PREPARATION METHOD FOR MOLYBDENUM-TELLURIUM-VANADIUM-NIOBIUM-BASED ODH CATALYSTS

TECHNICAL FIELD

The present invention relates to a process for the preparation of oxidative dehydrogenation catalyst (ODH) precursors in a single reactor carefully controlling the pH of the solution during the addition of the Mo, Te and V components then adding Nb20s and oxalic acid without separation of intermediate components. The resulting precursor, typically a slurry is then subject to a controlled pressure hydrothermal process and the final catalyst may optionally be further treated with a peroxide. The process is highly reproducible.

BACKGROUND ART

There are a number of patents which teach conducting the hydrothermal process in an autoclave. Representative of such art are the following patents.

United States Patent 7,319,179 issued Jan. 15, 2008 to Lopez Nieto et al., assigned to Consejo Superior De Investigaciones Cientificas, Universidad

Politecnica De Valencia, teaches in example 1 forming an oxidative

dehydrogenation catalyst by first dissolving ammonium heptamolybdate

tetrahydrate and telluric acid in water at 80°C and adjusting the pH to 7.5 using ammonium hydroxide. The resulting solution is dried and then dissolved in water and vanadyl sulphate and niobium (V) oxalate are added to the solution. There is no discussion of pH control for this last step. The resulting pre-catalyst is then hydrothermally treated. This teaches away from the subject matter of the present invention.

United States Patent 8,105,971 issued Jan. 31 , 2012 to Gaffney assigned to Lummus Technology Inc. teaches forming a multi-metal composition comprising Mo, V, Nb, Te and at least one of Ni and Sb; adjusting the pH of the multi-metal composition by adding nitric acid; drying the acidified multi-metal composition; calcining the dried multi-metal composition; and grinding the calcined multi-metal composition. Unfortunately no pH is specified for the addition of nitric acid. The catalyst of the 971 patent contains Sb and Ni which are absent from the catalysts of the present invention. .

United States Patent 8,519,210 issued Aug. 27, 2013 to Arnould et al., assigned to Lummus Technology Inc. contains similar teachings. Again there is no discussion of the desired or required pH. Published United States patent application 2014/0128653 in the name of Bal et al., assigned to the Council of Scientific & Industrial Research, New Delhi teaches preparing a component for an ODH catalyst by mixing titanium

isopropoxide Ti(i-Pr) ₄ , ethanol, and octadecyldimethyl (3-trimethoxy silylpropyl) ammonium chloride in the ratio ranging between 50:3500:1 to 100:3500:1 followed by adjusting pH between 3-10 to obtain a mixed solution. There is no second adjustment of the pH of the solution. This teaches away from the subject

Interestingly paragraph 8 of DE1 12009000404 discloses the problem of reproducability of the catalyst in production of small sacle laboratory proceedures.

W02009022780 in the name of Song et al. assigned to LG Chem, Ltd.

teaches a method to prepare a MoVNbTe catalyst precursor by forming a solution of ammonium paramolybdate, ammonium metavanadate, and telluric acid, and adding thereto a solution of ammonium oxylate. To this solution is added a mixture of oxalic acid, sulphuric acid and hydrogen peroxide. The solution is dried, pulverized and then heat treated. The reference teaches against a present disclosure.

The present seeks to provide a process for the production of ODH catalsyts prepared in a single reactor controlling the pH during the addition of the M, V and Te compounds and subsequently subjecting the pre catalyst to a hydrothermal treatment in which the activity of the catalyst is good and the consistency of the catalys is improved.

SUMMARY OF INVENTION

The present invention seeks to provide a process for preparing a catalyst comprising mixed oxides of MoVNbTe comprising the following steps:

i) forming an aqueous solution of ammonium heptamolybdate

(tetrahydrate) and telluric acid in a molar ratio of Mo:Te 1 : 0.14 to 0.20, in some instances from 1 :0.17, at a temperature from 30°C to 85°C and adjusting the pH of the solution to 6.5 to 8.5, preferably from 7 to 8, most preferably from 7.3 to 7.7 preferably with a nitrogen-containing base to form soluble salts of the metals;

ii) stirring the pH adjusted solution for a time of not less than 15 minutes, in some instances from not less than 2 hours, in some instances not more than 4 hours;

iii) adjust the pH of the resulting solution to from 4.5 to 5.5, preferably from 4.8 to 5.2, desirable from 5.0 to 5.2 with an acid, preferably sulfuric acid (0.01 - 18 M, typically 2-18 M) and stir the resulting solution at a temperature of 80°C until it is homogeneous in some instances with a stirring time up to 30 minutes; In some circumstances, to maintain 80°C temperature, a cooling device needs to be used to maintain temperature at 80°C;

iv) preparing an aqueous solution of vanadyl sulphate at a temperature from room temperature to 80°C (preferably 50°C to 70°C, most preferably 55°C to 65°C);

v) mixing the solutions from steps i) and iv) together to provide a molar ratio of V:Mo from 1.00-1.67 to 1 in some cases from 1.45-1.55 to 1.00;

vi) preparing a solution of H2C2O4 and Nb20sxH20 in a molar ratio from 5.0 to 6:0, in some instances 5.0-5.3:1 ;

vii) slowly (dropwise) adding the solution from step vi) to the solution of step v) to provide molar ratio of Nb:Mo from 5.56-7.14:1 in some instances from 6.20-6.40 to form a slurry; typically the addition is at temperatures between 20°C and 80°C; preferably 20°C to 30°C; and

vii) heating the resulting slurry in an autoclave under an inert gas, air, carbon dioxide, carbon monoxide and mixtures there-of at a pressure of not less than 1 psig and at a temperature from 140°C to 190°C for not less than 6 hours.

In a further embodiment the temperature for the hydrothermal treatment is from 140°C - 180°C, in some embodiments from 145°C to 175°C, preferably 160- 165°C.

In a further embodiment the pressure in the autoclave is 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 a further embodiment the gaseous product species are vented from the reactor (autoclave).

In a further embodiment optionally there is a condenser downstream of the autoclave outlet.

In a further embodiment the condenser is operated at a temperature above 0°C and below reaction temperature.

In a further embodiment that pressure inside the autoclave is maintained above atmospheric using one of the following: a liquid filled column, bubbler or pressure regulating device. In a further embodiment the time of the hydrothermal treatment is not less than 6 hours and in some case 60 hours or more.

In a further embodiment the aqueous slurry comprises Mo, V, Nb and Te salts in a molar ratio; Mo 1 ; V 0.4 to 0.70; Nb 0.14 to 0.18; and Te 0.14 to 0.20.

In a further embodiment the heat treated slurry from step vii) is treated with from 0.3-2.5 ml_ of a 30 wt. % solution of aqueous H2O2 per gram of catalyst precursor.

In a further embodiment the resulting pre-catalyst is separated from the aqueous phase and washed with (distilled) water and dried in an oven for not less than 6 hours at a temperature from 70°C to 120°C.

In a further embodiment optionally the dried precatalyst is ground, typically to a particle size less than 125pm.

In a further embodiment the dried precatalyst is calcined in an inert atmosphere at a temperature from 200°C to 650°C for a time from 1 to 20 hours.

In a further embodiment, the catalyst is ground to a particle size less than 125 micron and then re-dried in an oven at 90°C for not less than 2 hours before being subjected to a calcination procedure.

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 to 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 T1O2, Zr02 AI2O3, AIO(OH), Nb205 and mixtures thereof provided that Zr02 is not used in combination with an aluminum containing binder.

In a further embodiment there is provided a method 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 oxygenated species including CO and CO2 at a temperature greater than 320°C up to 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 over the above catalyst.

In a further embodiment the ODH process has a selectivity to ethylene of not less than 90%.

In a further embodiment 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 . In a further embodiment the temperature of the ODH process is less than 375°C, preferably less than 360°C.

In a further embodiment the catalyst in the ODH process forms a fixed bed.

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.

In the specification the phrase the temperature at which there is 25% conversion of ethane to ethylene is determined by plotting a graph of conversion to ethylene against temperature typically with data points below and above 25% conversion or the data is fit to an equation and the temperature at which there is a 25% conversion of ethane to ethylene is determined. In some instances in the examples the data had to be extrapolated to determine the temperature at which 25% conversion occurred.

In the specification the phrase selectivity at 25% conversion is determined by plotting the selectivity as function of temperature or fit to an equation. Then having calculated the temperature at which 25% conversion occurs one can determine either from the graph or from the equation the selectivity at that temperature.

In this specification non-antagonistic binder means a binder other than Nb205 which when incorporated into the agglomerated catalyst has less than a 5% antagonistic effect on the agglomerated catalysts. Some non-antagonistic binders include oxides of aluminum, titanium and zirconium. Silica oxides have an antagonistic effect on the agglomerated catalysts and the catalyst active sites.

The slurry (gel) has the following stoichiometric ratio: Mo1 :V0.50- 0.70:Te0.14-0.20:Nb0.14-0.18.

The catalysts of the present disclosure comprise mixed oxides of Mo, V, Nb and Te. The catalysts may be represented by the empirical formula:

Mo1.0V0.25-0.38Te0.10-0.i6Nb0.15-0.19Od

where d is a number to satisfy the valence of the oxide.

The catalyst precursor may be prepared by the following steps:

i) forming an aqueous solution of ammonium heptamolybdate

(tetrahydrate) and telluric acid in a molar ratio of Mo:Te 1 : 0.14 to 0.20, in some instances from 1 :0.16 to 1 :0.18 (e.g.1 :0.17), at a temperature from 30°C to 85°C and adjusting the pH of the solution to 6.5 to 8.5, preferably from 7 to 8, most preferably from 7.3 to 7.7 preferably with a nitrogen-containing base such as NH ₄ OH to form water soluble salts of the metals;

ii) stirring the pH adjusted solution for a time of not less than 15 minutes, in some instances from not less than 2, in some instances not more than 4 hours, typically from 2.5 hours to 3.5 hours; iii) adjusting the pH of the resulting solution to from 4.5 to 5.5, preferably from 4.8 to 5.2, desirable from 5.0 to 5.2, with an acid, preferably sulfuric acid (0.01 -18 M, typically 2-18 M) and stirring the resulting solution at a temperature from 75°C to 85°C (typically 80°C) until it is homogeneous in some instances with a stirring time up to 30 minutes; In some circumstances, to maintain the temperature, a cooling device needs to be used;

iv) preparing a 0.30 to 0.50 molar, typically a 0.36 to 0.48 molar, in some embodiments a 0.40 to 0.45 molar aqueous solution of vanadyl sulphate at a temperature from room temperature to 80°C (preferably 50°C to 70°C, most preferably 55°C to 65°C);

v) mixing the solutions from steps iii) and iv) together to provide a molar ratio of V:Mo from 1 .00-1 .67 to 1 .00 in some cases from 1 .45-1 .55 to 1 .00;

vi) preparing a solution of H2C2O4 and Nb20sxH20 in a molar ratio from 3:1 to 6.5:1 , in some instances from 4.5:1 to 6.5:1 , in some instances 6:1 ;

vii) slowly (dropwise) adding the solution from step vi) to the solution of step v) to provide molar ratio of Nb:Mo from 5.56-7.14:1 in some instances from 6.20-6.40; typically the resulting mixture will be a slurry generally a purple/grey colour; and

vii) heating the resulting slurry in an autoclave under an inert gas, air, carbon dioxide, carbon monoxide and mixtures there-of at a temperature from 150°C to 190°C typically for not less than 10 hours at a pressure generally up to 200 psig (1375 kPag)

The initial solution is prepared by dissolving ammonium heptamolybdate (tetrahydrate) ((NH ₄ )6Mozq24·4H2q) in a suitable solvent, typically water. The water is typically at a room temperature (20-25°C) and is stirred at medium speed (for example 150 to 500 rpm typically 250 to 350 rpm, in some embodiments 300 rpm) using a stirrer mechanical or magnetic. The initial solution may be from about 0.3 to 0.5 molar, typically from about 0.3 to 0.4 molar. The ammonium heptamolybdate (tetrahydrate) should dissolve in about 10 minutes forming a clear or turbid solution. A 0.2 to 0.3 molar solution of telluric acid is prepared in water. The solution should be clear before proceeding. The telluric acid solution is added to the ammonium heptamolybdate (tetrahydrate) dropwise at 0.20-0.50 L/min) using a dropper funnel or transfer lines. The resulting solution is clear and colorless. The resulting solution is heated to 80°C. The pH of the solution is measured. Generally it is in the range from about 3.0 to 3.5, typically 3.2 to 3.4. The pH of the solution is adjusted to from 7.2 to 7.7, typically from 7.4 to 7.6, in some embodiments 7 using a water soluble base typically ammonium hydroxide. The resulting solution was kept at 80°C under low agitation for not less than 1 hour, typically from 1 to 6 hours, in some

embodiments from 1 to 2 hours.

An aqueous solution of VOSO4 is prepared by dissolving VOSO4 in a water bath at a temperature from room temperature to 80°C (preferably 50°C to 70°C, most preferably 55°C to 65°C). The solution having a molar concentration of V from 1.30 to 1.70, typically 1.36 to 1.55, in some embodiments 1.50 to 1.55. The solution was clear blue after not less than 30, in some embodiments from 30 to 60 minutes of moderate stirring in the water bath. The solution of VOSO4 was added drop wise over a period of not less than 20 minutes, in some embodiments from 20 to 60 minutes, to the solution of Mo and Te which was maintained at 80°C to provide a molar ratio of V:Mo from 25:1 to 30:1 , in some instances 27 to 38 to 1 , typically 34-36 to 1. The resulting solution was a clear light blue. The solution was stirred under medium agitation, from 200 to 400 rpm, in some embodiments typically from 250 to 350 rpm in some embodiments from 275 to 325 rpm while the solution cooled to room temperature.

In some embodiments the vanadyl sulfate solution may be buffered with a glycine/sulphuric acid buffer. Other buffers would be known to those skilled in the art.

An aqueous solution of C2H2O4 and Nb20sxH20 in a molar ratio from 3:1 to 10:1 , typically from 4:1 to 7:1 typically 6:1 was prepared at 60 to 70°C with moderate stirring -100 to 300 rpm for from 16 to 30 hours, in some instances from 22 to 26 hours. This results in a turbid solution of niobium oxalate. The niobium oxalate solution was added drop wise to the solution of MoTeVOx with stirring at a rate from 700 to 1400 rpm, in some instances from 900 to 1300 rpm to provide molar ratio of Nb:V from 0.85 to 0.95:1 , in some instances from 0.89:1 to 0.91 :1. A precipitate began to form and the resulting slurry was purple/gray.

The resulting slurry was transferred to a pressurized reactor (e.g. Parr reactor or an autoclave) under an inert atmosphere and heated at 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.

The reactor is allowed to cool to room temperature, typically overnight. The reactor contents were filtered using a Buchner filter and washed with (distilled) water or an aqueous oxalic acid solution and dried in an oven for not less than 6 hours at a temperature from 70°C to 120°C. The dried precatalyst is ground, typically to a size less than 125 pm and calcined in an inert atmosphere such as nitrogen, at a temperature from 200°C to 650°C for a time from 1 to 20 hours.

In some embodiments the precatalyst is separated from the aqueous phase, typically by filtration or evaporation, and washed with (distilled or deionized) water or a (dilute) aqueous oxalic acid solution and dried in an oven for not less than 6 hours at a temperature from 70°C to 120°C. The precatalyst may be dried in an atmosphere of one or more inert gases or the atmosphere may contain oxygen (e.g. air). In some instances optionally, the dried precatalyst may be ground using mechanical means (e.g. a ball or roller mill) or the dried precatalyst could be subject to cryogenic grinding. The dried and ground precatalyst may in some instances be subject to sieving through a small particle size sieve to obtain a fraction having a particle size less than 250 microns, preferably less than 125 microns.

In some embodiments the product from the hydrothermal treatment is treated with from 0.3-2.5 ml_ of a 30 wt. % solution of aqueous H2O2 per gram of catalyst precursor. Generally the catalyst precursor (i.e. prior to calcining) has the formula:

Mo1.0V0.10-049Te0.06-0.17Nb0.13-0.19Od:

The calcined catalyst has the formula:

Mo1 V0.40-0.45Te0.06- 0.i6Nb0.13-0.i6Od. .

If the precatalyst is treated hydrothermally at pressures of less than about 10 psig (68.9 kPag), it has the formula:

Mo1.0V0.17-0.20Te0.06-0.07Nb0.19-0.20Od

If the hydrothermal treatment is conducted at pressures greater than 30 psig ((206 kPag) the precatalyst has the formula:

MoV0.40-0.45Te0.10-0.i 6Nb0.13-0.i6Od

The calcined catalyst has an XRD having a main peaks at 2 F at 22° having a half height peak width from 19 to 21 and broad secondary peak at 28° having a half width from 25 to 33°.

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 T1O2, Zr02 AI2O3, AIO(OH), Nb205 and mixtures thereof provided that Zr02 is not used in combination with an aluminum containing binder.

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 over 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 375°C, preferably less than 360°C.

In a further embodiment the catalyst in the ODH process forms a fixed bed.

In one embodiment the present invention provides a process for preparing a catalyst comprising mixed oxides of MoVNbTe comprising the following steps: i) forming an aqueous solution of ammonium heptamolybdate

(tetrahydrate) and telluric acid in a molar ratio of Mo:Te 1 : 0.14 to 0.20, at a temperature from 30°C to 85°C and adjusting the pH of the solution to 6.5 to 8.5, with a nitrogen-containing base to form soluble salts of the metals;

ii) stirring the pH adjusted solution for a time of not less than 15 minutes; iii) adjusting the pH of the resulting solution to from 4.5 to 5.5, with an acid, and stirring the resulting solution at a temperature of 75 to 85°C until it is homogeneous;

iv) preparing an aqueous 0.30 to0.50 molar solution of vanadyl sulphate at a temperature from room temperature to 80°C;

v) mixing the solutions from steps i) and iv) together to provide a molar ratio of V:Mo from 25 - 30 to 1 ;

vi) preparing a solution of H2C2O4 and Nb20sxH20 in a molar ratio from 3:1 to 6.5:1 ;

vii) slowly adding the solution from step vi) to the solution of step v) to provide molar ratio of Mo:Nb from 5.56 to 7.14:1 to form a slurry; and

viii) heating the resulting slurry in an autoclave under an inert gas, air, carbon dioxide, carbon monoxide and mixtures thereof at a pressure of not less than 1 psig at a temperature from 140°C to 190°C for not less than 6 hours.

In a further embodiment the present invention provides in combination with one or more other embodiments a process wherein the temperature for the hydrothermal treatment is from 140°C - 180°C.

In a further embodiment the present invention provides in combination with one or more other embodiments a process wherein the pressure in the autoclave is from 1 to 200 psig [(206 kPag to 1375 kPag), above atmospheric pressure.

In a further embodiment the present invention provides in combination with one or more other embodiments a process wherein the gaseous product species are vented from the reactor.

In a further embodiment the present invention provides in combination with one or more other embodiments a process wherein there is a condenser upstream of the autoclave outlet.

In a further embodiment the present invention provides in combination with one or more other embodiments a process wherein the condenser is operated at a temperature above 0°C and below reaction temperature.

In a further embodiment the present invention provides in combination with one or more other embodiments a process wherein the pressure inside the autoclave is maintained above atmospheric using a liquid filled column or bubbler or pressure regulating device.

In a further embodiment the present invention provides in combination with one or more other embodiments a process wherein the time of the hydrothermal treatment is from 6 to 60 hours.

In a further embodiment the present invention provides in combination with one or more other embodiments a process wherein the aqueous slurry fed to the autoclave comprises Mo, V, Nb and Te salts in a molar ratio; Mo 1 ;V 0.40 to 0.70;Nb 0.14 to 0.18; and Te 0.14 to 0.20.

In a further embodiment the present invention provides in combination with one or more other embodiments a process wherein heat treated slurry from step viii) is treated with from 0.3-2.5 ml_ of a 30 wt. % solution of aqueous H2O2 per gram of catalyst precursor.

In a further embodiment the present invention provides in combination with one or more other embodiments a process wherein the precatalyst from step viii) is separated from the aqueous phase and washed with (distilled) water or an aqueous oxalic acid solution and mixtures thereof and dried in an oven for not less than 6 hours at a temperature from 70°C to 120°C.

In a further embodiment the present invention provides in combination with one or more other embodiments a process wherein the dried precatalyst is ground, to a particle size less than 125pm. The dried catalyst may also be pre-dried in a 90°C oven for no less than 6 hours before calcination.

In a further embodiment the present invention provides in combination with one or more other embodiments a process wherein the dried precatalyst is calcined in an inert atmosphere at a temperature from 200°C to 650°C for a time from 1 to 20 hours.

In a further embodiment the present invention provides in combination with one or more other embodiments a process where the calcined material (catalyst) is mixed with 0.1 -10 weight % (relative to catalyst) Nb20sxH20 at 90°C in water then dried at 300°C in air.

In a further embodiment the present invention provides in combination with one or more other embodiments a process wherein from 10 to 95, weight % of the catalyst is bound or agglomerated with from 5 -90, weight % of a binder selected from the group consisting of acidic, basic or neutral binder slurries of T1O2, Zr02 AI2O3, AIO(OH), Nb205 and mixtures thereof provided that Zr02 is not used in combination with an aluminum containing binder.

In a further embodiment the present invention provides in combination with one or more other embodiments a method 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 oxygenated species including CO and CO2 at a temperature greater than 320°C up to 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 over a catalyst prepared according to any previous embodiment or combinations thereof.

In a further embodiment the present invention provides in combination with one or more other embodiments a method for the oxidative dehydrogenation of a lower C2-4 paraffin typically ethane to the corresponding olefin(s) having a selectivity to olefin typically ethylene of not less than 90% at a target ethane conversion of greater than 25-35%, typically 35%.

In a further embodiment the present invention provides in combination with one or more other embodiments a method for the oxidative dehydrogenation of a lower C2-4 paraffin typically ethane to the corresponding olefin(s) wherein the gas hourly space velocity of the ODH process is not less than 500 hr ¹ .

In a further embodiment the present invention provides in combination with one or more other embodiments a method for the oxidative dehydrogenation of a lower C2-4 paraffin typically ethane to the corresponding olefin(s) wherein the temperature is less than 375°C.

In a further embodiment the present invention provides in combination with one or more other embodiments a method for the oxidative dehydrogenation of a lower C2-4 paraffin typically ethane to the corresponding olefin(s) wherein the catalyst in the ODH process forms a fixed bed.

The following comparative example and examples of preparations in accordance with the present disclosure illustrate the invention.

Synthesis reaction with no pH adjustments: TABLE 1

Procedure:

• 1 1.37 g of Nb20 ₅ .XH ₂ 0 was charged into a 250 imL RBF with a magnetic stir bar and 130 mL of distilled H2O (dFteO) forming a milky white suspension.

• While this mixture was stirring 19.00 g of oxalic acid was charged into the 250 mL RBF.

• This mixture was left to stir overnight at 65°C and left to stir for 24 h (using a silicon oil bath) stirring at 300 rpm.

· The mixture was an opaque milky color.

• After 24 h of stirring at 65°C the solution was a turbid and colorless solution.

• To a 2 neck 500 mL RBF was charged 84.3011 g of (NFI ₄ )6Mo024.4Fl20 and 300 mL of dFteO.

· This mixture was stirred to dissolve, dissolution time = 7 minutes at 400 rpm.

• To a 300 mL beaker was charged 18.3022 g of Te(OFI)6 and 100 mL of dFteO and stirred to dissolve at RT at 400 rpm.

• The dissolution time for this mixture is 5 minutes.

· The now clear and colorless solution of telluric acid was charged dropwise into the clear and colorless (NFI ₄ )6M07O24.4Fl2O solution using a dropper funnel, the addition time was 15 minutes and the resulting pH was 3.0.

• The solution temperature was increased to 80°C using an oil bath, heating time to reach 80°C was 30 minutes.

· 70.31 g of VOSO4 was charged into a 250 mL beaker along with 100 mL of dH ₂ 0.

• This mixture was stirred to dissolve in a 60°C water bath, dissolution time was 30 minutes. • The now clear blue solution was charged dropwise to the 60°C MoTe solution from the previous step dropwise using an addition funnel, addition time was 20 minutes.

• The solution turns from a clear colorless solution to a dark purple / brown colored slurry.

• The pH of the resulting solution was 2.5 at 80°C.

• This slurry was cooled to RT, while stirring at 500 rpm the cool down time was approximately 1 hr.

• After the slurry had completely cooled to RT the Nb oxalate solution that was prepared previously and then held for later use was charged dropwise into the 2L RBF using an addition funnel, the previously thin slurry became thick after the addition on Nb and resulted in a grey / purple thick slurry.

• The addition time for the Niobium Oxalate was 20 minutes.

• The slurry was transferred to a 2L PARR reactor glass liner, which was placed inside the 2L PARR reactor.

• The sealed PARR reactor was evacuated and backfilled 10 x with nitrogen and vacuum, leaving 15 psi of nitrogen in the PARR reactor.

• The reactor was attached to the condenser / back pressure regulator set up with the overhead agitator stand.

• The sealed reactor was left to stir overnight at RT

• The following day the 15 psi left in the PARR reactor was vented through the condenser and back pressure regulator setup.

• The heater for the PARR reactor was set to 185°C, the inside thermowell target temperature is 175°C.

• After 6 h the heater to the PARR reactor was turned off and the reactor was left to cool overnight.

• The following day the purple slurry was filtered through 4 x Whatmann #4 filter papers.

• Filtration took 18 hours.

• The filtered powder was dried at 90°C overnight

Example 1

Example 1 : In situ preparation of catalyst with pH adjustments: TABLE 2

Step 1 : Addition of Materials in situ

Procedure:

• To a 2 neck round bottom flask (RBF) was charge 84.29 g of

(NH ) ₆ M07O24-4H ₂ O.

• To this 2L two neck RBF was charge 300 mL of distilled water.

• The mixture was left to stir to dissolve, approximately 5 minutes to fully dissolve.

• To a 300 mL beaker was charged 18.29 g of Te(OFI)6.

• To this beaker charge 100 mL of distilled water.

• This salt / water mixture was stirred to dissolve in the distilled water at room temperature.

• Dissolution time 8 - 10 minutes.

• ^* The resulting solution should be clear and colorless.

• The now clear and colorless solution of Te(OFI)6 is charged dropwise to the solution of (NFI ₄ )6Mo7024 through a dropper funnel.

• Addition time 10 - 12 minutes.

• Calibrate a pH probe to both a pH of 7 and a pH of 4

• Affix a pH probe to one of the two inlets of the two neck round bottom flask.

• Increase the temperature of the solution to 80°C.

• Monitor the pH until the temperature reaches 80°C.

• pH of solution should be around 3.3 at 80°C. • Adjust the pH of the solution from 3.3 to 7.5 using NH ₄ OH using a dropper funnel and starting with at least 45 mL of NH ₄ OH.

• Approximately 38-40 mL of NH ₄ OH may be required to adjust the pH.

• Agitate the pH adjusted solution at 80°C for 3 hours.

· To a beaker charge 70.32 g of VOSO4 and 100 mL of distilled water.

• This mixture was stirred to dissolve in a 60°C water bath.

• Agitate the mixture for 30 minutes.

• The result should be a clear blue solution.

• This solution is to be held for later use.

· Recalibrate the pH probe to pH 7 and pH 4 respectively.

• The pH meter was affixed to the 2 neck round bottom flask.

• The temperature was slowly increased while monitoring the pH as it approached 80°C.

TABLE 3

• Once the solution mixture reached 80.0°C the pH was measured at 3.1 1 .

• 50 mL of NH ₄ OH was charged into a 250 mL addition funnel to the catalyst mixture at 80°C.

• The pH was slowly adjusted dropwise using an addition funnel. TABLE 4

• The pH probe was removed and the solution was left to stir at 80°C for 3 hours.

· To a separate 300 mL beaker was charged 100 mL of distilled water.

• This beaker was placed into a 60°C water bath and stirred to dissolve in the warm water bath.

• After 30 minutes the solution became clear and blue in color, this solution was held at 60°C for later use.

· The pH adjusted MoTe clear colorless solution was adjusted back to 5.01 at 80°C using sulphuric acid.

• 100 mL of sulphuric acid was charged into a 250 mL addition funnel.

• The pH of the solution was adjusted dropwise using this addition funnel.

TABLE 5

• 79 mL of sulphuric acid was required to adjust the pH of the solution to

5.01.

• The solution remained clear and colorless.

• The VOSO4 clear blue solution that was being held at 60°C was charged into a 250 mL dropper funnel and added dropwise into the 2L RBF over 20 minutes at 80°C.

• 1 1.37g of Nb205xH20 was weighed into a 250 mL RBF; approximately 127 mL of distilled H2O and a magnetic stirbar was added to the RBF. While stirring, 19.09 g of H2C2O4 was added to the RBF. The RBF was put into an oil bath and heated to approximately 65°C for approximately 24 hours.

• The MoTeVOx containing solution was left to stir 300 rpm for 30 minutes while the temperature was reduced to room temperature.

• After the clear and colorless MoTeVOx containing solution had returned to room temperature the Niobium Oxalate solution (a turbid solution) that was set aside was charged into a 500 mL addition funnel.

• This solution was charged dropwise to the MoTeVOx containing solution via the addition funnel.

• Stir rate was increased to 1 100 rpm.

• Precipitate began to form during this addition.

• The purple/grey slurry was transferred to a 2L PARR reactor glass liner

• The PARR reactor was sealed, evacuated and back filled 10 times with 15 psi N2.

• PARR reactor was left under 15 psi nitrogen, insulated and connected to a backpressure regulator set-up stirring at 300 rpm.

• The reactor was left to stir sealed overnight.

Step 2: Hydrothermal Treatment

• The N2 (g) left in the PARR reactor was used to purge the set up.

• During the purging the backpressure regulator was dialed down to 160 psi.

• The PARR reactor was left stirring at 300 rpm. • PARR reactor set up was heated using a heat controller.

TABLE 6

• Ramp rate required for reactor to reach temperature was 10 minutes. · DT between heating jacket and thermowell was 7°C.

• The PARR reactor was stirred (300 rpm) at this temperature (185°C jacket and 172°C) for 6 hours.

• PARR reactor was left to cool overnight.

• PARR reactor contents were filtered using a Buchner filtration apparatus and external vacuum set up.

• Approximately 500 mL of distilled water was used to rinse the filter cake.

• At this point the filtrate ran clear.

Example 2

Synthesis of catalyst performed in situ while decreasing the temperature;

TABLE 7

Step 1 : Addition of Materials in situ

Procedure:

• To a 2 neck round bottom flask (RBF) was charge 84.29 g of

(NH ₄ )6Mq7q24·4H2q.

• To this 2L two neck RBF was charge 300 mL of distilled water. The mixture was left to stir to dissolve, approximately 5 minutes to fully dissolve.

• To a 300 ml_ beaker was charged 18.29 g of Te(OH)6.

• To this beaker charge 100 ml_ of distilled water.

• This salt / water mixture was stirred to dissolve in the distilled water at room temperature.

• Dissolution time 8 - 10 minutes.

• ^* The resulting solution should be clear and colorless.

• The now clear and colorless solution of Te(OH)6 is charged dropwise to the solution of (NH ₄ )6Mozq24 through a dropper funnel.

• Addition time 10 - 12 minutes.

• Calibrate a pH probe to both a pH of 7 and a pH of 4.

• Affix a pH probe to one of the two inlets of the two neck round bottom flask.

• Increase the temperature of the solution to 80°C.

• Monitor the pH until the temperature reaches 80°C.

• pH of solution should be around 3.3 at 80°C.

• Adjust the pH of the solution from 3.3 to 7.5 using NH ₄ OH using a dropper funnel and starting with at least 45 ml_ of NH ₄ OH.

• Approximately 38-40 ml_ of NH ₄ OH may be required to adjust the pH.

• Agitate the pH adjusted solution at 80°C for 3 hours.

• To a beaker charge 70.32 g of V0S04 and 100 ml_ of distilled water.

• This mixture was stirred to dissolve in a 60°C water bath.

• Agitate the mixture for 30 minutes.

• The result should be a clear blue solution.

• This solution is to be held for later use.

• Recalibrate the pH probe to pH 7 and pH 4 respectively.

• The pH meter was affixed to the 2 neck round bottom flask.

• The temperature was slowly increased while monitoring the pH as it approached 80°C. TABLE 8

• Once the solution mixture reached 80.0°C the pH was measured at 3.1 1.

• 50 mL of NH ₄ OH was charged into a 250 mL addition funnel to the catalyst mixture at 80°C.

• The pH was slowly adjusted dropwise using an addition funnel.

TABLE 9

• The pH probe was removed and the solution was left to stir at 80°C for 3 hours.

• To a separate 300 mL beaker was charged 100 mL of distilled water.

• This beaker was placed into a 60°C water bath and stirred to dissolve in the warm water bath.

• After 30 minutes the solution became clear and blue in color, this solution was held at 60°C for later use.

• The pH adjusted MoTe clear colorless solution was adjusted back to 5.01 at 80°C using sulphuric acid.

• 100 mL of sulphuric acid was charged into a 250 mL addition funnel. • The pH of the solution was adjusted dropwise using this addition funnel.

TABLE 10

• 79 mL of sulphuric acid was required to adjust the pH of the solution to 5.01.

• The solution remained clear and colorless.

• The V0S04 clear blue solution that was being held at 60°C was charged into a 250 mL dropper funnel and added dropwise into the 2L RBF over 20 minutes at 80°C.

· 1 1.37g of Nb205xH20 was weighed into a 250 mL RBF; approximately

127 mL of distilled H2O and a magnetic stirbar was added to the RBF. While stirring, 19.09 g of H2C2O4 was added to the RBF. The RBF was put into an oil bath and heated to approximately 65°C for approximately 24 hours.

• The MoTeVOx containing solution was left to stir 300 rpm for 30 minutes while the temperature was reduced to room temperature.

• After the clear and colorless MoTeVOx containing solution had returned to room temperature the Niobium Oxalate solution (a turbid solution) that was set aside was charged into a 500 mL addition funnel.

• This solution was charged dropwise to the MoTeVOx containing solution via the addition funnel.

• Stir rate was increased to 1 100 rpm. • Precipitate began to form during this addition.

• The purple/grey slurry was transferred to a 2L PARR reactor glass liner.

• The PARR reactor was sealed, evacuated and back filled 10 times with

15 psi N2.

• PARR reactor was left under 15 psi nitrogen, insulated and connected to a backpressure regulator set-up stirring at 300 rpm.

• The reactor was left to stir sealed overnight.

Step 2: Hydrothermal Treatment

• The N2 (g) left in the PARR reactor was used to purge the set up.

• During the purging the backpressure regulator was dialed down to 160 psi.

• The PARR reactor was left stirring at 300 rpm.

• PARR reactor set up was heated using a heat controller.

• As the PARR reactor was heated up the pressure was dialed down to

100 psi.

TABLE 1 1

• Ramp rate required for reactor to reach temperature was 10 minutes.

• DT between heating jacket and thermowell was 7°C.

• The PARR reactor was stirred (300 rpm) at this temperature (157°C jacket and 120°C) overnight.

• PARR reactor was left to cool overnight.

• PARR reactor contents were filtered using a Buchner filtration apparatus and external vacuum set up.

• Approximately 500 mL of distilled water was used to rinse the filter cake.

• At this point the filtrate ran clear.

The catalyst samples were tested for the dehydrogenation of ethane to ethylene. The catalyst samples of were loaded into a fixe bed reactor and ethane was passed through the sample. The activity at 25% conversion and selectivity at 25% conversion were recorded for each sample. TABLE 12

Catalyst Activities

The Examples show that catalysts prepared using the pH adjustment as described above have a 25% conversion at lower temperatures than the catalyst prepared without the pH adjustment (i.e. the catalysts are more reactive). Also, the catalysts prepared using the pH adjustment as described above have a slightly higher conversion to ethylene at 25% conversion.

INDUSTRIAL APPLICABILITY

The productivity of an oxidative dehydrogenation catalyst prepared using a hydrothermal process is improved by adjusting the pH of a precursor solution of ammonium heptamolybdate (tetrahydrate) and telluric acid to from 4.5 to 5.5, using an acid, preferably sulphuric acid.