first
catalyst, with a second catalyst consisting essentially of at least
one selected from the group of a dehydration catalyst and a water
gas shift catalyst.
[0068] Moreover, dimethyl ether can be produced by the method
comprising the steps of:
[0069] (a) reacting a raw material gas containing carbon monoxide
and hydrogen in the presence of a catalyst to produce a reaction
gas including dimethyl ether, carbon dioxide, carbon monoxide and
hydrogen;
[0070] (b) separating the reaction gas into the carbon monoxide and
the hydrogen, and the dimethyl ether and the carbon dioxide;
[0071] (c) recycling the carbon monoxide and the hydrogen which
were separated from the reaction gas in the step (b);
[0072] (d) removing the carbon dioxide from the dimethyl ether and
the carbon dioxide of the step (b) to gain the dimethyl ether,
and
[0073] (e) recycling the diethyl ether which was gained in the step
(d) to the step (b).
[0074] Further, dimethyl ether can be produced by the method
comprising the steps of:
[0075] preparing a slurry which is produced by dispersing a
dimethyl ether synthesis catalyst into a medium oil;
[0076] contacting a raw material gas containing carbon monoxide and
hydrogen with the slurry to produce a product gas containing a
vaporized medium oil;
[0077] cooling the product gas to condense the vaporized medium
oil;
[0078] obtaining dimethyl ether from the product gas from which the
vaporized medium oil was condensed;
[0079] removing a catalyst-deactivation ingredient from the
condensed medium oil; and
[0080] recycling the medium oil, from which the
catalyst-deactivation ingredient was removed, to the step of
preparing the slurry.
[0081] Further, the present invention provides an apparatus for
producing dimethyl ether comprising:
[0082] a slurry-bed reactor filled with a dimethyl ether synthesis
catalyst and a medium oil therefor;
[0083] a condenser for condensing a vaporized medium oil discharged
from the reactor;
[0084] an absorber for removing a catalyst-deactivation ingredient
from the medium oil condensed in the condenser; and
[0085] recycle means for recycling the medium oil to the slurry-bed
reactor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0086] FIG. 1 is a schematic representation showing the apparatus
for producing a dimethyl ether used in the embodiment 5.
[0087] FIG. 2 is a graph showing reaction equilibria of H.sub.2,
CO, methanol, CO.sub.2 and H.sub.2O.
[0088] FIG. 3 is a schematic representation showing the apparatus
for producing dimethyl ether used in the embodiment 6.
[0089] FIG. 4 is an enlarged view of the non-reacted gas separator
in FIG. 3 indicating the connection of pipelines.
[0090] FIG. 5 is a schematic representation showing the apparatus
for producing dimethyl ether used in the embodiment 7.
[0091] FIG. 6 is another schematic representation showing the
apparatus for producing dimethyl ether used in the embodiment
7.
[0092] FIG. 7 is a graph showing the change of dissolved sulfur
concentration with time in the case that the apparatus of FIG. 6
was used.
[0093] FIG. 8 is a graph showing the change in conversion of carbon
monoxide with time in the case that the apparatus of FIG. 6 was
used.
[0094] FIG. 9. is a schematic side view of a reactor of the
embodiment 8.
[0095] FIG. 10 is a part-enlarged view of the reactor of FIG.
9.
[0096] FIG. 11 is a schematic representation showing the apparatus
for producing dimethyl ether into which the reactor of the
embodiment 8 is installed.
[0097] FIG. 12 is a schematic side view of a reactor of the
embodiment 9.
[0098] FIG. 13 is a schematic side view of another reactor of the
embodiment 9.
[0099] FIG. 14 is a schematic representation showing the apparatus
for producing dimethyl ether into which the reactor of the
embodiment 9 is installed.
[0100] FIG. 15 is a graph showing reaction equilibria of H.sub.2,
CO, methanol, CO.sub.2 and H.sub.2O.
[0101] FIG. 16 is a schematic representation showing the apparatus
for producing dimethyl ether into which the reactor of the
embodiment 10 is installed.
DESCRIPTION OF THE EMBODIMENT
Embodiment 1
[0102] The catalyst according to the present invention comprises
alumina particles and a methanol synthesis catalyst layer formed
around each of the alumina particles. Alumina functions as a
methanol-dehydration catalyst, and alumina in use as an ordinary
catalyst may be applied without further processing. A preferable
size of alumina particles is fine, preferably 200 .mu.m or less of
average particle size, more preferably in an approximate range of
from 1 to 100 .mu.m, and most preferably in an approximate range of
from 1 to 50 .mu.m. To prepare the preferred average particle size,
alumina may be pulverized as needed.
[0103] Methanol synthesis catalyst may be copper oxide--zinc
oxide--alumina system and zinc oxide--chromium oxide--alumina
system. A preferable mixing ratio of individual ingredients of
copper oxide, zinc oxide, and alumina is: in an approximate range
of from 0.05 to 20 wt. parts of zinc oxide to 1 wt. parts of copper
oxide, more preferably in an approximate range of from 0.1 to 5 wt.
parts; in an approximate range of from 0 to 2 wt. parts of alumina,
more preferably in an approximate range of from 0 to 1 wt. parts. A
preferable mixing ratio of individual ingredients of zinc oxide,
chromium oxide, and alumina is: in an approximate range of from 0.1
to 1.0 of chromium oxide to 1 wt. parts of zinc oxide, more
preferably in an approximate range of from 0.5 to 5; and in an
approximate range of from 0 to 2 wt. parts of alumina, more
preferably in an approximate range of from 0 to 1 wt. parts.
[0104] A preferable ratio of the methanol synthesis catalyst layer
formed around alumina particle is in a range of from 0.05 to 5 by
wt. parts to 1 wt. parts of alumina, more preferably in a range of
from 0.1 to 3 wt. parts, and most preferably in a range of from 0.5
to 2 wt. parts.
[0105] The catalyst achieves 30% or higher CO conversion, or
normally in an approximate range of from 35 to 60%, and
particularly in an approximate range of from 45 to 55%, and
achieves 20% or higher dimethyl ether yield, or normally in an
approximate range of from 25 to 45%, and particularly in an
approximate range of from 35 to 45%. A preferred particle size of
the catalyst is small as far as possible within a range that no
agglomeration problem occurs. A preferable average particle size of
the catalyst is 200 .mu.m or less, more preferably in an
approximate range of from 1 to 100 .mu.m, and most preferably in an
approximate range of from 1 to 50 .mu.m.
[0106] The method for manufacturing the catalyst according to the
present invention is characterized in the steps of: forming a
methanol synthesis catalyst around each of alumina particles; and
washing the catalyst layer with an acid aqueous solution. For
manufacturing the catalyst, powdered alumina is charged into an
aqueous solution containing a metallic salt of active ingredient of
methanol synthesis catalyst, for example an aqueous solution of
copper salt, zinc salt, and aluminum salt, to prepare a slurry.
Copper salt, zinc salt, and aluminum salt may be either inorganic
salt or organic salt if only the salt is a water soluble salt.
Nevertheless, a salt that likely generates hydroxide in water is
not suitable. As for the salt of copper and of zinc (and chromium),
nitrate, carbonate, organic acid salt are applicable. For the salt
of halide and of aluminum, nitrate, carbonate, and organic salt are
applicable. A preferable concentration of each ingredient is in an
approximate range of from 0.1 to 3 mole/liter.
[0107] Thus prepared alumina slurry is then heated, and a base
solution is added dropwise to the heated slurry to neutralize to
deposit the active ingredient of the methanol synthesis catalyst
around each of alumina particles. The alumina particle may be
coated by copper salt, zinc salt, and aluminum salt separately at
need. A preferable temperature of the slurry during the period of
deposition is in a range of from 50 to 90.degree. C., more
preferably in a range of from 60 to 85.degree. C. Any kind of base
is applicable if only it can neutralize the acid in the slurry. The
neutralization is to deposit copper, zinc, and aluminum, and a
preferable pH value is in an approximate range of from 6 to 12,
more preferably in an approximate range of from 7 to 10. After
neutralization, the slurry is allowed to stand for an appropriate
time or is subjected to mild agitation for aging to sufficiently
develop the deposits.
[0108] The alumina particles on each of which the deposit is formed
are separated from liquid. Thus separated solid alumina particles
are washed with warm water. Normally, succeeding drying and
calcining treatment provides a catalyst configured by alumina
coated by a methanol synthesis catalyst. With the catalyst
according to the present invention, however, methanol which is
generated on the methanol synthesis catalyst migrates onto the
alumina which is a methanol-dehydration catalyst, where the
methanol undergoes dehydration and condensation by the action of
acid active centers on the alumina to yield dimethyl ether, which
mechanism is described later. In the deposit-forming operation
described above, alumina contacts with base solution, and the acid
active centers on alumina vanish. To recover the acid active
centers on alumina, the method for manufacturing catalyst according
to the present invention involves washing the alumina particles
with an acid aqueous solution after forming the above-described
deposit. For washing, the alumina particles may be suspended in an
acid aqueous solution. Applicable acid for washing is either
inorganic acid or organic acid. A preferable acid includes nitric
acid, hydrochloric acid, and acetic acid, and more preferably
nitric acid and hydrochloric acid. The concentration of acid for
acid washing is in an approximate range of from 0.1 to 5
mole/liter, more preferably in an approximate range of from 0.5 to
2 mole/liter. The temperature for washing may be room temperature,
and a warm temperature may also be applicable. The period for
washing may be in an approximate range of from 10 to 30 min.
[0109] The next step is washing the alumina particles and deposits
thoroughly with ion-exchanged water or the like to remove acid and
base ions, followed by drying and calcining. The calcining may be
carried out in air. The calcining temperature may be a temperature
level that the metal hydroxide in the catalyst ingredients for
methanol-synthesis is converted to metal oxide. For instance, a
preferable calcining condition is preferably carried out at a
temperature range of from 250 to 400.degree. C. for a period of
from 1 to 10 hours.
[0110] The above-described catalyst is used in a state of slurry of
a solvent The amount of catalyst in the solvent depends on the kind
of the solvent, the reaction conditions, and other variables.
Normally, the amount of catalyst is in a range of from 1 to 50 wt.
% to the amount of the solvent
[0111] The kind of solvent used for synthesizing dimethyl ether
according to the present invention is arbitrarily selected if only
the solvent is in a liquid phase under the reaction conditions.
Examples of the solvent are hydrocarbons of aliphatic, aromatic,
and alicyclic groups, alcohol, ether, ester, ketone, halide, or
their mixture.
[0112] Alternatively, gas oil after removing sulfur ingredients,
vacuum gas oil, high boiling point distillates of coal tar after
treated by hydrogenation are also applicable as the solvent.
[0113] By passing a mixed gas of carbon monoxide and hydrogen
through thus prepared slurry of catalyst with solvent, dimethyl
ether is obtained at a high yield. An applicable range of the molar
mixing ratio of hydrogen to carbon monoxide (H.sub.2/CO) is wide,
for instance, in a range of from 20 to 0.1 as (H.sub.2/CO), and
more preferably from 10 to 0.2.
[0114] According to the reaction system, the mixed gas does not
directly contact with catalyst only after being dissolved into a
solvent. Consequently, catalytic reaction system, but the carbon
monoxide and hydrogen contact with catalyst only after being
dissolved into a solvent. Consequently, selection of an adequate
kind of solvent taking into account of the solubility of carbon
monoxide and hydrogen to the solvent establishes a constant
composition of carbon monoxide and hydrogen in the solvent
independent of the gas composition, and sustains the supply of the
mixed gas at an established composition to the catalyst
surface.
[0115] In the case of a mixed gas with a significantly low ratio of
(H.sub.2/CO), for example, 0.1 or less, or in the case of solely
carbon monoxide without containing hydrogen, it is necessary to
separately supply steam to convert a part of the carbon monoxide
into hydrogen and carbon dioxide within the reactor.
[0116] Since solvent exists between the raw material gases and the
catalyst, the gas composition does not necessarily agree with the
composition on the catalyst surface. Therefore, it is acceptable
that the mixed gas of carbon monoxide and hydrogen, or solely
carbon monoxide gas includes a relatively high concentration of
carbon dioxide (in a range of from 20 to 50%).
[0117] The manufacturing method according to the present invention
significantly reduces the effect of ingredients that may act as a
catalyst-poison on the catalyst compared with the gas-solid contact
catalyst system. Examples of the catalyst-poisoning ingredients
which may exist in the raw material gas are sulfur compounds such
as hydrogen sulfide, cyan compounds such as hydrogen cyanide, and
chlorine compounds such as hydrogen chloride. Even when the
catalyst activity decreases as a result of poisoning, the
productivity of the total reactor system is maintained at a
constant level by withdrawing the slurry from the reactor and by
charging fresh slurry containing catalyst of high activity to the
reactor.
[0118] The reaction heat is recovered in a form of medium pressure
steam using a cooling coil installed inside of the reactor while
passing hot water through the cooling coil. The cooling system
controls the reaction temperature at an arbiter level.
[0119] A preferable reaction temperature is in a range of from 150
to 400.degree. C., and particularly preferable in a range of from
200 to 350.degree. C. The reaction temperature below 150.degree. C.
and above 400.degree. C. degrades the conversion of carbon
monoxide.
[0120] A preferable reaction pressure is in a range of from 10 to
300 kg/cm.sup.2, and particularly preferable in a range of from 15
to 150 kg/cm.sup.2. The reaction pressure below 10 kg/cm.sup.2
results in a low conversion of carbon monoxide, and that above 300
kg/cm.sup.2 requires a special design of the reactor and is
uneconomical because of the need of a large amount of energy for
pressuring the system.
[0121] A preferable space velocity (charge rate of mixed gas per 1
g of catalyst under standard condition) is in a range of from 100
to 50000 ml/gh, and particularly preferable from 500 to 30000
ml/gh. The space velocity above 50000 ml/gh degrades the conversion
of carbon monoxide, and that below 100 ml/gh is uneconomical
because of the need of an excessively large reactor.
[0122] The catalyst for manufacturing dimethyl ether according to
the present invention comprises alumina particles with a methanol
synthesis catalyst layer formed around each of the alumina
particles. The method for manufacturing the catalyst is
characterized in the steps of: forming a catalyst active
ingredients for synthesizing methanol around each of alumina
particles; and washing the catalyst active ingredients with an acid
aqueous solution. Since every catalyst ingredient has a size of a
molecular level and since each of the ingredients chemically
adsorbs by each other, they do not separate during the reaction
period. In addition, a very small distance of adjacent active
ingredients allows the reaction cycle described below to proceed
promptly, thus improving the yield of dimethyl ether. That is, the
sequent order of the reaction begins with the yielding of methanol
from carbon monoxide and hydrogen on the methanol synthesis
catalyst, then the produced methanol migrates onto the alumina
inside of the catalyst, where the methanol undergoes dehydration
and condensation on the acid active centers on alumina, thus
yielding dimethyl ether and water. Furthermore, the water migrates
onto the methanol synthesis catalyst, where the water reacts with
carbon monoxide to yield carbon dioxide and hydrogen. The reaction
follows the reaction formulae given below.
CO+2H.sub.2.fwdarw.C.sub.3OH
2CH.sub.3OH.fwdarw.CH.sub.3OCH.sub.3+H.sub.2O
CO+H.sub.2O.fwdarw.CO.sub.3+H.sub.2
[0123] The method for manufacturing dimethyl ether according to the
present invention significantly increases the yield of dimethyl
ether by using the catalyst which comprises alumina particles and
methanol synthesis catalyst layer formed around each of the alumina
particles in a state of slurry with a solvent. The method is free
from problems such as plugging of catalyst and mechanical strength
of catalyst, is designed to readily absorb the reaction heat
through a cooling pipe or the like, and is designed to conduct
withdrawing and filling of catalyst easily.
EXAMPLE
I. Preparation of Catalyst
Examples 1, 5 Through 8
[0124] Each of 185 g of copper nitrate
(Cu(NO.sub.3).sub.2.3H.sub.2O), 117 g of zinc nitrate
(Zn(NO.sub.3).sub.2.6H.sub.2O), and 52 g of aluminum nitrate
(Al(NO.sub.3).sub.3.9H.sub.2O) were dissolved into about 1 liter of
ion-exchanged water. To the solution, 100 g of fine powder of
.gamma.-alumina (N612, Nikki Kagaku Co.) having an approximate
particle size of 20 .mu.m or less was added. The prepared slurry
was heated to around 80.degree. C. and held at the temperature.
Separately, about 1.4 kg of sodium carbonate (Na.sub.2CO.sub.3) was
dissolved into about 1 liter of ion-exchanged water, which solution
was then heated to about 80.degree. C. The solution was added
dropwise to the slurry until the slurry reached to pH 8.0. After
completing the dropwise addition, the slurry was allowed to stand
for about 1 hour for aging. Then, the slurry was filtered, and the
cake was rinsed by ion-exchanged water at about 80.degree. C. until
sodium ion and nitric acid ion are not detected anymore. After the
rinse, the resultant alumina particles were suspended in about 1
liter of aqueous solution of 1 mole/liter nitric acid, and were
washed at room temperature for 20 min. The suspension was filtered
to recover the alumina particles. The alumina particles were
further rinsed with ion-exchanged water until no acid was detected
anymore. The alumina particles were then dried at 120.degree. C.
for 24 hours followed by calcining thereof in air at 350.degree. C.
for 5 hours. The calcined alumina particles were classified to
recover 120 .mu.m or finer ones as the target catalyst
[0125] Analysis of thus obtained catalyst gave the composition as
CuO:ZnO:Al.sub.2O.sub.3=31:16:53 (by weight).
Example 2
[0126] Each of 37.1 g of copper nitrate
(Cu(NO.sub.3).sub.2.3H.sub.2O), 23.4 g of zinc nitrate
(Zn(NO3).sub.2.6H.sub.2O), and 10.3 g of aluminum nitrate
(Al(NO.sub.3).sub.3.9H.sub.2O) were dissolved into about 1 liter of
ion-exchanged water. To the solution, 100 g of fine powder of
.gamma.-alumina (N612, Nikki Kagaku Co.) having an approximate
particle size of 20 .mu.m or less was added. The prepared slurry
was heated to around 80.degree. C. and held at the temperature.
Separately, about 0.3 kg of sodium carbonate (Na.sub.2CO.sub.3) was
dissolved into about 1 liter of ion-exchanged water, which solution
was then heated to about 80.degree. C. The solution was added
dropwise to the slurry until the slurry reached to pH 8.0. After
completing the dropwise addition, the slurry was allowed to stand
for about 1 hour for aging. Then, the slurry was filtered, and the
cake was rinsed by ion-exchanged water at about 80.degree. C. until
sodium ion and nitric acid ion were not detected anymore. After the
rinse, the resultant alumina particles were suspended in about 1
liter of aqueous solution of 1 mole/liter nitric acid, and were
washed following the procedure applied in Example 1. The alumina
particles were then dried at 120.degree. C. for 24 hours, followed
by calcining thereof in air at 350.degree. C. for 5 hours. The
calcined alumina particles were classified to recover 120 .mu.m or
finer ones as the target catalyst
[0127] Analysis of thus obtained catalyst gave the composition as
CuO:ZnO:Al.sub.2O.sub.3=20:11:69 (by weight).
Example 3
[0128] Each of 92.6 g of copper nitrate
(Cu(NO.sub.3).sub.2.3H.sub.2O), 58.5 g of zinc nitrate
(Zn(NO.sub.3).sub.2.6H.sub.2O), and 25.5 g of aluminum nitrate
(Al(NO.sub.3).sub.3.9H.sub.2O) were dissolved into about 1 liter of
ion-exchanged water. To the solution, 100 g of fine powder of
.gamma.-alumina (N612, Nikki Kagaku Co.) having an approximate
particle size of 20 .mu.m or less was added. The prepared slurry
was heated to around 80.degree. C. and held at the temperature.
Separately, about 0.7 kg of sodium carbonate (Na.sub.2CO.sub.3) was
dissolved into about 1 liter of ion-exchanged water, which solution
was then heated to about 80.degree. C. The solution was added
dropwise to the slurry until the slurry reached to pH 8.0. After
completing the dropwise addition, the slurry was allowed to stand
for about 1 hour for aging. Then, the slurry was filtered, and the
cake was rinsed by ion-exchanged water at about 80.degree. C. until
sodium ion, and nitric acid ion were not detected anymore. After
the rinse, the resultant alumina particles were suspended in about
1 liter of aqueous solution of 1 mole/liter nitric acid, and were
washed following the procedure applied in Example 1. The alumina
particles were then dried at 120.degree. C. for 24 hours, followed
by calcining thereof in air at 350.degree. C. for 5 hours. The
calcined alumina particles were classified to recover 120 .mu.m or
finer ones as the target catalyst
[0129] Analysis of thus obtained catalyst gave the composition as
CuO:ZnO:Al.sub.2O.sub.3=31:16:53 (by weight).
Example 4
[0130] Each of 185 g of copper nitrate
(Cu(NO.sub.3).sub.2.3H.sub.2O), 117 g of zinc nitrate
(Zn(NO.sub.3).sub.2.6H.sub.2O), and 52 g of aluminum nitrate
(Al(NO.sub.3).sub.3.9H.sub.2O) were dissolved into about 1 liter of
ion-exchanged water. To the solution, 50 g of fine powder of
.gamma.-alumina (N612, Nikki Kagaku Co.) having an approximate
particle size of 20 .mu.m or less was added. The prepared slurry
was heated to around 80.degree. C. and held at the temperature.
Separately, about 1.4 kg of sodium carbonate (Na.sub.2CO.sub.3) was
dissolved into about 1 liter of ion-exchanged water, which solution
was then heated to about 80.degree. C. The solution was added
dropwise to the slurry until the slurry reached to pH 8.0. After
completing the dropwise addition, the slurry was allowed to stand
for about 1 hr for aging. Then, the slurry was filtered, and the
cake was rinsed by ion-exchanged water at about 80.degree. C. until
sodium ion and nitric acid ion were not detected anymore. After the
rinse, the resultant alumina particles were washed by about 1 liter
of aqueous solution of 1 mole/liter nitric acid following the
procedure applied in Example 1. The alumina particles were then
dried at 120.degree. C. for 24 hours followed by calcining thereof
in air at 350.degree. C. for 5 hours. The calcined alumina
particles were classified to recover 120 .mu.m or finer ones as the
target catalyst
[0131] Analysis of thus obtained catalyst cave the composition as
CuO:ZnO:Al.sub.2O.sub.3=41:21:38 (by weight).
Example 9
[0132] A catalyst was prepared following the procedure applied in
Example 1 except that the temperature of slurry was set to
40.degree. C.
Example 10
[0133] A catalyst was prepared following the procedure applied in
Example 1 except that the temperature of slurry was set to
50.degree. C.
Example 11
[0134] A catalyst was prepared following the procedure applied in
Example 1 except that the temperature of slurry was set to
60.degree. C.
Example 12
[0135] A catalyst was prepared following the procedure applied in
Example 1 except that the temperature of slurry was set to
70.degree. C.
Example 13
[0136] A catalyst was prepared following the procedure applied in
Example 1 except that the temperature of slurry was set to
90.degree. C.
Example 14
[0137] A catalyst was prepared following the procedure applied in
Example 1 except that the temperature of slurry was set to
95.degree. C.
Comparative Example 1
[0138] A catalyst was prepared following the procedure applied in
Example 1 except that the temperature of slurry was set to
20.degree. C.
Comparative Example 2
[0139] A catalyst was prepared following the procedure applied in
Example 1 except that the cake was rinsed only with ion-exchanged
water and not rinsed with aqueous solution of nitric acid.
Comparative Example 3
[0140] Each of 185 g of copper nitrate
(Cu(NO.sub.3).sub.2.3H.sub.2O), 117 g of zinc nitrate
(Zn(NO.sub.3).sub.2.6H.sub.2O), and 52 g of aluminum nitrate
(Al(NO.sub.3).sub.3.9H.sub.2O) were dissolved into about 1 liter of
ion-exchanged water. Separately, about 1.4 kg of sodium carbonate
(Na.sub.2CO.sub.3) was dissolved into about 1 liter of
ion-exchanged water. Both of these solutions were added dropwise to
about 3 liters of ion-exchanged water in a stainless steel vessel
controlled at about 80.degree. C., for a period of about 2 hours
while maintaining the pH value of the mixture to 8.0.+-.0.5. After
completing the dropwise addition, the mixture was allowed to stand
for about 1 hour for aging. When, during the processing period, pH
value came outside of a range of 8.0.+-.0.5, an aqueous solution of
about 1 mole/liter nitric acid or of about 1 mole/liter sodium
carbonate was added dropwise to the mixture to sustain the pH value
in a range of 8.0.+-.0.5. Then, the generated precipitate was
filtered, and the cake was rinsed by ion-exchanged water until
nitric acid ion is not detected in the filtrate anymore. The cake
was then dried at 120.degree. C. for 24 hours followed by calcining
thereof in air at 350.degree. C. for 5 hours. A 50 g portion of the
calcined cake was powdered in a ball mill along with 50 g of
.gamma.-alumina (N612, Nikki Kagaku Co.) for about 3 hours. The
powder mixture was calcined in air at 450.degree. C. for 3.hours.
The calcined mixture was further powdered to about 120 .mu.m or
finer size as the target catalyst.
[0141] Analysis of thus obtained catalyst gave the composition as
CuO:ZnO:Al.sub.2O.sub.3=31:16:53 (by weight).
II. Method for Activating Catalyst and Reaction Method
[0142] A 24 g of n-hexadecane (31.1 ml) was charged to a
bubble-tower reactor having 2 cm of inside diameter and 2 m of
height, and 3.6 g of each of the above-described catalyst powders
was added to make the contents of the reactor in a suspended state.
In Examples 5 through 8, the catalyst of Example 1 was used. A
mixed gas of hydrogen, carbon monoxide, and nitrogen (at a molar
ratio H.sub.2:CO:N.sub.2 of 1:1:9) was introduced to pass through
the bubble-tower at a flow rate of about 300 ml/min. While flowing
the mixed gas through the bubble-tower, the temperature in the
bubble-tower was gradually raised from room temperature to
220.degree. C. within a period of several hours. At the same time,
the concentration of nitrogen in the mixed gas was gradually
reduced to a final level of zero. Then, the reaction system was
held at 220.degree. C. for about 3 hours to activate the
catalyst
[0143] The reaction was conducted at a specified temperature and
pressure while introducing the mixed gas of hydrogen, carbon
monoxide, and carbon dioxide at a molar ratio of
H.sub.2/CO/CO.sub.2=47.5/47.5/5.0 and at a flow rate of 336 mi/min.
(converted at a condition of normal temperature and pressure).
[0144] The obtained reaction products and non-reacted substances
were analyzed by gas chromatography.
III. Reaction Conditions and Experimental Results
[0145] The reaction conditions and experimental results are shown
in Tables 1 through5. TABLE-US-00001 TABLE 1 Example 1 Example 2
Example 3 Example 4 Condition Temperature (.degree. C.) 280 280 280
280 Pressure (kg/cm.sup.2-G) 30 30 30 30 Reaction CO conversion (%)
47.7 37.8 40.5 48.3 Result Yield Dimethyl ether 36.5 25.3 28.4 35.7
(C-mol %) Methanol 2.0 0.7 1.1 2.4 Hydrocarbons 0.3 0.2 0.3 0.1
CO.sub.2 8.9 11.6 10.7 10.1 Dimethyl ether space time yield 998 692
777 976 (g/kg-cat h)
[0146] TABLE-US-00002 TABLE 2 Example 5 Example 6 Example 7 Example
8 Condition Temperature (.degree. C.) 250 300 280 280 Pressure
(kg/cm.sup.2-G) 30 30 20 50 Reaction CO conversion (%) 40.3 45.1
38.4 55.9 Result Yield Dimethyl ether 24.2 33.8 26.5 43.6 (C-mol %)
Methanol 3.8 1.7 1.5 2.2 Hydrocarbons 0.1 2.8 0.4 0.8 CO.sub.2 12.2
6.8 10.0 93 Dimethyl ether space time yield 662 924 725 1192
(g/kg-cat h)
[0147] TABLE-US-00003 TABLE 3 Example 9 Example 10 Example 11
Example 12 Condition Temperature (.degree. C.) 280 280 280 280
Pressure (kg/cm.sup.2-G) 30 30 30 30 Reaction CO conversion (%)
38.8 40.2 46.9 47.8 Result Yield Dimethyl ether 28.5 31.1 36.1 35.9
(C-mol %) Methanol 3.1 2.4 1.8 2.2 Hydrocarbons 0.1 0.1 0.2 0.2
CO.sub.2 7.1 6.6 8.8 9.5 Dimethyl ether space time yield 779 850
987 982 (g/kg-cat h)
[0148] TABLE-US-00004 TABLE 4 Comparative Comparative Example 13
Example 14 Example 1 Example 2 Condition Temperature (.degree. C.)
280 280 280 280 Pressure (kg/cm.sup.2-G) 30 30 30 30 Reaction CO
conversion (%) 41.9 40.0 30.1 18.4 Result Yield Dimethyl ether 32.1
29.3 17.5 6.5 (C-mol %) Methanol 1.7 2.0 5.7 6.5 Hydrocarbons 0.1
0.2 0.1 0.1 CO.sub.2 8.0 8.5 6.8 1.3 Dimethyl ether space time
yield 878 801 478 178 (g/kg-cat h)
[0149] TABLE-US-00005 TABLE 5 Reaction Reaction result in result in
Example 1 Example 3 after 100 after 100 hours of hours of
continuous continuous reaction reaction Condition Temperature
(.degree. C.) 280 280 Pressure (kg/cm.sup.2-G) 30 30 Reaction CO
conversion (%) 41.9 27.3 Result Yield Dimethyl ether 36.3 13.8
(C-mol %) Methanol 1.8 9.8 Hydrocarbons 0.2 0.5 CO.sub.2 8.8 3.2
Dimethyl ether space 992 377 time yield (g/kg-cat h)
[0150] The catalyst for manufacturing dimethyl ether according to
the present invention provides effects of preventing separation of
individual catalyst ingredients from each other during reaction, of
assuring smooth progress of reaction cycle, and of achieving high
dimethyl ether yield owing to the configuration thereof comprising
alumina particles and methanol synthesis catalyst layer formed
around each of the alumina particles.
[0151] The method for manufacturing dimethyl ether according to the
present invention uses a slurry of solvent with a catalyst
comprising alumina particles and methanol synthesis catalyst layer
formed around each of the alumina particles, so the method provides
effects of achieving high space time yield of dimethyl ether, of
being free from problems of plugging of catalyst and of mechanical
strength of catalyst, of easiness for removing reaction heat and
for controlling reaction heat, of assuring wide application range
of the ratio of carbon monoxide to hydrogen, of progress of
reaction under the presence of high concentration of carbon
dioxide, and of less influence of impurities and catalyst
poisons.
Embodiment 2
[0152] The catalyst according to the present invention comprises an
alumina having micropores with deposits of copper oxide, zinc
oxide, and alumina therein. Alumina functions as a
methanol-dehydration catalyst, and alumina in use as an ordinary
catalyst may be applied without further processing. A preferable
size of alumina particles is a fine size, preferably 200 .mu.m or
less of average particle size, more preferably in an approximate
range of from 1 to 100 .mu.m, and most preferably in an approximate
range of from 1 to 50 .mu.m. To prepare the preferred average
particle size, alumina may be pulverized as needed.
[0153] The ratio of copper oxide, zinc oxide, and alumina which are
deposited on the surface of micropores in alumina is in an
approximate range of from 0.05 to 20 wt. parts of zinc oxide to 1
wt. parts of copper oxide, more preferably in an approximate range
of from 0.1 to 5 wt. parts; in an approximate range of from 0 to 2
wt. parts of alumina to 1 wt. parts of copper oxide, more
preferably in an approximate range of from 0 to 0.5 wt. parts. A
preferable deposition amount is in an approximate range of from
0.05 to 5 wt. parts of the sum of copper oxide, zinc oxide, and
alumina to 1 wt. parts of the alumina particles being deposited
thereon, and more preferably in an approximate range of from 0.1 to
3 wt. parts, and most preferably in an approximate range of from
0.5 to 2 wt. parts.
[0154] The catalyst achieves 25% or higher CO conversion, or
normally in an approximate range of from 30 to 50%, and
particularly in an approximate range of from 40 to 50%, and
achieves 20% or higher dimethyl ether yield, or normally in an
approximate range of from 25 to 35%, and particularly in an
approximate range of from 30 to 35%. A preferred particle size of
the catalyst is small as far as possible within a range that no
agglomeration problem occurs. A preferable average particle size of
the catalyst is 200 .mu.m or less, more preferably in an
approximate range of from 1 to 100 .mu.m, and most preferably in an
approximate range of from 1 to 50 .mu.m.
[0155] The method for manufacturing the catalyst according to the
present invention is characterized in the steps of: depositing
copper oxide, zinc oxide, and alumina onto the surface of
micropores in alumina using a base solution; then calcining the
alumina and the deposits. For manufacturing the catalyst,
granulated alumina particles or alumina powder is impregnated with
an aqueous solution containing adequate kinds of copper salt, zinc
salt, and aluminum salt. The kind of copper salt, zinc salt, and
aluminum salt may be either an inorganic salt or an organic salt if
only the salt is soluble in water. Nevertheless, a salt that likely
generates hydroxide in water by hydrolysis is not suitable. As for
the salt of copper and of zinc, nitrate, carbonate, organic acid
salt are applicable. For the salt of halide and of aluminum,
nitrate, carbonate, and organic salt are applicable. A preferable
concentration of each ingredient is in an approximate range of from
0.1 to 3 mole/liter.
[0156] After the aqueous solution of the salts fully penetrated
into the micropores in alumina, excess amount of aqueous solution
is removed as needed, then the remaining aqueous solution is
vaporized to dry. At the point that the surface water on the
alumina is vaporized off, or at the point that the total amount of
applied aqueous solution of the salts filled the micropores in
alumina, the alumina is brought into contact with a solution of the
deposition agent. The deposition agent is a base, which reacts with
an inorganic portion that structures the copper salt, the zinc
salt, and the aluminum salt to form a water-soluble salt, while the
deposition agent itself is able to be emitted by thermal
decomposition during the succeeding calcining step. A preferable
deposition agent includes ammonia, urea, and an organic base, and
particularly ammonia is preferred. A base which cannot be thermally
decomposed, such as sodium hydroxide, potassium hydroxide, and
sodium carbonate, is not favorable because that type of base
remains in micropores in alumina even after sufficient washing with
water to interfere with the catalyst activity. A preferable
concentration of the solution of deposition agent is in an
approximate range of from 0.5 to 10 mole/liter. With the addition
of solution of deposition agent, copper salt, zinc salt, and
aluminum salt are hydrolyzed within the micropores in alumina by
the base as a deposition agent, thus depositing those salts onto
the surface of the micropores. The deposition of copper, zinc, and
aluminum may be conducted separately, at need. Applicable
deposition temperature is around 80.degree. C. at the maximum, and
room temperature is preferred. As for the pH value, the pH in the
micropores is important, though the pH within the micropores cannot
be measured. The pH value in the solution of deposition agent is
always at alkali side (pH>12). The deposits are then fully
washed with ion-exchanged water or the like to remove base ions and
inorganic ions, and the alumina with deposits is dried and
calcined. The calcining may be conducted in air. The temperature of
calcining is preferably at a temperature that copper hydroxide,
zinc hydroxide, and aluminum hydroxide are converted into copper
oxide, zinc oxide, and alumina, respectively, and that base is
thermally decomposed to emit, or, for example, in a range of from
250 to 400.degree. C. for a period of 1 to 10 hours.
[0157] Thus prepared catalysts are used in a state of slurry with a
solvent after classifying to remove a portion of the catalysts
which excessively enlarged their size caused by deposition. The
amount of catalyst in the solvent depends on the kind of the
solvent, the reaction conditions, and other variables. Normally,
the amount of catalyst is in a range of from 1 to 50 wt. % to the
amount of the solvenl
[0158] The kind of solvent used for synthesizing dimethyl ether
according to the present invention is arbitrarily selected if only
the solvent is in a liquid phase under the reaction condition.
Examples of the solvent are hydrocarbons of aliphatic, aromatic,
and alicyclic groups, alcohol, ether, ester, ketone, halide, or
their mixture.
[0159] Alternatively, gas oil after removing sulfur ingredients,
vacuum gas oil, high boiling point distillates of coal tar after
treated by hydrogenation are also applicable as the solvent.
[0160] By passing a mixed gas of carbon monoxide and hydrogen
through thus prepared slurry of catalyst with solvent, dimethyl
ether is obtained at a high yield An applicable range of molar
mixing ratio of hydrogen to carbon monoxide (H.sub.2/CO) is wide,
for instance, in a range of from 20 to 0.1 as (H.sub.2/CO), and
more preferably from 10 to 0.2. According to the reaction system,
the mixed gas does not directly contact with the catalyst, which
direct contact occurs in a gas solid catalytic reaction system, but
the carbon monoxide and hydrogen contact with catalyst only after
dissolved into a solvent. Consequently, selection of an adequate
kind of solvent taking into account of the solubility of carbon
monoxide and hydrogen to the solvent establishes a constant
composition of carbon monoxide and hydrogen in the solvent
independent of the gas composition, and sustains the supply of the
mixed gas at an established composition to the catalyst
surface.
[0161] In the case of a mixed gas with a significantly low ratio of
(H.sub.2/CO), for example, 0.1 or less, or in the case of solely
carbon monoxide without containing hydrogen, it is necessary to
separately supply steam to convert a part of the carbon monoxide
into hydrogen and carbon dioxide within the reactor.
[0162] Since solvent exists between the raw material gases and the
catalyst, the gas composition does not necessarily agree with the
composition on the catalyst surface. Therefore, it is acceptable
that the mixed gas of carbon monoxide and hydrogen, or solely
carbon monoxide gas includes a relatively high concentration of
carbon dioxide (in a range of from 20 to 50%).
[0163] The manufacturing method according to the present invention
significantly reduces the effect of ingredients that may act as a
catalyst-poison on the catalyst compared with the gas solid contact
catalyst system. Examples of the catalyst-poisoning ingredients
which may exist in the raw material gas are sulfur compounds such
as hydrogen sulfide, cyan compounds such as hydrogen cyanide, and
chlorine compounds such as hydrogen chloride. Even when the
catalyst activity is decreased as a result of poisoning, the
productivity of the total reactor system is maintained at a
constant level by withdrawing the slurry from the reactor and by
charging fresh slurry containing catalyst of high activity to the
reactor.
[0164] The reaction heat is recovered in a form of medium pressure
steam using a cooling coil installed inside of the reactor while
passing hot water through the cooling coil. The cooling system
controls the reaction temperature at an arbitrary level.
[0165] A preferable reaction temperature is in a range of from 150
to 400.degree. C., and particularly preferable in a range of from
200 to 350.degree. C. The reaction temperature below 150.degree. C.
and above 400.degree. C. degrades the conversion of carbon
monoxide.
[0166] A preferable reaction pressure is in a range of from 10 to
300 kg/cm.sup.2, and particularly preferable in a range of from 15
to 150 kg/cm.sup.2. The reaction pressure below 10 kg/cm.sup.2
results in a low conversion of carbon monoxide, and that above 300
kg/cm.sup.2 requires a special design of the reactor and is
uneconomical because of the need of a large amount of energy for
pressurizing the system.
[0167] A preferable space velocity (charge rate of mixed gas per 1
g of catalyst under standard condition) is in a range of from 100
to 50000 ml/gh, and particularly preferable from 500 to 30000
ml/gh. The space velocity above 50000 ml/gh degrades the conversion
of carbon monoxide, and that below 100 ml/gh is uneconomical
because of the need of an excessively large reactor.
[0168] The catalyst for manufacturing dimethyl ether according to
the present invention is prepared by depositing copper oxide, zinc
oxide and alumina onto the surface of micropores in alumina.
Individual catalyst ingredients do not separate from each other
during the reaction process. Therefore, the reaction cycle proceeds
smoothly, and a high yield of dimethyl ether is attained.
[0169] The method for manufacturing dimethyl ether according to the
present invention significantly increases the yield of dimethyl
ether by using the catalyst in a state of a slurry with a solvent,
which catalyst is prepared by depositing copper oxide, zinc oxide,
and alumina on the surface of micropores in alumina. The method is
free from problems such as plugging of catalyst and mechanical
strength of catalyst, is designed to readily absorb the reaction
heat through a cooling pipe or the like, and is designed to conduct
withdrawing and filling of catalyst easily.
EXAMPLE
I. Preparation of Catalyst
Examples 1, 5 Through 8
[0170] Each of 185 g of copper nitrate
(Cu(NO.sub.3).sub.2.3H.sub.2O), 117 g of zinc nitrate
(Zn(NO.sub.3).sub.2.6H.sub.2O), and 52 g of aluminum nitrate
(Al(NO.sub.3).sub.3.9H.sub.2O) were dissolved into about 1 liter of
ion-exchanged water. To the solution 100 g of fine powder of
.gamma.-alumina (N612, Nikki Kagaku Co.) having an approximate
particle size of 20 .mu.m or less was added. The water of the
mixture was removed by vaporizing in a water-bath. The resulted
material was put into about 1 liter of about 5 mole/liter aqueous
ammonia. The mixture was held for about 1 hour. Then the mixture
was further washed until no ammonium ion nor nitric acid ion was
detected anymore. The mixture was dried at 120.degree. C. for 24
hours followed by calcined in air at 350.degree. C. for 5 hours.
The calcined particles were classified to recover 120 .mu.m or
finer ones as the target catalyst.
[0171] Analysis of thus obtained catalyst gave the composition as
CuO:ZnO:Al.sub.2O.sub.3=31:16:53 (by weight).
Example 2
[0172] Each of 37.1 g of copper nitrate
(Cu(NO.sub.3).sub.2.3H.sub.2O), 23.4 g of zinc nitrate
(Zn(NO.sub.3).sub.2.6H.sub.2O), and 10.3 g of aluminum nitrate
(Al(NO.sub.3).sub.3.9H.sub.2O) were dissolved into about 200 ml of
ion-exchanged water. To the solution, 100 g of fine powder of
.gamma.-alumina (N612, Nikki Kagaku Co.) having an approximate
particle size of 20 .mu.m or less was added. The water of the
mixture was removed by vaporzing in a water-bath. The resultant
material was put into about 1 liter of about 1 mole/liter aqueous
ammonia. The mixture was held for about 1 hour. Then the mixture
was further washed until no ammonium ion nor nitric acid ion was
detected anymore. The mixture was dried at 120.degree. C. for 24
hours. followed by calcined in air at 350.degree. C. for 5 hours.
The calcined particles were classified to recover 120 .mu.m or
finer ones as the target catalyst.
[0173] Analysis of thus obtained catalyst gave the composition as
CuO:ZnO:Al.sub.2O.sub.3=20:11:69 (by weight).
Example 3
[0174] Each of 92.6 g of copper nitrate
(Cu(NO.sub.3).sub.2.3H.sub.2O), 58.5 g of zinc nitrate
(Zn(NO.sub.3).sub.2.6H.sub.2O), and 25.5 g of aluminum nitrate
(Al(NO.sub.3).sub.3.9H.sub.2O) were dissolved into about 500 ml of
ion-exchanged water. To the solution, 100 g of fine powder of
.gamma.-alumina (N612, Nikki Kagaku Co.) having an approximate
particle size of 20 .mu.m or less was added. The water of the
mixture was removed by vaporizing in a water-bath. The resultant
material was put into about 1 liter of about 2.5 mole/liter aqueous
ammonia. The mixture was held for about 1 hour. Then the mixture
was further washed until no ammonium ion nor nitric acid ion was
detected anymore. The mixture was dried at 120.degree. C. for 24
hours followed by calcined in air at 350.degree. C. for 5 hours.
The calcined particles were classified to recover 120 .mu.m or
finer ones as the target catalyst.
[0175] Analysis of thus obtained catalyst gave the composition as
CuO:ZnO:Al.sub.2O.sub.3=31:16:53 (by weight).
Example 4
[0176] Each of 185 g of copper nitrate
(Cu(NO.sub.3).sub.2.3H.sub.2O), 117 g of zinc nitrate
(Zn(NO.sub.3).sub.2.6H.sub.2O), and 52 g of aluminum nitrate
(Al(NO.sub.3).sub.3.9H.sub.2O) were dissolved into about 1 liter of
ion-exchanged water. To the solution, 50 g of fine powder of
.gamma.-alumina (N612, Nikki Kagaku Co.) having an approximate
particle size of 20 .mu.m or less was added. The water of the
mixture was removed by vaporizing in a water-bath. The resulted
material was put into about 1 liter of about 5 mole/liter aqueous
ammonia. The mixture was held for about 1 hour. Then the mixture
was further washed until no ammonium ion nor nitric acid ion was
detected anymore. The mixture was dried at 120.degree. C. for 24
hours, followed by calcined in air at 350.degree. C. for 5 hours.
The calcined particles were classified to recover 120 .mu.m or
finer ones as the target catalyst
[0177] Analysis of thus obtained catalyst gave the composition as
CuO:ZnO:Al.sub.2O.sub.3=41:21:38 (by weight).
Example 9
[0178] Each of 185 g of copper nitrate
(Cu(NO.sub.3).sub.2.3H.sub.2O), 117 g of zinc nitrate
(Zn(NO.sub.3).sub.2.6H.sub.2O), and 52 g of aluminum nitrate
(Al(NO.sub.3).sub.3.9H.sub.2O) were dissolved into about 1 liter of
ion-exchanged water. To the solution, 100 g of fine powder of
.gamma.-alumina (N612, Nikki Kagaku Co.) having an approximate
particle size of 20 .mu.m or less was added. The water of the
mixture was removed by vaporizing in a water-bath. The resulted
material was put into about 1 liter of about 10 mole/liter aqueous
solution of urea. The mixture was heated to about 90.degree. C.
under agitation. At the point that pH value reached to about 8, the
mixture was allowed to stand for cooling. Then the mixture was
filtered, and the cake was rinsed. The cake was dried at
120.degree. C. for 24 hours, followed by calcined in air at
350.degree. C. for 5 hours. The calcined particles were classified
to recover 120 .mu.m or finer ones as the target catalyst.
[0179] Analysis of thus obtained catalyst gave the composition as
CuO:ZnO:Al.sub.2O.sub.3=31:16:53 (by weight).
II. Method for Activating Catalyst and Reaction Method
[0180] A 24 g of n-hexadecane (31.1 ml) was charged to a
bubble-tower reactor having 2 cm of inside diameter and 2 m of
height, and 3.6 g of each of the above-described catalyst powders
was added to make the contents of the reactor in a suspended state.
In Examples 5 through 8, the catalyst of Example 1 was used. A
mixed gas of hydrogen, carbon monoxide, and nitrogen (at a molar
ratio H.sub.2:CO:N.sub.2 of 1:1:9) was introduced to pass through
the bubble-tower at a flow rate of about 300 ml/min. While flowing
the mixed gas through the bubble-tower, the temperature in the
bubble-tower was gradually raised from room temperature to
220.degree. C. within a period of several hours. At the same time,
the concentration of nitrogen in the mixed gas was gradually
reduced to a final level of zero. Then, the reaction system was
held at 220.degree. C. for about 3 hours, to activate the
catalyst.
[0181] The reaction was conducted at a specified temperature and
pressure while introducing the mixed gas of hydrogen, carbon
monoxide, and carbon dioxide at a molar ratio of
H.sub.2/CO/CO.sub.2=473/47.5/5.0 and at a flow rate of 336 ml/min.
(converted at a condition of normal temperature and pressure).
[0182] The obtained reaction products and non-reacted substances
were analyzed by gas chromatography.
III. Reaction Conditions and Experimental Results
[0183] The reaction conditions and experimental results are shown
in Tables 6 through 8. TABLE-US-00006 TABLE 6 Example 1 Example 2
Example 3 Example 4 Condition Temperature (.degree. C.) 280 280 280
280 Pressure (kg/cm.sup.2-G) 30 30 30 30 Reaction CO conversion (%)
41.3 27.1 30.3 38.6 Result Yield Dimethyl ether 31.5 20.9 24.1 27.3
(C-mol %) Methanol 1.8 0.7 1.4 2.0 Hydrocarbons 0.1 0.2 0.2 0.1
CO.sub.2 7.9 5.3 4.6 9.2 Dimethyl ether space time yield 861 572
659 747 (g/kg-cat h)
[0184] TABLE-US-00007 TABLE 7 Example 5 Example 6 Example 7 Example
8 Condition Temperature (.degree. C.) 250 300 280 280 Pressure
(kg/cm.sup.2-G) 30 30 20 50 Reaction CO conversion (%) 29.5 38.4
32.2 45.6 Result Yield Dimethyl ether 23.8 32.4 24.6 33.2 (C-mol %)
Methanol 2.1 1.1 0.8 1.7 Hydrocarbons 0.1 0.6 0.1 0.5 CO.sub.2 3.5
4.3 6.7 10.2 Dimethyl ether space time yield 651 886 673 908
(g/kg-cat h)
[0185] TABLE-US-00008 TABLE 8 Example 9 Condition Temperature
(.degree. C.) 280 Pressure (kg/cm.sup.2-G) 30 Reaction CO
conversion (%) 40.8 Result Yield Dimethyl ether 30.7 (C-mol %)
Methanol 1.7 Hydrocarbons 0.2 CO.sub.2 8.2 Dimethyl ether space
time yield 840 (g/kg-cat h)
[0186] The catalyst for manufacturing dimethyl ether according to
the present invention provides effects of preventing separation of
individual catalyst ingredients from each other during reaction, of
assuring smooth progress of reaction cycle, and of achieving high
dimethyl ether yield owing to the configuration thereof comprising
an alumina having micropores with deposits of copper oxide, zinc
oxide, and alumina therein.
[0187] The method for manufacturing dimethyl ether according to the
present invention uses a slurry of solvent with a catalyst
comprising an alumina having micropores with deposits of copper
oxide, zinc oxide, and alumina therein, so the method provides
effects of achieving high space time yield of dimethyl ether, of
being free from problems of plugging of catalyst and of mechanical
strength of catalyst, of easiness for removing reaction heat and
for controlling reaction heat, of assuring wide application range
of the ratio of carbon monoxide to hydrogen, of progress of
reaction under the presence of high concentration of carbon
dioxide, and of less influence of impurities and catalyst
poisons.
Embodiment 3
[0188] The catalyst for manufacturing dimethyl ether according to
the present invention is characterized in that at least a methanol
synthesis catalyst and a methanol-dehydration catalyst are
integrated together using a binder.
[0189] The method for manufacturing dimethyl ether according to the
present invention comprises the step of charging a mixed gas of
carbon monoxide and hydrogen, or a mixed gas of carbon monoxide,
hydrogen, and further containing carbon dioxide and/or water vapor
to a slurry of the catalyst with a solvent.
[0190] The catalyst according to the present invention is basically
a catalyst in which a methanol synthesis catalyst, a
methanol-dehydration catalyst, and a water gas shift catalyst are
integrated together. Since, however, the methanol synthesis
catalyst is inherently an excellent water gas shift catalyst, the
methanol synthesis catalyst may play a role of the water gas shift
catalyst.
[0191] The methanol synthesis catalyst maybe copper oxide--zinc
oxide--alumina system and zinc oxide--chromium oxide--alumina
system. A preferable mixing ratio of individual ingredients of
copper oxide, zinc oxide, and alumina is: in an approximate range
of from 0.05 to 20 wt. parts of zinc oxide to 1 wt. parts of copper
oxide, more preferably in an approximate range of from 0.1 to 5 wt.
parts; in an approximate range of from 0 to 2 wt. parts of alumina,
more preferably in an approximate range of from 0 to 1 wt. parts. A
preferable mixing ratio of individual ingredients of zinc oxide,
chromium oxide, and alumina is: in an approximate range of from 0.1
to 10 of chromium oxide to 1 wt. parts of zinc oxide, more
preferably in an approximate range of from 0.5 to 5; and in an
approximate range of from 0 to 2 wt. parts of alumina, more
preferably in an approximate range of from 0 to 1 wt. parts.
Applicable methanol-dehydration catalysts includes .gamma.-alumina,
silica-alumina, and zeolite. Examples of metallic oxide ingredient
in zeolite are oxide of alkali metal such as sodium and potassium,
and oxide of alkali earth metal such as calcium and magnesium. As
described above, the methanol synthesis catalyst may substitute for
the water gas shift catalyst Other than the methanol synthesis
catalyst, iron oxide--chromium oxide may substitute for the water
gas shift catalyst. A preferable ratio of chromium oxide to iron
oxide is in an approximate range of from 0.1 to 20 wt. parts to 1
wt. parts of iron oxide, more preferably in an approximate range of
from 0.5 to 10.
[0192] Each of these methanol synthesis catalyst,
methanol-dehydration catalyst, and water gas shift catalyst may be
manufactured by known methods. For example, a water soluble salt of
each metallic ingredient is used to prepare an aqueous solution
containing these salts. The kind of salt is either inorganic salt
or organic salt. Nevertheless, a salt that likely generates
hydroxide in water is not suitable. Nitrate, carbonate, organic
acid salt, and halide are applicable as the salt. A preferable
concentration of each ingredient is in an approximate range of from
0.1 to 3 mole/liter. A base is added to the aqueous solution to
neutralize the solution and to precipitate hydroxide. Then the
solid is separated from liquid, which is then rinsed and dried,
followed by calcining to obtain the target catalyst. Alternatively,
a commercial catalyst may be used.
[0193] The mixing ratio of above-described methanol synthesis
catalyst, methanol-dehydration catalyst, and water gas shift
catalyst is not specifically limited, and is selected at an
adequate ratio corresponding to the kind of each ingredient and the
reaction condition. A preferable mixing ratio is often in an
approximate range of from 0.5 to 10 wt. parts of
methanol-dehydration catalyst per 1 wt. parts of methanol synthesis
catalyst, and in an approximate range of from 0 to 5 wt. parts of
water gas shift catalyst per 1 wt. parts of methanol synthesis
catalyst.
[0194] These catalysts are co-pulverized, or pulverized in a mixed
state. Co-pulverization is preferably done to an approximate
average particle size of 200 .mu.m or less, more preferably in an
approximate range of from 1 to 100 .mu.m, and most preferably in an
approximate range of from 1 to 50 .mu.m.
[0195] Thus prepared catalyst mixture particles are blended with a
binder. The binder needs to have characteristics of durability to
calcining (alteration is acceptable), function to bind individual
catalysts to integrate them after calcining, and not degrading the
activity of each catalyst Alumina sol and clay are examples of the
binder. A preferable ratio of binder to catalyst is in a range of
from 0.005 to 1 wt. parts to 1 wt. parts of catalyst, more
preferably in a range of from 0.01 to 1, and most preferably in a
range of from 0.05 to 1.
[0196] After the co-pulverization, the mixture is processed by
drying and calcining. The calcining may be carried out at a
temperature ranging approximately from 250 to 500.degree. C. For a
period of approximately from 2 to 10 hours.
[0197] After the calcining, the mixture is pulverized for use.
[0198] Preferably, the pulverization is conducted to an average
particle size of 200 .mu.m or less, more preferably to an
approximate range of from 1 to 100 .mu.m, and most preferably to an
approximate range of from 1 to 50 .mu.m.
[0199] Thus prepared catalyst achieves 35% or higher CO conversion,
normally in an approximate range of from 40 to 60%, and
particularly in an approximate range of from 50 to 60%, and
achieves 25% or higher dimethyl ether yield, or normally in an
approximate range of from 30 to 40%.
[0200] A primary characteristic of the method according to the
present invention is to integrate a methanol synthesis catalyst, a
methanol-dehydration catalyst, and a water gas shift catalyst using
a binder. The integration is conducted for ensuring swift progress
of the reaction cycle described below by making the distance among
these catalysts very short, so that the catalysts are very close to
each other without separating them from each other during the
reaction period, thus improving the yield of dimethyl ether. That
is, the reaction proceeds in the sequent order of: Yielding
methanol on the methanol synthesis catalyst from carbon monoxide
and hydrogen; moving the methanol onto the methanol-dehydration
catalyst to yield dimethyl ether and water by
dehydration-condensation; moving the water onto the water gas shift
catalyst and/or the methanol synthesis catalyst to yield hydrogen
by reacting with carbon monoxide. The reaction is expressed by the
formulae given below. CO+2H.sub.2.fwdarw.CH.sub.3OH
2CH.sub.3OH.fwdarw.CH.sub.3OCH.sub.3+H.sub.2O
CO+H.sub.2O.fwdarw.CO.sub.3+H.sub.2
[0201] The above-described catalyst is used in a state of slurry of
a solvent The amount of catalyst in the solvent depends on the kind
of the solvent, the reaction conditions, and other variables.
Normally, the amount of catalyst is in a range of from 1 to 50 wt.
% to the amount of the solvent
[0202] The kind of solvent used for synthesizing dimethyl ether
according to the present invention is arbitrarily selected if only
the solvent is in a liquid phase under the reaction condition.
Examples of the solvent are hydrocarbons of aliphatic, aromatic,
and alicyclic groups, alcohol, ether, ester, ketone, halide, or
their mixture.
[0203] Alternatively, gas oil after removing sulfur ingredients,
vacuum gas oil, high boiling point distillates of coal tar after
treated by hydrogenation are also applicable as the solvent.
[0204] By passing a mixed gas of carbon monoxide and hydrogen
through thus prepared slurry of catalyst with solvent, dimethyl
ether is obtained at a high yield. Applicable range of molar mixing
ratio of hydrogen to carbon monoxide (H.sub.2/CO) is wide, for
instance, in a range of from 20 to 0.1 as (H.sub.2/CO), and more
preferably from 10 to 0.2.
[0205] According to the reaction system, the mixed gas does not
directly contact with the catalyst, which direct contact occurs in
a gas solid catalytic reaction system, but the carbon monoxide and
hydrogen contact with catalyst only after being dissolved into a
solvent. Consequently, selection of an adequate kind of solvent
taking into account of the solubility of carbon monoxide and
hydrogen to the solvent establishes a constant composition of
carbon monoxide and hydrogen in the solvent independent of the gas
composition, and sustains the supply of the mixed gas at an
established composition to the catalyst surface.
[0206] In the case of a mixed gas with a significantly low ratio of
(H.sub.2/CO), for example, 0.1 or less, or in the case of solely
carbon monoxide without containing hydrogen, it is necessary to
separately supply steam to convert a part of the carbon monoxide
into hydrogen and carbon dioxide within the reactor.
[0207] Since solvent exists between the raw material gases and the
catalyst, the gas composition does not necessarily agree with the
composition on the catalyst surface. Therefore, it is acceptable
that the mixed gas of carbon monoxide and hydrogen, or solely
carbon monoxide gas includes a relatively high concentration of
carbon dioxide (in a range of from 20 to 50%).
[0208] The manufacturing method according to the present invention
significantly reduces the effect of ingredients that may act as a
catalyst-poison on the catalyst compared with the gas solid contact
catalyst system. Examples of the catalyst-poisoning ingredients
which may exist in the raw material gas are sulfur compounds such
as hydrogen sulfide, cyan compounds such as hydrogen cyanide, and
chlorine compounds such as hydrogen chloride. Even when the
catalyst activity is decreased as a result of poisoning, the
productivity of total reactor system is maintained at a constant
level by withdrawing the slurry from the reactor and by charging
fresh slurry containing catalyst of high activity to the
reactor.
[0209] The reaction heat is recovered in a form of medium pressure
steam using a cooling coil installed inside of the reactor while
passing hot water through the cooling coil. The cooling system
controls the reaction temperature at an arbitrary level.
[0210] A preferable reaction temperature is in a range of from 150
to 400.degree. C., and particularly preferable in a range of from
200 to 350.degree. C. The reaction temperature below 150.degree. C.
and above 400.degree. C. degrades the conversion of carbon
monoxide.
[0211] A preferable reaction pressure is in a range of from 10 to
300 kg/cm.sup.2, and particularly preferable in a range of from 15
to 150 kg/cm.sup.2. The reaction pressure below 10 kg/cm.sup.2
results in a low conversion of carbon monoxide, and that above 300
kg/cm.sup.2 requires a special design of the reactor and is
uneconomical because of the need of a large amount of energy for
pressurizing the system.
[0212] A preferable space velocity (charge rate of mixed gas per 1
g of catalyst under standard condition) is in a range of from 100
to 50000 ml/gh, and particularly preferable from 500 to 30000
ml/gh. The space velocity above 50000 ml/gh degrades the conversion
of carbon monoxide, and that below 100 ml/gh is uneconomical
because of the need of an excessively large reactor.
[0213] The catalyst for manufacturing dimethyl ether according to
the present invention and a method therefor apply integration of a
methanol synthesis catalyst, a methanol-dehydration catalyst, and a
water gas shift catalyst with a binder, so the individual catalyst
ingredients do not separate from each other during the reaction
period. As a result, the reaction cycle proceeds smoothly and a
high dimethyl ether yield is achieved.
[0214] The method for manufacturing dimethyl ether according to the
present invention significantly increases the yield of dimethyl
ether by using the catalyst which comprises an integrated condition
of a methanol synthesis catalyst, a methanol-dehydration catalyst,
and a water gas shift catalyst, in a state of a slurry with a
solvent. The method is free from problems such as plugging of
catalyst and mechanical strength of catalyst, is designed to
readily absorb the reaction heat through a cooling pipe or the
like, and is designed to conduct withdrawing and filling of
catalyst easily.
EXAMPLE
I. Preparation of Catalyst
1) Preparation of CuO--ZnO--Al.sub.2O.sub.3 Catalyst
[0215] Each of 185 g of copper nitrate
(Cu(NO.sub.3).sub.2.3H.sub.2O), 117 g of zinc nitrate
(Zn(NO.sub.3).sub.2.6H.sub.2O), and 52 g of aluminum nitrate
(Al(NO.sub.3).sub.3.9H.sub.2O) were dissolved into about 1 liter of
ion-exchanged water. Separately, about 1.4 kg of sodium carbonate
(Na.sub.2CO.sub.3) was dissolved into about 1 liter of
ion-exchanged water. Both of the solutions were added dropwise to
about 3 liters of ion-exchanged water in a stainless steel vessel
which was controlled at about 60.degree. C. within about 2 hours,
while maintaining the contents to pH 7.0.+-.0.5. Then, the contents
were allowed to stand for about 1 hour for aging. When, during the
treatment, the pH value went out from a range of pH 7.0.+-.0.5,
either of an aqueous solution of about 1 mole/liter nitric acid or
an aqueous solution of about 1 mole/liter sodium carbonate was
added dropwise to keep the range of pH 7.0.+-.0.5. The resultant
precipitate was filtered, and the cake was rinsed by ion-exchanged
water, until nitric acid ion was not detected anymore. After the
rinse, the cake was dried at 120.degree. C. for 24 hours, followed
by calcining thereof in air at 350.degree. C. For 5 hours to obtain
the target methanol synthesis catalyst.
[0216] Analysis of thus obtained catalyst gave the composition as
CuO:ZnO:Al.sub.2O.sub.3=31:32:7 (by weight).
2) Preparation of CuO--Cr.sub.2O.sub.3--ZnO Catalyst
[0217] Each of 0.30 kg of copper nitrate
(Cu(NO.sub.3).sub.2.3H.sub.2O), 105 g of chromium nitrate
(Cr(NO.sub.3).sub.2.3H.sub.2O), and 256 g of zinc nitrate
(Zn(NO.sub.3).sub.2.6H.sub.2O), were dissolved into about 1 liter
of ion-exchanged water. Separately, about 130 g of sodium carbonate
(Na.sub.2CO.sub.3) was dissolved into about 1 liter of
ion-exchanged water. Both of the solutions were added dropwise to
about 3 liters of ion-exchanged water in a stainless steel vessel
which was controlled at about 60.degree. C. within about 2 hours
while maintaining the contents to pH 8.5.+-.0.5. Then, the contents
were allowed to stand for about 1 hr for aging. When, during the
treatment, the pH value went out from a range of pH 8.5.+-.0.5,
either of an aqueous solution of about 1 mole/liter nitric acid or
an aqueous solution of about 1 mole/liter sodium carbonate was
added dropwise to keep the range of pH 8.5.+-.0.5. The resultant
precipitate was filtered, and the cake was rinsed by ion-exchanged
water until nitric acid ion was not detected anymore. After the
rinse, the cake was dried at 120.degree. C. for 24 hours followed
by calcining thereof in air at 350.degree. C. for 5 hours to obtain
the target methanol synthesis catalyst.
[0218] Analysis of thus obtained catalyst gave the composition as
CuO:CR.sub.2O.sub.3:ZnO:=1:2:3 (by weight).
3) Preparation of Cu--Al.sub.2O.sub.3 Catalyst
[0219] A 15.7 g of copper acetate (Cu(CH.sub.3COO).sub.2.H.sub.2O)
was dissolved into about 200 ml of ion-exchanged water. A 95 g of
.gamma.-alumina (N612, Nikki Kagaku Co.) was further added to the
mixture. The mixture was then vaporized to dry. The dried material
was further dried in air at 120.degree. C. for 24 hours, followed
by calcining in air at 450.degree. C. for 4 hours. The calcined
material was treated in hydrogen gas stream at 400.degree. C. for 3
hours to obtain a catalyst. Analysis of the catalyst gave the
composition as Cu:Al.sub.2O.sub.3=5:95 (by weight).
Examples 1, 3, and 4
[0220] An 100 g aliquot of CuO--ZnO--Al.sub.2O.sub.3 catalyst
prepared in the above treatment, 50 g of commercially available
alumina (N612, Nikki Kagaku Co.), and a 50 g aliquot of
CuO--Cr.sub.2O.sub.3--ZnO catalyst prepared in the above treatment
were pulverized together in a ball mill for about 3 hours to a fine
powder having about 20 .mu.m or less of particle size. A 50 g of
alumina sol (Alumina sol-520, Nissan Chemical Industries, Ltd.) was
added to the catalyst powder to uniformly mix them together. The
mixture was dried in air at 120.degree. C. for 24 hours followed by
calcining in air at 450.degree. C. for 3 hours to unify these
ingredients. The calcined material was pulverized to 120 .mu.m or
smaller particle size to obtain a catalyst.
Example 2
[0221] A 200 g aliquot of CuO--ZnO--Al.sub.2O.sub.3 catalyst
prepared in the above treatment, 50 g of commercially available
alumina (N612, Nikki Kagaku Co.), and a 50 g aliquot of
CuO--Cr.sub.2O.sub.3--ZnO catalyst prepared in the above treatment
were pulverized together in a ball mill for about 3 hours to a fine
powder having about 20 .mu.m or less of particle size. A 50 g of
alumina sol. (Alumina sol-520, Nissan Chemical Industries, Ltd.)
was added to the catalyst powder to uniformly mix them together.
The mixture was dried in air at 120.degree. C. for 24.hours
followed by calcining in air at 450.degree. C. for 3 hours to unify
these ingredients. The calcined material was pulverized to 120
.mu.m or smaller particle size to obtain a catalyst
Examples 5, 7, 8, 9, and 10
[0222] An 100 g aliquot of CuO--ZnO--Al.sub.2O.sub.3 catalyst
prepared in the above treatment and a 50 g aliquot of
Cu--Al.sub.2O.sub.3 catalyst prepared in the above treatment were
pulverized together in a ball mill for about 3 hours to a fine
powder having about 20 .mu.m or less of particle size. A 50 g of
alumina sol (Alumina sol-520, Nissan Chemical Industries, Ltd.) was
added to the catalyst powder to uniformly mix them together. The
mixture was dried in air at 120.degree. C. for 24 hours followed by
calcining in air at 450.degree. C. For 3 hours to unify these
ingredients. The calcined material was pulverized to 120 .mu.m or
smaller particle size to obtain an integrated catalyst.
Example 6
[0223] A 200 g aliquot of CuO--ZnO--Al.sub.2O.sub.3 catalyst
prepared in the above treatment and a 50 g aliquot of
Cu--Al.sub.2O.sub.3 catalyst prepared in the above treatment were
pulverized together in a ball mill for about 3 hours to a fine
powder having about 20 .mu.m or less of particle size. A 50 g of
alumina sol (Alumina sol-520, Nissan Chemical Industries, Ltd.) was
added to the catalyst power to uniformly mix them together. The
mixture was dried in air at 120.degree. C. for 24 hours, followed
by calcining in air at 450.degree. C. for 3 hours to unify these
ingredients. The calcined material was pulverized to 120 .mu.m or
smaller particle size to obtain an integrated catalyst.
Example 11
[0224] An 100 g aliquot of CuO--ZnO--Al.sub.2O.sub.3 catalyst
prepared in the above treatment, 50 g of commercially available
alumina (N612, Nikki Kagaku Co.), and a 50 g aliquot of
CuO--Cr.sub.2O.sub.3--ZnO catalyst prepared in the above treatment
were pulverized together in a ball mill for about 3 hours to a fine
powder having about 20 .mu.m or less of particle size. A 50 g of
clay. (Kunipia, Kunimine Kogyo Co.) was added to the catalyst
powder to uniformly mix them together. The mixture was dried in air
at 120.degree. C. for 24 hours followed by calcining in air at
450.degree. C. for 3 hours to unify these ingredients. The calcined
material was pulverized to 120 .mu.m or smaller particle size to
obtain a catalyst.
Comparative Example
[0225] An 100 g aliquot of CuO--ZnO--Al.sub.2O.sub.3 catalyst
prepared in the above treatment, 50 g of commercially available
alumina (N612, Nikki Kagaku Co.), and a 50 g aliquot of
CuO--Cr.sub.2O.sub.3--ZnO catalyst prepared in the above treatment
were pulverized together in a ball mill for about 3 hours to a fine
powder having about 20 .mu.m or less of particle size. The mixture
was calcined in air at 450.degree. C. for 3 hours. The calcined
material was pulverized to 120 .mu.m or smaller particle size to
obtain a catalyst.
II. Method for Activating Catalyst and Reaction Method
[0226] A 24 g of n-hexadecane (31.1 ml) was charged to a
bubble-tower reactor having 2 cm of inside diameter and 2 m of
height, and 3.6 g of each of the above-described catalyst powders
was added to make the contents of the reactor in a suspended state.
A mixed gas of hydrogen, carbon monoxide, and nitrogen (at a molar
ratio H.sub.2:CO:N.sub.2 of 1:1:9) was introduced to pass through
the bubble-tower at a flow rate of about 300 ml/min. While flowing
the mixed gas through the bubble-tower, the temperature in the
bubble-tower was gradually raised from room temperature to
220.degree. C. within a period of several hours. At the same time,
the concentration of nitrogen in the mixed gas was gradually
reduced to a final level of zero. Then, the reaction system was
held at 220.degree. C. for about 3 hours to activate the
catalyst.
[0227] The reaction was conducted at a specified temperature and
pressure while introducing the mixed gas of hydrogen, carbon
monoxide, and carbon dioxide at a molar ratio of
H.sub.2/CO/CO.sub.2=47.5/47.5/5.0 and at a flow rate of 336 ml/min
(converted at a condition of normal temperature and pressure).
[0228] The obtained reaction products and non-reacted substances
were analyzed by gas chromatography.
III. Reaction Conditions and Experimental Results
[0229] The reaction conditions and experimental results are shown
in Tables 9 and 10. TABLE-US-00009 TABLE 9 Example 1 Example 2
Example 3 Example 4 Example 5 Example 6 Condition Temperature
(.degree. C.) 280 280 250 300 280 280 Pressure (kg/cm.sup.2-G) 30
30 30 30 30 30 Reaction CO conversion (%) 51.7 48.3 45.4 47.1 52.9
51.3 Result Yield Dimethyl 35.2 31.4 27.7 29.6 35.8 33.9 (C-mol %)
ether Methanol 2.1 5.3 6.9 1.8 2.4 2.6 Hydrocarbons 0.5 0.6 0.4 3.0
0.8 1.3 CO.sub.2 14.0 11.1 10.4 12.7 13.9 13.5 Dimethyl ether space
time 963 859 758 809 979 927 yield (-g/kg-cat h)
[0230] TABLE-US-00010 TABLE 10 Example Example Comparative Example
7 Example 8 Example 9 10 11 Example Condition Temperature(.degree.
C.) 260 300 280 280 280 280 Pressure (kg/cm.sup.2-G) 30 30 20 50 30
30 Reaction CO conversion (%) 46.5 50.4 38.8 57.1 44.8 32.4 Result
Yield Dimethyl 25.1 33.9 27.2 37.1 29.5 22.9 (C-mol %) ether
Methanol 5.9 2.2 3.1 2.9 3.1 1.1 Hydrocarbons 0.3 3.3 0.5 1.7 0.6
0.2 CO.sub.2 15.2 11.0 8.0 15.4 11.6 8.2 Dimethyl ether space time
686 927 744 1015 807 626 yield (g/kg-cat h)
[0231] The catalyst for manufacturing dimethyl ether according to
the present invention provides effects of preventing separation of
individual catalyst ingredients from each other during reaction, of
assuring smooth progress of reaction cycle, and of achieving high
dimethyl ether yield owing to the configuration thereof comprising
a methanol synthesis catalyst, a methanol-dehydration catalyst, and
a water gas shift catalyst being integrated together using a
binder.
[0232] The method for manufacturing dimethyl ether according to the
present invention uses a slurry of solvent with a catalyst
comprising a methanol synthesis catalyst, a methanol-dehydration
catalyst, and a water gas shift catalyst being integrated together
using a binder, so the method provides effects of achieving high
space time yield of dimethyl ether, of being free from problems of
plugging of cyst and of mechanical strength of catalyst, of
easiness for removing reaction he and for controlling reaction
heat, of assuring wide application range of the ratio of carbon
monoxide to hydrogen, of progress of reaction under the presence of
high concentration of carbon dioxide, and of less influence of
impurities and catalyst poisons.
Embodiment 4
[0233] The inventors developed a method for manufacturing a
catalyst to produce dimethyl ether, which method comprises:
suspending a methanol synthesis catalyst, a methanol-dehydration
catalyst, and a water gas shift catalyst in a solvent while
maintaining the difference in an A value within
.+-.1.times.10.sup.-6 g/cm among the methanol synthesis catalyst,
the methanol-dehydration catalyst, and the water gas shift
catalyst, wherein the A is defined by an equation of
A=D.sup.2(P-S), where D denotes average particle size of catalyst
concerned, (cm), P denotes particle density of catalyst concerned,
(g/cm.sup.3), and S denotes solvent density, (g/cm.sup.3). The
inventors found that the use of thus prepared catalyst in a slurry
state achieved the production of dimethyl ether at a high yield and
a high space time yield from a mixed gas of carbon monoxide and
hydrogen, or further containing carbon dioxide and/or water vapor.
Thus the inventors completed the present invention.
[0234] According to the present invention, each of the methanol
synthesis catalyst, the methanol-dehydration catalyst, and the
water gas shift catalyst is prepared under a control of the
particle density and the particle size, then they are mixed
together by a physical means. As a result, the method according to
the present invention ensures prompt progress of the reaction
described below to improve the yield of dimethyl ether by making
the distance among these catalysts close to each other while
preventing separation thereof during the reaction period. That is,
the reaction proceeds in sequent order of: yielding methanol on the
methanol synthesis catalyst from carbon monoxide and hydrogen;
moving the methanol onto the methanol-dehydration catalyst to yield
dimethyl ether and water by dehydration-condensation; moving the
water onto the water gas shift catalyst and/or the methanol
synthesis catalyst to yield hydrogen by the reaction of the water
with carbon monoxide. The reaction is expressed by the formulae
given below. CO+2H.sub.2.fwdarw.C.sub.3OH
2CH.sub.3OH.fwdarw.CH.sub.3OCH.sub.3+H.sub.2O
CO+H.sub.2O.fwdarw.CO.sub.3+H.sub.2
[0235] The catalyst according to the present invention basically
comprises a methanol synthesis catalyst, a methanol-dehydration
catalyst, and a water gas shift catalyst. Since, however, the
methanol synthesis catalyst is inherently an excellent water gas
shift catalyst, the methanol synthesis catalyst may function also
the water gas shift catalyst.
[0236] Methanol synthesis catalyst may be copper oxide--zinc
oxide--alumina system and zinc oxide--chromium oxide--alumina
system. A preferable mixing ratio of individual ingredients of
copper oxide, zinc oxide, and alumina is: in an approximate range
of from 0.05 to 20 wt. parts of zinc oxide to 1 wt. parts of copper
oxide, more preferably in an approximate range of from 0.1 to 5 wt.
parts; in an approximate range of from 0 to 2 wt. parts of alumina,
more preferably in an approximate range of from 0 to 1 wt. parts. A
preferable mixing ratio of individual ingredients of zinc oxide,
chromium oxide, and alumina is: in an approximate range of from 0.1
to 10 of chromium oxide to 1 wt. parts of zinc oxide, more
preferably in an approximate range of from 0.5 to 5; and in an
approximate range of from 0 to 2 wt. parts of alumina, more
preferably in an approximate range of from 0 to 1 wt. parts.
Applicable methanol-dehydration catalysts includes .gamma.-alumina,
silica-alumina, and zeolite. Examples of metallic oxide ingredient
in zeolite are oxide of alkali metal such as sodium and potassium,
and oxide of alkali earth metal such as calcium and magnesium
Examples of water gas shift catalyst are a copper oxide-zinc oxide
system and an iron oxide-chromium oxide system. A preferable ratio
of copper oxide to zinc oxide is in an approximate range of from
0.1 to 20 wt. parts of copper oxide to 1 wt. parts of iron oxide,
more preferably in an approximate range of from 0.5 to 10. A
preferable ratio of iron oxide to chromium oxide is in an
approximate range of from 0.1 to 20 wt. parts of chromium oxide to
1 wt. parts of iron oxide, more preferably in an approximate range
of from 0.5 to 10. A copper (including copper oxide)--alumina
system is a catalyst which functions both as a methanol-dehydration
catalyst and as a water gas shift catalyst.
[0237] Each of these methanol synthesis catalyst,
methanol-dehydration catalyst, and water gas shift catalyst may be
manufactured by known methods. For example, a water soluble salt of
each metallic ingredient is used to prepare an aqueous solution
containing these salts. The kind of salt is either an inorganic
salt or an organic salt. Nevertheless, a salt that likely generates
hydroxide in water is not suitable. Nitrate, carbonate, organic
acid salt, and halide are applicable as the salt. A preferable
concentration of each ingredient is in an approximate range of from
0.1 to 3 mole/l. A base is added to the aqueous solution to
neutralize thereof and to precipitate hydroxide. Then the solid is
separated from liquid, which is then rinsed and dried, followed by
calcining to obtain the target catalyst. Alternatively, a
commercial catalyst may be used.
[0238] The mixing ratio of the above-described methanol synthesis
catalyst, methanol-dehydration catalyst, and water gas shift
catalyst is not specifically limited, and is selected at an
adequate ratio corresponding to the kind of each ingredient and the
reaction condition. A preferable mixing ratio is often in an
approximate range of from 0.5 to 10 wt. parts of
methanol-dehydration catalyst per 1 wt. parts of methanol synthesis
catalyst, and in an approximate range of from 0 to 5 wt. parts of
water gas shift catalyst per 1 wt. parts of methanol synthesis
catalyst.
[0239] A preferable difference in value of A that is derived from
the above-described equation among individual catalyst types is
within .+-.1.times.10.sup.-6 g/cm which was given before, and more
preferably within .+-.5.times.10.sup.-7 g/cm. If the difference in
A value exceeds .+-.1.times.10.sup.-6, then the conversion of
carbon monoxide decreases. The method for controlling the value A
is not specifically limited. Generally, however, the control is
carried out based mainly on the average particle size and the
particle density of catalyst concerned because the density of
solvent shows no significant change. If only the average particle
size is kept constant, the particle density does not show
significant change. Accordingly, the control of average particle
size is a simple control method. Pulverization by ball mill is a
method for controlling the average particle size. The determination
of average particle sue is done by sieve method (JIS Z8801-1982),
sedimentation method, or other methods. The determination of
particle density is carried out by picnometer method (JIS R-5201)
and buoyancy method (JIS R6125).
[0240] The catalyst is used as a slurry with a solvent. The amount
of catalyst in the solvent depends on the kind of the solvent, the
reaction conditions, and other variables. Normally, the amount of
catalyst is in a range of from 1 to 50 wt. % to the amount of the
solvent.
[0241] The kind of solvent used for synthesizing dimethyl ether
according to the present invention is arbitrarily selected if only
the solvent is in a liquid phase under the reaction condition.
Examples of the solvent are hydrocarbons of aliphatic, aromatic,
and alicyclic groups, alcohol, ether, ester, ketone, halide, or
their mixture.
[0242] Alternatively, gas oil after removing sulfur ingredients,
vacuum gas oil, high boiling point distillates of coal tar after
treated by hydrogenation are also applicable as the solvent.
[0243] By passing a mixed gas of carbon monoxide and hydrogen
through thus prepared slurry of catalyst with solvent, dimethyl
ether is obtained at a high yield. Applicable range of molar mixing
ratio of hydrogen to carbon monoxide (H.sub.2/CO) is wide, for
instance, in a range of from 20 to 0.1 as (H.sub.2/CO), and more
preferably from 10 to 0.2.
[0244] According to the reaction system, the mixed gas does not
directly contact with the catalyst, which direct contact occurs in
a gas-solid catalytic reaction system, but the carbon monoxide and
hydrogen contact with catalyst only after dissolved into a solvent.
Consequently, selection of an adequate kind of solvent taking into
account of the solubility of carbon monoxide and hydrogen to the
solvent establishes a constant composition of carbon monoxide and
hydrogen in the solvent independent of the gas composition, and
sustains the supply of the mixed gas at an established composition
to the catalyst surface.
[0245] In the case of a mixed gas with a significantly low ratio of
(H.sub.2/CO), for example, 0.1 or less, or in the case of solely
carbon monoxide without containing hydrogen, it is necessary to
separately supply steam to convert a part of the carbon monoxide
into hydrogen and carbon dioxide within the reactor.
[0246] Since solvent exists between the raw material gases and the
catalyst, the gas composition does not necessarily agree with the
composition on the catalyst surface. Therefore, it is acceptable
that the mixed gas of carbon monoxide and hydrogen, or solely
carbon monoxide gas includes a relatively high concentration of
carbon dioxide (in a range of from 20 to 50%).
[0247] The manufacturing method according to the present invention
significantly reduces the effect of ingredients that may act as a
catalyst-poison on the catalyst compared with the gas-solid contact
catalyst system. Examples of the catalyst-poisoning ingredients
which may exist in the raw material gas are sulfur compounds such
as hydrogen sulfide, cyan compounds such as hydrogen cyanide, and
chlorine compounds such as hydrogen chloride. Even when the
catalyst activity is decreased as a result of poisoning, the
productivity of the total reactor system is maintained at a
constant level by withdrawing the slurry from the reactor and by
charging fresh slurry containing catalyst of high activity to the
reactor.
[0248] The reaction heat is recovered in a form of medium pressure
steam using a cooling coil installed inside of the reactor while
passing hot water through the cooling coil. The cooling system
controls the reaction temperature at an arbitrary level.
[0249] A preferable reaction temperature is in a range of from 150
to 400.degree. C., and particularly preferable in a range of from
200 to 350.degree. C. The reaction temperature below 150.degree. C.
and above 400.degree. C. degrades the conversion of carbon
monoxide.
[0250] A preferable reaction pressure is in a range of from 10 to
300 kg/cm.sup.2, and particularly preferable in a range of from 15
to 150 kg/cm.sup.2. The reaction pressure below 10 kg/cm.sup.2
results in a low conversion of carbon monoxide, and that above 300
kg/cm.sup.2 requires special design of reactor and is uneconomical
because of the need of a large amount of energy for pressurizing
the system.
[0251] A preferable space velocity (charge rate of mixed gas per 1
g of catalyst under standard condition) is in a range of from 100
to 50000 ml/gh, and particularly preferable from 500 to
30000.ml/gh. The space velocity above 50000 ml/gh degrades the
conversion of carbon monoxide, and that below 100 ml/gh is
uneconomical because of the need of an excessively large
reactor.
EXAMPLE
I. Preparation of Catalyst
1) Preparation of Catalyst [1]
[0252] Each of 185 g of copper nitrate
(Cu(NO.sub.3).sub.23H.sub.2O), 117 g of zinc nitrate
(Zn(NO.sub.3).sub.26H.sub.2O), and 52 g of aluminum nitrate
(Al(NO.sub.3).sub.39H.sub.2O) were dissolved into about 1 liter of
ion-exchanged water. Separately, about 200 g of sodium carbonate
(Na.sub.2CO.sub.3) was dissolved into about 1 liter of
ion-exchanged water. Both of the solutions were added dropwise to
about 3 liters of ion-exchanged water in a stainless steel vessel
which was controlled at about 60.degree. C. within about 2 hours
while maintaining the contents to pH 7.0.+-.0.5. Then, the contents
were allowed to stand for about 1 hour for aging. When, during the
treatment, the pH value went out from a range of pH 7.0.+-.0.5,
either of an aqueous solution of about 1 mole/liter nitric acid or
an aqueous solution of about 1 mole/liter sodium carbonate was
added dropwise to keep the range of pH 7.0.+-.0.5. The resulted
precipitate was filtered, and the cake was rinsed by ion-exchanged
water until nitric acid ion was not detected anymore. After the
rinse, the cake was dried at 120.degree. C. for 24 hours, followed
by calcining thereof in air at 350.degree. C. for 3 hours to obtain
the catalyst [1].
[0253] Analysis of thus obtained catalyst [1] gave the composition
as CuO:ZnO:Al.sub.2O.sub.3=61:37:7 (by weight).
2) Preparation of Catalyst [2]
[0254] Each of 91 g of copper nitrate (Cu(NO.sub.3).sub.23H.sub.2O)
and 256 g of zinc nitrate (Zn(NO.sub.3).sub.26H.sub.2O), were
dissolved into about 1 liter of ion-exchanged water. Separately,
about 130 g of sodium carbonate (Na.sub.2CO.sub.3) was dissolved
into about 1 liter of ion-exchanged water. Both of the solutions
were added dropwise to about 3 liters of ion-exchanged water in a
stainless steel vessel which was controlled at about 60.degree. C.
within about 2 hours, while maintaining the contents to pH
8.5.+-.0.5. Then, the contents were allowed to stand for about 1 hr
for aging. When, during the treatment, the pH value went out from a
range of pH 8.5.+-.0.5, either of an aqueous solution of about 1
mole/i nitric acid or an aqueous solution of about 1 mole/liter
sodium carbonate was added dropwise to keep the range of pH
8.5.+-.0.5. The resultant precipitate was filtered, and the cake
was rinsed by ion-exchanged water until nitric acid ion was not
detected anymore. After the rinse, the cake was dried at
120.degree. C. for 24 hours, followed by calcining thereof in air
at 350.degree. C. for 3 hours to obtain the catalyst [2].
[0255] Analysis of thus obtained catalyst [2] gave the composition
as CuO:ZnO=3:7 (by weight).
3) Preparation of Catalyst [3]
[0256] An 100 g of alumina (N612, Nikki Kagaku Co.) was dried in
air at 120.degree. C. for 24 hours, followed by calcining in air at
450.degree. C. for 3 hours to obtain the target alumina catalyst
[3].
4) Preparation of Catalyst [4]
[0257] A 15.7 g of copper acetate (Cu(CH.sub.3COO).sub.2H.sub.2O)
was dissolved into about 200 ml of ion-exchanged water. A 95 g
aliquot of alumina catalyst prepared in the step 3) was further
added to the mixture. The mixture was then vaporized to dry. The
dried material was further dried in air at 120.degree. C. for 24
hours, followed by calcining in air at 450.degree. C. for 3 hours.
The calcined material was treated in hydrogen gas stream at
400.degree. C. for 3 hours to obtain the catalyst [4]. Analysis of
the catalyst gave the composition as Cu:Al.sub.2O.sub.3=5:95 by
weight).
5) Preparation of Catalyst [5]
[0258] A 736 g of aluminum nitrate ((Al(NO.sub.3).sub.39H.sub.2O)
was dissolved into about 2 liters of ion-exchanged water.
Separately, about 350 g of sodium carbonate (Na.sub.2CO.sub.3) was
dissolved into about 2 liters of ion-exchanged water. Both of the
solutions were added dropwise to about 3 liters of ion-exchanged
water in a stainless steel vessel at room temperature within about
2 hours while maintaining the contents to pH 7.5.+-.0.5. Then, the
contents were allowed to stand for about 1 hour for aging. When,
during the treatment, the pH value went out from a range of pH
7.5.+-.0.5, either of an aqueous solution of about 1 mole/liter
nitric acid or an aqueous solution of about 1 mole/liter sodium
carbonate was added dropwise to keep the range of pH 7.5.+-.0.5.
The resulted precipitate was filtered, and the cake was rinsed by
ion-exchanged water until nitric acid ion was not detected anymore.
After the rinse, the cake was dried at 120.degree. C. for 24 hours,
followed by calcining thereof in air at 350.degree. C. for 3 hours
to obtain alumina.
[0259] Then, 15.7 g of copper acetate
(Cu(CH.sub.3COO).sub.2H.sub.2O) was dissolved into about 200 ml of
ion-exchanged water. A 95 g aliquot of the prepared alumina was
added to the mixture, which mixture was then evaporated to dry. The
dried material was further dried in air at 120.degree. C. for 24
hours followed by calcining in air at 450.degree. C. for 4 hours.
The calcined material was treated in hydrogen gas stream at
400.degree. C. for 3 hours to obtain the catalyst [5]. Analysis of
thus obtained catalyst [5] gave the composition as
CuO:ZnO:Al.sub.2O.sub.3=5:95 (by weight).
Example 1
[0260] The catalyst [1] was pulverized in a ball mill to fine
powder having an average particle size of 16.9 .mu.m. The catalyst
[2] was pulverized in a ball mill to fine powder having an average
particle size of 15.6 .mu.m. The catalyst [3] was pulverized in a
ball mill to fine powder having an average particle size of 15.5
.mu.m. A 2.4 g aliquot of the fine powder of catalyst [1], an 1.2 g
aliquot of the fine powder of catalyst [2], and an 1.2 g aliquot of
the fine powder of catalyst [3] were physically mixed together.
Example 2
[0261] The catalyst [1] was pulverized in a ball mill to fine
powder having an average particle size of 16.9 .mu.m. The catalyst
[4] was pulverized in a ball mill to fine powder having an average
particle size of 15.2 .mu.m. A 2.4 g aliquot of the fine powder of
catalyst [1] and an 1.2 g aliquot of the fine powder of catalyst
[4] were physically mixed together.
Example 3
[0262] A 2.4 g aliquot of the fine powder of catalyst [1] having an
average particle size of 14.4 .mu.m and an 1.2 g aliquot of the
fine powder of catalyst [4] having an average particle size of 12.9
.mu.m were physically mixed together.
Example 4
[0263] A 2.4 g aliquot of the fine powder of catalyst [1] having an
average particle size of 16.9 .mu.m and an 1.2 g aliquot of the
fine powder of catalyst [5] having an average particle size of 18.4
.mu.m were physically mixed together.
Comparative Example 1
[0264] Catalysts were mixed conforming to the procedure of Example
1 except that the average particle size of the catalyst [2] was
20.1 .mu.m and that the average particle size of the catalyst [3]
was 18.5 .mu.m.
Comparative Example 2
[0265] Catalysts were mixed conforming to the procedure of Example
2 except that the average particle size of the catalyst [4] was
12.9 .mu.m.
II. Method for Activating Catalyst and Reaction Method
[0266] A 24 g of n-hexadecane (31.1 ml) was charged to a
bubble-tower reactor having 2 cm of inside diameter and 2 m of
height, and 3.6 g of each of the above-described catalyst powders
was added to make the contents of the reactor in a suspended state.
A mixed gas of hydrogen, carbon monoxide, and nitrogen (at a molar
ratio H.sub.2:CO:N.sub.2 of 1:1:9) was introduced to pass through
the bubble-tower at a flow rate of about 300 ml/min. While flowing
the mixed gas through the bubble-tower, the temperature in the
bubble-tower was gradually raised from room temperature to
220.degree. C. within a period of several hours. At the same time,
the concentration of nitrogen in the mixed gas was gradually
reduced to a final level of zero. Then, the reaction system was
held at 220.degree. C. for about 3 hours to activate the
catalyst.
[0267] The reaction was conducted at a specified temperature and
pressure while introducing the mixed gas of hydrogen, carbon
monoxide, and carbon dioxide at a molar ratio of
H.sub.2/CO/CO.sub.2=475/475/5.0 and at a flow rate of 336 ml/min
(converted at a condition of normal temperature and pressure).
[0268] The obtained reaction products and non-reacted substances
were analyzed by gas chromatography.
III. Reaction Conditions and Experimental Results
[0269] The reaction conditions and experimental results are shown
in Tables 11 and 12. Conversion .times. .times. of .times. .times.
dimethylether .times. .times. ( % ) = Charge .times. .times. rate
.times. .times. of .times. .times. dimethylether - Discharge
.times. .times. rate .times. .times. of .times. .times. non .times.
- .times. reacted .times. .times. dimethyleter Charge .times.
.times. rate .times. .times. of .times. .times. dimethylether
.times. 100 ##EQU1## Yield .times. .times. of .times. .times.
methanol .times. .times. ( % ) = 1 2 .times. Yielding .times.
.times. rate .times. .times. methanol Charge .times. .times. rate
.times. .times. of .times. .times. dimethyether .times. 100
##EQU1.2## Yield .times. .times. of .times. .times. hydrocarbons
.times. .times. ( % ) = [ n / 2 .times. yielding .times. .times.
rate .times. .times. of .times. .times. hydrocarbons ( number
.times. .times. of .times. .times. carbons .times. : .times.
.times. n ) Charge .times. .times. rate .times. .times. of .times.
.times. dimethylether .times. 100 ##EQU1.3## Yield .times. .times.
of .times. .times. CO 2 .times. .times. ( % ) = 1 4 .times.
Yielding .times. .times. rate .times. .times. of .times. .times. CO
2 Charge .times. .times. rate .times. .times. of .times. .times.
dimethylether .times. 100 ##EQU1.4## TABLE-US-00011 TABLE 11
Example 1 Example 2 Example 3 Catalyst Catalyst No. {circle around
(1)} {circle around (2)} {circle around (3)} {circle around (1)}
{circle around (4)} {circle around (1)} {circle around (4)}
Particle Density(g/cm.sup.2) 28.2 3.17 3.20 2.82 3.31 2.82 3.31
Particle size(cm) .times. 10.sup.4 16.9 15.6 15.5 16.9 15.2 14.4
12.9 Weight (g) 2.4 1.2 1.2 2.4 1.2 2.4 1.2 Value of A (g/cm)
.times. 10.sup.5 5.85 5.83 5.83 5.85 5.86 4.25 4.22 Condition
Temperature (.degree. C.) 280 280 280 Pressure (kg/cm.sup.2-G) 30
30 30 Reaction CO conversion (%) 40.1 53.9 52.1 Result Yield
Dimethyl ether 31.2 36.2 34.0 (C-mol %) Methanol 2.5 2.5 2.6
Hydrocarbons 1.2 0.8 0.5 CO.sub.2 5.5 14.4 15.0 Dimethyl ether
space time 853 990 930 yield (g/kg-cat h)
[0270] TABLE-US-00012 TABLE 12 Comparative Comparative Example 1
example 1 example 2 Catalyst Catalyst No. {circle around (1)}
{circle around (5)} {circle around (1)} {circle around (2)} {circle
around (3)} {circle around (1)} {circle around (4)} Particle
Density(g/cm.sup.2) 2.82 2.50 2.82 3.17 3.20 2.82 3.31 Particle
size(cm) .times. 10.sup.4 16.9 18.4 16.9 20.1 18.5 16.9 12.9 Weight
(g) 2.4 1.2 2.4 2.4 1.2 2.4 1.2 Value of A (g/cm) .times. 10.sup.5
5.85 5.85 5.85 9.68 8.31 5.85 4.22 Condition Temperature (.degree.
C.) 280 280 280 Pressure (kg/cm.sup.2-G) 30 30 30 Reaction CO
conversion (%) 52.7 33.4 41.6 Result Yield Dimethyl ether 35.1 23.3
26.9 (C-mol %) Methanol 2.1 1.2 2.0 Hydrocarbons 0.9 0.8 0.5
CO.sub.2 14.6 8.1 12.2 Dimethyl ether space time 960 637 736 yield
(g/kg-cat h)
[0271] The catalyst for manufacturing dimethyl ether according to
the present invention provides effects of preventing separation of
individual catalyst ingredients from each other during reaction, of
assuring smooth progress of reaction cycle, and of achieving high
dimethyl ether yield owing to the controlled particle density and
particle size for each of the methanol synthesis catalyst, the
methanol-dehydration catalyst, and the water gas shift catalyst
conforming to a derived equation.
[0272] The method for manufacturing dimethyl ether according to the
present invention uses a slurry of solvent with a catalyst
comprising a methanol synthesis catalyst, a methanol-dehydration
catalyst, and a water gas shift catalyst being integrated together,
so the method provides effects of achieving high space time yield
of dimethyl ether, of being free from problems of plugging of
catalyst and of mechanical strength of catalyst, of easiness for
removing reaction heat and for controlling reaction heat, of
assuring wide application range of the ratio of carbon monoxide to
hydrogen, of progress of reaction under the presence of high
concentration of carbon dioxide, and of less influence of
impurities and catalyst poisons.
Embodiment 5
[0273] Synthesis of dimethyl ether proceeds following the three
equilibrium reactions shown below.
CO+2H.sub.2.revreaction.CH.sub.3OH (1) (Methanol synthesis
reaction) 2CH.sub.3OH.revreaction.CH.sub.3OCH.sub.3+H.sub.2O (2)
(Dehydration reaction) H.sub.2O+CO.revreaction.H.sub.2+CO.sub.2 (3)
(Shift reaction)
[0274] In the case that the reaction (1) is solely carried out, the
reaction is what is called the methanol synthesis reaction. The
methanol synthesis reaction has a limitation of equilibrium, and a
high pressure (80 to 120 kg/cm.sup.2) is necessary to obtain a
target conversion. In the single stage process, however, the
reaction (2) which is significantly superior in terms of
equilibrium successively proceeds within the same reactor to
consume the methanol as the reaction product, so the inferior
reaction equilibrium of reaction (1) is compensated. As a result,
the dimethyl ether synthesis becomes very easy compared with
conventional methanol synthesis process. That is, the single stage
process increases the conversion of CO/H.sub.2.
[0275] The reaction mixture comprises non-reacted CO and H.sub.2,
reaction products methanol, dimethyl ether, and CO.sub.2, and
slight amount of byproducts such as alkane. Since the composition
depends on the reaction rate and equilibrium of each of the
reactions (1) through (3), the single stage process cannot increase
the amount of solely a target product. In particular, methanol as
an intermediate is unavoidably left in the reaction products.
[0276] Reaction rate in each reaction is controlled by changing the
ratio of methanol synthesis catalyst, dehydration catalyst, and
shift catalyst Thus the composition of the reaction products is
controlled. Since, however, these three types of reactions proceed
simultaneously and since all of these three reactions are
equilibrium reactions, the control has a limitation owing to the
limit of equilibrium. With that type of reaction system and under a
normal reaction condition, it is very difficult to attain the
selectivity of dimethyl ether over 95% (in the products excluding
CO.sub.2).
[0277] The difficulty is described below referring to a
thermodynamic calculation.
[0278] FIG. 2 shows reaction equilibria of H.sub.2, CO, methanol,
CO.sub.2, and water, on the basis of reactions (1), (2), and(3).
For instance, under a condition of 300.degree. C. of reaction
temperature, 50 atm of reaction pressure, and 1 of initial
CO/H.sub.2 ratio, the selectivity of dimethyl ether (starting
material of CO, carbon molar basis, excluding CO.sub.2) at the
reaction equilibrium is 98%. Establishing a reaction equilibrium
is, however, impossible in actual process, and the selectivity of
dimethyl ether becomes significantly lower level than the
calculated value owing to the presence of methanol as an
intermediate. In a state of lower temperature than the above
example, for instance at 240.degree. C. of reaction temperature, 50
atm of reaction pressure, and 1 of initial CO/H.sub.2 ratio, the
selectivity of dimethyl ether at a reaction equilibrium becomes 99%
which is somewhat higher than that in the above example. Under the
condition, however, the rate of methanol-synthesis reaction (1) is
low and actually the reaction equilibrium is never established.
[0279] The method according to the present invention uses a mixture
of methanol synthesis catalyst, dehydration catalyst or dehydration
and shift catalyst in the first stage reaction to yield crude
dimethyl ether, and uses dehydration and/or shift catalyst in the
second stage reaction to convert most of the remained methanol into
dimethyl ether, thus attains a high selectivity of dimethyl
ether.
[0280] That is, the first stage reaction increases the conversion
of CO/H.sub.2 raw material mixed gas by using a combined methanol
synthesis catalyst+dehydration catalyst+shift catalyst. The second
stage reaction uses dehydration catalyst and/or shift catalyst, and
adopts a reaction condition particularly suitable for the
above-described reactions, thus achieving the conversion of most
part of the remaining methanol into dimethyl ether to increase the
selectivity of dimethyl ether.
[0281] The second stage reaction uses only dehydration and/or shift
catalyst without applying methanol synthesis catalyst. When the
second stage reaction adopts a reaction condition particularly
suitable for the dehydration and/or shift reaction, solely the
dehydration and/or shift reaction proceeds and only these reactions
approach the equilibrium state. In a reaction system where no
methanol synthesis catalyst exists, no additional methanol yields,
and the remained methanol is converted into dimethyl ether, so the
selectivity of dimethyl ether increases.
[0282] Accordingly, the present invention provides a method for
manufacturing dimethyl ether comprising the steps of: using a mixed
gas as a raw material gas containing carbon monoxide and either or
both of hydrogen and water vapor, or further containing carbon
dioxide; conducting a first stage reaction by contacting the raw
material gas with a catalyst containing a synthesis catalyst, a
methanol-dehydration catalyst, and a shift catalyst; and conducting
a second stage reaction by contacting the first stage product gas
with a catalyst containing at least one of the dehydration catalyst
and the shift catalyst.
[0283] The catalyst used in the first stage according to the
present invention is a combination of known methanol synthesis
catalyst, known dehydration catalyst, and known water gas shift
catalyst. Applicable methanol synthesis catalyst includes common
industrial catalysts for methanol synthesis, such as those of
copper oxide--zinc oxide system, zinc oxide--chromium oxide system,
copper oxide--zinc oxide/chromium oxide system, copper oxide--zinc
oxide/alumina system. Examples of dehydration catalyst are
acid-base catalyst such as .gamma.-alumina, silica, silica-alumina,
and zeolite. Examples of the metallic oxide ingredient in zeolite
are oxide of alkali metal such as sodium and potassium, and oxide
of alkali earth metal such as calcium and magnesium. Examples of
water gas shift catalyst are copper oxide--zinc oxide system,
copper oxide--chromium oxide--zinc oxide system, and iron
oxide--chromium oxide system. Since methanol synthesis catalyst has
a strong activity as a shift catalyst, it can substitute for the
water gas shift catalyst. A copper oxide supported by alumina is
applicable as a dehydration catalyst and also as a water gas shift
catalyst.
[0284] The mixing ratio of the above-described methanol synthesis
catalyst, dehydration catalyst, and water gas shift catalyst is not
specifically limited, and it depends on the kind of each ingredient
and reaction condition. Normally the ratio is often in an
approximate range of from 0.1 to 5 wt. parts of dehydration
catalyst to 1 wt. parts of methanol synthesis catalyst, more
preferably in an approximate range of from 0.2 to 2; in an
approximate range of from 0.2 to 5 wt. parts of water gas shift
catalyst, more preferably in an approximate range of from 0.5 to 3.
When the methanol synthesis catalyst substitutes for the water gas
shift catalyst, the above-described amount of the water gas shift
catalyst is added to the amount of the methanol synthesis
catalyst.
[0285] The catalyst used in the second stage reaction is a
combination of dehydration catalyst, dehydration-shift catalyst,
and a combination of dehydration catalyst+shift catalyst. The
dehydration-shift catalyst may use a catalyst of copper oxide
supported by .gamma.-alumina as the catalyst having activity of
both dehydration and shifting.
[0286] Preferable catalysts used in the second stage reaction
include those listed as examples of dehydration catalyst, shift
catalyst, and dehydration-shift catalyst in the first stage
reaction.
[0287] Above-described catalysts in both of first and second stage
reactions are used in a powder state. A preferable average particle
size is 300 .mu.m or less, more preferably in an approximate range
of from 1 to 200 .mu.m, and most preferably in an approximate range
of from 10 to 150 .mu.m. To prepare powder of that range of
particle size, the catalysts may further be pulverized.
[0288] The type of the catalyst reactor for the first stage and the
second stage may be either a fixed bed type or a slurry bed type.
When the fixed bed type reactor is applied, the catalysts are
granulated to a suitable size by a known method. When the slurry
bed type reactor is applied, the applicable solvent is an arbitrary
kind if only the solvent maintains liquid state under the reaction
condition. Examples of the solvent are hydrocarbons of aliphatic,
aromatic, and alicyclic groups, alcohol, ether, ester, ketone,
halide, or their mixture. Alternatively, gas oil after removing
sulfur ingredients, vacuum gas oil, high boiling point distillates
of coal tar after treated by hydrogenation are also applicable as
the solvent. The amount of catalyst in solvent depends on the kind
of solvent and the reaction condition. Normally, a preferable range
of the catalyst is from 1 to 50 wt. % to the amount of solvent,
more preferably in a range of from 2 to 30 wt. %.
[0289] The mixing ratio of hydrogen and carbon monoxide may be in a
range of from 20 to 0.1 as H.sub.2/CO molar ratio, more preferably
in a range of from 10 to 0.2. In the case of a mixed gas with
significantly low ratio of (H.sub.2/CO), for example, 0.1 or less,
or in the case of sole carbon monoxide without containing hydrogen,
it is necessary to separately supply steam to conduct the shift
reaction (3) in the reactor to convert a part of the carbon
monoxide into hydrogen and carbon dioxide. A preferable charge rate
of steam is 1 or less to the charge rate of CO. A preferable amount
of carbon dioxide yielded from the reaction is 50% or less.
[0290] A preferable condition of the first stage reaction is the
reaction temperature in a range of from 150 to 400.degree. C.,
particularly in a range of from 200 to 350.degree. C. The reaction
temperature below 150.degree. C. and above 400.degree. C. results
in a reduction of carbon monoxide conversion. A preferable reaction
pressure is in a range of from 10 to 300 kg/cm.sup.2, particularly
in a range of from 15 to 150 kg/cm.sup.2. The reaction pressure
below 10 kg/cm.sup.2 results in a low conversion of carbon
monoxide, and that above 300 kg/cm.sup.2 requires special design of
reactor and is uneconomical because of the need of a large amount
of energy for pressurizing the system. A preferable space velocity
(charge rate of mixed gas per 1 g of catalyst under standard
condition) is in a range of from 100 to 50000 l/kgh, and
particularly preferable from 500 to 30000 l/kgh. The space velocity
above 50000 l/kgh degrades the conversion of carbon monoxide, and
that below 100 l/kgh is uneconomical because of the need of an
excessively large reactor.
[0291] The condition of the second stage reaction may be the same
with that of the first stage reaction. A major characteristic of
the method according to the present invention is to conduct the
second stage reaction separately from the first one, which allows
selecting an optimum condition particularly for the dehydration
reaction (2) and for the shift reaction (3). That is, according to
an analysis of reaction equilibrium, the reactions of (2) and (3)
become advantageous at a low temperature level, and these reactions
attain sufficient levels of reaction rate at a low temperature
compared with the reaction of (1). Therefore, the second stage
reaction favorably adopts lower temperature than the first stage
reaction. Since the reaction pressure does not affect the reaction
equilibrium, low pressure level is applicable.
[0292] A practical reaction condition is in a temperature range of
from room temperature to 300.degree. C., more preferably in a range
of from 100 to 300.degree. C., and preferably in a pressure range
of from atmospheric pressure to the pressure of first stage
reaction. Higher pressure is preferable because the reactor volume
decreases. Nevertheless, it is not preferable to apply higher
pressure than that of the first stage reaction because of the
necessity of additional energy for pressurizing the system. Space
velocity depends on the intensity of catalyst activity. A
preferable space velocity is normally in a range of from 100 to
50000 l/kgh, and particularly preferable from 500 to 30000 l/kgh.
The space velocity above 50000 l/kgh results in failing to fully
approach to the equilibrium and failing to increase the selectivity
of dimethyl ether.
[0293] The ratio of the amount of catalyst in the first and second
stages depends on the activity of individual catalysts. A
preferable ratio of them (first stage/second stage) is normally in
a range of from 1:10 to 10:1, more preferably in a range of from
1:5 to 5:1.
[0294] The CO conversion, the selectivity of dimethyl ether, and
the selectivity of methanol referred to herein are defined as
follows. [0295] Amount of CO gas charged to reactor
(Nl/min.):Fin(CO) [0296] Amount of CO gas discharged from
reactor:Fout(CO) [0297] Amount of DME gas discharged from
reactor:Fout(DME) [0298] Amount of MeOH gas discharged from
reactor:Fout(MeOH) [0299] Amount of methane gas discharged from
reactor:Fout(CH.sub.4) ( CO .times. .times. conversion ) = Fin
.times. .times. ( CO ) - Fout .times. .times. ( CO ) Fin .times.
.times. ( CO ) .times. 100 .times. ( % ) ##EQU2## ( Selectivity
.times. .times. of .times. .times. dimethylether ) = 2 .times. Fout
.times. .times. ( DME ) 2 .times. Fout .function. ( DME ) + Fout
.function. ( MeOH ) + Fout .function. ( CH 4 ) ##EQU2.2## (
Selectivity .times. .times. of .times. .times. methanol ) = Fout
.times. .times. ( MeOH ) 2 .times. Fout .function. ( DME ) + Fout
.function. ( MeOH ) + Fout .function. ( CH 4 ) .times.
##EQU2.3##
EXAMPLE
Example 1
[0300] Applied apparatus is shown in FIG. 1. The apparatus
comprises a series of a first stage reactor 1 which is a slurry bed
type and a second stage reactor 2 which is a fixed bed type. To the
bottom of the first stage reactor 1, a q gas piping and a CO gas
piping are connected, each of which is equipped with an automatic
pressure control valve and with a mass flow rate controller (FRCA).
The top of the first stage reactor 1 is connected to the bottom of
the second stage reactor 2. The top of the second stage reactor 2
is connected to a gas-liquid separator 4 via a cooler 3. The gas
exit of the gas-liquid separator 4 is connected to an exhaust line
via a gas meter 5. The liquid exit of the gas-liquid separator 4 is
connected to a product storage tank 6. A branch is located on the
line between the exit of the reactor 2 and the cooler 3, through
which the composition of exit gas is analyzed.
Catalyst A: CuO--ZnO--Al.sub.2O.sub.3 catalyst
[0301] Each of 185 g of copper nitrate
(Cu(NO.sub.3).sub.23H.sub.2O), 117 g of zinc nitrate
(Zn(NO.sub.3).sub.26H.sub.2O), and 52 g of aluminum nitrate
((Al(NO.sub.3).sub.39H.sub.2O) were dissolved into about 1 liter of
ion-exchanged water. Separately, about 1.4 kg of sodium carbonate
(Na.sub.2CO.sub.3) was dissolved into about 1 liter of
ion-exchanged water. Both of the solutions were added dropwise to
about 3 liters of ion-exchanged water in a stainless steel vessel
which was controlled at about 60.degree. C. within about 2 hours
while maintaining the contents to pH 7.0.+-.0.5. Then, the contents
were allowed to stand for about 1 hour for aging. When, during the
treatment, the pH value went out from a range of pH 7.0.+-.0.5, an
aqueous solution of about 1 mole/liter sodium carbonate was added
dropwise to keep the range of pH 7.0.+-.0.5. The resulted
precipitate was filtered, and the cake was rinsed by ion-exchanged
water until nitric acid ion was not detected anymore. After the
rinse, the cake was dried at 120.degree. C. for 24 hours followed
by calcining thereof in air at 350.degree. C. for 5 hours to obtain
the target catalyst. Analysis of thus obtained catalyst gave the
composition as CuO:ZnO:Al.sub.2O.sub.3=61:32:7 (by weight).
Catalyst B: CuO--Al.sub.2O.sub.3 catalyst
[0302] A 15.7 g of copper acetate (Cu(CH.sub.3COO).sub.2H.sub.2O)
was dissolved into about 200 ml of ion-exchanged water. A 95 g of
.gamma.-alumina (N612, Nikki Kagaku Co.) was further added to the
mixture. The mixture was then vaporized to dry. The dried material
was calcined in air at 450.degree. C. for 4 hours. The calcined
material was treated in hydrogen gas stream at 400.degree. C. for 3
hours to obtain a catalyst. Analysis of the catalyst gave the
composition as Cu:Al.sub.2O.sub.3=5:95 (by weight).
[0303] Each of the catalyst thus prepared was pulverized in a ball
mill to a particle size of 120 .mu.m or less.
[0304] The reactor (1) was filled with 5584 ml of n-hexadecane as
the heating medium oil, 430 g of the catalyst A, and 215 g of
catalyst B: that is, (catalyst A/catalyst B)=2/1, and
(catalyst/heating medium oil)=15/100. The reactor B was filled
solely with 645 g of catalyst B.
Preliminary Reduction
[0305] Under a condition of 10 kg/cm.sup.2 of reactor pressure,
220.degree. C. of reactor temperature, a mixed gas
(H.sub.2/N.sub.2=1/4) was introduced to the reactor at a flow rate
of 10 l/min. for 12 hours to conduct preliminary reduction.
Examples 1 Through 4
[0306] A mixed gas (H.sub.2/CO=1/1) was introduced to the reaction
system at a flow rate of 80 l/min. The condition of the reactor 1
was kept unchanged at 50 kg/cm.sup.2 of reaction pressure and
260.degree. C. of reaction temperature, while the condition of the
reactor 2 was changed for conducting the dimethyl ether synthesis.
A gas chromatograph was used for analyzing the gas composition, and
a gas meter was used to determine the gas flow rate at exit of the
reaction system. Thus, the CO conversion and the selectivity of
each reaction product (carbon molar basis, in the products
excluding CO.sub.2) were computed. The result is shown in table 13.
TABLE-US-00013 TABLE 13 Example 1 (Comparative Example) Example 2
Example 3 Example 4 Pressure in the Reactor (2) 30 10 30 reactor
(2) (kg/cm.sup.2) was by-passed Temperature in the 240 240 260
reactor (2) (.degree. C.) CO conversion(%) 34.0 42.4 42.2 41.4 DME
selectivity(%) 67.1 96.1 94.4 93.6 Methanol 32.8 3.8 5.5 6.3
selectivity(%) Methane 0.1 0.1 0.1 0.1 selectivity(%)
Examples 5 Through 8
[0307] A mixed gas (H.sub.2/CO=1.511) was introduced to the
reaction system at a flow rate of 66.7 l/min. The condition of the
reactor (1) was kept unchanged at 50 kg/cm.sup.2 of reaction
pressure and 280.degree. C. of reaction temperature, while the
condition of the reactor (2) was changed for conducting the
dimethyl ether synthesis. With the same analytical method as in
Examples 1 through 4, the CO conversion and the selectivity of each
reaction product were determined. The result is shown in Table 14.
TABLE-US-00014 TABLE 14 Example 5 (Comparative Example) Example 6
Example 7 Example 8 Pressure in the Reactor (2) 30 10 30 reactor
(2) (kg/cm.sup.2) was by-passed Temperature in the 240 240 260
reactor (2) (.degree. C.) CO conversion(%) 51.5 66.4 64.4 64.9 DME
selectivity(%) 84.4 94.9 93.8 93.2 Methanol 15.3 4.8 5.9 6.5
selectivity(%) Methane 0.3 0.3 0.3 0.3 selectivity(%)
[0308] The method according to the present invention yields
dimethyl ether from carbon monoxide and hydrogen (or water vapor)
at a high conversion and a high selectivity. As a result, dimethyl
ether is obtained from the reaction products readily at a high
purity, thus manufactures dimethyl ether at a large volume at a low
cost
Embodiment 6
[0309] The inventors studied a means to maintain a high CO
conversion level while decreasing the concentration of CO.sub.2 in
the recycle gas to increase the use efficiency of raw material gas,
or a means to fully remove CO.sub.2 from the non-reacted gas. A
method for removing CO.sub.2 may be the one to pass the non-reacted
gas containing high concentration level of CO.sub.2 through an
alkali solution such as aqueous caustic soda to remove thereof
through reaction-absorption operation. The method is, however, not
a favorable one because it needs a complex process, high investment
cost, and high operation cost to recover and reuse alkali. The
inventors focused on the solubility and absorbability of CO2 in DUE
( dimethyl ether), and found that CO.sub.2 is efficiently removed
from the reacted gas by recycling a part of DME which was separated
from CO.sub.2 to the non-reacted gas separation step (S2) and by
using CO.sub.2 as a material being absorbed.
[0310] In concrete terms, the present invention relates to a method
for manufacturing dimethyl ether which comprises: letting a raw
material gas containing at least carbon monoxide and hydrogen
catalytically react to yield dimethyl ether; and letting carbon
monoxide and hydrogen left in reaction products recycle for reuse
thereof wherein carbon dioxide accompanied by the recycling carbon
monoxide and hydrogen is removed therefrom by making the recycling
gas mixture contact with a liquid dimethyl ether which was
separated from the reaction products to absorb and remove the
carbon dioxide from the recycling gas mixture.
[0311] An applicable mixing ratio of hydrogen to carbon monoxide in
the raw material gas is in a molar ratio (H.sub.2CO) ranging from
0.1 to 20, more preferably from 0.2 to 5. Examples of the raw
material gas are coal gasified gas and synthesis gas produced from
natural gas.
[0312] A mixed catalyst of a methanol synthesis catalyst and a
methanol-dehydration catalyst is used as the dimethyl
ether-synthesis catalyst, and, at need, further a water gas shift
catalyst is added to the mixed catalyst system. Alternatively, the
water gas shift catalyst may be separately used to configure a
two-stage reaction system. The present invention is applicable to
any of these catalysts.
[0313] An applicable methanol synthesis catalyst includes common
industrial catalysts for methanol synthesis, such as those of
copper oxide--zinc oxide system, zinc oxide--chromium oxide system,
copper oxide--zinc oxide/chromium oxide system, copper oxide--zinc,
oxide/alumina system. Examples of methanol-dehydration catalyst are
acid-base catalyst such as .gamma.-alumina, silica, silica-alumina,
and zeolite. Examples of the metallic oxide ingredient in zeolite
are oxide of alkali metal such as sodium and potassium, and oxide
of alkali earth metal such as calcium and magnesium. Examples of
water gas shift catalyst are copper oxide zinc oxide system, copper
oxide--chromium oxide--zinc oxide system, and iron oxide--chromium
oxide system. Since a methanol synthesis catalyst has a strong
activity as a shift catalyst, it can substitute for the water gas
shift catalyst. A copper oxide supported by alumina is applicable
as a methanol-dehydration catalyst and also as a water gas shift
catalyst.
[0314] The mixing ratio of the above-described methanol synthesis
catalyst, methanol-dehydration catalyst, and water gas shift
catalyst is not specifically limited, and it depends on the kind of
each ingredient and reaction condition. Normally the ratio is often
in an approximate range of from 0.1 to 5 wt. parts of methanol
dehydration catalyst to 1 wt. parts of methanol synthesis catalyst,
more preferably in an approximate range of from 0.2 to 2; in an
approximate range of from 0.2 to 5 wt. parts of water gas shift
catalyst, more preferably in an approximate range of from 0.5 to 3.
When the methanol synthesis catalyst substitutes for the water gas
shift catalyst, the above-described amount of the water gas shift
catalyst is added to the amount of the methanol synthesis
catalyst.
[0315] The above-described catalysts are applicable to any type of
reaction in fixed bed, fluidized bed, and slurry-bed type reactors.
In particular, the slurry-bed reaction provides uniform temperature
within the reactor and yields less by-products. The following
description deals with the slurry-bed reaction as a typical
mode.
[0316] For the case of a slurry-bed reaction, the catalyst is used
in a fine powder shape. A preferable average particle size is 300
.mu.m or less, more preferably in an approximate range of from 1 to
200 .mu.m, and most preferably in an approximate range of from 10
to 150 .mu.m. To prepare powder of that range of particle size, the
catalysts may further be pulverized.
[0317] An applicable kind of medium oil is an arbitrary one if only
the medium oil maintains liquid state under the reaction condition.
For example, the medium oil may be hydrocarbons of aliphatic,
aromatic, and alicyclic groups, alcohol, ether, ester, ketone,
halide, or their mixture. Alternatively, gas oil after removing
sulfur ingredients, vacuum gas oil, high boiling point distillates
of coal tar after treated by hydrogenation, Fischer-Tropsch
synthesis oil, and high boiling point food oil are also applicable
as the medium oil. The amount of catalyst in solvent depends on the
kind of solvent and the reaction condition. Normally, a preferable
range of the catalyst is from 1 to 50 wt. % to the amount of
solvent, more preferably in a range of from 2 to 30 wt. %.
[0318] For the reaction condition in a slurry-bed reactor, a
preferable reaction temperature in the reactor is m a range of from
150 to 400.degree. C., and particularly preferable in a range of
from 250 to 350.degree. C. The reaction temperature below
150.degree. C. and above 400.degree. C. degrades the conversion of
carbon monoxide. A preferable reaction pressure is in a range of
from 10 to 300 kg/cm.sup.2, more preferably in a range of from 15
to 150 kg/cm.sup.2, and most preferably in a range of from 20 to 70
kg/cm.sup.2. The reaction pressure below 10 kg/cm.sup.2 results in
a low conversion of carbon monoxide, and that above 300 kg/cm.sup.2
requires a special design of reactor and is uneconomical because of
the need of a large amount of energy for pressurizing the system. A
preferable space velocity (charge rate of mixed gas per 1 kg of
catalyst under standard condition) is in a range of from 100 to
50000 l/kgh, and particularly preferable from 500 to 30000 l/kgh.
The space velocity above 50000 l/kgh degrades the conversion of
carbon monoxide, and that below 100 l/kgh is uneconomical because
of the need of an excessively large reactor.
[0319] Thus obtained reacted gas contains carbon dioxide, carbon
monoxide, hydrogen water, and methanol, adding to dimethyl ether,
and further contains by-products such as methane, and impurities
carried-in by the raw material gas. An approximate composition of
the reacted gas is: 1 to 40% of dimethyl ether, normally 3 to 25%;
1 to 40% of carbon dioxide, normally 3 to 25%; 10 to 70% of carbon
monoxide, normally 20 to 50%; 10 to 70% of hydrogen, normally 20 to
50%; 0.2 to 5% of methanol, normally 0.5 to 3%; 0.05 to 0.8% of
water, normally 0.1 to 0.5%; and 0 to 5% of other ingredients.
[0320] Arbitrary means is applicable to separate dimethyl ether
from the reacted gas, and a method to use difference in
condensation temperature or to use difference in boiling point is a
preferable one. For the case that the difference in condensation
temperature is used, firstly methanol and water condense during the
passage of cooling of reacted gas. The condensate may be utilized
for other uses or may be further separated into water and methanol,
and the methanol may be recycled to the reactor. Further cooling of
the reacted gas induces the condensation of dimethyl ether to which
carbon dioxide dissolves thereinto, while leaving carbon monoxide
and hydrogen, which are the non-reacted gas ingredients, in the gas
phase. Separation of carbon dioxide from dimethyl ether may be
conducted by distillation.
[0321] According to the method of the present invention, the
above-described carbon monoxide and hydrogen as the non-reacted gas
are brought into contact with the liquid dimethyl ether which was
treated in the CO.sub.2 separator to remove the dissolved carbon
dioxide. Thus the carbon dioxide existing in the non-reacted gas is
removed by dissolving into the dimethyl ether. Any type of the
non-reacted gas separator may be used if only the separator cools
the reacted gas and dimethyl ether and maintains the contact
thereof by each other in a satisfactory degree. Examples of the
separator are a shell-tube heat exchanger with a liquid holder, and
a tank holding liquefied dimethyl ether with an injector of reacted
gas thereinto. By the contact of reacted gas with dimethyl ether,
CO.sub.2 is dissolved into and absorbed by the liquefied dimethyl
ether. The liquefaction of dimethyl ether occurs at -25.degree. C.
under atmospheric pressure. The liquefaction becomes easy and the
CO.sub.2 solubility increases with increased pressure (partial
pressure of dimethyl ether) and decreased temperature. When the
separation temperature is low, the CO.sub.2 separation efficiency
increases, but the necessary scale of refrigerator also increases
to increase the investment cost. Accordingly, a preferable
temperature of the non-reacted gas separator is in a range of from
0 to -70.degree. C., more preferably from -20 to -50.degree. C. The
pressure in separation stage may normally be the same with that of
the reaction process.
[0322] The amount of recycling dimethyl ether is in a range of from
1 to 10 fold of the amount of CO.sub.2 in the reacted gas which is
brought to contact with the liquid dimethyl ether, and more
preferably in a range of from 2 to 5 fold.
[0323] Based on the following definitions, the formulae 1 through 3
are derived. [0324] Flow rate of CO gas fed to reactor
(Nl/min.):Fin(CO) [0325] Flow rate of CO gas discharged from
reactor:Fout(CO) [0326] Flow rate of DME gas discharged from
reactor:Fout(DME) [0327] Flow rate of MeOH gas discharged from
reactor:Fout(MeOH) [0328] Flow rate of methane gas discharged from
reactor:Fout(CH.sub.4) ( CO .times. .times. conversion ) = Fin
.times. .times. ( CO ) - Fout .times. .times. ( CO ) Fin .times.
.times. ( CO ) .times. 100 .times. ( % ) ##EQU3## ( Selectivity
.times. .times. of .times. .times. dimethylether ) = 2 .times. Fout
.times. .times. ( DME ) 2 .times. Fout .function. ( DME ) + Fout
.function. ( MeOH ) + Fout .function. ( CH 4 ) ##EQU3.2## (
Selectivity .times. .times. of .times. .times. methanol ) = Fout
.times. .times. ( MeOH ) 2 .times. Fout .function. ( DME ) + Fout
.function. ( MeOH ) + Fout .function. ( CH 4 ) .times.
##EQU3.3##
[0329] FIG. 3 shows an example of apparatus applied to the method
according to the present invention. The apparatus is structured
while adding a DME recycle line 111 which branches from the DME
line 109 coming from the CO.sub.2 separator S3 and which returns to
the non-reacted gas separator S2.
[0330] FIG. 4 shows an enlarged view of the non-reacted gas
separator S2 used in the apparatus of FIG. 3. The non-reacted gas
separator S2 comprises a vessel with a cooling jacket, and a set of
pipelines, namely, a reacted gas line 105 at lower portion thereof,
a DME, CO.sub.2 line 106 at bottom thereof, a DME recycle line 111
at upper portion thereof, and a recycle gas line 107 at top
thereof.
EXAMPLE
Example 1
[0331] A reaction experiment was conducted using an apparatus shown
in FIG. 3 adopting a bubble-tower reactor R (90 mm of inner
diameter, 2000 mm of height) under a reaction condition of
280.degree. C. and 30 kg/cm.sup.2. The content of the reactor was a
slurry of 860 g of catalyst powder with 5730 g of n-hexadecane. The
unit S1 separated methanol and water from the reactor exit gas, and
discharge the separated methanol and water and discharged thereof
through a methanol-water line 104. The unit S2 separated a part of
the DME and CO.sub.2 gas and discharge thereof through a DME,
CO.sub.2 line. Thus the non-reacted gas was refined. The refined
non-reacted gas was recycled to the inlet of reactor via a recycle
gas line 107. The consumed CO gas and hydrogen gas were supplied,
and the flow rate through a CO gas and hydrogen gas make up gas
line 101 was adjusted to maintain the flow rate of CO gas and
hydrogen gas at the inlet of reactor to 30 Nl/min. The recycle gas
contains CO.sub.2 gas left un-separated in the S2 unit, and the
purge rate of the recycle gas was adjusted to maintain the CO.sub.2
gas flow rate at inlet of the reactor to 9 Nl/min. By assuring the
gas composition at the inlet of reactor to the above-described
level, the CO conversion was kept to 42%. The S2 unit was
controlled to a state of -30.degree. C. and 30 kg/cm.sup.2; and the
DME from which CO.sub.2 was removed in the S3 unit was recycled at
a flow rate of 0.5 mole/min. through a line 111. The purge rate of
the recycle gas in the above case was 3.8%, and the loss of CO gas
and hydrogen gas relative to the make up rate was 5.0% and 3.4%,
respectively.
Comparative Example 1
[0332] An experiment was conducted under the same condition with
Example 1 except that the DME from which CO.sub.2 was removed in
the S3 unit was not recycled. The purge rate of the recycle gas in
that case was 29.7%, and the loss of CO gas and hydrogen gas
relative to the make up rate was 29.1% and 21.5%, respectively.
Example 2
[0333] Using a vessel with a cooling jacket, which is shown in FIG.
4, a test gas (CO.sub.2:DME:CO:H.sub.2=10:10:40:40) was introduced
to the reactor at a flow rate of 50 mmole/min. through a line 103,
and DME was introduced to the reactor at a flow rate of 5
mmole/min. through a line 111. At the same time, a discharged gas
was collected through a line 107, and DME was withdrawn from the
reactor through a line 106 to maintain the amount of liquefied DME
in the vessel at a fixed level. The internal pressure of the vessel
was 50 kg/cm.sup.2G, and the internal temperature of the vessel was
-30.degree. C. The collected gas flow rate was determined by a gas
meter, and the composition thereof was analyzed by a
gas-chromatograph (detector:TCD). The CO.sub.2 in the discharged
gas was 1.9 mmole/min. and the CO.sub.2 separation efficiency was
38%.
Example 3
[0334] An experiment was conducted under the same condition with
Example 2 except that the DME introduction flow rate through the
line 111 was set to 10 mmole/min, The CO.sub.2 in the discharged
gas was 2.6 mmole/min and the CO.sub.2 separation efficiency was
52%.
Example 4
[0335] An experiment was conducted under the same condition with
Example 2 except that the DME introduction flow rate: through the
line 111 was set to 20 mmole/min. The CO.sub.2 in the discharged
gas was 4.1 mmole/min. and the CO.sub.2 separation efficiency was
82%.
Comparative Example 2
[0336] An experiment was conducted under the same condition with
Example 2 except that the DME introduction through the line 111 was
not applied. The CO.sub.2 in the discharged gas was 1.0 mmole/min.
and the CO.sub.2 separation efficiency was 20%.
Example 5
[0337] An experiment was conducted under the same condition with
Example 3 except that the internal temperature of the vessel was
set to -40.degree. C. The CO.sub.2 in the discharged gas was 3.1
mmole/min. and the CO.sub.2 separation efficiency was 62%.
Example 6
[0338] An experiment was conducted under the same condition with
Example 3 except that the internal temperature of the vessel was
set to -25.degree. C. The CO.sub.2 in the discharged gas was 2.4
mmole/min. and the CO.sub.2 separation efficiency was 48%.
[0339] The method according to:the present invention suppresses the
CO.sub.2 concentration in the recycle gas to a low level and
maintains the CO conversion in DME synthesis reaction to a high
level. Since the method allows to minimize the purge of the recycle
gas or does not need to purge thereof, both CO and H are
effectively utilized. In addition, the method allows to use the
product DME as a CO.sub.2 absorbent which is readily separated from
the reacted products, and the process becomes a simple one.
Embodiment 7
[0340] The present invention relates to an apparatus for
manufacturing dimethyl ether comprising: a slurry-bed reactor
filled with a dimethyl ether-synthesis catalyst and a medium oil
therefor; a condenser for condensing a gasified medium oil
discharged from the reactor; a desulfurization tank for adsorbing
to remove a catalyst-deactivation ingredient from the medium oil
condensed in the condenser; and a recycle line for recycling the
medium oil by connecting the reactor, the condenser, and the
desulfurization tank. And relates to a method for manufacturing
dimethyl ether comprising the steps of: letting a raw material gas
containing at least carbon monoxide and hydrogen contact a slurry
of a suspended dimethyl ether-synthesis catalyst in a medium oil;
cooling a reaction product gas generated from a catalytic reaction
to condense to separate a gasified medium oil carried along with
the reaction product gas; obtaining dimethyl ether from the
reaction product gas; removing a catalyst-deactivation ingredient
from a condensed medium oil to recycle the medium oil free of
catalyst-deactivation ingredient to the slurry.
[0341] The reactor according to the present invention may be an
arbitrary type if only it is a slurry-bed type.
[0342] A dimethyl ether-synthesis catalyst according to the present
invention is a mixture of a methanol synthesis catalyst and a
methanol-dehydration catalyst, and, if needed, a water gas shift
catalyst is further added to the catalyst system. These catalyst
ingredients may be used in a mixed state, or the water gas shift
catalyst may be separated from other two catalyst ingredients to
configure a two stage reaction system. The present invention is
applicable for any types of the above-described catalyst
systems.
[0343] Examples of a methanol synthesis catalyst are copper
oxide--zinc oxide system, zinc oxide--chromium oxide system, copper
oxide--zinc oxide/chromium oxide system, copper oxide--zinc
oxide/alumina system which catalyst systems are commonly used in
industrial methanol synthesis. Examples of a methanol-dehydration
catalyst are acid-base catalyst such as .gamma.-alumina, silica,
silica-alumina and zeolite. Examples of the metallic oxide
ingredient in zeolite are oxide of alkali metal such as sodium and
potassium, and oxide of alkali earth metal such as calcium and
magnesium. Examples of a water gas shift catalyst are copper
oxide--zinc oxide system, copper oxide--chromium oxide--zinc oxide
system, and iron oxide--chromium oxide system. Since a methanol
synthesis catalyst has a strong activity as a shift catalyst, it
can substitute for the water gas shift catalyst. A copper oxide
supported by alumina is applicable as dehydration catalyst and also
as water gas shift catalyst.
[0344] The mixing ratio of above-described methanol synthesis
catalyst, methanol-dehydration catalyst, and water gas shift
catalyst is not specifically limited, and it depends on the kind of
each ingredient and reaction condition. Normally the ratio is often
in an approximate range of from 0.1 to 5 wt. parts of
methanol-dehydration catalyst to 1 wt. parts of methanol synthesis
catalyst, more preferably in an approximate range of from 0.2 to 2;
in an approximate range of from 0.2 to 5 wt. parts of water gas
shift catalyst, more preferably in an approximate range of from 0.5
to 3. When the methanol synthesis catalyst substitutes for the
water gas shift catalyst, the above-described amount of the water
gas shift catalyst is added to the amount of the methanol synthesis
catalyst.
[0345] The above-described catalysts are used in a powder state. A
preferable average particle size is 300 .mu.m or less, more
preferably in an approximate range of from 1 to 200 .mu.m, and most
preferably in an approximate range of from 10 to 150 .mu.m. To
prepare powder of that range of particle size, the catalysts may
further be pulverized.
[0346] An applicable kind of medium oil is arbitrary if only the
medium oil maintains liquid state under the reaction condition.
Examples of the medium oil are hydrocarbons of aliphatic, aromatic,
and alicyclic groups, alcohol, ether, ester, ketone, halide, or
their mixture. Alternatively, gas oil after removing sulfur
ingredients, vacuum gas oil, high boiling point distillates of coal
tar after treated by hydrogenation, Fischer-Tropsch synthesis oil,
and high boiling point food oil are also applicable as the medium
oil. The amount of catalyst in the solvent depends on the kind of
solvent and the reaction conditions. Normally, a preferable range
of the catalyst is from 1 to 50 wt. % to the amount of solvent,
more preferably in a range of from 2 to 30 wt. %.
[0347] The condenser according to the present invention is
arbitrary if only it condenses vaporized medium oil. A heat
exchanger or other types may be applied.
[0348] Removal of catalyst deactivation ingredients is preferably
carried out using an adsorbent. An applicable type of the adsorbent
may be the commonly used one such as .gamma.-alumina, activated
carbon, and zeolite absorber. A necessary amount of the adsorbent
depends on the adsorption capacity of the applied adsorbent. The
number of absorbers is preferably more than one to ensure
continuous adsorption operation during regeneration cycle of an
absorber.
[0349] The recycle line establishes a recycle passage through the
slurry-bed reactor, the condenser, and the absorber. A means to
prevent backflow is located in the line. The backflow-preventive
means may be a simple check valve or may be a forced circulation
system using a pump.
[0350] The apparatus according to the present invention is further
provided with a storage tank, an intermediate tank, valves, and
instruments, as needed.
[0351] The molar mixing ratio of hydrogen and carbon monoxide,
(H.sub.2/CO), may be in a range of from 0.5 to 3.0, more preferably
from 0.8 to 2.0. In the case of a mixed gas with significantly low
ratio of (H.sub.2/CO), for example, 0.5 or less, or in the case of
sole carbon monoxide without containing hydrogen, it is necessary
to separately supply steam to convert a part of the carbon monoxide
into hydrogen and carbon dioxide within the reactor. The amount of
steam supply is equal to the amount of carbon monoxide to be
converted (equal to the insufficient amount of hydrogen). The
amount of carbon dioxide becomes the same molar amount of the
converted carbon monoxide. Examples of that type of raw material
gas are coal gasified gas, synthesis gas derived from natural gas,
and methane in coal stratum. When sulfur compounds exist in the raw
material gas, a preliminary desulfurization is needed to prevent
catalyst deactivation. The desulfurization treatment reduces the
concentration of sulfur compounds to several hundreds of ppm or
less, normally in an approximate range of from 50 to 200 ppm.
Sulfur compounds include SOx, H.sub.2S, and COS.
[0352] A preferable reaction temperature in the slurry-bed reactor
is in a range of from 150 to 400.degree. C., and particularly
preferable in a range of from 250 to 350.degree. C. The reaction
temperature below 150.degree. C. and above 400.degree. C. degrades
the conversion of carbon monoxide. A preferable reaction pressure
is in a range of from 10 to 300 kg/cm.sup.2, more preferably in a
range of from 15 to 150 kg/cm.sup.2, and most preferably in a range
of from 20 to 70 kg/cm.sup.2. The reaction pressure below 10
kg/cm.sup.2 results in a low conversion of carbon monoxide, and
that above 300 kg/cm.sup.2 requires a special design of reactor and
is uneconomical because of the need of a large amount of energy for
pressurizing the system. A preferable space velocity (charge rate
of mixed gas per 1 kg of catalyst under standard condition) is in a
range of from 100 to 50000 l/kgh, and particularly preferable from
500 to 30000 l/kgh. The space velocity above 50000 l/kgh degrades
the conversion of carbon monoxide, and that below 10.0 l/kgh is
uneconomical because of the need of an excessively large
reactor.
[0353] A condition for eliminating the catalyst deactivation
ingredients is to reduce the concentration of catalyst deactivation
ingredients remaining in a medium oil after removal thereof by
adsorption to 100 ppm or less, and more preferably to 50 ppm or
less.
EXAMPLE
Example 1
[0354] FIG. 5 shows an apparatus for manufacturing dimethyl ether
as an example according to the present invention. The apparatus
comprises a slurry reactor 201, a condenser 202, a gas-liquid
separator 203, an absorber 204, and a pump 205. These units are
connected each other by pipes to form a recirculation line 206. A
raw material gas is charged to the bottom of the slurry reactor 201
via a raw material gas feed pipe 207. A medium oil which is
vaporized from the slurry reactor 201 or which is discharged from
the slurry reactor 201 along with a high temperature reacted gas is
cooled to a temperature of condensing point or below by exchanging
heat thereof in the condenser 202. The cooled and partially
condensed medium oil enters the gas-liquid separator 203 to
separate thereof to reacted products and non-reacted gas. Thus
separated and collected medium oil is sent to the absorber 204,
where the catalyst deactivation ingredients are adsorbed to remove
thereof from the medium oil. The clean medium oil is then recycled
to the reactor 201 by the pump 205 to maintain the concentration of
catalyst deactivation ingredients in the medium oil at a low level.
The desulfurization in the adsorption-desulfurization tank 204 may
be carried out under the same high pressure condition with that in
the reactor or may be conducted at atmospheric pressure after
depressurizing. The number of absorbers 204 may be two or more for
alternative use.
[0355] An gas-flow type autoclave was used as the slurry-bed
reactor. The reaction experiment was carried out under the
conditions of 30 kg/cm.sup.2G of pressure, 280.degree. C. of
temperature. The charged raw material gas contained carbon monoxide
and hydrogen at a ratio of 1:1. The ratio of the weight of catalyst
to the molar flow rate of carbon monoxide was W/F=4.0
g-cat.h/CO-mole. The used medium oil contained different levels of
dissolved sulfur ingredient concentration for each run. The applied
catalyst was a mixture of methanol synthesis catalyst of
copper-zinc-alumina system and methanol-dehydration catalyst of
copper-alumina system at a weight ratio of 2 to 1, both in powder
form.
[0356] A medium oil was n-cetane which contained no sulfur
ingredient. A medium oil was industrial gas oil 1 which was refined
to a level of 250 ppm of sulfur ingredients. A medium oil was
industrial gas oil 2 which was refined to a level of 100 ppm of
sulfur ingredients. A medium oil was industrial gas oil 3 which was
refined to a level of 50 ppm of sulfur ingredients.
[0357] The resulted conversion of carbon monoxide was: 50.5% in
n-cetane medium oil, 8.1% in industrial gas oil 1 containing 250
ppm of sulfur ingredients, 35.2% in industrial gas oil 2 containing
100 ppm of sulfur ingredients, and 45.6% in industrial gas oil 3
containing 50 ppm of sulfur ingredients. Therefore, according to
the present invention, the concentration of sulfur ingredients in a
medium oil after the sulfur ingredients were removed by adsorption
is necessary to 100 ppm or less, and preferably to 50 ppm or
less.
[0358] The above-described experimental result is shown in Table
15. The reaction ratio is expressed by the conversion of carbon
monoxide, a raw material, on molar basis. TABLE-US-00015 TABLE 15
Concentration of Carbon monoxide dissolved sulfur conversion Medium
oil ingredients (ppm) (C-mol %) Industrial gas oil 1 250 8.1
Industrial gas oil 2 100 35.2 Industrial gas oil 3 50 45.6
[0359] For the case that a n-cetane having 286.8.degree. C. of
boiling point and 226 of molecular weight was used as the medium
oil, and that the internal condition of the reactor was set to 30
kg/cm.sup.2G, 280.degree. C., W/F (ratio of catalyst weight to raw
material gas carbon monoxide)=6 kg-cat/CO-kgmol, and 20 wt. % of
slurry concentration, the calculated amount of medium oil
discharged from the reactor determined from a vapor-liquid
equilibrium relation under the internal condition of reactor
results in about 50%/h in terms of weight ratio to the initially
existing amount of the medium oil in the reactor.
[0360] The actual discharge amount of the medium oil is, however,
less than the calculated value owing to the temperature decrease at
upper part of the reactor and to other variables. Nevertheless,
under a normal condition, sufficient amount of medium oil for
rectifying thereof recirculates to the adsorber 204 in FIG. 5.
Example 2
[0361] Same procedure as in Example 1 was conducted using the
medium oils listed in Table 16. The result is shown in Table 16.
TABLE-US-00016 TABLE 16 Conversion of Concentration of dissolved
carbon monoxide Medium oil metallic carbonyl (ppm) (C-mol %)
Industrial gas oil 4 230 (iron carbonyl) 9.2 Industrial gas oil 5
51 (iron carbonyl) 32.7 Industrial gas oil 6 3 (iron carbonyl) 44.8
Industrial gas oil 7 190 (nickel carbonyl) 7.6 Industrial gas oil 8
45 (nickel carbonyl) 31.1 Industrial gas oil 9 2 (nickel carbonyl)
43.6
Example 3
[0362] A continuous flow high pressure reaction gas was used to
suppress continuously the concentration of sulfur ingredients in
the medium oil. The effectiveness of the apparatus and method
according to the present invention was confirmed.
[0363] The applied apparatus is shown in FIG. 6. Adding to the
configuration of the apparatus in FIG. 5, a second condenser 208
and a second gas-liquid separator 209 are located to the gas
exhaust line of the gas-liquid separator 203.
[0364] The reacted and refined gas which was separated from medium
oil in the gas-liquid separator 203 is cooled in the second
condenser 208, and is then separated into liquid phase containing
dimethyl ether, methanol, and water, and gas phase containing
non-reacted gas and carbon dioxide in the second gas-liquid
separator 209. The liquid phase is recovered through a line 210,
and the gas phase is recovered through a line 211.
[0365] The reaction condition was the same with that in Example 1.
The raw material charged to the reactor was a mixture of carbon
monoxide and hydrogen at 1:1 ratio containing 600 ppm of hydrogen
sulfide as the impurity. The applied medium oil was n-cetane
containing no sulfur ingredient. The adsorbent used was granular
.gamma.-alumina A sufficient volume of adsorbent to adsorb and
desulfurize are the hydrogen sulfide dissolved in the medium oil
was charged into the adsorber 204.
[0366] The result of the reaction is shown in FIGS. 7 and 8.
[0367] FIG. 7 shows the change in concentration of sulfur
ingredients in the medium oil for the case of empty adsorber 204
and of adsorber 204 containing adsorbent. For the case of
application of desulfurization treatment, the sulfur concentration
in the recycling medium oil is kept to near zero level. For the
case of non-application of desulfurization treatment, however, the
sulfur concentration in the medium oil increases with the operating
time.
[0368] FIG. 8 shows the change in conversion of carbon monoxide as
a raw material responding to the change in sulfur ingredients with
time shown in FIG. 7. For the case of application of
desulfurization treatment, the conversion of carbon monoxide as a
raw material keeps nearly the initial level. For the case of
non-application of desulfurization treatment, however, the
conversion of carbon monoxide as a raw material shows an abrupt
decrease with time. The phenomena prove the effectiveness of the
present invention.
[0369] According to the apparatus and method of present invention,
a raw material mixed gas consisting mainly of carbon monoxide in a
coal gasified gas, a synthesis gas produced from natural gas, or
the like, and hydrogen is charged to a slurry of reaction catalyst
with medium oil in a reactor to synthesize dimethyl ether, wherein
the slight amount of catalyst deactivation ingredients existing in
the raw material gas is continuously removed to maintain the
concentration of catalyst deactivation ingredients in the medium
oil to a low level, thus keeping a high catalyst activity for a
long period.
Embodiment 8
[0370] The present invention relates to a slurry-bed reactor which
comprises: a catalyst reaction layer in a state of slurry of a
suspending powder catalyst with a high boiling point medium oil,
charging a reaction raw material gas thereto at a bottom portion of
the reactor, a condenser to condense the medium oil vaporized from
the catalyst slurry layer inside of the reactor, wherein the
condenser and the catalyst slurry layer are separated from each
other by a separation member having a liquid seal mechanism to form
a condensation chamber.
[0371] The reactor according to the present invention is a
slurry-bed reactor, and the section for holding catalyst slurry as
the slurry-bed is equipped with a cooling mechanism for removing
reaction heat.
[0372] At an upper space of the reactor, a condenser is installed
to condense the high boiling point medium oil vaporized from the
catalyst slurry bed. The condenser may be an arbitrary type, and a
preferable one is a multi-tube type. When the upper space in the
reactor is insufficient for installing the condenser, the upper
portion of the reactor may be extended in length or extending in
diameter to secure the space for the installation area thereof.
[0373] The condenser and the catalyst slurry bed are separated from
each other by a separation member having a liquid seal mechanism to
create a condensation chamber that is separated from the catalyst
slurry bed. The liquid seal mechanism means a mechanism that allows
passing a gas freely therethrough in an empty state and that
prohibits gas passing freely therethrough when the mechanism is
filled with liquid while the gas is allowed to pass the filled
liquid by a pressure difference or by dissolving into and
vaporizing from the filled liquid. An example of a preferred liquid
seal member is a bubble-cap plate which is used in a distillation
column.
[0374] There is a need to prepare a return line for smoothly
returning the medium oil condensed in the condensation chamber to
the catalyst slurry layer. The return line is required to maintain
the independence of the condensation chamber from the catalyst
slurry layer. Accordingly, the line has a sealed structure separate
from the space between the catalyst slurry layer and the
condensation chamber. In addition, for assuring the independence of
the line exit, it is preferable to apply a liquid seal mechanism.
In that case, the discharge opening of the liquid seal mechanism is
necessary at a lower level than the liquid level in the liquid seal
mechanism of the separation member so as the condensed liquid to be
collected to the return line and to be discharged into the catalyst
slurry layer. It is also preferable that the lower end of the
return line is positioned inside of the catalyst slurry layer to
let the catalyst slurry layer function as the liquid seal
mechanism. In any way, it is preferable that the return of
condensed liquid to the catalyst slurry layer is done by a natural
flow down motion.
[0375] The sections in the reactor other than the above-described
sections may be similar with those in conventional reactors. The
raw material gas charge line is connected to the bottom or near the
bottom of the reactor. The reaction product gas discharge line is
connected to the top or near the top of the reactor. For the case
of dimethyl ether-synthesis rector, the recycle line of a mixed gas
of carbon monoxide and hydrogen separated from the reaction product
gas is connected to either the passage of the raw material gas
charge line or the reactor directly. In addition, instruments such
as a pressure gauge and a thermometer, and if necessary, an
agitator and an auxiliary raw material charge line may be mounted
to the reactor.
[0376] A dimethyl ether-synthesis apparatus that contains the
dimethyl ether-synthesis reactor using the reactor according to the
present invention may be the same configuration with conventional
apparatus except that the condenser to condense the medium oil and
the gas-liquid separator to separate the condensed medium oil are
not required. That is, at the exit of the reactor, a series of
equipment are connected in a sequent order of: a methanol-water
separator which cools the reaction product gas to condense methanol
and water to separate them from the gas phase; a non-reacted gas
separator which further cools the gas to condense dimethyl ether
and carbon dioxide, thus separating thereof from carbon monoxide
and hydrogen; and a CO.sub.2 separator which separates dimethyl
ether and carbon dioxide from the condensed mixture. Each of the
methanol-water separator and the non-reacted gas separator may
further be divided into a condenser and a gas-liquid separator.
Alternatively, methanol, water, dimethyl ether, and carbon dioxide
may be condensed or solidified together, then carbon monoxide and
hydrogen may be separated, followed by separating dimethyl ether
from the condensed solid.
[0377] FIG. 11 shows an example of the apparatus implementing the
above-described alternative method. The apparatus comprises a
reactor R, a methanol-water separator S1, a non-reacted gas
separator S2, and a CO.sub.2 separator S3. A raw material gas
charge line 302 is connected to the bottom of the reactor R. To the
raw material gas charge line 302, a make-up (fresh) gas line 301
through which the fresh raw material gas is supplied, and a recycle
gas line 307 through which the non-reacted CO and H.sub.2 gases are
supplied are connected. A reaction product gas line 303 to
discharge the reaction products connects the top of the reactor R
to the inlet of the methanol-water separator S1. A methanol-water
line 304 is connected to the exit of methanol-water separator S1. A
reaction product gas line 305 is connected to the exit of reaction
products on the methanol-water separator S1. The other end of the
reaction product gas line 305 is connected to the inlet of the
non-reacted gas separator S2. The other end of the recycle gas line
7 is connected to the exit of non-reacted gas on the non-reacted
gas separator S2. The recycle gas line 7 is provided with a
branched purge line 310 to draw out apart of the gas. A DME,
CO.sub.2 line 306 is connected to the exit of DME, CO.sub.2 on the
non-reacted gas separator S2. The other end of the DME, CO.sub.2
line 306 is connected to the CO.sub.2 separator S3. A CO.sub.2 line
308 is connected to the CO.sub.2 exit on the CO.sub.2 separator S3.
A DME line 309 is connected to the exit of DME on the CO.sub.2
separator S3.
[0378] When the reactor according to the present invention is used
as the dimethyl ether-synthesis reactor, a mixed catalyst of a
methanol synthesis catalyst and a methanol-dehydration catalyst is
used as the dimethyl ether-synthesis catalyst to fill the reactor,
and, if needed, a water gas shift catalyst is further added to the
mixed catalyst system
[0379] An applicable kind of medium oil is arbitrary if only the
medium oil maintains liquid state under the reaction condition. In
the case of dimethyl ether synthesis, for example, the medium oil
may be hydrocarbons of aliphatic, aromatic, and alicyclic groups,
alcohol, ether, ester, ketone, halide, or their mixture.
Alternatively, gas oil after removing sulfur ingredients, vacuum
gas oil, high boiling point distillates of coal tar after treated
by hydrogenation, Fischer-Tropsch synthesis oil, and high boiling
point food oil are also applicable as the medium oil. The amount of
catalyst in the solvent depends on the kind of solvent and the
reaction condition. Normally, a preferable range of the catalyst is
from 1 to 50 wt. % to the amount of solvent, more. preferably in a
range of from 2 to 30 wt. %.
[0380] For the case of a dimethyl ether synthesis reaction, a
preferable reaction temperature in the reactor is in a range of
from 150 to 400.degree. C., and particularly preferable in a range
of from 250 to 350.degree. C. The reaction temperature below
150.degree. C. and above 400.degree. C. degrades the conversion of
carbon monoxide. A preferable reaction pressure is in a range of
from 10 to 300 kg/cm.sup.2, more preferably in a range of from 15
to 150 kg/cm.sup.2, and most preferably in a range of from 20 to 70
kg/cm.sup.2. The reaction pressure below 10 kg/cm.sup.2 results in
a low conversion of carbon monoxide, and that above 300 kg/cm.sup.2
requires special design of reactor and is uneconomical because of
the need of large amount of energy for pressurizing the system. A
preferable space velocity (charge rate of mixed gas per 1 kg of
catalyst under standard condition) is in a range of from 100 to
50000 l/kgh, and particularly preferable from 500 to 30000 l/kgh.
The space velocity above 50000 l/kgh degrades the conversion of
carbon monoxide, and that below 100 l/kgh is uneconomical because
of the need of an excessively large reactor.
EXAMPLE
[0381] FIG. 9 shows the structure of reactor as an example
according to the present invention. FIG. 10 shows a
partial-enlarged view of the upper portion of the reactor.
[0382] The body 313 of the reactor R is in a cylindrical shape. A
slurry-bed chamber 311 located at the lower part of the body 313 is
filled with a catalyst slurry 318. A heat transfer tube 317 is
located in the catalyst slurry phase 318 to remove reaction heat.
The reactor body 313 is extended upward, and a condensation chamber
312 at the upper portion of the body 313 contains a multi-tube
condenser 314 to condense a medium oil, to which condenser 314 a
coolant pipe 319 is connected. The condensation chamber 312 and the
slurry-bed chamber 311 are separated from each other by a
bubble-cap plate 315. The bubble-cap plate 315 has a structure of a
plate with multiple short-pipes 320 penetrating therethrough, with
a cap 321 on each of the short pipes 320. In an operating state,
the medium oil condensed in the condenser 314 falls dropwise onto
the plate to be held thereon, which hold-up fills the gap between
the short pipe 320 and the cap 321 to function as a liquid seal. A
down corner 316 is located at one side of the plate 315 to return
the condensed medium oil to the catalyst slurry layer 318, and the
lower end of the downcorner enters into the catalyst slurry layer
318. A raw material gas line 302 is connected to the bottom of the
reactor body 313, and a reaction product gas line 303 is connected
to the top thereof. A mixed powder of a methanol synthesis catalyst
and a methanol-dehydration catalyst is used in the reactor R, and
further, at need, powder of a water gas shift catalyst is mixed
thereinto. To the catalyst, a high boiling point medium oil such as
n-cetane having 286.8.degree. C. of boiling point and 226 of
molecular weight is added to form a slurry of the catalyst with
liquid. Concentration of the slurry is at around 20 wt. %. A raw
material gas such as synthesis gas containing carbon monoxide and
hydrogen as main raw materials is supplied through the pipe 302
into the lower part of the reactor R. The raw material gas reacts
during the ascending passage through the catalyst slurry layer 318,
and the reacted products are discharged from the pipe 303 at top of
the reactor R. The reaction is carried out under a condition of 30
kg/cm.sup.2G, 280.degree. C., and W/F=6 kgcat/COkgmole of raw
material gas charge rate (W/F is the ratio of the weight of
catalyst to the charge rate of raw material carbon monoxide). Since
the dimethyl ether synthesis is a significantly exothermic
reaction, a heat transfer tube 317 is located in the catalyst
slurry layer 318 within the reactor R to remove the reaction heat.
During the operation of the reactor, the upper side of the
bubble-cap plate 315 is covered with the cooled and condensed high
boiling point medium oil. As a result, a part of the vapor of high
boiling point medium oil came from lower section of the reactor is
caught by the liquid high boiling point medium oil during the
passage of crossing the bubble-cap plate 315. The vapor of high
boiling point medium oil which was not caught by the liquid on the
bubble s plate 315 is cooled in the condenser 314 to fall onto the
bubble-cap plate 315 as droplets. The high boiling point medium oil
thus efficiently cooled and separated from the reaction product gas
returns to the catalyst slurry layer passing through a downcorner
316 which connects the bubble-cap plate 315 with the catalyst
slurry layer 318 and which immerses the bottom end thereof into the
catalyst slurry layer 318. A low temperature heating medium may be
introduced to the condenser 314 to cool the ascended vapor of high
boiling point medium oil, or a low temperature process fluid such
as the raw material gas may be used as the cooling medium.
[0383] If no cooling for recovering the medium oil is applied, the
n-cetane concentration in the discharged gas reaches to as high as
2 to 4 mole %. Since the volume of discharged gas is large, the net
amount of discharged n-cetane becomes large.
[0384] According to the present invention, there is no need to
recycle the discharged medium oil to the reactor, and the operation
of the reactor is stabilized. In particular, the structure of
reaction product gas line of the reactor becomes significantly
simple, and there is no need to apply high pressure pump nor
gas-liquid separator for recycling the medium oil.
Embodiment 9
[0385] Regarding the dimethyl ether-synthesis reaction in a
slurry-bed reactor, six molar volumes of raw material gas changes
to two molar volumes of reaction product gas when the reaction
proceeded to 100%. Since, however, actual one-pass conversion of
the raw material gas is at about 50%, six molar volumes of raw
material gas changes to one fold of volume of reaction product gas,
and three fold of volume of reaction gas is discharged from the
reactor as the non-reacted gas. That is, the gas volume reduces to
one third.
[0386] According to the present invention, the principle of the
above-described gas volume reduction is utilized. In concrete
terms, the internal of the reactor is divided into two sections:
upper reaction tank and lower reaction tank. The lower tank firstly
makes the non-reacted recycle gas react, thus reducing the volume
of non-reacted gas flowing through the reactor. Then, the gas is
added to the make up gas to let these gases react in the upper
tank.
[0387] Therefore, according to the present invention, a reactor
with a smaller inner diameter maintains the flow condition in the
reactor at a uniform bubble-tower state owing to the reduction of
the gas volume by reacting the non-reacted recycle gas firstly in
the reactor.
[0388] The reactor according to the present invention is a
slurry-bed reactor which is divided into two tanks: upper tank and
lower tank Each of the upper tank and the lower tank has a
slurry-bed holding section and an upper space. The slurry-bed
holding section, or the catalyst slurry holding section, is
provided with a cooling mechanism to remove reaction heat. The
boundary of the upper tank and the lower tank is necessary to have
a structure that the slurry in the upper tank does not flow down
into the lower tank and that the reaction product gas in the lower
tank enters into the slurry-bed in the upper tank. A structure
having the necessary functions is to open a connection hole on the
bottom plate of the upper tank while mounting a check valve to the
connection hole to prevent the slurry in the upper tank from
flowing down into the lower tank. An alternative structure is to
install a connection pipe between the upper space of the lower tank
and the upper tank, which connection pipe is extended to a height
that the slurry in the upper tank does not flow down into the lower
tank even when the reaction stops. The latter structure may further
be assured its function by installing an open/close valve to the
connection pipe. The connection pipe may be installed either inside
or outside of the tanks. For both structures, there is no need for
the separation wall between the upper tank and the lower tank to
have pressure-resistant performance as a high pressure vessel
because the pressure difference between these tanks is within
several atm.
[0389] The raw material gas feed pipe through which the fresh raw
material gas is charged to the reactor may be connected to either
of the upper space of the lower tank or the slurry-bed of the upper
tank.
[0390] Other sections than those described above may be similar
with those in conventional reactors, and instruments such as a
pressure gauge and a thermometer, and if necessary, an agitator and
an auxiliary raw material charge line may be mounted to the
reactor.
[0391] A dimethyl ether-synthesis apparatus that contains the
dimethyl ether-synthesis reactor using a reactor according to the
present invention may be the same configuration with conventional
apparatus. That is, at the exit of the reactor, a series of
equipment are connected in a sequent order of: a condenser to
condense the medium oil vaporized from the reactor; a gas-liquid
separator to separate the condensed medium oil; a methanol-water
separator which cools the reaction product gas to condense methanol
and water to separate them from the gas phase; a non-reacted gas
separator which further cools the gas to condense dimethyl ether
and carbon dioxide, thus separating thereof from carbon monoxide
and hydrogen; and a CO.sub.2 separator which separates dimethyl
ether and carbon dioxide from the condensed mixture. Each of the
methanol-water separator and the non-reacted gas separator may
further be divided into a condenser and a gas-liquid separator.
Alternatively, methanol, water, dimethyl ether, and carbon dioxide
may be condensed or solidified together, then carbon monoxide and
hydrogen may be separated, followed by separating dimethyl ether
from the condensed solid.
[0392] FIG. 14 shows an example of the apparatus implementing the
above-described method. The apparatus comprises a reactor R, a
methanol-water separator S1, a non-reacted gas separator S2, and a
CO.sub.2 separator S3. A make up (fresh) gas line 401 is connected
to the center part of the reactor R. A recycle gas line 402 through
which the non-reacted CO and H2 are recycled to charge is connected
to the bottom of the reactor. A reaction product gas line 403 to
discharge the reaction products connects the top of the reactor R
to the inlet of the methanol-water separator S1, (the condenser for
medium oil and the gas-liquid separator therefor are installed
upstream of the methanol-water separator S1, if needed). A
methanol-water line 404 is connected to the exit of methanol-water
on the methanol-water separator S1. A reaction product gas line 405
is connected to the exit of reaction products on the methanol-water
separator S1. The other end of the reaction product gas line 405 is
connected to the inlet of the non-reacted gas separator S2. The
other end of the recycle gas line 402 is connected to the exit of
non-reacted gas on the non-reacted gas separator S2. The recycle
gas line 402 is provided with a branched purge line 407 to withdraw
a part of the gas. A DME, CO.sub.2 line 406 is connected to the
exit of DME, CO.sub.2 on the non-reacted gas separator S2. Other
end of the DME, CO.sub.2 line 406 is connected to the CO.sub.2
separator S3. A CO.sub.2 line 408 is connected to the CO.sub.2 exit
on the CO.sub.2 separator S3. A DME line 409 is connected to the
exit of DME on the CO.sub.2 separator S3.
[0393] A mixed catalyst of a methanol synthesis catalyst and a
methanol-dehydration catalyst is used as the dimethyl
ether-synthesis catalyst to fill the reactor according to the
present invention, and, if needed, a water gas shift catalyst is
added to the mixed catalyst system.
[0394] An applicable kind of medium oil is arbitrary if only the
medium oil maintains liquid state under the reaction condition. In
the case of dimethyl ether synthesis, for example, the medium oil
may be hydrocarbons of aliphatic, aromatic, and alicyclic groups,
alcohol, ether, ester, ketone, halide, or their mixture.
Alternatively, gas oil after removing sulfur ingredients, vacuum
gas oil, high boiling point distillates of coal tar after treated
by hydrogenation, Fischer-Tropsch synthesis oil, and high boiling
point food oil are also applicable as the medium oil. The amount of
catalyst in the solvent depends on the kind of solvent and the
reaction condition. Normally, a preferable range of the catalyst is
from 1 to 50 wt. % to the amount of solvent, more preferably in a
range of from 2 to 30 wt. %.
[0395] For the case of dimethyl ether synthesis reaction, a
preferable reaction temperature in the reactor is in a range of
from 150 to 400.degree. C., and particularly preferable in a range
of from 250 to 350.degree. C. The reaction temperature below
150.degree. C. and above 400.degree. C. degrades the conversion of
carbon monoxide. A preferable reaction pressure is in a range of
from 10 to 300 kg/cm.sup.2, more preferably in a range of from 15
to 150 kg/cm.sup.2, and most preferably in arrange of from 20 to 70
kg/cm.sup.2. The reaction pressure below 10 kg/cm.sup.2 results in
a low conversion of carbon monoxide, and that above 300 kg/cm.sup.2
requires special design of reactor and is uneconomical because of
the need of large amount of energy for pressurizing the system. A
preferable space velocity (charge rate of mixed gas per 1 kg of
catalyst under standard condition) is in a range of from 100 to
50000 l/kgh, and particularly preferable from 500 to 30000 l/kgh.
The space velocity above 50000 l/kgh degrades the conversion of
carbon monoxide, and that below 100 l/kgh is uneconomical because
of the need of an excessively large reactor.
EXAMPLE
[0396] FIG. 12 shows the structure of reactor as an example
according to the present invention.
[0397] A reactor R is totally in a longitudinal cylindrical shape.
Inside of the reactor is divided into an upper tank 411 and a lower
tank 412 with a dish-shaped separation plate 413. At the center of
the separation plate 413, a connection pipe 414 having a check
valve 415 is located to connect the upper tank with the lower tank
while preventing the slurry-bed of the upper tank from flowing
down. A gas distributor 416 is located at the upper end of the
connection pipe 414 in the upper tank. Both of the upper tank 411
and the lower tank 412 are filled with slurry-bed. Each of the
slurry-beds 417, 418 has a heat transfer tube 419, 420,
respectively, to remove the reaction heat.
[0398] According to the reactor, only the non-reacted gas is pumped
to the bottom of the lower tank 412 of the reactor through a
recycle gas line 402. The raw material make up gas is supplied
through a make up gas line 401 into the upper space of the catalyst
slurry layer 418 in the lower tank 412 of the reactor to mix with
the reaction product gas coming from the non-reacted recycle gas
line. The mixed gas then passes through the connection pipe 414 in
the reactor, enters the upper tank 411 of the reactor, and after
reacted, flows out from the reaction product Gas line 403.
[0399] When the reactor treats 1000 Nm.sup.3/min. of make up raw
material gas and four fold of volume of non-reacted recycle gas at
an one-pass conversion of 50% under a condition of 30 kg/cm.sup.2G
of reaction pressure and 300.degree. C. of reaction temperature,
the non-reacted recycle gas of 4000 Nm.sup.3/min. reduces its
volume in the lower tank 412 of the reactor to 4000.times.2/3=2667
Nm.sup.3/min. As a result, the gas is mixed with the make up raw
material gas of 1000 Nm.sup.3/min. to become a volume of 3667
Nm.sup.3/min. That is, the upper tank 411 to which the maximum
volume of gas enters in the reactor accepts the gas of 3667
Nm.sup.3/min.
[0400] Under a sustained state of internal flow condition of the
reactor, the cross sectional area of the reactor is proportional to
the maximum gas flow rate. Since the cross sectional area of the
reactor is proportional the square of the inner diameter thereof,
the inner diameter of the reactor is proportional to the square
root of the maximum gas flow rate. Accordingly, the example
calculation given above results in about 10.4 m of inner diameter
of reactor to treat the gas of 5000 Nm.sup.3/min. compared with
about 12.2 m of inner diameter in conventional reactor for the same
gas flow rate. The difference is a significant merit for
fabricating a commercial large scale reactor.
[0401] FIG. 13 is another example of reactor according to the
present invention. For the reactor R, a connection pipe 414 comes
out from the upper space of the lower tank to outside of the
reactor, and extends upward to the upper level than the surface of
the slurry-bed 417 in the upper tank 411, then connects with a make
up as line 401 to enter the upper tank 411 down into the bottom
section of the upper tank 411, and finally joins to a gas
distributor 416. The other structure is the same with that of FIG.
12.
[0402] A reactor according to the present invention synthesizes
dimethyl ether by charging a raw material gas such as coal gasified
gas and synthesis gas produced from natural gas, containing carbon
monoxide and hydrogen as the main raw materials, to a slurry
reactor in which a reaction catalyst is suspended in a medium oil.
By decreasing the maximum gas flow rate inside of the reactor
relative to the same throughput, the reactor size is decreased,
thus reducing the fabrication cost of the high pressure reactor,
which cost occupies a large portion of the investment cost in a
high pressure process.
Embodiment 10
[0403] Synthesis of dimethyl ether proceeds following the three
equilibrium reactions shown below.
[0404] (1) (Methanol synthesis reaction)
[0405] (2) (Dehydration reaction)
[0406] (3) (Shift reaction)
[0407] In the case that the reaction (1) is solely carried out, the
reaction is what is called the methanol synthesis reaction. The
methanol synthesis reaction has a limitation of equilibrium, and a
high pressure (80 to 120 kg/cm.sup.2) is necessary to obtain a
target conversion. In the single stage process, however, the
reaction (2) which is significantly superior in terms of
equilibrium successively proceeds within the same reactor to
consume the methanol as the reaction product, so the inferior
reaction equilibrium of reaction (1) is compensated. As a result,
the dimethyl ether synthesis becomes very easy compared with
conventional methanol synthesis process. In other words, the single
stage process increases the conversion of CO/H.sub.2.
[0408] The reaction products comprise non-reacted CO and H.sub.2 ,
reaction products methanol, dimethyl ether, and CO.sub.2, and
slight amount of byproducts such as alkane. Since the composition
depends on the reaction rate and equilibrium of each of the
reactions (1) through (3), the single stage process cannot increase
the amount of solely a target product. In particular, methanol as
an intermediate is unavoidably left in the reaction products.
[0409] The reaction rate in each reaction is controlled by changing
the ratio of methanol synthesis catalyst, dehydration catalyst, and
shift catalyst. Thus the composition of the reaction products is
controlled. Since, however, these three types of reactions proceed
simultaneously and since all of these three reactions are
equilibrium reactions, the control has a limitation owing to the
limit of equilibrium. With that type of reaction system and under a
normal reaction condition, it is very difficult to attain the
selectivity of dimethyl ether over 95% (in the products excluding
CO.sub.2).
[0410] The difficulty is described below referring to a
thermodynamic calculation.
[0411] FIG. 15 shows reaction equilibria of H.sub.2, CO, methanol,
CO.sub.2, and water, on the basis of reactions (1), (2), and (3).
For instance, under a condition of 300.degree. C. of reaction
temperature, 50 atm of reaction pressure, and 1 of initial
CO/H.sub.2 ratio, the selectivity of dimethyl ether (starting
material of CO, carbon molar basis, excluding CO.sub.2) at the
reaction equilibrium is 98%. Establishing a reaction equilibrium
is, however, impossible in actual process, and the selectivity of
dimethyl ether becomes significantly lower level than the
calculated value owing to the presence of methanol as an
intermediate. In a state of a lower temperature than the above
example, for instance at 240.degree. C. of reaction temperature, 50
atm of reaction pressure, and 1 of initial CO/H.sub.2 ratio, the
selectivity of dimethyl ether at a reaction equilibrium becomes 99%
which is somewhat higher than that in the above example. Under the
condition, however, the rate of methanol-synthesis reaction (1) is
low and actually the reaction equilibrium is never established.
[0412] To cope with the situation, the method according to the
present invention uses a mixture of a methanol synthesis catalyst,
a dehydration catalyst or a dehydration and a shift catalyst in the
first stage reaction to yield crude dimethyl ether, and uses a
dehydration and/or a shift catalyst in the second stage reaction to
convert most of the remaining methanol into dimethyl ether, thus
attains a final high selectivity of dimethyl ether.
[0413] When the second stage reaction uses only a dehydration
and/or a shift catalyst without applying a methanol synthesis
catalyst, solely the dehydration and/or shift reaction proceeds and
only these reactions approach the equilibrium state. In a reaction
system where no methanol synthesis catalyst exists, no additional
methanol yields, and the remained methanol is converted into
dimethyl ether, so the selectivity of dimethyl ether increases.
[0414] The above-described process, however, needs an additional
reactor, which increases investment cost. In this respect, the
inventors developed a reactor having two separated sections therein
using the similarity of reaction condition (temperature and
pressure) for both the first stage reaction and the second stage
reaction. The reactor is described below.
[0415] The present invention was completed on the basis of the
above-described concept, and the above-described object is attained
by providing a reaction apparatus for synthesizing dimethyl ether
which comprises: a reactor for synthesizing dimethyl ether from a
mixed gas as a raw material gas containing carbon monoxide and
either or both of hydrogen and water vapor, or from a mixed gas as
a raw material gas containing carbon monoxide, either or both of
hydrogen and water vapor, and carbon dioxide, which reactor
comprises a lower stage holding a catalyst slurry and an upper
stage holding a catalyst fixed bed; a raw material gas feed pipe
connected to the lower stage; a reaction product gas discharge pipe
connected to the upper stage.
[0416] The lower stage of the reactor according to the present
invention is a vertical type slurry-bed reactor which holds a
catalyst slurry and has a heat exchanger therein to remove reaction
heat.
[0417] The catalyst used in the slurry-bed is a combination of
known methanol synthesis catalyst, known dehydration catalyst, and
known water gas shift catalyst. An applicable methanol synthesis
catalyst includes common industrial catalysts for methanol
synthesis, such as those of copper oxide--zinc oxide system, zinc
oxide--chromium oxide system, copper oxide--zinc oxide/chromium
oxide system, copper oxide--zinc oxide/alumina system. Examples of
dehydration catalyst are acid-base catalyst such as
.gamma.-alumina, silica, silica-alumina, and zeolite. Examples of
the metallic oxide ingredient in zeolite are oxide of alkali metal
such as sodium and potassium, and oxide of alkali earth metal such
as calcium and magnesium. Examples of water gas shift catalyst are
copper, oxide--zinc oxide system, copper oxide--chromium
oxide--zinc oxide system, and iron oxide--chromium oxide system.
Since methanol synthesis catalyst has a strong activity as a shift
catalyst, it can substitute for the water gas shift catalyst A
copper oxide supported by alumina is applicable as a dehydration
catalyst and also as a water gas shift catalyst
[0418] The mixing ratio of the above-described methanol synthesis
catalyst, dehydration catalyst, and water gas shift catalyst is not
specifically limited, and it depends on the kind of each ingredient
and reaction condition. Normally the ratio is often in an
approximate range of from 0.1 to 5 wt. parts of dehydration
catalyst to 1 wt. parts of methanol synthesis catalyst, more
preferably in an approximate range of from 0.2 to 2; in an
approximate range of from 0.2 to 5 wt. parts of water gas shift
catalyst, more preferably in an approximate range of from 0.5 to 3.
When the methanol synthesis catalyst substitutes for the water gas
shift catalyst, the above-described amount of the water gas shift
catalyst is added to the amount of the methanol synthesis
catalyst.
[0419] The above-described catalyst is used in a powder state. A
preferable average particle size is 300 .mu.m or less, more
preferably in an approximate range of from 1 to 200 .mu.m, and most
preferably in an approximate range of from 10 to 150 .mu.m. To
prepare powder of that range of particle size, the catalysts may
further be pulverized.
[0420] An applicable kind of heating medium oil for dispersing
catalyst is arbitrary if only the heating medium oil maintains
liquid state under the reaction condition. For example, the heating
medium oil may be hydrocarbons of aliphatic, aromatic, and
alicyclic groups, alcohol, ether, ester, ketone, halide, or their
mixture. Alternatively, gas oil after removing sulfur ingredients,
vacuum gas oil, high boiling point distillates of coal tar after
being tread by hydrogenation, Fischer-Tropsch synthesis oil, and
high boiling point food oil are also applicable as the heating
medium oil. The amount of catalyst in the solvent depends on the
kind of solvent and the reaction condition. Normally, a preferable
range of the catalyst is from 1 to 50 wt. % to the amount of
solvent, more preferably in an approximate range of from 10 to 30
wt. %.
[0421] A raw material gas is injected from a gas-injection nozzle
mounted to the slurry-bed reactor section to make the raw material
gas contact with the catalyst. With agitation to mix the slurry in
the reactor, the reaction is enhanced. By inserting heat transfer
tubes into the reactor, the reaction heat is removed from the
reactor. The removed reaction heat may be recovered to be utilized
in other applications. Since a slurry-bed reactor is easy for
agitation, the reaction heat is uniformly dispersed to the whole
reaction system. As a result, hot spots hardly appear, which makes
the heat recovery easy. In addition, temperature distribution
within the reactor hardly becomes irregular, so the amount of
yielded byproducts is small. Furthermore, that type of reactor is
easy for charge and withdrawal of catalyst, and easy for start up
and stop operation.
[0422] As described before, however, a reaction in a slurry-bed
unavoidably leave methanol in the reaction system as an
intermediate product of the reaction.
[0423] To cope with the residual methanol issue, a fixed bed
reactor section is installed at the upper part of the reactor to
convert the remaining methanol into dimethyl ether. A catalyst
applied to the fixed bed reactor contains at least one of
dehydration catalyst and dehydration and shift catalyst. As for the
dehydration catalyst, one of the above-described groups may be
used. For the dehydration and shift catalyst, copper oxide
supported by .gamma.-alumina may be used as a catalyst having both
the dehydration activity and the shift activity. The catalyst in
the fixed bed needs to be firmly held in the bed and also needs to
have a void that allows for a gas to pass freely through the fixed
bed. To do this, the catalyst particle size may be granulated to an
approximate size ranging from 1 to 20 mm, more preferably from 1.5
to 10 mm. Members such as perforated plate and meshed material are
installed at the bottom of the bed, as needed, to support the
catalyst particles. The catalyst may be a porous block having lots
of through hole pores.
[0424] The ratio of the amount of catalyst in a slurry-bed to that
in a fixed bed depends on the activity of the catalyst in each bed.
Normally, the weight ratio of the catalyst (slurry bed)/(fixed bed)
is in a range of from 1:10 to 10:1, more preferably from 1:5 to
5:1.
[0425] The boundary between the upper stage and the lower stage is
in an arbitrary state if only gas freely passes therethrough.
Entrainment emitted from the lower fluidized catalyst layer is
allowed to attach the upper fixed bed.
[0426] The raw material gas feed pipe is connected to the lower
stage of the reactor to charge the raw material gas into the
fluidized catalyst layer. The reaction product gas discharge pipe
is connected to the upper stage to let the gas pass through the
fixed catalyst bed and exit from the reactor.
[0427] Other sections than those described above may be similar
with those in conventional reactors, and instruments such as a
pressure gauge and a thermometer, and if necessary, an agitator and
an auxiliary raw material charge line may be mounted to the
reactor.
[0428] A dimethyl ether-synthesis apparatus that contains the
dimethyl ether-synthesis reactor using the reactor according to the
present invention may be the same configuration with a conventional
apparatus. That is, at the exit of reactor, a series of equipment
are connected in a sequent order of: a condenser to condense the
heating medium oil vaporized from the reactor; a gas-liquid
separator to separate the condensed heating medium oil; a
methanol-water separator which cools the reaction product gas to
condense methanol and water to separate them from the gas phase; a
non-reacted gas separator which further cools the gas to condense
dimethyl ether and carbon dioxide, thus separating thereof from
carbon monoxide and hydrogen; and a CO.sub.2 separator which
separates dimethyl ether and carbon dioxide from the condensed
mixture. Each of the methanol-water separator and the non-reacted
gas separator may further be divided into a condenser and a
gas-liquid separator. Alternatively, methanol, water, dimethyl
ether, and carbon dioxide may be condensed or solidified together,
then carbon monoxide and hydrogen may be separated, followed by
separating dimethyl ether from the condensed solid.
[0429] FIG. 16 shows an example of the apparatus implementing the
above-described method. The apparatus comprises a reactor R, a
methanol-water separator S1, a non-reacted gas separator S2, and a
CO.sub.2 separator S3. A raw material gas line 502 is connected to
the bottom of reactor R. To the raw material gas line 502, a make
up (fresh) gas line 501 which supplies fresh raw material gas and a
recycle gas line 507 through which the non-reacted CO and H2 are
recycled to charge are connected A reaction product gas line 503 to
discharge the reaction products connects the top of reactor R to
the inlet of methanol-water separator S1, (a condenser for heating
medium oil and a gas liquid separator therefor are instilled
upstream of the methanol-water separator S1, at need). A
methanol-water line 504 is connected to the exit of methanol-water
on the methanol-water separator S1. A reaction product gas line 505
is connected to the exit of reaction products on the methanol-water
separator S1. The other end of the reaction product gas line 505 is
connected to the inlet of the non-reacted gas separator S2. The
other end of the recycle gas line 507 is connected to the exit of
non-reacted gas on the non-reacted gas separator S2. The recycle
gas line 507 is provided with a branched purge line 510 to withdraw
apart of the gas. A DME, CO, line 506 is connected to the exit of
DME, CO.sub.2 on the non-reacted gas separator S2. Other end of the
DME, CO.sub.2 line 6 is connected to the CO.sub.2 separator S3. A
CO.sub.2 line 508 is connected to the CO.sub.2 exit on the CO.sub.2
separator S3. A DME line 509 is connected to the exit of DME on the
CO.sub.2 separator S3.
[0430] The mixing ratio of hydrogen and carbon monoxide may be in a
range of from 20 to 0.1 as H.sub.2/CO molar ratio, more preferably
in a range of from 10 to 0.2. In the case of a mixed gas with a
significantly low ratio of (H.sub.2/CO), for example, 0.1 or less,
or in the case of solely carbon monoxide without containing
hydrogen, it is necessary to separately supply steam to conduct the
shift reaction in the reactor to convert a part of the carbon
monoxide into hydrogen and carbon dioxide. A preferable charge rate
of steam is 1 or less to the charge rate of CO. A preferable amount
of carbon dioxide yielded from the reaction is 50% or less.
[0431] A preferable condition for both the upper and lower stage
reactions is the reaction temperature in a range of from 150 to
400.degree. C., particularly in a range of from 200 to 350.degree.
C. The reaction temperature below 150.degree. C. and above
400.degree. C. results in a reduction of carbon monoxide
conversion. A preferable reaction pressure is in a range of from 10
to 300 kg/cm.sup.2, particularly in a range of from 15 to 70
kg/cm.sup.2. The reaction pressure below 10 kg/cm.sup.2 results in
a low conversion of carbon monoxide, and that above 300 kg/cm.sup.2
requires a special design of reactor and is uneconomical because of
the need of a large amount of energy for pressurizing the system. A
preferable space velocity (charge rate of mixed gas per 1 g of
catalyst under standard condition) is in a range of from 100 to
50000 l/kgh, and particularly preferable from 500 to 30000 l/kgh.
The space velocity above 50000 l/kgh degrades the conversion of
carbon monoxide, and that below 100 l/kgh is uneconomical because
of the need of an excessively large reactor.
[0432] For the reactor according to the present invention, the use
of a combination of methanol synthesis catalyst, dehydration
catalyst, and shift catalyst in the first stage reaction increases
the conversion of CO/H.sub.2 in the raw material gas, and the use
of dehydration catalyst and/or shift catalyst in the second stage
reaction converts most part of the remained methanol into dimethyl
ether, thus the selectivity of dimethyl ether increases. In spite
of two stage reaction, the reactor is designed to a compact type
configuring two separated sections integrated in a single vessel
utilizing almost the same reaction condition (temperature and
pressure) for both stages. [0433] Amount of CO gas charged to
reactor (Nl/min.):Fin(CO) [0434] Amount of CO gas discharged from
reactor:Fout(CO) [0435] Amount of DME gas discharged from
reactor:Fout(DME) [0436] Amount of MeOH gas discharged from
reactor:Fout(MeHO) [0437] Amount of methane gas discharged from
reactor:Fout(CH.sub.4) ( CO .times. .times. conversion ) = Fin
.times. .times. ( CO ) - Fout .times. .times. ( CO ) Fin .times.
.times. ( CO ) .times. 100 .times. ( % ) ##EQU4## ( Selectivity
.times. .times. of .times. .times. dimethylether ) = 2 .times. Fout
.times. .times. ( DME ) 2 .times. Fout .function. ( DME ) + Fout
.function. ( MeOH ) + Fout .function. ( CH 4 ) ##EQU4.2## (
Selectivity .times. .times. of .times. .times. methanol ) = Fout
.times. .times. ( MeOH ) 2 .times. Fout .function. ( DME ) + Fout
.function. ( MeOH ) + Fout .function. ( CH 4 ) .times.
##EQU4.3##
EXAMPLE
Catalyst A: CuO--ZnO--Al.sub.2O.sub.3
[0438] Each of 185 g of copper nitrate
(Cu(NO.sub.3).sub.23H.sub.2O), 117 g of zinc nitrate
(Zn(NO.sub.3).sub.26H.sub.2O), and 52 g of aluminum nitrate
(Al(NO.sub.3).sub.39H.sub.2O) were dissolved into about 1 liter of
ion-exchanged water. Separately, about 1.4 kg of sodium carbonate
(Na.sub.2CO.sub.3) was dissolved into about 1 liter of
ion-exchanged water. Both of the solutions were added dropwise to
about 3 liters of ion-exchanged water in a stainless steel vessel
which was controlled at about 60.degree. C. within about 2 hours,
while maintaining the contents to pH 7.0.+-.0.5. Then, the contents
were allowed to stand for about 1 hour for aging. When, during the
treatment, the pH value went out from a range of pH 7.0.+-.0.5, an
aqueous solution of about 1 mole/liter sodium carbonate was added
dropwise to keep the range of pH 7.0.+-.0.5. The resultant
precipitate was filtered, and the cake was rinsed by ion-exchanged
water until nitric acid ion was not detected anymore. After the
rinse, the cake was dried at 120.degree. C. for 24 hours, followed
by calcining thereof in air at 350.degree. C. for 5 hours to obtain
the target catalyst. Analysis of the thus obtained catalyst gave
the composition as CuO:ZnO:Al.sub.2O.sub.3=61:32:7 (by weight).
Catalyst B: CuO--Al.sub.2O.sub.3 catalyst
[0439] A 15.7 g of copper acetate (Cu(CH.sub.3COO).sub.2H.sub.2O)
was dissolved into about 200 ml of ion-exchanged water. A 95 g of
.gamma.-alumina (N612, Nikki Kagaku Co.) was further added to the
mixture. The mixture was then vaporized to dry. The dried material
was calcined in air at 450.degree. C. for 4 hours. The calcined
material was treated in hydrogen gas stream at 400.degree. C. for 3
hours to obtain a catalyst Analysis of the catalyst gave the
composition as Cu:Al.sub.2O.sub.3=5:95 (by weight).
[0440] Each of the catalyst thus prepared was pulverized in a ball
mill to a particle size of 120 .mu.m or less.
[0441] The lower stage of the reactor was filled with 5584 ml of
n-hexadecane as the heating medium oil, 430 g of the catalyst A,
and 215 g of catalyst B: that is, (catalyst A/catalyst B)=2/1, and
(catalyst/heating medium oil)=15/100. The upper stage of the
reactor was filled solely with 645 g of catalyst B.
Preliminary Reduction
[0442] Under a condition of 10 kg/cm.sup.2 of reactor pressure,
220.degree. C. of reactor temperature, a mixed gas
(H.sub.2/N.sub.2=1/4) was introduced to the reactor at a flow rate
of 10 l/min. for 12 hours to conduct preliminary reduction.
[0443] A gas of H.sub.2/CO=1/1 was introduced to the reaction
system at a flow rate of 18 l/min. to conduct the dimethyl ether
synthesis under a condition of 50 kg/cm.sup.2G and 260.degree. C.
for both the upper and the lower stages. Gas analysis was conducted
by gas-chromatography, and the gas flow rate at the exit of
reaction system was determined by a gas meter. From the analysis
and flow rate determination, CO conversion and selectivity Of each
reaction product were calculated, (carbon molar basis, excluding
CO.sub.2). The result showed 41.0% of CO conversion, 95.5% of DME
selectivity, 4.4% of methanol selectivity, and 0.1% of methane
selectivity.
Comparative Example
[0444] Dimethyl ether synthesis was conducted under the same
conditions in the preceding Example except that the upper stage of
the reactor did not contain catalyst. The result showed 34.0% of CO
conversion, 67.1% of DME selectivity, 32.8% of methanol
selectivity, and 0.1% of methane selectivity. The DME selectivity
was at a low level.
[0445] The reactor according to the present invention provides
dimethyl ether from carbon monoxide and hydrogen (or water vapor)
at a high conversion and high selectivity. As a result, high purity
dimethyl ether is obtained from the reaction products, thus
allowing mass production of dimethyl ether at a low cost.
* * * * *