Method of producing 1,3-butadiene from N-butene using continuous-flow dual-bed reactor

1. A method of producing 1,3 butadiene using a continuous-flow dual bed reactor, comprising:

a) charging the continuous-flow dual bed reactor with a bismuth molybdate-based first catalyst and a ferrite-based second catalyst layer to form a first catalyst layer and a second catalyst layer such that a quartz layer is disposed between the first and second catalyst layers to separate the first and second catalyst layers;

b) passing a reactant including a C4 mixture containing n-butene, air and steam through the catalyst layers of the continuous-flow dual bed reactor to conduct an oxidative dehydrogenation reaction; and

c) obtaining 1,3-butadiene by the oxidative dehydrogenation reaction.

2. The method according to claim 1 , wherein the C4 mixture includes 0.5˜50 wt % of n-butane, 40˜99 wt % of n-butene, and 0.5˜10 wt % of residual C4 compounds.

3. The method according to claim 1 , wherein the reactant includes n-butene, air and steam such that a ratio of n-butene:air:steam is 1:0.5˜10:1˜50.

4. The method according to claim 1 , wherein, in b), the oxidative dehydrogenation reaction is conducted at a reaction temperature of 300˜600° C. and a gas hourly space velocity (GHSV) of 50˜5000 h−1.

5. The method according to claim 1 , wherein the first catalyst is a bismuth molybdate catalyst including four kinds of metals, and

wherein the bismuth molybdate catalyst is prepared by:

a1) providing a first solution including a precursor of a metal having bivalent cations, selected from the group consisting of manganese, cobalt and nickel, an iron precursor, and a bismuth precursor,

b1) providing a second solution in which a molybdenum precursor is dissolved;

c1) dripping the first solution into the second solution to form a coprecipitation solution;

d1) stirring the coprecipitation solution for 1˜2 hours and then removing moisture therefrom to obtain a solid sample; and

e1) drying the solid sample at 150˜200° C. and then heat-treating the dried solid sample at 400˜600° C.

6. The method according to claim 5 , wherein the metal having bivalent cations is cobalt.

7. The method according to claim 5 , wherein a molar ratio of the metal precursor:the iron precursor:the bismuth precursor:the molybdenum precursor is 7˜10:2˜4:1:5˜20.

8. The method according to claim 5 , wherein, in a1), the metal precursor is manganese nitrate, cobalt nitrate or nickel nitrate, the iron precursor is iron nitrate, and the bismuth precursor is bismuth nitrate.

9. The method according to claim 5 , wherein, in b1), the molybdenum precursor is ammonium molybdate.

10. The method according to claim 1 , wherein the second catalyst is a zinc ferrite catalyst, and

wherein the zinc ferrite catalyst is prepared by:

a2) dissolving a zinc precursor and an iron precursor in distilled water to form an aqueous precursor solution;

b2) mixing a sodium hydroxide solution having a molar concentration of 1.5˜4.0 M with the aqueous precursor solution to form a mixed solution having a pH of 6˜10;

c2) filtering the mixed solution to obtain a solid catalyst;

d2) drying the solid catalyst at 70˜200° C.; and

e2) heat-treating the dried the solid catalyst at 350˜800° C.

11. The method according to claim 10 , wherein, in a2), the ratio of number of zinc atoms of the zinc precursor and number of iron atoms of the iron precursor is 1.5˜2.5.

12. The method according to claim 10 , wherein, in a2), the zinc precursor is zinc chloride or zinc nitrate, and the iron precursor is iron chloride or iron nitrate.

13. The method according to claim 1 , wherein, when the C4 mixture includes more 1-butene than 2-butene, in a), the first catalyst layer, the quartz layer and the second catalyst layer are sequentially disposed downward.

14. The method according to claim 1 , wherein, when the C4 mixture includes more 2-butene than 1-butene, in a), the second catalyst layer, the quartz layer and the first catalyst layer are sequentially disposed downward.