JP2014534902A5 - - Google Patents

Claims (32)

A method for producing a supported catalyst, comprising:
The method is as follows:
(I) a porous catalyst support comprising a framework having an internal pore structure containing one or more pores, steps internal pore structure to provide a porous catalyst support containing a basic precipitating agent;
(Ii) the catalytic support in a dried form so that the particles containing the catalytically active metal precipitate in the internal pore structure of the framework of the catalytic support upon contact with the precipitant; step of contacting a solution or colloidal suspension containing
A method comprising the steps of:   The process of claim 1 wherein the catalyst support is an oxide.   The method of claim 1 or 2, wherein the internal pore structure has one or more regions or "cages" accessible through pores or "windows" of smaller diameter sections. 4. The method of claim 3, wherein the particles comprising the catalytically active metal have a larger effective diameter than the pores of the smaller diameter section.   The method according to any one of claims 1 to 4, wherein the pore diameter or the diameter of the pore "window" is greater than 0.2 nm.   6. The process as claimed in claim 1, wherein the catalyst support has a zeotype structure.   The process of claim 6 wherein the catalyst support is an aluminosilicate zeolite.   8. The process of claim 7, wherein the aluminosilicate zeolite has a silicon to aluminum molar ratio of less than 10, for example in the range of 2-5.   9. The process as claimed in claim 1, wherein the catalyst support framework adopts a FAU, BEA or MWW structure according to the International Zeolite Society database of zeolite structure.   10. The method of any one of claims 1 to 9, wherein the catalyst support comprises a negatively charged framework that is equilibrated by one or more charge balancing cations.   11. The method of claim 10, wherein the charge balancing cation is selected from alkali metal or alkaline earth metal cations, preferably potassium.   12. The method of claim 10 or 11, wherein the framework charge balancing cations can act as promoters or cocatalysts.   13. A process according to claim 11 or 12, wherein the precipitating agent comprises the same cation as the charge balancing cation and the total content of cations in the supported catalyst is greater than the total ion exchange capacity of the catalyst support. The catalytically active metal is one or more elements selected from the group consisting of nickel, cobalt, iron, ruthenium, osmium, platinum, iridium, rhenium, molybdenum, chromium, tungsten, vanadium, rhodium, and manganese. Item 14. The method according to any one of Items 1 to 13 . In addition, the catalyst support is a solution or colloidal suspension comprising one or more metals selected from the group consisting of yttrium, lanthanum, cerium, and any other lanthanide metal that also forms part of the catalytically active metal-containing particles. 15. The method of claim 14 , comprising contacting with a suspension. The method further comprises contacting the catalyst support with one or more elements selected from the group consisting of copper, zinc, gallium, zirconium, and palladium that also form part of the catalytically active metal-containing particles. 14 or 15 methods. The catalyst support The resulting material comprises a catalytically active metal-containing particles were calcined in air may be carried out as appropriate after drying the resulting material, including the further step, The process of any one of claims 1-16 . The method according to any one of claims 1 to 17 , wherein the particles containing a catalytically active metal have a crystal structure. 19. The method of claim 18 , wherein the particles comprising the catalytically active metal have a spinel or perovskite structure. The method according to any one of claims 1 to 19 , wherein the structure of the particles containing the catalytically active metal contains a cation vacancy. 21. The method of claim 20 , wherein the particles comprising the catalytically active metal interact electrostatically with the charge balancing cations of the catalyst support framework. The method according to any one of claims 1 to 21 , wherein the supported catalyst comprises Fe, Cu, K. 23. A process as claimed in any one of claims 1 to 22 , comprising the further step of chemically reducing the catalytically active metal-containing particles, for example in the presence of hydrogen gas at an elevated temperature. Precipitating agent is initially charged in the interior pore structure of the catalyst support framework, The method of any one of claims 1 to 23. 25. A process according to any one of claims 1 to 24 , wherein the precipitating agent is a carbonate or bicarbonate, for example potassium carbonate or potassium bicarbonate. Catalyst support, with the incipient wetness impregnation method, is contacted with a solution or colloidal suspension containing the catalytically active metal, process of any one of claims 1 to 25. 27. A method according to any one of claims 1 to 26 , wherein the catalyst support is contacted with a solution of catalytically active metal. 28. A process according to any one of claims 1 to 27 , wherein the supported catalyst is a Fischer-Tropsch catalyst. A supported catalyst produced by the method according to any one of claims 1 to 28 . 30. Use of the supported catalyst of claim 29 as a catalyst in a catalytic chemical process. 31. Use according to claim 30 , wherein the catalytic chemical process is a Fischer-Tropsch process. 30. A process for producing one or more hydrocarbons from one or more carbon oxides and hydrogen, wherein one or more carbon oxides are contacted with hydrogen in the presence of the catalyst of claim 29 .