含钒氧化物和复合氧化物催化剂的制备及其在甲烷和丙烷选择氧化反应中的应用研究
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摘要
随着全球范围内石油的有限贮存量及日益严重的能源危机,寻找可以替代石油的其它能源形式已经越来越引起人们的关注,其中围绕天然气的有效利用而开展的研究在世界范围内广泛展开。众所周知,饱和的低碳烷烃(主要以甲烷,乙烷,丙烷等为主)是天然气中的主要成分,通过催化过程实现低碳烷烃的功能化是天然气有效利用的主要途径。
目前文献报道的甲烷转化途径有直接转化和间接转化两种,间接转换是目前甲烷利用的主要形式,例如由甲烷经水蒸气重整反应制合成气,然后由F-T合成等反应进一步转化为液体燃料和有机化工原料;但这些工艺过程存在诸多缺点,如设备复杂、过程繁琐、投资大、操作条件苛刻、需高温高压、设备要耐腐蚀等等。如果能够实现甲烷的直接转化,则必然大大节约生产成本及能耗,符合国民经济可持续发展的要求。在甲烷的直接转化过程中,甲烷选择氧化制甲醛是近年来研究较多的方向之一。在甲烷选择氧化制甲醛的研究中,所采用的活性组分大部分是过渡金属元素,其中以Mo和V居多,所用载体主要包括Al_2O_3、TiO_2、ZrO_2以及SiO_2等,以SiO_2为主。总体而言,这些催化剂的活性均不够高,除与活性组分有关外,还与活性组分在载体上的分散程度有关。介孔材料以其规则孔道结构、高比表面积和热稳定性成为一类受到广泛关注的新型载体,在低碳烷烃的选择性氧化反应中以介孔材料MCM-41、MSU-2、SBA-1、SBA-15等为载体的负载型催化剂显示出比较好的催化活性。
丙烯是现代石油化工重要的基础原料之一,从丙烯出发可以生产一系列重要的丙烯衍生物,如丙烯腈、丙烯醛、丙烯酸、聚丙烯、异丙橡胶等。目前丙烯主要来自于石油蒸汽裂解,随着石油资源的日趋短缺,势必影响丙烯的产出,难以满足丙烯日益增加的旺盛需求。天然气中有着相对丰富的丙烷资源,而从丙烷催化选择氧化制丙烯则被认为是生产丙烯的一条可能途径。含有钒基的氧化物负载型催化剂在丙烷催化选择氧化制丙烯中具有较好的催化作用,在已报道的研究体系中,所使用的载体有SiO_2,Al_2O_3,TiO_2,ZrO_2和MgO等。经研究发现,催化剂的酸碱性、催化剂表面钒物种的状态、表面钒物种的还原性能、载体的比表面和孔道结构等因素都会影响催化剂的选择氧化性能。一般认为在具有大孔径和孔容的氧化硅上有较好的丙烷选择氧化制丙烯的催化效果。随着MCM-41系列介孔分子筛的开发,氧化物负载在介孔分子筛上作为催化剂已有大量报道,一般是以负载法制备催化剂。这种方法制备的催化剂活性组分主要分布在孔道表面,其优点是制备过程简便实用,但其缺点是负载上的组分容易阻塞孔道,高温反应后易团聚。如果能将纳米氧化物颗粒以高度分散的形式嵌入到介孔分子筛孔壁,使得活性组分更容易和载体相互作用,不但不会阻塞孔道,而且还具有比较高的活性比表面,增加抗团聚性能,从而有可能提高催化效果。
本论文旨在开发应用于甲烷和丙烷选择氧化的新型金属氧化物催化剂,提高活性组分在载体中的分散度及增强活性组分与载体之间的相互作用,减少活性组分的流失;另外,本论文还研究了不同的制备方法对催化剂制备及性能的影响。通过各种现代表征手段,研究活性组分的存在状态及在反应中的作用,进一步关联催化活性与催化剂微观结构的关系。
论文的主要工作及结果如下:
一、以杂多酸为前驱体,浸渍和原位合成含PMoV复合氧化物分子筛催化剂及在甲烷选择氧化中的催化性能研究
近年来的研究表明,负载型MoO_3或V_2O_5催化剂中添加P元素具有很好的修饰作用,在甲烷选择氧化制备甲醛的反应中能够显著提高甲醛的选择性。第三章和第四章内容主要是围绕处在研究开发阶段的甲烷直接选择氧化制备甲醛(MPO)反应而展开的。
我们选用含PMoV的杂多酸H_5PMo_(10)V_2O_(40)作为合成催化剂的前驱体,具有孔径分布均一,热稳定性较好的介孔SBA-15为载体,通过常温下湿法浸渍制备了不同含量的负载型PMoV/SBA-15,对其甲烷选择氧化反应(MPO)性能进行了比较,考察了负载量、反应温度、空速等对甲烷转化率和甲醛选择性的影响,结果表明甲烷转化率随负载量的增大和反应温度的升高而提高,甲醛的选择性随反应温度的升高而降低、随负载量的增大先升后降,加大空速甲烷的转化率降低而甲醛的选择性升高,在考察范围内催化剂在反应条件为:T=640℃、GHSV=48320L/Kg·h、氧化物负载量为2.89%时,甲醛的时空产率为最高(295g·Kg_(cat)~(-1)h~(-1))。XRD、氮吸附、NH_3-TPD、H_2-TPR、Raman和FT-IR结果表明,氧化物含量≤2.89%时,P-Mo-V氧化物在载体介孔孔道内以高度分散的状态存在,催化剂的酸性和氧化还原性质与负载量相关,这些特征和性质进而影响催化剂的反应活性。
众所周知,在介孔材料的合成中,盐酸和硝酸一般作为酸度调节剂来使用。考虑杂多酸既可溶于水又可溶于醇类中,利用其溶解后可以完全电离出氢离子的特点,我们选用含有PMoV杂多酸H_5PMo_(10)V_2O_(40)作为合成介孔材料的酸度调节剂和活性组分的前驱体,在乙醇体系中,合成出具有规整孔道结构的PMoV-mesoSiO_2介孔材料,杂多酸的添加量会直接影响合成样品的形貌和孔结构特点。通过TG-DTA,XRD,XRF,氮吸附,TEM,FTIR和拉曼等的表征,发现这些介孔材料具有类似MCM-48的三维立方结构。P-Mo-V氧化物的含量低于6.68%时,复合氧化物在mesoSiO_2中具有很好的分散性,而适当氧化物含量的催化剂在甲烷选择氧化制备甲醛反应中具有较好的催化活性。同时在相近的含量下,比较由共合成法和普通浸渍法制备的催化剂的催化活性,发现由共合成法制备出的3.40PMoV-mesoSiO_2催化剂具有较高的催化活性。在优化的反应条件下,该催化剂上甲醛的最高时空产率为330 g Kg_(cat)~(-1)h~(-1)。
二、共合成法制备含钒介孔分子筛及在丙烷选择氧化中的催化性能研究
基于前人大量研究结果表明:含钒基的二氧化硅催化剂在丙烷选择氧化制丙烯中有较好催化活性。本部分主要是利用可溶于水的硫酸氧钒作为前驱体,在不同的条件下,原位共合成了含钒不同类型的介孔分子筛并应用于丙烷选择氧化反应。
因为新型介孔分子筛SBA-15具有大的比表面及孔径,自从问世以来,一直被人们广泛应用在催化领域。在第五章中,我们在水相中以硫酸氧钒为前驱体,P123为模板剂,通过调节水热混合液的pH值,经过水热及焙烧处理后制备出含钒分子筛,分别用TG-DTA,XRD,XRF,氮吸附,TEM,拉曼,NH_3-TPD和H_2-TPR等研究了催化剂的物化性质并测试了其在丙烷选择氧化反应的催化性能。结果表明,由pH调节法所合成出的V-SBA-15催化剂具有大约350 m~2/g的比表面、10 nm左右的平均孔径且典型的两维六角的孔道结构;氧化钒在分子筛的骨架内主要是以高度分散的孤立态的四面体钒氧形式存在,这正是丙烷选择氧化反应中的活性中心位。通过优化反应温度、空速和丙烷与氧气之间的比例等条件,0.98V-SBA-15催化剂对于丙烷选择氧化反应取得较好的催化活性结果:T=600℃,GHSV=15000 L·Kg~(-1)·h~(-1),丙烯的单程最大产率为13.3%。
具有大的比表面及热稳定性和水热稳定性的HMS分子筛一直是催化工作者关注的热点。第六章中主要是在合成蠕虫状材料HMS的过程中,加入硫酸氧钒制备出V-HMS分子筛。通过对合成出的分子筛进行相应的物化表征分析,显示我们合成出的V-HMS样品具有大的比表面和孔容,分别为930 m~2/g和0.8 cm~3/g左右。钒物种进入了分子筛骨架并与硅形成稳定的Si-O-V键。发现催化剂中氧化钒含量≤6.21%时,钒物种以高度分散的孤立态的钒氧四面体存在。在优化的反应条件下,6.21V-HMS上丙烯选择性为43.0%,单程最大产率为16.6%。优于文献中报道的负载型V/HMS催化剂。
考虑在介孔材料中所使用的模板剂一般都是长链的嵌段共聚物,价格较昂贵,而采用比较环保的化学试剂是现代绿色化学的一个要求,第七章中我们使用毒性较小且价格相对便宜的有机二元羧酸(戊二酸)来作为模板剂,采用溶胶—凝胶法,将氧化钒纳米粒子嵌入到硅骨架,得到高分散、高比表面(～600 m~2/g)、较大孔径(～5 nm)的钒硅分子筛催化材料,并研究其在丙烷选择氧化反应中的催化活性。研究表明,催化剂制备前后钒物种基本无损失,合成得到的钒硅介孔分子筛中钒物种分布均匀,主要以孤立态四面体构型为主。3.96V-meso-SiO_2在T=600℃,GHSV=18750 L·Kg~(-1)·h~(-1)时,丙烷有较大转化率(45.8%),丙烯产率为14.8%。
三、双溶剂法制备大孔径、负载型钒基催化剂及在丙烷选择氧化中的应用研究
MCM-41和SBA-15是催化领域应用非常广泛的介孔分子筛,二者的结构均属P6mm相,是两维孔道结构。但在选择氧化反应中,传质和扩散的因素使人们还注意到开拓更大孔径的载体及具有三维连续孔结构材料。最近一种新的介孔泡沫材料MCF被合成出来。它是一种具有超大孔径、三维连续孔道结构、极好的热稳定性的新型材料,其形貌类似于蜂窝或海绵。这种介孔材料的孔分布很窄,晶胞(Cell)之间通过窗口(Window)相连接,因而更有利于物质的扩散和传输。另外MCF具有易合成、孔径可调、孔壁厚和热稳定性好的优点。
在第八章中,我们采用双溶剂法,通过正己烷作为有机相,硫酸氧钒溶液为水相,介孔材料MCF为载体,利用双溶剂法可以通过毛细管凝聚和硫酸氧钒溶液和正己烷之间的亲水憎水作用,使得水溶液大部分进入到载体孔道内的优点,合成出不同负载量的VOx/MCF催化剂,在优化的反应条件下,7.03V/MCF催化剂上丙烷的单程产率可以达到17.3%。另外采用普通浸渍法和双溶剂法合成出相近含量的VOx/MCF催化剂。通过对它们进行相应的物化表征和丙烷选择氧化制丙烯的催化活性测试,得出由双溶剂法制备出的催化剂,可以保证氧化钒尽可能进入载体的内表面,在载体中高度分散,而普通浸渍法制备的样品表面则有大量聚集态甚至是晶态的氧化钒,双溶剂法制备的催化剂在催化丙烷选择氧化的性能明显优于普通浸渍所得催化剂。
Studies on the synthesis and catalytic application of vanadium-based metal oxides in the selective oxidation of methane and propane
Because of the worsening global energy crisis and limited natural oil resource, more and more attention has been paid on other alternative energy sources.One of the promising ways is the effective utilization of natural gas,and as a result, investigations focused on this area are carried on by many groups worldwide.The natural gas consists of light alkanes,such as methane and propane,so one of the most popular ways in utilization of natural gas is to directly produce organic products through catalytic conversion of light alkanes.
There are direct and indirect ways of transforming methane to other products. The indirect process has been commercialized.For example,methane is firstly converted to synthesis gas and then to liquid fuel and organic chemicals.Indirect process suffers some drawbacks,such as the request of heavy investment,high temperature and pressure,etc.So,much effort has been paid in the direct transforming of methane.Among this research,methane selective oxidation(MPO)to formaldehyde is one of the attractive reactions.The active species in the catalysts are mainly molybdenum and vanadium oxide as well as other transition metal oxides. Various supports are used,such as silica,Al_2O_3 and TiO_2.However,catalytic performance of MPO over these catalysts is still under expectation.
Propene is one of the most important chemicals,and a variety of derivatives can be produced from propene,such as polypropene,acrylonitrile,acrolein,acrylic acid, etc.Propene is mainly produced from oil-cracking,and as a result of the increasingly shortage of oil resource,the production of propene in this way cannot meet the growing demand.As there is a considerable amount of propane in natural gas, producing of propene from catalytic oxidative dehydrogenation of propane(ODP)is now very desirable.It is reported that catalysts containing vanadium oxide have remarkable activity in ODP and the supports may be SiO_2,Al_2O_3,TiO_2,ZrO_2 and MgO,etc.The results show that catalytic performance in ODP can be affected by a series of aspects,such as the surface acidity,the redox state of vanadium species, surface area and porous structure of the catalyst.It is found that better catalytic activity can obtained in silica with large pore diameter and pore volume.As the discovery and application of MCM-41 type mesoporous silica,many supported metal oxide catalysts are prepared using mesoporous silica as supports.Most of these catalysts are obtained through a simple two-step process:support is prepared first and then active components are loaded on its inner surface by impregnation.However,the mesopores may be easily blocked and the active species may sinter at high temperature.These problems can be solved if the active components are embedded in the wall of mesopores in a highly dispersive state.
The main purpose of this dissertation is,therefore,to develop some methods for preparing mesoporous silica based metal oxides catalysts for the selective oxidation of methane and propane,in which the dispersion of the active species has been improved and the interaction between the active species and the supports has been strengthened. All the catalysts were characterized using various characterization techniques and the relationship between the intrinsic state of metal oxide species and their catalytic activity were studied.
1.Synthesis of mesoporous materials containing PMoV mixed oxides by impregnation and co-synthesis methods using hyteropolyacid as precursor and their application in the selective oxidation of methane to formaldehyde
Recently,some investigations indicated that MoO_3 or V_2O_5 supported on ordered mesoporous silicas showed better catalytic activities than that supported on commercial amorphous silica.It is also showed that the supported phosphorus-assisted vanadium or molybdenum oxide exhibited better activity due to the formation of active dispersed oxide species or molybdophosphoric acid-like species on the support.
We prepared PMoV mixed oxide supported on SBA-15 with different loadings using wet impregnation method and hyteropolyacid H_5PMo_(10)V_2O_(40)as the precursor and studied its catalytic activity in the MPO reaction.In order to understand their catalytic performance in MPO reaction,we studied the influences of various factors to the conversion and selectivity,such as loading,temperature and space velocity.It showed that the higher loading and temperature,the higher conversion of methane, while the selectivity of formaldehyde reached a highest value at certain loading.When increasing space velocity,the conversion of methane increased while the selectivity of formaldehyde decreased.The best reaction condition is as follows:T=640℃、GHSV =48320 L/(Kg·h).The maximum space yield of HCHO reached 295 g·Kg_(cat)~(-1)h~(-1)at 2.89%loading.Characterization result of XRD,as well as N_2 adsorption,NH_3-TPD, shows that when the loading of oxides is below 2.89%,P-Mo-V oxides exist in a highly dispersed state in the mesopores of the support,and the acidity,redox property of catalyst are related with the loading.All these aspects and property can affect the catalytic activity.
It is known that during the process of synthesizing mesoporous materials,HCl and HNO_3 are usually applied as acidity regulator.Since hyteropolyacid could be dissolved in water or alcohol and release hydrogen-ion,we used hyteropolyacid as the acidity regulator and mixed oxide precursor to synthesis mixed oxide-containing mesoporous materials.Another part of work was mainly focused on the synthesis of PMoV-silica mesoporous composite and its catalytic application.H_5PMo_(10)V_2O_(40)was used as the acid regulator and inorganic precursor and ethanol as solvent.We obtained PMoV-mesoSiO_2 catalytic materials with orderly mesopores.The amount of added H_5PMo_(10)V_2O_(40)can affect the morphology and structure of the product.XRD and TEM characterization results showed these mesoporous materials are MCM-48-type structure.Oxides composite is highly dispersed in mesoporous silica when its content is not high than 6.68 wt%.Under certain content of oxide composites,the products exhibit good catalytic activity in MPO to formaldehyde.Compared the catalysts prepared with co-synthesis and wet impregnation methods,the former have better catalytic activity at nearly the same content of the active component.The maximum space yield of HCHO 330 g·Kg_(cat)~(-1)h~(-1)over the catalyst prepared with co-synthesis method with a PMoVO loading of 3.40%.
2.Synthesis of V-containing mesoporous materials and their application in the selective oxidation of propane
Mesoporous SBA-15 has been widely applied in catalytic research for its high surface area and pore diameter.The silica supported vanadium oxides are good catalysts for the propane selective oxidation based on the previous researches.This part of work mostly consist of the synthesis of V-containging mesoporous materials with VOSO_4 as a precursor and to apply in the selective oxidation of propane.In Chapter 5,we developed pH-adjusting method to synthesize V-containing mesoporous silica using VOSO_4 and TEOS as the V and Si sources,P123 as template,and ammonia solution to adjust the pH of the mixture.Characterizations,such as TG-DTA, XRD,XRF,N_2 adsorption,TEM,Raman spectroscopy,NH_3-TPD and H_2-TPR are carried out.It showed that the material has a BET specific surface area of approximately 350 m~2/g,average pore diameter of 10 nm and a SBA-15 type 2D hexagonal arranged pore structure.V species are highly dispersed in a form of V-O tetrahedron in mesopores.Catalytic performance in the selective oxidation of propane reaction under optimized conditions are yield of propene reached 13.3%at T=600 and GHSV=15000 L·Kg~(-1)·h~(-1)over the catalyst of 0.98V-SBA-15.
Mesoporous HMS is a material of high surface area,thermostability and hydrothermostability.We obtained V-HMS using VOSO_4 as the precursor.Its BET surface area is approximately 930 m~2/g and pore volume is 0.8 cm~3/g,and vanadium is embedded in silica matrix.The sample show better catalytic performance in the selective oxidation of propane reaction than the V-containg mesoporous SBA-15 with yield of HCHO reached 16.6%over the catalyst of 6.21V-HMS.And the sample also has better catalytic performance than the Vanadium oxide impregnated with HMS reported on the before literature.
Triblock copolymer is widely used as soft template in synthesis of mesoporous materials.However,the cost of this template is relatively high.We employ a cheaper organic acid-glutaric acid as template,through a sol-gel process,to synthesize V-containing silica catalyst.Vanadium oxide embedded into the silica matrix and highly dispersed and the catalyst has high surface area.approximately 600 m~2/g, average pore diameter of 5 nm.Characterizations denote that the vanadium has little loss and a form of V-O tetrahedron in mesopores.The yield of propene reached 13.3% at T=600 and GHSV=15000 L·Kg~(-1)·g~(-1)over the catalyst of 0.98V-SBA-15.
3.Double solvent system used in preparing of effective catalysts with large pore diameter and its application in the selective oxidation of propane
The most widely used mesoporous materials in catalytic field are MCM-41 and SBA-15 which are both 2D hexagonal,P6mm group.However,their pore sizes are limited to hundred nanometers.It was reported that larger pore size benefits the molecular diffusion and transportation even in the reactions involving small molecules,such as selective oxidation of propane.Therefore,people seek to find materials with macropore and 3D continuous porous structure.Recently a noval foam material MCF is synthesized,which possesses ultra large pore diameter and 3D continuous pores,and shows thermal stability.This kind of material has a narrow distribution of pore diameter and'cells' are connected through'window',which greatly favor diffusion and transportation.
We synthesized vanadium oxide loaded MCF by impregnation with the double solvent method using n-hexane as organic phase and VOSO_4 aqueous solution as water phase.Catalytic performance in the selective oxidation of propane reaction under optimized conditions are yield of propene reached 17.3%over the catalyst of 7.03V/MCF The catalytic activity of VOx/MCF in the selective oxidation of propane reaction to propene reaction,along with the catalyst with the same V loading by commom impregnation were studied.The results showed that catalyst prepared by double solvent impregnation has a better activity which can be explained by vanadium oxides dispersed better on the catalyst prepared by double solvent impregnation.
目前文献报道的甲烷转化途径有直接转化和间接转化两种,间接转换是目前甲烷利用的主要形式,例如由甲烷经水蒸气重整反应制合成气,然后由F-T合成等反应进一步转化为液体燃料和有机化工原料;但这些工艺过程存在诸多缺点,如设备复杂、过程繁琐、投资大、操作条件苛刻、需高温高压、设备要耐腐蚀等等。如果能够实现甲烷的直接转化,则必然大大节约生产成本及能耗,符合国民经济可持续发展的要求。在甲烷的直接转化过程中,甲烷选择氧化制甲醛是近年来研究较多的方向之一。在甲烷选择氧化制甲醛的研究中,所采用的活性组分大部分是过渡金属元素,其中以Mo和V居多,所用载体主要包括Al_2O_3、TiO_2、ZrO_2以及SiO_2等,以SiO_2为主。总体而言,这些催化剂的活性均不够高,除与活性组分有关外,还与活性组分在载体上的分散程度有关。介孔材料以其规则孔道结构、高比表面积和热稳定性成为一类受到广泛关注的新型载体,在低碳烷烃的选择性氧化反应中以介孔材料MCM-41、MSU-2、SBA-1、SBA-15等为载体的负载型催化剂显示出比较好的催化活性。
丙烯是现代石油化工重要的基础原料之一,从丙烯出发可以生产一系列重要的丙烯衍生物,如丙烯腈、丙烯醛、丙烯酸、聚丙烯、异丙橡胶等。目前丙烯主要来自于石油蒸汽裂解,随着石油资源的日趋短缺,势必影响丙烯的产出,难以满足丙烯日益增加的旺盛需求。天然气中有着相对丰富的丙烷资源,而从丙烷催化选择氧化制丙烯则被认为是生产丙烯的一条可能途径。含有钒基的氧化物负载型催化剂在丙烷催化选择氧化制丙烯中具有较好的催化作用,在已报道的研究体系中,所使用的载体有SiO_2,Al_2O_3,TiO_2,ZrO_2和MgO等。经研究发现,催化剂的酸碱性、催化剂表面钒物种的状态、表面钒物种的还原性能、载体的比表面和孔道结构等因素都会影响催化剂的选择氧化性能。一般认为在具有大孔径和孔容的氧化硅上有较好的丙烷选择氧化制丙烯的催化效果。随着MCM-41系列介孔分子筛的开发,氧化物负载在介孔分子筛上作为催化剂已有大量报道,一般是以负载法制备催化剂。这种方法制备的催化剂活性组分主要分布在孔道表面,其优点是制备过程简便实用,但其缺点是负载上的组分容易阻塞孔道,高温反应后易团聚。如果能将纳米氧化物颗粒以高度分散的形式嵌入到介孔分子筛孔壁,使得活性组分更容易和载体相互作用,不但不会阻塞孔道,而且还具有比较高的活性比表面,增加抗团聚性能,从而有可能提高催化效果。
本论文旨在开发应用于甲烷和丙烷选择氧化的新型金属氧化物催化剂,提高活性组分在载体中的分散度及增强活性组分与载体之间的相互作用,减少活性组分的流失;另外,本论文还研究了不同的制备方法对催化剂制备及性能的影响。通过各种现代表征手段,研究活性组分的存在状态及在反应中的作用,进一步关联催化活性与催化剂微观结构的关系。
论文的主要工作及结果如下:
一、以杂多酸为前驱体,浸渍和原位合成含PMoV复合氧化物分子筛催化剂及在甲烷选择氧化中的催化性能研究
近年来的研究表明,负载型MoO_3或V_2O_5催化剂中添加P元素具有很好的修饰作用,在甲烷选择氧化制备甲醛的反应中能够显著提高甲醛的选择性。第三章和第四章内容主要是围绕处在研究开发阶段的甲烷直接选择氧化制备甲醛(MPO)反应而展开的。
我们选用含PMoV的杂多酸H_5PMo_(10)V_2O_(40)作为合成催化剂的前驱体,具有孔径分布均一,热稳定性较好的介孔SBA-15为载体,通过常温下湿法浸渍制备了不同含量的负载型PMoV/SBA-15,对其甲烷选择氧化反应(MPO)性能进行了比较,考察了负载量、反应温度、空速等对甲烷转化率和甲醛选择性的影响,结果表明甲烷转化率随负载量的增大和反应温度的升高而提高,甲醛的选择性随反应温度的升高而降低、随负载量的增大先升后降,加大空速甲烷的转化率降低而甲醛的选择性升高,在考察范围内催化剂在反应条件为:T=640℃、GHSV=48320L/Kg·h、氧化物负载量为2.89%时,甲醛的时空产率为最高(295g·Kg_(cat)~(-1)h~(-1))。XRD、氮吸附、NH_3-TPD、H_2-TPR、Raman和FT-IR结果表明,氧化物含量≤2.89%时,P-Mo-V氧化物在载体介孔孔道内以高度分散的状态存在,催化剂的酸性和氧化还原性质与负载量相关,这些特征和性质进而影响催化剂的反应活性。
众所周知,在介孔材料的合成中,盐酸和硝酸一般作为酸度调节剂来使用。考虑杂多酸既可溶于水又可溶于醇类中,利用其溶解后可以完全电离出氢离子的特点,我们选用含有PMoV杂多酸H_5PMo_(10)V_2O_(40)作为合成介孔材料的酸度调节剂和活性组分的前驱体,在乙醇体系中,合成出具有规整孔道结构的PMoV-mesoSiO_2介孔材料,杂多酸的添加量会直接影响合成样品的形貌和孔结构特点。通过TG-DTA,XRD,XRF,氮吸附,TEM,FTIR和拉曼等的表征,发现这些介孔材料具有类似MCM-48的三维立方结构。P-Mo-V氧化物的含量低于6.68%时,复合氧化物在mesoSiO_2中具有很好的分散性,而适当氧化物含量的催化剂在甲烷选择氧化制备甲醛反应中具有较好的催化活性。同时在相近的含量下,比较由共合成法和普通浸渍法制备的催化剂的催化活性,发现由共合成法制备出的3.40PMoV-mesoSiO_2催化剂具有较高的催化活性。在优化的反应条件下,该催化剂上甲醛的最高时空产率为330 g Kg_(cat)~(-1)h~(-1)。
二、共合成法制备含钒介孔分子筛及在丙烷选择氧化中的催化性能研究
基于前人大量研究结果表明:含钒基的二氧化硅催化剂在丙烷选择氧化制丙烯中有较好催化活性。本部分主要是利用可溶于水的硫酸氧钒作为前驱体,在不同的条件下,原位共合成了含钒不同类型的介孔分子筛并应用于丙烷选择氧化反应。
因为新型介孔分子筛SBA-15具有大的比表面及孔径,自从问世以来,一直被人们广泛应用在催化领域。在第五章中,我们在水相中以硫酸氧钒为前驱体,P123为模板剂,通过调节水热混合液的pH值,经过水热及焙烧处理后制备出含钒分子筛,分别用TG-DTA,XRD,XRF,氮吸附,TEM,拉曼,NH_3-TPD和H_2-TPR等研究了催化剂的物化性质并测试了其在丙烷选择氧化反应的催化性能。结果表明,由pH调节法所合成出的V-SBA-15催化剂具有大约350 m~2/g的比表面、10 nm左右的平均孔径且典型的两维六角的孔道结构;氧化钒在分子筛的骨架内主要是以高度分散的孤立态的四面体钒氧形式存在,这正是丙烷选择氧化反应中的活性中心位。通过优化反应温度、空速和丙烷与氧气之间的比例等条件,0.98V-SBA-15催化剂对于丙烷选择氧化反应取得较好的催化活性结果:T=600℃,GHSV=15000 L·Kg~(-1)·h~(-1),丙烯的单程最大产率为13.3%。
具有大的比表面及热稳定性和水热稳定性的HMS分子筛一直是催化工作者关注的热点。第六章中主要是在合成蠕虫状材料HMS的过程中,加入硫酸氧钒制备出V-HMS分子筛。通过对合成出的分子筛进行相应的物化表征分析,显示我们合成出的V-HMS样品具有大的比表面和孔容,分别为930 m~2/g和0.8 cm~3/g左右。钒物种进入了分子筛骨架并与硅形成稳定的Si-O-V键。发现催化剂中氧化钒含量≤6.21%时,钒物种以高度分散的孤立态的钒氧四面体存在。在优化的反应条件下,6.21V-HMS上丙烯选择性为43.0%,单程最大产率为16.6%。优于文献中报道的负载型V/HMS催化剂。
考虑在介孔材料中所使用的模板剂一般都是长链的嵌段共聚物,价格较昂贵,而采用比较环保的化学试剂是现代绿色化学的一个要求,第七章中我们使用毒性较小且价格相对便宜的有机二元羧酸(戊二酸)来作为模板剂,采用溶胶—凝胶法,将氧化钒纳米粒子嵌入到硅骨架,得到高分散、高比表面(～600 m~2/g)、较大孔径(～5 nm)的钒硅分子筛催化材料,并研究其在丙烷选择氧化反应中的催化活性。研究表明,催化剂制备前后钒物种基本无损失,合成得到的钒硅介孔分子筛中钒物种分布均匀,主要以孤立态四面体构型为主。3.96V-meso-SiO_2在T=600℃,GHSV=18750 L·Kg~(-1)·h~(-1)时,丙烷有较大转化率(45.8%),丙烯产率为14.8%。
三、双溶剂法制备大孔径、负载型钒基催化剂及在丙烷选择氧化中的应用研究
MCM-41和SBA-15是催化领域应用非常广泛的介孔分子筛,二者的结构均属P6mm相,是两维孔道结构。但在选择氧化反应中,传质和扩散的因素使人们还注意到开拓更大孔径的载体及具有三维连续孔结构材料。最近一种新的介孔泡沫材料MCF被合成出来。它是一种具有超大孔径、三维连续孔道结构、极好的热稳定性的新型材料,其形貌类似于蜂窝或海绵。这种介孔材料的孔分布很窄,晶胞(Cell)之间通过窗口(Window)相连接,因而更有利于物质的扩散和传输。另外MCF具有易合成、孔径可调、孔壁厚和热稳定性好的优点。
在第八章中,我们采用双溶剂法,通过正己烷作为有机相,硫酸氧钒溶液为水相,介孔材料MCF为载体,利用双溶剂法可以通过毛细管凝聚和硫酸氧钒溶液和正己烷之间的亲水憎水作用,使得水溶液大部分进入到载体孔道内的优点,合成出不同负载量的VOx/MCF催化剂,在优化的反应条件下,7.03V/MCF催化剂上丙烷的单程产率可以达到17.3%。另外采用普通浸渍法和双溶剂法合成出相近含量的VOx/MCF催化剂。通过对它们进行相应的物化表征和丙烷选择氧化制丙烯的催化活性测试,得出由双溶剂法制备出的催化剂,可以保证氧化钒尽可能进入载体的内表面,在载体中高度分散,而普通浸渍法制备的样品表面则有大量聚集态甚至是晶态的氧化钒,双溶剂法制备的催化剂在催化丙烷选择氧化的性能明显优于普通浸渍所得催化剂。
Studies on the synthesis and catalytic application of vanadium-based metal oxides in the selective oxidation of methane and propane
Because of the worsening global energy crisis and limited natural oil resource, more and more attention has been paid on other alternative energy sources.One of the promising ways is the effective utilization of natural gas,and as a result, investigations focused on this area are carried on by many groups worldwide.The natural gas consists of light alkanes,such as methane and propane,so one of the most popular ways in utilization of natural gas is to directly produce organic products through catalytic conversion of light alkanes.
There are direct and indirect ways of transforming methane to other products. The indirect process has been commercialized.For example,methane is firstly converted to synthesis gas and then to liquid fuel and organic chemicals.Indirect process suffers some drawbacks,such as the request of heavy investment,high temperature and pressure,etc.So,much effort has been paid in the direct transforming of methane.Among this research,methane selective oxidation(MPO)to formaldehyde is one of the attractive reactions.The active species in the catalysts are mainly molybdenum and vanadium oxide as well as other transition metal oxides. Various supports are used,such as silica,Al_2O_3 and TiO_2.However,catalytic performance of MPO over these catalysts is still under expectation.
Propene is one of the most important chemicals,and a variety of derivatives can be produced from propene,such as polypropene,acrylonitrile,acrolein,acrylic acid, etc.Propene is mainly produced from oil-cracking,and as a result of the increasingly shortage of oil resource,the production of propene in this way cannot meet the growing demand.As there is a considerable amount of propane in natural gas, producing of propene from catalytic oxidative dehydrogenation of propane(ODP)is now very desirable.It is reported that catalysts containing vanadium oxide have remarkable activity in ODP and the supports may be SiO_2,Al_2O_3,TiO_2,ZrO_2 and MgO,etc.The results show that catalytic performance in ODP can be affected by a series of aspects,such as the surface acidity,the redox state of vanadium species, surface area and porous structure of the catalyst.It is found that better catalytic activity can obtained in silica with large pore diameter and pore volume.As the discovery and application of MCM-41 type mesoporous silica,many supported metal oxide catalysts are prepared using mesoporous silica as supports.Most of these catalysts are obtained through a simple two-step process:support is prepared first and then active components are loaded on its inner surface by impregnation.However,the mesopores may be easily blocked and the active species may sinter at high temperature.These problems can be solved if the active components are embedded in the wall of mesopores in a highly dispersive state.
The main purpose of this dissertation is,therefore,to develop some methods for preparing mesoporous silica based metal oxides catalysts for the selective oxidation of methane and propane,in which the dispersion of the active species has been improved and the interaction between the active species and the supports has been strengthened. All the catalysts were characterized using various characterization techniques and the relationship between the intrinsic state of metal oxide species and their catalytic activity were studied.
1.Synthesis of mesoporous materials containing PMoV mixed oxides by impregnation and co-synthesis methods using hyteropolyacid as precursor and their application in the selective oxidation of methane to formaldehyde
Recently,some investigations indicated that MoO_3 or V_2O_5 supported on ordered mesoporous silicas showed better catalytic activities than that supported on commercial amorphous silica.It is also showed that the supported phosphorus-assisted vanadium or molybdenum oxide exhibited better activity due to the formation of active dispersed oxide species or molybdophosphoric acid-like species on the support.
We prepared PMoV mixed oxide supported on SBA-15 with different loadings using wet impregnation method and hyteropolyacid H_5PMo_(10)V_2O_(40)as the precursor and studied its catalytic activity in the MPO reaction.In order to understand their catalytic performance in MPO reaction,we studied the influences of various factors to the conversion and selectivity,such as loading,temperature and space velocity.It showed that the higher loading and temperature,the higher conversion of methane, while the selectivity of formaldehyde reached a highest value at certain loading.When increasing space velocity,the conversion of methane increased while the selectivity of formaldehyde decreased.The best reaction condition is as follows:T=640℃、GHSV =48320 L/(Kg·h).The maximum space yield of HCHO reached 295 g·Kg_(cat)~(-1)h~(-1)at 2.89%loading.Characterization result of XRD,as well as N_2 adsorption,NH_3-TPD, shows that when the loading of oxides is below 2.89%,P-Mo-V oxides exist in a highly dispersed state in the mesopores of the support,and the acidity,redox property of catalyst are related with the loading.All these aspects and property can affect the catalytic activity.
It is known that during the process of synthesizing mesoporous materials,HCl and HNO_3 are usually applied as acidity regulator.Since hyteropolyacid could be dissolved in water or alcohol and release hydrogen-ion,we used hyteropolyacid as the acidity regulator and mixed oxide precursor to synthesis mixed oxide-containing mesoporous materials.Another part of work was mainly focused on the synthesis of PMoV-silica mesoporous composite and its catalytic application.H_5PMo_(10)V_2O_(40)was used as the acid regulator and inorganic precursor and ethanol as solvent.We obtained PMoV-mesoSiO_2 catalytic materials with orderly mesopores.The amount of added H_5PMo_(10)V_2O_(40)can affect the morphology and structure of the product.XRD and TEM characterization results showed these mesoporous materials are MCM-48-type structure.Oxides composite is highly dispersed in mesoporous silica when its content is not high than 6.68 wt%.Under certain content of oxide composites,the products exhibit good catalytic activity in MPO to formaldehyde.Compared the catalysts prepared with co-synthesis and wet impregnation methods,the former have better catalytic activity at nearly the same content of the active component.The maximum space yield of HCHO 330 g·Kg_(cat)~(-1)h~(-1)over the catalyst prepared with co-synthesis method with a PMoVO loading of 3.40%.
2.Synthesis of V-containing mesoporous materials and their application in the selective oxidation of propane
Mesoporous SBA-15 has been widely applied in catalytic research for its high surface area and pore diameter.The silica supported vanadium oxides are good catalysts for the propane selective oxidation based on the previous researches.This part of work mostly consist of the synthesis of V-containging mesoporous materials with VOSO_4 as a precursor and to apply in the selective oxidation of propane.In Chapter 5,we developed pH-adjusting method to synthesize V-containing mesoporous silica using VOSO_4 and TEOS as the V and Si sources,P123 as template,and ammonia solution to adjust the pH of the mixture.Characterizations,such as TG-DTA, XRD,XRF,N_2 adsorption,TEM,Raman spectroscopy,NH_3-TPD and H_2-TPR are carried out.It showed that the material has a BET specific surface area of approximately 350 m~2/g,average pore diameter of 10 nm and a SBA-15 type 2D hexagonal arranged pore structure.V species are highly dispersed in a form of V-O tetrahedron in mesopores.Catalytic performance in the selective oxidation of propane reaction under optimized conditions are yield of propene reached 13.3%at T=600 and GHSV=15000 L·Kg~(-1)·h~(-1)over the catalyst of 0.98V-SBA-15.
Mesoporous HMS is a material of high surface area,thermostability and hydrothermostability.We obtained V-HMS using VOSO_4 as the precursor.Its BET surface area is approximately 930 m~2/g and pore volume is 0.8 cm~3/g,and vanadium is embedded in silica matrix.The sample show better catalytic performance in the selective oxidation of propane reaction than the V-containg mesoporous SBA-15 with yield of HCHO reached 16.6%over the catalyst of 6.21V-HMS.And the sample also has better catalytic performance than the Vanadium oxide impregnated with HMS reported on the before literature.
Triblock copolymer is widely used as soft template in synthesis of mesoporous materials.However,the cost of this template is relatively high.We employ a cheaper organic acid-glutaric acid as template,through a sol-gel process,to synthesize V-containing silica catalyst.Vanadium oxide embedded into the silica matrix and highly dispersed and the catalyst has high surface area.approximately 600 m~2/g, average pore diameter of 5 nm.Characterizations denote that the vanadium has little loss and a form of V-O tetrahedron in mesopores.The yield of propene reached 13.3% at T=600 and GHSV=15000 L·Kg~(-1)·g~(-1)over the catalyst of 0.98V-SBA-15.
3.Double solvent system used in preparing of effective catalysts with large pore diameter and its application in the selective oxidation of propane
The most widely used mesoporous materials in catalytic field are MCM-41 and SBA-15 which are both 2D hexagonal,P6mm group.However,their pore sizes are limited to hundred nanometers.It was reported that larger pore size benefits the molecular diffusion and transportation even in the reactions involving small molecules,such as selective oxidation of propane.Therefore,people seek to find materials with macropore and 3D continuous porous structure.Recently a noval foam material MCF is synthesized,which possesses ultra large pore diameter and 3D continuous pores,and shows thermal stability.This kind of material has a narrow distribution of pore diameter and'cells' are connected through'window',which greatly favor diffusion and transportation.
We synthesized vanadium oxide loaded MCF by impregnation with the double solvent method using n-hexane as organic phase and VOSO_4 aqueous solution as water phase.Catalytic performance in the selective oxidation of propane reaction under optimized conditions are yield of propene reached 17.3%over the catalyst of 7.03V/MCF The catalytic activity of VOx/MCF in the selective oxidation of propane reaction to propene reaction,along with the catalyst with the same V loading by commom impregnation were studied.The results showed that catalyst prepared by double solvent impregnation has a better activity which can be explained by vanadium oxides dispersed better on the catalyst prepared by double solvent impregnation.
引文
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