Jacob S. Kruger*,
Tao Dong,
Gregg T. Beckham and
Mary J. Biddy
National Renewable Energy Laboratory, National Bioenergy Center, 15013 Denver West Parkway, Golden, CO 80401, USA. E-mail: Jacob.Kruger@nrel.gov
First published on 2nd July 2018
Renewed interest in production of 1,3-butadiene from non-petroleum sources has motivated research into novel production routes. In this study, we investigated an integrated process comprising 1-butanol dehydration over a γ-Al2O3 catalyst to produce a mixture of linear butenes, coupled with a downstream K-doped Cr2O3/Al2O3 catalyst to convert the butenes into butadiene. Linear butene yields greater than 90% are achievable at 360 °C in the dehydration step, and single-pass 1,3-butadiene yields greater than 40% are achieved from 1-butene in a N2 atmosphere in the dehydrogenation step. In the integrated process, 1,3-butadiene yields are 10–15%. In all cases, linear C4 selectivity is greater than 90%, suggesting that 1,3-butadiene yields could be significantly improved in a recycle reactor. Doping the Cr2O3 catalyst with different metals to promote H2 consumption in a CO2 atmosphere did not have a large effect on catalyst performance compared to an undoped Cr2O3 catalyst, although doping with K in an N2-diluted atmosphere and with Ni in a CO2-enriched atmosphere showed slight improvement. In contrast, doping with K and Ca in a CO2-enriched atmosphere showed slightly decreased performance. Similarly, employing a CO2-enriched atmosphere in general did not improve 1,3-butadiene yield or selectivity compared to reactions performed in N2. Overall, this study suggests that an integrated dehydration/dehydrogenation process to convert 1-butanol into 1,3-butadiene could be feasible with further catalyst and process development.
Several pathways to convert biomass to a renewable C4 stream exist commercially, incorporating syngas, methanol, and ethanol intermediates en route to 1-butanol, isobutanol, succinic acid, or butanediol.2,6 The pathways to convert these C4s into 1,3-butadiene are less technically developed, though the embodied chemistries are relatively mature. Specifically, 1-butanol could be dehydrated to 1- and 2-butenes, and these butenes could be dehydrogenated to 1,3-butadiene (Scheme 1).
A single-stage integrated process would be challenging due to the different conditions required for alcohol dehydration and olefin dehydrogenation. In particular, olefin dehydrogenation is typically carried out at temperatures greater than 550 °C and weight-hourly space velocities (WHSVs) greater than 150 h−1. High temperature is required to activate the olefins on the dehydrogenation catalyst, and the high WHSV is required to minimize unfavourable side reactions that lead to C1–C3 cracking products and coke. Additionally, dehydrogenation catalysts (Cr2O3 or Fe2O3 supported on Al2O3) are typically doped with K2CO3 or K2O, which neutralize catalyst acidity that would be necessary for alcohol dehydration. Similarly, alcohols tend to react by dehydrogenation at such temperatures to produce an undesired carbonyl, rather than by dehydration to produce a desirable olefin.7 On the other hand, 1-butanol can be dehydrated to linear butenes in greater than 95% yield over a γ-Al2O3 catalyst at temperatures of 350–410 °C and WHSVs of 1–10 h−1.8 This difference in reaction conditions may be one reason that it has been suggested,1 but never demonstrated, that an integrated dehydration–dehydrogenation process to convert 1-butanol to 1,3-butadiene could be feasible.
We hypothesized that olefin dehydrogenation could also be operated at lower temperature by decreasing the space velocity, and that the lower temperature would also be advantageous in mitigating side reactions. While cracking equilibria still strongly favour C1–C3 products at temperatures as low as 450 °C, the kinetics of these reactions are much slower.9 Thus, we were motivated to explore the integrated conversion of 1-butanol to 1,3-butadiene in a combined dehydration–dehydrogenation reactor.
Additionally, we were interested in improving yields in the butene dehydrogenation step. Linear butenes can typically be directly dehydrogenated over CrOx/Al2O3 or Fe2O3-containing catalysts in single-pass yields of 40–50% or oxidatively dehydrogenated over ZnFe2O4, Bi2MoO6, or Sn/Sb-containing catalysts in single-pass yields of 60–70%.1,9–12 The oxidative dehydrogenation shifts the dehydrogenation equilibrium toward 1,3-butadiene by converting the produced H2 to H2O. The presence of O2 and H2O concomitantly mitigate coke formation on the catalyst surface.
In dehydrogenation without O2, alternative concepts for shifting the dehydrogenation equilibrium may also be feasible. In particular, (1) coke gasification or methanation, (2) CO2 methanation, and (3) reverse water-gas shift (RWGS) are three reactions that could consume produced H2.
C + 2H2 → CH4 | (1) |
CO2 + 4H2 → CH4 + 2H2O | (2) |
H2 + CO2 → H2O + CO | (3) |
Of these three, reaction (3) has proven promising in dehydrogenation of ethylbenzene to styrene and diethylbenzene to divinyl benzene13–15 and to some extent in butene dehydrogenation.16–19
To this end, certain catalysts are known to promote these desired reactions. In particular, coke gasification can be promoted by K, Ca, and Ni;20 Ni, Fe, and Mo can hydrogenate CO2 to CH4;21,22 and RWGS can be promoted by Fe2O3 and Cu/CeO2.13,23 K and Ca can also help to poison catalyst acid sites that lead to unfavourable cracking reactions, which in turn lead to coke.9
Thus, in addition to demonstrating an integrated butanol-to-butadiene process, we were motivated to explore the potential of new equilibrium-shifting catalysts for butene dehydrogenation. Herein we report process development for 1-butene dehydrogenation over a series of Cr2O3/Al2O3 catalysts doped with K, Ca, Ni, Mo, Fe, and Cu/CeO2, and integration with 1-butanol dehydration.
After depositing the salt solution, the catalysts were dried under vacuum at 40 °C overnight, then transferred to a ceramic dish and calcined by the following program: ramp to 95 °C at 25 °C min−1, hold for 1 h, ramp to 550 °C at 5 °C min−1, hold for 10 h.
NH3 pulse chemisorption was carried out on an Altamira Instruments AMI-390 unit. Samples were treated for 2 h at 450 °C under 50 mL min−1 Ar, then cooled to 120 °C under flowing He before dosing the sample with 25 × 5 mL pulses of 10% NH3 in He. The average of the post-saturation pulses (typically the last 15–20 pulses) was used as the reference peak area. The adsorbed peak area was calculated as the sum of the difference between the observed peak area and the reference peak area for the unsaturated pulses (typically first 5–10 pulses). The NH3 areas were quantified on a TCD and converted to a quantity of adsorbed molecules assuming ideal gas behaviour of the pulse gas.
XRD was carried out on a Rigaku Ultima IV X-ray diffractometer using Cu K-α radiation. The operating voltage and current were 40 kV and 44 mA, respectively. A scan range of 5–80° 2θ, a scan speed of 5° min−1 and a point spacing of 0.05° 2θ were used.
During reactor operation, a reaction-purge–regeneration-purge cycle using four mass flow controllers was implemented, with the reactor control software automatically switching between steps. The temperature, time, and flow parameters used for each cycle unless otherwise indicated are shown in Table 1.
Parameter | Reaction | Reaction purge | Regeneration | Regeneration purge |
---|---|---|---|---|
Temperature | 450 °C | 450 °C | 450 °C | 450 °C |
Duration | 72 min | 6 min | 74 min | 6 min |
Gas feed | 100 sccm N2 or CO2 + 100 sccm 1-butene mix | 200 sccm N2 or CO2 | 100 sccm Ar + 100 sccm zero air | 200 sccm Ar |
For dehydration experiments, a 0.2 g bed of the same γ-Al2O3 material used to support the Cr2O3 catalysts was positioned 5 inches (12.7 cm) above the centre of the reactor tube. At this point, the reactor temperature was 360 °C when the axial centre of the reactor tube was at 450 °C. The butanol flow rate was 0.02 mL min−1, selected to approximate the conditions of the 5.4 mol% 1-butene mixture used in the dehydrogenation catalyst screening experiments. The N2 flow rate was 177 sccm. For integrated dehydration–dehydrogenation experiments, the configuration for both sets of experiments was combined. A 0.2 g bed of γ-Al2O3 was positioned 5 inches (12.7 cm) above the reactor centre and a 0.6 g bed of K–Cr2O3/Al2O3 was positioned at the reactor centre, the 1-butanol flow rate was 0.02 mL min−1 and the N2 flow rate was 177 sccm.
Reactor effluent passed through a condenser and then to local exhaust ventilation, with a slip stream sampled by online GCMS. The system consisted of an Agilent 6890 Plus GC equipped with a TCD, FID, and a 5973 MS, which analysed samples in parallel. The GC column was a 30 m × 0.32 mm ID GS-GASPRO column, operating in ramped flow mode with the following program: 2.3 mL min−1 for 3 min, ramp at 1 mL min−2 to 2.7 mL min−1, hold at 2.7 mL min−1. The corresponding oven program was 50 °C for 3 min, ramp at 15 °C min−1 to 75 °C, hold for 2 min, ramp at 50 °C min−1 to 250 °C, hold for 2.83 min. The inlet conditions were 250 °C, initial pressure of 10.64 psi, and a split ratio of 20:1. The carrier gas for the system was He. Hydrocarbons were quantified on the FID, using N2 (detected on the TCD) as an internal standard, and gas mixes of authentic standards for C1–C4 compounds to develop response factors. For C5 and heavier compounds, FID response factors were calculated based on the method of Scanlon,24 though these compounds typically comprised less than 0.5% carbon yield.
Yields and selectivities are reported on a carbon molar basis. Selectivities are based on the amount of butene fed rather than as a fraction of products detected.
Fig. 1 Dehydration of 1-butanol to 1- and 2-butenes over a γ-Al2O3 catalyst. Reaction conditions: 0.02 mL min−1 butanol, 177 sccm N2, 0.2 g catalyst, 350–400 °C. |
We also explored butanol reactivity at 450 °C, consistent with the butene dehydrogenation conditions reported below. Butanol conversion in a SiO2-packed tube (without catalyst) was 100%, but selectivity to butenes was low, and a significant amount of black solid was deposited in the reactor. Because conversion of butenes under these conditions was negligible (see below), the high conversion of butanol suggests thermal reactions through non-butene routes predominated, such as cracking, coke formation, dehydrogenation to butyraldehyde, and decarbonylation of butyraldehyde to produce propene and CO.
We attempted to mitigate these nonselective reactions by inserting a γ-Al2O3 catalyst bed upstream of the axial tube centre to convert the butanol to butenes at 450 °C. However, when the γ-Al2O3 bed was positioned within the isothermal zone of the reactor, a significant amount of isobutene was produced through skeletal isomerization. Thus, we measured the temperature profile within the reactor tube and placed the γ-Al2O3 bed 5 inches (12.7 cm) above the axial centre of the reactor, at which point the temperature was 360 °C (Fig. S1†), consistent with Pine and Haags.8 This was the location of the γ-Al2O3 bed in the integrated experiments.
Fig. 2 Yields and selectivity for butene dehydrogenation over a Cr2O3/Al2O3 catalyst. Results calculated at 50 min time on stream with a 2.7 mol% concentration of 1-butene in N2. |
Thus, we established 450 °C and a space velocity of 0.76 h−1 WHSV as the operating conditions for our remaining experiments. Notably, the butadiene selectivity and yields are comparable to common industrial catalysts reported for direct dehydrogenation.9 Under these same conditions, a control reaction (reactor tube packed with only SiO2) showed <5% conversion of 1-butene (Fig. S2†).
The CO2-enriched atmosphere did not lead to higher butadiene yields as hypothesized, despite the more favourable equilibria for H2 conversion. (For example, correlations for the water-gas shift equilibrium25 at 1 atm and 450 °C predict greater than 98% conversion of produced H2 in a 50% CO2 atmosphere). In these reactions, there was not a significantly higher amount of CH4 produced (as would be expected from methanation of C or CO2), nor was any condensate collected from the reactor knockout pot, (as may be expected from H2O production via enhanced RWGS activity). Thus, it seems that the catalysts synthesized here are either not capable of activating CO2 or not capable of catalysing the desired reactions at 450 °C. Further catalyst development will be the focus of future work.
The yield of butadiene in the integrated process is lower than expected from the previous runs, which produced >40% yields of butadiene from 1-butene at 30 min TOS. We tentatively ascribe the lower yields to the water sensitivity of Cr2O3/Al2O3 catalysts,9 as H2O is produced in the dehydration step. Indeed, dehydrogenation activity was much lower when co-feeding 0.02 mL min−1 of H2O with the 1-butene/N2 mixture over these catalysts (Fig. S5†)
Notably, while the single-pass butadiene yield is only 13%, the average selectivity to linear C4 compounds is >95% (Fig. S6†). The remaining mass is likely due to coke formation, as some CO2 could be detected during the regeneration cycle. Thus, with a recycle reactor, the overall achievable yield of butadiene from butanol would be nearly quantitative using the present conditions.
Catalyst | BET surface area (m2 g−1) | NH3 uptake (μmol g−1) |
---|---|---|
Al2O3 | 153 | 242 |
Cr2O3 | 139 | 424 |
1K-Cr2O3 | 137 | 334 |
The γ-Al2O3 support had a surface area of 153 m2 g−1, which was reduced slightly after deposition of Cr2O3 and calcining to decompose the precursor salt. The presence of K in the Cr precursor solution does not significantly decrease the surface area further. Because high-valent Cr catalysts are known to decompose NH3 at temperatures above about 500 °C,26 we quantified acid sites by NH3 pulse chemisorption instead of NH3 TPD. The NH3 uptake on the γ-Al2O3 support suggests an acid site content of 242 μmol sites/g. Addition of Cr2O3 increases the acid site content to 424 μmol sites/g, while the presence of K in the Cr precursor solution mitigates the increase in acid sites to 334 μmol sites/g. Doping Cr oxide catalysts with K has been hypothesized to poison acid sites,9 though recent work has suggested that K also changes the surface morphology of the supported Cr oxide phase.27 Any structural changes were not apparent by XRD, as only peaks for the γ-Al2O3 support could be detected in the prepared catalysts (Fig. S7†).
Footnote |
† Electronic supplementary information (ESI) available: Reactor temperature profile, control reaction product distributions, additional doped catalyst results, effect of H2O-rich. See DOI: 10.1039/c8ra02977f |
This journal is © The Royal Society of Chemistry 2018 |