Methods and systems for generating polyols

• US 7,989,664 B2
• Filed: 07/12/2010
• Issued: 08/02/2011
• Est. Priority Date: 05/08/2006
• Status: Active Grant

• Current Assignee: Virent, Inc. (Marathon Petroleum Corporation)
• Original Assignee: Virent Energy Systems, Inc. (Marathon Petroleum Corporation)
• Inventors: Cortright, Randy D.
• Primary Examiner(s): WITHERSPOON, SIKARL A
• Application Number:
  US12/834,306
• Publication Number:
  US 20100280275A1
• Time in Patent Office: 386 Days
• Field of Search: 568/400, 568/420, 568/700, 568/840, 568/852, 568/861, 568/403
• US Class Current: 568/403
• CPC Class Codes: B01J 23/8906 Iron and noble metals
• CPC Class Codes: C01B 2203/0233 the reforming step being a steam reforming step
• CPC Class Codes: C01B 2203/06 Integration with other chemical processes
• CPC Class Codes: C01B 2203/1047 Group VIII metal catalysts
• CPC Class Codes: C01B 2203/1052 Nickel or cobalt catalysts
• CPC Class Codes: C01B 2203/1058 Nickel catalysts
• CPC Class Codes: C01B 2203/1064 Platinum group metal catalysts
• CPC Class Codes: C01B 2203/107 Platinum catalysts
• CPC Class Codes: C01B 2203/1076 Copper or zinc-based catalysts
• CPC Class Codes: C01B 2203/1211 Organic compounds or organic mixtures used in the process for making hydrogen or synthesis gas
• CPC Class Codes: C01B 2203/1217 Alcohols
• CPC Class Codes: C01B 3/323 Catalytic reaction of gaseous or liquid organic compounds other than hydrocarbons with gasifying agents
• CPC Class Codes: C07C 27/06 by hydrogenation of oxides of carbon
• CPC Class Codes: C07C 29/60 by elimination of -OH groups, e.g. by dehydration C07C29/34 takes precedence
• CPC Class Codes: C07C 31/205 1,3-Propanediol; 1,2-Propanediol
• CPC Class Codes: Y02P 20/52 using catalysts, e.g. selective catalysts
• CPC Class Codes: Y02P 30/20 using bio-feedstock

Abstract

Disclosed are methods for generating propylene glycol, ethylene glycol and other polyols, diols, ketones, aldehydes, carboxylic acids and alcohols from biomass using hydrogen produced from the biomass. The methods involve reacting a portion of an aqueous stream of a biomass feedstock solution over a catalyst under aqueous phase reforming conditions to produce hydrogen, and then reacting the hydrogen and the aqueous feedstock solution over a catalyst to produce propylene glycol, ethylene glycal and the other polyols, diols, ketones, aldehydes, carboxylic acids and alcohols. The disclosed methods can be run at lower temperatures and pressures, and allows for the production of oxygenated hydrocarbons without the need for hydrogen from an external source.

Claims

1. A method of generating ketones or alcohols, the method comprising the steps of:

a. contacting a first catalytic material comprising one or more Group VIII metals with a first portion of an aqueous feedstock solution comprising water and at least one water-soluble oxygenated hydrocarbon having two or more carbon atoms under conditions sufficient to produce hydrogen; and

b. reacting the hydrogen with a second portion of the aqueous feedstock solution over a second catalytic material, the second catalytic material different than the first catalytic material and comprising iron, ruthenium, copper, rhenium, cobalt, nickel, an alloy of at least two of the foregoing, or mixtures of at least two of the foregoing, under conditions sufficient to produce one or more ketones selected from the group consisting of acetone, propanone, butanone, pentanone, and hexanone, or one or more alcohols selected from the group consisting of methanol, ethanol, iso-propyl alcohol, propanol, butanol, pentanol, and hexanol.

2. The method of claim 1 further comprising the step of adding a supplemental hydrogen to react with at least a portion of the second portion of the aqueous feedstock solution.

3. The method of claim 1, wherein the first catalytic material contacts the first portion of the aqueous feedstock at:

a. a temperature of about 80°

C. to 400°

C.; and

b. a pressure where at least a portion of the water and the oxygenated hydrocarbons are condensed liquids.

4. The method of claim 1, wherein the hydrogen reacts with a second portion of the feedstock solution at:

a. a temperature of about 100°

C. to 300°

C.; and

b. a pressure of about 72 psig to about 1300 psig.

5. The method of claim 1, wherein the second portion of the feedstock solution further comprises oxygenated hydrocarbons formed by contacting the feedstock solution with the first catalytic material.

6. The method of claim 1, wherein the second portion of the feedstock solution is contacted with the hydrogen and the second catalytic material at a pressure greater than about 365 psig.

7. The method of claim 1, wherein the molar ratio of the first catalytic material to the second catalytic material is about 5:

1 to 1;

5.

8. The method of claim 1, wherein the first catalytic material comprises at least one transition metal selected from the group consisting of platinum, nickel, palladium, ruthenium, rhodium, rhenium, iridium, an alloy of at least two of the foregoing, and mixtures of at least two of the foregoing.

9. The method of claim 1, wherein the second catalytic material is selected from the group consisting of iron, nickel, rhenium, ruthenium, and cobalt.

10. The method of claim 1, wherein the first catalytic material and the second catalytic material are combined in a catalytic mixture.

11. The method of claim 10, wherein the first catalytic material comprises at least one transition metal selected from the group consisting of:

platinum, nickel, palladium, ruthenium, rhodium, rhenium, iridium, an alloy of at least two of the foregoing and mixtures of at least two of the foregoing; and

the second catalytic metal is iron or rhenium.

12. The method of claim 11, wherein the first catalytic material is platinum and the second catalytic material is rhenium.

13. The method of claim 10, wherein the first portion of the feedstock solution and the second portion of the feedstock solution are contacted with the first catalytic material and the second catalytic material in a reactor vessel at a temperature of about 200°

C. to 270°

C.

14. The method of claim 10, wherein the catalytic mixture is adhered to a support.

15. The method of claim 14, wherein the support is selected from the group consisting of carbon, silica, silica-alumina, alumina, zirconia, titania, ceria, vanadia, and mixtures thereof.

16. The method of claim 15, wherein the support is an activated carbon.

17. The method of claim 15, wherein the support comprises zirconia.

18. The method of claim 1, wherein the first portion of the feedstock solution is contacted with the first catalytic material at a temperature of about 150°

C. to 270°

C. and the second portion of the feedstock solution is contacted with the second catalytic material at a temperature of about 200°

C. to 270°

C.

19. A method of generating ketones or alcohols, the method comprising the steps of:

a. contacting a first catalytic material comprising one or more Group VIII metals with a first portion of an aqueous feedstock solution comprising water, a recycle stream and at least one water-soluble oxygenated hydrocarbon having two or more carbon atoms under conditions sufficient to produce hydrogen; and

b. reacting the hydrogen with a second portion of the aqueous feedstock solution over a second catalytic material, the second catalytic material different than the first catalytic material and selected from the group consisting of;

iron, ruthenium, copper, rhenium, cobalt, nickel, an alloy of at least two of the foregoing, and mixtures of at least two of the foregoing, under conditions sufficient to produce an effluent stream comprising unreacted oxygenated hydrocarbons, byproducts and one or more ketones selected from the group consisting of acetone, propanone, butanone, pentanone, and hexanone, or one or more alcohols selected from the group consisting of methanol, ethanol, iso-propyl alcohol, propanol, butanol, pentanol, and hexanol; and

c. separating at least a portion of the unreacted oxygenated hydrocarbons and byproducts from the effluent stream into the recycle stream; and

d. mixing at least a portion of the recycle stream with one or more water-soluble oxygenated hydrocarbons to provide the aqueous feedstock solution.

20. The method of claim 19 further comprising the step of adding a supplemental hydrogen to react with at least a portion of the second portion of the aqueous feedstock solution.

21. The method of claim 19, wherein the first catalytic material contacts the first portion of the aqueous feedstock at:

a. a temperature of about 80°

C. to 400°

C.; and

b. a pressure where at least a portion of the water and the oxygenated hydrocarbons are condensed liquids.

22. The method of claim 19, wherein the hydrogen reacts with a second portion of the feedstock solution at:

a. a temperature of about 100°

C. to 300°

C.; and

b. a pressure of about 72 psig to about 1300 psig.

23. The method of claim 19, wherein the second portion of the feedstock solution is contacted with the hydrogen and the second catalytic material at a pressure greater than about 365 psig.

24. The method of claim 19, wherein the molar ratio of the first catalytic material to the second catalytic material is about 5:

1 to 1;

5.

25. The method of claim 19, wherein the first catalytic material comprises at least one transition metal selected from the group consisting of platinum, nickel, palladium, ruthenium, rhodium, rhenium, iridium, an alloy of at least two of the foregoing, and mixtures of at least two of the foregoing.

26. The method of claim 19, wherein the second catalytic material is selected from the group consisting of iron, nickel, rhenium, ruthenium, and cobalt.

27. The method of claim 19, wherein the first catalytic material and the second catalytic material are combined in a catalytic mixture.

28. The method of claim 27, wherein the first catalytic material comprises at least one transition metal selected from the group consisting of:

platinum, nickel, palladium, ruthenium, rhodium, rhenium, iridium, an alloy of at least two of the foregoing and mixtures of at least two of the foregoing; and

the second catalytic metal is iron or rhenium.

29. The method of claim 27, wherein the first catalytic material is platinum and the second catalytic material is rhenium.

30. The method of claim 27, wherein the first catalytic material and the second catalytic material are adhered to a support.

31. The method of claim 30, wherein the support is selected from the group consisting of carbon, silica, silica-alumina, alumina, zirconia, titania, ceria, vanadia, and mixtures thereof.

32. The method of claim 31, wherein the support is an activated carbon.

33. The method of claim 31, wherein the support comprises zirconia.

34. The method of claim 19, wherein the first portion of the feedstock solution is contacted with the first catalytic material at a temperature of about 150°

C. to 270°

C. and the second portion of the feedstock solution is contacted with the second catalytic material at a temperature of about 200°

C. to 270°

C.

35. A method of generating ketones or alcohols, the method comprising the steps of:

a. contacting a first catalytic material comprising one or more Group VIII metals with a first portion of an aqueous feedstock solution comprising water and at least one water-soluble oxygenated hydrocarbon having two or more carbon atoms under conditions sufficient to produce aqueous phase reforming (APR) hydrogen; and

b. reacting the APR hydrogen and a supplemental hydrogen with a second portion of the aqueous feedstock solution over a second catalytic material, the second catalytic material different than the first catalytic material and comprising iron, ruthenium, copper, rhenium, cobalt, nickel, an alloy of at least two of the foregoing, or mixtures of at least two of the foregoing, under conditions sufficient to produce one or more ketones selected from the group consisting of acetone, propanone, butanone, pentanone, and hexanone, or one or more alcohols selected from the group consisting of methanol, ethanol, iso-propyl alcohol, propanol, butanol, pentanol, and hexanol.

36. The method of claim 35, wherein the first catalytic material contacts the first portion of the aqueous feedstock at:

a. a temperature of about 80°

C. to 400°

C.; and

b. a pressure where at least a portion of the water and the oxygenated hydrocarbons are condensed liquids.

37. The method of claim 35, wherein the APR hydrogen and the supplemental hydrogen react with a second portion of the feedstock solution at:

a. a temperature of about 100°

C. to 300°

C.; and

b. a pressure of about 72 psig to about 1300 psig.

38. The method of claim 35, wherein the second portion of the feedstock solution is contacted with the APR hydrogen, the supplemental hydrogen and the second catalytic material at a pressure greater than about 365 psig.

39. The method of claim 35, wherein the molar ratio of the first catalytic material to the second catalytic material is about 5:

1 to 1;

5.

40. The method of claim 35, wherein the first catalytic material comprises at least one transition metal selected from the group consisting of platinum, nickel, palladium, ruthenium, rhodium, rhenium, iridium, an alloy of at least two of the foregoing, and mixtures of at least two of the foregoing.

41. The method of claim 35, wherein the second catalytic material is selected from the group consisting of iron, nickel, rhenium, ruthenium, and cobalt.

42. The method of claim 35, wherein the first catalytic material and the second catalytic material are combined in a catalytic mixture.

43. The method of claim 42, wherein the first catalytic material and second catalytic material are adhered to a support.

44. The method of claim 43, wherein the support is selected from the group consisting of carbon, silica, silica-alumina, alumina, zirconia, titania, ceria, vanadia, and mixtures thereof.