Metal catalyst synthesis and acid/metal bifunctional catalyst systems thereof

Patent metadata

Field	Value
Publication number	US-2021046460-A1
Application number	US-202016947699-A
Country	US
Kind code	A1
Filing date	Aug 13, 2020
Priority date	Aug 15, 2019
Publication date	Feb 18, 2021
Grant date	—

Abstract

Methods of producing metal catalysts can include mixing two or more metal salts and an aluminum salt in water to produce a metal catalyst precursor solution having a pH of about 2.5 to about 4.0; mixing the metal catalyst precursor solution and a basic solution having a pH of about 10 to about 13 to produce a mixture with a pH of about 6 to about 7 and a precipitate; producing a powder from the precipitate; and calcining the powder to produce a metal catalyst. Such metal catalysts may be useful in producing bifunctional catalyst systems that are useful in, among other things, converting syngas to dimethyl ether in a single reactor.

First claim

The invention claimed is:

1 . A method comprising:
mixing two or more metal salts and an aluminum salt in water to produce a metal catalyst precursor solution having a pH of about 2.5 to about 4.0; mixing the metal catalyst precursor solution and a basic solution having a pH of about 10 to about 13 to produce a mixture with a pH of about 6 to about 7 and a precipitate; producing a powder from the precipitate; and calcining the powder to produce a metal catalyst.

2 . The method of claim 1 , wherein producing the powder from the precipitate comprises:
washing the precipitate; drying the precipitate; and grinding the precipitate, wherein the powder comprises 5 wt % or less of the water.

3 . The method of claim 1 , wherein the metal catalyst precursor solution is at 40° C. to 90° C. when mixing with the basic solution.

4 . The method of claim 1 , wherein the basic solution comprises sodium carbonate, sodium hydroxide, ammonia hydroxide, ammonia carbonate, sodium hydrogen bicarbonate, and any combination thereof.

5 . The method of claim 1 , wherein the two or more metal salts comprise a first metal salt that is a salt of a first metal selected from the group consisting of Cu, Cr, Ag, Au, Ru, Rh, Pd, Re, Os, Ir, and Pt and a second metal salt that is a salt of a second metal selected from the group consisting of Ti, V, Cr, Mn, Fe, Co, Ni, Zn, a rare earth metal, a La series metal, and a Y series metal.

6 . The method of claim 5 , wherein two or more first metal catalysts are included in the metal catalyst precursor solution.

7 . The method of claim 5 , wherein two or more second metal catalysts are included in the metal catalyst precursor solution.

8 . The method of claim 1 , wherein the metal catalyst is a M1/M2/Al catalyst, wherein M1 is selected from the group consisting of Cu, Cr, Ag, Au, Ru, Rh, Pd, Re, Os, Ir, Pt, and any combination thereof, wherein M2 is selected from the group consisting of Ti, V, Cr, Mn, Fe, Co, Ni, Zn, a rare earth metal, a La series metal, a Y series metal, and any combination thereof, and wherein M1 and M2 are different.

9 . The method of claim 1 , wherein calcining is performed in air at 200° C. to 400° C.

10 . The method of claim 1 , wherein the metal catalyst has an average diameter of 0.01 μm to 10 μm.

11 . The method of claim 1 , wherein the metal catalyst has a N 2 BET surface area according to ASTM D3663-03 (2015) of about 40 m 2 /g to about 200 m 2 /g.

12 . The method of claim 1 , wherein the metal catalyst has an average pore volume according to about 0.01 mL/g to about 0.1 mL/g.

13 . The method of claim 1 , wherein the metal catalyst has an average pore size according to ASTM D4641-17 of about 15 nm to about 30 nm.

14 . The method of claim 1 further comprising:
dry mixing the metal catalyst with an acid catalyst to produce an acid/metal bifunctional catalyst system.

15 . The method of claim 1 further comprising:
mixing the metal catalyst with an acid catalyst and a binder to form a dough; and
extruding the dough to produce an acid/metal bifunctional catalyst system.

16 . The method of claim 1 further comprising:
mixing the metal catalyst with an acid catalyst and a solvent to form a slurry;
heating the slurry; and
drying the slurry to produce an acid/metal bifunctional catalyst system.

17 . The method of claim 14 , wherein the acid catalyst is selected from the group consisting of a zeolite, an ion exchanged zeolite, a molecular sieve, a metal oxide, and any combination thereof

18 . The method of claim 14 , wherein the acid catalyst is present at 10 wt % to 80 wt % relative to the total catalyst weight in the acid/metal bifunctional catalyst system.

19 . The method of claim 14 , wherein the acid catalyst is present at 10 wt % to 50 wt % relative to the total catalyst weight in the acid/metal bifunctional catalyst system.

20 . The method of claim 14 further comprising:
activating the acid/metal bifunctional catalyst system in the presence hydrogen at 150° C. to 350° C.; and
reacting the activated acid/metal bifunctional catalyst system with a feedstream comprising hydrogen and carbon monoxide.

21 . The method of claim 20 , wherein reacting is at a temperature of about 200° C. to about 300° C., a pressure of about 20 bar to about 50 bar, and a gas hourly space velocity (GHSV) of about 1,000 hr −1 to about 8,000 hr −1 .

22 . The method of claim 20 , wherein the reacting the activated acid/metal bifunctional catalyst system with the feedstream is in the presence of steam.

Assignees

• Exxonmobil Res & Eng Co

Inventors

• Bai Chuansheng
• CUNNINGHAM Majosefina
• Daaka Jihad M
• Kamakoti Preeti
• Ramkrishnan Aruna

Classifications

• B01J2235/15

  X-ray diffraction · CPC title

• B01J35/45

  Nanoparticles · CPC title

• B01J35/80

  characterised by their amorphous structures · CPC title

• B01J37/04

  Mixing {(B01J37/0009, B01J37/0018 take precedence)} · CPC title

• B01J2523/00

  Constitutive chemical elements of heterogeneous catalysts · CPC title