U.S. patent application number 12/021809 was filed with the patent office on 2008-06-12 for hydrogenation of aromatic compounds.
This patent application is currently assigned to CATALYTIC DISTILLATION TECHNOLOGIES. Invention is credited to J. Yong Ryu.
Application Number | 20080139383 12/021809 |
Document ID | / |
Family ID | 38534396 |
Filed Date | 2008-06-12 |
United States Patent
Application |
20080139383 |
Kind Code |
A1 |
Ryu; J. Yong |
June 12, 2008 |
HYDROGENATION OF AROMATIC COMPOUNDS
Abstract
A catalyst useful for hydrogenation of aromatic compounds to
produce hydrogenated cyclic compound, the catalyst comprising from
4 to 10 wt. % Ni and 0.2 up to about 0.9 wt. % Cu deposited on a
transition alumina support having a BET surface area from about 40
to 180 m.sup.2/g and pore volume from about 0.3 to about 0.8
cc/g.
Inventors: |
Ryu; J. Yong; (League City,
TX) |
Correspondence
Address: |
OSHA LIANG LLP / CDTECH
1221 MCKINNEY STREET, SUITE 2800
HOUSTON
TX
77010
US
|
Assignee: |
CATALYTIC DISTILLATION
TECHNOLOGIES
Pasadena
TX
|
Family ID: |
38534396 |
Appl. No.: |
12/021809 |
Filed: |
January 29, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11389955 |
Mar 27, 2006 |
7348463 |
|
|
12021809 |
|
|
|
|
Current U.S.
Class: |
502/327 ;
502/331 |
Current CPC
Class: |
C07C 2523/75 20130101;
B01J 23/892 20130101; C07C 2523/755 20130101; B01J 35/10 20130101;
B01J 35/1019 20130101; B01J 35/1042 20130101; B01J 23/755 20130101;
C07C 5/10 20130101; B01J 23/883 20130101; C07C 5/10 20130101; B01J
23/80 20130101; B01J 35/1014 20130101; B01J 23/8896 20130101; Y02P
20/52 20151101; B01J 35/1038 20130101; C07C 13/18 20130101 |
Class at
Publication: |
502/327 ;
502/331 |
International
Class: |
B01J 23/89 20060101
B01J023/89 |
Claims
1. A copper modified nickel catalyst useful for the hydrogenation
of aromatic compound to produce a hydrogenated cyclic compound, the
catalyst comprising 4 to 10 wt. % Ni and about 0.2 to 0.9 wt. % Cu
deposited on a transition alumina support having a BET surface area
from about 40 to 180 m.sup.2/g and a pore volume from about 0.3 to
about 0.8 cc/g.
2. The catalyst according to claim 1 wherein the catalyst contains
one or more modifiers selected from the group consisting of Ag, Ru,
Re, Zn, Mo and Pd.
3. The catalyst according to claim 1 wherein the Cu content is
about 0.2 to 0.4 wt. %.
4. The catalyst according to claim 1 wherein the Ni content of the
catalyst is about 9 to 10 wt %.
5. The catalyst according to claim 1: wherein the Ni content of the
catalyst is about 9 to 10 wt %; wherein the Cu content is about 0.2
to 0.4 wt. %; and wherein the catalyst contains one or more
modifiers selected from the group consisting of Ag, Ru, Re, Zn, Mo
and Pd.
6. The catalyst according to claim 1, wherein the transition
alumina support is obtained by calcining at a temperature in the
range from about 850 to about 1200.degree. C.
7. The catalyst according to claim 1, wherein the transition
alumina support has a BET surface area from about 50 to about 120
m.sup.2/g.
8. The catalyst according to claim 1, wherein the transition
alumina comprises one or more of delta alumina, theta alumina, and
kappa alumina.
9. A copper modified nickel catalyst useful for the hydrogenation
of benzene to produce cyclohexane, the catalyst comprising 4 to 10
wt. % Ni and about 0.2 to 0.9 wt. % Cu deposited on a transition
alumina support having a BET surface area from about 40 to 180
m.sup.2/g and a pore volume from about 0.3 to about 0.8 cc/g.
10. The catalyst according to claim 9 wherein the catalyst contains
one or more modifiers selected from the group consisting of Ag, Ru,
Re, Zn, Mo and Pd.
11. The catalyst according to claim 9 wherein the Cu content is
about 0.2 to 0.4 wt. %.
12. The catalyst according to claim 9 wherein the Ni content of the
catalyst is about 9 to 10 wt %.
13. The catalyst according to claim 9: wherein the Ni content of
the catalyst is about 9 to 10 wt %; wherein the Cu content is about
0.2 to 0.4 wt. %; and wherein the catalyst contains one or more
modifiers selected from the group consisting of Ag, Ru, Re, Zn, Mo
and Pd.
14. The catalyst according to claim 9, wherein the transition
alumina support is obtained by calcining at a temperature in the
range from about 850 to about 1200.degree. C.
15. The catalyst according to claim 9, wherein the transition
alumina support has a BET surface area from about 50 to about 120
m.sup.2/g.
16. The catalyst according to claim 9, wherein the transition
alumina comprises one or more of delta alumina, theta alumina, and
kappa alumina.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application, pursuant to 35 U.S.C. .sctn. 120, claims
benefit to U.S. patent application Ser. No. 11/389,955, filed Mar.
27, 2006. That application is incorporated by reference in its
entirety.
BACKGROUND OF INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a process for hydrogenation
of aromatic compounds such as the hydrogenation of benzene to
cyclohexane and the supported nickel catalyst modified with up to
0.9 wt. % Cu therefore.
[0004] 2. Background
[0005] Cyclohexane is the main precursor for the production of
nylon products and as such, the demand remains strong. Cyclohexane
was first obtained by the direct fractional distillation of
suitable crude petroleum refinery streams. Now the major portion of
cyclohexane is obtained from the direct hydrogenation of benzene.
Conventionally the reaction is carried out in vapor or mixed phase
using a fixed bed reaction. The reactor temperature is controlled
to be between 350 to 500.degree. F. Higher temperatures can lead to
thermodynamic limitations on benzene conversion, thermal cracking
and increased byproduct. In general, the amount of byproducts in
the effluent stream from a hydrogenation reactor increases with
hydrogenation temperature or conversion of benzene or both.
[0006] Peterson, in U.S. Pat. No. 2,373,501, discloses a liquid
phase process for the hydrogenation of benzene to cyclohexane
wherein a temperature differential is maintained between the top of
the catalyst bed where benzene is fed and the outlet where
substantially pure cyclohexane is withdrawn. The temperature
differential is due to the change in the exothermic heat of
reaction released as less and less benzene is converted as the
concentration of benzene decreases. Specifically the top of the
catalyst bed is at a higher temperature than the lower catalyst
bed. Hydrogen is supplied countercurrent to the benzene/cyclohexane
flow. Temperature control coils are disposed within the reactor to
maintain the temperature differential if the exothermic heat of
reaction is not sufficient or to cool the bed if too much heat is
released. Peterson recognizes that although the bulk of his
reaction takes place in the liquid phase a portion of the benzene
and cyclohexane will be vaporized, especially near the top of the
reactor where the benzene concentration is highest and conversion
is highest. A reflux condenser is provided to condense the
condensable material and return it to the reactor. Thus, a
substantial portion of the heat of reaction is removed by
condensation of the reactants vaporized throughout the reaction.
Peterson maintains a liquid level above the topmost catalyst bed
but allows room for vapors to escape to the condenser where the
heat of reaction is removed.
[0007] Larkin et al., in U.S. Pat. No. 5,189,233, disclose another
liquid phase process for the hydrogenation of benzene to
cyclohexane. However, Larkin et al. utilize high pressure (2500
psig) to maintain the reactants in the liquid state. In addition
Larkin, et al disclose the use of progressively more active
catalyst as the concentration of benzene decreases to control the
temperature and unwanted side reactions.
[0008] Hui et al, in U.S. Pat. No. 4,731,496, disclose a gas phase
process for the hydrogenation of benzene to cyclohexane over a
specific catalyst. The catalyst reported therein is nickel
supported on a mixture of titanium dioxide and zirconium
dioxide.
[0009] U.S. Pat. No. 6,750,374 discloses a process for the
hydrogenation of benzene using hydrogen containing up to about 15
mole % impurities, such as carbon monoxide and light hydrocarbons
with an alumina supported catalyst containing from about 15 to 35
wt. % Ni and from about 1 to 15 wt. % Cu. The catalyst may contain
additional elements such as Mo, Zn, Co, Fe.
SUMMARY OF THE INVENTION
[0010] The present invention is a process and a catalyst used in
the process for hydrogenation of aromatic compounds, such as
benzene, aniline, naphthalene, phenol and benzene polycarboxylates,
by hydrogenating the aromatic compound in the presence of a
catalyst comprising from 4 to 14 wt. % Ni, preferably 9 to 10 wt. %
Ni and up to about 0.9 wt. % Cu, preferably about 0.2 to 0.4 wt. %
Cu deposited on a transition alumina support having a BET surface
area from about 40 to 180 m.sup.2/g, and a pore volume from about
0.3 to about 0.8 cc/g. The hydrogenation of aromatic compounds is
advantageously carried out in the presence of a high boiling
solvent. The preferred solvent will have at least 10.degree. F.
higher boiling point than the aromatic compound to be hydrogenated
and hydrogenated cyclic compound. The advantages of using a high
boiling solvent are higher productivity of cyclohexane and keeping
the temperature of catalytic reaction zone in a desired range. The
high boiling solvent provides improvement in productivity of the
reaction system whether or not the nickel catalyst is modified with
copper.
[0011] In the production cyclohexane, benzene is present in the
reaction stream in an amount of 1 to 60 wt. %, preferentially of 3
to 40 wt. %. The hydrogen stream may be pure hydrogen or may
contain up to 5 mole % impurities including carbon monoxide. The
remaining components in the reaction stream can be cyclohexane, a
high boiling solvent or a mixture of cyclohexane and a high boiling
solvent. If a high boiling solvent is used, the solvent may
comprise 10 to 90 wt. %, preferably 20 to 80 wt % of the reaction
stream. The high boiling solvent may be recovered from the effluent
recycle stream and recycled to hydrogenation reactor. The content
of cyclohexane in the recycle solvent stream can be 0.0 to 80 wt.
%, preferably from 0.5 to 30 wt %.
[0012] The present invention also includes a copper modified nickel
catalyst used in the hydrogenation of aromatic compound to produce
a hydrogenated cyclic compound comprising 4 to 14 wt. % Ni and
about 0.2 to 0.4 wt. % Cu deposited on a transition alumina support
having a BET surface area from about 40 to 180 m.sup.2/g and a pore
volume from about 0.3 to about 0.8 cc/g.
[0013] Other aspects and advantages will be apparent from the
following description and the appended claims.
DETAILED DESCRIPTION
[0014] This invention pertains to a catalytic hydrogenation process
of aromatic compounds such as benzene, aniline, naphthalene and
phenol in the presence of improved copper modified nickel-based
catalyst supported on a porous support. Hydrogenation of benzene
yields cyclohexane. But the hydrogenation product stream from the
catalytic reactor contains other undesired by-products such as
pentane, cyclopentane, methyl cyclopentane, n-hexane and methyl
cyclohexane. The product stream usually contains a trace amount of
benzene, up to about 200 ppm by weight. Less than 10 ppm benzene is
highly desirable for the production of high purity cyclohexane. In
general, the amount of by-products in the effluent stream from a
hydrogenation reactor increases with hydrogenation temperature or
conversion of benzene or both. Especially the amount of the
by-products rapidly increases with hydrogenation temperature higher
than about 340.degree. F. The hydrogenation of aniline yields
cyclohexylamine. But the undesired side reactions are deamination,
formation of di and triphenylamine and various heavier products. An
advantage of the present invention is reduced by-products so that
simple distillation of hydrogenation product stream produces high
purity cyclohexane product. Preferably the cyclohexane product
contains no more than about 50 ppm, preferably no more 30 ppm by
weight impurities including unconverted benzene excluding
impurities came in with the feed benzene. The hydrogenation reactor
effluent contains small amounts of cyclohexene. Since cyclohexene
can easily be hydrogenated to cyclohexane by recycling the reactor
effluent or using a small separate reactor without producing
significant amounts of by-product, it is not considered as an
undesired by-product. The present invention provides a significant
improvement of the productivity of cyclohexane as well as reducing
total impurities in the product cyclohexane stream from the
catalytic reaction zone to less than 10 ppm, if the benzene
hydrogenation is carried out in the presence of a heavy solvent
such as decalin and decane. An additional advantage of using heavy
solvent is substantially less recycle of hydrogen.
[0015] The hydrogenation reaction can be carried out in any
physical device such as catalytic distillation column, fixed bed
reactor, boiling point reactor, stirred tank reactor, trickle bed
reactors or any combination of these. Since the benzene
hydrogenation reaction is exothermic reaction, the hydrogenation
reaction for the traditional fixed bed operation is preferably
carried out by recycling the reactor effluent stream to dilute the
fresh benzene feed, which dilutes the heat of reaction. Although
recycling the reactor effluent is not necessary for the catalytic
distillation reactor, one may choose to do so.
[0016] The present catalysts preferably comprise Ni and Cu and
optionally one or more elements selected from the group consisting
of Ag, Ru, Re, Zn, Mo and Pd which are deposited on a support
comprising transitional aluminas such as crystalline alumina of
gamma, kappa, delta, theta and alpha or a mixture comprised of two
or three selected therefrom. A preferred nickel content of the
catalyst is from about 9 to 10 wt. % and a preferred copper
contents is from about 0.2 to 0.4 wt. %. The catalyst used in this
invention is prepared by depositing nickel and copper on a porous
support. Copper serves to improve the catalyst activity and
selectivity. The catalyst may contain one or more elements as the
second optional modifiers from Ag, Ru, Re, Zn, Mo, and Pd. The
deposition of active metal components can be carried out by any
technique such as incipient impregnation, spray coating
impregnation. The preferred support will have average of size from
about 0.5 mm to about 3 mm, preferably from about 1 mm to about 2.5
mm.
[0017] The transition alumina is obtained by calcining at about 850
to about 1200.degree. C., and preferably having the following
physical properties after calcining at from 850 to 1200.degree. C.:
BET surface from about 40 to about 180 m.sup.2/g, preferably from
50 to 120 m.sup.2/g and pore volume from about 0.3 to about 0.8
cc/g. The transition alumina is the crystalline alumina of delta,
theta, kappa or a mixture composed of two or three from gamma,
kappa, delta, theta and alpha.
[0018] The physical shapes of the preferred aluminas in this
invention can be any shape such as spheres, extrudates, pellets and
granules which preferably have diameters of less than about 1/4
inch, preferably 1/8 inch and less than about 1/2 inch length, and
preferably less than 1/4 inch length for extrudates or pellets.
[0019] Deposition of the nickel on a support can be carried out by
single or multiple impregnations. A solution of the nickel compound
is prepared by dissolving a nickel compound or an organo nickel
compound in organic solvent or water. The examples of the nickel
compounds are nickel salts such as nickel nitrate or organo
metallic nickel compounds such as nickel acetate, nickel formate,
nickel acetylacetonate and nickel alkoxides. The impregnation
product is dried and calcined at temperature in a range from
200.degree. to 600.degree. C., preferably from 250.degree. to
500.degree. C.
[0020] When the hydrogenation of benzene is carried out in a fixed
bed reactor, which is operated in boiling point mode, or in a
catalytic distillation reactor, the heat of hydrogenation reaction
is utilized to vaporize the product cyclohexane. The result of the
vaporization is the internal cooling of the hydrogenation reaction
zone. The overhead vapor stream from a catalytic distillation
reactor, which is operated in the presence or absence of a high
boiling solvent, comprises cyclohexane and hydrogen.
CONTROL EXAMPLE 1
[0021] A commercial 28 wt. % Ni catalyst (1.2 mm diameter trilobe
extrudates) was tested to hydrogenate of benzene. The crystal form
of alumina support of this catalyst is gamma-alumina. The physical
properties of this catalyst were 113 m.sup.2/g BET, 0.43 cc/g total
nitrogen pore volume and an average pore diameter of 15 nm. 50
grams of the catalyst was loaded in a vertically mounted up-flow
stainless steel fixed bed reactor (1 inch diameter by 20 inches
long). Two thermocouples at each end of catalyst zone were
installed to control the reactor temperature. The catalyst was
supplied by the manufacturer as activated and passivated form, and
recommended reactivation at 482.degree. F. in hydrogen gas flow.
The catalyst was reactivated at 250.degree. F. in 300 cc/min gas
flow of 33 volume % hydrogen gas in nitrogen for 1.5 hours and then
575.degree. F. for 5 hours in 350 cc/min flow of pure hydrogen gas.
The hydrogenation of benzene was carried out under various
conditions. The results are listed in Table 1.
TABLE-US-00001 TABLE 1 Temperature, .degree. F. 300 320 340 340 350
360 Pressure, psig 250 250 250 250 250 250 Benzene Rate, ml/min 6 6
11.2 6 6 6 Benzene Conversion, % 18.21 20.21 21.59 17.71 18.41
17.86 Selectivity of cyclohexane and cyclohexene 99.95 99.87 99.91
99.84 99.84 99.82 (mole %) By-products in product stream based on
10)% cyclohexane and cyclohexene combined (wt. ppm) Cyclopentane
439 1114 644 1296 1359 1520 Methylcyclohexane 0 0 7 0 0 0 Hexane 0
0 7 0 0 0 Methyl Cyclopentane 692 1306 472 1546 1669 1881 Sum of
by-products 1131 2420 1130 2842 3028 3401 Cyclohexene 854 165 1661
1201 1309 2056
EXAMPLE 2
[0022] A spherical gamma-alumina (1.68 mm diameter) support was
calcined at 1100.degree. C. for 3 hours. The alumina spheres prior
to the calcination had 145 m.sup.2/g BET surface area, a total
nitrogen volume of 0.925 cc/g and an average pore diameter of 21.6
nm. After calcination, the diameter of alumina spheres was changed
to 1.45 mm, which had 56 m.sup.2/g BET, a total nitrogen pore
volume of 0.701 cc/g and an average pore diameter of 36.2 nm. Its
x-ray diffraction indicated mostly theta-alumina with minor amount
of delta.
[0023] A mixed solution of nickel nitrate and copper nitrate was
prepared by dissolving 86.5 grams of Ni(NO.sub.3).sub.22.5H.sub.2O
in 25.95 grams of water. 300 grams of the calcined alumina was
placed in a rotary impregnator. The mixed solution was sprayed on
rolling alumina spheres inside the rotary impregnator by using a
liquid sprayer over a period of about 15 minutes. The content in
the rotary impregnator was dried by blowing hot air in at about
200.degree. C. The dried product was calcined at 350.degree. C. for
2 hours.
[0024] The second mixed solution was prepared by dissolving 65
grams of Ni(NO.sub.3).sub.26H.sub.2O and 1.8 grams of
Cu(NO.sub.3).sub.22.5H.sub.2O in 19.5 grams of water. The second
impregnation was performed on the first impregnation product in
similar manner to the first impregnation. The dried impregnation
product was calcined at 380.degree. C. for 2 hours.
[0025] Based on the amount of materials used, the finished catalyst
would contain 9.22 wt % Ni and 0.35 wt. % Cu. The examination of
the catalyst spheres under microscope indicated that the active
metal components were deposited in an outer layer of spheres. The
average layer thickness was about 0.33 mm. The physical properties
of this catalyst were 60 m.sup.2/g, 0.56 cc/g total nitrogen pore
volume and an average pore diameter of 39 nm. 50 grams of this
catalyst was loaded in the same reactor used in the Control Example
1. The catalyst was activated at 250.degree. F. in 300 cc/min gas
flow of 33 volume % hydrogen gas in nitrogen for 1.5 hours and then
for 3 hours at each 670 and 770.degree. F. by passing 350 cc/min of
pure hydrogen gas. The hydrogenation of benzene was carried out
under various conditions. The results are listed in Table 2. As
shown in Table 2, the hydrogenation reaction product streams from
the reactor do not contain any detectable amounts of by-products.
The performance of this catalyst is superior to the conventional
nickel catalysts.
TABLE-US-00002 TABLE 2 Temperature, .degree. F. 300 320 320 340 340
350 360 Pressure, psig 250 250 250 250 250 250 250 Benzene Rate,
ml/min 6 6 11.2 11.2 6 6 6 Benzene Conversion, % 24.45 18.69 28.28
21.48 25.59 14.34 19.44 Selectivity of cyclohexane and 100 100 100
100 100 100 100 cyclohexene (mole %) By-products in product stream
based on 10)% cyclohexane and cyclohexene combined (wt. ppm)
Cyclopentane 0 0 0 0 0 0 0 Methylcyclohexane 0 0 0 0 0 0 0 Hexane 0
0 0 0 0 0 0 Methyl Cyclopentane 0 0 0 0 0 0 0 Sum of by-products 0
0 0 0 0 0 0 Cyclohexene 1613 4734 1285 12088 1549 3115 2235
EXAMPLE 3
[0026] A nickel catalyst was prepared according to US Publication
No. 2005-0033099-A1. Gamma-Alumina (1.3 mm diameter trilobe
extrudates) was calcined at about 1000.degree. C. for 3 hours in
air. The gamma-alumina had 252 m.sup.2/g BET, a total nitrogen pore
volume of 0.571 cc/g and an average pore diameter of 8.85 nm. A
solution of nickel nitrate was prepared by dissolving 183.6 g
Ni(NO.sub.3).sub.26H.sub.2O in 295 grams water. 300 g of the
calcined alumina support was placed in a rotary impregnator and
then the nickel nitrate solution was poured on tumbling alumina
extrudates in the rotary impregnator. After 15 minutes cold roll,
the content in the rotary impregnator was dried at about
200.degree. C. by blowing hot air into the rotary drier. The dried
product was calcined at 380.degree. C. for 2 hours. Based on the
amount of nickel nitrate used to prepare this catalyst, the
finished catalyst would have 11 wt % Ni on alumina support.
Measurement of the physical properties of the finished catalyst
indicated 133 m.sup.2/g BET surface area, a total nitrogen pore
volume of 0.622 cc/g and an average pore diameter of 18.6 nm.
[0027] 50 grams of this catalyst was loaded in the same reactor
used in the Control Example 1. The catalyst was activated in
identical manner to the Example 2. The hydrogenation of benzene was
carried out under various conditions. The results are listed in
Table 3. Comparing the performance data of this catalyst in Table 3
with those in the Table 1 of the Control Example 1 indicates a
superior performance of this catalyst to conventional nickel
catalysts, although it was not as good as the catalyst in the
Example 2.
TABLE-US-00003 TABLE 3 Temperature, .degree. F. 300 320 340 340 350
360 Pressure, psig 250 250 250 250 250 250 Benzene Rate, ml/min 6 6
11.2 6 6 6 Benzene Conversion, % 18.92 28.28 21.48 25.59 14.34
19.44 Selectivity of cyclohexane and cyclohexene 100.00 100.00
99.97 99.94 99.95 99.97 (mole %) By-products in product stream
based on 10)% cyclohexane and cyclohexene combined (wt. ppm)
Cyclopentane 0 0 225 493 386 273 Methylcyclohexane 0 0 0 0 0 0
Hexane 0 0 0 0 0 0 Methyl Cyclopentane 0 0 0 0 0 0 Sum of
by-products 0 0 225 493 386 273 Cyclohexene 555 846 890 565 765
1846
EXAMPLE 4
[0028] This example demonstrates the hydrogenation of benzene with
recycle of reactor effluent in the absence of a heavy solvent. But
the feed to the reactor comprises fresh benzene feed and reactor
effluent stream, which is cyclohexane. This experiment demonstrates
hydrogenation of mixed feed stream to hydrogenation, where the
mixed feed represents a stream obtained by mixing 1 weight portion
of fresh benzene with 3 weight portion of the reactor effluent
recycle steam.
[0029] The same catalyst (50 grams) in the Example 2 was in the
same reactor used in the Control Example 1. The catalyst was
activated in same manner to the Example 2. A feed mixture of
benzene and cyclohexane was prepared. The composition of the feed
was 0.11 wt % lights, 25.41 wt % benzene and 74.48 wt %
cyclohexane. The hydrogenation of benzene was carried out under
various conditions. The impurities in the feed and product streams
were analyzed with a trace go analysis method. The result is listed
in Table 4. The impurities in product streams mostly originated
from impurities in the feed. All combined, the total amount of
various impurities (listed in Table 4) produced during the
hydrogenation of benzene according to this invention is less than
10 ppm. The conversion of benzene could be forced so high that the
benzene contents in the reactor effluent streams could be reduced
to less than 35 ppm by weight. This example demonstrates that it is
possible to obtain extremely high conversion (>99.99%) of
benzene with a cyclohexane selectivity equivalent to about 99.999
mole %. The productivity of cyclohexane at two conditions of the
two right columns in Table 4 was 29.2 and 31.8 m/fur per kg
catalyst. This is a demonstration of superior catalyst performance
compared to the prior art represented by Example 1.
TABLE-US-00004 TABLE 4 Temperature - in, .degree. F. 144 158 145
160 159 160 Temperature - out, .degree. F. 299 329 310 300 322 322
Pressure, psig 230 230 230 230 230 230 Hydrogen Rate, cc/min 155
185 287.5 340 500 500 Flow rate of feed sole, ml/min 6 6 11.2 11
29.6 10.5 WHSV, h.sup.-1 5.8 5.8 10.8 10.8 9.2 10.1 Benzene
Conversion, % 77.26 99.81 74.21 83.26 100 99.99 Productivity of
cyclohexane 29.2 31.8 (m/hr/kg) Trace Analysis (wt. ppm) Feed
Isopentane 1.7 1.2 1.9 0.9 1.0 1.8 1.9 Methylpentane 12.5 12.0 14.3
12.7 13.1 10.9 10.9 Pentane 1.3 1.9 1.6 1.6 1.8 1.7 1.8
Cyclopentane 5.9 8.1 6.4 7.2 7.4 5.8 5.9 Hexane 13.5 13.3 15.3 13.9
14.0 12.4 12.5 Methyl Cyclopentane 11.1 12.4 13.1 12.1 12.2 10.8
10.9 Benzene -- 5.78* 0.05* 6.59* 4.27* 9.9 34.2 Cyclohexane -- --
-- -- -- -- -- Cyclohexene 4.7 14.8 5.5 24.9 4.8 4.5 0 Methyl
cyclohexane 7.2 8.9 7.6 8.7 9.4 9.3 9.4 Toluene 3.1 3.2 3.2 2.3 1.7
0 0 *Weight %
EXAMPLE 5
[0030] This example demonstrates the hydrogenation of benzene in
the presence of decalin as high boiling solvent, where the
conversions of benzene to cyclohexane are close to 100%.
[0031] 50 grams of the catalyst prepared in the Example 2 was
loaded in the same reactor used in the Control Example 1. The
catalyst was activated in same manner to the Example 2. The feed
was a mixture of 0.44 wt % lights, 25.26 wt % benzene and 74.30 wt
% decalin. The average total combined impurities in the feed, which
boil at temperatures near to cyclohexane, were about 14.8 ppm. The
hydrogenation of benzene was carried out under various conditions.
The impurities in the feeds and product streams were analyzed with
a regular GC analysis method and a trace GC analysis method. The
results are listed in Table 5. The impurities in products under
various conditions were mostly originated from impurities in feed.
All combined, the total amount of various impurities produced
during the hydrogenation of benzene according to this invention is
less than 4 ppm by weight based on 100% cyclohexane. The trace
amount of benzene in product stream can be reduced to less than 2
ppm in the product cyclohexane by adjusting the flow rate of
hydrogen to the hydrogenation reactor at a given feed rate of
benzene.
[0032] Surprisingly no trace amount of cyclohexene in any product
stream was found. The productivity of cyclohexane was at least 40%
higher than carrying out hydrogenation in the absence of a high
boiling solvent in Example 4.
TABLE-US-00005 TABLE 5 Temperature - in, .degree. F. 218 220 219
220 Temperature - out, .degree. F. 322 330 328 333 Pressure, psig
230 230 230 230 Hydrogen Rate, cc/min 400 430 385 405 Flow rate of
feed sole, ml/min 15 15 13 13 WHSV, h.sup.-1 16 16 13.9 13.9
Benzene Conversion, % 100 100 100 100 Productivity of cyclohexane
50.9 50.9 44.2 44.3 (m/hr/kg) Trace Analysis (wt. ppm) Feed
Isopentane 1.0 1.4 1.2 1.6 0.3 Pentane 1 0.3 0.3 0.3 0.3
Cyclopentane 0 0.6 0.4 0.3 0.3 Hexane 5.0 0.4 0.3 1.3 1.3 Methyl
Cyclopentane 1.1 0.6 0.4 0.4 0.4 Benzene -- 14.9 5.1 0.3 0.3
Cyclohexane -- -- -- -- -- Cyclohexene 0.2 0 0 0 0 Methyl
cyclohexane 4.7 7.0 6.7 6.7 6.5 Toluene 2.1 0 0 0 0
EXAMPLE 6
[0033] This example demonstrates the hydrogenation of benzene in
the presence of decane as high boiling solvent. The conversions of
benzene were so high that the benzene contents in the product
steams were close to undetectable.
[0034] 50 grams of the catalyst prepared in the Example 2 was
loaded in the same reactor used in the Control Example 1. The
catalyst was activated in same manner to the Example 2. The feed
was a mixture of 0.10 wt % lights, 30.26 wt % benzene and 69.64 wt
% decane. The average total combined impurities (excluding benzene)
in the feed, which boil at temperatures near to cyclohexane, was
about 5.77 ppm. The hydrogenation of benzene was carried out under
various conditions. The impurities in the feeds and product streams
were analyzed with a regular GC analysis method and a trace GC
analysis method. The result is listed in Table 6. The impurities in
products under various conditions mostly originated from impurities
in the feed. All combined, the total amount of various impurities
produced during the hydrogenation of benzene according to this
invention is about 11 ppm based on 100% cyclohexane. The
productivity of cyclohexane was equivalent or better than the case
of performing the hydrogenation in the absence of a high boiling
solvent in Example 4.
TABLE-US-00006 TABLE 6 Temperature - in, .degree. F. 165 165 164
Temperature - out, .degree. F. 335 327 334 Pressure, psig 230 230
230 Hydrogen Rate, cc/min 400 400 450 Flow rate of feed sole,
ml/min 9 8.5 10 WHSV, h.sup.-1 9.6 8 11 Benzene Conversion, % 100
100 100 Productivity of cyclohexane 36.4 32.6 40.5 (m/hr/kg) Trace
Analysis (wt. ppm) Feed Isopentane 0.2 0.2 0.3 0.2 Cyclopentane 0.1
0.9 1.0 0.9 Methyl Pentane <0.1 0.1 0.2 <0.1 Hexane 0.2 0.9
1.0 0.5 Methyl Cyclopentane 1.7 2.4 2.4 2.0 Benzene -- 0.02
<0.01 0.02 Cyclohexane 2.5 -- -- -- Cyclohexene <0.1 1.4 1.3
0 Methyl cyclohexane 2.3 4.6 4.4 4.5 Toluene 1.7 0 0 0
[0035] While the disclosure includes a limited number of
embodiments, those skilled in the art, having benefit of this
disclosure, will appreciate that other embodiments may be devised
which do not depart from the scope of the present disclosure.
Accordingly, the scope should be limited only by the attached
claims.
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