EP3515593A1

EP3515593A1 - Method for activating a fixed catalyst bed which contains monolithic shaped catalyst bodies or consists of monolithic shaped catalyst bodies

Info

Publication number: EP3515593A1
Application number: EP17764624.7A
Authority: EP
Inventors: Michael Schreiber; Zeljko KOTANJAC; Michael Nilles; Irene DE WISPELAERE; Michael Schwarz; Rolf Pinkos; Marie Katrin Schroeter
Original assignee: BASF SE
Current assignee: BASF SE
Priority date: 2016-09-23
Filing date: 2017-09-14
Publication date: 2019-07-31
Also published as: WO2018054759A1; CN109789399A; SG11201901567PA; US20200016579A1; JP2019530571A; KR20190059272A

Abstract

The present invention relates to a novel method for activating a fixed catalyst bed, to a method for providing a reactor which contains such an activated fixed catalyst bed and to the use in hydrogenation reactions of the activated fixed catalyst bed and of reactors that contain such an activated fixed catalyst bed.

Description

METHOD FOR ACTIVATING A CATALYST FIXED BIN CONTAINING MONOLITHIC CATALYST SHAPED BODIES OR CONSISTING OF MONOLITHIC CATALYST SHAPED BODIES

BACKGROUND OF THE INVENTION The present invention relates to a novel process for activating a fixed catalyst bed, a process for providing a reactor containing such an activated fixed catalyst bed and the use of the activated fixed catalyst bed and reactors containing such activated fixed catalyst bed for hydrogenation reactions.

STATE OF THE ART

Raney metal catalysts are highly active catalysts that have found wide commercial use, especially for the hydrogenation of mono- or polyunsaturated organic compounds. Typically, Raney catalysts are alloys containing at least one catalytically active metal and at least one alkali-soluble (leachable) alloy component. Typical catalytically active metals include Ni, Fe, Co, Cu, Cr, Pt, Ag, Au and Pd, and typical leachable alloy components are e.g. B. Al, Zn and Si. Such Raney metal catalysts and processes for their preparation are, for. In US 1, 628,190,

US 1,915,473 and US 1,563,587. Prior to their use in heterogeneously catalyzed chemical reactions, especially in a hydrogenation reaction, Raney metal alloys generally require activation. Conventional methods for activating Raney metal catalysts include grinding the alloy into a fine powder if it is not already powdered by the prior art. For activation, the powder is subjected to treatment with an aqueous liquor, wherein the leachable metal is partially removed from the alloy and the highly active non-leachable metal remains. The powders thus activated are pyrophoric and are usually stored under water or organic solvents in order to avoid contact with oxygen and the associated deactivation of the Raney metal catalysts.

According to a known method for activating suspended Raney nickel catalysts, a nickel-aluminum alloy with 15 to 20 wt .-% strength sodium hydroxide solution is treated at temperatures of 100 ° C or higher. In US 2,948,687 it is described to prepare a Raney nickel molybdenum catalyst from a milled Ni-Mo-Al alloy having particle sizes in the range of 80 mesh (about 0.177 mm) or finer by first placing the alloy at 50 ° C with 20 wt .-% NaOH solution treated and the temperature to 100 to 1 15 ° C raises.

A significant disadvantage of powdered Raney metal catalysts is the need to separate them from the reaction medium of the catalyzed reaction by expensive sedimentation and / or filtration processes.

It is known to use Raney metal catalysts in the form of larger particles. Thus, US Pat. No. 3,448,060 describes the preparation of structured Raney metal catalysts, wherein in a first embodiment an inert carrier material is coated with an aqueous suspension of a pulverulent nickel-aluminum alloy and freshly precipitated aluminum hydroxide. The resulting structure is dried, heated and contacted with water, releasing hydrogen. Subsequently, the structure is hardened. Optionally, leaching with an alkali hydroxide solution is provided. In a second embodiment, an aqueous suspension of a powdered nickel-aluminum alloy and freshly precipitated aluminum hydroxide is subjected to shaping without the use of a carrier material. The structure thus obtained is activated analogously to the first embodiment. Other suitable for use in fixed bed catalysts Raney metal catalysts may have hollow bodies or spheres or otherwise supported. Such catalysts are z. In EP 0 842 699, EP 1 068 900, US 6,747,180,

US 2,895,819 and US 2009/0018366. US 2,950,260 describes a method for activating a catalyst of a granular nickel-aluminum alloy by treatment with an aqueous alkali solution. Typical particle sizes of this granular alloy range from 1 to 14 mesh (about 20 to 1.4 mm). It has been found that contacting a Raney metal alloy, such as a Ni-Al alloy, with an aqueous liquor results in an exothermic reaction to produce larger amounts of hydrogen. The following reaction equations are intended to illustrate, by way of example, possible reactions which take place when a Ni-Al alloy is brought into contact with an aqueous alkali metal hydroxide, such as NaOH:

2 NaOH + 2 Al + 2 H ₂ 0 - 2 NaAI0 ₂ + 3 H ₂

2 Al + 6 H ₂ O - 2 Al (OH) ₃ + 3 H ₂

2 Al (OH) ₃ - ^> Al ₂ O ₃ + 3 H ₂ O US 2,950,260 has for its object to provide an activated granular hydrogenation catalyst of a Ni-Al alloy with improved activity and lifetime available. For this purpose, the activation is carried out with a 0.5 to 5 wt .-% strength NaOH or KOH, wherein the temperature is maintained by cooling to below 35 ° C and the contact time is chosen so that not more than 1, 5 parts H2 mole per mole equivalent Leach are liberated. In contrast to a powdery, suspended catalyst, the treatment of granular Raney metal catalysts removes a significantly lower proportion of aluminum from the structure. This is in a range of only 5 to 30 wt .-%, based on the amount of aluminum originally present. Catalyst particles having a porous activated nickel surface and an unchanged metal core are obtained. A disadvantage of the catalysts thus obtained, in which only the outermost layer of the particles is catalytically active, is their sensitivity to mechanical stress or abrasion, which can lead to a rapid deactivation of the catalyst. The teaching of US Pat. No. 2,950,260 is restricted to granular shaped catalyst bodies which fundamentally differ from larger structured shaped bodies.

EP 2 764 916 A1 describes a process for the preparation of foam-form catalyst bodies which are suitable for hydrogenations, in which: a) a metal foam molding is provided which contains at least one first metal, for example selected from Ni, Fe, Co, Cu, Cr, Pt, Ag, Au and Pd, b) on the surface of the metal foam molding at least a second leachable component or an alloyable by alloy in a leachable component component applies, for example, is selected from Al, Zn and Si, and by alloying the metal foam molding obtained in step b) at least on a part of the surface, and subjecting the foam-like alloy obtained in step c) to treatment with an agent capable of leaching the leachable components of the alloy.

This document teaches to use for the step d) a 1 to 10 molar, ie 4 to 40% by weight aqueous NaOH. The temperature in step d) is 20 to 98 ° C and the treatment time is 1 to 15 minutes. It is generally mentioned that the foam-like shaped bodies according to the invention can also be formed in situ in a chemical reactor, although any concrete details are missing. EP 2 764 916 A1 does not contain the slightest information on the dimension of the chemical reactors for the use of the foam-shaped moldings, the type, amount and dimensioning of the moldings introduced into the reactor and for introducing the moldings into the reactor. In particular, there is no indication as to how a fixed catalyst bed actually located in a chemical reactor can be activated.

Thus, it has been found that the mode of activation of fixed bed of immobilized structured shaped articles and especially foam-like shaped bodies is critical for the activity and service life of the resulting packed beds. Thus, for example, the uncontrolled formation of relatively large amounts of hydrogen during the activation not only lead to a negative mechanical stress on the catalytically active outer layer of the moldings, but also destroy the backbone of the moldings. It is critically important that the freshly formed Raney metal remains bound within or on the surface of the moldings and does not leak out. Otherwise, significantly less catalytically active sites in the catalyst structure of the fixed bed catalyst and during the activation with aqueous alkali, the Raney metal can be discharged from the structure. In the worst case, the Raney metal is even found in the later hydrogenation product. It is an object of the present invention to provide an improved process for activating fixed catalyst beds which overcomes as many of the aforementioned disadvantages as possible.

Surprisingly, it has now been found that highly active Raney metal catalysts are obtained in the form of immobilized fixed beds from structured catalyst shaped bodies, if the concentration of the aqueous base used for activation is kept within a not too high range and the temperature gradient resulting from the activation does not exceed an upper limit in the fixed catalyst bed. This form of activation is particularly suitable for fixed catalyst beds in reactors for hydrogenation reactions on an industrial scale. SUMMARY OF THE INVENTION

A first aspect of the invention is a process for activating a fixed catalyst bed containing monolithic shaped catalyst bodies or consisting of monolithic shaped catalyst bodies containing at least one first metal selected from Ni, Fe, Co, Cu, Cr, Pt, Ag, Au and Pd, and containing at least one second component which is selected from Al, Zn and Si, and wherein subjecting the fixed catalyst bed for activation of a treatment with a maximum of 3.5 wt .-% aqueous base, wherein the base is selected from Alkali metal hydroxides, alkaline earth metal hydroxides and mixtures thereof, and wherein the fixed catalyst bed has a temperature gradient and the temperature difference between the coldest point of the catalyst fixed bed and the warmest point of the fixed catalyst bed is maintained in a range of 0.1 to 50 K. Another object of the invention is a process for providing a reactor containing an activated fixed catalyst bed, comprising a) introducing into a reactor a fixed catalyst bed containing monolithic shaped catalyst bodies or consists of monolithic catalyst form bodies containing at least one first metal selected is Ni, Fe, Co, Cu,

Cr, Pt, Ag, Au and Pd and containing at least one second component selected from Al, Zn and Si; b) subjecting the fixed catalyst bed to activation with a maximum of 3.5% by weight aqueous base wherein the base is selected from

Alkali metal hydroxides, alkaline earth metal hydroxides and mixtures thereof, and wherein the fixed catalyst bed has a temperature gradient and the temperature difference between the coldest point of the fixed catalyst bed and the warmest point of the fixed catalyst bed is maintained in a range of 0.1 to 50K; c) the one obtained in step b) d) optionally subjecting the fixed catalyst bed obtained after the treatment in step c) to a dopant having at least one element selected from the first metal and the catalyst bed second component of the catalyst molding used in step a) is different. Another object of the invention is a process for the hydrogenation of hydrogenatable organic compounds, in particular organic compounds having at least one carbon-carbon double bond, carbon-nitrogen double bond, carbon-oxygen double bond, carbon-carbon triple bond, carbon-nitrogen Triple bond or nitrogen-oxygen double bond, in the presence of an activated fixed catalyst bed obtainable by a method as defined above and below.

EMBODIMENTS OF THE INVENTION

The invention includes the following preferred embodiments:

1 . A process for activating a fixed catalyst bed containing monolithic catalyst bodies or consisting of monolithic catalyst bodies containing at least one first metal selected from Ni, Fe, Co,

Cu, Cr, Pt, Ag, Au and Pd, and containing at least one second component selected from Al, Zn and Si, and wherein the fixed catalyst bed to activate a treatment having a maximum of 3.5 wt .-% aqueous base, the base being selected from alkali metal hydroxides, alkaline earth metal hydroxides and mixtures thereof, and wherein the fixed catalyst bed has a temperature gradient during activation and the temperature difference between the coldest point of the fixed catalyst bed and the warmest point of the fixed catalyst bed is maintained at a maximum of 50K.

A process for providing a reactor comprising an activated fixed catalyst bed, comprising: a) introducing into a reactor a fixed bed of catalyst containing monolithic shaped catalyst bodies or monolithic shaped catalyst bodies containing at least one first metal selected from Ni, Fe, Co; Cu, Cr, Pt, Ag, Au and Pd, and containing at least one second component which is selected from Al, Zn and Si, b) the fixed catalyst bed for activating a treatment with a maximum of 3.5 wt .-% aqueous Base, wherein the base is selected from alkali metal hydroxides, alkaline earth metal hydroxides and mixtures thereof, and wherein the fixed catalyst bed has a temperature gradient and the temperature difference between the coldest point of the Ka c) subjecting the activated fixed catalyst bed obtained in step b) to a treatment with a washing medium selected from water, C 1 -C 4 -alkanols and mixtures thereof, d) if appropriate the said catalyst fixed bed and the warmest point of the catalyst fixed bed Fixed catalyst bed during and / or after the treatment in step c) brings into contact with a dopant having at least one promoter element which is different from the first metal and the second component of the catalyst molding used in step a). Process according to embodiment 2, wherein the reactor has an internal volume in the range from 0.1 to 100 m ³ , preferably from 0.5 to 80 m ³ . Method according to one of the preceding embodiments, wherein the monolithic catalyst form used body, based on the entire shaped body, a smallest dimension in a direction of at least 1 cm, preferably at least 2 cm, in particular at least 5 cm.

Process according to one of the preceding embodiments, wherein a stream of the aqueous base is passed through the fixed catalyst bed for activation.

Method according to one of the preceding embodiments, wherein the aqueous base used for activation is at least partially guided in a liquid circulation stream.

The process of embodiment 6, wherein in addition to the base carried in the liquid recycle stream, fresh aqueous base is added to the fixed catalyst bed.

Method according to one of embodiments 6 or 7, wherein the ratio of recycled aqueous base to freshly supplied aqueous base in a range from 1: 1 to 1000: 1, preferably from 2: 1 to 500: 1, in particular from 5 : 1 to 200: 1.

Method according to one of embodiments 1 to 5, wherein the feed rate of the aqueous base is at most 5 L / min per liter of fixed catalyst bed, preferably highest at least 1.5 L / min per liter of fixed catalyst bed, more preferably at most 1 L / min per liter of fixed catalyst bed, based on the total volume of the fixed catalyst bed. 10. The process according to any of embodiments 1 to 8, wherein the aqueous base used for the activation is conducted at least partially in a liquid circulation stream and the feed rate of the freshly fed aqueous base is at most 5 L / min per liter fixed catalyst bed, preferably at most 1.5 L / min per liter of fixed catalyst bed, more preferably at most 1 L / min per liter fixed catalyst bed, based on the total volume of the fixed catalyst bed.

Process according to one of the preceding embodiments, wherein the flow rate of the aqueous base through the reactor containing the fixed catalyst bed is at least 0.5 m / h, preferably at least 3 m / h, in particular at least 5 m / h, especially at least 10 m / h.

Method according to one of the preceding embodiments, wherein the flow rate of the aqueous base through the reactor containing the fixed catalyst bed in a range of 0.5 m / h to 100 m / h.

Method according to one of the preceding embodiments, wherein the temperature difference between the coldest point of the fixed catalyst bed and the warmest point of the fixed catalyst bed at a maximum of 40 K, preferably at a maximum of 25 K, is maintained.

Method according to one of the preceding embodiments, wherein the temperature difference between the coldest point of the fixed catalyst bed and the warmest point of the fixed catalyst bed at the beginning of activation in a range of 0.1 to 50 K, preferably in a range of 0.5 to 40 K, in particular in a range of 1 to 25 K, is maintained.

Method according to one of the preceding embodiments, wherein during the activation of the content of nickel in the loaded aqueous base or, if a liquid circulation stream is used for activation, in the circulation stream, at most 0.1 wt .-%, particularly preferably at most 100 wt. ppm, in particular at most 10 ppm by weight. 16. The method according to any one of the preceding embodiments, wherein the obtained during the activation of the loaded aqueous base is at least partially discharged.

Method according to one of the preceding embodiments, wherein from the activation a discharge of laden aqueous base is removed and subjected to a gas / liquid separation, whereby a hydrogen-containing gas phase and a liquid phase are obtained. 18. The method of embodiment 17, wherein the liquid phase is at least partially recycled as a liquid partial stream in the activation.

19. The method according to any one of the preceding embodiments, wherein the activation at a temperature of at most 50 ° C, preferably at a temperature of at most 40 ° C, is performed.

20. The method according to any one of the preceding embodiments, wherein the monolithic catalyst form body in the form of a foam. 21. Method according to one of the preceding embodiments, wherein to provide the monolithic shaped catalyst bodies: a1) provides a metal foam molded body containing at least one first metal selected from Ni, Fe, Co, Cu, Cr, Pt, Ag, Au and Pd, a2) applies to the surface of the metal foam molding at least a second component containing an element selected from Al, Zn and Si, and a3) by alloying the metal foam molding obtained in step a2) at least on a part the surface forms an alloy.

22. The method according to any one of the preceding embodiments, wherein the first metal contains Ni or consists of Ni.

23. Method according to one of the preceding embodiments, wherein the second component contains Al or consists of Al. Method according to one of the preceding embodiments, wherein the catalyst moldings for activating a treatment with a 0.5 to

3.5% by weight aqueous base.

Method according to one of the preceding embodiments, wherein the aqueous base is selected from aqueous NaOH, aqueous KOH and mixtures thereof.

Method according to one of the preceding embodiments, wherein the washing medium used in step c) contains water or consists of water.

Method according to one of embodiments 2 to 26, wherein the treatment with the washing medium is carried out in step c) until the effluent washing medium has a conductivity at 20 ° C of at most 200 mS / cm, preferably at most 100 mS / cm, in particular at most 10 mS / cm.

Method according to one of embodiments 2 to 27, wherein in step c) water is used as the washing medium and the treatment is carried out with the washing medium until the effluent washing medium has a pH at 20 ° C of at most 9, more preferably of at most 8, in particular of at most 7.

Method according to one of embodiments 2 to 28, wherein in step c) the treatment with the washing medium at a temperature in the range of 20 to 100 ° C, preferably from 20 to 80 ° C, in particular from 25 to 70 ° C, performed.

Method according to one of embodiments 2 to 29, wherein the monolithic shaped catalyst bodies used for activation already have at least one promoter element, and / or

the catalyst fixed bed during the activation in step b) is brought into contact with a dopant which has at least one promoter element, and / or

the catalyst fixed bed is brought into contact with a dopant during and / or after the treatment with a washing medium in step c), which has at least one promoter element. 31. The method of any one of Embodiments 2 to 30, wherein the dopant contains at least one promoter element selected from Ti, Ta, Zr, V, Cr, Mo, W, Mn, Re, Fe, Ru, Co, Rh, Ir, Ni , Pd, Pt, Cu, Ag, Au, Ce and Bi.

Method according to one of embodiments 2 to 31, wherein the dopant contains Mo as a promoter element, preferably Mo contains as a single promoter element.

The method of any one of Embodiments 2 to 32, wherein the fixed catalyst bed contains Ni / Al shaped catalyst bodies or Ni / Al shaped catalyst bodies doped with Mo, and wherein the fixed catalyst bed has a gradient in Mo direction with respect to the flow direction.

Process for the hydrogenation of hydrogenatable organic compounds, in particular of organic compounds which have at least one carbon-carbon double bond, carbon-nitrogen double bond, carbon-oxygen double bond, carbon-carbon triple bond, carbon-nitrogen triple bond or nitrogen-oxygen Having double bond, in the presence of an activated fixed catalyst bed, obtainable by a method as defined in any one of claims 1 to 33.

Process according to embodiment 34 for the hydrogenation of 1,4-butynediol to give 1,4-butanediol or for the hydrogenation of 4-butyraldehyde to give n-butanol.

Method according to one of the embodiments 34 or 35, wherein the hydrogenation is carried out according to the inventive method in the presence of CO.

Process according to embodiment 36, wherein during hydrogenation the

CO content in the gas phase within the reactor in a range from 0.1 to 10,000 ppm by volume, preferably in a range from 0.15 to 5000 ppm by volume, in particular in a range from 0.2 to 1000 ppm by volume, lies.

DESCRIPTION OF THE INVENTION

The process according to the invention for activating a fixed catalyst bed is also referred to below as "process 1" for short. The process according to the invention for providing a reactor comprising an activated fixed catalyst bed is also referred to below as "process 2" for short. Unless otherwise stated below expressly stated otherwise, statements on suitable and preferred embodiments apply equally to method 1 and method 2.

Provision of the fixed catalyst bed (= step a))

In the context of the invention, a fixed catalyst bed is understood to be a device installed in a reactor which is stationary (immobilized) during the activation according to the invention, the subsequent doping and the subsequent hydrogenation and which comprises one or preferably several monolithic shaped catalyst bodies. The introduction of the fixed catalyst bed into the reactor takes place by fixed installation of the monolithic shaped catalyst bodies. The resulting fixed catalyst bed has a plurality of channels through which the liquid treatment medium (i.e., aqueous base) used for activation, the dopant, if used, the wash medium, and the reaction mixture of the heterogeneously catalyzed hydrogenation can be flowed through.

To produce a suitable fixed catalyst bed, the monolithic shaped catalyst bodies can be installed side by side and / or one above the other in the interior of the reactor. Processes for incorporation of catalyst form bodies are known in principle to the person skilled in the art. Thus, for example, one or more layers of a foam-like catalyst can be introduced into the reactor. Monoliths, each consisting of a ceramic block, can be stacked next to and above each other in the interior of the reactor. As a rule, care must be taken that the liquid treatment medium and the reaction mixture of the catalyzed reaction flow exclusively or essentially past the shaped catalyst bodies and not past them. In order to ensure a bypass-free flow as possible, the monolithic shaped catalyst bodies can be sealed against each other and / or to the inner wall of the reactor by means of suitable devices. These include z. As sealing rings, sealing mats, etc., which consist of an inert under the treatment and reaction conditions material.

The shaped catalyst bodies are preferably incorporated into the reactor in one or more essentially horizontal layers with channels, which make it possible to flow through the catalyst bed in the flow direction of the aqueous base used for activation and of the reaction mixture of the catalyzed reaction. Preferably, the installation is carried out in such a way that the fixed catalyst bed fills the reactor cross-section as completely as possible. If desired, the fixed catalyst bed can also contain other internals, such as power distributors, devices for feeding gaseous gene or liquid reactants, measuring elements, in particular for a temperature measurement, or Inertpackungen.

The processes according to the invention are suitable in principle for pressure-resistant reactors, as are usually used for exothermic, heterogeneous reactions with the introduction of a gaseous and a liquid educt and especially for hydrogenation reactions. These include the commonly used reactors for gas-liquid reactions, such. B. tube reactors, tube bundle reactors and gas circulation reactors. A special embodiment of the tube reactors are shaft reactors. Such reactors are known in principle to the person skilled in the art. In particular, a cylindrical reactor with a vertical longitudinal axis is used, which has at the bottom or top of the reactor one or more inlet devices for feeding a reactant mixture which contains at least one gaseous and at least one liquid component. If desired, partial streams of the gaseous and / or the liquid starting material can additionally be fed to the reactor via at least one further feed device. The hydrogenation reaction mixture is generally present in the reactor in the form of a two-phase mixture having a liquid and a gaseous phase. It is also possible that in addition to the gas phase two liquid phases are present, for. B. if other components are in the hydrogenation gene. The heat of reaction liberated in the activation of the fixed catalyst bed or in the hydrogenation can be at least partially removed by active cooling. This can be done by indirect heat exchange by means of inside or outside the reactor mounted heat exchanger through which a coolant is passed. This is one way to keep the temperature difference between the coldest point of the fixed catalyst bed and the warmest point of the fixed catalyst bed below the maximum value. As a coolant for conventional liquids or gases can be used. Preferably, the coolant used is water, for example softened and degassed water (so-called boiler feed water).

On the other hand, the heat of reaction liberated in the activation of the fixed catalyst bed or in the hydrogenation can be at least partially removed by passive cooling. In this embodiment, no heat is removed from the reactor by means of active cooling, but it is transferred to the treatment medium so that, as it were, an adiabatic mode of operation is achieved. In this case, the heating of the liquid reaction mixture must be limited so that the maximum temperature difference between the coldest point of the fixed catalyst bed and the warmest point of the catalyst fixed bed and maintained the desired maximum temperature during activation is not exceeded. This can be z. B. via the concentration of the aqueous base used.

The novel processes are particularly suitable for activating catalyst catalyst beds for hydrogenation reactions which are to be carried out on an industrial scale. The reactor then preferably has an internal volume in the range from 0.1 to 100 m ³ , preferably from 0.5 to 80 m ³ . The term internal volume refers to the volume including the fixed catalyst beds present in the reactor and optionally further existing internals. Of course, the technical advantages associated with the activation according to the invention also already appear in reactors with a smaller internal volume.

In the inventive process 1 and 2 "monolithic" shaped catalyst bodies are used. Monolithic shaped bodies in the sense of the invention are structured shaped bodies which are suitable for the production of immobilized, structured fixed catalyst beds. In contrast to particulate catalysts, it is possible to produce fixed monolithic beds from monolithic shaped bodies which are substantially coherent and seamless. This corresponds to the definition of monolithic in the sense of "consisting of one piece". The monolithic shaped catalyst bodies according to the invention are characterized, in contrast to catalyst beds, for. B. from pellets, often by a higher ratio of axial flow (longitudinal flow) over radial flow (cross-flow) from. Monolithic shaped catalyst bodies accordingly have channels in the flow direction of the reaction medium of the hydrogenation reaction. Particulate catalysts usually have the catalytically active sites on an external surface. Catalyst fixed beds of monolithic moldings have a plurality of channels, wherein the catalytically active sites are arranged on the surface of the channel walls. The reaction mixture of the hydrogenation reaction can flow through these channels in the flow direction through the reactor. Thus, a much stronger contacting of the reaction mixture with the catalytically active sites generally takes place than with catalyst beds of particulate shaped bodies.

The monolithic shaped bodies used in accordance with the invention are not shaped bodies of individual catalyst bodies having a greatest length extension in any direction of less than 1 cm. Such non-monolithic moldings lead to fixed catalyst beds in the form of conventional catalyst beds. The monolithic catalyst form body used according to the invention have a regular planar or spatial structure and thereby differ from carriers in particle form, which are used as a loose debris. The monolithic catalyst form body used according to the invention have, based on the entire molded body, a smallest dimension in a direction of preferably at least 1 cm, more preferably at least 2 cm, in particular at least 5 cm. The maximum value for the largest dimension in one direction is in principle not critical and usually results from the production process of the moldings. So z. B. moldings in the form of foams be plate-like structures having a thickness in the range of millimeters to centimeters, a width in the range of a few centimeters to several hundred centimeters and a length (as the largest dimension in one direction) of up to several meters can.

The monolithic shaped catalyst bodies used in accordance with the invention can, in contrast to bulk solids, preferably form-fit to larger units or consist of units which are larger than bulk materials.

The monolithic shaped catalyst bodies used according to the invention generally also differ from particulate catalysts or their supports in that they are present in substantially fewer parts. Thus, according to the invention, a fixed catalyst bed can be used in the form of a single shaped body. In general, however, several moldings are used to prepare a fixed catalyst bed. The monolithic shaped catalyst bodies used according to the invention generally have extensive three-dimensional structures. The shaped catalyst bodies used according to the invention are generally permeated by continuous channels. The continuous channels may have any geometry, for example, they may be in a honeycomb structure. Suitable shaped catalyst bodies can also be produced by deforming flat carrier structures, for example by rolling up or buckling the two-dimensional structures into three-dimensional structures. Starting from flat substrates, the outer shape of the molded bodies can be easily adapted to given reactor geometries.

The monolithic catalyst form bodies used according to the invention are distinguished by the fact that they can be used to produce fixed catalyst beds, in which a controlled flow through the fixed catalyst bed is possible. A movement of the catalyst bodies under the conditions of the catalyzed reaction, for. B. a juxtaposition of the shaped catalyst body is avoided. Due to the ordered structure of the shaped catalyst bodies and the resulting catalyst solid Bedts arise improved possibilities for the fluidically optimal operation of the fixed catalyst bed.

The monolithic catalyst moldings used in the process according to the invention are preferably in the form of a foam, mesh, woven fabric, knitted fabric, knitted fabric or monoliths different therefrom. The term monolithic catalyst in the context of the invention also includes catalyst structures known as "honeycomb catalysts". The catalyst fixed beds used according to the invention have at any section in the normal plane to the flow direction (ie, horizontal) through the fixed catalyst bed, based on the total area of the section, preferably at most 5%, more preferably at most 1%, in particular at most 0.1% free area, the not part of the catalyst bodies. The area of the pores and channels which open at the surface of the shaped catalyst body is not calculated to this free area. The indication of the free area refers exclusively to sections through the fixed catalyst bed in the region of the shaped catalyst body and not any internals, such as power distribution. In the context of the invention, pores are understood to mean cavities in the catalyst moldings which have only one opening on the surface of the catalyst mold body. In the context of the invention, channels are understood to mean cavities in the catalyst moldings which have at least two openings on the surface of the catalyst mold body.

If the catalyst fixed beds used in accordance with the invention comprise shaped catalyst bodies which have pores and / or channels, then at least 90% of the pores and channels, more preferably at least 98% of the pores and channels, have an area at any section in the normal plane to the flow direction through the fixed catalyst bed of not more than 3 mm ² .

If the fixed catalyst beds used in accordance with the invention comprise shaped catalyst bodies which have pores and / or channels, then at least 90% of the pores and channels, particularly preferably at least 98% of the pores and channels, preferably have an arbitrary section in the normal plane to the flow direction through the catalyst bed. an area of at most 1 mm ² .

If the catalyst fixed beds used in accordance with the invention comprise shaped catalyst bodies which have pores and / or channels, then they preferably have one any cut in the normal plane to the flow direction through the fixed catalyst bed at least 90% of the pores and channels, more preferably at least 98% of the pores and channels, an area of at most 0.7 mm ² . In the case of the fixed catalyst beds according to the invention, at least 95% of the reactor cross section, more preferably at least 98% of the reactor cross section, in particular at least 99% of the reactor cross section, is preferably filled with shaped catalyst bodies over at least 90% length in the reactor longitudinal axis. The monolithic shaped catalyst bodies used in processes 1 and 2 according to the invention are preferably in the form of a foam, mesh, woven fabric, knitted fabric, knitted fabric or monoliths different therefrom. The term monolithic catalyst in the context of the invention also includes catalyst structures known as "honeycomb catalysts".

In a specific embodiment, the shaped catalyst bodies are in the form of a foam. The shaped catalyst bodies may have any suitable outer shapes, for example cubic, cuboidal, cylindrical, etc. Suitable fabrics may be produced with different weaves, such as smooth weave, body tissue, tassel, five-shaft atlas or other special weave fabrics. Also suitable are wire mesh made of weavable metal wires, such as iron, spring steel, brass, phosphor bronze, pure nickel, monel, aluminum, silver, nickel silver (copper-nickel-zinc alloy), nickel, chrome nickel, chrome steel, stainless, acid-resistant and highly heat-resistant chromium nickel steel - like titanium. The same applies to knitted and knitted fabrics. Also, woven, knitted or knitted fabrics of inorganic materials such as AI2O3 and / or S1O2 may be used. Also suitable are woven, knitted or knitted fabrics made of plastics, such as polyamides, polyesters, polyolefins (such as polyethylene, polypropylene), polytetrafluoroethylene, etc. The abovementioned woven, knitted or knitted fabrics, but also other flat-structured catalyst supports can lead to larger spatial structures, so-called monoliths are deformed. It is also possible not to build monoliths from laminar supports, but to produce them directly without intermediate stages, for example the ceramic monoliths with flow channels known to those skilled in the art.

Suitable catalyst bodies are those which are described, for example, in EP-A 0 068 862, EP-A-0 198 435, EP-A 201 614, EP-A 448 884, EP 0 754 664 A2, DE 433 32 93, EP 2 764 916 A1 and US 2008/0171218 A1 are described. Thus, EP 0 068 862 describes a monolithic molded body comprising alternating layers of smooth and corrugated sheets in the form of a roll having channels and wherein the smooth sheets contain woven, knitted or knitted textile materials and the corrugated sheets contain a mesh material. The

EP-A-0 198 435 describes a process for the preparation of catalysts in which the active components and the promoters are applied to support materials by vapor deposition in ultra-high vacuum. The carrier materials used are reticulated or web-like carrier materials. The vapor-deposited catalyst webs are assembled into "catalyst packages" for incorporation into the reactor, and the shape of the catalyst packages is adapted to the flow conditions in the reactor.

Suitable methods for vapor deposition and sputtering of metals in vacuum are known.

Preferably, the shaped catalyst bodies contain at least one element selected from Ni, Fe, Co, Cu, Cr, Pt, Ag, Au and Pd. In a specific embodiment, the shaped catalyst bodies contain Ni. In a specific embodiment, the shaped catalyst bodies contain no palladium. This is understood to mean that no palladium is actively added to produce the shaped catalyst bodies, neither as a catalytically active metal nor as a promoter element, nor to provide the shaped bodies which serve as a carrier material.

The catalyst form bodies are preferably a Raney metal catalyst.

The monolithic catalyst form is particularly preferably in the form of a foam. In principle, metal foams with different morphological properties with regard to pore size and shape, layer thickness, areal density, geometric surface, porosity, etc. are suitable. The preparation can be carried out in a manner known per se. For example, a foam of an organic polymer may be coated with at least a first metal and then the polymer removed, e.g. Example by pyrolysis or dissolution in a suitable solvent, wherein a metal foam is obtained. For coating with at least a first metal or precursor thereof, the organic polymer foam may be contacted with a solution or suspension containing the first metal. This can be z. B. done by spraying or dipping. Also possible is a deposition by means of chemical vapor deposition (CVD). So z. B. a polyurethane foam coated with the first metal and then the polyurethane foam are pyrolyzed. A suitable for the production of shaped catalyst bodies in the form of a foam polymer foam preferably has a pore size in the range of 100 to 5000 μηη, more preferably from 450 to 4000 μηη and in particular from 450 to 3000 μηη. A suitable polymer foam preferably has a layer thickness of 5 to 60 mm, particularly preferably 10 to 30 mm. A suitable polymer foam preferably has a density of from 300 to 1200 kg / m ³ . The specific surface area is preferably in a range of 100 to 20000 m ² / m ³ , particularly preferably 1000 to 6000 m ² / m ³ . The porosity is preferably in a range of 0.50 to 0.95. The order of the second component can be done in many ways, for. Example by bringing the molded article obtained from the first component with the second component by rolling or dipping in contact or applying the second component by spraying, sprinkling or pouring. For this purpose, the second material may be liquid or preferably in the form of a powder. Also possible is the application of salts of the second component and subsequent reduction. It is also possible to apply the second component in combination with an organic binder. The production of an alloy on the surface of the molding is carried out by heating to the alloying temperature. The alloying conditions make it possible, as stated above, to control the leaching properties of the alloy. When Al is used as a second component, the alloying temperature is preferably in a range of 650 to 1000 ° C, more preferably 660 to 950 ° C. When a NiAl powder is used as the second component, the alloying temperature is preferably in a range of 850 to 900 ° C, more preferably 880 to 900 ° C. It may be advantageous to continuously raise the temperature during the alloy and then keep it at the maximum for a time. Subsequently, the foam-shaped coated and heated shaped catalyst body is allowed to cool.

In a preferred embodiment, to provide the monolithic shaped catalyst bodies: a1) a metal foam molding is provided which comprises at least one first metal selected from Ni, Fe, Co, Cu, Cr, Pt, Ag, Au and Pd, a2) on the surface of the metal foam molding at least a second component applied component containing an element selected from Al, Zn and Si, and by alloying the obtained in step a2) metal foam molding least on a part of the surface of an alloy educated. Suitable alloying conditions result from the phase diagram of the metals involved, z. B. the phase diagram of Ni and Al. So z. B. the proportion of Al-rich and leachable components, such as N1AI3 and N12AI3, are controlled. The shaped catalyst bodies may contain dopants in addition to the first and second components. These include z. Mn, V, Ta, Ti, W, Mo, Re, Ge, Sn, Sb or Bi.

Such shaped catalyst bodies and processes for their preparation are described in EP 2 764 916 A1, to which reference is made in its entirety.

Preference is given to shaped catalyst bodies in which the first metal contains Ni or consists of Ni. Preference is furthermore given to shaped catalyst bodies in which the second component contains Al or consists of Al. A specific embodiment is shaped catalyst bodies which contain nickel and aluminum.

For the production of a monolithic shaped catalyst body in the form of a foam, preference is given to using an aluminum powder having a particle size of at least 5 μm. The aluminum powder preferably has a particle size of at most 75 μm.

For the production of a monolithic shaped catalyst body in the form of a foam a1), it is preferred to provide a metal foam body containing Ni, a2) applying to the surface of the metal foam body an aluminum-containing suspension in a solvent, a3) by alloying in step a2) obtained metal foam molding formed at least on a part of the surface an alloy.

Particularly preferably, the aluminum-containing suspension additionally contains polyvinylpyrrolidone. The amount of polyvinylpyrrolidone is preferably 0.1 to 5 wt .-%, particularly preferably 0.5 to 3 wt .-%, based on the total weight of the aluminum-containing suspension. The molecular weight of the polyvinylpyrrolidone is preferably in a range of 10,000 to 1,300,000 g / mol.

Particularly preferably, the aluminum-containing suspension contains a solvent which is selected from water, ethylene glycol and mixtures thereof. The alloying is preferably carried out by stepwise heating in the presence of a gas mixture containing hydrogen and at least one inert gas under the reaction conditions. Nitrogen is preferably used as the inert gas. Suitable is z. Example, a gas mixture containing 50 vol .-% N2 and 50 vol .-% H2. The alloy formation can z. B. done in a rotary kiln. Suitable heating rates are in a range of 1 to 10 K / min, preferably 3 to 6 K / min. It may be advantageous to maintain the temperature substantially constant (isothermal) once or several times during the high heating for a certain time. So z. B. during heating, the temperature at about 300 ° C, about 600 ° C and / or about 700 ° C are kept constant. The time during which the temperature is kept constant is preferably about 1 to 120 minutes, more preferably 5 to 60 minutes. Preferably, the temperature is kept constant in a range of 650 to 920 ° C during the heating. When the temperature is kept constant several times, the last stage is preferably in a range of 650 to 920 ° C. The alloy formation is furthermore preferably carried out with gradual cooling. Preferably, the cooling is carried out to a temperature in the range of 150 to 250 ° C in the presence of a gas mixture containing hydrogen and at least one inert gas under the reaction conditions. Nitrogen is preferably used as the inert gas. Suitable is z. Example, a gas mixture containing 50 vol .-% N2 and 50 vol .-% H2. Preferably, the further cooling takes place in the presence of at least one inert gas, preferably in the presence of nitrogen.

Preferably, the weight of the monolithic shaped catalyst body in the form of a foam is 35 to 60%, particularly preferably 40 to 50% higher than the weight of the metal foam molding used for its production.

Preferably, the intermetallic phases thus obtained on the support metal skeleton consist mainly of N12Al3 and NlAl3.

Activation (= step b))

Preferably, the shaped catalyst bodies used for activation have, based on the total weight, 60 to 95% by weight, particularly preferably 70 to 80% by weight, of a first metal which is selected from Ni, Fe, Co, Cu, Cr, Pt, Ag, Au and Pd.

Preferably, the shaped catalyst bodies used for activation, based on the total weight of 5 to 40 wt .-%, particularly preferably 20 to 30 wt .-%, of a second component which is selected from Al, Zn and Si. Preferably, the shaped catalyst bodies used for activation based on the total weight of 60 to 95 wt .-%, particularly preferably 70 to 80 wt .-%, Ni. Preferably, the shaped catalyst bodies used for activation based on the total weight of 5 to 40 wt .-%, particularly preferably 20 to 30 wt .-%, AI.

During the activation, the fixed catalyst bed is subjected to a treatment with an aqueous base as the treatment medium, wherein the second (leachable) component of the shaped catalyst bodies is at least partially dissolved and removed from the shaped catalyst bodies. As previously stated, the aqueous base treatment is exothermic so that the fixed catalyst bed heats up as a result of activation. The heating of the fixed catalyst bed is dependent on the concentration of the aqueous base used. If no heat is removed from the reactor by active cooling, but transferred to the treatment medium, so that in a sense an adiabatic procedure is realized, then formed during activation of a temperature gradient in the fixed catalyst bed, the temperature increases in the current direction of the aqueous base. However, even if heat is removed from the reactor by active cooling, a temperature gradient is formed in the fixed catalyst bed during activation.

Preferably 30 to 70 wt .-%, particularly preferably 40 to 60 wt .-%, of the second component, based on the original weight of the second component removed from the shaped catalyst bodies by the activation.

Preferably, the catalyst moldings used for activation contain Ni and Al and, by activation, becomes 30 to 70% by weight, particularly preferably 40 to

60 wt .-%, of AI, based on the original weight removed. The determination of the dissolved out of the catalyst moldings amount of the second component, for. As aluminum, for example, can be done by elemental analysis by determining the content of the second component in the total amount of discharged laden aqueous base and the washing medium. Alternatively, the determination of the amount dissolved out of the shaped catalyst bodies on the second component can be determined by the amount of hydrogen formed during the course of the activation. In the case in which aluminum is used, in each case 3 mol of hydrogen are produced by dissolving 2 mol of aluminum. The activation of a catalyst by the process 1 according to the invention or in step a) of the process 2 according to the invention can be carried out in a liquid or trickle mode. Preference is given to the upflow method, in which case the fresh aqueous base is fed to the bottom of the fixed catalyst bed and, after passing through the catalyst bed, is discharged on the top side.

After passing through the fixed catalyst bed, a loaded aqueous base is obtained. The loaded aqueous base has a lower base concentration than the aqueous base before passing through the fixed catalyst bed and is enriched in the reaction products formed during activation and at least partially soluble in the base. These reaction products include, for. Example, when using aluminum as the second (leachable) component alkali aluminates, aluminum hydroxide hydrates, hydrogen, etc. (see, for example, US 2,950,260).

The statement that the fixed catalyst bed has a temperature gradient during activation is understood in the context of the invention to mean that over a longer period of the total activation the fixed catalyst bed has this temperature gradient. The fixed catalyst bed preferably has a temperature gradient until at least 50% by weight, preferably at least 70% by weight, in particular at least 90% by weight, of the amount of aluminum to be removed has been removed from the shaped catalyst bodies. Unless during the activation the strength of the aqueous base used is increased and / or the temperature of the fixed catalyst bed is increased by less cooling than at the beginning of activation or external heating, the temperature difference between the coldest point of the fixed catalyst bed and the warmest point of the fixed catalyst bed in the course of activation are increasingly lower and can then take the value of zero towards the end of the activation.

According to the invention, the temperature difference between the coldest point of the catalyst fixed bed and the warmest point of the fixed catalyst bed is kept at a maximum of 50 K. To determine the temperature difference in the course of the fixed catalyst bed, this can be provided with conventional measuring devices for temperature measurement. For determining the temperature difference between the warmest point of the fixed catalyst bed and the coldest point of the fixed catalyst bed, it is generally sufficient for a non-actively cooled reactor to determine the temperature difference between the most upstream location of the fixed catalyst bed and the most downstream location of the fixed catalyst bed , In an actively cooled reactor, it may be useful to move in the direction of flow between the most upstream location of the fixed catalyst bed and the most to provide at least one further temperature sensor downstream of the fixed catalyst bed (eg 1, 2 or 3 further temperature sensors).

Particularly preferably, the temperature difference between the coldest point of the catalyst fixed bed and the warmest point of the fixed catalyst bed is maintained at a maximum of 40 K, in particular at a maximum of 25 K.

Preferably, the temperature difference between the coldest point of the fixed catalyst bed and the warmest point of the fixed catalyst bed at the beginning of activation in a range of 0.1 to 50 K, preferably in a range of 0.5 to 40 K, in particular in a range of 1 to 25K, kept. It is possible initially to initially introduce an aqueous medium without base and then to add fresh base until the desired concentration has been reached. In this case, the temperature difference between the coldest point of the fixed catalyst bed and the warmest point of the fixed catalyst bed at the beginning of the activation means the time at which the desired base concentration at the reactor inlet is reached for the first time.

The control of the size of the temperature gradient in the fixed catalyst bed can be carried out in a non-actively cooled reactor by selecting the amount and concentration of the supplied aqueous base according to the heat capacity of the medium used for activation. In order to control the size of the temperature gradient in the fixed catalyst bed in an actively cooled reactor, heat is also removed from the medium used for activation by heat exchange. Such removal of heat can be done by cooling the medium used for activation in the reactor used and / or, if present, the liquid circulation stream.

According to the invention, the shaped catalyst bodies are subjected to the activation of a treatment with a maximum of 3.5% by weight aqueous base. The use of a maximum of 3.0% by weight aqueous base is preferred. The shaped catalyst bodies are preferably subjected to the activation of a treatment with a 0.1 to 3.5% by weight aqueous base, particularly preferably a 0.5 to 3.5% strength by weight aqueous base. The concentration specification refers to the aqueous base prior to its contact with the shaped catalyst bodies. If, for activation, the aqueous base is brought into contact only once with the shaped catalyst bodies, the concentration information relates to the fresh aqueous base. If, for activation, the aqueous base is guided at least partly in a liquid circulation stream, the laden base obtained after activation can be activated before being used again the catalyst tablet fresh base are added. The previously indicated concentration values apply analogously.

By maintaining the above-mentioned concentrations for the aqueous base catalyst shaped bodies of Raney metal catalysts are obtained with high activity and very good stability. This is especially true for the activation of fixed catalyst beds for hydrogenation reactions on an industrial scale. Surprisingly, an excessively high temperature increase and the uncontrolled formation of hydrogen in the activation of the catalysts are effectively avoided with the given concentration ranges of the base. This advantage has a special effect on reactors on an industrial scale.

In a preferred embodiment, the aqueous base used for activation is at least partially conducted in a liquid circulation stream. In a first embodiment, the reactor is operated with the catalyst to be activated in the upflow mode. Then, in a vertically oriented reactor, the aqueous base is fed to the sump side of the reactor, passed from bottom to top through the fixed catalyst bed, taken above the fixed catalyst bed a discharge and returned to the sump side in the reactor. The discharged stream is preferably a workup, z. B. by separation of hydrogen and / or the discharge of a portion of the loaded aqueous base. In a second embodiment, the reactor is operated in trickle mode with the catalyst to be activated. Then, in a vertically oriented reactor, the aqueous base is fed into the top of the reactor, passed from top to bottom through the fixed catalyst bed, removed below the fixed catalyst bed and discharged back into the reactor at the top. In this case, the discharged current is preferably in turn a workup, z. B. by separation of hydrogen and / or the discharge of a portion of the loaded aqueous base. Preferably, the activation takes place in a vertical reactor in the upflow mode (ie with an upward flow through the fixed catalyst bed). Such a procedure is advantageous if the formation of hydrogen during activation also produces a low gas load, since this can be more easily removed overhead. In a preferred embodiment, fresh aqueous base is added to the fixed catalyst bed in addition to the base carried in the liquid recycle stream. The supply of fresh base can be done in the liquid recycle stream or separately in the reactor. The fresh aqueous base can also be concentrated higher than 3.5% by weight, if, after mixing with the recycled aqueous base, the base concentration is not higher than 3.5% by weight.

The ratio of aqueous base passed in the circulation stream to freshly supplied aqueous base is preferably in a range from 1: 1 to 1000: 1, more preferably from 2: 1 to 500: 1, in particular from 5: 1 to 200: 1.

Preferably, the feed rate of the aqueous base (when the aqueous base used for activation is not conducted in a liquid recycle stream) is at most 5 L / min per liter fixed catalyst bed, preferably at most 1.5 L / min per liter fixed catalyst bed, more preferably at most 1 L / min per liter of fixed catalyst bed, based on the total volume of the fixed catalyst bed.

The aqueous base used for activation is preferably conducted at least partly in a liquid circulation stream and the feed rate of the freshly fed aqueous base is at most 5 L / min per liter of fixed catalyst bed, preferably at most 1.5 L / min per liter of fixed catalyst bed, more preferably at most 1 L / min per liter of fixed catalyst bed, based on the total volume of the fixed catalyst bed.

Preferably, the feed rate of the aqueous base (when the aqueous base used for activation is not carried in a liquid recycle stream) is in the range of 0.05 to 5 L / min per liter of fixed catalyst bed, more preferably in the range of 0.1 to 1 , 5 L / min per liter of fixed catalyst bed, in particular in a range of 0.1 to 1 L / min per liter of fixed catalyst bed, based on the total volume of Kata lysatorf estbetts.

Preferably, the maximum of 3.5 wt .-% aqueous base used for activation is at least partially conducted in a liquid circulation stream and is the feed rate of the freshly supplied aqueous base in a range of 0.05 to 5 L / min per liter Fixed catalyst bed, more preferably in a range of 0.1 to 1, 5 L / min per liter of fixed catalyst bed, in particular in a range of 0.1 to 1 L / min per liter of fixed catalyst bed, based on the total volume of the fixed catalyst bed. This control of the fresh aqueous base feed rate is an effective way to maintain the temperature gradient resulting in the fixed catalyst bed within the desired range of values. The flow rate of the aqueous base through the reactor containing the fixed catalyst bed is preferably at least 0.5 m / h, more preferably at least 3 m / h, especially at least 5 m / h, especially at least 10 m / h. In order to avoid mechanical stress and abrasion of the newly formed porous catalyst metal, it may be useful not to choose the flow rate too high. The flow rate of the aqueous base through the reactor containing the fixed catalyst bed is preferably at most 100 m / h, more preferably at most 50 m / h, especially at most 40 m / h.

The above-mentioned flow rates can be achieved particularly well if at least some of the aqueous base is conducted in a liquid circulation stream. The base used to activate the fixed catalyst bed is selected from alkali metal hydroxides, alkaline earth metal hydroxides and mixtures thereof. Preferably, the base is selected from NaOH, KOH, and mixtures thereof. Preferably, the base is selected from NaOH and KOH. Specifically, NaOH is used as the base. The base is used for activation in the form of an aqueous solution.

The catalyst fixed bed activation process 1 of the present invention and the process 2 of the present invention for providing a catalyst containing a fixed catalyst bed of such an activated catalyst make it possible to effectively minimize separation of the catalytically active metal such as nickel during activation. A suitable measure of the effectiveness of the activation and the stability of the obtained Raney metal catalyst is the metal content in the loaded aqueous base. When using a liquid circulation stream, the metal content in the circulation stream is a suitable measure of the effectiveness of the activation and the stability of the resulting Raney metal catalyst. The content of nickel during the activation in the loaded aqueous base or, if the liquid circulation stream is used for activation, in the circulation stream is preferably at most 0.1% by weight, particularly preferably at most 100 ppm by weight, in particular at most 10 ppm by weight. The determination of the nickel content can be done by elemental analysis. The same advantageous values are generally also achieved in the following process steps, such as treatment of the activated catalyst fixed bed with a washing medium, treatment of the fixed catalyst bed with a dopant and use in a hydrogenation reaction. The processes according to the invention enable a homogeneous distribution of the catalytically active Raney metal over the moldings used and overall over the resulting activated fixed catalyst bed. No or only a slight gradient with respect to the distribution of the catalytically active Raney metal in the direction of flow of the activation medium through the fixed catalyst bed is formed. In other words, the concentration of catalytically active sites upstream of the fixed catalyst bed is substantially equal to the concentration of catalytically active sites downstream of the fixed catalyst bed. This advantageous effect is achieved, in particular, if the aqueous base used for the activation is guided at least partially in a liquid circulation stream. The inventive method also allow a homogeneous distribution of the leached second component, eg. As the aluminum, on the moldings used and a total of the resulting activated fixed catalyst bed. There is no or only a slight gradient with respect to the distribution of the dissolved-out second component in the flow direction of the activation medium through the fixed catalyst bed.

Another advantage, if the aqueous base used for activation is at least partially conducted in a liquid circulation stream, is that the required amount of aqueous base can be significantly reduced. Thus, a straight pass of the aqueous base (without recycling) and the subsequent discharge of the loaded base leads to a high demand for fresh base. By supplying suitable amounts of fresh base in the recycle stream, it is ensured that there is always sufficient base for the activation reaction. All in all, significantly lower quantities are required for this.

As stated above, after passing through the fixed catalyst bed, a charged aqueous base is obtained which has a lower base concentration than the aqueous base before passing through the fixed catalyst bed and which reacts at least partially on the base formed during activation and in the base - Enriched products. Preferably, at least part of the loaded aqueous base is discharged. Thus, even if a portion of the aqueous base is passed in a recycle stream, excessive dilution and accumulation of undesirable impurities in the aqueous base used for activation can be avoided. The amount of aqueous base freshly supplied per unit time preferably corresponds to the amount of laden aqueous base removed.

A discharge of laden aqueous base is preferably taken from the activation and subjected to a gas / liquid separation, a hydrogen-containing gas phase and a liquid phase being obtained. For gas / liquid separation, the customary and known to those skilled devices are used, such as the usual separation vessel. The hydrogen-containing gas phase obtained in the phase separation can be discharged from the process and z. B. a thermal utilization can be supplied. The liquid phase obtained in the phase separation, which contains the discharged laden aqueous base is preferably at least partially recycled as a liquid recycle stream in the activation. Preferably, part of the liquid phase obtained in the phase separation, which contains the discharged laden aqueous base, is discharged. Thus, as previously described, excessive dilution and accumulation of undesirable impurities in the aqueous base used for activation can be avoided.

To control the progress of the activation and to determine the amount of the second component dissolved out of the shaped catalyst bodies, e.g. As aluminum, the amount of hydrogen formed during the activation can be determined. In the case in which aluminum is used, in each case 3 mol of hydrogen are produced by dissolving 2 mol of aluminum.

Preferably, the activation according to the invention of a catalyst (process 1) and the activation of a fixed catalyst bed in step b) of the inventive method for providing a reactor (process 2) at a temperature of at most 50 ° C, preferably at a temperature of at most 40 ° C.

The activation according to the invention preferably takes place at a pressure in the range from 0.1 to 10 bar, more preferably from 0.5 to 5 bar, especially at ambient pressure.

Treatment with a washing medium (= step c))

In step c) of the process according to the invention for providing a reactor (process 2), the activated catalyst fixed bed obtained in step b) is subjected to a treatment with a washing medium selected from water,

C 1 -C 4 alkanols and mixtures thereof. Likewise, the activated catalyst obtained by process 1 may be subjected to treatment with such a washing medium. Suitable C 1 -C 4 -alkanols are methanol, ethanol, n-propanol, isopropanol, n-butanol and isobutanol.

Preferably, the washing medium used in step c) contains water or consists of water. The treatment with the washing medium is preferably carried out in step c) until the effluent washing medium has a conductivity at 20 ° C. of at most 200 mS / cm, particularly preferably at most 100 mS / cm, in particular at most

10 mS / cm.

In step c), water is preferably used as the washing medium and the treatment with the washing medium is carried out until the effluent washing medium has a pH at 20 ° C. of not more than 9, particularly preferably not more than 8, in particular not more than 7.

The treatment with the washing medium is preferably carried out in step c) until the effluent washing medium has an aluminum content of at most 5% by weight, more preferably of at most 5000 ppm by weight, in particular of at most 500 ppm by weight.

In step c), the treatment with the washing medium is preferably carried out at a temperature in the range from 20 to 100.degree. C., particularly preferably from 20 to 80.degree. C., in particular from 25 to 70.degree.

Doping (= step d))

A doping refers to the introduction of foreign atoms in a layer or in the base material of a catalyst. The amount introduced in this process is generally small compared to the rest of the catalyst material. The doping specifically changes the properties of the starting material.

In a specific embodiment of the process 2 according to the invention, the catalyst fixed bed is brought into contact during and / or after the treatment in step c) with a doping agent which has at least one element selected from the first metal and the second component of the process described in step a ) is used different shaped catalyst bodies. Such elements are referred to hereinafter as "promoter elements". The use of promoter elements in hydrogenation catalysts, such as Raney metal

Catalysts, eg. B. to improve the yield, selectivity and / or activity of the hydrogenation and thus to improve the quality of the products obtained is described in the literature. See US 2,953,604, US 2,953,605, US 2,967,893, US 2,950,326, US 4,885,410, US 4,153,578, GB 2104794, US 8,889,911 1,

US 2,948,687 and EP 2,764,916.

The use of promoter elements serves, for example, side reactions such. As isomerization reactions, or is advantageous for the partial or complete hydrogenation of intermediates. As a rule, the remaining hydrogenation properties of the doped catalyst are not adversely affected. The promoter elements may either already be present in the alloy (the catalyst precursor) or they may be added subsequently to the shaped catalyst bodies.

For the modification of the shaped catalyst bodies by the process according to the invention, the following four methods are suitable in principle:

The promoter elements are already present in the alloy for producing the catalyst body (method 1),

the shaped catalyst bodies are brought into contact with a dopant during activation (method 2),

the shaped catalyst bodies are brought into contact after activation with a dopant (Method 3),

- The shaped catalyst bodies are brought into contact during the hydrogenation with a dopant and / or a dopant is introduced during the hydrogenation in the reactor (Method 4).

The doping according to method 3 can be carried out before, during or after the washing of the freshly activated catalyst.

The above-mentioned method 1, in which at least one promoter element is already contained in the alloy for the preparation of the shaped catalyst body is z. B. in the already mentioned US 2,948,687 described. Accordingly, a finely ground nickel-aluminum-molybdenum alloy is used to prepare the catalyst to produce a molybdenum-containing Raney nickel catalyst. The use of shaped catalyst bodies which already contain at least one promoter element is expressly permitted by the processes according to the invention. In such a case, as a rule, it is possible to dispense with bringing the fixed catalyst bed into contact with a dopant during and / or after the treatment in step c).

The above method 2 is z. For example, in US 2010/01741 16 A1 (= US 8,889,911 1) described. Thereafter, a doped catalyst is prepared from a Ni / Al alloy. which is modified during and / or after its activation with at least one promoter metal. In this case, the catalyst can optionally be subjected to a first doping before activation. The promoter element used for doping by absorption on the surface of the catalyst during and / or after activation is selected from Mg, Ca, Ba, Ti, Zr, Ce, Nb, Cr, Mo, W, Mn, Re, Fe, Co, Ir, Ni, Cu, Ag, Au, Bi, Rh and Ru. If the catalyst precursor is already subjected to doping before activation, then the promoter element is selected from Ti, Ce, V, Cr, Mo, W, Mn, Re, Fe, Ru, Co, Rh, Ir, Pd, Pt and Bi. Die The above method 3 is z. As described in GB 2104794. This document relates to Raney nickel catalysts for the reduction of organic compounds, especially the reduction of carbonyl compounds and the preparation of 1,4-butanediol from 1,4-butynediol. To prepare these catalysts, a Raney nickel catalyst is subjected to a doping with a molybdenum compound, which may be solid, as a dispersion or as a solution. Other promoter elements, such as Cu, Cr, Co, W, Zr, Pt or Pd may additionally be used. Method 3 is a particularly preferred method.

The above method 4, z. In US Pat. No. 2,967,893 or US Pat. No. 2,950,326. Thereafter, copper in the form of copper salts is added to a nickel catalyst for the hydrogenation of 1,4-butynediol in the aqueous.

According to EP 2 486 976 A1, supported activated Raney metal catalysts are subsequently doped with an aqueous metal salt solution.

The aforementioned EP 2 764 916 A1 teaches that promoter elements can be used in the preparation of foam-like shaped catalyst bodies. The doping can be carried out together with the application of the leachable component on the surface of the previously prepared metal foam molding. The doping can also take place in a separate step following the activation.

By doping, the activity of a metal catalyst can also be influenced so that the hydrogenation terminates at an intermediate stage. It is known to use for partial hydrogenation of 1, 4-butynediol to 1, 4-butenediol a copper-modified palladium catalyst (GB832141). In principle, the activity and / or the selectivity of a catalyst can thus be increased or decreased by doping with at least one promoter metal. By such a doping, the remaining hydrogen properties of the doped catalyst should as far as possible not be be influenced in part. Also, such a chemical modification is expressly permitted for the inventive method 2.

A specific embodiment is a process for providing a reactor containing an activated fixed catalyst bed (= process 2), wherein the catalyst form used for the activation, which contains the fixed catalyst bed or of which the fixed catalyst bed consists already have at least one promoter element, and / or

the catalyst fixed bed is brought into contact with a dopant during activation in step b) which has at least one promoter element, and / or

During and / or after the treatment with a washing medium in step c), the fixed catalyst bed is brought into contact with a dopant which has at least one promoter element and / or

bringing the catalyst fixed bed during the hydrogenation with a dopant in contact having at least one promoter element.

The dopant used according to the invention preferably contains at least one promoter element which is selected from Ti, Ta, Zr, V, Cr, Mo, W, Mn, Re, Fe, Ru, Co, Rh, Ir, Ni, Pd, Pt, Cu, Ag, Au, Ce and Bi.

It is possible that the dopant contains at least one promoter element which simultaneously fulfills the definition of a first metal in the sense of the invention. Such promoter elements are selected from Ni, Fe, Co, Cu, Cr, Pt, Ag, Au and Pd. In this case, the monolithic molded article contains, based on the reduced metallic form, a major amount (ie, more than 50% by weight) of the first metal and a minor amount (ie, less than 50% by weight) of a different metal as a dopant , When specifying the total amount of the first metal which contains the monolithic shaped catalyst body, however, all metals which fulfill the definition of a first metal in the meaning of the invention are expected to have their full weight fraction (irrespective of whether they function as hydrogenation-active component or as promoter). , In a specific embodiment, the dopant does not contain a promoter element which fulfills the definition of a first metal in the sense of the invention. The dopant then preferably contains exclusively one promoter element or more than one promoter element which is selected from Ti, Ta, Zr, Ce, V, Mo, W, Mn, Re, Ru, Rh, Ir and Bi. Preferably, the dopant contains Mo as a promoter element. In a specific embodiment, the dopant contains Mo as the sole promoter element.

The promoter elements are particularly preferably used for doping in the form of their salts. Suitable salts are, for example, the nitrates, sulfates, acetates, formates, fluorides, chlorides, bromides, iodides, oxides or carbonates. The promoter elements either separate by themselves in their metallic form due to their nobler character compared to Ni or can be brought into contact with a reducing agent such as e.g. As hydrogen, hydrazine, hydroxylamine, etc., are reduced in their metallic form. If the promoter elements are added during the activation process, then they can also be in their metallic form. In this case, it may be useful for the formation of metal-metal compounds to subject the fixed catalyst bed after the storage of the promoter metals first an oxidative treatment and then a reducing treatment.

In a specific embodiment, the fixed catalyst bed is contacted during and / or after treatment with a wash medium in step c) with a dopant containing Mo as a promoter element. More specifically, the dopant contains Mo as the sole promoter element. Suitable molybdenum compounds are selected from molybdenum trioxide, the nitrates, sulfates, carbonates, chlorides, iodides and bromides of molybdenum and the molybdates. Preference is given to the use of ammonium molybdate. In a preferred embodiment, a molybdenum compound is used which has good water solubility. Good solubility in water is understood to mean a solubility of at least 20 g / l at 20 ° C. When using molybdenum compounds, which have a lower water solubility, it may be useful before they are used as a dopant to filter the solution. Suitable solvents for doping are water, polar solvents which are different from water and inert solvents under the doping conditions with respect to the catalyst, and mixtures thereof. Preferably, the solvent used for doping is selected from water, methanol, ethanol, n-propanol, isopropanol, n-butanol, isobutanol and mixtures thereof.

The temperature during the doping is preferably in a range from 10 to 100 ° C., more preferably from 20 to 60 ° C., in particular from 20 to 40 ° C.

The concentration of the promoter element in the dopant is preferably in a range of about 20 g / L to the maximum soluble amount of the dopant under the doping conditions. As a rule, one will assume a maximum of one solution saturated at ambient temperature. The duration of the doping is preferably 0.5 to 24 hours.

If the doping takes place during the activation in step b) or during and / or after the treatment with a washing medium in step c), it may be advantageous for the doping to take place in the presence of an inert gas. Suitable inert gases are for. As nitrogen or argon.

In a specific embodiment for doping foam-like shaped catalyst bodies, a molybdenum source is dissolved in water and this solution is passed through the previously activated foam. When using hydrates of ammonium molybdate, such as. B. (ΝΗ4) 6Μθ7θ24 x 4 H2O, this is dissolved in water and this solution used. The usable amount depends strongly on the solubility of the ammonium molybdate and is in principle not critical. Conveniently, less than 430 grams of ammonium molybdate are dissolved per liter of water at room temperature (20 ° C). If the doping is carried out at a higher temperature than room temperature, then larger amounts can be used. The ammonium molybdate solution is then passed over the activated and washed foam at a temperature of 20 to 100 ° C, preferably at a temperature of 20 to 40 ° C. The treatment time is preferably 0.5 to 24 hours, more preferably 1 to 5 hours. In a specific embodiment, the contacting takes place in the presence of an inert gas, such as nitrogen. The pressure is preferably in a range of 1 to 50 bar, especially at about 1 bar absolute. Thereafter, the doped Raney nickel foam can be used either without further work-up or after repeated washing for the hydrogenation.

The doped catalyst bodies preferably contain from 0.01 to 10% by weight, particularly preferably from 0.1 to 5% by weight, of promoter elements based on the reduced metallic form of the promoter elements and the total weight of the catalyst moldings.

The fixed catalyst bed may contain the promoter elements substantially homogeneously or heterogeneously distributed in their concentration. In a specific embodiment, the fixed catalyst bed has a gradient in the flow direction with respect to the concentration of the promoter elements. In particular, the fixed catalyst bed contains or consists of Ni / Al catalyst moldings which are activated by the process according to the invention and / or which are doped with Mo and have a gradient with respect to the Mo concentration in the flow direction. It is possible to obtain a fixed-bed catalyst which is fixedly installed in a reactor and which contains at least one promoter element which substantially homogeneously distributes in its concentration, ie does not exist in the form of a gradient. To provide such a fixed bed catalyst, it is possible not to dope the catalyst in built-in form in the fixed bed reactor itself, possibly with circulation, whereby a concentration gradient can arise. Preferably, the doping is then carried out in an external container without circulation, which is infinitely back-mixed, such. B. a batch reactor without continuous feed and drain. After doping and, if appropriate, a washing, such catalysts can be incorporated in a fixed bed reactor with or without a circulation and are thus without gradients.

To provide a fixed catalyst bed having a gradient in the flow direction with respect to the concentration of promoter elements, one can proceed by passing a liquid stream of the dopant through the fixed catalyst bed. If the reactor has a circulation stream, it is alternatively or additionally possible to feed the dopant in liquid form into the circulation stream. In such an approach, a concentration gradient of the promoter elements is formed over the entire length of the fixed catalyst bed in the flow direction. If it is desired that the concentration of the promoter element in the flow direction of the reaction medium of the reaction to be catalyzed decreases, the liquid flow of the dopant is conducted in the same direction as the reaction medium of the reaction to be catalyzed by the fixed catalyst bed. If it is desired that the concentration of the promoter element increases in the direction of flow of the reaction medium of the reaction to be catalyzed, the liquid flow of the dopant is directed in the opposite direction as the reaction medium of the reaction to be catalyzed by the fixed catalyst bed.

In a first preferred embodiment, the activated catalyst fixed bed obtained by process 1 according to the invention or the reactor provided by process 2 according to the invention which contains such an activated fixed catalyst bed is used for the hydrogenation of 1,4-butynediol to give 1,4-butanediol , It has now surprisingly been found that a particularly high selectivity is achieved in the hydrogenation, if one uses a fixed catalyst bed of Ni / Al catalyst moldings, which are activated by the novel process and / or which are doped with Mo and wherein the concentration of the molybdenum in the flow direction of the reaction medium of the hydrogenation reaction increases. The molybdenum content of the shaped catalyst bodies at the entry of the reaction medium into the fixed catalyst bed is preferably 0 to 3% by weight, particularly preferably 0 to 2.5% by weight, in particular dere 0.01 to 2 wt .-%, based on metallic molybdenum and the total weight of the shaped catalyst body. Preferably, the molybdenum content of the catalyst molding is at the outlet of the reaction medium from the catalyst fixed bed 0.1 to

10 wt .-%, particularly preferably 0.1 to 7 wt .-%, in particular 0.2 to 6 wt .-%, based on metallic molybdenum and the total weight of the shaped catalyst body.

In a second preferred embodiment, the activated catalyst fixed bed obtained by process 1 according to the invention or the reactor provided by process 2 according to the invention which contains such an activated fixed catalyst bed is used for the hydrogenation of 4-butyraldehyde to give n-butanol. It has now surprisingly been found that a particularly high selectivity is achieved in the hydrogenation, if one uses a fixed catalyst bed of Ni / Al catalyst moldings which are activated by the novel process and / or which are doped with Mo and wherein the concentration of the molybdenum in the flow direction of the reaction medium of the hydrogenation reaction decreases. Preferably, the molybdenum content of the catalyst molding is at the entry of the reaction medium in the fixed catalyst bed 0.5 to 10 wt .-%, particularly preferably 1 to 9 wt .-%, in particular 1 to 7 wt .-%, based on metallic molybdenum and the total weight of catalyst bodies. Preferably, the molybdenum content of the shaped catalyst bodies at the outlet of the reaction medium from the fixed catalyst bed 0 to 7 wt .-%, particularly preferably 0.05 to 5 wt .-%, in particular 0.1 to 4.5 wt .-%, based on metallic molybdenum and the total weight of the shaped catalyst bodies. It has been found that it is advantageous for the efficiency of the doping of Raney metal catalysts and especially Raney nickel catalysts with a promoter element, especially Mo, if after activation and before doping the activated fixed catalyst bed of a treatment is subjected to a washing medium. This applies in particular if foam-like Raney nickel catalysts are used for the doping. It has been found, in particular, that the adsorption of molybdenum on the shaped catalyst bodies is incomplete if, after activation, the content of washable aluminum is still too high. Preference is therefore given to the treatment with a washing medium in step c) is carried out prior to doping in step d) until the effluent washing medium at a temperature of 20 ° C has a conductivity of at most 200 mS / cm. The treatment with the washing medium is preferably carried out in step c) until the effluent washing medium has an aluminum content of at most 500 ppm by weight. The activated catalyst fixed beds obtained by the process according to the invention, which optionally contain doped shaped catalyst bodies, are generally distinguished by high mechanical stability and long service life. Nevertheless, the fixed bed catalyst is mechanically stressed when it is flowed through in the liquid phase with the components to be hydrogenated. In the long term, wear or removal of the outer layers of the active catalyst species may occur. If the Raney nickel foam catalyst was prepared by leaching and doping, then the subsequently doped metal element is preferably on the outer active catalyst layers, which can also be removed by mechanical liquid or gas loading. Removal of the promoter element may result in reduced activity and selectivity of the catalyst. Surprisingly, it has now been found that the original activity can be restored by the doping process is carried out again. Alternatively, the doping agent can also be added for hydrogenation, in which case it is then post-doped in situ (Method 4).

hydrogenation

In the context of the invention, hydrogenation is generally understood as meaning the reaction of an organic compound with H 2 addition to this organic compound. Preferably, functional groups are hydrogenated to the correspondingly hydrogenated groups. These include, for example, the hydrogenation of nitro groups, nitroso groups, nitrile groups or imine groups to amine groups. This includes, for example, the hydrogenation of aromatics to saturated cyclic compounds. This includes, for example, the hydrogenation of carbon-carbon triple bonds to double bonds and / or single bonds. This includes, for example, the hydrogenation of carbon-carbon double bonds to single bonds. This includes, for example, the hydrogenation of ketones, aldehydes, esters, acids or anhydrides to alcohols.

Preferably, the hydrogenation of carbon-carbon triple bonds, carbon-carbon double bonds, aromatic compounds, carbonyl-containing compounds, nitriles and nitro compounds. Carbonyl-containing compounds suitable for hydrogenation are ketones, aldehydes, acids, esters and anhydrides.

Particularly preferred is the hydrogenation of carbon-carbon triple bonds, carbon-carbon double bonds, nitriles, ketones and aldehydes. The hydrogenatable organic compound is particularly preferably selected from 1,4-butynediol, 1,4-butenediol, 4-hydroxybutyraldehyde, hydroxypivalic acid, hydroxypivalaldehyde n- and isobutyraldehyde, n- and isovaleraldehyde, 2-ethylhex-2-enal, 2-ethylhexanal, nonanals, 1, 5,9-cyclododecatriene, benzene, furan, furfural, phthalic acid esters, acetophenone, and alkyl-substituted acetophenones. The hydrogenatable organic compound is most preferably chosen from 1,4-butynediol, 1,4-butenediol, n- and isobutyraldehyde, hydroxypivalaldehyde, 2-ethylhex-2-enal, nonanals and 4-isobutylacetophenone. The hydrogenation according to the invention leads to hydrogenated compounds which accordingly no longer contain the group to be hydrogenated. Contains a compound at least 2 different hydrogenatable groups, it may be desirable to hydrogenate only one of the unsaturated groups, for. For example, when a compound has an aromatic ring and additionally a keto group or an aldehyde group. This includes z. B. the hydrogenation of 4-isobutylacetophenone to 1- (4'-isobutylphenyl) ethanol or the hydrogenation of a CC-unsaturated ester to the corresponding saturated ester. In principle, at the same time or instead of a hydrogenation in the context of the invention, an undesired hydrogenation of other hydrogenatable groups can be carried out, for. As of carbon-carbon single bonds or C-OH bonds to water and hydrocarbons. This includes z. B. the hydrogenolysis of

1, 4-butanediol to propanol or butanol. These latter hydrogenations usually lead to undesirable by-products and are therefore not desirable. The hydrogenation according to the invention is preferably characterized in the presence of a suitably activated catalyst by a high selectivity with respect to the desired hydrogenation reactions. This includes in particular the hydrogenation of

1, 4-butynediol or 1, 4-butenediol to 1, 4-butanediol. In particular, this includes the hydrogenation of n- and iso-butyraldehyde to n- and iso-butanol. In particular, this includes the hydrogenation of hydroxypivalaldehyde or of hydroxypivalic acid to neopentyl glycol. In particular, this includes the hydrogenation of 2-ethylhex-2-enal to 2-ethylhexanol. In particular, this includes the hydrogenation of nonanals to nonanols. In particular, this includes the hydrogenation of 4-isobutylacetophenone to give 1- (4'-isobutylphenyl) ethanol.

The hydrogenation is preferably carried out continuously.

In the simplest case, the hydrogenation takes place in a single hydrogenation reactor. In a specific embodiment of the process according to the invention, the hydrogenation is carried out in n hydrogenation reactors connected in series (in series), n being an integer of at least 2. Suitable values for n are 2, 3, 4, 5, 6, 7, 8, 9 and 10. n is 2 to 6 and in particular 2 or 3. In this embodiment, the hydrogenation is preferably carried out continuously.

The reactors used for the hydrogenation in step d) can have a fixed catalyst bed which is formed from identical or different shaped catalyst bodies. The fixed catalyst bed may have one or more reaction zones. Various reaction zones may comprise shaped catalyst bodies of different chemical composition of the catalytically active species. Different reaction zones may also have catalyst moldings of the same chemical composition of the catalytically active species but in different concentrations. If at least two reactors are used for the hydrogenation, the reactors may be the same or different reactors. These can be z. B. each have the same or different mixing characteristics and / or be subdivided by internals one or more times.

Suitable pressure-resistant reactors for the hydrogenation are known to the person skilled in the art. These include the commonly used reactors for gas-liquid reactions, such as. Pipe reactors, shell and tube reactors, gas recycle reactors, etc. A particular embodiment of the tubular reactors are shaft reactors.

The process according to the invention will be carried out in a fixed bed procedure. The fixed bed mode can be z. B. in sump or in trickle run. The reactors used for the hydrogenation contain a catalyst fixed bed activated by the method according to the invention, through which the reaction medium flows. The fixed catalyst bed can be formed from a single variety of shaped catalyst bodies or from different shaped catalyst bodies. The fixed catalyst bed may have one or more zones, wherein at least one of the zones contains a material active as a hydrogenation catalyst. Each zone can have one or more different catalytically active materials and / or one or more different inert materials. Different zones may each have the same or different compositions. It is also possible to provide a plurality of catalytically active zones, which are separated from each other, for example, by inert beds or spacers. The individual zones may also have different catalytic activity. For this purpose, various catalytically active materials can be used and / or at least one of the zones an inert material can be added. The reaction medium which is bound by the catalyst solid Bed flows, contains at least one liquid phase. The reaction medium may also contain a gaseous phase in addition.

In a specific embodiment, the hydrogenation is carried out according to the inventive method in the presence of CO.

During the hydrogenation, the CO content in the gas phase within the reactor is preferably in a range from 0.1 to 10,000 ppm by volume, more preferably in a range from 0.15 to 5000 ppm by volume, in particular in a range from 0, 2 to 1000 ppm by volume. The total CO content within the reactor is composed of CO in the gas and liquid phases, which are in equilibrium with each other. Conveniently, the CO content is determined in the gas phase and the values given here refer to the gas phase. In this case, a concentration profile over the reactor is advantageous, wherein the concentration of CO in the flow direction of the reaction medium of the hydrogenation along the reactor should increase.

It has now surprisingly been found that in the hydrogenation a particularly high selectivity is achieved when the concentration of CO in the flow direction of the reaction medium of the hydrogenation reaction increases. The CO content at the outlet of the reaction medium from the fixed catalyst bed is preferably at least 5 mol% higher, more preferably at least 25 mol% higher, in particular at least 75 mol% higher, than the CO content when the reaction medium enters the fixed catalyst bed. To generate a CO gradient in the flow direction of the reaction medium through the fixed catalyst bed, for example, CO can be fed into the fixed catalyst bed at one or more points.

The content of CO is determined, for example, by gas chromatography via removal of individual samples or preferably by online measurement. When samples are taken, it is advantageous, in particular in front of the reactor, to remove both gas and liquid and to relax in order to ensure that a balance between gas and liquid has formed; CO is then determined from the gas phase.

The online measurement can be done directly in the reactor, z. B. before the reaction medium enters the fixed catalyst bed and after the exit of the reaction medium from the fixed catalyst bed. The CO content may, for. B. be adjusted by the addition of CO to the hydrogen used for the hydrogenation. Of course, CO can also be fed separately from the hydrogen in the reactor. If the hydrogenation reaction mixture is at least partly conducted in a liquid circulation stream, CO can also be fed into this circulation stream. CO can also be formed from components contained in the hydrogenation reaction mixture, e.g. B. as starting materials to be hydrogenated or as incurred in the hydrogenation intermediates or by-products. So can CO z. B. formed in the reaction mixture of the hydrogenation formic acid, formates or formaldehyde are formed by decarbonylation the. Similarly, CO can also be formed by decarbonylation of aldehydes other than formaldehyde or by dehydrogenation of primary alcohols to aldehydes and subsequent decarbonylation. These undesirable side reactions include, for. As CC or CX cleavages, such as the formation of propanol or butanol formation of 1, 4-butanediol. It has furthermore been found that the conversion in the hydrogenation can only be insufficient if the CO content in the gas phase within the reactor is too high, ie especially above 10,000 ppm by volume.

The conversion in the hydrogenation is preferably at least 90 mol%, particularly preferably at least 95 mol%, in particular at least 99 mol%, especially at least 99.5 mol%, based on the total weight of hydrogenatable components in the hydrogenation used starting material. The conversion refers to the amount of target compound obtained, regardless of how many molar equivalents of hydrogen have taken up the starting compound to reach the target compound. When a starting compound used in the hydrogenation contains a plurality of hydrogenatable groups or contains a hydrogenatable group which can take up several equivalents of hydrogen (eg an alkyne group), the desired target compound can be both the product of a partial hydrogenation (eg alkyne to alkene) or a complete hydrogenation (eg, alkyne to alkane). As already stated above for the inventive activation of the fixed catalyst bed, it is important for the success of the hydrogenation according to the invention that the reaction mixture of the hydrogenation (ie gas and liquid stream) predominantly flows through the structured catalyst and does not flow past it, as it does For example, in the case of ordinary, packed fixed bed catalysts is the case.

Preferably, more than 90% of the material stream (ie the sum of gas and liquid stream) should flow through the fixed catalyst bed, preferably over 95%, more preferably> 99%. As stated above, the fixed catalyst beds used according to the invention have, at an arbitrary section in the normal plane to the flow direction (ie, horizontal) through the fixed catalyst bed, preferably at most 5%, particularly preferably at most 1%, in particular at most 0.1%, based on the total area of the section Surface on which is not part of the catalyst bodies. As a free surface, which is part of the shaped catalyst body, the surface of the pores and channels of the shaped catalyst body is understood. This information refers to cuts through the fixed catalyst bed in the area of the catalyst mold body and not any internals, such as power distribution.

In order for good mass transfer to take place in the structured catalysts, the rate at which the reaction mixture flows through the fixed catalyst bed should not be too low. The flow rate of the reaction mixture through the reactor containing the fixed catalyst bed is preferably at least 30 m / h, preferably at least 50 m / h, in particular at least 80 m / h. The flow rate of the reaction mixture through the reactor containing the fixed catalyst bed is preferably at most 1000 m / h, particularly preferably at most 500 m / h, in particular at most 400 m / h. The flow direction of the reaction mixture is, in principle in an upright reactor, not of critical importance. The hydrogenation can thus be carried out in bottoms or Rieselfahrweise. The upflow mode, wherein the reaction mixture to be hydrogenated is fed to the marsh side of the fixed catalyst bed and is discharged at the top end after passing through the fixed catalyst bed, may be advantageous. This is especially true when the gas load should be low (eg <50 m / h). These flow rates are generally achieved by recycling a portion of the liquid stream leaving the reactor, with the recycle stream combining with the reactant stream either before the reactor or in the reactor. The educt stream can also be supplied distributed over the length and / or width of the reactor.

In a preferred embodiment, the hydrogenation reaction mixture is at least partially conducted in a liquid recycle stream. The ratio of reaction mixture conducted in the circulation stream to freshly fed educt stream is preferably in a range from 1: 1 to 1000: 1, preferably from 2: 1 to 500: 1, in particular from 5: 1 to 200: 1. A discharge is preferably taken from the reactor and subjected to a gas / liquid separation, a hydrogen-containing gas phase and a product-containing liquid phase being obtained. For gas / liquid separation, it is possible to use the customary devices known to the person skilled in the art, such as the customary separation containers (separators). The temperature in the gas / liquid separation is preferably equal to or lower than the temperature in the reactor. The pressure in the gas / liquid separation is preferably equal to or less than the pressure in the reactor. The gas / liquid separation preferably takes place essentially at the same pressure as in the reactor. The pressure difference between reactor and

Gas / liquid separation is preferably at most 10 bar, in particular at most 5 bar. It is also possible to design the gas / liquid separation in two stages. The absolute pressure in the second gas / liquid T rennung is then preferably in a range of 0.1 to 2 bar. The product-containing liquid phase obtained in the gas / liquid separation is generally at least partially discharged. From this discharge, the product of the hydrogenation can be isolated, if appropriate after a further work-up. In a preferred embodiment, the product-containing liquid phase is at least partially recycled as a liquid circulation stream in the hydrogenation.

The hydrogen-containing gas phase obtained in the phase separation can be at least partially discharged as exhaust gas. Furthermore, the hydrogen-containing gas phase obtained in the phase separation can be at least partially attributed to the hydrogenation. The amount of hydrogen discharged via the gas phase is preferably 0 to 500 mol% of the amount of hydrogen which is consumed in molar amounts of hydrogen in the hydrogenation. For example, with a consumption of one mole of hydrogen, 5 moles of hydrogen can be discharged as exhaust gas. Particularly preferably, the amount of hydrogen discharged via the gas phase is at most 100 mol%, in particular at most 50 mol%, of the amount of hydrogen which is consumed by molar amount of hydrogen in the hydrogenation. By means of this discharge stream can control the CO content in the gas phase in the reactor. In a specific embodiment, the hydrogen-containing gas phase obtained in the phase separation is not recycled. However, if it should be desired, this is preferably up to 1000% of the amount based on the amount of gas required chemically for the reaction, more preferably up to 200%.

The gas loading, expressed by the gas empty tube velocity at the reactor outlet, under reaction conditions is generally below 200 m / h, preferably below 100 m / h, more preferably below 70 m / h, most preferably below 50 m / h. The gas loading consists essentially of hydrogen, preferably at least 60% by volume. The gas velocity at the beginning of the reactor is extremely variable, since hydrogen can also be added to intermediate feeds. However, if all hydrogen should be added at the beginning, the gas velocity is generally higher than at the reactor end.

The absolute pressure in the hydrogenation is preferably in a range from 1 to 330 bar, particularly preferably in a range from 5 to 100 bar, in particular in a range from 10 to 60 bar.

The temperature in the hydrogenation is preferably in a range of 60 to 300 ° C, particularly preferably from 70 to 220 ° C, in particular from 80 to 200 ° C.

In a specific embodiment, the fixed catalyst bed has a temperature gradient during the hydrogenation. Preferably, the temperature difference between the coldest point of the fixed catalyst bed and the warmest point of the fixed catalyst bed is maintained at a maximum of 50 K. Preferably, the temperature difference between the coldest point of the fixed catalyst bed and the warmest point of the fixed catalyst bed is maintained in a range of 0.5 to 40K, preferably in a range of 1 to 30K.

The following examples serve to illustrate the invention without limiting it in any way. EXAMPLES

The educts used and the products obtained were analyzed undiluted using standard gas chromatography and FID detector. The following quantities are GC data in area% (no water included).

The nickel-aluminum catalyst moldings used in the application examples were prepared as follows, following the examples in EP 2 764 916 A1 for the preparation of foam-form catalysts: Variant a):

0.5 g of polyvinylpyrrolidone (molecular weight: 40,000 g / mol) were dissolved in 29.5 g of demineralized water and 20 g of aluminum powder (particle size 75 μηη) was added. The resulting mixture was then shaken so that a homogeneous suspension was obtained. on was born. Thereafter, a nickel foam having an average pore size of 580 μηη, a thickness of 1, 9 mm and a weight per unit area of 1000 g / m ^{2 was added} to the suspension and again shaken vigorously. The foam thus coated was placed on a paper towel and the excess suspension was carefully dabbed off. In a rotary kiln, the thus coated foam was heated at a heating rate of 5 ° C / min to 300 ° C, then kept isothermally at 300 ° C for 30 min, further heated at 5 ° C / min to 600 ° C, for 30 min kept isothermal and further heated at 5 ° C / min to 700 ° C and kept isothermic for 30 min. The heating was carried out in a gas stream consisting of 20 NL / h nitrogen and 20 NL / h hydrogen. The cooling phase up to a temperature of 200 ° C was also in one

Gas flow from 20 NL / h N2 and 20 NL / h H2. Thereafter, nitrogen was further cooled to room temperature in a stream of 100 NL / h. The foam produced in this way had a weight increase of 42% compared to the originally used nickel foam.

Variant b):

A nickel foam with an average pore size of 580 μm, a thickness of 1.9 mm and a weight per unit area of 1000 g / m ² was poured into a 1% strength by weight polyvinylpyrrolidone solution (molecular weight: 40 000 g / mol). dipped. After immersion, the foam was squeezed out on a flow cloth to remove the binder from the voids of the pores. The foam laden with the binder was then clamped in a shaker and coated with aluminum powder (particle size <75 μηη). By shaking, a uniform distribution of the powder was obtained on the surface of the open-pore foam structure and then removed excess aluminum powder. In a rotary kiln, the thus coated foam was heated at a heating rate of 5 ° C / min to 300 ° C, then kept isothermally at 300 ° C for 30 min, further heated at 5 ° C / min to 600 ° C, for 30 min kept isothermal and further heated at 5 ° C / min to 700 ° C and kept isothermic for 30 min. The heating was carried out in a gas stream consisting of 20 NL / h nitrogen and 20 NL / h hydrogen. The cooling phase up to a temperature of 200 ° C was also carried out in a gas stream of 20 NL / h N2 and 20 NL / h H2. Thereafter, nitrogen was further cooled to room temperature in a stream of 100 NL / h. The foam produced in this way had a weight increase of 36% compared to the originally used nickel foam.

The hydrogenation of 1,4-butynediol (BID) to 1,4-butanediol (BDO) is typically carried out on an industrial scale, continuously with a recycle stream, with the BID being metered into and diluted with the recycle stream. In the following, no BID Used solutions containing more than 50 wt .-% BID in water. The aqueous Bl D feedstock was prepared according to Example 1 of EP 2 121 549 A1. The feedstock was adjusted to a pH of 7.5 with sodium hydroxide solution and contained in addition to BID and water about 1 wt .-% propynol, 1, 2 wt .-% formaldehyde and a number of other by-products with proportions of well below 1 wt. -%.

The following examples were carried out in a continuous hydrogenation apparatus consisting of a tubular reactor, a gas-liquid separator, a heat exchanger and a circulation stream with a gear pump. The catalyst charges mentioned in the examples are based on the total volume occupied by the nickel-aluminum catalyst bodies incorporated in the reactor.

Application Example 1

Step a):

A device with a tubular reactor with an internal diameter of 25 mm was used. 35 ml of a nickel-aluminum catalyst molding in the form of foam boards (prepared according to variant a)) was cut with a water jet cutter into round disks with a diameter of 25 mm. The disks were stacked and installed in the tubular reactor. So that the disks had no space in front of the reactor wall, a PTFE sealing ring was installed after every 5 disks.

Step b):

The reactor and the circulation stream were filled with demineralized water and then fed to a 0.5 wt .-% NaOH solution in the upflow mode and the fixed catalyst bed over a period of 2 hours at 25 ° C activated. The feed rate of the NaOH solution was 0.54 mL / min per mL of shaped catalyst body. The circulation rate was adjusted to 18 kg / h, so that a feed-to-circulation ratio of 1:16 was obtained. The flow rate of the aqueous base through the reactor was 37 m / h.

During activation, no active Raney nickel in the form of fine free particles was detected in the recycle stream or in the reactor effluent. Elemental analysis of the activating solution showed a nickel content of less than 1 ppm. The aluminum content in the activating solution at the beginning of the activation was about 4.1% and decreased over the activation period to 0.02%. The maximum temperature gradient of the fixed catalyst bed during activation was 8 K.

Step c):

After about 2 hours of activation, the evolution of hydrogen dropped significantly and the supply of sodium hydroxide solution was stopped and then rinsed at 40 ° C with demineralized water until a sample of circulating liquid at 20 ° C has a pH of 7.5 and had a conductivity of 1 14 με / ηηη. The flow rate of fully desalinated water was 380 mL / h at a circulatory rate of 18 kg / h, d. H. an inlet to circulation ratio of 1: 47 was obtained. The flow rate of the washing solution through the reactor was 37 m / h.

Step d):

Subsequently, an aqueous solution of 0.40 g (ΝΗ4) Μθ7θ24 x 4 H2O in 20 ml of water over a period of 1 hour at 25 ° C in trickle mode supplied. After complete addition, the liquid was recirculated for 3 hours in the circulation stream at a circulation rate of 15 kg / h.

hydrogenation:

The hydrogenation was carried out with an aqueous 50 wt .-% strength Bl D solution at 155 ° C, a hydrogen pressure of 45 bar hydrogen and a catalyst loading of 0.5 kgBiD / (Lkataiysatorformkör xh) at a cycle flow rate of 23 kg / h in upflow mode. Hydrogenation yielded 94.7% BDO, 1.7% n-butanol, 0.7% methanol, 1.8% propanol and 2000 ppm 2-methylbutane-1,4-diol in the effluent over 15 days. Subsequently, the catalyst load on

1, 0 kgBiD (Lkataiysatorformkör x x h) increased at a constant cycle flow amount. The product stream consisted of (anhydrous) 94.8% BDO, 1.7% n-butanol, 0.7% methanol, 1.4% propanol, 3200 ppm 2-methylbutan-1, 4-diol and about 1% on additional secondary components.

The shaped catalyst bodies had a molybdenum gradient, which increased in the direction of flow of the hydrogenation reaction mixture through the fixed catalyst bed over the entire reactor length of 0.54 wt .-% to 1, 0 wt .-%. Comparative Example 1 a:

Step a): A device with a tubular reactor with an internal diameter of 25 mm, as described above, was used. 35 ml_ of a nickel-aluminum catalyst shaped body in the form of foam plates (prepared according to variant a)) was cut with a water jet cutter into round disks with a diameter of 25 mm. The disks were stacked on top of each other and installed in the tubular reactor. So that the disks had no space in front of the reactor wall, a PTFE sealing ring was installed after every 5 disks.

Step b): The reactor and the circulation stream were filled with demineralized water (DI water) and then fed to a 30 wt .-% NaOH solution in the upflow mode and the fixed catalyst bed over a period of 2 hours at 100 ° C activated. The feed rate of the NaOH solution was 0.54 mL / min per mL of shaped catalyst body. The circulation rate was adjusted to 15 kg / h, so that a feed-to-circulation ratio of 1:13 was obtained. The flow rate of the aqueous base through the reactor was 31 m / h.

During activation, a significant amount of active Raney nickel in the form of fine free particles was detected in the recycle stream and in the effluent.

Step c):

After about 2 h of activation, the evolution of hydrogen dropped significantly and the supply of sodium hydroxide solution was stopped and then rinsed with demineralized water at 40 ° C. until a sample of the recirculated liquid had a pH of 7 at 20 ° C. 5 and a conductivity of 467 με / ηηη had. The flow rate of deionized water was 380 mL / h at a circulatory rate of 18 kg / h, d. H. an inlet to circulation ratio of 1: 47 was obtained. The flow rate of the washing solution through the reactor was 37 m / h.

Step d):

hydrogenation:

The hydrogenation was carried out with an aqueous 50 wt .-% strength Bl D solution at 155 ° C, a hydrogen pressure of 45 bar hydrogen and a catalyst loading of 0.3 kgBiD / (Lkataiysatorformkör xh) with a cycle flow rate of 23 kg / h in upflow mode. Hydrogenation gave 91.0% BDO, 3.6% n-butanol, 1.8% methanol, 2.2% propanol and 5500 ppm 2-methyl-butane-1,4-diol over 15 days.

Comparative Example 1 b: Step a):

35 ml of a nickel-aluminum catalyst shaped body in the form of foam sheets (prepared according to variant a)) was cut into pieces of 2 × 2 mm and introduced into the reactor likewise described in Example 1. The lower packing density led to a catalyst bed of 53 mL.

Step b):

The reactor and the recycle stream were charged with demineralized water (DI water) and then fed to a 30 wt% NaOH solution in the bulk mode and the fixed catalyst bed activated at 100 ° C over a period of 2 hours. The feed rate of the NaOH solution was 0.54 mL / min per mL of shaped catalyst body. The circulation rate was adjusted to 15 kg / h, so that a feed-to-circulation ratio of 1:13 was obtained. The flow rate of the aqueous base through the reactor was 31 m / h.

During activation, a large amount of active Raney nickel in the form of fine free particles was detected in the recycle stream and in the effluent. Over the activation period, the amounts of nickel in the recycle stream decreased from 300 ppm to 10 ppm and the amount of aluminum in the recycle stream decreased from 3.7% to 220 ppm. Step c):

After about 2 h of activation, the evolution of hydrogen dropped significantly and the supply of sodium hydroxide solution was stopped and then rinsed with demineralized water at 40 ° C. until a sample of the recirculated liquid had a pH of 7 at 20 ° C. 5 and a conductivity of 653 με / οηη had. The flow rate of deionized water was 380 mL / h at a circulatory rate of 15 kg / h, d. H. an inlet to circulation ratio of 1:37 was obtained. The flow rate of the washing solution through the reactor was 37 m / h.

Step d):

Subsequently, an aqueous solution of 0.40 g (ΝΗ4) Μθ7θ24 x 4 H2O in 20 ml of water within 1 hour at 25 ° C in trickle mode supplied. After complete addition, the liquid was recirculated for 3 hours in the circulation stream at a circulation rate of 15 kg / h.

Hydrogenation: The hydrogenation was carried out with an aqueous 50% strength by weight BlD solution at 155 ° C., a hydrogen pressure of 45 bar hydrogen and a catalyst loading of 0.3 kgBiD / (Lkataiysatorformkör xh) with a cycle flow rate of 23 kg / h in the swamp way. Hydrogenation gave 88.5% BDO, 1.3% 2-butene-1, 4-diol, 6.0% n-butanol, 0.8% methanol, 0.5% propanol and 7600 over 2 days ppm 2-methylbutane-1,4-diol. Complete conversion was only at a reduced catalyst loading of 0.17 kg of BdD (catalytic converter xh) with 91.6% BDO, 5.5% n-butanol, 0.9% methanol, 0.7% propanol and 4500 ppm 2-methylbutane -1, 4-diol achieved.

The removed catalyst moldings after hydrogenation showed a gradient of molybdenum which increased in the direction of flow of the hydrogenation reaction mixture through the fixed catalyst bed over the entire reactor length from 0.4% by weight to 0.9% by weight.

Comparative Example 1 c)

The steps a) to c) were carried out analogously to Example 1. Step d):

The catalyst was removed under argon atmosphere from the tube reactor again and filled the catalyst plates in a metal basket. The metal basket with the catalyst plates was placed in a stirred vessel with 400 ml of demineralized water. Thereafter, an aqueous solution of 0.40 g (ΝΗ4) Μθ7θ24 x 4 H2O in 20 ml of water was added and stirred for 3 hours at 25 ° C. Thereafter, the catalyst was re-installed under argon atmosphere in the tube reactor. hydrogenation:

The hydrogenation was carried out with an aqueous 50 wt .-% strength Bl D solution at 155 ° C, a hydrogen pressure of 45 bar hydrogen and a catalyst loading of 0.5 kgBiD (Lkataiysatorformkör xh) at a circulation rate of 23 kg / h in the upflow mode , The hydrogenation yielded 93.8% BDO, 2.1% n-butanol, 1.2% methanol, 1.8% propanol, and 3500 ppm 2-methyl-butane-1, 4-diol in the effluent over 15 days.

The catalyst bodies had a molybdenum content of 0.6%, which was homogeneously distributed over the catalyst bed.

Application Example 2:

Step a):

A device with a tubular reactor with an internal diameter of 25 mm was used. 600 ml of a nickel-aluminum catalyst molding in the form of foam boards (prepared according to variant a)) was cut with a water jet cutter into round disks with a diameter of 25 mm. The disks were stacked and installed in the tubular reactor. So that the disks had no space in front of the reactor wall, a PTFE sealing ring was installed after every 5 disks.

Step b):

The reactor and the recycle stream were charged with demineralized water (DI water) and then fed to a 0.5 wt% NaOH solution in the bulk mode and the fixed catalyst bed activated at 25 ° C over a period of 7 hours. The feed rate of the NaOH solution was 0.14 ml / min per mL of catalyst molding. by. The circulation rate was adjusted to 19 kg / h, so that a feed-to-circulation ratio of 1: 4 was obtained. The flow rate of the aqueous base through the reactor was 39 m / h. The maximum temperature gradient of the fixed catalyst bed, measured between reactor inlet and reactor outlet during the activation was 15 K.

During activation, no active Raney nickel in the form of fine free particles was detected in the recycle stream or in the reactor effluent. Elemental analysis of the activating solution showed a nickel content of less than 1 ppm. The aluminum content in the activation solution was about 4.5% at the beginning of the activation and decreased to 0.7% over the activation period.

Step c): After 7 h of activation, the evolution of hydrogen dropped significantly and the supply of sodium hydroxide solution was stopped and then rinsed at 40 ° C demineralized water until a sample of recirculated liquid at 20 ° C has a pH of 7.5 and had a conductivity of 5 με / ηηη. The flow rate of deionized water was 1 L / h at a circulation rate of 15 kg / h, d. H. an inlet to circulation ratio of 1:15 was obtained. The flow rate of the washing solution through the reactor was 31 m / h.

Step d): Subsequently, an aqueous solution of 6.86 g (ΝΗ4) Μθ7θ24 x 4 H2O in 300 ml of water over a period of 7 hours at 25 ° C in trickle mode supplied. After complete addition, the liquid was recirculated overnight in the circulation stream at a circulation rate of 15 kg / h. hydrogenation:

The hydrogenation was carried out with an aqueous 50 wt .-% strength Bl D solution at 155 ° C, a hydrogen pressure of 45 bar hydrogen and different catalyst loads and cycle flow amounts, as shown in Table 1. The CO concentrations are given in vol. Ppm at the reactor inlet and outlet. Table 1 :

5 BDO = 1, 4-butanediol

MeOH = methanol

BuOH = n-butanol

PrOH = n-propanol

MBDO = 2-methylbutane-1, 4-diol

10 BED = 2-butene-1, 4-diol

The expanded catalyst bodies exhibited, after hydrogenation, a molybdenum gradient of 0.4% by weight to 1.0% by weight in the flow direction over the entire reactor length.

Application Example 3

Steps a) - d):

Analogously to Application Example 1, 35 ml of a nickel-aluminum catalyst molding (prepared according to variant b)) were introduced into a tubular reactor having an internal diameter of 25 mm, activated and washed with demineralized water. During the doping, in turn, an aqueous solution of 0.40 g (ΝΗ4) Μθ7θ24 x 4 H2O in 20 mL of water was added over a period of 1 hour at 25 ° C and pumped in the circulation in the upflow mode. Thereby, a molybdenum gradient was obtained, which decreases in the flow direction of the reaction mixture of the hydrogenation through the fixed catalyst bed. After complete addition, the liquid was recirculated for 3 hours in the circulation at a circulation rate of 15 kg / h.

hydrogenation:

The hydrogenation of undiluted n-butyraldehyde (n-BA) was carried out at 140 ° C, 40 bar hydrogen pressure and a catalyst loading of 1, 5 kg _n -BA / (Lkataiysatorformkör xh) performed with a loop rate of 23 kg / h in the upflow mode. Hydrogenation afforded 99.6% n-butanol, 0.08% butyl acetate, 0.01% dibutyl ether, 0.01% butyl butyrate, 0.07% ethylhexanediol and 0.03% acetal over a period of 8 days. The expanded catalyst moldings after hydrogenation showed a molybdenum gradient which decreased in the direction of flow of the hydrogenation reaction mixture through the fixed catalyst bed over the entire reactor length from 1.0% by weight to 0.3% by weight.

Claims

claims

1 . Process for activating a fixed catalyst bed containing monolithic shaped catalyst bodies or consisting of monolithic shaped catalyst bodies containing at least one first metal selected from Ni, Fe, Co,

Process for providing a reactor comprising an activated fixed catalyst bed in which a fixed catalyst bed containing monolithic shaped catalyst bodies or consisting of monolithic shaped catalyst bodies containing at least one first metal selected from Ni, Fe, Co, Cu, is placed in a reactor Cr, Pt, Ag, Au and Pd, and containing at least one second component selected from Al, Zn and Si, the catalyst fixed bed for activating a treatment with a maximum of 3.5 wt .-% aqueous base subjected, the base is selected from alkali metal hydroxides, alkaline earth metal hydroxides and mixtures thereof, and wherein the fixed catalyst bed has a temperature gradient and the temperature difference between the coldest point of the fixed catalyst bed and the warmest point of the fixed catalyst bed is kept at a maximum of 50 K, the activated fixed catalyst bed obtained in step b) Behan subjected to treatment with a washing medium which is selected from water, Ci-C4-alkanols and mixtures thereof, optionally the catalyst fixed bed during and / or after the treatment in step c) brings into contact with a dopant having at least one promoter element, which of the first metal and the second component of the catalyst molding used in step a) is different.

3. The method according to any one of the preceding claims, wherein the monolithic shaped catalyst bodies used, based on the entire shaped body, a smallest dimension in a direction of at least 1 cm, preferably at least 2 cm, in particular at least 5 cm.

Method according to one of the preceding claims, wherein the aqueous base used for activation is at least partially guided in a liquid circulation stream.

The process of claim 4, wherein in addition to the base carried in the liquid recycle stream, fresh aqueous base is added to the fixed catalyst bed, wherein the ratio of recycle-passed aqueous base to freshly added aqueous base is in the range of 1: 1 to 1000: 1 from 2: 1 to 500: 1, especially from 5: 1 to 200: 1.

Method according to one of claims 1 to 5, wherein the feed rate of the aqueous base at most 5 L / min per liter of fixed catalyst bed, preferably at most 1, 5 L / min per liter of fixed catalyst bed, more preferably at most 1 L / min per liter of fixed catalyst bed, based on the Total volume of the fixed catalyst bed, is.

Method according to one of the preceding claims, wherein the temperature difference between the coldest point of the fixed catalyst bed and the warmest point of the fixed catalyst bed at a maximum of 40 K, preferably at a maximum of 25 K, is maintained.

Method according to one of the preceding claims, wherein the monolithic shaped catalyst bodies are in the form of a foam.

Method according to one of the preceding claims, wherein to provide the monolithic shaped catalyst bodies: a1) provides a metal foam molded body containing at least one first metal selected from Ni, Fe, Co, Cu, Cr, Pt, Ag, Au and Pd, a2) applies to the surface of the metal foam molding at least a second component containing an element selected from Al, Zn and Si, and a3) by alloying the metal foam molding obtained in step a2) at least on a part of the surface forms an alloy.

Method according to one of the preceding claims, wherein the first metal contains Ni or consists of Ni and wherein the second component contains Al or consists of Al. Method according to one of claims 2 to 10, wherein the monolithic shaped catalyst bodies used for activation already have at least one promoter element, and / or

the catalyst fixed bed is brought into contact with a dopant during and / or after the treatment with a washing medium in step c), which has at least one promoter element.

A process according to any one of claims 2 to 11, wherein the fixed catalyst bed contains Ni / Al shaped catalyst bodies or consists of Ni / Al shaped catalyst bodies doped with Mo, and wherein the fixed catalyst bed has a gradient with respect to the Mo concentration in the flow direction.

Process for the hydrogenation of hydrogenatable organic compounds, in particular of organic compounds which have at least one carbon-carbon double bond, carbon-nitrogen double bond, carbon-oxygen double bond, carbon-carbon triple bond, carbon-nitrogen triple bond or nitrogen-oxygen Having double bond, in the presence of an activated fixed catalyst bed, obtainable by a method as defined in any one of claims 1 to 12.

A process as claimed in claim 13 for the hydrogenation of 1,4-butynediol to give 1,4-butanediol or for the hydrogenation of 4-butyraldehyde to give n-butanol.

15. The method according to any one of claims 13 or 14, wherein the hydrogenation is carried out according to the inventive method in the presence of CO.