초록 ▼

This invention relates to a process for converting a hydrocarbon reactant to a product comprising an oxygenate or a nitrile, the process comprising: (A) flowing a reactant composition comprising the hydrocarbon reactant, and oxygen or a source of oxygen, and optionally ammonia, through a microchanne

This invention relates to a process for converting a hydrocarbon reactant to a product comprising an oxygenate or a nitrile, the process comprising: (A) flowing a reactant composition comprising the hydrocarbon reactant, and oxygen or a source of oxygen, and optionally ammonia, through a microchannel reactor in contact with a catalyst to convert the hydrocarbon reactant to the product, the hydrocarbon reactant undergoing an exothermic reaction in the microchannel reactor; (B) transferring heat from the microchannel reactor to a heat exchanger during step (A); and (C) quenching the product from step (A).

대표청구항 ▼

The invention claimed is: 1. A process for converting a hydrocarbon reactant to a product, the process comprising: (A) flowing a reactant composition comprising the hydrocarbon reactant, and oxygen or a source of oxygen, and optionally ammonia, in a microchannel reactor in contact with a catalyst t

The invention claimed is: 1. A process for converting a hydrocarbon reactant to a product, the process comprising: (A) flowing a reactant composition comprising the hydrocarbon reactant, and oxygen or a source of oxygen, and optionally ammonia, in a microchannel reactor in contact with a catalyst to convert the hydrocarbon reactant to the product, the product comprising an oxygenate or a nitrile, the oxygen or source of oxygen being added to the hydrocarbon reactant, and optionally ammonia, using staged addition wherein oxygen or a source of oxygen is added to the hydrocarbon reactant, and optionally ammonia, at various points in the microchannel reactor, the hydrocarbon reactant undergoing an exothermic reaction in the microchannel reactor; (B) transferring heat from the microchannel reactor to a heat exchanger during step (A); and (C) quenching the product from step (A). 2. The process of claim 1 wherein the microchannel reactor comprises at least one process microchannel containing the catalyst, and the heat exchanger is adjacent to the process microchannel. 3. The process of claim 1 wherein the microchannel reactor comprises a plurality of process microchannels containing the catalyst, the reactant composition entering the process microchannels and the product exiting the process microchannels, the temperature of the reactant composition entering the process microchannels being within about 200째 C. of the temperature of the product exiting the process microchannels. 4. The process of claim 1 wherein the reactant composition is preheated prior to step (A). 5. The process of claim 1 wherein the reactant composition and oxygen or oxygen source are mixed prior to step (A). 6. The process of claim 1 wherein the reactant composition and oxygen or oxygen source are mixed during step (A). 7. The process of claim 1 wherein the microchannel reactor comprises a plurality of process microchannels containing the catalyst, a header providing a flow passageway for fluid to enter the process microchannels, and a footer providing a flow passageway for fluid to leave the process microchannels. 8. The process of claim 7 wherein each process microchannel has an internal dimension of width or height of up to about 10 mm. 9. The process of claim 7 wherein each of the process microchannels has an entrance, an exit and an elongated section extending between the entrance and the exit, the process microchannels further comprising at least one additional entrance in the elongated section, the oxygen or source of oxygen entering the process microchannels through the at least one additional entrance. 10. The process of claim 7 wherein the process microchannels are made of a material comprising: steel; monel; inconel; aluminum; titanium; nickel; copper; brass; an alloy of any of the foregoing metals; a polymer; ceramics; glass; a composite comprising a polymer and fiberglass; quartz; silicon; or a combination of two or more thereof. 11. The process of claim 7 wherein the heat exchanger comprises heat exchange channels in thermal contact with the process microchannels. 12. The process of claim 11 wherein the heat exchange channels comprise microchannels. 13. The process of claim 12 wherein each heat exchange microchannel has an internal dimension of width or height of up to about 10 mm. 14. The process of claim 11 wherein the heat exchange channels are made of a material comprising: steel; monel; inconel; aluminum; titanium; nickel; copper; brass; an alloy of any of the foregoing metals; a polymer; ceramics; glass; a composite comprising polymer and fiberglass; quartz; silicon; or a combination of two or more thereof. 15. The process of claim 1 wherein the product exiting the microchannel reactor is at a temperature in the range of about 100 to about 1000째 C., and during step (C) it is cooled to a temperature in the range of about 50 to about 300째 C. in about 5 to about 100 milliseconds. 16. The process of claim 1 wherein the microchannel reactor has an entrance and an exit, the product exits the microchannel reactor through the exit, and at least part of the product exiting the microchannel reactor is recycled to the entrance to the microchannel reactor. 17. The process of claim 1 wherein the hydrocarbon reactant comprises: a saturated aliphatic compound, an unsaturated aliphatic compound, an aldehyde, an alkyl or alkylene substituted aromatic compound, or a mixture of two or more thereof. 18. The process of claim 1 wherein the hydrocarbon reactant comprises an alkane containing 1 to about 20 carbon atoms per molecule. 19. The process of claim 1 wherein the hydrocarbon reactant comprises methane, ethane, propane, isopropane, butane, isobutane, a pentane, a hexane, a heptane, an octane, a nonane, a decane, or a mixture of two or more thereof. 20. The process of claim 1 wherein the hydrocarbon reactant comprises an alkene containing 2 to about 20 carbon atoms. 21. The process of claim 1 wherein the hydrocarbon reactant comprises ethylene; propylene; 1-butene; 2-butene; isobutylene; 1-pentene; 2-pentene; 3-methyl-1-butene; 2-methyl-2-butene; 1-hexene; 2,3-dimethyl-2-butene; 1-heptene; 1-octene; 1-nonene; 1-decene; or a mixture of two or more thereof. 22. The process of claim 1 wherein the hydrocarbon reactant comprises a polyene containing 3 to about 20 carbon atoms. 23. The process of claim 1 wherein the hydrocarbon reactant comprises 1,2-propadiene; 1,3-butadiene; 2-methyl-1,3-butadiene; 1,3-pentadiene; 1,4-pentadiene; 1,5-hexadiene; 2,4-hexadiene; 2,3-dimethyl-1,3-butadiene; or a mixture of two or more thereof. 24. The process of claim 1 wherein the hydrocarbon reactant comprises an aldehyde containing 1 to about 20 carbon atoms. 25. The process of claim 1 wherein the hydrocarbon reactant comprises formaldehyde; acetaldehyde; propionaldehyde; n-butyraldehyde; n-valeraldehyde; caproaldehyde; acrolein; tran-2-cis-6-nonadienal; n-heptylaldehyde; trans-2-hexenal; hexadeconal; benzaldehyde; phenylacetaldehyde; o-tolualdehyde; m-tolualdehyde; p-tolualdehyde; salicylaldehyde; p-hydroxybenzaldehyde; or a mixture of two or more thereof. 26. The process of claim 1 wherein the hydrocarbon reactant comprises an alkyl or alkylene substituted aromatic compound. 27. The process of claim 1 wherein the hydrocarbon reactant comprises toluene, o-xylene, m-xylene, p-xylene, hemimellitene, pseudocumene, mesitylene, prehnitene, isodurene, durene, pentamethylbenzene, hexamethylbenzene, ethylbenzene, n-propylbenzene, cumene, n-butylbenzene, isobutylbenzene, sec-butylbenzene, tert-butylbenzene, p-cymene, styrene, or a mixture of two or more thereof. 28. The process of claim 1 wherein the reactant composition comprises ammonia. 29. The process of claim 1 wherein the source of oxygen comprises air. 30. The process of claim 1 wherein the reactant composition further comprises a diluent material. 31. The process of claim 11 wherein the process microchannels are cooled using a heat exchange fluid flowing through the heat exchange channels. 32. The process of claim 31 wherein the heat exchange fluid undergoes a phase change as it flows through the heat exchange channels. 33. The process of claim 11 wherein the process microchannels are cooled by an endothermic chemical reaction conducted in the heat exchange channels. 34. The process of claim 33 wherein the endothermic chemical reaction comprises a steam reforming reaction or a dehydrogenation reaction. 35. The process of claim 11 wherein the reactant composition flows through the process microchannels in a first direction, and a heat exchange fluid flows through the heat exchange channels in a second direction, the second direction being cross current relative to the first direction. 36. The process of claim 11 wherein the reactant composition flows through the process microchannels flow in a first direction, and a heat exchange fluid flows through the heat exchange channels in a second direction, the second direction being cocurrent relative to the first direction. 37. The process of claim 11 wherein the hydrocarbon reactant composition flows through the process microchannels in a first direction, and a heat exchange fluid flows through the heat exchange channels in a second direction, the second direction being counter current relative to the first direction. 38. The process of claim 11 wherein a heat exchange fluid flows through the heat exchange channels, the heat exchange fluid comprising air, steam, liquid water, carbon dioxide, gaseous nitrogen, liquid nitrogen, a gaseous hydrocarbon or a liquid hydrocarbon. 39. The process of claim 1 wherein the catalyst comprises a flow-by structure or a flow-through structure. 40. The process of claim 7 wherein the process microchannels have an interior surface and the catalyst is coated on the interior surface of the process microchannels. 41. The process of claim 1 wherein the catalyst is in the form of particulate solids, foam, felt, wad, honeycomb, insertable fin, or a combination of two or more thereof. 42. The process of claim 1 wherein the catalyst has a serpentine configuration. 43. The process of claim 1 wherein the catalyst is in the form of a flow-by structure with an adjacent gap, a foam with an adjacent gap, a fin structure with gaps, a washcoat on an inserted substrate, or a gauze that is parallel to the flow direction with a corresponding gap for flow. 44. The process of claim 1 wherein the catalyst comprises a porous support, an interfacial layer, and a catalytic material. 45. The process of claim 1 wherein the catalyst comprises a porous support, a buffer layer, an interfacial layer, and a catalytic material. 46. The process of claim 1 wherein the catalyst comprises at least one metal, metal oxide or mixed metal oxide of a metal selected from the group consisting of Mo, W, V, Nb, Sb, Sn, Pt, Pd, Cs, Zr, Cr, Mg, Mn, Ni, Co, Ce, and mixtures of two or more thereof. 47. The process of claim 46 wherein the catalyst further comprises a metal, oxide or mixed metal oxide of an alkali or alkaline earth metal, a transition metal, a rare earth metal, a lanthanide, or a mixture of two or more thereof. 48. The process of claim 44 wherein the catalyst further comprises P, Bi or a mixture thereof. 49. The process of claim 1 wherein the catalyst comprises a support comprising a metal oxide, silica, mesoporus material, refractory material, or a combination of two or more thereof. 50. The process of claim 1 wherein the contact time of the reactant composition and/or product with the catalyst is from about 0.1 milliseconds to about 100 seconds. 51. The process of claim 7 wherein the temperature of the reactant composition entering the process microchannels is in the range of about 150째 C. to about 1000째 C. 52. The process of claim 7 wherein the pressure of the reactant composition entering the process microchannels is in the range of about 0.5 to about 100 atmospheres. 53. The process of claim 7 wherein the space velocity for the flow of the reactant composition and product through the process microchannels is at least about 100 hr.-1. 54. The process of claim 1 wherein the product comprises a monool or a polyol. 55. The process of claim 1 wherein the product comprises methanol, ethyl alcohol, propyl alcohol, butyl alcohol, isobutyl alcohol, pentyl alcohol, cyclopentyl alcohol, crotyl alcohol, hexyl alcohol, cyclohexyl alcohol, allyl alcohol, benzyl alcohol, glycerol, or a mixture of two or more thereof. 56. The process of claim 1 wherein the product comprises an epoxide. 57. The process of claim 1 wherein the product comprises ethylene oxide, propylene oxide, butylene oxide, isobutylene oxide, cyclopentene oxide, cyclohexene oxide, styrene oxide, or a mixture of two or more thereof. 58. The process of claim 1 wherein the product comprises an aldehyde. 59. The process of claim 1 wherein the product comprises formaldehyde; acetaldehyde; propionaldehyde; n-butyraldehyde; n-valeraldehyde; caproaldehyde; acrolein; tran-2-cis-6-nonadienal; n-heptylaldehyde; trans-2-hexenal; hexadeconal; benzaldehyde; phenylacetaldehyde; o-tolualdehyde; m-tolualdehyde; p-tolualdehyde; salicylaldehyde; p-hydroxybenzaldehyde; or a mixture of two or more thereof. 60. The process of claim 1 wherein the product comprises a carboxylic acid, a carboxylic acid anhydride, or a mixture thereof. 61. The process of claim 1 wherein the product comprises formic acid, acetic acid, propionic acid, butyric acid, isobutyric acid, valeric acid, caproic acid, caprylic acid, capric acid, acrylic acid, methacrylic acid, benzoic acid, toluic acid, phthalic acid, salicylic acid, acetic anhydride, maleic anhydride, phthalic anhydride, benzoic anhydride, or a mixture of two or more thereof. 62. The process of claim 1 wherein the product comprises an ester. 63. The process of claim 1 wherein the product comprises methylacetate, vinyl acetate, ethyl acetate, n-propyl acetate, n-butyl acetate, n-pentyl acetate, isopentyl acetate, benzyl acetate, phenyl acetate, or a mixture of two or more thereof. 64. The process of claim 1 wherein the product comprises a nitrile. 65. The process of claim 1 wherein the product comprises formonitrile, acrylonitrile, methacrylonitrile, or a mixture of two or more thereof. 66. The process of claim 1 wherein the fluid hydrocarbon reactant comprises methane, and the product comprises methanol, formaldehyde, formontrile, or a mixture of two or more thereof. 67. The process of claim 1 wherein the fluid hydrocarbon reactant comprises ethane, and the product comprises ethyl alcohol, ethylene oxide, acetic acid, vinyl acetate, or a mixture of two or more thereof. 68. The process of claim 1 wherein the fluid hydrocarbon reactant comprises ethylene, and the product comprises ethyl alcohol, ethylene oxide, acetic acid, vinyl acetate, or a mixture of two or more thereof. 69. The process of claim 1 wherein the fluid hydrocarbon reactant comprises propane, and the product comprises propylene oxide, acrylic acid, acrolein, acrylonitrile, or a mixture thereof. 70. The process of claim 1 wherein the fluid hydrocarbon reactant comprises propylene, and the product comprises propylene oxide, acrylic acid, acrolein, acrylonitrile, or a mixture thereof. 71. The process of claim 1 wherein the fluid hydrocarbon reactant comprises n-butane, and the product comprises n-butanol, maleic anhydride, or a mixture thereof. 72. The process of claim 1 wherein the fluid hydrocarbon reactant comprises n-butene, and the product comprises n-butanol, maleic anhydride, or a mixture thereof. 73. The process of claim 1 wherein the fluid hydrocarbon reactant comprises isobutane, and the product comprises isobutanol, methacrylic acid, methacrylonitrile, or a mixture thereof. 74. The process of claim 1 wherein the fluid hydrocarbon reactant comprises isobutylene, and the product comprises isobutanol, methacrylic acid, methacrylonitrile, or a mixture thereof. 75. The process of claim 1 wherein the fluid hydrocarbon reactant comprises toluene, and the product comprises benzyl alcohol, benzoic acid, benzaldehyde, or a mixture thereof. 76. The process of claim 1 wherein the fluid hydrocarbon reactant comprises xylene, and the product comprises toluic acid, phthalic acid, phthalic anhydride, or a mixture thereof. 77. The process of claim 1 wherein the fluid hydrocarbon reactant comprises cyclopentene, and the product comprises cyclopentene oxide. 78. The process of claim 1 wherein the fluid hydrocarbon reactant comprises cyclohexene, and the product comprises cyclohexene oxide. 79. The process of claim 1 wherein the fluid hydrocarbon reactant comprises styrene, and the product comprises styrene oxide. 80. The process of claim 1 wherein the fluid hydrocarbon reactant comprises acrolein and the product comprises acrylic acid. 81. The process of claim 11 wherein a heat exchange fluid flows through the heat exchange channels, the total pressure drop for the heat exchange fluid flowing through the heat exchange channels being up to about 10 atmospheres. 82. A process for converting a hydrocarbon reactant to a product, the process comprising: (A) flowing a reactant composition comprising the hydrocarbon reactant, and oxygen or a source of oxygen, and optionally ammonia, in a microchannel reactor in contact with a catalyst to convert the hydrocarbon reactant to the product, the product comprising an oxygenate or a nitrile; the hydrocarbon reactant undergoing an exothermic reaction in the microchannel reactor; the microchannel reactor comprising a plurality of process microchannels containing the catalyst, each of the process microchannels having an entrance, an exit and an elongated section extending between the entrance and the exit, each of the process microchannels further comprising at least one additional entrance in the elongated section, the hydrocarbon reactant and optionally ammonia flowing through the entrance into the process microchannels, the oxygen or source of oxygen entering the process microchannels through the at least one additional entrance and contacting the hydrocarbon reactant and optionally ammonia in the process microchannels; (B) transferring heat from the microchannel reactor to a heat exchanger during step (A), the heat exchanger comprising heat exchange channels, the heat exchange channels being adjacent to the process microchannels; and (C) quenching the product from step (A). 83. A process for converting a hydrocarbon reactant to a product, the process comprising: (A) flowing a reactant composition comprising the hydrocarbon reactant, and oxygen or a source of oxygen in a microchannel reactor in contact with a catalyst to convert the hydrocarbon reactant to the product, the product comprising an oxygenate, the oxygen or source of oxygen being in the form of a gas, the hydrocarbon reactant undergoing an exothermic reaction in the microchannel reactor, the microchannel reactor comprising a plurality of process microchannels containing the catalyst, the hydrocarbon reactant flowing in the process microchannels, the oxygen or source of oxygen entering the process microchannels at different points along the length of the process microchannels; (B) transferring heat from the microchannel reactor to a heat exchanger during step (A), the heat exchanger comprising heat exchange microchannels in thermal contact with the process microchannels; and (C) quenching the product from step (A). 84. A process for converting a hydrocarbon reactant to a product, the process comprising: (A) flowing a reactant composition comprising the hydrocarbon reactant, and oxygen or a source of oxygen, and ammonia, in a microchannel reactor in contact with a catalyst to convert the hydrocarbon reactant to the product, the product comprising a nitrile, the oxygen or source of oxygen being in the form of a gas, the hydrocarbon reactant undergoing an exothermic reaction in the microchannel reactor, the microchannel reactor comprising a plurality of process microchannels containing the catalyst, the hydrocarbon reactant and ammonia flowing in the process microchannels, the oxygen or source of oxygen being added to the hydrocarbon reactant and ammonia at different points along the length of the process microchannels; (B) transferring heat from the microchannel reactor to a heat exchanger during step (A), the heat exchanger comprising heat exchange microchannels in thermal contact with the process microchannels; and (C) quenching the product from step (A). 85. A process for converting a hydrocarbon reactant to a product, the process comprising: (A) flowing a reactant composition comprising the hydrocarbon reactant, and oxygen or a source of oxygen, and optionally ammonia, in a microchannel reactor in contact with a catalyst to convert the hydrocarbon reactant to the product, the product comprising an oxygenate or a nitrile, the microchannel reactor comprising at least one process microchannel, the catalyst being in the process microchannel, the oxygen or source of oxygen being mixed with the hydrocarbon reactant and optionally ammonia in the process microchannel, the hydrocarbon reactant undergoing an exothermic reaction in the process microchannel; (B) transferring heat from the process microchannel to a heat exchanger during (A); and (C) quenching the product formed in (A) by reducing the temperature of the product by up to about 950째 C. within a period of up to about 500 milliseconds. 86. A process for converting a hydrocarbon reactant to a product, the process comprising: (A) flowing a reactant composition comprising the hydrocarbon reactant, and oxygen or a source of oxygen, and optionally ammonia, in a microchannel reactor in contact with a catalyst to convert the hydrocarbon reactant to the product, the product comprising an oxygenate or a nitrile, the microchannel reactor comprising at least one process microchannel, the catalyst being in the process microchannel, the oxygen or source of oxygen being mixed with the hydrocarbon reactant and optionally ammonia in the process microchannel, the hydrocarbon reactant undergoing an exothermic reaction in the process microchannel; (B) transferring heat from the process microchannel to a heat exchanger during (A); and (C) quenching the product formed in (A) by flowing the product through a quenching apparatus having a dimension equal to or below the quench diameter of the reaction. 87. A process for converting a hydrocarbon reactant to a product, the process comprising: (A) flowing a reactant composition comprising the hydrocarbon reactant, and oxygen or a source of oxygen, and optionally ammonia, in a microchannel reactor in contact with a catalyst to convert the hydrocarbon reactant to the product, the product comprising an oxygenate or a nitrile, the microchannel reactor comprising at least one process microchannel, the catalyst being in the process microchannel, the hydrocarbon reactant undergoing an exothermic reaction in the process microchannel; and (B) transferring heat from the process microchannel to a heat exchanger during (A), the heat exchanger comprising at least one heat exchange channel in thermal contact with the process microchannel, a heat exchange fluid in the heat exchange channel undergoing phase change in the heat exchange channel. 88. A process for converting a hydrocarbon reactant to a product, the process comprising: (A) flowing a reactant composition comprising the hydrocarbon reactant, and oxygen or a source of oxygen, and optionally ammonia, in a microchannel reactor in contact with a catalyst to convert the hydrocarbon reactant to the product, the product comprising an oxygenate or a nitrile, the microchannel reactor comprising at least one process microchannel, the catalyst being in the process microchannel, the hydrocarbon reactant undergoing an exothermic reaction in the process microchannel; and (B) transferring heat from the process microchannel to a heat exchanger during (A), the heat exchanger comprising at least one heat exchange channel in thermal contact with the process microchannel, an endothermic reaction being conducted in the heat exchange channel. 89. A process for converting a hydrocarbon reactant to a product, the process comprising: (A) flowing a reactant composition comprising the hydrocarbon reactant, and oxygen or a source of oxygen, and optionally ammonia, in a microchannel reactor in contact with a catalyst to convert the hydrocarbon reactant to the product, the product comprising an oxygenate or a nitrile, the microchannel reactor comprising at least one process microchannel, the catalyst being in the process microchannel, the hydrocarbon reactant undergoing an exothermic reaction in the process microchannel; (B) transferring heat from the process microchannel to a heat exchanger during (A) to maintain the temperature of the reactant composition at the entrance to the process microchannel within about 200째 C. of the temperature of the product exiting the process microchannel, the heat exchanger comprising a heat exchange fluid which undergoes a phase change or an endothermic reaction. 90. A process for converting a hydrocarbon reactant to a product, the process comprising: (A) flowing a reactant composition comprising the hydrocarbon reactant, and oxygen or a source of oxygen, and optionally ammonia, in a microchannel reactor in contact with a catalyst to convert the hydrocarbon reactant to the product, the product comprising an oxygenate or a nitrile, the microchannel reactor comprising at least one process microchannel, the catalyst being in the process microchannel, the oxygen or source of oxygen flowing into the process microchannel to contact the hydrocarbon reactant and optionally ammonia at various points along the length of the process microchannel, the hydrocarbon reactant undergoing an exothermic reaction in the process microchannel; and (B) transferring heat from the process microchannel to a heat exchanger during (A). 91. A process for converting a hydrocarbon reactant to a product, the process comprising: (A) flowing a reactant composition comprising the hydrocarbon reactant, and oxygen or a source of oxygen, and optionally ammonia, in a microchannel reactor in contact with a catalyst to convert the hydrocarbon reactant to the product, the product comprising an oxygenate or a nitrile, the microchannel reactor comprising at least one process microchannel, the catalyst being in the process microchannel, the oxygen or source of oxygen being mixed with the hydrocarbon reactant and optionally ammonia in the process microchannel, the hydrocarbon reactant undergoing an exothermic reaction in the process microchannel; and (B) transferring heat from the process microchannel to a heat exchanger during (A).