Dealuminized catalyst support, method for producing said catalyst support and method for hydrating C2- or C3-olefins with water in the presence of a catalyst consisting of this catalyst support impregnated with acid

Abstract

What is claimed is a dealuminated catalyst carrier, a process for producing a catalyst carrier with reduced aluminium content based on naturally occurring lattice-layer silicates, such as, for example, montmorillonite, as well as a process for the hydration reaction of C 2 - or C 3 -olefins in which said catalyst carrier with reduced aluminium content is used. For acid-catalysed hydration reaction the catalyst carrier is impregnated with phosphoric acid. The improvements according to the invention of the hydration reaction compared to conventional processes include the fact that no aluminium is leached out of the carrier in the presence of the phosphoric acid. As a result no more blockage of the succeeding apparatus due to aluminum phosphate is expected.

1 - 35 . (canceled)  
     
     
         36 . A catalyst/catalyst carrier having an aluminum content of less than 0.3% by weight, said catalyst/catalyst carrier being obtained from layer-lattice silicates by reducing the aluminum content by a dealuminating process, wherein the dealuminating process comprises treatment with an acid and hydrothermally treating the acid-impregnated lattice-layer silicate at a temperature of between 160 and 300° C. and a partial water vapor pressure of between 4 and 80 bar abs .  
     
     
         37 . The catalyst/catalyst carrier according to  claim 36  wherein the aluminum content is less than 0.03% by weight.  
     
     
         38 . The catalyst/catalyst carrier according to any one of claims  36  or  37  wherein said lattice layer silicate is a smectite.  
     
     
         39 . The catalyst/catalyst carrier according to any one of claims  36  or  37  wherein said lattice-layer silicate has a montmorillonite structure.  
     
     
         40 . The catalyst/catalyst carrier according to any one of claims  36  or  37  wherein the cumulative pore volume is between 0.2 and 0.9 ml/g.  
     
     
         41 . The catalyst/catalyst carrier according to  claim 40  wherein the cumulative pore volume is between 0.6 and 0.7 ml/g.  
     
     
         42 . The catalyst/catalyst carrier according to any one of claims  36  or  37  in the shape of a spherical body.  
     
     
         43 . The catalyst/catalyst carrier according to  claim 42  wherein said spherical body comprises a ball.  
     
     
         44 . The catalyst/catalyst carrier according to  claim 42  wherein said spherical body has a diameter of between 1 and 10 mm.  
     
     
         45 . The catalyst/catalyst carrier according to  claim 44  wherein said spherical body has a diameter of between 4 and 6 mm.  
     
     
         46 . The catalyst/catalyst carrier according to any one of claims  36  or  37  wherein the pressure resistance is at least 10 N/mm.  
     
     
         47 . The catalyst/catalyst carrier according to  claim 46  wherein the pressure resistance is at least 20 N/mm.  
     
     
         48 . The catalyst/catalyst carrier according to  claim 36  or  37  where said hydrothermal treatment is conducted at a temperature of between 220 and 260° C. and a partial water vapor pressure of between 16 and 25 bar abs .  
     
     
         49 . The catalyst/catalyst carrier of any one of claims  36  or  37  wherein said hydrothermal treatment is conducted, at least in part, during the use of said catalyst carrier in a hydration reaction.  
     
     
         50 . A catalyst/catalyst carrier produced by the process according to any one of claims  36  or  37 .  
     
     
         51 . A catalyst/catalyst carrier according to any one of claims  36  or  37  having at least partially a cristobalite-like structure.  
     
     
         52 . A catalyst/catalyst carrier comprising an aluminum content of less than 0.3% by weight, said catalyst/catalyst carrier being obtained from layer-lattice silicates having smectite and/or montmorillionite structure wherein the aluminum content is reduced by a dealuminating process, and wherein the catalyst comprises a phosphoric acid.  
     
     
         53 . The catalyst/catalyst carrier of  claim 52 , wherein the dealuminating process comprises treatment with an acid and hydrothermally treating the acid-impregnated lattice-layer silicate at a temperature of between 160 and 300° C. and a partial water vapor pressure of between 4 and 80 bar abs .  
     
     
         54 . Process for hydration of olefins, preferably C 2  or C 3  olefins, with water in the presence of at least one catalyst, which is made from a catalyst/catalyst carrier comprising an aluminum content of less than 0.3% by weight obtainable from mainly layer-lattice silicates which contain aluminum by a dealuminating process, said catalyst/catalyst carrier being impregnated with acid.  
     
     
         55 . Process according to  claim 54 , wherein the hydration reaction is carried out in a reactor wherein 
 the olefin to water molar ratio is adjusted to between 0.1 and 0.8    gas hourly space velocity is from 10 to 100 1 n /min/1 cat      said catalyst contains 5 to 60% by weight of acid, and    the hydration reaction of the olefins is carried out at a temperature of between 160 and 300° C. and an pressure of between 20 and 200 bar absolute .    
     
     
         56 . Process according to any one of claims  54  or  55 , wherein said acid with which the catalyst/catalyst carrier is impregnated is a 10 to 90% by weight phosphoric acid.  
     
     
         57 . Process according to  claim 56 , wherein said acid with which the catalyst/catalyst carrier is impregnated is a 50 to 60% by weight phosphoric acid.  
     
     
         58 . Process according to any one of claims  54  or  55 , wherein said catalyst contains 5 to 60% of an acid, calculated as pure acid, in particular a mineral acid.  
     
     
         59 . Process according to any one of claims  54  or  55 , wherein the hydration reaction for producing ethanol from ethene is carried out at a temperature of between 220 and 260° C. and a pressure of between 60 and 80 bar.  
     
     
         60 . Process according to any one of the claims  54  or  55 , wherein the olefin and water are introduced into the reaction in gaseous form.  
     
     
         61 . Process according to any one of claims  54  or  55 , wherein said acid is introduced during the course of the hydration reaction.  
     
     
         62 . Process according to  claim 61 , wherein said acid used is phosphoric acid.  
     
     
         63 . Process according to any one of claims  54  or  55 , wherein said acid is injected continuously during the course of the hydration reaction.  
     
     
         64 . Process according to any one of claims  54  or  55 , wherein said catalyst/catalyst carrier has an aluminum content of less than 0.03% by weight.  
     
     
         65 . Process according to any one of claims  54  or  55 , wherein said layer-lattice silicates used are smectite and/or have preferably montmorillonite structures.  
     
     
         66 . Process according to any one of claims  54  or  55 , wherein said catalyst/catalyst carrier has a cumulative pore volume of between 0.2 and 0.9 ml/g.  
     
     
         67 . Process according to any one of claims  54  or  55 , wherein said catalyst/catalyst carrier has a total pore volume of between 0.6 and 0.7 ml/g.  
     
     
         68 . Process according to any one of claims  54  or  55 , wherein said catalyst/catalyst carrier has the shape of a spherical body.  
     
     
         69 . Process according to any one of claims  54  or  55 , wherein said catalyst/catalyst carrier has the shape of a ball.  
     
     
         70 . Process according to any one of claims  54  or  55 , wherein said catalyst/catalyst carrier has a diameter of between 1 and 10 mm.  
     
     
         71 . Process according to any one of claims  54  or  55 , wherein said catalyst/catalyst carrier has a diameter of between 4 and 6 mm.  
     
     
         72 . Process according to any one of claims  54  or  55 , wherein said catalyst/catalyst carrier has a pressure resistance of at least 10 N/mm.  
     
     
         73 . Process according to any one of claims  54  or  55 , wherein said catalyst/catalyst carrier has a pressure resistance of at least 20 N/mm.  
     
     
         74 . Process according to any one of claims  54  or  55 , wherein said catalyst/catalyst carrier is obtained by 
 impregnating said layer-lattice silicates containing alumina to produce an impregnated layer-lattice silicate with an acid    treating said acid impregnated layer-lattice silicates hydrothermally to produce a hydrothermally treated impregnated layer-lattice silicate    washing said hydrothermally treated impregnated layer-lattice silicate with an acidic, a basic or a neutral solution; and    optionally rinsing with water.    
     
     
         75 . Process according to  claim 74 , wherein said impregnating with an acid comprises impregnating with a mineral acid, in particular with phosphoric acid.  
     
     
         76 . Process according to  claim 74 , wherein said hydrothermal treatment takes place at a temperature of between 160 and 300° C. and/or at a partial water vapor pressure of between 4 and 80 bar abs .  
     
     
         77 . Process according to  claim 74 , wherein said hydrothermal treatment takes place at a temperature of between 220 and 260° C. and/or at a partial water vapor pressure of between 16 and 25 bar abs .  
     
     
         78 . Process according to  claim 74 , wherein said hydrothermal treatment takes place completely or in part during said hydration reaction.  
     
     
         79 . Process according to  claim 74 , wherein said washing takes place at a temperature of between 25 and 100° C.  
     
     
         80 . Process according to  claim 74 , wherein said washing takes place at a temperature of between 70 and 90° C.  
     
     
         81 . Process according to  claim 74 , wherein said washing takes place with water, with hydrochloric acid or with water containing some amount up to 30 parts of concentrated hydrochloric acid.  
     
     
         82 . Process according to  claim 74 , wherein said rinsing takes place until the washing water becomes neutral.