Tuning the Activity and Selectivity of CuCl2/gamma-Al2O3 Ethene Oxychlorination Catalyst by Selective Promotion

CuCl2/gamma-Al2O3 catalysts with and without promoter metal chlorides (Cu5.0, K3.1Cu5.0, La10.9Cu5.0, Li0.5Cu5.0, Cs10.4Cu5.0, Mg1.9Cu5.0, Ce5.5La5.45Cu5.0, and K1.55La5.45Cu5.0) were studied for the ethene oxychlorination reaction in a fixed-bed reactor at 503 and 573 K, with C2H4:HCl:O-2:He = 1.0:1.1:0.38:14.4 (mole ratio), P(tot) = 1 atm and weight hourly space velocity (WHSV) = 1.5 g g(-1) h(-1) (based on ethene). It was found that all promoter metals enhanced the activity of the catalyst, as well as its selectivity towards the target product 1,2-dichloroethane (1,2-EDC). Co-promoted catalysts (K1.55La5.45Cu5.0 and Ce5.5La5.45Cu5.0) gave even higher activity and product selectivity than the single metal promoted catalysts. The activity of the CuCl2/gamma-Al2O3 catalyst, as well as the gamma-Al2O3 support, both with and without metal chloride promoter(s), were further tested for 1,2-EDC conversion to byproducts in a fixed-bed reactor at 503 K, under a feed stream of 1,2-EDC:Ar = 1:11.5 (mole ratio), at P(tot) = 1 atm and WHSV = 1.5 g g(-1) h(-1) (based on 1,2-EDC). Prior to testing, the catalysts were pretreated in flowing ethene, HCl and/or O-2. It was observed that Lewis and Bronsted acid sites on the alumina surface were main reaction sites for conversion of 1,2-EDC to chlorinated byproducts: vinyl chloride monomer (VCM), 1,1-EDC, 1,2-dichloroethene (1,2-DCE) and ethyl chloride (EC) as well as dimerisation (butadiene) and aromatisation reactions (toluene), both with and without the presence of the Cu phase. The Cu phase was shown to contribute mainly to CO2 and trichloroethane formation from 1,2-EDC via VCM. Co-promotion (K1.55La5.45Cu5.0) was found to enhance the activity of the Cu phase, and to mask acid sites on the alumina surface, thereby promoting ethene oxychlorination while at the same time hindering undesired conversion of the target product 1,2-EDC.