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• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C209/00—Preparation of compounds containing amino groups bound to a carbon skeleton
  • C07C209/30—Preparation of compounds containing amino groups bound to a carbon skeleton by reduction of nitrogen-to-oxygen or nitrogen-to-nitrogen bonds
  • C07C209/32—Preparation of compounds containing amino groups bound to a carbon skeleton by reduction of nitrogen-to-oxygen or nitrogen-to-nitrogen bonds by reduction of nitro groups
  • C07C209/36—Preparation of compounds containing amino groups bound to a carbon skeleton by reduction of nitrogen-to-oxygen or nitrogen-to-nitrogen bonds by reduction of nitro groups by reduction of nitro groups bound to carbon atoms of six-membered aromatic rings in presence of hydrogen-containing gases and a catalyst
• • 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
• • 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
  • B01J35/00—Catalysts, in general, characterised by their form or physical properties
  • B01J35/40—Catalysts, in general, characterised by their form or physical properties characterised by dimensions, e.g. grain size
  • B01J35/45—Nanoparticles
• • 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
  • B01J37/0215—Coating
  • B01J37/0221—Coating of particles
• • 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
  • B01J37/031—Precipitation
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
  • B22F1/05—Metallic powder characterised by the size or surface area of the particles
  • B22F1/054—Nanosized particles
  • B22F1/056—Submicron particles having a size above 100 nm up to 300 nm
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
  • B22F1/16—Metallic particles coated with a non-metal
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B82—NANOTECHNOLOGY
  • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
  • B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C5/00—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms
  • C07C5/32—Preparation of hydrocarbons from hydrocarbons containing the same number of carbon atoms by dehydrogenation with formation of free hydrogen
  • C07C5/327—Formation of non-aromatic carbon-to-carbon double bonds only
  • C07C5/333—Catalytic processes
  • C07C5/3335—Catalytic processes with metals
  • C07C5/3337—Catalytic processes with metals of the platinum group
• • 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
  • B01J2235/00—Indexing scheme associated with group B01J35/00, related to the analysis techniques used to determine the catalysts form or properties
• • 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
  • B01J2235/00—Indexing scheme associated with group B01J35/00, related to the analysis techniques used to determine the catalysts form or properties
  • B01J2235/30—Scanning electron microscopy; Transmission electron microscopy
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
  • B22F2998/10—Processes characterised by the sequence of their steps
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2521/00—Catalysts comprising the elements, oxides or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium or hafnium
  • C07C2521/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2521/00—Catalysts comprising the elements, oxides or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium or hafnium
  • C07C2521/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
  • C07C2521/08—Silica
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2523/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00
  • C07C2523/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of noble metals
  • C07C2523/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group C07C2521/00 of noble metals of the platinum group metals
  • C07C2523/44—Palladium

Definitions

• the invention relates to a novel thermostable palladium catalyst, a process for its preparation and its use in hydrogenations specifically, hydrogenations of nitro compounds.
• the sintering process could be slowed down in individual cases.
• thermostable catalysts which, due to their structure, prevent sintering.
• thermostable palladium catalysts which can completely prevent sintering by their specific structure.
• the activity of the catalyst should be maintained over as long a period as possible.
• the object is surprisingly achieved by the catalyst according to the invention described below, which is composed of nano-particulate palladium and a porous zirconium oxide shell.
• a similar construction principle is already known for gold catalysts (Arnal et al., Angew Chem, 2006, 18, 8404-8407), which find use in CO oxidation.
• gold catalysts Arnal et al., Angew Chem, 2006, 18, 8404-8407
• palladium-based catalysts based on this or a similar principle are currently unknown. This is probably due to the high tendency of the gold to form nanoparticles relative to other metals, which greatly simplifies the preparation of such catalysts.
• the invention relates to a catalyst for use in hydrogenations and dehydrogenations based on at least one palladium nanoparticle with a gas- and liquid-permeable shell containing zirconium oxide.
• the palladium nanoparticle has an average particle size distribution (d 50 ) preferably in the range of 0.1-100 nm and more preferably of 0.3-70 nm and most preferably in the range of 0.5-30 nm.
• the inner diameter of the shell containing zirconium oxide is preferably 10-1000 nm, more preferably 15-500 nm and most preferably 20-300 nm.
• the layer thickness of the shell containing zirconium oxide is usually in the range of 10 to 100 nm, preferably 15 to 80 nm, particularly preferably 15-40 nm.
• the catalyst according to the invention comprises a plurality of palladium nanoparticles with a gas- and liquid-permeable shell containing zirconium oxide.
• Another object of the invention is a process for the preparation of a catalyst comprising the steps:
• palladium nanoparticles are used, these being prepared by the reduction of a palladium-containing precursor in the liquid phase.
• palladium salts which are soluble in alcohols, for example PdCl 2 , H 2 PdCl 4 , Pd (NO 3 ) 2 , palladium (II) trifluoroacetate, bis (acetonitrile) palladium (II) chloride and palladium (II) hexafluoroacetylacetonate used as palladium-containing precursor.
• the reduction of the palladium-containing precursor can be carried out chemically and / or electrochemically.
• the ratio of palladium-containing precursor and reducing agent can be used to influence the particle size and particle size distribution.
• the reduction of the palladium-containing precursor is usually carried out at temperatures of 0-250 0 C, preferably at 10-200 0 C and particularly preferably at temperatures of 15-150 0 C.
• the reduction of the palladium-containing precursor can take place both without and with a surface-active stabilizer (also called stabilizers or surfactants).
• a surface-active stabilizer also called stabilizers or surfactants.
• the synthesis of the palladium nanoparticles preferably takes place using stabilizers that prevent agglomeration of the palladium nanoparticles and allow a controlled adjustment of the particle size and morphology of the nanoparticles.
• colloidal stabilizers such as polyvinylpyrrolidone (PVP), alcohol-Polyethelenglycolethern (eg Marlipal®), polyacrylates, polyols, long-chain n-alkyl acids, long-chain n-alkyl esters, long-chain n-alkyl alcohols and ionic surfactants (eg AOT, CTAB) are used.
• PVP polyvinylpyrrolidone
• alcohol-Polyethelenglycolethern eg Marlipal®
• polyacrylates polyols
• polyols long-chain n-alkyl acids
• long-chain n-alkyl esters long-chain n-alkyl alcohols
• ionic surfactants eg AOT, CTAB
• the educts mentioned for the production of palladium nanoparticles can also be dissolved in the drop volume of liquid-liquid emulsions (eg miniemulsions or microemulsions) and then reacted by mixing both emulsion solutions.
• the obtained by one of the methods described palladium colloids preferably have a very narrow distribution of particle size, wherein the average of the
• Particle size distribution (d 50 ) preferably in the range of 0.1-100 nm and more preferably from 0.3-70 nm and most preferably in the range 0.5-30 nm.
• Solvent be redispersed. Preference is given to using a solvent which is suitable for the application of an SiO 2 layer, for example water, methanol, ethanol and further alcohols.
• step b) the palladium nanoparticles prepared in step a) are coated after separation by centrifugation, sedimentation, etc. with a silicate shell.
• the coating with SiC> 2 can be carried out by hydrolysis or precipitation of a hydrolyzable Si precursor.
• Preferred hydrolyzable Si precursors are tetramethyl orthosilicate, tetraethyl orthosilicate, tetrapropyl orthosilicate or similar hydrolyzable Si compounds.
• the hydrolysis can preferably be carried out by a hydrolysis liquid comprising ammonia solution, methanol, ethanol, propanol, isopropanol, butanol, 1,3-propanediol, glycerol etc. or by mixtures thereof.
• the hydrolysis can be carried out in particular at room temperature (20 ° C.) up to the boiling point of the hydrolysis liquid. Most preferably, the hydrolysis is carried out at room temperature.
• the diameter of the Pd-SiO 2 particles obtained in step b) is preferably 10-1000 nm and more preferably 15-500 nm and more preferably 20-300 nm.
• the Pd-SiO 2 particles are preferably by cycles of separation, cleaned by, for example, sedimentation, centrifugation or evaporation and washing with washing liquids.
• step c) the preferably spherical Pd-SiO 2 nanoparticles produced in step b) are completely encapsulated with a gas-permeable and liquid-permeable shell containing zirconium oxide.
• the coating with ZrO 2 can be carried out by hydrolysis or precipitation of a hydrolyzable Zr precursor.
• Preferred hydrolyzable Zr precursors are zirconium alkoxides, such as zirconium methoxide, zirconium ethoxide, zirconium n-propoxide, Zirconium n-butoxide, or zirconium halides such as ZrCl 4 , ZrBr 4 , ZrI 4 or similar hydrolyzable Zr compounds.
• the hydrolysis may preferably be carried out by compounds having active hydrogen atoms such as water, methanol, ethanol, propanol, glycerin and so on.
• the hydrolysis is most preferably carried out in the presence of colloid stabilizers such as alcohol-polyethylene glycol ethers (eg Marlipal®), PVP, polyacrylates, polyols, long-chain n-alkyl acids, long-chain n-alkyl acid esters, long-chain n-alkyl alcohols.
• the hydrolysis can be carried out at temperatures of 0-200 0 C. Most preferably, temperatures of 10-100 0 C are used.
• the amount of hydrolyzable Zr precursor used makes it possible to adjust the thickness of the zirconium oxide layer.
• aging is preferably carried out over a period of one hour to five days.
• the particles are separated from the liquid by conventional technical methods - centrifugation, sedimentation, filtration, etc. - and dried in an oven and then calcined.
• the drying may be carried out separately from the calcination in two separate steps or by gradually increasing the temperature from room temperature to calcining temperature.
• the drying is preferably carried out in the temperature range of 100-250 0 C, while the calcination can preferably be carried out at temperatures of 250-900 0 C.
• step d) the removal of the SiO 2 jacket from the cup-shaped and substantially spherical Pd-SiO 2 -ZrO 2 produced in step c) takes place.
• the removal of the SiO 2 is preferably carried out by dissolving the SiO 2 with a basic solution.
• a basic solution all alkali and alkaline earth metal hydroxides such as. NaOH, KOH, LiOH, Mg (OH) 2 , Ca (OH) 2 , etc. are used.
• the solution may be aqueous or alcoholic (MeOH, EtOH, PrOH, i-PrOH, etc.).
• the dissolution of the SiO 2 -Keme is usually carried out at temperatures of 0-250 0 C and preferably at temperatures of 10-100 0 C.
• the action of the alkaline solution takes place until complete dissolution of the SiO 2 core. Usually, this requires an exposure time of the alkaline solution over a period of 2-24 hours. Preference is also a multiple implementation of step d) with fresh alkaline solution.
• the obtained Pd-ZrO 2 nanoparticles are usually separated off and dried.
• the separation is preferably carried out by centrifugation, filtration or
• the drying is preferably carried out in an air stream at temperatures of 100.degree. 250 0 C performed. Alternatively, the drying can also be carried out under protective gas or hydrogen.
• a further preferred embodiment of the method is that the initially present in powder form catalyst is processed into moldings. Moldings in the form of spheres, rings, stars (trilobes or tetralobes), tablets, cylinders or carriage wheels are preferably produced. Preferably, the dimensions are 0.2-10 mm, most preferably 0.5-7 mm.
• Processing is carried out by known methods such as pressing, spray-drying and extrusion, in particular in the presence of a binder.
• Another preferred alternative is the application of the catalyst according to the invention as a washcoat to structured catalysts
• the Pd-SiCV nanoparticles according to the invention are suitable for use as thermostable catalysts. Due to the ZrO 2 barrier sintering of the Pd nanoparticles is not possible, so that in comparison to conventional catalysts, the service life or the cycle time can be significantly increased under process conditions. Due to the increase in production time (elimination of the catalyst regeneration) or extension of the production cycles, the production costs of hydrogenation or dehydrogenation can be significantly reduced.
• the invention further relates to the use of the catalyst according to the invention in hydrogenations of nitro compounds such as nitrobenzene, alkenes such as ethylene, propylene, butene, butadiene, styrene, ⁇ -methylstyrene, of nuclear hydrogenations such as benzene to cyclohexane, naphthalene to decalin, of nitrile compounds to amines, etc.
• the hydrogenations can be carried out at temperatures of 100-800 0 C and most preferably at temperatures of 150-700 0 C in the gas phase.
• Hydrogen is preferably used as hydrogenation reagent.
• the stability of the compounds or products to be hydrogenated and the vapor pressures of the reaction components or the pressure resistance of the reaction apparatus have a limiting effect here. Usually, hydrogenations are carried out at pressures of 1-200 bar.
• the invention further relates to the use of the catalyst according to the invention in transfer hydrogenations of nitro compounds such as nitrobenzene, dinitrobenzene, dinitrotoluene, nitrotoluene, nitrochlorobenzenes, nitronaphthalene, dinitronaphthalene, etc.
• the hydrogenations can, depending on the process - liquid phase or gas phase - at temperatures of 100- 600 0 C. be performed.
• the invention further relates to the use of the catalyst according to the invention in dehydrogenations such as, for example, propane to propylene, ethane to ethylene, butane to butene and butadiene and ethylbenzene to styrene.
• Another object of the invention is a hydrogenation process for the reaction of nitrobenzene to aniline with hydrogen in the gas phase in the presence of a catalyst, characterized in that a catalyst according to the invention is used.
• the catalytic hydrogenations or dehydrogenations may preferably adiabatic or isothermal or approximately isothermal, batchwise, but preferably continuously as flow or
• 800 ° C preferably 150 to 700 0 C, more preferably 200 to 650 0 C and a pressure of 1 to
• Catalytic hydrogenations or dehydrogenations 250 bar (10,000 to 250,000 hPa), preferably 1 to 200 bar.
• Conventional reactors in which the catalytic hydrogenations or dehydrogenations are carried out are fixed bed or fluidized bed reactors.
• the catalytic hydrogenations or dehydrogenations can preferably also be carried out in multiple stages.
• FIG. 1 shows a TEM image (device: Tecnai 20 LaB 6 cathode, camera: Tietz F114T IxIK, Fa. FEI / Philips, method according to the manufacturer) of the obtained palladium nanoparticles.
• the mean particle diameter is 8 nm.
• the palladium nanoparticles from step a) are redispersed in 3 ml H 2 O (ultrasound bath: 10 min).
• the following solutions must be provided: a. Ethanol-NH 3 solution (total 10.5 mL): 0.5 mL concentrated ammonia solution (28-30%) is mixed with 10 mL ethanol b. Ethanol TEOS solution (total 7.6 mL): 0.6 mL tetraethylorthosilicate is mixed with 7 mL ethanol.
• the aqueous palladium nanoparticle dispersion (3 mL) is stirred vigorously (5 min). Subsequently, the ethanol-NH 3 mixture is added.
• the reaction mixture is stirred overnight at room temperature (20 ° C).
• the Pd-SiO 2 nanoparticles are centrifuged (10000 rpm, 25 min) and washed twice with water and once with absolute ethanol, by decanting the supernatant after centrifuging and the remaining solid (colloids) in the corresponding washing liquid by means of ultrasonic bath (5 min) before centrifuging again.
• the Pd-SiO 2 nanoparticles are taken up in absolute ethanol (40 g) and redispersed by ultrasonic bath (5 min US bath). The resulting Pd-SiO 2 nanoparticles can be stored or used directly in the next step.
• Figure 2 shows a TEM image (device: Tecnai 20 LaB 6 cathode, camera: Tietz F1 14T 1x1 K, Fa. FEI / Philips, method according to the manufacturer's instructions) of the resulting Pd-SiO 2 - Nanoparticles shown.
• the average diameter of the resulting Pd-SiO 2 nanoparticles is 120 nm.
• a Marlipal® O13 / 40 solution (ethoxylated isotridecanol, from Sasol) is prepared by dissolving 0.43 g of Marlipal® in 11 g of H 2 O.
• Pd-SiO 2 nanoparticles (30 .mu.mol metal batch) are dispersed in 40 g of ethanol and are transferred with absolute ethanol (25 g) in a closed by septum 100 mL flask and then heated to 30 0 C.
• To the tempered and stirred at 30 0 C dispersion of Pd-SiO 2 nanoparticles 0.125 mL (125 ⁇ L) of the previously prepared aqueous Marlipal® solution was added.
• step c) The Pd-SiO 2 -ZrO 2 nanoparticles obtained in step c) (30 ⁇ mol metal batch) are stirred for about 3 h in 50 ml of 1 molar NaOH solution at room temperature. Subsequently, the
• FIG. 3 a shows a TEM image (device: Tecnai 20 LaB6 cathode,
• FIG. 3b shows the result of the XPS analysis (device: Phoenix, EDAX / Ametek;
• the mean diameter of the Pd-ZrO 2 particles is 130 nm.
• the XPS analysis shows that there is no longer any SiO 2 in the nanoparticles.

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