WO2002102511B1 - Textured catalysts comprising catalyst metal and metal oxide on carbon support, methods of making textured catalysts, and use in hydrogenation reactions conducted in hydrothermal conditions - Google Patents

Textured catalysts comprising catalyst metal and metal oxide on carbon support, methods of making textured catalysts, and use in hydrogenation reactions conducted in hydrothermal conditions

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Publication number
WO2002102511B1
WO2002102511B1 PCT/US2002/019253 US0219253W WO02102511B1 WO 2002102511 B1 WO2002102511 B1 WO 2002102511B1 US 0219253 W US0219253 W US 0219253W WO 02102511 B1 WO02102511 B1 WO 02102511B1
Authority
WO
WIPO (PCT)
Prior art keywords
catalyst
metal oxide
support
catalyst component
reactant
Prior art date
Application number
PCT/US2002/019253
Other languages
French (fr)
Other versions
WO2002102511A1 (en
Inventor
Todd A Werpy
Jr John G Frye
Yong Wang
Alan H Zacher
Original Assignee
Battelle Memorial Institute
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Battelle Memorial Institute filed Critical Battelle Memorial Institute
Publication of WO2002102511A1 publication Critical patent/WO2002102511A1/en
Publication of WO2002102511B1 publication Critical patent/WO2002102511B1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B01J23/44—Palladium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/18—Carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B01J23/46—Ruthenium, rhodium, osmium or iridium
    • B01J23/464—Rhodium
    • B01J35/56—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/0201—Impregnation
    • B01J37/0211—Impregnation using a colloidal suspension
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • B01J37/03—Precipitation; Co-precipitation
    • B01J37/038—Precipitation; Co-precipitation to form slurries or suspensions, e.g. a washcoat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
    • B01J21/063—Titanium; Oxides or hydroxides thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
    • B01J21/066—Zirconium or hafnium; Oxides or hydroxides thereof

Abstract

A textured catalyst having a hydrothermally-stable support, a metal oxide and a catalyst component is described. Methods of conducting aqueous phase reactions that are catalized by a textured catalyst are also described. The invention also provides methods of making textured calalysts and methods of making chemical products using a textured catalyst. Specific examples relate to zirconia and palladium or rhodium supported on carbon. These catalysts are used for the hydrogenation of succinic acid or diammonium succinate carried out in the aqueous phase.

Claims

AMENDED CLAIMS[received by the Iri'ternational Bureau on 28 January 2003 (28.01.03); original claims 8,9,11 and 12 amended; remaining claims unchanged (5 page)]
1. A method of making a catalyst comprising: providing a porous, hydrothermally-stable support, wherein the support comprises carbon; contacting the support with a sol comprising metal oxide particles; adding a catalyst component; and drying; wherein the porous, hydrothermally-stable support is directly contacted with the sol comprising metal oxide particles.
2. The method of claim 1 wherein the metal oxide particles comprise an oxide of a metal or metals selected from the group consisting of: Ti, V, W, Hf, Ta, Nb, Mo and .
3. The method of claim 2 wherein the metal oxide particles comprise colloidal sized particles.
4. The method of claim 1 wherein the catalyst component is in an aqueous suspension, and wherein the metal oxide particles and the catalyst component are co-precipitated.
5. The method of claim 1 further comprising, subsequent to the step of adding the catalyst component, reducing the catalyst component.
6. The method of claim 1 wherein the sol comprising metal oxide particles is in an aqueous solution having a pH between 1 and 6,
7. The method of claim 6 wherein the sol comprises a colloidal suspension.
8. A method of conducting a catalyzed reaction under hydrothermal conditions, comprising: passing an aqueous solution comprising at least one reactant into a reaction chamber; providing a catalyst within the reaction chamber, the catalyst comprising: a hydrothermally stable support having an exterior surface; a metal oxide; and a catalytic metal, at least 5% of the catalytic metal being disposed within pores that are at least about 10 μ away from the exterior surface of the support; reducing the at least one reactant in the presence of the catalyst and under hydrothermal conditions, the reducing occurring at a pH of from about 1 to about 6; and obtaining at least one reduction product from the reaction chamber; wherein the reduction product obtained has a higher purity or a higher yield than where the reaction is conducted at a pH that is 4 or more pH units from the pH of said aqueous solution.
9. The method of claim 8 wherein the aqueous solution has a pH between 2 and 5,
10. The method of claim 8 wherein the reaction occurs in a temperature range of 120 °C to 260 °C.
11. A method of conducting a catalyzed reaction under hydrothermal conditions, comprising: passing an aqueous solution comprising at least one reactant into a reaction chamber; providing a catalyst within the reaction chamber, the catalyst comprising: a porous, hydrothermally-stable support having a total pore volume, at least 20% of the total pore volume being contributed by pores having diameters of greater than about 20 angstroms; a metal oxide deposited on the support; and a catalyst metal component;
- 15 - reacting the at least one reactant in the presence of the catalyst and under hydrothermal conditions; and obtaining at least one product from the reaction chamber.
12. The method of claim 11 further comprising adding a second reactant to the reaction chamber in a non-aqueous solvent.
13. The method of claim 11 wherein the step of reacting occurs in a temperature range of 120 °C to 260 °C.
14. The method of claim 11 wherein the step of reacting occurs at a pH of l to .
15. The method of claim 11 wherein the reactant is completely dissolved in aqueous solution.
16. The method of claim 11 further comprising addition of hydrogen gas to the reaction chamber.
17. The method of claim 16 wherein the reactant comprises succinic acid.
18. The method of claim 11 wherein the support comprises carbon, and wherein the metal oxide comprises one or more of Zr, Ti, Hf, Ta, Nb, Mo, and .
19. A textured catalyst comprising: a hydrothermally-stable, porous support comprising a porous interior and an exterior surface; a metal oxide; and a catalyst metal; wherein the porous support has a minimum, smallest dimension of at least about 100 μm; at least about 70% of the catalyst component is within about 5 μm of the minimum area that encompasses about 80% of the metal oxide; and
- 16 - wherein at least about 5% of the catalyst component is at least about 10 μm --rom the exterior of the support.
20. The catalyst of claim 19 wherein the support comprises carbon, and wherein the metal oxide comprises one or more of Zr, Ti, Hf, Ta, Nb, Mo, and .
21. The catalyst of claim 19 wherein the catalyst is made by a process in which the catalyst component and metal oxide are coprecipitated.
22. The catalyst of claim 19 wherein the catalyst component is fully reduced.
23. The catalyst of claim 1 wherein the support is hydrothermally-stable such that it loses less than 5% of its surface area after 72 hours in water at 150 ύC.
24. The catalyst of claim 23 comprising carbon particles.
25. The catalyst of claim 1 wherein the metal oxide comprises 5 to 10 weight percent of the dried catalyst and wherein the metal oxide comprises at least 90%, by mass, of an oxide or oxides of one or more of Zr, Ti, Hf, Ta, Nb, Mo, and W.
26. The catalyst of claim 25 wherein the catalyst component comprises 0.1 to 10 weight % of an element selected from the group consisting of Pd, Ru, Rh, Pt, Re, Ni, Cu, Au, Ag, Co, Fe, Os, and Ir.
27. The catalyst of claim 25 wherein the metal oxide comprises zirconia or titania and the catalyst component comprises Pd or Rh.
28. The catalyst of claim 19 wherein at least about 70% of the catalyst component is within about 2 μm of the minimum area that encompasses about 80% of the metal oxide
- 17 -
29- The catalyst of claim 19 wherein at least 10% of the metal oxide is located at least about 20 μm away from the exterior of the support.
30. A method of making a chemical product comprising reacting at least one reactant over the catalyst of claim 19.
31. The catalyst of claim 19 wherein the 80% of metal oxide plus 5 μm margin occupies less than 40% of the total cross-sectional area.
32. The catalyst of claim 19 wherein at least 80%, of the metal oxide is within about 5 μm of the minimum area of 80% of the catalyst component.
33. A catalyst made by the method of claim 1.
34. The catalyst of claim 19 wherein at least 50% of the catalyst component is within about 10 μm of the exterior of the support.
35. The catalyst of claim 19 wherein the support comprises internal pores and wherein some internal pores have at least 2 times as much of the catalyst component as compared with the metal oxide.
36. The catalyst of claim 19 the majority of catalyst component that is located at least about 10 μm of the exterior of the support is located in pores having at least one dimension of at least about 5 μm.
37. The method of claim 2 wherein the support is impregnated with the sol comprising metal oxide particles, and then dried to remove water.
- 18 -
PCT/US2002/019253 2001-06-18 2002-06-17 Textured catalysts comprising catalyst metal and metal oxide on carbon support, methods of making textured catalysts, and use in hydrogenation reactions conducted in hydrothermal conditions WO2002102511A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US09/884,606 2001-06-18
US09/884,606 US6670300B2 (en) 2001-06-18 2001-06-18 Textured catalysts, methods of making textured catalysts, and methods of catalyzing reactions conducted in hydrothermal conditions

Publications (2)

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WO2002102511A1 WO2002102511A1 (en) 2002-12-27
WO2002102511B1 true WO2002102511B1 (en) 2003-11-13

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US20030004055A1 (en) 2003-01-02
US20040058807A1 (en) 2004-03-25
US20070135303A1 (en) 2007-06-14
WO2002102511A1 (en) 2002-12-27
US7776782B2 (en) 2010-08-17
US6670300B2 (en) 2003-12-30

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