Process and catalyst for the production of pyridine and alkyl derivatives thereof
A process for increasing the overall yield of pyridine or its alkyl pyridine derivatives during a base synthesis reaction is disclosed. The process comprises reacting a C 2 to C 5 aldehyde, a C 3 to C 5 ketone or a combination thereof, with ammonia and, optionally, formaldehyde, in the gas phase and in the presence of an effective amount of a particulate catalyst comprising a zeolite, zinc, a binder, and clay and optionally a matrix, wherein the catalyst has a L/B ratio of about 1.5 to about 4.0. Preferably, the zeolite is ZSM-5. A process for enhancing the catalytic activity of a zinc and zeolite containing catalyst to increase the overall yield of pyridine and/or its derivatives during a base synthesis reaction is also disclosed.
1. A base synthesis process for the preparation of pyridine or its alkyl pyridine derivatives comprising reacting a C 2 to C 5 aldehyde, a C 3 to C 5 ketone or a combination thereof, with ammonia and, optionally, formaldehyde, in the gas phase and in the presence of an effective amount of a particulate catalyst comprising a zeolite selected from the group consisting of ZSM-5, ZSM-11 and combinations thereof, zinc, a binder and clay, wherein the catalyst has a L/B ratio of about 1.5 to about 4.0.
2. The process of claim 1 wherein the catalyst further comprises a matrix material.
3. The process of claim 1 wherein the zeolite is ZSM-5.
4. The process of claim 1 wherein the organic reactants are acetaldehyde and formaldehyde, and comprising the additional step of recovering pyridine and beta-picoline as the products of said process.
5. The process of claim 1 wherein the zeolite has been treated with a compound of zinc prior to incorporation into the catalyst composition.
6. The process of claim 1 wherein a compound of zinc is incorporated as a component of the catalyst during formulation of the catalyst composition.
7. The process of claim 1 wherein a compound of zinc is ion exchanged on preformed catalyst particles.
8. The process of claim 6 wherein the compound of zinc is selected from the group consisting of nitrate, halides, acetates and combinations thereof.
9. The process of claim 1 wherein the catalyst has an L/B ratio of about 2.0 to about 3.6.
10. The process of claim 1 wherein the binder is an alumina binder.
11. The process of claim 1 wherein the zeolite has a silica to alumina ratio of about 100 or less.
12. The process of claim 11 wherein the zeolite has a silica/alumina ratio of from about 20 to about 80.
13. The process of claim 3 wherein the zeolite has a silica/alumina ratio of about 28 to about 55.
14. The process of claim 1 wherein the zeolite is present in an amount ranging from about 35 wt % to about 50 wt % based on the total weight of the catalyst composition.
15. The process of claim 1 wherein the binder is present in an amount ranging from about 10 wt % to about 30 wt % based on the total weight of the catalyst composition.
16. The process of claim 1 wherein the clay component is present in an amount ranging from about 30 wt % to about 50 wt % based on the total weight of the catalyst composition.
17. The process of claim 1 wherein the particulate catalyst has a particle size sufficient for use in a fluid bed reactor.
18. The process of claim 17 wherein the particulate catalyst has a particle size ranging from about 40 μm to about 200 μm.
19. The process of claim 1 wherein the particulate catalyst has a Davison Index (DI) of less than 20.
20. The process of claim 1 wherein pyridine and beta-picoline are recovered as the products of said process.