CA2499203A1 - Mesoporous material and use thereof for the selective oxidation of organic compounds - Google Patents
Mesoporous material and use thereof for the selective oxidation of organic compounds Download PDFInfo
- Publication number
- CA2499203A1 CA2499203A1 CA002499203A CA2499203A CA2499203A1 CA 2499203 A1 CA2499203 A1 CA 2499203A1 CA 002499203 A CA002499203 A CA 002499203A CA 2499203 A CA2499203 A CA 2499203A CA 2499203 A1 CA2499203 A1 CA 2499203A1
- Authority
- CA
- Canada
- Prior art keywords
- transition metal
- group
- catalytically active
- noble metal
- metal
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000007254 oxidation reaction Methods 0.000 title claims abstract description 25
- 230000003647 oxidation Effects 0.000 title claims abstract description 24
- 150000002894 organic compounds Chemical class 0.000 title claims abstract description 15
- 239000013335 mesoporous material Substances 0.000 title description 5
- 239000000463 material Substances 0.000 claims abstract description 56
- 229910000510 noble metal Inorganic materials 0.000 claims abstract description 29
- 229910052723 transition metal Inorganic materials 0.000 claims abstract description 28
- 150000003624 transition metals Chemical class 0.000 claims abstract description 28
- 229910052809 inorganic oxide Inorganic materials 0.000 claims abstract description 22
- 229910052751 metal Inorganic materials 0.000 claims abstract description 10
- 239000002184 metal Substances 0.000 claims abstract description 10
- 238000000034 method Methods 0.000 claims description 52
- 239000003054 catalyst Substances 0.000 claims description 49
- 239000000203 mixture Substances 0.000 claims description 35
- MWUXSHHQAYIFBG-UHFFFAOYSA-N Nitric oxide Chemical compound O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 claims description 27
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 claims description 20
- HGCIXCUEYOPUTN-UHFFFAOYSA-N cyclohexene Chemical compound C1CCC=CC1 HGCIXCUEYOPUTN-UHFFFAOYSA-N 0.000 claims description 18
- 229910052760 oxygen Inorganic materials 0.000 claims description 17
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 16
- 239000001301 oxygen Substances 0.000 claims description 16
- 239000010936 titanium Substances 0.000 claims description 16
- 238000001354 calcination Methods 0.000 claims description 15
- 230000015572 biosynthetic process Effects 0.000 claims description 13
- 238000003786 synthesis reaction Methods 0.000 claims description 13
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 claims description 12
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 12
- 238000002441 X-ray diffraction Methods 0.000 claims description 12
- 238000010438 heat treatment Methods 0.000 claims description 12
- 229910052719 titanium Inorganic materials 0.000 claims description 12
- 238000006243 chemical reaction Methods 0.000 claims description 11
- GSEJCLTVZPLZKY-UHFFFAOYSA-N Triethanolamine Chemical compound OCCN(CCO)CCO GSEJCLTVZPLZKY-UHFFFAOYSA-N 0.000 claims description 10
- 239000007789 gas Substances 0.000 claims description 10
- 229910052709 silver Inorganic materials 0.000 claims description 10
- 239000004332 silver Substances 0.000 claims description 10
- ZWEHNKRNPOVVGH-UHFFFAOYSA-N 2-Butanone Chemical compound CCC(C)=O ZWEHNKRNPOVVGH-UHFFFAOYSA-N 0.000 claims description 9
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 claims description 9
- 239000010931 gold Substances 0.000 claims description 9
- 239000007800 oxidant agent Substances 0.000 claims description 9
- OFBQJSOFQDEBGM-UHFFFAOYSA-N Pentane Chemical compound CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 claims description 8
- BOTDANWDWHJENH-UHFFFAOYSA-N Tetraethyl orthosilicate Chemical group CCO[Si](OCC)(OCC)OCC BOTDANWDWHJENH-UHFFFAOYSA-N 0.000 claims description 8
- 239000003795 chemical substances by application Substances 0.000 claims description 8
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims description 8
- 229910052737 gold Inorganic materials 0.000 claims description 8
- -1 silicon alkoxide Chemical class 0.000 claims description 8
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 7
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 claims description 7
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims description 7
- 229910052804 chromium Inorganic materials 0.000 claims description 7
- 239000011651 chromium Substances 0.000 claims description 7
- 150000001875 compounds Chemical class 0.000 claims description 7
- 238000001035 drying Methods 0.000 claims description 7
- 150000002432 hydroperoxides Chemical class 0.000 claims description 7
- 150000004967 organic peroxy acids Chemical class 0.000 claims description 7
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims description 7
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 claims description 6
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 claims description 6
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 6
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 6
- DNIAPMSPPWPWGF-UHFFFAOYSA-N Propylene glycol Chemical compound CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 claims description 6
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical group O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 6
- 150000001335 aliphatic alkanes Chemical class 0.000 claims description 6
- 150000001491 aromatic compounds Chemical class 0.000 claims description 6
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 claims description 6
- 238000006735 epoxidation reaction Methods 0.000 claims description 6
- 150000002576 ketones Chemical class 0.000 claims description 6
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 5
- 150000001336 alkenes Chemical class 0.000 claims description 5
- 239000010949 copper Substances 0.000 claims description 5
- 150000002736 metal compounds Chemical class 0.000 claims description 5
- 229910052720 vanadium Inorganic materials 0.000 claims description 5
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 claims description 5
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 claims description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 4
- SXVPOSFURRDKBO-UHFFFAOYSA-N Cyclododecanone Chemical compound O=C1CCCCCCCCCCC1 SXVPOSFURRDKBO-UHFFFAOYSA-N 0.000 claims description 4
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 claims description 4
- 229910052782 aluminium Inorganic materials 0.000 claims description 4
- 239000001273 butane Substances 0.000 claims description 4
- 229910052802 copper Inorganic materials 0.000 claims description 4
- 239000010948 rhodium Substances 0.000 claims description 4
- 229910052710 silicon Inorganic materials 0.000 claims description 4
- 239000010703 silicon Substances 0.000 claims description 4
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 3
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 3
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 claims description 3
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 3
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 claims description 3
- SMZOGRDCAXLAAR-UHFFFAOYSA-N aluminium isopropoxide Chemical group [Al+3].CC(C)[O-].CC(C)[O-].CC(C)[O-] SMZOGRDCAXLAAR-UHFFFAOYSA-N 0.000 claims description 3
- 229910017052 cobalt Inorganic materials 0.000 claims description 3
- 239000010941 cobalt Substances 0.000 claims description 3
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims description 3
- 125000002887 hydroxy group Chemical group [H]O* 0.000 claims description 3
- 229910052741 iridium Inorganic materials 0.000 claims description 3
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 claims description 3
- 229910052742 iron Inorganic materials 0.000 claims description 3
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 claims description 3
- KWKAKUADMBZCLK-UHFFFAOYSA-N methyl heptene Natural products CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 claims description 3
- 229910052750 molybdenum Inorganic materials 0.000 claims description 3
- 239000011733 molybdenum Substances 0.000 claims description 3
- 229910052759 nickel Inorganic materials 0.000 claims description 3
- 229910052762 osmium Inorganic materials 0.000 claims description 3
- SYQBFIAQOQZEGI-UHFFFAOYSA-N osmium atom Chemical compound [Os] SYQBFIAQOQZEGI-UHFFFAOYSA-N 0.000 claims description 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical group O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 3
- 229910052763 palladium Inorganic materials 0.000 claims description 3
- 229910052697 platinum Inorganic materials 0.000 claims description 3
- 229910052702 rhenium Inorganic materials 0.000 claims description 3
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 claims description 3
- 229910052703 rhodium Inorganic materials 0.000 claims description 3
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 claims description 3
- 229910052707 ruthenium Inorganic materials 0.000 claims description 3
- 229910052814 silicon oxide Inorganic materials 0.000 claims description 3
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 3
- 229910052721 tungsten Inorganic materials 0.000 claims description 3
- 239000010937 tungsten Substances 0.000 claims description 3
- 229910052725 zinc Inorganic materials 0.000 claims description 3
- 239000011701 zinc Substances 0.000 claims description 3
- 229910052726 zirconium Inorganic materials 0.000 claims description 3
- LZDKZFUFMNSQCJ-UHFFFAOYSA-N 1,2-diethoxyethane Chemical compound CCOCCOCC LZDKZFUFMNSQCJ-UHFFFAOYSA-N 0.000 claims description 2
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 claims description 2
- XDTMQSROBMDMFD-UHFFFAOYSA-N Cyclohexane Chemical compound C1CCCCC1 XDTMQSROBMDMFD-UHFFFAOYSA-N 0.000 claims description 2
- VQTUBCCKSQIDNK-UHFFFAOYSA-N Isobutene Chemical group CC(C)=C VQTUBCCKSQIDNK-UHFFFAOYSA-N 0.000 claims description 2
- UWHCKJMYHZGTIT-UHFFFAOYSA-N Tetraethylene glycol, Natural products OCCOCCOCCOCCO UWHCKJMYHZGTIT-UHFFFAOYSA-N 0.000 claims description 2
- 229910021529 ammonia Inorganic materials 0.000 claims description 2
- 125000003118 aryl group Chemical group 0.000 claims description 2
- 230000033444 hydroxylation Effects 0.000 claims description 2
- 238000005805 hydroxylation reaction Methods 0.000 claims description 2
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 claims description 2
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical compound CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 claims description 2
- 150000002923 oximes Chemical class 0.000 claims description 2
- 239000001294 propane Substances 0.000 claims description 2
- HXJUTPCZVOIRIF-UHFFFAOYSA-N sulfolane Chemical compound O=S1(=O)CCCC1 HXJUTPCZVOIRIF-UHFFFAOYSA-N 0.000 claims description 2
- FAGUFWYHJQFNRV-UHFFFAOYSA-N tetraethylenepentamine Chemical compound NCCNCCNCCNCCN FAGUFWYHJQFNRV-UHFFFAOYSA-N 0.000 claims description 2
- ZIBGPFATKBEMQZ-UHFFFAOYSA-N triethylene glycol Chemical compound OCCOCCOCCO ZIBGPFATKBEMQZ-UHFFFAOYSA-N 0.000 claims description 2
- 150000003623 transition metal compounds Chemical class 0.000 claims 3
- KWOLFJPFCHCOCG-UHFFFAOYSA-N Acetophenone Chemical compound CC(=O)C1=CC=CC=C1 KWOLFJPFCHCOCG-UHFFFAOYSA-N 0.000 claims 2
- 150000004703 alkoxides Chemical class 0.000 claims 2
- JHIVVAPYMSGYDF-UHFFFAOYSA-N cyclohexanone Chemical compound O=C1CCCCC1 JHIVVAPYMSGYDF-UHFFFAOYSA-N 0.000 claims 2
- FPCJKVGGYOAWIZ-UHFFFAOYSA-N butan-1-ol;titanium Chemical group [Ti].CCCCO.CCCCO.CCCCO.CCCCO FPCJKVGGYOAWIZ-UHFFFAOYSA-N 0.000 claims 1
- 150000002118 epoxides Chemical class 0.000 claims 1
- 150000002430 hydrocarbons Chemical class 0.000 abstract description 8
- 229930195733 hydrocarbon Natural products 0.000 abstract description 7
- 239000011148 porous material Substances 0.000 description 13
- 238000003756 stirring Methods 0.000 description 11
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 10
- 239000012071 phase Substances 0.000 description 7
- 235000013616 tea Nutrition 0.000 description 7
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 6
- 230000003197 catalytic effect Effects 0.000 description 6
- YHWCPXVTRSHPNY-UHFFFAOYSA-N butan-1-olate;titanium(4+) Chemical compound [Ti+4].CCCC[O-].CCCC[O-].CCCC[O-].CCCC[O-] YHWCPXVTRSHPNY-UHFFFAOYSA-N 0.000 description 5
- 239000000243 solution Substances 0.000 description 5
- 239000002245 particle Substances 0.000 description 4
- WVDDGKGOMKODPV-UHFFFAOYSA-N Benzyl alcohol Chemical compound OCC1=CC=CC=C1 WVDDGKGOMKODPV-UHFFFAOYSA-N 0.000 description 3
- YMWUJEATGCHHMB-UHFFFAOYSA-N Dichloromethane Chemical compound ClCCl YMWUJEATGCHHMB-UHFFFAOYSA-N 0.000 description 3
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Natural products OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 239000007864 aqueous solution Substances 0.000 description 3
- 239000011363 dried mixture Substances 0.000 description 3
- 238000004817 gas chromatography Methods 0.000 description 3
- 239000008240 homogeneous mixture Substances 0.000 description 3
- 238000011068 loading method Methods 0.000 description 3
- 229910052757 nitrogen Inorganic materials 0.000 description 3
- 239000002243 precursor Substances 0.000 description 3
- 239000000376 reactant Substances 0.000 description 3
- OOCCDEMITAIZTP-QPJJXVBHSA-N (E)-cinnamyl alcohol Chemical compound OC\C=C\C1=CC=CC=C1 OOCCDEMITAIZTP-QPJJXVBHSA-N 0.000 description 2
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 2
- WRMNZCZEMHIOCP-UHFFFAOYSA-N 2-phenylethanol Chemical compound OCCC1=CC=CC=C1 WRMNZCZEMHIOCP-UHFFFAOYSA-N 0.000 description 2
- GOOHAUXETOMSMM-UHFFFAOYSA-N Propylene oxide Chemical compound CC1CO1 GOOHAUXETOMSMM-UHFFFAOYSA-N 0.000 description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
- HUMNYLRZRPPJDN-UHFFFAOYSA-N benzaldehyde Chemical compound O=CC1=CC=CC=C1 HUMNYLRZRPPJDN-UHFFFAOYSA-N 0.000 description 2
- IAQRGUVFOMOMEM-UHFFFAOYSA-N but-2-ene Chemical compound CC=CC IAQRGUVFOMOMEM-UHFFFAOYSA-N 0.000 description 2
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 description 2
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 description 2
- MJSNUBOCVAKFIJ-LNTINUHCSA-N chromium;(z)-4-oxoniumylidenepent-2-en-2-olate Chemical compound [Cr].C\C(O)=C\C(C)=O.C\C(O)=C\C(C)=O.C\C(O)=C\C(C)=O MJSNUBOCVAKFIJ-LNTINUHCSA-N 0.000 description 2
- 239000008367 deionised water Substances 0.000 description 2
- 229910021641 deionized water Inorganic materials 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000007791 liquid phase Substances 0.000 description 2
- 229910044991 metal oxide Inorganic materials 0.000 description 2
- 150000004706 metal oxides Chemical class 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000002105 nanoparticle Substances 0.000 description 2
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 2
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 2
- CIHOLLKRGTVIJN-UHFFFAOYSA-N tert‐butyl hydroperoxide Chemical compound CC(C)(C)OO CIHOLLKRGTVIJN-UHFFFAOYSA-N 0.000 description 2
- 229940073455 tetraethylammonium hydroxide Drugs 0.000 description 2
- LRGJRHZIDJQFCL-UHFFFAOYSA-M tetraethylazanium;hydroxide Chemical compound [OH-].CC[N+](CC)(CC)CC LRGJRHZIDJQFCL-UHFFFAOYSA-M 0.000 description 2
- LPSKDVINWQNWFE-UHFFFAOYSA-M tetrapropylazanium;hydroxide Chemical compound [OH-].CCC[N+](CCC)(CCC)CCC LPSKDVINWQNWFE-UHFFFAOYSA-M 0.000 description 2
- 238000004627 transmission electron microscopy Methods 0.000 description 2
- 230000007306 turnover Effects 0.000 description 2
- 238000005406 washing Methods 0.000 description 2
- ZWAJLVLEBYIOTI-OLQVQODUSA-N (1s,6r)-7-oxabicyclo[4.1.0]heptane Chemical compound C1CCC[C@@H]2O[C@@H]21 ZWAJLVLEBYIOTI-OLQVQODUSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- 229910016523 CuKa Inorganic materials 0.000 description 1
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 239000005977 Ethylene Substances 0.000 description 1
- IAYPIBMASNFSPL-UHFFFAOYSA-N Ethylene oxide Chemical compound C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 description 1
- 229910003771 Gold(I) chloride Inorganic materials 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- 229910025794 LaB6 Inorganic materials 0.000 description 1
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- 238000003917 TEM image Methods 0.000 description 1
- LJYCJDQBTIMDPJ-UHFFFAOYSA-N [P]=O.[V] Chemical compound [P]=O.[V] LJYCJDQBTIMDPJ-UHFFFAOYSA-N 0.000 description 1
- GNKTZDSRQHMHLZ-UHFFFAOYSA-N [Si].[Si].[Si].[Ti].[Ti].[Ti].[Ti].[Ti] Chemical compound [Si].[Si].[Si].[Ti].[Ti].[Ti].[Ti].[Ti] GNKTZDSRQHMHLZ-UHFFFAOYSA-N 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 230000001476 alcoholic effect Effects 0.000 description 1
- 150000001298 alcohols Chemical class 0.000 description 1
- 229910052783 alkali metal Inorganic materials 0.000 description 1
- 150000001340 alkali metals Chemical class 0.000 description 1
- OOCCDEMITAIZTP-UHFFFAOYSA-N allylic benzylic alcohol Natural products OCC=CC1=CC=CC=C1 OOCCDEMITAIZTP-UHFFFAOYSA-N 0.000 description 1
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- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 150000003863 ammonium salts Chemical class 0.000 description 1
- 150000001450 anions Chemical class 0.000 description 1
- 235000019445 benzyl alcohol Nutrition 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 150000001805 chlorine compounds Chemical class 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 150000001896 cresols Chemical class 0.000 description 1
- 239000002178 crystalline material Substances 0.000 description 1
- XNMQEEKYCVKGBD-UHFFFAOYSA-N dimethylacetylene Natural products CC#CC XNMQEEKYCVKGBD-UHFFFAOYSA-N 0.000 description 1
- 238000004821 distillation Methods 0.000 description 1
- 239000012153 distilled water Substances 0.000 description 1
- LYCAIKOWRPUZTN-UHFFFAOYSA-N ethylene glycol Natural products OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 1
- 125000003827 glycol group Chemical group 0.000 description 1
- FDWREHZXQUYJFJ-UHFFFAOYSA-M gold monochloride Chemical compound [Cl-].[Au+] FDWREHZXQUYJFJ-UHFFFAOYSA-M 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 238000005342 ion exchange Methods 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 150000002823 nitrates Chemical class 0.000 description 1
- 229910000069 nitrogen hydride Inorganic materials 0.000 description 1
- 238000002429 nitrogen sorption measurement Methods 0.000 description 1
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- 150000002924 oxiranes Chemical class 0.000 description 1
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- 125000004817 pentamethylene group Chemical class [H]C([H])([*:2])C([H])([H])C([H])([H])C([H])([H])C([H])([H])[*:1] 0.000 description 1
- WVDDGKGOMKODPV-ZQBYOMGUSA-N phenyl(114C)methanol Chemical compound O[14CH2]C1=CC=CC=C1 WVDDGKGOMKODPV-ZQBYOMGUSA-N 0.000 description 1
- 235000021317 phosphate Nutrition 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- 238000002459 porosimetry Methods 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 238000000634 powder X-ray diffraction Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 239000011541 reaction mixture Substances 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- SQGYOTSLMSWVJD-UHFFFAOYSA-N silver(I) nitrate Inorganic materials [Ag+].[O-]N(=O)=O SQGYOTSLMSWVJD-UHFFFAOYSA-N 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 238000001179 sorption measurement Methods 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 125000000383 tetramethylene group Chemical group [H]C([H])([*:1])C([H])([H])C([H])([H])C([H])([H])[*:2] 0.000 description 1
- 150000003609 titanium compounds Chemical class 0.000 description 1
- 229930195735 unsaturated hydrocarbon Natural products 0.000 description 1
- 239000012808 vapor phase Substances 0.000 description 1
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- C10G27/00—Refining of hydrocarbon oils in the absence of hydrogen, by oxidation
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- C10G29/00—Refining of hydrocarbon oils, in the absence of hydrogen, with other chemicals
- C10G29/20—Organic compounds not containing metal atoms
- C10G29/205—Organic compounds not containing metal atoms by reaction with hydrocarbons added to the hydrocarbon oil
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- C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
- C10G45/02—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing
- C10G45/04—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used
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- C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
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- C10G45/04—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used
- C10G45/12—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used containing crystalline alumino-silicates, e.g. molecular sieves
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- C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
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- C10G45/60—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins characterised by the catalyst used
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- C10G45/60—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins characterised by the catalyst used
- C10G45/62—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins characterised by the catalyst used containing platinum group metals or compounds thereof
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- C10G45/60—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins characterised by the catalyst used
- C10G45/64—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins characterised by the catalyst used containing crystalline alumino-silicates, e.g. molecular sieves
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- C10G47/00—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions
- C10G47/02—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used
- C10G47/10—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used with catalysts deposited on a carrier
- C10G47/12—Inorganic carriers
- C10G47/14—Inorganic carriers the catalyst containing platinum group metals or compounds thereof
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- C10G49/00—Treatment of hydrocarbon oils, in the presence of hydrogen or hydrogen-generating compounds, not provided for in a single one of groups C10G45/02, C10G45/32, C10G45/44, C10G45/58 or C10G47/00
- C10G49/02—Treatment of hydrocarbon oils, in the presence of hydrogen or hydrogen-generating compounds, not provided for in a single one of groups C10G45/02, C10G45/32, C10G45/44, C10G45/58 or C10G47/00 characterised by the catalyst used
- C10G49/08—Treatment of hydrocarbon oils, in the presence of hydrogen or hydrogen-generating compounds, not provided for in a single one of groups C10G45/02, C10G45/32, C10G45/44, C10G45/58 or C10G47/00 characterised by the catalyst used containing crystalline alumino-silicates, e.g. molecular sieves
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- C10G50/00—Production of liquid hydrocarbon mixtures from lower carbon number hydrocarbons, e.g. by oligomerisation
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- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2229/00—Aspects of molecular sieve catalysts not covered by B01J29/00
- B01J2229/30—After treatment, characterised by the means used
- B01J2229/32—Reaction with silicon compounds, e.g. TEOS, siliconfluoride
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- B01J2229/00—Aspects of molecular sieve catalysts not covered by B01J29/00
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- B01J29/00—Catalysts comprising molecular sieves
- B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
- B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
- B01J29/70—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65
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- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
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Abstract
A material especially useful for the selective oxidation of hydrocarbons and-other organic compounds includes a non-crystalline, porous inorganic oxide having at least 97 volume percent mesopores based on micropores and mesopores, and at least one catalytically active metal selected from the group consisting of one or more transition metal and one or more noble metal.
Description
MESOPOROUS MATERIAL AND USE THEREOF FOR THE
SEIrECTIVE OXIDATION OF ORGANIC COMPOUNDS
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation in part of U.S. application Serial No. 09/995,227 filed November 27, 2001 and incorporated by reference herein, which is a continuation in part of U.S. application Serial No.
09/390,276 filed September 7, 1999, now issued as U.S.
Patent ~de. x,'58,486 B1, to which priority is claimed.
BACKGROUND
1. Field of the Invention The present invention relates to a mesoporous material, particularly a catalytic material, and use of the mesoporous material for the selective oxidation of organic compounds, particularly hydrocarbons.
SEIrECTIVE OXIDATION OF ORGANIC COMPOUNDS
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation in part of U.S. application Serial No. 09/995,227 filed November 27, 2001 and incorporated by reference herein, which is a continuation in part of U.S. application Serial No.
09/390,276 filed September 7, 1999, now issued as U.S.
Patent ~de. x,'58,486 B1, to which priority is claimed.
BACKGROUND
1. Field of the Invention The present invention relates to a mesoporous material, particularly a catalytic material, and use of the mesoporous material for the selective oxidation of organic compounds, particularly hydrocarbons.
2, Background of the Prior Art Various processes and catalysts are known for the selective oxidation of~organic compounds. For example, U.S.
Patent No. 5,948,683 (Koermer et al.) discloses a catalytic material for the selective oxidation of_ unsaturated hydrocar.~bons in the presence of carbon monoxide. The catalytic material includes a phosphated ceria made by mixing ceria particles with a solution of phosphates, and then calcining the particles after separation from the solution.
U.S. Patent No. 5,811,599 (Alive et al.) discloses a process for the oxidation of hydrocarbons using an aqueous solution of hydrogen peroxide in the presence of a titanium silicate catalyst.
U.S. Patent No. 5,707,917 (Geus et al.) discloses a catalyst for the selective oxidation of hydrocarbons which comprises a support based on one or more metal oxides and vanadium-phosphorus oxide dispersed over the surface of the support. The process comprises an oxidation and reduction phase. The hydrocarbon is contacted with the catalyst in the reduction phase and in oxidized or non-oxidized form is adsorbed onto the catalyst. The loaded catalyst is then brought into the oxidation phase wherein the desired product is formed in the presence of gaseous oxygen and subsequently separated.
There is yet need for an improved process and catalyst for the selective oxidation of hydrocarbons and other organic compounds.
SUMMARY OF THE INVENTION
A material is provided herein which comprises a non-crystalline, porous inorganic.oxide having at least 97 volume percent mesopores based on micropores and mesopores, and at least one catalytically active metal selected from the group consisting of one or more transition metal and one or more noble metal. Also provided herein are a method for making the material and use of the material as a catalyst for the selective oxidation of organic compounds.
The process and catalyst herein provide for the selective oxidation of hydrocarbons and other organic compounds with very high selectivity.
BRIEF DESCRIPTION OF THE DRAWIDIGS
Various embodiments are described below with reference to the drawings wherein:
FIG. 1A is a plot showing the X-ray diffraction pattern of the catalyst material of Example 1;
FIG. 1B is a transmission electron microscopy image of the catalytic material of Example 1;
FIG. 2 graphically presents pore volume and pore size data pertaining to the catalytic material of Example 1;
FIG. 3 is a graph showing the X-ray diffraction patterns of the catalyst materials of Examples 4, 5, 6 and 7; and, FIG. 4 is a graph showing the X-ray diffraction pattern of the catalyst material of Example 8.
DETAILED DESCRIPTTON OF PREFERRED EMBODTMENT(S) The catalyst of the present invention includes a three-dimensional, stable, porous inorganic oxide material that is substantially mesoporous in structure. The material possesses a non-crystalline,'but regularized (pseudo-crystalline) structure. Mesoporous materials are described in U.S. Patent No. 6,358,486 B1, which is herein incorporated by reference in its entirety. The catalyst further includes one or more noble metal and/or one or more transition metal.
The amorphous inorganic oxide material of the present invention generally contains both mesopores and micropores.
Micropores are defined as pores having a diameter of less than about 2 nm. Mesopores are defined as pores having a diameter of from about 2 nm to about 50 nm. The inorganic oxide material of the present invention has a volume percentage of mesopores of at least about 97o and preferably at least about 980.
A method for making a preferred porous silica-containing catalyst support is described in U.S. Patent No.
6,358,486 B1. The average mesopore size of the preferred catalyst as determined from N2-porosimetry ranges from about 2 nm to about 25 nm. Generally, the mesoporous inorganic oxide is prepared by heating a mixture of (1) a precursor of the inorganic oxide in water, and (2) an organic templating agent that mixes well with the oxide precursor or the oxide species generated from the precursor, and preferably forms hydrogen bonds with it. .
The starting material is generally an amorphous material and may be comprised of one or more inorganic oxides such as silicon oxide or aluminum oxide, with or without additional metal oxides. The silicon or aluminum atoms may be replaced in part by catalytically active transition metal atoms such as titanium, vanadium, copper, zirconium, manganese, zinc, chromium, molybdenum, tungsten, nickel, cobalt and iron and the like. The composition by weight of the transition metal is preferably up to about 600, more preferably from about O.OOlo to about 20o based on the total weight of the catalyst. The additional metals may optionally be incorporated into the material prior to initiating the process for producing a structure that contains mesopores. For example, homogeneous synthesis mixtures containing transition metal alkoxide, silicon or aluminum alkoxide (e.g., tetraethyl orthosilicate "TEOS", or aluminum isopropoxide), and organic templating agent can be prepared. The synthesis mixture can then be aged, dried, and calcined to produce a mesoporous structure. Drying of the synthesis mixture can be performed by heating the synthesis mixture to a drying temperature of from about 50°C
to about 150°C, preferably 60°C to about 120°C, for a period of time sufficient to drive off the water and/or volatile organic liquids. Calcining of the dried mixture can be performed by heating the dried mixture to a calcining temperature of from about 300°C to about 1,000°C, preferably from about 400°C to about 700°C, for a period of time sufficient to form the mesoporous structure. Calcining times typically range from about 2 hours to about 40 hours, , depending, at least in part, on the calcining temperature.
After heating to remove water and/or volatile organic compounds and before calcining, there is an optional step of heating the dried mixture in a container at a temperature of from about 130°C to about 200°C for a period of time of from about 2 hours to about 96 hours. This step can be used to manipulate the mesopore size, surface area and pore volume of the final composition.
-G-Also, after preparation of the material, rations in the system may optionally be replaced with other ions such as those of an alkali metal (e, g.-, sodium, potassium, lithium, etc.). .
The organic mesopore-forming templating agent is preferably a glycol (a compound that includes two or more hydroxyl groups), such as glycerol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, and the like, or members) of the group consisting of triethanolamine, sulfolane, tetraethylene pentamine and diethylglycol dibenzoate. Preferably, the templating agent has a boiling point of at least about 150°C.
The mesoporous catalyst support is a pseudo-crystalline material (i.e. - no crystallinity is observed by presently available x-ray diffraction techniques). The wall thickness of the mesopores is preferably from about 3 nm to about 25 nm. The surface area of the catalyst support as determined by BET (N~) preferably ranges from about 400 m=/g to about 2200 m~/g. The catalyst pore volume preferably ranges from about 0.3 cm3/g to about 2.2 cm3/g.
During mixing, the appropriately selected active metal forms complexes with the templates (e. g., triethanolamine, or "TEA"). After drying the complexes together with free organic compound (such as TEA) act as a templating agent for the mesopores. Next, during calcining, the complexes decompose; and any organic species are removed.
Consequently, transition metals homogeneously coat the internal surfaces of the mesopores.. Depending on the loading of the transition metals, the coordination states of these transition metals can be controlled. Most of the active sites are easily accessible because they are preferentially enriched on the mesopore surfaces. In addition, the three-dimensional mesopore system also facilitates intraparticle mass transfer.
The inorganic oxide support, with or without transition metal, can be further modified by incorporation therein of a catalytically effective amount of one or more noble metals such as gold (Au), silver. (Ag), platinum (Pt), palladium' (Pd), iridium (Ir), rhodium (Rh), ruthenium (Ru), rhenium (Re) or osmium (Os). These noble metals can form nano-sized particles having a diameter of 10 nm or less in the mesopores. The percentage by weight of the noble metal can range up to about 600, preferably from about 0.1o to about 40o, based on the total catalyst weight.
The noble metal can be incorporated into the inorganic mesoporous oxide by any suitable method such as ion exchange or by impregnating the inorganic oxide with a solution of a soluble, decomposable compound of the noble metal, then _g_ washing, drying, and subjecting the impregnated inorganic oxide to a process such as calcining to decompose the noble metal compound, thereby producing an activated catalyst having free noble metal in the pores of the inorganic oxide.
Suitable noble metal compounds include salts such as nitrates, chlorides, ammonium complexes, and the like.
Washing of the noble metal impregnated inorganic oxide catalyst is optionally performed with water to remove some anions. Drying of the catalyst to remove water and/or other volatile compounds can be.accomplished by heating the catalyst to a drying temperature of from about 50°C to about 190°C. Calcining to activate the catalyst can be performed at a temperature of from about 150°C to about 600°C for a sufficient period of time. Generally, calcining can be.
performed for 2 to 40 hours depending, at least in part, on the calcining temperature.
The resulting catalyst can be employed in selective oxidation processes such as described below:
A) Epoxidation of alkenes to produce epoxides.
Suitable alkenes include CZto Coo unsaturated hydrocarbon compounds such as, for example, ethylene, propylene, the butenes (1-butene, 2-butene, isobutylene) butadiene, the pentenes, linear or branched chain hexene, 1-octene, cyclohexene, and the like. Oxidi~irig agents can include _c~_ oxygen, oxygen-containing gas, hydrogen peroxide (H_O=), nitrogen oxides, organic hydroperoxides, organic peracids, and the like. Epoxidation is .typically carried out at a temperature of from about 30° to about 300°C, preferably 50°C to about 250°C, a pressure of from about atmospheric to about 40 bars, and a space velocity of from about 10 WHSV to about 2000 WHSV. The reaction can be carried out in the gas phase, liquid phase, or mixed (gas/liquid) phase.
B) Partial oxidation of alkanes to produce ketonic or alcoholic derivatives. Suitable alkanes include propane, butane, pentane, cyclohexane, and the like. Suitable oxidizing agents can include oxygen, oxygen-containing gas, hydrogen peroxide, nitrogen oxides, organic hydroperoxides, and organic per-acids. Partial oxidation of alkanes to ketones is typically carried out at a temperature of from about 0°C to about 200°C, a pressure of from about 1 bar to about 30 bars, and a space WHSV velocity of from about 100 hr-1 to about 100,000 hr-1. Alcohol production normally is carried out at a temperature of from about 60°C to about 450° under a pressure of up to about 60 bars. The reaction can be carried out in the gas phase, liquid phase, or mixed phases. .
C) Partial oxidation of alcohol.s. Suitable alcohols include, for example, benzyl alcohol, phenylethanol, phenol, and cinnamyl alcohol. Suitable oxidizing agents can include oxygen, oxygen-containing gas, hydrogen peroxide, nitrogen oxides, organic hydroperoxides, and organic per-acids. For example, benzaldehyde can be obtained by partial oxidation of benzyl alcohol using a catalyst of the present disclosure containing, e.g., copper (Cu), at about 300°C to about 500°C
and under a pressure up to about 20 bars.
Hydroxylation of aromatic compounds to add hydroxyl groups) to the aromatic ring structure. Said aromatic compounds preferably include benzene and toluene, although other aromatic compounds can also be used. Suitable oxidizing agents can include oxygen, oxygen containing gas, hydrogen peroxide, nitrogen oxides, organic hydroperoxides, and organic per-acids. Benzene oxidized into phenol and toluene into cresols can be conducted at a temperature from 25°C to 500°C and up to a pressure of 65 bars. The process also can be carried out in a distillation column reactor at a temperature in the range of from above 100°C to X70°C and a benzene partial pressure in the range of from about 0.1 atm to about 45 atm.
E) Ammoximation of ketones with ammonia.(NH3) and hydrogen peroxide or nitrogen oxide to produce corresponding oximes. Suitable ltetones include, for example, acetone, methylethyl ketone (MEK), acetopherione, cvclohexanone, cyclododecanone, and the like. Reaction conditions typically include a temperature of from about 25°C to about 150°C, preferably 40°C to about 120°C, and a pressure of from abciut 1 to 10 atmospheres, . preferabltT 1 to 5 atmospheres..
Various features of the invention are illustrated by the Examples given below. X-ray powder diffraction patterns (XRD)of the resulting materials were recorded using CuKa radiation on a Philips PW 1840 diffractometer equipped with a graphite monochromator.. The samples were scanned in the range of 0.5-40° 28 with steps of 0.02°. Transmission electron microscopy (TEM) was performed using a Philips CM30T electron microscope with a LaB6 filament as the source of electrons operated at 300 kV. Nitrogen sorption isotherms were measured on the Quantachrome Autosorb-6B at 77 K. Mesoporr~sity was calculated using the BHJ model. All composition parts are by weight unless indicated otherwise.
A catalyst of the present invention containing titanium was prepared and tested in accordance with the following procedure. First, 1.1 parts of titanium (IV) n-butoxide was mixed with 35.0 parts of tetraethyl orthosilicate ("TEOS").
Then 25.3 parts of triethanolamine~("TEP.")- were added drop-wise into the above mixture while stirring, After stirring for 1 hour, 21.3 parts of deionized water was drop-wise added into the above mixture while stirring. After another 1 hour of stirring, 17.3 parts of tetraethylammonium hydroxide ("TEAOH") (250) was added drop-wise into the above-mixture. The final homogeneous mixture was aged at room temperature for 24 hours, dried at 100°C for 24 hours and then calcined at 700 °C for 10 hours in a ramp rate of 1°C min-1 in air.
The XRD pattern of the resulting material is shown in FIG, lA, and reveals only one intensive peak between 0.5°
and 2.5° at about 1.0° in 2~, indicating that the product was a meso-structured material. FIG. 1B is a TEM image of the resulting material. FIG. 1B shows that curved and tortuous pores are randomly connected to form a three-dimensional pore network. The BET surface area of the material as determined by nitrogen absorption was about 917 m=/g. Referring to FIG. 2, the average mesopore diameter of the material was 4.5 nm and the total pore volume was about 0 . 8 9 cm3! g .
Next cyclohexene epoxidation was used 'as model reaction to demonstrate and quantify catalytic activity using, tert-butyl hydroperoxide as an oxidant and was carried out at 40°C under N~. The reaction mixture consisted of 1 part catalyst, 9.6 parts cyclohexene (99~, dried using anhydrous MgSO~ before use) and 13.2 parts dichloromethane (990).
Samples were analyzed by gas chromatography (WAX 52 CB).
After 6 hours, about 45.60 of the cyclohexene was converted with almost 1000 selectivity. The turnover frequency (defined as moles cyclohexene converted per mole of titanium per hour) was 20.2 h-~.
COMPARATIVE EXAMPLE A
A titanium bearing catalyst not in accordance with the present invention, designated as Ti-MCM-41 was synthesized according to a procedure set forth in a~previous report (L,.Y. Chen, G.K. Chuah, S. Jaenicke, Catal. Lett. 50 (1998) 107.) It had BET surface are of 934 m'-/g and an average pore diameter of about ~.3 nm. It was tested under the identical conditions as example l, but it showed the turnover frequency of only 3.6 h"1, which was less than 200 of the cyclohexene conversion achieved by the catalyst of Example 1.
Nano-sized particles of gold were introduced into the catalyst prepared in Example 1. An aqueous solution. of AuCl~- was prepared by adding 0.34 parts by weight of HAuCl~~4H..0 into 400 parts of H,O. This was heated to 70°C, and its pH was adjusted using aqueous NaOH solution to about 7.0, Then 2 parts of the catalyst of Example 1 were suspended.in the above solution, the pH~was adjusted again .
to 7Ø The suspension was aged at 70°C for 1 hour, and washed 3 times with distilled water, dried at 100°C for 2 hours, and finally calcined in air at 300°C for 4 hours.
Vapor-phase epoxidation of propylene to propylene oxide was carried out in a vertical fixed-bed quartz reactor filled with catalyst. The reactant feed contained 10 vol.~
each of C3Hb, H, and 0, in Ar at a gaseous hourly space velocity (GHSV) of 10, 000 h-1 ml g-~ of catalyst . The reaction temperature was kept at 120°C. The feed and products were analyzed by on-line.gas chromatography(GC).
About 3.5% propylene was converted to propylene oxide with a selectivity of about 960.
A siliceous material was synthesized according to the procedure of Example 1 of U.S. Patent No. 6,358,486 as follows:
First, 1.3 parts ~by weight aluminum isopropoxide was dissolved in 39.1 parts tetrapropylammonium hydroxide (400) aqueous solution. Next, 47.88 parts TEA (970) and 14.0 parts water were mixed. The aqueous TEA mixture was added drop-wise (8-10 g/min) to the aluminum containing mixture under stirring. Finally, 33.1 parts TEOS (980) was added drop-wise (4-6 g/min) to the resulting mixture while stirring. The final mixture was aged at room temperature for 48 hours, spread out in a dish to form a layer that had a height of 1.0-1.2 cm and dried at 100°C. for 18 hours in a static air furnace. The resulting material was calcined in air using the following procedure: the material was heated t~ 500°C with a heating rate of 1°C/min, then held for 4 hours, then heated to 550°C with a heating rate of 1°C/min, then held for -10 hours.
The resulting material was used to prepare a silver containing catalyst by the impregnation into the material of AgN03 aqueous sdlution. After being impregnated, the material was calcined at 250°C for 4 hours. The impregnated catalyst was analyzed using ICP and revealed about 30.50 of silver loading.
The silver-containing catalyst was kept in a microflow reactor under atmospheric condition at 220°C. The reactant stream contained 20 volo elthylene, 40 volo oxygen and 40 vol% nitrogen. The total reactant stream GHSV was 4,500 hr-1. The products were analyzed by gas chromatography.
Within an hour, the conversion of ethylene reached 19.8, and the select.i_vity to ethylene oxide was about 29°s.
1.7 Parts of titanium (IV) n-butoxide (99%) was mixed with 106 parts of TEOS (980). Then a mixture of 77 parts TEA (97a) and 58 parts of deionized water were added drop-wise into the above mixture while stirring. After about 1 hour stirring, 63 parts of TEAOH (25o) was added drop-wise to the mixture. The Si/Ti molar ratio of the synthesis mixture was 100. The final homogeneous mixture was aged at room temperature for 24 hours, dried at 98°C for 24 hours and then calcined at 650°C for 10 hours at a ramp rate of 1°C/min in air. The XRD pattern of the material is shown in FIG. 3.
The same procedure as in Example 4 was followed except that 3.4 parts by weight of titanium (IV) n-butoxide were used and the Si/Ti ratio of the mixture was 50. The XRD
pattern of the resulting material is shown in FIG. 3.
The same procedure as in Example 4 was followed except that 8.6 parts of titanium (IV) n-butoxide were used, and the Si/Ti ratio was 20. The XRD pattern of the resulting material is shown in FIG. 3.
The same procedure as in Example 4 was followed except that 17.2 parts of titanium (IV) n-butoxide were used and the Si/Ti ratio was 10. .The XRD pattern of the resulting material is shown in FIG. 3.
As can be seen from Examples 4-7, adding the appropriate amounts of titanium compound in the initial synthesis mixture can easily control the titanium loading of the catalyst material of the present invention. The XRD
patterns of the resulting materials of Examples 4-7 indicate that these materials are mesoporous.
First, 1.2 parts (by weight) of chromium (III) acetylacetonate (97o) was mixed with 34.5 parts of TEaS
(980). Then 25 parts of TEA (970) was added drop-wise into the above mixture while stirring: After stirring for 1 hour, 18.8 parts of dei.onized water was drop-wise added into -l~-the above mixture while stizr:ing. After another 1 hour of stirring, 20.5 parts of tetraethylammonium hydroxide (25~) was added drop-wise into the above mixture. The final homogeneous mixture was aged at room temperature for 24 hours, dried at 100°C for 24 hours. The dried gel was heated in an autoclave at 180°C for 8 hours, and finally calcined at 650°C for 10 hours in a ramp rate of 1°C min-= in air.
FIG. 4 shows the XRD pattern of this material, presenting an intensive peak at around 1.3° in 28. Nitrogen adsorption reveals the surface area of 618 m2/g, the pore volume of 0.67 cm3/g and the average pore size diameter of 5.5 nm. The data show that the chromium-containing material of this Example 8 is mesoporous in structure. This material was tested as a catalyst for cyclohexene epoxidation under identical conditions in Example 1. After six hours, about 460 of the cyclohexene was converted with a selectivity of about 94o to cyclohexene epoxide.
L~lhile the above description contains many specifics, these specifics should not be construed as limitations on the scope of the invention, but merely as exemplifications of preferred embodiments thereof. Those skilled in the art will envision many other possibilities within the scope and spirit of the invention as defined by the claims appended hereto.
Patent No. 5,948,683 (Koermer et al.) discloses a catalytic material for the selective oxidation of_ unsaturated hydrocar.~bons in the presence of carbon monoxide. The catalytic material includes a phosphated ceria made by mixing ceria particles with a solution of phosphates, and then calcining the particles after separation from the solution.
U.S. Patent No. 5,811,599 (Alive et al.) discloses a process for the oxidation of hydrocarbons using an aqueous solution of hydrogen peroxide in the presence of a titanium silicate catalyst.
U.S. Patent No. 5,707,917 (Geus et al.) discloses a catalyst for the selective oxidation of hydrocarbons which comprises a support based on one or more metal oxides and vanadium-phosphorus oxide dispersed over the surface of the support. The process comprises an oxidation and reduction phase. The hydrocarbon is contacted with the catalyst in the reduction phase and in oxidized or non-oxidized form is adsorbed onto the catalyst. The loaded catalyst is then brought into the oxidation phase wherein the desired product is formed in the presence of gaseous oxygen and subsequently separated.
There is yet need for an improved process and catalyst for the selective oxidation of hydrocarbons and other organic compounds.
SUMMARY OF THE INVENTION
A material is provided herein which comprises a non-crystalline, porous inorganic.oxide having at least 97 volume percent mesopores based on micropores and mesopores, and at least one catalytically active metal selected from the group consisting of one or more transition metal and one or more noble metal. Also provided herein are a method for making the material and use of the material as a catalyst for the selective oxidation of organic compounds.
The process and catalyst herein provide for the selective oxidation of hydrocarbons and other organic compounds with very high selectivity.
BRIEF DESCRIPTION OF THE DRAWIDIGS
Various embodiments are described below with reference to the drawings wherein:
FIG. 1A is a plot showing the X-ray diffraction pattern of the catalyst material of Example 1;
FIG. 1B is a transmission electron microscopy image of the catalytic material of Example 1;
FIG. 2 graphically presents pore volume and pore size data pertaining to the catalytic material of Example 1;
FIG. 3 is a graph showing the X-ray diffraction patterns of the catalyst materials of Examples 4, 5, 6 and 7; and, FIG. 4 is a graph showing the X-ray diffraction pattern of the catalyst material of Example 8.
DETAILED DESCRIPTTON OF PREFERRED EMBODTMENT(S) The catalyst of the present invention includes a three-dimensional, stable, porous inorganic oxide material that is substantially mesoporous in structure. The material possesses a non-crystalline,'but regularized (pseudo-crystalline) structure. Mesoporous materials are described in U.S. Patent No. 6,358,486 B1, which is herein incorporated by reference in its entirety. The catalyst further includes one or more noble metal and/or one or more transition metal.
The amorphous inorganic oxide material of the present invention generally contains both mesopores and micropores.
Micropores are defined as pores having a diameter of less than about 2 nm. Mesopores are defined as pores having a diameter of from about 2 nm to about 50 nm. The inorganic oxide material of the present invention has a volume percentage of mesopores of at least about 97o and preferably at least about 980.
A method for making a preferred porous silica-containing catalyst support is described in U.S. Patent No.
6,358,486 B1. The average mesopore size of the preferred catalyst as determined from N2-porosimetry ranges from about 2 nm to about 25 nm. Generally, the mesoporous inorganic oxide is prepared by heating a mixture of (1) a precursor of the inorganic oxide in water, and (2) an organic templating agent that mixes well with the oxide precursor or the oxide species generated from the precursor, and preferably forms hydrogen bonds with it. .
The starting material is generally an amorphous material and may be comprised of one or more inorganic oxides such as silicon oxide or aluminum oxide, with or without additional metal oxides. The silicon or aluminum atoms may be replaced in part by catalytically active transition metal atoms such as titanium, vanadium, copper, zirconium, manganese, zinc, chromium, molybdenum, tungsten, nickel, cobalt and iron and the like. The composition by weight of the transition metal is preferably up to about 600, more preferably from about O.OOlo to about 20o based on the total weight of the catalyst. The additional metals may optionally be incorporated into the material prior to initiating the process for producing a structure that contains mesopores. For example, homogeneous synthesis mixtures containing transition metal alkoxide, silicon or aluminum alkoxide (e.g., tetraethyl orthosilicate "TEOS", or aluminum isopropoxide), and organic templating agent can be prepared. The synthesis mixture can then be aged, dried, and calcined to produce a mesoporous structure. Drying of the synthesis mixture can be performed by heating the synthesis mixture to a drying temperature of from about 50°C
to about 150°C, preferably 60°C to about 120°C, for a period of time sufficient to drive off the water and/or volatile organic liquids. Calcining of the dried mixture can be performed by heating the dried mixture to a calcining temperature of from about 300°C to about 1,000°C, preferably from about 400°C to about 700°C, for a period of time sufficient to form the mesoporous structure. Calcining times typically range from about 2 hours to about 40 hours, , depending, at least in part, on the calcining temperature.
After heating to remove water and/or volatile organic compounds and before calcining, there is an optional step of heating the dried mixture in a container at a temperature of from about 130°C to about 200°C for a period of time of from about 2 hours to about 96 hours. This step can be used to manipulate the mesopore size, surface area and pore volume of the final composition.
-G-Also, after preparation of the material, rations in the system may optionally be replaced with other ions such as those of an alkali metal (e, g.-, sodium, potassium, lithium, etc.). .
The organic mesopore-forming templating agent is preferably a glycol (a compound that includes two or more hydroxyl groups), such as glycerol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, and the like, or members) of the group consisting of triethanolamine, sulfolane, tetraethylene pentamine and diethylglycol dibenzoate. Preferably, the templating agent has a boiling point of at least about 150°C.
The mesoporous catalyst support is a pseudo-crystalline material (i.e. - no crystallinity is observed by presently available x-ray diffraction techniques). The wall thickness of the mesopores is preferably from about 3 nm to about 25 nm. The surface area of the catalyst support as determined by BET (N~) preferably ranges from about 400 m=/g to about 2200 m~/g. The catalyst pore volume preferably ranges from about 0.3 cm3/g to about 2.2 cm3/g.
During mixing, the appropriately selected active metal forms complexes with the templates (e. g., triethanolamine, or "TEA"). After drying the complexes together with free organic compound (such as TEA) act as a templating agent for the mesopores. Next, during calcining, the complexes decompose; and any organic species are removed.
Consequently, transition metals homogeneously coat the internal surfaces of the mesopores.. Depending on the loading of the transition metals, the coordination states of these transition metals can be controlled. Most of the active sites are easily accessible because they are preferentially enriched on the mesopore surfaces. In addition, the three-dimensional mesopore system also facilitates intraparticle mass transfer.
The inorganic oxide support, with or without transition metal, can be further modified by incorporation therein of a catalytically effective amount of one or more noble metals such as gold (Au), silver. (Ag), platinum (Pt), palladium' (Pd), iridium (Ir), rhodium (Rh), ruthenium (Ru), rhenium (Re) or osmium (Os). These noble metals can form nano-sized particles having a diameter of 10 nm or less in the mesopores. The percentage by weight of the noble metal can range up to about 600, preferably from about 0.1o to about 40o, based on the total catalyst weight.
The noble metal can be incorporated into the inorganic mesoporous oxide by any suitable method such as ion exchange or by impregnating the inorganic oxide with a solution of a soluble, decomposable compound of the noble metal, then _g_ washing, drying, and subjecting the impregnated inorganic oxide to a process such as calcining to decompose the noble metal compound, thereby producing an activated catalyst having free noble metal in the pores of the inorganic oxide.
Suitable noble metal compounds include salts such as nitrates, chlorides, ammonium complexes, and the like.
Washing of the noble metal impregnated inorganic oxide catalyst is optionally performed with water to remove some anions. Drying of the catalyst to remove water and/or other volatile compounds can be.accomplished by heating the catalyst to a drying temperature of from about 50°C to about 190°C. Calcining to activate the catalyst can be performed at a temperature of from about 150°C to about 600°C for a sufficient period of time. Generally, calcining can be.
performed for 2 to 40 hours depending, at least in part, on the calcining temperature.
The resulting catalyst can be employed in selective oxidation processes such as described below:
A) Epoxidation of alkenes to produce epoxides.
Suitable alkenes include CZto Coo unsaturated hydrocarbon compounds such as, for example, ethylene, propylene, the butenes (1-butene, 2-butene, isobutylene) butadiene, the pentenes, linear or branched chain hexene, 1-octene, cyclohexene, and the like. Oxidi~irig agents can include _c~_ oxygen, oxygen-containing gas, hydrogen peroxide (H_O=), nitrogen oxides, organic hydroperoxides, organic peracids, and the like. Epoxidation is .typically carried out at a temperature of from about 30° to about 300°C, preferably 50°C to about 250°C, a pressure of from about atmospheric to about 40 bars, and a space velocity of from about 10 WHSV to about 2000 WHSV. The reaction can be carried out in the gas phase, liquid phase, or mixed (gas/liquid) phase.
B) Partial oxidation of alkanes to produce ketonic or alcoholic derivatives. Suitable alkanes include propane, butane, pentane, cyclohexane, and the like. Suitable oxidizing agents can include oxygen, oxygen-containing gas, hydrogen peroxide, nitrogen oxides, organic hydroperoxides, and organic per-acids. Partial oxidation of alkanes to ketones is typically carried out at a temperature of from about 0°C to about 200°C, a pressure of from about 1 bar to about 30 bars, and a space WHSV velocity of from about 100 hr-1 to about 100,000 hr-1. Alcohol production normally is carried out at a temperature of from about 60°C to about 450° under a pressure of up to about 60 bars. The reaction can be carried out in the gas phase, liquid phase, or mixed phases. .
C) Partial oxidation of alcohol.s. Suitable alcohols include, for example, benzyl alcohol, phenylethanol, phenol, and cinnamyl alcohol. Suitable oxidizing agents can include oxygen, oxygen-containing gas, hydrogen peroxide, nitrogen oxides, organic hydroperoxides, and organic per-acids. For example, benzaldehyde can be obtained by partial oxidation of benzyl alcohol using a catalyst of the present disclosure containing, e.g., copper (Cu), at about 300°C to about 500°C
and under a pressure up to about 20 bars.
Hydroxylation of aromatic compounds to add hydroxyl groups) to the aromatic ring structure. Said aromatic compounds preferably include benzene and toluene, although other aromatic compounds can also be used. Suitable oxidizing agents can include oxygen, oxygen containing gas, hydrogen peroxide, nitrogen oxides, organic hydroperoxides, and organic per-acids. Benzene oxidized into phenol and toluene into cresols can be conducted at a temperature from 25°C to 500°C and up to a pressure of 65 bars. The process also can be carried out in a distillation column reactor at a temperature in the range of from above 100°C to X70°C and a benzene partial pressure in the range of from about 0.1 atm to about 45 atm.
E) Ammoximation of ketones with ammonia.(NH3) and hydrogen peroxide or nitrogen oxide to produce corresponding oximes. Suitable ltetones include, for example, acetone, methylethyl ketone (MEK), acetopherione, cvclohexanone, cyclododecanone, and the like. Reaction conditions typically include a temperature of from about 25°C to about 150°C, preferably 40°C to about 120°C, and a pressure of from abciut 1 to 10 atmospheres, . preferabltT 1 to 5 atmospheres..
Various features of the invention are illustrated by the Examples given below. X-ray powder diffraction patterns (XRD)of the resulting materials were recorded using CuKa radiation on a Philips PW 1840 diffractometer equipped with a graphite monochromator.. The samples were scanned in the range of 0.5-40° 28 with steps of 0.02°. Transmission electron microscopy (TEM) was performed using a Philips CM30T electron microscope with a LaB6 filament as the source of electrons operated at 300 kV. Nitrogen sorption isotherms were measured on the Quantachrome Autosorb-6B at 77 K. Mesoporr~sity was calculated using the BHJ model. All composition parts are by weight unless indicated otherwise.
A catalyst of the present invention containing titanium was prepared and tested in accordance with the following procedure. First, 1.1 parts of titanium (IV) n-butoxide was mixed with 35.0 parts of tetraethyl orthosilicate ("TEOS").
Then 25.3 parts of triethanolamine~("TEP.")- were added drop-wise into the above mixture while stirring, After stirring for 1 hour, 21.3 parts of deionized water was drop-wise added into the above mixture while stirring. After another 1 hour of stirring, 17.3 parts of tetraethylammonium hydroxide ("TEAOH") (250) was added drop-wise into the above-mixture. The final homogeneous mixture was aged at room temperature for 24 hours, dried at 100°C for 24 hours and then calcined at 700 °C for 10 hours in a ramp rate of 1°C min-1 in air.
The XRD pattern of the resulting material is shown in FIG, lA, and reveals only one intensive peak between 0.5°
and 2.5° at about 1.0° in 2~, indicating that the product was a meso-structured material. FIG. 1B is a TEM image of the resulting material. FIG. 1B shows that curved and tortuous pores are randomly connected to form a three-dimensional pore network. The BET surface area of the material as determined by nitrogen absorption was about 917 m=/g. Referring to FIG. 2, the average mesopore diameter of the material was 4.5 nm and the total pore volume was about 0 . 8 9 cm3! g .
Next cyclohexene epoxidation was used 'as model reaction to demonstrate and quantify catalytic activity using, tert-butyl hydroperoxide as an oxidant and was carried out at 40°C under N~. The reaction mixture consisted of 1 part catalyst, 9.6 parts cyclohexene (99~, dried using anhydrous MgSO~ before use) and 13.2 parts dichloromethane (990).
Samples were analyzed by gas chromatography (WAX 52 CB).
After 6 hours, about 45.60 of the cyclohexene was converted with almost 1000 selectivity. The turnover frequency (defined as moles cyclohexene converted per mole of titanium per hour) was 20.2 h-~.
COMPARATIVE EXAMPLE A
A titanium bearing catalyst not in accordance with the present invention, designated as Ti-MCM-41 was synthesized according to a procedure set forth in a~previous report (L,.Y. Chen, G.K. Chuah, S. Jaenicke, Catal. Lett. 50 (1998) 107.) It had BET surface are of 934 m'-/g and an average pore diameter of about ~.3 nm. It was tested under the identical conditions as example l, but it showed the turnover frequency of only 3.6 h"1, which was less than 200 of the cyclohexene conversion achieved by the catalyst of Example 1.
Nano-sized particles of gold were introduced into the catalyst prepared in Example 1. An aqueous solution. of AuCl~- was prepared by adding 0.34 parts by weight of HAuCl~~4H..0 into 400 parts of H,O. This was heated to 70°C, and its pH was adjusted using aqueous NaOH solution to about 7.0, Then 2 parts of the catalyst of Example 1 were suspended.in the above solution, the pH~was adjusted again .
to 7Ø The suspension was aged at 70°C for 1 hour, and washed 3 times with distilled water, dried at 100°C for 2 hours, and finally calcined in air at 300°C for 4 hours.
Vapor-phase epoxidation of propylene to propylene oxide was carried out in a vertical fixed-bed quartz reactor filled with catalyst. The reactant feed contained 10 vol.~
each of C3Hb, H, and 0, in Ar at a gaseous hourly space velocity (GHSV) of 10, 000 h-1 ml g-~ of catalyst . The reaction temperature was kept at 120°C. The feed and products were analyzed by on-line.gas chromatography(GC).
About 3.5% propylene was converted to propylene oxide with a selectivity of about 960.
A siliceous material was synthesized according to the procedure of Example 1 of U.S. Patent No. 6,358,486 as follows:
First, 1.3 parts ~by weight aluminum isopropoxide was dissolved in 39.1 parts tetrapropylammonium hydroxide (400) aqueous solution. Next, 47.88 parts TEA (970) and 14.0 parts water were mixed. The aqueous TEA mixture was added drop-wise (8-10 g/min) to the aluminum containing mixture under stirring. Finally, 33.1 parts TEOS (980) was added drop-wise (4-6 g/min) to the resulting mixture while stirring. The final mixture was aged at room temperature for 48 hours, spread out in a dish to form a layer that had a height of 1.0-1.2 cm and dried at 100°C. for 18 hours in a static air furnace. The resulting material was calcined in air using the following procedure: the material was heated t~ 500°C with a heating rate of 1°C/min, then held for 4 hours, then heated to 550°C with a heating rate of 1°C/min, then held for -10 hours.
The resulting material was used to prepare a silver containing catalyst by the impregnation into the material of AgN03 aqueous sdlution. After being impregnated, the material was calcined at 250°C for 4 hours. The impregnated catalyst was analyzed using ICP and revealed about 30.50 of silver loading.
The silver-containing catalyst was kept in a microflow reactor under atmospheric condition at 220°C. The reactant stream contained 20 volo elthylene, 40 volo oxygen and 40 vol% nitrogen. The total reactant stream GHSV was 4,500 hr-1. The products were analyzed by gas chromatography.
Within an hour, the conversion of ethylene reached 19.8, and the select.i_vity to ethylene oxide was about 29°s.
1.7 Parts of titanium (IV) n-butoxide (99%) was mixed with 106 parts of TEOS (980). Then a mixture of 77 parts TEA (97a) and 58 parts of deionized water were added drop-wise into the above mixture while stirring. After about 1 hour stirring, 63 parts of TEAOH (25o) was added drop-wise to the mixture. The Si/Ti molar ratio of the synthesis mixture was 100. The final homogeneous mixture was aged at room temperature for 24 hours, dried at 98°C for 24 hours and then calcined at 650°C for 10 hours at a ramp rate of 1°C/min in air. The XRD pattern of the material is shown in FIG. 3.
The same procedure as in Example 4 was followed except that 3.4 parts by weight of titanium (IV) n-butoxide were used and the Si/Ti ratio of the mixture was 50. The XRD
pattern of the resulting material is shown in FIG. 3.
The same procedure as in Example 4 was followed except that 8.6 parts of titanium (IV) n-butoxide were used, and the Si/Ti ratio was 20. The XRD pattern of the resulting material is shown in FIG. 3.
The same procedure as in Example 4 was followed except that 17.2 parts of titanium (IV) n-butoxide were used and the Si/Ti ratio was 10. .The XRD pattern of the resulting material is shown in FIG. 3.
As can be seen from Examples 4-7, adding the appropriate amounts of titanium compound in the initial synthesis mixture can easily control the titanium loading of the catalyst material of the present invention. The XRD
patterns of the resulting materials of Examples 4-7 indicate that these materials are mesoporous.
First, 1.2 parts (by weight) of chromium (III) acetylacetonate (97o) was mixed with 34.5 parts of TEaS
(980). Then 25 parts of TEA (970) was added drop-wise into the above mixture while stirring: After stirring for 1 hour, 18.8 parts of dei.onized water was drop-wise added into -l~-the above mixture while stizr:ing. After another 1 hour of stirring, 20.5 parts of tetraethylammonium hydroxide (25~) was added drop-wise into the above mixture. The final homogeneous mixture was aged at room temperature for 24 hours, dried at 100°C for 24 hours. The dried gel was heated in an autoclave at 180°C for 8 hours, and finally calcined at 650°C for 10 hours in a ramp rate of 1°C min-= in air.
FIG. 4 shows the XRD pattern of this material, presenting an intensive peak at around 1.3° in 28. Nitrogen adsorption reveals the surface area of 618 m2/g, the pore volume of 0.67 cm3/g and the average pore size diameter of 5.5 nm. The data show that the chromium-containing material of this Example 8 is mesoporous in structure. This material was tested as a catalyst for cyclohexene epoxidation under identical conditions in Example 1. After six hours, about 460 of the cyclohexene was converted with a selectivity of about 94o to cyclohexene epoxide.
L~lhile the above description contains many specifics, these specifics should not be construed as limitations on the scope of the invention, but merely as exemplifications of preferred embodiments thereof. Those skilled in the art will envision many other possibilities within the scope and spirit of the invention as defined by the claims appended hereto.
Claims (43)
1. A material which comprises:
a) a non-crystalline, porous inorganic oxide having at least 97 volume percent mesopores based,on micropores and mesopores, said mesopores being interconnected; and b) at least one catalytically active metal selected from the group consisting of one or more transition metal and one or more noble metal.
a) a non-crystalline, porous inorganic oxide having at least 97 volume percent mesopores based,on micropores and mesopores, said mesopores being interconnected; and b) at least one catalytically active metal selected from the group consisting of one or more transition metal and one or more noble metal.
2. The material of claim 1 wherein the transition metal is selected from the group consisting of titanium, vanadium, copper, zirconium, manganese, zinc, iron, nickel, cobalt, chromium, molybdenum and tungsten.
3. The material of claim 1 wherein the noble metal is selected from the group consisting of gold, silver, platinum, palladium, iridium, rhodium, ruthenium, rhenium and osmium.
4. The material of claim 1 wherein the catalytically active metal is gold or silver.
5. The material of claim 1 wherein the catalytically active metal is chromium.
6. The material of claim 1 wherein the catalytically active metal is titanium.
7. The material of claim 1 wherein the non-crystalline porous inorganic oxide is characterized by an X ray diffraction pattern having a 2.theta. peak between 0.5° and 2.5°.
8. The material of claim 1 wherein the non-crystalline porous inorganic oxide contains at least 98 volume percent mesopores.
9. The material of claim 1 wherein the mesopores have a size ranging from about 2 nm to about 25 nm.
10. The material of claim 1 wherein the inorganic oxide is silicon oxide.
11. The material of claim 1 wherein the inorganic oxide is aluminum oxide.
12. The material of claim 1 wherein the composition percentage by weight of the transition metal ranges up to about 60%.
13. The material of claim 1 wherein the composition by weight of the transition metal ranges from about 0.001% to about 20%.
14. The material of claim 1 wherein the composition percentage by weight of the noble metal ranges up to about 60%.
15. The material of claim 1 wherein the composition percentage by weight of the noble metal ranges from about 0.1% to about 400.
16. A method for making a catalyst comprising the steps of:
a) combining at least one source of inorganic oxide and at least one mesopore forming agent and optionally one or more source of catalytically active transition metal to form a synthesis mixture;
b) drying the synthesis mixture;
c) heating the dried synthesis mixture to a calcining temperature for a period of time sufficient to form a non-crystalline support structure having at least 97 volume percent mesopores; and, d) incorporating at least one catalytically active noble metal and/or transition metal into the catalyst.
a) combining at least one source of inorganic oxide and at least one mesopore forming agent and optionally one or more source of catalytically active transition metal to form a synthesis mixture;
b) drying the synthesis mixture;
c) heating the dried synthesis mixture to a calcining temperature for a period of time sufficient to form a non-crystalline support structure having at least 97 volume percent mesopores; and, d) incorporating at least one catalytically active noble metal and/or transition metal into the catalyst.
17. The method of claim 16 wherein the inorganic oxide is selected from the group consisting of aluminum oxide and silicon oxide.
18. The method of claim 17 wherein the source of inorganic oxide is selected from the group consisting of silicon alkoxide and aluminum alkoxide.
19. The method of claim 18 wherein the silicon alkoxide is tetraethyl orthosilicate and the aluminum alkoxide is aluminum isopropoxide.
20. The method of claim 16 wherein the catalytically active transition metal is incorporated into the catalyst by combining a compound containing the transition metal with the source of inorganic oxide in step (a) to form the synthesis mixture.
21. The method of claim 16 wherein the catalytically active transition metal is incorporated into the catalyst by incorporating a compound containing the transition metal into the catalyst after step (c) of heating the dried synthesis mixture to a calcining temperature.
22. The method of claim 16 wherein the transition metal is selected from the group consisting of titanium, vanadium, copper, zirconium, manganese, zinc, chromium, molybdenum, tungsten, nickel, cobalt and iron.
23. The method of claim 20 wherein the compound containing the transition metal is an alkoxide of titanium.
24. The method of claim 23 wherein the alkoxide of titanium is titanium n-butoxide.
25. The method of claim 16 wherein heating the dried synthesis mixture to a calcining temperature includes heating the dried synthesis mixture to a temperature of from about 120°C to about 200°C for a period of time of about from 2 hours to about 96 hours.
26. The method of claim 16 wherein the noble metal is selected from the group consisting of gold, silver, platinum, palladium, iridium, rhodium, ruthenium, rhenium and osmium.
27. The method of claim 16 wherein the step (d) of incorporating at least one catalytically active noble metal or transition metal into the catalyst comprises impregnating the non-crystalline support structure with a solution of a soluble, decomposable compound of the noble metal and/or transition metal, and thereafter decomposing the noble metal compound and/or transition metal compound.
28. The method of claim 37 wherein the step of decomposing the noble metal compound and/or transition metal compound comprises calcining the noble metal and/or transition metal impregnated non-crystalline support at a temperature sufficient to decompose the noble metal compound and/or transition metal compound.
29. The method of claim 28 wherein the noble metal is gold or silver.
30. The method of claim 16 wherein the mesopore forming agent is selected from the group consisting of glycerol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, triethanolamine, sulfolane, tetraethylene pentamine and diethylglycol dibenzoate.
31. The method of claim 16 wherein the step (d) of incorporating at least one catalytically active noble metal and/or transition metal comprises incorporating both a catalytically active noble metal and transition metal into the catalyst.
32. A process for the selective oxidation of an organic compound comprising:
contacting the organic compound with an oxidising agent under partial oxidation reaction conditions in the presence of a catalyst which includes a non-crystalline, porous inorganic oxide having at least 97 volume percent mesopores based on micropores and mesopores, and at least one catalytically active metal selected from the group consisting of one or more transition metal and one or more noble metal.
contacting the organic compound with an oxidising agent under partial oxidation reaction conditions in the presence of a catalyst which includes a non-crystalline, porous inorganic oxide having at least 97 volume percent mesopores based on micropores and mesopores, and at least one catalytically active metal selected from the group consisting of one or more transition metal and one or more noble metal.
33. The process of claim 32 wherein the organic compound is an alkene and the selective oxidation process comprises epoxidation of the alkene to produce a corresponding epoxide.
34. The process of claim 33 wherein the alkene is selected from the group consisting of ethylene, propylene, 1-butane, 2-butane, isobutylene, butadiene, pentane, hexene, 1-octane and cyclohexene, the oxidizing agent is selected from the group consisting of oxygen, oxygen-containing gas, hydrogen peroxide, nitrogen oxide, organic hydroperoxide and organic peracid, and the reaction conditions include a temperature of from about 50°C to about 250°C, a pressure of from about atmospheric pressure to about 60 bars, and a space velocity of from about 10 WHSV to about 2000 WHSV.
35. The process of claim 32 wherein the catalytically active metal is selected from the group consisting of titanium, chromium, vanadium, gold and silver.
36. The process of claim 32 wherein the organic compound is an alkane and the selective oxidation process is the partial oxidation of the alkane to produce a corresponding ketone or alcohol.
37. The process of claim 36 wherein the alkane is selected from the group consisting of propane, butane, pentane and cyclohexane, the oxidizing agent is selected from the group consisting of oxygen, oxygen-containing gas, hydrogen peroxide, nitrogen oxide, organic hydroperoxide and organic peracid, and the reaction conditions include a temperature of from about 0°C to about 200°C, a pressure of from about 1 bar to about 30 bars, and a space velocity of from about 100 hr-1 to about 1000 hr-.
38. The process of claim 32 wherein the organic compound is a ketone and the selective oxidation process is the ammoximation of the ketone to produce a corresponding oxime.
39. The process of claim 38 wherein the ketone is selected from the group consisting of acetone, methylethyl ketone, acetophenone, cyclohexanone and cyclododecanone, the oxidizing agent is hydrogen peroxide or nitrogen oxide which is mixed with ammonia, and the reaction conditions include a temperature of from about 25° to about 150°, and a pressure of from about 1 atmosphere to about 10 atmospheres.
40. The process of claim 32 wherein the organic compound is an aromatic compound and the selective oxidation process is the hydroxylation of the aromatic compound to add at least one hydroxyl group to the aromatic ring structure.
41. The process of claim 40 wherein said aromatic compound is selected from the group consisting of benzene and toluene, and the oxidizing agent is selected from the group consisting of oxygen, oxygen-containing gas, hydrogen peroxide, nitrogen oxide, organic hydroperoxide and organic per-acid, and the reaction conditions include a temperature of from 125°C to about 500°C and a pressure up to 65 bars.
42. The process of claim 32 wherein the catalytically active transition metal is selected from the group consisting of titanium, vanadium and chromium.
43. The process of claim 32 wherein the catalytically active noble metal is gold or silver.
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US10/246,495 | 2002-09-18 | ||
US10/246,495 US6906208B2 (en) | 1999-09-07 | 2002-09-18 | Mesoporous material and use thereof for the selective oxidation of organic compounds |
PCT/US2003/030009 WO2004026473A1 (en) | 2002-09-18 | 2003-09-17 | Mesoporous material and use thereof for the selective oxidation of organic compounds |
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US (2) | US6906208B2 (en) |
EP (1) | EP1542799A1 (en) |
JP (1) | JP2005538842A (en) |
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CN (1) | CN1681594A (en) |
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BR (1) | BR0314321A (en) |
CA (1) | CA2499203A1 (en) |
IN (1) | IN212257B (en) |
MX (1) | MXPA05002909A (en) |
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JP2005538842A (en) | 2005-12-22 |
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EP1542799A1 (en) | 2005-06-22 |
TWI309582B (en) | 2009-05-11 |
US20030017943A1 (en) | 2003-01-23 |
WO2004026473A1 (en) | 2004-04-01 |
CN1681594A (en) | 2005-10-12 |
IN2005MU00187A (en) | 2005-12-02 |
KR20050050659A (en) | 2005-05-31 |
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