SYSTEMS INCLUDING CATALYSTS IN POROUS ZEOLITE MATERIALS WITHIN A REACTOR FOR USE IN SYNTHESIZING HYDROCARBONS

• US 20110085944A1
• Filed: 12/16/2010
• Published: 04/14/2011
• Est. Priority Date: 08/15/2006
• Status: Active Grant

• Current Assignee: Battelle Energy Alliance LLC (Battelle Memorial Institute)
• Original Assignee: Battelle Energy Alliance LLC (Battelle Memorial Institute)
• Inventors: Rolllins, Harry W., Petkovic, Lucia M., Ginosar, Daniel M.
• Granted Patent: US 8,226,909 B2
• Time in Patent Office: Days
• US Class Current: 422/211
• CPC Class Codes: B01J 29/005 Mixtures of molecular sieves comprising at least one molecular sieve which is not an aluminosilicate zeolite, e.g. from groups B01J29/03 - B01J29/049 or B01J29/82 - B01J29/89
• CPC Class Codes: B01J 29/035 Microporous crystalline materials not having base exchange properties, such as silica polymorphs, e.g. silicalites
• CPC Class Codes: B01J 29/041 Mesoporous materials having base exchange properties, e.g. Si/Al-MCM-41
• CPC Class Codes: B01J 29/061 containing metallic elements added to the zeolite
• CPC Class Codes: B01J 29/072 Iron group metals or copper
• CPC Class Codes: B01J 29/40 of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
• CPC Class Codes: B01J 29/46 Iron group metals or copper
• CPC Class Codes: B01J 29/80 Mixtures of different zeolites
• CPC Class Codes: B01J 37/0018 Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat)
• CPC Class Codes: C07C 1/20 starting from organic compounds containing only oxygen atoms as heteroatoms
• CPC Class Codes: C07C 11/02 Alkenes
• CPC Class Codes: C07C 2529/46 Iron group metals or copper
• CPC Class Codes: C07C 2529/84 Aluminophosphates containing other elements, e.g. metals, boron
• CPC Class Codes: C07C 2529/85 Silicoaluminophosphates (SAPO compounds)
• CPC Class Codes: C10G 2400/20 C2-C4 olefins
• CPC Class Codes: C10G 2400/22 Higher olefins
• CPC Class Codes: C10G 3/45 containing iron group metals or compounds thereof
• CPC Class Codes: C10G 3/47 containing platinum group metals or compounds thereof
• CPC Class Codes: C10G 3/49 containing crystalline aluminosilicates, e.g. molecular sieves
• CPC Class Codes: C10G 3/50 in the presence of hydrogen, hydrogen donors or hydrogen generating compounds
• CPC Class Codes: Y02P 30/40 : Ethylene production

Abstract

Catalytic structures include a catalytic material disposed within a zeolite material. The catalytic material may be capable of catalyzing a formation of methanol from carbon monoxide and/or carbon dioxide, and the zeolite material may be capable of catalyzing a formation of hydrocarbon molecules from methanol. The catalytic material may include copper and zinc oxide. The zeolite material may include a first plurality of pores substantially defined by a crystal structure of the zeolite material and a second plurality of pores dispersed throughout the zeolite material. Systems for synthesizing hydrocarbon molecules also include catalytic structures. Methods for synthesizing hydrocarbon molecules include contacting hydrogen and at least one of carbon monoxide and carbon dioxide with such catalytic structures. Catalytic structures are fabricated by forming a zeolite material at least partially around a template structure, removing the template structure, and introducing a catalytic material into the zeolite material.

Claims

1. A system for synthesizing hydrocarbon molecules having two or more carbon atoms from hydrogen and at least one of carbon monoxide and carbon dioxide, the system comprising:

a reactor configured to receive a reactant mixture comprising hydrogen and at least one of carbon monoxide and carbon dioxide; and

a catalytic structure disposed within the reactor, the catalytic structure comprising;

a zeolite material capable of catalyzing the formation of hydrocarbon molecules having two or more carbon atoms from methanol, the zeolite material comprising;

a first plurality of pores substantially defined by a crystal structure of the zeolite material; and

a second plurality of pores dispersed throughout the zeolite material; and

at least one catalytic material disposed within at least one pore of at least one of the first plurality of pores and the second plurality of pores, the first catalytic material capable of catalyzing the formation of methanol from at least one of carbon monoxide and carbon dioxide in the presence of hydrogen.

2. The system of claim 1, further comprising a device configured to heat the catalytic structure to a temperature of greater than about 200°

C.

3. The system of claim 2, further comprising a device configured to pressurize the reactor to a pressure of greater than about 0.5 megapascals.

4. The system of claim 1, wherein the at least one catalytic material comprises a plurality of metallic particles.

5. The system of claim 4, wherein the plurality of metallic particles has an average particle size of less than about 500 angstroms.

6. The system of claim 4, wherein each metallic particle of the plurality of metallic particles comprises at least one of copper, magnesium, zinc, cobalt, iron, nickel, ruthenium, platinum, palladium, or cesium.

7. The system of claim 4, wherein the at least one catalytic material further comprises a plurality of metal oxide particles.

8. The system of claim 7, wherein the plurality of metal oxide particles has an average particle size of less than about 200 angstroms.

9. The system of claim 7, wherein each metal oxide particle of the plurality of metal oxide particles comprises at least one of zinc oxide, magnesium oxide, zirconium oxide, iron oxide, and tungsten oxide.

10. The system of claim 1, wherein the at least one catalytic material comprises copper and zinc oxide.

11. The system of claim 1, wherein the second plurality of pores comprises a plurality of elongated channels.

12. The system of claim 11, wherein each elongated channel of the plurality of elongated channels is generally cylindrical and has an average diameter in a range extending from about 20 angstroms to about 500 angstroms.

13. The system of claim 11, wherein the second plurality of pores further comprises a plurality of generally spherical pores.

14. The system of claim 1, wherein the zeolite material has a framework type selected from MFI, BEA, FAU, MOR, FER, ERI, OFF, CHA and AEI.

15. The system of claim 14, wherein the zeolite material comprises an aluminosilicate-based material, an aluminophosphate-based material, or a silicoaluminophosphate-based material.

16. The system of claim 15, wherein the zeolite material comprises ZSM-5.

17. The system of claim 1, wherein the first plurality of pores comprises a plurality of micropores and the second plurality of pores comprises a plurality of mesopores.