REMOVING AND CLEANING DEHYDROGENATION CATALYSTS

TECHNICAL FIELD

The present invention relates to removing mixed oxide catalysts used to dehydrogenate one or more C2-4 paraffins to corresponding alkenes from one or more reactors and connected piping.

BACKGROUND ART

There is increasing interest in the oxidative dehydrogenation of one or more C2-4 paraffins to corresponding alkenes and derivatives such as acetic acid, vinyl acetates and acrylate esters. There is very little art relating to removing catalyst or residues from reactors and inter-connected piping. Removal of catalysts and residues tends to involve physical treatment of the reactors and piping and result in the formation of catalyst dust which may be harmful.

U.S. Patent 8,221 ,640 issued July 17, 2012 to Magnaldo assigned to

Commissariat a L’Energie Atomic; Compagnie General des Matiers Nucleates teaches a method to remove build-up of solids deposited in the pipes of nuclear reactors using a mixture of nitric acid and polycarboxylic acids such as oxalic acid. The reference does not suggest using oxalic acid alone to solubilize such deposits, nor does it refer to oxidative dehydrogenation catalysts for preparing olefins.

There are a number of references which disclose the formation of multi component metal oxide catalysts, such as Lopes-Nieto (US 7,319,179 now lapsed) and Simanzhenkov (US 20170210685). These methods typically include forming solutions of the components and subjecting them to a hydrothermal process and drying the pre-catalyst and then subjecting it to oxidation. For example, the catalyst may be prepared by mixing aqueous solutions of soluble metal compounds such as hydroxides, sulphates, nitrates, halides, lower (C1-5) mono or di carboxylic acids and ammonium salts or the metal acid per se. For instance, the catalyst could be prepared by blending solutions such as ammonium metavanadate, niobium oxalate, ammonium molybdate, telluric acid, etc. The resulting solution is then dried typically in air at 100-150°C and calcined in a flow of inert gas such as those selected from the group consisting of N2, He, Ar, Ne and mixtures thereof at 200- 600°C, preferably at 300-500°C. The calcining step may take from 1 to 20, typically from 5 to 15 usually about 10 hours. The resulting oxide is a friable solid typically insoluble in water. It is surprising in view of the above procedures and particularly the drying and oxidation step that the catalyst could be dissolved simply with the use of oxalic acid. Further it was unexpected that alumina support would be dispersed by the oxalic acid.

SUMMARY OF INVENTION

The present invention seeks to provide a method to remove from one or more vessels and associated piping a bed of a catalyst selected from the group consisting of:

i) catalysts comprising

Moo.9-i.ioVo.i-iNbo.i-o.2Teo.oi-o.i7Xo-20d where X is selected from Pd, Sb Ba, Al, W, Ga, Bi, Sn, Cu, Ti, Fe, Co, Ni, Cr, Zr, Pt, Ca and oxides and mixtures thereof, and d is a number to satisfy the valence of the catalyst; and

ii) catalysts of the formula

MOaVbNbcT eeOd

wherein:

a is from 0.75 to 1.25, preferably from 0.90 to 1.10;

b is from 0.1 to 0.5, preferably from 0.25 to 0.4;

c is from 0 to 0.5, preferably from 0.1 to 0.35;

e is from 0 to 0.35 preferably from 0.1 to 0.3; and

d is a number to satisfy the valence state of the mixed oxide catalyst,

optionally on an alumina support typically comprising alumina in the form of AI2O3 or AI(0)OFI or combination thereof comprising contacting the catalyst with from 10 to 100 ml_ of not less than a 0.5 molar solution typically not less than 1 M up to the solubility limit of oxalic acid in an aqueous solution at the temperature of treatment per g of catalyst at a temperature from 20°C up to the boiling temperature of a saturated solution preferably greater than 60°C most preferably greater than 80°C for a period of time for at least 1 hour in some cases 20 or more hours .

Preferably the treatment is carried out using agitation (e.g. cyclic pumping of the solution through reactor tubes).

In a further embodiment there is provided the above method wherein the catalyst comprises:

M00.9-1.lVo.12-0.49Nbo.1-0.17Teo.1-0.17Xo-20d (2) wherein d is a number to satisfy the valence of the catalyst. In a further embodiment there is provide any of the above embodiments wherein the catalyst comprises:

MOO.9-1.1 VO.32-0.49Nbo.14-0.17Teo.10-0.17Xo-20d (3)

wherein d is a number to satisfy the valence of the catalyst.

In a further embodiment there is provide any of the above embodiments wherein the catalyst comprises:

MqO.9-1.1 Vo.25-0.45Nbo.13-0.16Teo.1-0.16Xo-20d (4)

wherein d is a number to satisfy the valence of the catalyst.

In a further embodiment there is provide any of the above embodiments wherein the catalyst comprises:

M00.9-1 ,l Vo.25-0.35Nbo.13-0.16Teo.1 -0.16Xo-20d (5)

wherein d is a number to satisfy the valence of the catalyst.

In a further embodiment there is provided any of the above embodiments wherein the catalyst comprises:

MqO.9-1.1 V0.12-0.19Nb0.19-0.20Te0.06-0.07X0-2Od wherein d is a number to satisfy the valence of the catalyst.

In a further embodiment there is provide any of the above embodiments wherein the catalyst forms fouling on the piping associated with the reactor.

In a further embodiment there is provide any of the above embodiments wherein the piping is steel or stainless steel.

In a further embodiment there is provide any of the above embodiments wherein the catalyst is a bed in one or more reactors.

In a further embodiment there is provide any of the above embodiments wherein the catalyst is supported on alumina.

In a further embodiment valuable metals including Pd, Pt and Au are separated from the solution of catalyst and optional support by one or more suitable means including filtration, precipitation, and floatation.

BRIEF DESCRIPTION OF DRAWINGS

Figure 1 is a photo of catalyst sample prior to the addition of the oxalic acid. Figure 2 is a photo of the solubilized catalyst and the dispersed support.

Figure 3 is a photo of a stainless steel rod contaminated with catalyst (see circle in Figure 3).

Figure 4 is a close-up photo of a stainless steel rod of Figure 3 cleaned of catalyst by treatment with oxalic acid. DESCRIPTION OF EMBODIMENTS

Numbers Ranges

Other than in the operating examples or where otherwise indicated, all numbers or expressions referring to quantities of ingredients, reaction conditions, etc. used in the specification and claims are to be understood as modified in all instances by the term“about”. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that can vary depending upon the properties that the present invention desires to obtain. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of“1 to 10” is intended to include all sub-ranges between and including the recited minimum value of 1 and the recited maximum value of 10; that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10. Because the disclosed numerical ranges are continuous, they include every value between the minimum and maximum values. Unless expressly indicated otherwise, the various numerical ranges specified in this application are approximations.

All compositional ranges expressed herein are limited in total to and do not exceed 100 percent (volume percent or weight percent) in practice. Where multiple components can be present in a composition, the sum of the maximum amounts of each component can exceed 100 percent, with the understanding that, and as those skilled in the art readily understand, the amounts of the components actually used will conform to the maximum of 100 percent.

As used in this specification vessels means, vessels or reactors comprising metallic components (e.g. walls and or agitators etc.) and associated piping which may be used in the manufacture of mixed oxide oxidative dehydrogenation catalysts as described below or in the oxidative dehydrogenation of alkanes to olefins, including vessels having one or more metallic components used for holding, mixing, hydrothermal treatment, peroxide treatment and extrusion of such catalysts.

The catalyst may comprise a mixture of metal oxides having a composition:

MoiVo.i-iNbo.o-iTeo.o-o.2Xo-20d where X is selected from Pd, Sb Ba, Al, W, Ga, Bi,

Sn, Cu, Ti, Fe, Co, Ni, Cr, Zr, Ca and oxides and mixtures thereof, and d is a number to satisfy the valence of the catalyst.

In a further embodiment the catalyst comprises catalysts of the formula

MoaVbNbcTeeOd

wherein:

a is from 0.75 to 1.25, preferably from 0.90 to 1.10;

b is from 0.1 to 0.5, preferably from 0.25 to 0.4;

c is from 0.1 to 0.5, preferably from 0.1 to 0.35;

e is from 0.1 to 0.35 preferably from 0.1 to 0.3; and

d is a number to satisfy the valence state of the mixed oxide catalyst.

The catalyst may have the formula:

MOl V0.25-0.45Te0.10-0.16Nb0.13-0.16X0-02Od (i)

wherein d is a number to satisfy the valence of the catalyst.

In a further embodiment the catalyst may have the formula:

MOlV0.12-0.49Nb0-0.17Te0-0.17X0-2Od (2)

wherein d is a number to satisfy the valence of the catalyst.

In a further embodiment the catalyst may have the formula:

MOl .oVo.32-0.49Nbo.14-0.17Teo.10-0.17Xo-20d (3) wherein d is a number to satisfy the valence of the catalyst.

In a further embodiment the catalyst may have the formula:

MOlVo.25-0.45Nbo.13-0.16Teo.1 -0.16Xo-20d (4)

wherein d is a number to satisfy the valence of the catalyst.

In a further the catalyst may have the formula:

MOlVo.25-0.35Nbo.13-0.16Teo.1-0.16Xo-20d (5)

wherein d is a number to satisfy the valence of the catalyst.

In a further embodiment the catalyst may have the formula:

Mo1.0V0.12-0.19Nb0.19-0.20Te0.06-0.07 Xo-20d (6) wherein d is a number to satisfy the valence of the catalyst.

In the catalysts of formula i) element X may be present in an amount from 0 up to 2 atoms per atom of Mo, in some embodiments from 0 up to 1 atoms per atom of Mo, in some embodiments from 0.001 to 1 atom per atom of Mo, in further embodiments from 0.001 to 0.5 atoms per atom of Mo, in further embodiments from 0.001 to 0.01 atoms per atom of Mo.

The methods of preparing the catalysts are known to those skilled in the art.

For example, the catalyst may be prepared by mixing aqueous solutions of soluble metal compounds such as hydroxides, sulphates, nitrates, halides, salts of lower (C1-5) mono or di carboxylic acids and ammonium salts or the metal acid per se. For instance, the catalyst could be prepared by blending solutions such as ammonium metavanadate, niobium oxalate, ammonium molybdate, telluric acid etc. and in some embodiments subjecting the resulting solution to a hydrothermal process under an inert atmosphere and heating to a temperature from 140°C to 190°C, in some embodiments from 140°C to 180°C, in some embodiments from

145°C to 175°C for not less than 6 hours in some instances not less than 12 hours in some embodiments up to 30 hours, or more.

The pressure in the reactor (Parr reactor or autoclave) may range from 1 to 200 psig (6.89 kPag to 1375 kPag).

In some embodiments the pressure in the pressurized reactor is adjusted and maintained from 30 to 200 psig (206 kPag to 1375 kPag), in some

embodiments from 55 psig (380 kPag) to 170 psig (1 170 kPag) above atmospheric pressure.

In further embodiments the pressure in the reactor (autoclave) may be up to about 10 psig (68.9 kPag), preferably from 1 to 8 psig (6.89 kPag to 55.1 kPag), in some embodiments less than 5 psig (34.4 kPag) above atmospheric pressure.

The pressures in the reactor is maintained using a pressure relief valve. At lower pressures the pressure may be maintained by passing the off gas through a column of a fluid such as water or a dense fluid (e.g. mercury). Optionally there may be a condenser upstream of the reactor outlet. If present the condenser is operated at a temperature above 0°C and below reaction temperature. Gaseous product species are vented from the reactor as described above. In some embodiments the solution for the hydrothermal treatment (catalyst precursor) may comprise small amounts of H2O2 from 0.3-2.5 ml_ of a 30 wt. % solution of aqueous H2O2 per gram of catalyst precursor.

The resulting solution is then dried typically in air at 100-150°C and calcined in a flow of inert gas such as those selected from the group consisting of N2, He, Ar, Ne and mixtures thereof at 200-600°C, preferably at 300-500°C. The calcining step may take from 1 to 20, typically from 5 to 15 usually about 10 hours. The resulting oxide is a friable solid typically insoluble in water.

In some embodiments the product from the hydrothermal treatment is treated with from 0.3-2.5 ml_ of a 30 weight % solution of aqueous H2O2 per gram of catalyst precursor. In some embodiments there may be a double peroxide treatment in the hydrothermal process and subsequent to drying the catalyst. The dried catalyst is then deposited on an alumina support using conventional methods such as a wet impregnation method or spray drying and the like. In a further embodiment from 10 to 95, preferably from 25 to 80, desirably from 30 to 45, weight % of the catalyst is bound or agglomerated with from 5-90, preferably from 20 to 75, desirably from 55 to 70 weight % of a binder selected from the group consisting of acidic, basic or neutral binder slurries of AI2O3, and AIO(OH) , and mixtures thereof, preferably AI(0)OH .

The catalyst is loaded into one or more reactors in series or parallel. The reactors maybe be fixed or fluidized bed reactors, in some cases similar to FCC type crackers. In some embodiments the reactor may be a tube shell type reactor with the catalyst loaded into the tube and tube plates above and below the tubes to permit reactants to flow through the catalyst bed.

The catalyst may be used for the oxidative dehydrogenation of a mixed feed comprising ethane and oxygen in a volume ratio from 70:30 to 95:5 and optionally one or more C3-6 alkanes or alkenes and optionally a further oxygenated species including CO and CO2 at a temperature less than 385°C, a gas hourly space velocity of not less than 100 hr ¹ , and a pressure from 0.8 to 7 atmospheres comprising passing said mixture through the above catalyst. The ODH process should have a selectivity to ethylene of not less than 90%. The gas hourly space velocity of the ODH process is not less than 500 hr ¹ desirably not less than 1500 hr ¹ in some embodiments 3000 hr ¹ . The temperature of the ODH process is less than 415°C preferably less than 375°C, desirably less than 360°C. Depending on the reaction conditions the product stream comprises ethylene, water, and one or more of carbon dioxide, carbon monoxide, carbonic acid and acetic acid. The product stream, and particularly water, carbonic acid and acetic acid may leach one or more components from the catalyst or support.

Depending on the duration of the reaction this can result in dissolution of the catalyst or its components and the dissolution of the support and deposition of the components or support and salts thereof such as carbonates and acetates on the walls of the reactor, and potentially among catalyst particles. This result in reduced operating efficiency of the reactor system (reactors and associated piping). This may result in costly down time to clean the catalyst beds, (particularly in tube and shell type reactors) and the associated piping. Not only may the work be time consuming it may expose workers to potentially hazardous dust.

It has been found that the catalyst, support (AI2O3, and AIO(OH)), and associated bi-products (e.g. salts etc.) can be removed from the catalyst beds and associated piping by dissolving or contacting them with from 10 to 100 ml of a up to the boiling temperature of a saturated solution not less than 0.5 of oxalic per 1 to 5 g of catalyst and associated bi-products at a temperature from 20°C to up to the boiling temperature of a saturated solution preferably greater than 60°C desirably greater than 80°C for a period of time for at least 1 hour in some cases 20 or more hours.

The amount of catalyst, support and associated catalyst and support bi products in the solution of oxalic acid may be determined by a number of conventional means such as analysis of the solution (FTIR) etc.

The solution of the catalyst and support and bi-products may be subject first to filtration to remove particulates such as catalyst support, and then the solution may be dried or substantially dried to recover the metal components of the catalyst. If the solution contains valuable metals such as Pd, Pt and Au one could separate them by suitable means including filtration, precipitation, floatation, etc. Potentially the solution of catalyst components might be used as“starter” to begin a fresh hydrothermal treatment. One could analyze the solution for metallic components and might adjust the composition to that require for a hydro thermal treatment and potentially regenerate the catalyst. In it’s broadest embodiments the present invention provides a method to remove from one or more reactors and associated piping a catalyst selected from the group consisting of:

i) catalysts comprising

Moo.9-i.iVo.i-iNbo.i-iTeo.oi-o.2Xo-20d where X is selected from Pd, Sb Ba, Al, W, Ga, Bi, Sn, Cu, Ti, Fe, Co, Ni, Cr, Zr, Pt, Ca and oxides and mixtures thereof, and d is a number to satisfy the valence of the catalyst; and

ii) catalysts of the formula

MOaVbNbcT eeOd

wherein:

a is from 0.75 to 1.25;

b is from 0.1 to 0.5;

c is from 0 to 0.5;

e is from 0 to 0.35; and

d is a number to satisfy the valence state of the mixed oxide catalyst,

optionally on an alumina support comprising contacting the catalyst with from 10 to 100 ml_ of not less than 0.5 molar solution of an oxalic acid per 1 to 5 g of catalyst at a temperature from 20°C to 100°C for a period of time of not less than 1 hour.

In a further embodiment there is provided a method according to one or more other embodiments, wherein the treatment is carried out using agitation including cyclic pumping of the solution through reactor tubes.

In a further embodiment there is provided a method according to one or more other embodiments, wherein the catalyst and optional support forms fouling on the piping associated with the reactor.

In a further embodiment there is provided a method according to one or more other embodiments, wherein the piping is steel or stainless steel.

In a further embodiment there is provided a method according to one or more other embodiments wherein the catalyst is a bed in one or more reactors.

In a further embodiment there is provided a method according to one or more other embodiments, wherein the catalyst is supported on alumina (AI(O)OH).

In a further embodiment there is provided a method according one or more other embodiments, wherein valuable metals including Pd, Pt and Au are separated from the solution of catalyst and optional support by one or more suitable means including filtration, precipitation, and floatation. In a further embodiment there is provided a method according to one or more other embodiments, wherein the catalyst has the formula:

MOlV0.25-0.45Te0.10-0.16Nb0.13-0.16X0-02Od

wherein d is a number to satisfy the valence of the catalyst.

In a further embodiment there is provided a method according to one or more other embodiments, wherein the catalyst has the formula:

MOlVo.12-0.49Nbo.1-0.17Teo.1-0.17Xo-20d

wherein d is a number to satisfy the valence of the catalyst.

In a further embodiment there is provided a method according to one or more other embodiments, wherein the catalyst has the formula:

MOl.oVo.32-0.49Nbo.14-0.17Teo.10-0.17Xo-20d

wherein d is a number to satisfy the valence of the catalyst.

In a further embodiment there is provided a method according to one or more other embodiments, wherein the catalyst has the formula:

MOlVo.25-0.45Nbo.13-0.16Teo.1-0.16Xo-20d

wherein d is a number to satisfy the valence of the catalyst.

In a further embodiment there is provided a method according to one or more other embodiments, wherein the catalyst has the formula:

MOlVo.25-0.35Nbo.13-0.16Teo.1-0.16Xo-20d

wherein d is a number to satisfy the valence of the catalyst.

In a further embodiment there is provided a method according to one or more other embodiments, wherein the catalyst has the formula

Mo1.0V0.12-0.19Nb0.19-0.20Te0.06-0.07

wherein d is a number to satisfy the valence of the catalyst.

In a further embodiment there is provided a method according to one or more other embodiments, wherein in formula i) X may be present in an amount from 0 up to 1 atoms per atom of Mo.

In a further embodiment there is provided a method according to one or more other embodiments, wherein in formula i) X may be present in an amount from 0.001 to 1 atoms per atom of Mo.

The present invention will now be illustrated by the following examples. Example 1

Ten grams of oxalic acid was dissolved in 100 ml_ of distilled water. This mixture was heated to 80°C in a hot water bath for 30 minutes. To this clear, colorless solution was charged 1.0 g of extruded catalyst of the formula M01 Vo.43Teo.17Nbo.i 6Od supported on alumina (AI(O)OH) (catalyst Figure 1 ). The mixture was left to sit unstirred in the 80°C water bath for 30 minutes. After which 98% of the catalyst was dissolved. After 1 hour in the 80°C water bath the catalyst was completely dissolved. The alumina from the extruded catalyst remained undissolved (Figure 2).

Example 2

Thirty grams of oxalic acid was dissolved in 300 ml_ of distilled water. This mixture was heated to 80°C in a hot water bath for 30 minutes. To this colourless solution was charged 3.0 g of extruded catalyst of the formula with alumina. The mixture was left stirring at 600 rpm in the 80°C water bath for overnight. After which the catalyst and alumina (AI(O)OFI) was completely dissolved. A clear, blue solution was formed.

Example 3

The 1/8” stainless steel 316 tube contaminated with catalyst residue (Figure

3) was submerged approximately 1.5 cm below the surface of a mixture of 3.0 g catalyst of the formula M01Vo.43Teo.17Nbo.i6Od, 30 g oxalic acid mixture, in 300 ml_ of distilled water, in an 80°C oil bath for 24 hours. After 24 hours no visible signs of corrosion or etching of the stainless steel was visible (Figure 4).

The above examples show that mixed oxide catalysts comprising

M01 Vo.43Teo.17Nbo.i 6Od are soluble in aqueous solutions of oxalic acid and that such solutions do not etch or attack stainless steel.

INDUSTRIAL APPLICABILITY

Residues of mixed metal oxide catalysts for the oxidative dehydrogenation of lower alkanes may be removed from equipment by dissolution in oxalic acid solutions.