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WO-2026096199-A1 - TANTALUM CATALYST COMPOSITION AND METHOD OF USING THE SAME

WO2026096199A1WO 2026096199 A1WO2026096199 A1WO 2026096199A1WO-2026096199-A1

Abstract

Disclosed herein are aspects of a method for converting an oxygenate feedstock into an olefin-rich product. In some aspects, the method comprises exposing an oxygenate feedstock to a tantalum catalyst composition to form an olefin-rich product. In some aspects, the tantalum catalyst composition comprises tantalum and a support comprising (i) aluminum and/or silicon, and (ii) oxygen.

Inventors

  • DAGLE, VANESSA
  • DAGLE, ROBERT A.
  • AFFANDY, Martin

Assignees

  • BATTELLE MEMORIAL INSTITUTE

Dates

Publication Date
20260507
Application Date
20251014
Priority Date
20241028

Claims (20)

  1. 1 . A method, comprising: exposing an oxygenate feedstock to a tantalum catalyst composition to form an olefin-rich product, the tantalum catalyst composition comprising a support comprising (i) aluminum and/or silicon, and (ii) oxygen.
  2. 2. The method of claim 1 , wherein the tantalum catalyst composition comprises a tantalum oxide in an amount ranging from 1% to 50% based on total weight of the tantalum catalyst composition
  3. 3. The method of claim 1 or claim 2, wherein the support is present in an amount ranging from 10% to 90% based on total weight of the tantalum catalyst composition.
  4. 4. The method of any one of claims 1 -3, wherein the feedstock is exposed to the tantalum catalyst composition at a temperature ranging from 325 °C to 400 °C.
  5. 5. The method of any one of claims 1 -4, further comprising exposing the feedstock, the olefin-rich product, or a combination thereof to a second catalyst composition that catalyzes formation of additional olefin-rich product.
  6. 6. The method of claim 5, wherein the oxygenate feedstock is exposed to the tantalum catalyst composition in a first catalyst bed to form an intermediate composition, and the intermediate composition is exposed to the second catalyst composition in a second catalyst bed.
  7. 7. The method of claim 5, wherein the oxygenate feedstock is exposed to the tantalum catalyst composition and the second catalyst composition in a mixed catalyst bed that comprises the tantalum catalyst composition and the second catalyst composition.
  8. 8. The method of any one of claims 1 -7, wherein the oxygenate feedstock comprises a C2-C4 alcohol, a C2-C4 ether, a C 2 -C 4 aldehyde, a C 2 -C 4 ketone, a C 2 -C 4 carboxylic acid, a C2-C4 ester, or a combination thereof.
  9. 9. The method of any one of claims 1 -8, wherein the oxygenate feedstock comprises ethanol, acetaldehyde, ethyl acetate, diethyl ether, butyraldehyde, butanol, crotonaldehyde, crotyl alcohol or a combination thereof. 23-112252-02 32996 FILED ELECTRONICALLY ON: October 14, 2025
  10. 10. The method of any one of claims 1 -9, wherein the tantalum catalyst composition further comprises a metal dopant.
  11. 11 . The method of claim 10, wherein the metal dopant comprises a Group 6, Group 11 , or Group 12 transition metal.
  12. 12. The method of claim 11 , wherein the metal dopant is selected from Or, Zn, Cu, Ag, or a combination thereof.
  13. 13. The method of any one of claims 1 -12, wherein forming the olefin-rich product comprises forming butene with a selectivity of greater than or equal to 50%.
  14. 14. The method of any one of claims 1 -13, wherein the tantalum catalyst composition comprises TazOs, the method further comprising increasing the amount of tantalum oxide to promote increased conversion and total olefin selectivity.
  15. 15. A method of making a tantalum catalyst composition for converting an oxygenate feedstock into an olefin-rich product, the method comprising impregnating a support comprising (i) aluminum and/or silicon, and (ii) oxygen, with a tantalum precursor to form a catalyst precursor.
  16. 16. The method of claim 15, further comprising calcining the catalyst precursor to form the tantalum catalyst composition.
  17. 17. The method of claim 15 or claim 16, further comprising impregnating the support with a second precursor material containing at least one metal dopant.
  18. 18. The method of any one of claims 15-17, wherein calcining the catalyst precursor comprises heating the catalyst precursor under air.
  19. 19. The method of claim 16, wherein the support is first impregnated with the tantalum precursor and then impregnated with the second precursor material.
  20. 20. A tantalum catalyst composition for converting an oxygenate feedstock into an olefin-rich product, the tantalum catalyst composition comprising: 23-112252-02 32996 FILED ELECTRONICALLY ON: October 14, 2025 a tantalum oxide in an amount ranging from 1% to 50% based on total weight of the tantalum catalyst composition; and a support comprising aluminum and/or silicon.

Description

23-112252-02 32996 FILED ELECTRONICALLY ON: October 14, 2025 TANTALUM CATALYST COMPOSITION AND METHOD OF USING THE SAME CROSS REFERENCE TO RELATED APPLICATION [0001 ] This application claims the benefit of and priority to the earlier filing date of U.S. Patent Application No. 18/929,391 , filed October 28, 2024, the entirety of which is herein incorporated by reference in their entirety. ACKNOWLEDGMENT OF GOVERNMENT SUPPORT [0002] This invention was made with government support under Contract DE-AC0576RL01830 awarded by the U.S. Department of Energy. The government has certain rights in the invention. FIELD [0003] The present disclosure concerns a tantalum catalyst composition, methods of making the tantalum catalyst composition, and methods of using the tantalum catalyst composition. BACKGROUND [0004] Petroleum depletion and environmental concerns have led to renewed interest in using biomass as a carbon source for the production of biofuels. Ethanol and ethanol-derived aldehyde conversion to biofuels represent an appealing bioenergy technology. Accordingly, ethanol and ethanol-derived aldehydes are commercially produced from renewable biomass or waste sources. Additionally, advancements in production efficiency and feedstock diversification may potentially lead to excess ethanol having competitive pricing for production of a wide range of fuels and/or commodity chemicals. Moreover, with the lightening of feedstocks to steam crackers, due to the increasing use of shale gas instead of naphtha as feed, there may be a shortage of C3 and C4 olefins as industrial starting materials. Thus, there is a need for methods of converting oxygenated feedstocks, such as ethanol, into olefins. SUMMARY [0005] Disclosed embodiments of the present disclosure advantageously provide a tantalum catalyst composition for producing an olefin-rich product from an oxygenate feedstock with greater selectivity and thermal stability than Zr-based catalysts. Certain disclosed aspects concern a method, comprising: exposing an oxygenate feedstock to a tantalum catalyst composition to form an olefin-rich product, the tantalum catalyst composition comprising a support comprising (i) aluminum and/or silicon, and (ii) oxygen. [0006] Certain disclosed aspects concern a method of making a tantalum catalyst composition for converting an oxygenate feedstock into an olefin-rich product. In some aspects, the method comprises impregnating a support comprising (i) aluminum and/or silicon, and (ii) oxygen, with a tantalum precursor to form a catalyst precursor. 23-112252-02 32996 FILED ELECTRONICALLY ON: October 14, 2025 [0007] Certain disclosed aspects concern a tantalum catalyst composition for converting an oxygenate feedstock into an olefin-rich product, the tantalum catalyst composition comprising: a tantalum oxide in an amount ranging from 1% to 50% based on total weight of the tantalum catalyst composition; and a support comprising aluminum and/or silicon. [0008] The foregoing and other objects, features, and advantages of the present disclosure will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures. BRIEF DESCRIPTION OF THE DRAWINGS [0009] FIG. 1 shows a diagram of a system for producing an olefin-rich product from an oxygenate feedstock according to aspects of the present disclosure. [0010] FIG. 2 shows a diagram of a system for producing an olefin-rich product from an oxygenate feedstock according to additional aspects of the present disclosure. [0011 ] FIG. 3 shows a diagram of a system for producing an olefin-rich product from an oxygenate feedstock according to yet additional aspects of the present disclosure. [0012] FIG. 4 shows a flow diagram of an exemplary method for making a tantalum catalyst composition for converting an oxygenate feedstock into an olefin-rich product. [0013] FIG. 5 shows a flow diagram of an exemplary method for producing an olefin-rich product from an oxygenate feedstock. [0014] FIG. 6 shows a plot of conversion and selectivity toward total olefins, acetaldehyde, and ethylene using 4%Cu/6%Ta20s supported on silicon-containing materials. [0015] FIG. 7 shows a plot of conversion and selectivity toward total olefins, acetaldehyde, and C2-C5 alkanes using 4%Cu/6%Ta20s supported on SBA-16 silica. [0016] FIG. 8 shows a plot of conversion and selectivity toward total olefins, acetaldehyde, and C2-C5 alkanes using 4%Cu/6%Ta20s supported on DAVISIL® 646 silica gel. [0017] FIG. 9 shows a plot of conversion and selectivity toward ethylene, propene, butene, and C5+ olefins using 4%Cu/6%Ta20s supported on DAVISIL® 646 silica gel. [0018] FIG. 10 shows a plot of conversion and selectivity over time toward total olefins, acetaldehyde, and C2-C5 alkanes using two catalyst compositions according to aspects of the present disclosure. 23-112252-02 32996 FILED ELECTRONICALLY ON: October 14, 2025 [0019] FIG. 11 shows a plot of conversion and selectivity toward to