阅读说明：本技术 钼-碲-钒-铌基odh催化剂的制备方法 (Preparation method of molybdenum-tellurium-vanadium-niobium-based ODH catalyst ) 是由 高效良 M·巴恩斯 V·西蒙申科夫 D·沙利文 Y·金 H·德拉格 P·德维特 于 2019-01-29 设计创作，主要内容包括：可通过以下原位制备高活性ODH催化剂或前体而不分离中间体物种：在约3.3至7.5的pH下混合Mo、Te的溶液,将所得溶液的pH调回到约5,并添加VOSO<Sub>4</Sub>并添加Nb<Sub>2</Sub>O<Sub>5</Sub>和草酸的溶液,并在受控压力的水热法中处理所得的前体浆体以获得最终的催化剂,然后可将其从浆体中分离出来。(The high activity ODH catalyst or precursor can be prepared in situ without isolation of intermediate species by: mixing a solution of Mo, Te at a pH of about 3.3 to 7.5, adjusting the pH of the resulting solution back to about 5, and adding VOSO 4 And adding Nb 2 O 5 And oxalic acid, and treating the resulting precursor slurry in a controlled pressure hydrothermal process to obtain the final catalyst, which can then be separated from the slurry.)

1. A method of preparing a catalyst comprising a mixed oxide of MoVNbTe, the method comprising the steps of:

i) forming an aqueous solution of ammonium heptamolybdate (tetrahydrate) and telluric acid at a Mo: Te molar ratio of 1: 0.14 to 0.20 at a temperature of 30 ℃ to 85 ℃ and adjusting the pH of the solution to 6.5 to 8.5 with a nitrogenous base to form a soluble salt of the metal;

ii) stirring the pH adjusted solution for a time of not less than 15 minutes;

iii) adjusting the pH of the resulting solution to 4.5 to 5.5 with an acid and stirring the resulting solution at a temperature of 75 to 85 ℃ until homogeneous;

iv) preparing an aqueous solution of 0.30 to 0.50 moles of vanadyl sulfate at a temperature of room temperature to 80 ℃;

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

vi) preparation of H in a molar ratio of 3:1:1 to 6.5: 1₂C₂O₄And Nb₂O₅xH₂A solution of O;

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

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

2. The method of claim 1, wherein the temperature for the hydrothermal treatment is 140-180 ℃.

3. The process of claim 1, wherein the pressure in the autoclave is from 1 to 200 psig [ above atmospheric, (206 kPag to 1375kPag) ].

4. The method of claim 1, wherein gaseous product species are vented from the reactor.

5. The process of claim 4, wherein there is a condenser upstream of the autoclave outlet.

6. The method of claim 5, wherein the condenser is operated at a temperature above 0 ℃ and below the reaction temperature.

7. The method of claim 4, wherein the pressure within the autoclave is maintained above atmospheric pressure using a liquid packed column or bubbler or a pressure regulating device.

8. The method of claim 1, wherein the hydrothermal treatment is for a time of 6 to 60 hours.

9. The method of claim 1, wherein the aqueous slurry fed to the autoclave comprises Mo, V, Nb, and Te salts in molar ratios of Mo 1, V0.40 to 0.70, Nb0.14 to 0.18, and Te0.14 to 0.20.

10. The process of claim 9, wherein the heat-treated slurry from step viii) is treated with 0.3-2.5 mL of 30 wt.% H per gram of catalyst precursor₂O₂And (4) treating with an aqueous solution.

11. The process of claim 1, 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 at a temperature of 70 ℃ to 120 ℃ for not less than 6 hours.

12. The method of claim 11, wherein the dried pre-catalyst is ground to a particle size of less than 125 μm, the dried catalyst may also be pre-dried in a 90 ℃ oven for not less than 6 hours prior to calcination.

13. The method of claim 12, wherein the dried precatalyst is calcined in an inert atmosphere at a temperature of from 200 ℃ to 650 ℃ for a time of from 1 to 20 hours.

14. The method according to claim 13, wherein the calcined material is admixed with 0.1-10 wt.% (relative to catalyst) of Nb₂O₅xH₂O was mixed in water at 90 ℃ and then dried in air at 300 ℃.

15. The method of claim 14, wherein 10 to 95 weight percent of the catalyst is mixed with 5 to 90 weight percent of a catalyst selected from TiO₂、ZrO₂、Al₂O₃、AlO(OH)、Nb₂O₅And mixtures thereof, with the proviso that ZrO is not bound or agglomerated₂In combination with an aluminum-containing binder.

16. At a temperature of above 320 deg.C to below 385 deg.C for not less than 100hr^-1And a pressure of 0.8 to 7 atmospheres, the mixed feed comprising ethane and oxygen in a volume ratio of 70:30 to 95:5, optionally one or more C_3-6Alkanes or alkenes and including CO and CO₂The method comprising passing the mixture over a catalyst prepared according to claim 1.

17. The process according to claim 16, having a selectivity to ethylene of not less than 90%, with a target ethane conversion of more than 25-35%, typically 35%.

18. The process of claim 17, wherein the gas hourly space velocity of the ODH process is not less than 500hr^-1。

19. The method of claim 18, wherein the temperature is less than 375 ℃.

20. The process according to claim 19, wherein the catalyst in the ODH process forms a fixed bed.

Technical Field

The invention relates to a method for carefully controlling the pH of a solution during the addition of Mo, Te and V components in a single reactor, and then adding Nb₂O₅And oxalic acid without isolation of intermediate components to prepare an oxidative dehydrogenation catalyst (ODH) precursor. The resulting precursor (typically a slurry) is then subjected to a controlled pressure hydrothermal process and the final catalyst may optionally be further treated with peroxide. The method is highly reproducible.

Background

There are many patents that teach hydrothermal processes in autoclaves. Representative of such techniques are the following patents.

U.S. patent 7,319,179 issued to Lopez Nieto et al, to concejo Superior deivestigiosis cis, university political De Valencia, on 15.1.2008, teaches in example 1 the formation of 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 aqueous ammonia. The resulting solution was dried, then dissolved in water and vanadyl sulfate and niobium (V) oxalate were added to the solution. The pH control is not discussed for this last step. The resulting precatalyst is then subjected to a hydrothermal treatment. This teaching is remote from the subject matter of the present invention.

U.S. patent 8,105,971 issued to Gaffney on 31/2012, and assigned to Lummus Technology Inc. teaches forming a multimetallic composition comprising Mo, V, Nb, Te and at least one of Ni and Sb; adjusting the pH of the multimetal composition by adding nitric acid; drying the acidified multimetal composition; calcining the dried multimetallic composition; and grinding the calcined multimetal composition. Unfortunately, the pH at which nitric acid is added is not specified. The catalyst of the' 971 patent contains Sb and Ni that are not present in the catalyst of the present invention.

Us patent 8,519,210 issued to Arnould et al, entitled Lummus Technology inc, 8/27 in 2013 contains similar teachings. Also, the desired or required pH is not discussed.

Under the name of Bal et al, from Council of Scientific&Published U.S. patent application 2014/0128653 to Industrial Research (New Delhi) teaches the use of titanium isopropoxide Ti (i-Pr) by mixing in a ratio ranging between 50:3500:1 and 100:3500:1₄Ethanol and octadecyl dimethyl (3-trimethoxysilylpropyl) ammonium chloride, then adjusting the pH to between 3 and 10 to obtain a mixed solution to prepare the components of the ODH catalyst. There was no second adjustment of the pH of the solution. This teaching is remote from the present subject matter.

Interestingly, paragraph 8 of DE112009000404 discloses a problem of reproducibility of catalysts in the production of small-scale laboratory procedures.

WO2009022780 in the name of Song et al, assigned to LG Chem, ltd, teaches a process for preparing a MoVNbTe catalyst precursor by forming a solution of ammonium paramolybdate, ammonium metavanadate and telluric acid and adding a solution of ammonium oxalate thereto. To this solution is added a mixture of oxalic acid, sulfuric acid and hydrogen peroxide. The solution is dried, crushed and then heat treated. The teachings of this reference are contrary to this disclosure.

The present invention seeks to provide a method of producing an ODH catalyst prepared by controlling the pH during the addition of M, V and Te compounds in a single reactor and then subjecting a pre-catalyst to hydrothermal treatment, in which the activity of the catalyst is good and the consistency of the catalyst is improved.

Disclosure of Invention

The present invention seeks to provide a method of preparing a catalyst comprising a mixed oxide of MoVNbTe, the method comprising the steps of:

i) forming an aqueous solution of ammonium heptamolybdate (tetrahydrate) and telluric acid at a Mo: Te molar ratio of from 1: 0.14 to 0.20, in some cases from 1: 0.17, at a temperature of from 30 ℃ to 85 ℃ and adjusting the pH of the solution preferably to from 6.5 to 8.5, preferably from 7 to 8, most preferably from 7.3 to 7.7 with a nitrogenous base to form a soluble salt of the metal;

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

iii) adjusting the pH of the resulting solution to 4.5 to 5.5, preferably 4.8 to 5.2, ideally 5.0 to 5.2, with an acid, preferably sulphuric acid (0.01-18M, usually 2-18M) and stirring the resulting solution at a temperature of 80 ℃ until homogeneous, in some cases for a period of up to 30 minutes; in some cases, to maintain a temperature of 80 ℃, a cooling device needs to be used to maintain the temperature at 80 ℃;

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

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

vi) producing H at a molar ratio of 5.0-6: 0, and in some cases 5.0-5.3: 1₂C₂O₄And Nb₂O₅xH₂Solution of O；

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

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

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

In further embodiments, the pressure in the autoclave is from 30 to 200 psig (206 kPag to 1375kPag), in some embodiments from 55 psig (380 kPag) to 170 psig (1170kPag) above atmospheric pressure.

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

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

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

In a further embodiment, the pressure within the autoclave is maintained above atmospheric pressure using one of the following: a liquid packed column, a bubbler or a pressure regulating device.

In further embodiments, the time of the hydrothermal treatment is not less than 6 hours, and in some cases 60 hours or more.

In a further embodiment, the aqueous slurry comprises Mo, V, Nb, and Te salts in a molar ratio of Mo 1, V0.4 to 0.70, Nb0.14 to 0.18, and te0.14 to 0.20.

In a further embodiment, the heat treated slurry from step vii) is treated with 0.3-2.5 mL of 30 wt% H per gram of catalyst precursor₂O₂And (4) treating with an aqueous solution.

In a further embodiment, the resulting precatalyst is separated from the aqueous phase and washed with (distilled) water and dried in an oven at a temperature of 70 ℃ to 120 ℃ for not less than 6 hours.

In a further embodiment, the dried pre-catalyst is optionally ground, typically to a particle size of less than 125 μm.

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

In a further embodiment, the catalyst is ground to a particle size of less than 125 microns prior to being subjected to the calcination procedure and then re-dried in an oven at 90 ℃ for no less than 2 hours.

In a further embodiment, 10 to 95 wt%, preferably 25 to 80 wt%, ideally 30 to 45 wt% of the catalyst is mixed with 5 to 90 wt%, preferably 20 to 75 wt%, ideally 55 to 70 wt% of a catalyst selected from TiO₂、ZrO₂、Al₂O₃、AlO(OH)、Nb₂O₅And mixtures thereof, with the proviso that ZrO is not bound or agglomerated₂In combination with an aluminum-containing binder.

In a further embodiment, a method of treating a mammal at a temperature of greater than 320 ℃ to less than 385 ℃ for not less than 100hr is provided^-1And a pressure of 0.8 to 7 atmospheres, the mixed feed comprising ethane and oxygen in a volume ratio of 70:30 to 95:5, and optionally one or more C_3-6Alkanes or alkenes and including CO and CO₂The method comprising passing the mixture over the above catalyst.

In a further embodiment, the ODH process has a selectivity to ethylene of no less than 90%.

In a further embodiment, the gas hourly space velocity of the ODH process is not less than 500hr^-1Ideally not less than 1500hr^-1In some embodiments not less than 3000 hr^-1。

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

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

Detailed Description

Numerical range

Other than in the operating examples, or where otherwise indicated, all numbers or expressions referring to quantities of ingredients, reaction conditions, and the like, 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 may vary depending upon the desired properties to be obtained by the present invention. 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 value, however, inherently contains 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 the recited minimum value of 1 and the recited maximum value of 10 and all sub-ranges including the recited minimum value of 1 and the recited maximum value of 10; i.e. having a minimum value equal to or greater than 1 and a maximum value 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.

In practice, all compositional ranges expressed herein are limited to and do not exceed 100% (volume percent or weight percent) in total. Where multiple components may be present in the composition, the sum of the maximum amounts of each component may exceed 100%, but it will be understood and readily appreciated by those skilled in the art that the amounts of components actually used will correspond to a maximum of 100%.

In this specification, the expression of the temperature at which 25% conversion of ethane to ethylene occurs is determined by plotting the conversion to ethylene versus temperature, typically with data points below and above 25% conversion, or fitting the data to an equation and determining the temperature at which 25% conversion of ethane to ethylene occurs. In some cases in the examples, the data must be extrapolated to determine the temperature at which 25% conversion occurs.

In the present specification, the expression selectivity at 25% conversion is determined by plotting the selectivity as a function of temperature or fitting to an equation. Thus, after calculating the temperature at which 25% conversion occurs, the selectivity at that temperature can be determined from the graph or from the equation.

In this specification, non-antagonistic binder refers to non-Nb₂O₅When incorporated into an agglomerated catalyst, has less than 5% antagonism of the agglomerated catalyst. Some non-antagonistic binders include oxides of aluminum, titanium, and zirconium. Silica oxides have an antagonistic effect on agglomerated catalysts and catalyst active sites.

The slurry (gel) had the following stoichiometric ratio: mo 1, V0.50-0.70, Te 0.14-0.20 and Nb0.14-0.18.

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

Mo_1.0V_0.25-0.38Te_0.10-0.16Nb_0.15-0.19O_d

wherein d is a number satisfying the valence of the oxide.

The catalyst precursor may be prepared by the steps of:

i) an aqueous solution of ammonium heptamolybdate (tetrahydrate) and telluric acid is formed at a Mo: Te molar ratio of from 1: 0.14 to 0.20, in some cases from 1: 0.16 to 1: 0.18 (e.g., 1: 0.17) at a temperature of from 30 ℃ to 85 ℃ and preferably with a nitrogen containing base such as NH₄OH to adjust the pH of the solution to 6.5 to 85, preferably 7 to 8, most preferably 7.3 to 7.7 to form soluble salts of the metal;

ii) stirring the pH adjusted solution for a period of not less than 15 minutes, in some cases not less than 2 hours, in some cases not more than 4 hours, typically from 2.5 hours to 3.5 hours;

iii) adjusting the pH of the resulting solution to 4.5 to 5.5, preferably 4.8 to 5.2, ideally 5.0 to 5.2 with an acid, preferably sulphuric acid (0.01-18M, usually 2-18M) and stirring the resulting solution at a temperature of 75 ℃ to 85 ℃ (usually 80 ℃) until homogeneous, in some cases for a period of up to 30 minutes; in some cases, in order to maintain this temperature, it is necessary to use a cooling device;

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

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

vi) producing H at a molar ratio of from 3:1 to 6.5: 1, in some cases from 4.5: 1 to 6.5: 1, in some cases from 6: 1₂C₂O₄And Nb₂O₅xH₂A solution of O;

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

vii) heating the resulting slurry in an autoclave at a temperature of 150 ℃ to 190 ℃ for no less than 10 hours at a pressure typically up to 200 psig (1375 kPag) under inert gas, air, carbon dioxide, carbon monoxide and mixtures thereof.

By reacting ammonium heptamolybdate (tetrahydrate) ((NH)₄)₆Mo₇O₂₄·4H₂O) in a suitable solvent (usually water) to prepare the initial solution. Water is usually at room temperature (20-25 deg.C) and moderate with a mechanical or magnetic stirrerStirring is at a speed (e.g., 150 to 500 rpm, typically 250 to 350 rpm, and in some embodiments 300 rpm). The initial solution may be about 0.3 to 0.5 moles, typically about 0.3 to 0.4 moles. Ammonium heptamolybdate (tetrahydrate) should dissolve in about 10 minutes to form a clear or cloudy solution. A 0.2 to 0.3 molar solution of telluric acid is prepared in water. The solution should be clear before continuing the operation. The telluric acid solution was added dropwise (0.20-0.50L/min) to ammonium heptamolybdate (tetrahydrate) using a dropping funnel or transfer line. The resulting solution was clear and colorless. The resulting solution was heated to 80 ℃. The pH of the solution was measured. Typically, it is in the range of about 3.0 to 3.5, typically 3.2 to 3.4. In some embodiments 7 the pH of the solution is adjusted to 7.2 to 7.7, typically 7.4 to 7.6 using a water soluble base (typically aqueous ammonia). The resulting solution is maintained at 80 ℃ for no less than 1 hour, typically 1 to 6 hours, and in some embodiments 1 to 2 hours, under low agitation.

By reacting VOSO₄Preparation of VOSO by dissolution in a water bath at a temperature of room temperature to 80 deg.C (preferably 50 deg.C to 70 deg.C, most preferably 55 deg.C to 65 deg.C)₄An aqueous solution of (a). The molar concentration of V in the solution is 1.30 to 1.70, typically 1.36 to 1.55, and in some embodiments 1.50 to 1.55. After moderate stirring in the water bath for no less than 30 minutes, in some embodiments 30 to 60 minutes, the solution is a clear blue color. Dropwise addition of VOSO to a solution of Mo and Te maintained at 80 ℃ over a period of not less than 20 minutes, in some embodiments 20 to 60 minutes₄To provide a molar ratio of V to Mo of from 25: 1 to 30: 1, in some cases from 27 to 38 to 1, typically from 34-36 to 1. The resulting solution was clear, light blue. The solution is stirred with moderate agitation at 200 to 400rpm, in some embodiments typically 250 to 350 rpm, in some embodiments 275 to 325 rpm, while the solution is cooled to room temperature.

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

Preparing a molar ratio of 3:1 to 26 hours at 60 to 70 ℃ with moderate stirring at 100 to 300 rpm for 16 to 30 hours, in some cases 22 to 26 hoursC of 10: 1, typically 4: 1 to 7: 1, typically 6: 1₂H₂O₄And Nb₂O₅xH₂An aqueous solution of O. This produced a cloudy solution of niobium oxalate. Adding the niobium oxalate solution to MoTeVO dropwise_XWhile stirring at a rate of 700 to 1400 rpm, in some cases 900 to 1300 rpm, to provide a Nb: V molar ratio of 0.85 to 0.95: 1, in some cases 0.89: 1 to 0.91: 1. A precipitate began to form and the resulting slurry was purple/gray in color.

The resulting slurry is transferred under an inert atmosphere to a pressurized reactor (e.g., Parr reactor or autoclave) and heated at a temperature of 140 ℃ to 190 ℃, in some embodiments 140 ℃ to 180 ℃, in some embodiments 145 ℃ to 175 ℃ for no less than 6 hours, in some embodiments no less than 12 hours, in some embodiments up to 30 hours or more.

The pressure in the reactor (Parr reactor or autoclave) may be in the range of 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 1375kPag) above atmospheric pressure, in some embodiments from 55 psig (380 kPag) to 170 psig (1170kPag) above atmospheric pressure.

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

The pressure in the reactor was maintained using a pressure relief valve. At lower pressures, the pressure may be maintained by flowing the flue 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 ℃ and below the reaction temperature. Gaseous product species are vented from the reactor as described above.

The reactor was 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 at a temperature of 70 ℃ to 120 ℃ for not less than 6 hours. The dried pre-catalyst is ground to a size typically less than 125 μm and calcined in an inert atmosphere such as nitrogen at a temperature of 200 ℃ to 650 ℃ for a time of 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 (dilute) aqueous oxalic acid solution, and dried in an oven at a temperature of 70 ℃ to 120 ℃ for not less than 6 hours. 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 cases, optionally, the dried precatalyst may be milled using mechanical methods (e.g., ball mill or roll mill) or may be subjected to cryogenic milling. In some cases, the dried and milled pre-catalyst may be sieved through a small particle size sieve to obtain a fraction having a particle size of less than 250 microns, preferably less than 125 microns.

In some embodiments, the product from the hydrothermal treatment is treated with 0.3 to 2.5 mL of 30 wt% H per gram of catalyst precursor₂O₂And (4) treating with an aqueous solution.

Typically, the catalyst precursor (i.e., prior to calcination) has the formula:

Mo_1.0V_0.10-049Te_0.06-0.17Nb_0.13-0.19O_d

the calcined catalyst has the formula:

Mo₁V_0.40-0.45Te_{0.06- 0.16}Nb_0.13-0.16O_d

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

Mo_1.0V_0.17-0.20Te_0.06-0.07Nb_0.19-0.20O_d

if the hydrothermal treatment is carried out at a pressure above 30 psig (206 kPag), the precatalyst has the formula:

MoV_0.40-0.45Te_0.10-0.16Nb_0.13-0.16O_d

the XRD of the calcined catalyst has a main peak at 2 Φ of 22 ° with a full width at half maximum of 19 to 21 and a broad secondary peak at 28 ° with a full width at half maximum of 25 to 33 °.

In a further embodiment, 10 to 95 wt%, preferably 25 to 80 wt%, ideally 30 to 45 wt% of the catalyst is mixed with 5-90 wt%, preferably 20 to 75 wt%, ideally 55 to 70 wt% of a catalyst selected from TiO₂、ZrO₂、Al₂O₃、AlO(OH)、Nb₂O₅And mixtures thereof, with the proviso that ZrO is not bound or agglomerated₂In combination with an aluminum-containing binder.

The catalyst may be used to comprise ethane and oxygen in a volume ratio of 70:30 to 95:5, and optionally one or more C_3-6Alkanes or alkenes and optionally including CO and CO₂At a temperature of less than 385 ℃ for not less than 100hr^-1And a pressure of 0.8 to 7 atmospheres, comprising passing the 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 method is not less than 500hr^-1Ideally not less than 1500hr^-1And in some embodiments 3000 hr^-1. The temperature of the ODH process is less than 375 deg.c, preferably less than 360 deg.c.

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

In one embodiment, the present invention provides a method of preparing a catalyst comprising a mixed oxide of MoVNbTe, the method comprising the steps of:

i) forming an aqueous solution of ammonium heptamolybdate (tetrahydrate) and telluric acid at a Mo: Te molar ratio of 1: 0.14 to 0.20 at a temperature of 30 ℃ to 85 ℃ and adjusting the pH of the solution to 6.5 to 8.5 with a nitrogenous base to form a soluble salt of the metal;

ii) stirring the pH-adjusted solution for not less than 15 minutes;

iii) adjusting the pH of the resulting solution to 4.5 to 5.5 with an acid and stirring the resulting solution at a temperature of 75 to 85 ℃ until homogeneous;

iv) preparing 0.30 to 0.50 molar aqueous solution of vanadyl sulfate at a temperature of room temperature to 80 ℃;

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

vi) preparation of H in a molar ratio of 3:1 to 6.5: 1₂C₂O₄And Nb₂O₅xH₂A solution of O;

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

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

In a further embodiment, in combination with one or more other embodiments, the present invention provides a method wherein the temperature of the hydrothermal treatment is in the range of 140 ℃ to 180 ℃.

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

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

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

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

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

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

In a further embodiment, in combination with one or more other embodiments, the present invention provides a process wherein the aqueous slurry fed to the autoclave comprises Mo, V, Nb and Te salts in a molar ratio of Mo 1, V0.40 to 0.70, Nb0.14 to 0.18 and Te0.14 to 0.20.

In a further embodiment, in combination with one or more other embodiments, the present invention provides a process wherein the heat-treated slurry from step viii) is used with 0.3-2.5 mL of 30 wt% H per gram of catalyst precursor₂O₂And (4) treating with an aqueous solution.

In a further embodiment, in combination with one or more other embodiments, the present invention provides a process wherein the pre-catalyst 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 at a temperature of 70 ℃ to 120 ℃ for not less than 6 hours.

In a further embodiment, in combination with one or more other embodiments, the present invention provides a process wherein the dried precatalyst is milled to a particle size of less than 125 microns. The dried catalyst may also be pre-dried in an oven at 90 ℃ for not less than 6 hours prior to calcination.

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

In a further embodiment, in combination with one or more other embodiments, the invention provides a process wherein the calcined material (catalyst) is admixed with 0.1 to 10 wt.% (relative to the catalyst) of Nb₂O₅xH₂O at 90 deg.CMixed in water and then dried in air at 300 ℃.

In a further embodiment, in combination with one or more other embodiments, the present invention provides a process wherein 10 to 95 wt% of the catalyst is combined with 5 to 90 wt% of a catalyst selected from TiO₂、ZrO₂、Al₂O₃、AlO(OH)、Nb₂O₅And mixtures thereof, with the proviso that ZrO is not bound or agglomerated₂In combination with an aluminum-containing binder.

In a further embodiment, in combination with one or more other embodiments, the present invention provides a process for the production of a catalyst comprising ethane and oxygen in a volume ratio of 70:30 to 95:5, and optionally one or more C_3-6Alkanes or alkenes and including CO and CO₂At a temperature of from above 320 ℃ to below 385 ℃, for not less than 100hr^-1And a pressure of 0.8 to 7 atmospheres, comprising passing the mixture over a catalyst prepared according to any of the preceding embodiments or combinations thereof.

In a further embodiment, in combination with one or more other embodiments, the present invention provides a process for the preparation of a low-grade C_2-4The oxidative dehydrogenation of a paraffin (usually ethane) to the corresponding olefin(s) has a selectivity to olefin (usually ethylene) of not less than 90% with a targeted ethane conversion of more than 25-35%, usually 35%.

In a further embodiment, in combination with one or more other embodiments, the present invention provides a process for the preparation of a low-grade C_2-4Oxidative dehydrogenation of a paraffin (usually ethane) to the corresponding olefin(s), wherein the gas hourly space velocity of the ODH process is not less than 500hr^-1。

In a further embodiment, in combination with one or more other embodiments, the present invention provides a process for the preparation of a low-grade C_2-4Oxidative dehydrogenation of a paraffin (usually ethane) to the corresponding olefin(s) at a temperature below 375 ℃.

In a further embodiment, in combination with one or more other embodiments, the present invention provides a process for the preparation of a low-grade C_2-4Oxidative dehydrogenation of a paraffin (usually ethane) to the corresponding olefin(s), wherein the catalyst in the ODH process forms a fixed bed.

The following comparative examples and examples prepared in accordance with the present disclosure illustrate the invention.

Comparative examples

Synthesis reaction without pH adjustment:

TABLE 1

Reactants/solvents	Required amount (g)	Amount used (g)	Batch number
				Nb2O5.H2O	11.30	11.3792
(NH4)6Mo7O24•4H2O	84.30	84.3011
				Te(OH)6	18.30	18.3022	BCBF3366V
VOSO4•3.46H2O	70.30	70.3022
				H2C2O4	19.00	19.0041

The procedure is as follows:

to a column with a magnetic stir bar and 130 mL of distilled H₂O (dH₂O) 250 mL of RBF was added 11.37gNb₂O₅.XH₂O, forming a milky white suspension.

While stirring the mixture, 19.00g of oxalic acid was added to 250 mL of RBF.

The mixture was allowed to stir at 65 ℃ overnight and for 24 hours (using a silicon oil bath), stirring was carried out at 300 rpm.

The mixture was opaque, milky white.

After stirring at 65 ℃ for 24 hours, the solution was cloudy and colorless.

To 500 mL of 2 necked RBF was added 84.3011g (NH)₄)₆MoO₂₄.4H₂O and 300 mL dH₂O。

The mixture was stirred at 400rpm to dissolve, with a dissolution time = 7 minutes.

To a 300 mL flask, 18.3022g of Te (OH) was added₆And 100 mL dH₂O and dissolved by stirring at 400rpm at room temperature.

The dissolution time of the mixture was 5 minutes.

Dropwise addition of the now clear and colorless telluric acid solution to the clear and colorless (NH) solution using a dropping funnel₄)₆Mo₇O₂₄.4H₂To the O solution, the addition time was 15 minutes, and the resulting pH was 3.0.

The temperature of the solution was raised to 80 ℃ using an oil bath, and the heating time for heating to 80 ℃ was 30 minutes.

And 100 mL dH₂O one step adding 70.31g of VOSO into a 250 mL beaker₄。

The mixture was dissolved by stirring in a water bath at 60 ℃ for 30 minutes.

The now clear blue solution was added dropwise to the 60 ℃ solution of MoTe from the previous step using an addition funnel over a 20 minute addition time.

The solution changed from a clear colorless solution to a dark purple/brown slurry.

The pH of the resulting solution at 80 ℃ was 2.5.

The slurry was cooled to room temperature with stirring at 500 rpm for about 1 hour.

After the slurry had cooled completely to room temperature, the previously prepared and then retained for later use Nb oxalate solution was added dropwise to the 2L RBF using an addition funnel, the previously dilute slurry thickened after Nb addition and produced a gray/purple thick slurry.

The addition time of niobium oxalate was 20 minutes.

Transfer the slurry to a 2L PARR reactor glass liner, which is placed inside the 2L PARR reactor.

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

Connect the reactor to a back pressure regulator device/condenser with overhead agitator frame.

The sealed reactor was allowed to stir at room temperature overnight.

The next day, the remaining 15psi in the PARR reactor was vented through a condenser and back pressure regulator device.

The heater of the PARR reactor was set to 185 ℃ and the target temperature in the thermowell was 175 ℃.

After 6 hours the heater of the PARR reactor was turned off and the reactor was allowed to cool overnight.

The next day, the purple slurry was filtered through a 4 x Whatmann #4 filter paper.

The time taken for filtration was 18 hours.

The filtered powder was dried at 90 ℃ overnight.