Catalyst and method of manufacture

Patent metadata

Field	Value
Publication number	US-9895678-B2
Application number	US-201314388862-A
Country	US
Kind code	B2
Filing date	Mar 28, 2013
Priority date	Mar 30, 2012
Publication date	Feb 20, 2018
Grant date	Feb 20, 2018

Abstract

A method for making a solid material which is useful as a heterogeneous catalyst including the steps of: forming at least one copper oxide suspension comprising solid particles of copper oxide in a liquid; forming at least one carrier suspension comprising solid particles of a carrier material in a liquid; combining the copper oxide suspension and the carrier suspension; subjecting the combined suspensions to mechanical energy; separating the suspension liquid from the solid particles in the combined suspension; and subjecting the solid material to a thermal decomposition step. A catalyst made by the method has a BET surface area greater than 150 m 2 /g, a particle size distribution in which D 50 is in the range from 25-35 μm, and wherein the D 50 after 60 minutes ultrasound treatment is at least 30% of the original value.

First claim

The invention claimed is:

1. A solid particulate catalyst comprising copper oxide and a solid carrier material, wherein said solid particulate catalyst is in the form of a powder having a BET surface area greater than 150 m 2 /g, a particle size distribution in which D 50 is in the range from 25-35 μm, and wherein the D 50 after 60 minutes ultrasound treatment is at least 30% of the original value.

2. A solid particulate catalyst according to claim 1 which is obtainable by the preparation method of comprising the steps of:
(a) forming at least one copper oxide suspension comprising solid particles of copper oxide in a liquid;
(b) forming at least one carrier suspension comprising solid particles of a carrier material in a liquid;
(c) combining the copper oxide suspension and the carrier suspension;
d) subjecting the combined suspensions to mechanical energy;
(e) separating the suspension liquid from the solid particles in the combined suspension; and
(f) subjecting the separated solid particles to a thermal decomposition step.

3. A solid particulate catalyst according to any claim 1 , wherein the carrier material comprises a metal oxide.

4. A solid particulate catalyst according to claim 3 , wherein the carrier material comprises silica-alumina, silica, alumina, zirconia or titania.

5. A method for making the solid particulate catalyst of claim 1 which is useful as a heterogeneous catalyst comprising the steps of:
(a) forming at least one copper oxide suspension comprising solid particles of copper oxide in a liquid;
(b) forming at least one carrier suspension comprising solid particles of a carrier material in a liquid;
(c) combining the copper oxide suspension and the carrier suspension;
(d) subjecting the combined suspensions to mechanical energy;
(e) separating the suspension liquid from the solid particles in the combined suspension; and
(f) subjecting the separated solid particles to a thermal decomposition step.

6. A method according to claim 5 consisting essentially of steps (a)-(f).

7. A method according to claim 5 , wherein the material comprises from 5% to 90% by weight of copper oxide.

8. A method according to claim 5 , wherein step (d) comprises subjecting the combined suspensions to a milling or grinding process.

9. A method according to claim 5 , wherein in step (d) the mechanical energy applied to the combined suspensions is greater than 500 W/liter.

10. A method according to claim 5 , wherein the carrier material comprises a metal oxide.

11. A method according to claim 10 , wherein the carrier material comprises silica-alumina, silica, alumina, zirconia or titania.

12. A process for carrying out a chemical reaction selected from the type of reaction including hydrogenation, hydrogenolysis, amination and dehydrogenation, comprising adding a solid particulate catalyst according to claim 1 to a reaction mixture.

13. The process according to claim 12 , wherein the reaction is for hydrogenation of carbonyl groups.

14. The process according to claim 13 , wherein the reaction is for the production of a fatty alcohol.

Assignees

• Johnson Matthey Plc

Inventors

• Pohl Joachim
• Zwijnenburg Aalbert

Classifications

• B01J37/00 Primary

  Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts · CPC title

• C07C29/149

  with hydrogen or hydrogen-containing gases · CPC title

• C11C3/00 Primary

  Fats, oils, or fatty acids by chemical modification of fats, oils, or fatty acids obtained therefrom (sulfonated fats or oils C07C309/62; factice C08H; drying oils C09F) · CPC title

• C11C3/126

  using catalysts based principally on other metals or derivates · CPC title

• C10G3/48

  further characterised by the catalyst support · CPC title