US20210253505A1 - Catalyst for hydrogenation of carbonyl compound and alcohol production method - Google Patents
Catalyst for hydrogenation of carbonyl compound and alcohol production method Download PDFInfo
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- US20210253505A1 US20210253505A1 US17/237,134 US202117237134A US2021253505A1 US 20210253505 A1 US20210253505 A1 US 20210253505A1 US 202117237134 A US202117237134 A US 202117237134A US 2021253505 A1 US2021253505 A1 US 2021253505A1
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- 239000003054 catalyst Substances 0.000 title claims abstract description 437
- 238000005984 hydrogenation reaction Methods 0.000 title claims abstract description 85
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 58
- 150000001728 carbonyl compounds Chemical class 0.000 title claims abstract description 45
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 title abstract description 104
- 229910052751 metal Inorganic materials 0.000 claims abstract description 237
- 239000002184 metal Substances 0.000 claims abstract description 224
- 229910052702 rhenium Inorganic materials 0.000 claims abstract description 95
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 claims abstract description 87
- 229910052732 germanium Inorganic materials 0.000 claims abstract description 55
- 230000000737 periodic effect Effects 0.000 claims abstract description 55
- GNPVGFCGXDBREM-UHFFFAOYSA-N germanium atom Chemical compound [Ge] GNPVGFCGXDBREM-UHFFFAOYSA-N 0.000 claims abstract description 49
- 229910052738 indium Inorganic materials 0.000 claims abstract description 25
- APFVFJFRJDLVQX-UHFFFAOYSA-N indium atom Chemical compound [In] APFVFJFRJDLVQX-UHFFFAOYSA-N 0.000 claims abstract description 24
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 22
- 239000010703 silicon Substances 0.000 claims abstract description 22
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 20
- GYHNNYVSQQEPJS-UHFFFAOYSA-N Gallium Chemical compound [Ga] GYHNNYVSQQEPJS-UHFFFAOYSA-N 0.000 claims abstract description 18
- 229910052733 gallium Inorganic materials 0.000 claims abstract description 18
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 136
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 claims description 120
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 108
- 238000000034 method Methods 0.000 claims description 77
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 76
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 claims description 76
- 229910052742 iron Inorganic materials 0.000 claims description 54
- 239000000463 material Substances 0.000 claims description 46
- 229910052759 nickel Inorganic materials 0.000 claims description 38
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims description 27
- 229910001928 zirconium oxide Inorganic materials 0.000 claims description 27
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 claims description 24
- 229910052707 ruthenium Inorganic materials 0.000 claims description 24
- 230000001590 oxidative effect Effects 0.000 claims description 18
- 238000006243 chemical reaction Methods 0.000 abstract description 136
- YJCJVMMDTBEITC-UHFFFAOYSA-N 10-hydroxycapric acid Chemical compound OCCCCCCCCCC(O)=O YJCJVMMDTBEITC-UHFFFAOYSA-N 0.000 description 106
- 239000002245 particle Substances 0.000 description 77
- 238000006722 reduction reaction Methods 0.000 description 66
- 150000002739 metals Chemical class 0.000 description 63
- MWKFXSUHUHTGQN-UHFFFAOYSA-N decan-1-ol Chemical compound CCCCCCCCCCO MWKFXSUHUHTGQN-UHFFFAOYSA-N 0.000 description 60
- 230000003197 catalytic effect Effects 0.000 description 58
- FOTKYAAJKYLFFN-UHFFFAOYSA-N decane-1,10-diol Chemical compound OCCCCCCCCCCO FOTKYAAJKYLFFN-UHFFFAOYSA-N 0.000 description 57
- ZWRUINPWMLAQRD-UHFFFAOYSA-N nonan-1-ol Chemical compound CCCCCCCCCO ZWRUINPWMLAQRD-UHFFFAOYSA-N 0.000 description 54
- 230000009467 reduction Effects 0.000 description 49
- 239000007789 gas Substances 0.000 description 45
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 44
- 150000001732 carboxylic acid derivatives Chemical class 0.000 description 43
- 239000006227 byproduct Substances 0.000 description 37
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 34
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 33
- 229910052804 chromium Inorganic materials 0.000 description 33
- 239000011651 chromium Substances 0.000 description 33
- 239000002994 raw material Substances 0.000 description 31
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 31
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 30
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 30
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 30
- 239000001301 oxygen Substances 0.000 description 30
- GHVNFZFCNZKVNT-UHFFFAOYSA-N decanoic acid Chemical compound CCCCCCCCCC(O)=O GHVNFZFCNZKVNT-UHFFFAOYSA-N 0.000 description 29
- 230000000694 effects Effects 0.000 description 28
- FBUKVWPVBMHYJY-UHFFFAOYSA-N nonanoic acid Chemical compound CCCCCCCCC(O)=O FBUKVWPVBMHYJY-UHFFFAOYSA-N 0.000 description 27
- 238000002360 preparation method Methods 0.000 description 27
- 230000002829 reductive effect Effects 0.000 description 27
- 239000005968 1-Decanol Substances 0.000 description 26
- 239000002253 acid Substances 0.000 description 26
- 150000001875 compounds Chemical class 0.000 description 26
- 239000000243 solution Substances 0.000 description 26
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 25
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 24
- 239000002904 solvent Substances 0.000 description 23
- 229910052760 oxygen Inorganic materials 0.000 description 22
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 21
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 21
- 239000012298 atmosphere Substances 0.000 description 21
- 229910052717 sulfur Inorganic materials 0.000 description 21
- 239000011593 sulfur Substances 0.000 description 21
- 239000001257 hydrogen Substances 0.000 description 20
- 229910052739 hydrogen Inorganic materials 0.000 description 20
- -1 iron and nickel Chemical class 0.000 description 19
- 239000000047 product Substances 0.000 description 19
- 238000007086 side reaction Methods 0.000 description 19
- 238000004458 analytical method Methods 0.000 description 18
- 230000000052 comparative effect Effects 0.000 description 18
- 230000006641 stabilisation Effects 0.000 description 17
- 238000011105 stabilization Methods 0.000 description 17
- 229910052763 palladium Inorganic materials 0.000 description 16
- GXMNGLIMQIPFEB-UHFFFAOYSA-N tetraethoxygermane Chemical compound CCO[Ge](OCC)(OCC)OCC GXMNGLIMQIPFEB-UHFFFAOYSA-N 0.000 description 15
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 14
- 230000018044 dehydration Effects 0.000 description 14
- 238000006297 dehydration reaction Methods 0.000 description 14
- 229910052750 molybdenum Inorganic materials 0.000 description 14
- 239000011733 molybdenum Substances 0.000 description 14
- 229910000510 noble metal Inorganic materials 0.000 description 14
- 239000007795 chemical reaction product Substances 0.000 description 13
- 238000006555 catalytic reaction Methods 0.000 description 12
- YBMRDBCBODYGJE-UHFFFAOYSA-N germanium oxide Inorganic materials O=[Ge]=O YBMRDBCBODYGJE-UHFFFAOYSA-N 0.000 description 12
- 229910052697 platinum Inorganic materials 0.000 description 12
- 229910017052 cobalt Inorganic materials 0.000 description 11
- 239000010941 cobalt Substances 0.000 description 11
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 11
- 238000002354 inductively-coupled plasma atomic emission spectroscopy Methods 0.000 description 11
- 229910052741 iridium Inorganic materials 0.000 description 11
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 description 11
- 238000001479 atomic absorption spectroscopy Methods 0.000 description 10
- 238000001514 detection method Methods 0.000 description 10
- 230000008569 process Effects 0.000 description 10
- 150000003839 salts Chemical class 0.000 description 10
- 238000010438 heat treatment Methods 0.000 description 9
- 238000001095 inductively coupled plasma mass spectrometry Methods 0.000 description 9
- 229910052757 nitrogen Inorganic materials 0.000 description 9
- 229910052703 rhodium Inorganic materials 0.000 description 9
- 239000010948 rhodium Substances 0.000 description 9
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 9
- 150000001735 carboxylic acids Chemical class 0.000 description 8
- 230000007797 corrosion Effects 0.000 description 8
- 238000005260 corrosion Methods 0.000 description 8
- DIOQZVSQGTUSAI-UHFFFAOYSA-N decane Chemical compound CCCCCCCCCC DIOQZVSQGTUSAI-UHFFFAOYSA-N 0.000 description 8
- 229910001873 dinitrogen Inorganic materials 0.000 description 8
- 229910001882 dioxygen Inorganic materials 0.000 description 8
- 238000005886 esterification reaction Methods 0.000 description 8
- 230000000670 limiting effect Effects 0.000 description 8
- 229910044991 metal oxide Inorganic materials 0.000 description 8
- 150000004706 metal oxides Chemical class 0.000 description 8
- BKIMMITUMNQMOS-UHFFFAOYSA-N nonane Chemical compound CCCCCCCCC BKIMMITUMNQMOS-UHFFFAOYSA-N 0.000 description 8
- 238000000746 purification Methods 0.000 description 8
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 7
- 150000001733 carboxylic acid esters Chemical class 0.000 description 7
- 229910052802 copper Inorganic materials 0.000 description 7
- 239000010949 copper Substances 0.000 description 7
- 238000006114 decarboxylation reaction Methods 0.000 description 7
- 238000006731 degradation reaction Methods 0.000 description 7
- 239000011261 inert gas Substances 0.000 description 7
- CXMXRPHRNRROMY-UHFFFAOYSA-N sebacic acid Chemical compound OC(=O)CCCCCCCCC(O)=O CXMXRPHRNRROMY-UHFFFAOYSA-N 0.000 description 7
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 6
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 6
- 229910052586 apatite Inorganic materials 0.000 description 6
- BVKZGUZCCUSVTD-UHFFFAOYSA-N carbonic acid Chemical compound OC(O)=O BVKZGUZCCUSVTD-UHFFFAOYSA-N 0.000 description 6
- 239000012295 chemical reaction liquid Substances 0.000 description 6
- 239000003795 chemical substances by application Substances 0.000 description 6
- VSIIXMUUUJUKCM-UHFFFAOYSA-D pentacalcium;fluoride;triphosphate Chemical compound [F-].[Ca+2].[Ca+2].[Ca+2].[Ca+2].[Ca+2].[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O.[O-]P([O-])([O-])=O VSIIXMUUUJUKCM-UHFFFAOYSA-D 0.000 description 6
- 229910001925 ruthenium oxide Inorganic materials 0.000 description 6
- YBCAZPLXEGKKFM-UHFFFAOYSA-K ruthenium(iii) chloride Chemical compound [Cl-].[Cl-].[Cl-].[Ru+3] YBCAZPLXEGKKFM-UHFFFAOYSA-K 0.000 description 6
- 239000007858 starting material Substances 0.000 description 6
- 238000003860 storage Methods 0.000 description 6
- 239000000758 substrate Substances 0.000 description 6
- LLZRNZOLAXHGLL-UHFFFAOYSA-J titanic acid Chemical compound O[Ti](O)(O)O LLZRNZOLAXHGLL-UHFFFAOYSA-J 0.000 description 6
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 6
- 229910052721 tungsten Inorganic materials 0.000 description 6
- 239000010937 tungsten Substances 0.000 description 6
- OFOBLEOULBTSOW-UHFFFAOYSA-N Malonic acid Chemical compound OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 5
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 5
- 239000000654 additive Substances 0.000 description 5
- 125000003158 alcohol group Chemical group 0.000 description 5
- 150000001299 aldehydes Chemical class 0.000 description 5
- BFNBIHQBYMNNAN-UHFFFAOYSA-N ammonium sulfate Chemical compound N.N.OS(O)(=O)=O BFNBIHQBYMNNAN-UHFFFAOYSA-N 0.000 description 5
- 229910052921 ammonium sulfate Inorganic materials 0.000 description 5
- 235000011130 ammonium sulphate Nutrition 0.000 description 5
- 150000001244 carboxylic acid anhydrides Chemical class 0.000 description 5
- 239000000969 carrier Substances 0.000 description 5
- 239000000567 combustion gas Substances 0.000 description 5
- 238000001035 drying Methods 0.000 description 5
- 230000006698 induction Effects 0.000 description 5
- 239000007791 liquid phase Substances 0.000 description 5
- 229910021645 metal ion Inorganic materials 0.000 description 5
- YQCIWBXEVYWRCW-UHFFFAOYSA-N methane;sulfane Chemical compound C.S YQCIWBXEVYWRCW-UHFFFAOYSA-N 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- 238000007254 oxidation reaction Methods 0.000 description 5
- 239000007787 solid Substances 0.000 description 5
- 229910052719 titanium Inorganic materials 0.000 description 5
- 239000010936 titanium Substances 0.000 description 5
- IVORCBKUUYGUOL-UHFFFAOYSA-N 1-ethynyl-2,4-dimethoxybenzene Chemical compound COC1=CC=C(C#C)C(OC)=C1 IVORCBKUUYGUOL-UHFFFAOYSA-N 0.000 description 4
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- XTHFKEDIFFGKHM-UHFFFAOYSA-N Dimethoxyethane Chemical compound COCCOC XTHFKEDIFFGKHM-UHFFFAOYSA-N 0.000 description 4
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 4
- WYURNTSHIVDZCO-UHFFFAOYSA-N Tetrahydrofuran Chemical compound C1CCOC1 WYURNTSHIVDZCO-UHFFFAOYSA-N 0.000 description 4
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 4
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 4
- 239000003377 acid catalyst Substances 0.000 description 4
- 230000000996 additive effect Effects 0.000 description 4
- 230000002411 adverse Effects 0.000 description 4
- 229910052782 aluminium Inorganic materials 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- ROOXNKNUYICQNP-UHFFFAOYSA-N ammonium persulfate Chemical compound [NH4+].[NH4+].[O-]S(=O)(=O)OOS([O-])(=O)=O ROOXNKNUYICQNP-UHFFFAOYSA-N 0.000 description 4
- AYJRCSIUFZENHW-UHFFFAOYSA-L barium carbonate Chemical compound [Ba+2].[O-]C([O-])=O AYJRCSIUFZENHW-UHFFFAOYSA-L 0.000 description 4
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 4
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 4
- 125000004432 carbon atom Chemical group C* 0.000 description 4
- 125000002915 carbonyl group Chemical group [*:2]C([*:1])=O 0.000 description 4
- 229910000420 cerium oxide Inorganic materials 0.000 description 4
- 239000013065 commercial product Substances 0.000 description 4
- 230000007423 decrease Effects 0.000 description 4
- 238000004821 distillation Methods 0.000 description 4
- 238000010828 elution Methods 0.000 description 4
- 238000004817 gas chromatography Methods 0.000 description 4
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 4
- 229910052737 gold Inorganic materials 0.000 description 4
- 239000010931 gold Substances 0.000 description 4
- MRELNEQAGSRDBK-UHFFFAOYSA-N lanthanum(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[La+3].[La+3] MRELNEQAGSRDBK-UHFFFAOYSA-N 0.000 description 4
- 239000007788 liquid Substances 0.000 description 4
- 229910052749 magnesium Inorganic materials 0.000 description 4
- 239000011777 magnesium Substances 0.000 description 4
- 229910052748 manganese Inorganic materials 0.000 description 4
- 239000011572 manganese Substances 0.000 description 4
- 229910000000 metal hydroxide Inorganic materials 0.000 description 4
- 150000004692 metal hydroxides Chemical class 0.000 description 4
- 238000002156 mixing Methods 0.000 description 4
- 238000006386 neutralization reaction Methods 0.000 description 4
- 229910052758 niobium Inorganic materials 0.000 description 4
- 239000010955 niobium Substances 0.000 description 4
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 4
- 229910000484 niobium oxide Inorganic materials 0.000 description 4
- URLJKFSTXLNXLG-UHFFFAOYSA-N niobium(5+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[Nb+5].[Nb+5] URLJKFSTXLNXLG-UHFFFAOYSA-N 0.000 description 4
- 230000003647 oxidation Effects 0.000 description 4
- BMMGVYCKOGBVEV-UHFFFAOYSA-N oxo(oxoceriooxy)cerium Chemical compound [Ce]=O.O=[Ce]=O BMMGVYCKOGBVEV-UHFFFAOYSA-N 0.000 description 4
- 230000035484 reaction time Effects 0.000 description 4
- 229910052814 silicon oxide Inorganic materials 0.000 description 4
- 238000001179 sorption measurement Methods 0.000 description 4
- 239000012798 spherical particle Substances 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- KDYFGRWQOYBRFD-UHFFFAOYSA-N succinic acid Chemical compound OC(=O)CCC(O)=O KDYFGRWQOYBRFD-UHFFFAOYSA-N 0.000 description 4
- YLQBMQCUIZJEEH-UHFFFAOYSA-N tetrahydrofuran Natural products C=1C=COC=1 YLQBMQCUIZJEEH-UHFFFAOYSA-N 0.000 description 4
- VXUYXOFXAQZZMF-UHFFFAOYSA-N titanium(IV) isopropoxide Chemical compound CC(C)O[Ti](OC(C)C)(OC(C)C)OC(C)C VXUYXOFXAQZZMF-UHFFFAOYSA-N 0.000 description 4
- 238000004876 x-ray fluorescence Methods 0.000 description 4
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- WFDIJRYMOXRFFG-UHFFFAOYSA-N Acetic anhydride Chemical compound CC(=O)OC(C)=O WFDIJRYMOXRFFG-UHFFFAOYSA-N 0.000 description 3
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 3
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 3
- MUBZPKHOEPUJKR-UHFFFAOYSA-N Oxalic acid Chemical compound OC(=O)C(O)=O MUBZPKHOEPUJKR-UHFFFAOYSA-N 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 3
- 125000001931 aliphatic group Chemical group 0.000 description 3
- 150000003863 ammonium salts Chemical class 0.000 description 3
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 description 3
- 238000011049 filling Methods 0.000 description 3
- 150000004820 halides Chemical class 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 description 3
- 229910052500 inorganic mineral Inorganic materials 0.000 description 3
- 238000004255 ion exchange chromatography Methods 0.000 description 3
- 150000002596 lactones Chemical class 0.000 description 3
- 239000011707 mineral Substances 0.000 description 3
- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical compound CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 3
- 125000000962 organic group Chemical group 0.000 description 3
- 229910052725 zinc Inorganic materials 0.000 description 3
- 239000011701 zinc Substances 0.000 description 3
- GYSCBCSGKXNZRH-UHFFFAOYSA-N 1-benzothiophene-2-carboxamide Chemical compound C1=CC=C2SC(C(=O)N)=CC2=C1 GYSCBCSGKXNZRH-UHFFFAOYSA-N 0.000 description 2
- LCPVQAHEFVXVKT-UHFFFAOYSA-N 2-(2,4-difluorophenoxy)pyridin-3-amine Chemical compound NC1=CC=CN=C1OC1=CC=C(F)C=C1F LCPVQAHEFVXVKT-UHFFFAOYSA-N 0.000 description 2
- WXUAQHNMJWJLTG-UHFFFAOYSA-N 2-methylbutanedioic acid Chemical compound OC(=O)C(C)CC(O)=O WXUAQHNMJWJLTG-UHFFFAOYSA-N 0.000 description 2
- YEJRWHAVMIAJKC-UHFFFAOYSA-N 4-Butyrolactone Chemical compound O=C1CCCO1 YEJRWHAVMIAJKC-UHFFFAOYSA-N 0.000 description 2
- NOEGNKMFWQHSLB-UHFFFAOYSA-N 5-hydroxymethylfurfural Chemical compound OCC1=CC=C(C=O)O1 NOEGNKMFWQHSLB-UHFFFAOYSA-N 0.000 description 2
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- NLXLAEXVIDQMFP-UHFFFAOYSA-N Ammonia chloride Chemical compound [NH4+].[Cl-] NLXLAEXVIDQMFP-UHFFFAOYSA-N 0.000 description 2
- 229910052582 BN Inorganic materials 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 2
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 2
- WKBOTKDWSSQWDR-UHFFFAOYSA-N Bromine atom Chemical compound [Br] WKBOTKDWSSQWDR-UHFFFAOYSA-N 0.000 description 2
- FERIUCNNQQJTOY-UHFFFAOYSA-N Butyric acid Chemical compound CCCC(O)=O FERIUCNNQQJTOY-UHFFFAOYSA-N 0.000 description 2
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Classifications
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- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/16—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
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- B01J21/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
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- B01J21/066—Zirconium or hafnium; Oxides or hydroxides thereof
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- B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
- B01J23/54—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
- B01J23/56—Platinum group metals
- B01J23/64—Platinum group metals with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
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- B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
- B01J23/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
- B01J23/84—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36 with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
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- B01J27/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
- B01J27/02—Sulfur, selenium or tellurium; Compounds thereof
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- B01J37/18—Reducing with gases containing free hydrogen
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- C07C29/00—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
- C07C29/132—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group
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- C07C29/136—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH
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- C07C29/132—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group
- C07C29/136—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH
- C07C29/14—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH of a —CHO group
- C07C29/141—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH of a —CHO group with hydrogen or hydrogen-containing gases
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- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
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- C07C29/132—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group
- C07C29/136—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH
- C07C29/147—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH of carboxylic acids or derivatives thereof
- C07C29/149—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH of carboxylic acids or derivatives thereof with hydrogen or hydrogen-containing gases
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- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C31/00—Saturated compounds having hydroxy or O-metal groups bound to acyclic carbon atoms
- C07C31/02—Monohydroxylic acyclic alcohols
- C07C31/125—Monohydroxylic acyclic alcohols containing five to twenty-two carbon atoms
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- C—CHEMISTRY; METALLURGY
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- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C31/00—Saturated compounds having hydroxy or O-metal groups bound to acyclic carbon atoms
- C07C31/18—Polyhydroxylic acyclic alcohols
- C07C31/20—Dihydroxylic alcohols
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- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C51/00—Preparation of carboxylic acids or their salts, halides or anhydrides
- C07C51/347—Preparation of carboxylic acids or their salts, halides or anhydrides by reactions not involving formation of carboxyl groups
- C07C51/367—Preparation of carboxylic acids or their salts, halides or anhydrides by reactions not involving formation of carboxyl groups by introduction of functional groups containing oxygen only in singly bound form
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C59/00—Compounds having carboxyl groups bound to acyclic carbon atoms and containing any of the groups OH, O—metal, —CHO, keto, ether, groups, groups, or groups
- C07C59/01—Saturated compounds having only one carboxyl group and containing hydroxy or O-metal groups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/08—Heat treatment
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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- Y02P20/50—Improvements relating to the production of bulk chemicals
- Y02P20/52—Improvements relating to the production of bulk chemicals using catalysts, e.g. selective catalysts
Definitions
- the present invention relates specifically to a catalyst useful as a catalyst for hydrogenation of a carbonyl compound and an alcohol production method in which a carbonyl compound is hydrogenated using the catalyst.
- a carbonyl compound is hydrogenated to form a corresponding alcohol
- a common alcohol production method from an organic carboxylic acid is to esterify a carboxylic acid with a lower alcohol and subsequently perform reduction using an Adkins catalyst (copper chromite catalyst).
- the above catalysts are suitable catalysts that have a high reaction activity and high reaction selectivity in the reduction of a carboxylic acid and/or a carboxylic acid eater.
- a hydrogenation reaction of a particular carboxylic acid In which a cobalt catalyst that includes lanthanum and palladium, which is an example of the above-described catalysts, is used (e.g., PTL 4).
- catalysts that do not include any of the expensive noble metals belonging to Groups 8 to 10 of the periodic table.
- a catalyst including rhenium that serves as a catalytic component has been reported since a long time ago (e.g., NPL 2).
- a tin-containing rhenium catalyst for use in a hydrogenation reaction of a particular carboxylic acid e.g., PTL 5
- a metal-supporting catalyst including rhenium that serves as a catalytic activity component is used (e.g., NPLs 3 and 4).
- catalysts including rhenium that serves as a catalytic activity component have lower catalytic activity than catalysts including a noble metal
- NPL 4 Chemistry A European Journal 23 (2017) 1001-1006
- NPL 5 ACS Catalysis 5 (2015) 7034-7047
- a catalyst including a noble metal belonging to Groups 6 to 10 of the periodic table which serves as a catalytic activity component, which is produced using an expensive noble metal increases the costs of production of a catalyst.
- a catalyst typically causes side reactions, such as a degradation reaction that involves decarboxylation, a defunctionalization reaction associated with dehydration and hydrogenation of the reaction product, and an esterification reaction of a carboxylic acid used as a raw material with an alcohol produced. Thus, it is necessary to reduce the above side reactions.
- the addition of tin or the like increases reaction selectivity.
- the addition of such catalytic components may disadvantageously reduce catalytic activity. This results in a necessity to further use a large amount of expensive noble metal, such as platinum, and increases the costs of production or a catalyst.
- the catalyst including rhenium that serves as a principal catalytic activity component allows a highly economical process to be realized in the sense that the catalyst does not include any expensive noble metal.
- catalysts typically have lower activity than catalysts that include a noble metal.
- an esterification reaction of a carboxylic acid used as a raw material with an alcohol produced is likely to occur due to high Lewis acidity of rhenium and, particularly at a later stage of the reaction, a defunctionalization reaction may significantly occur due to the dehydration and hydrogenation of the alcohol produced. This significantly reduces the selectivity of the alcohol that is t.c be produced.
- An object of the present Invention is to provide a highly economical alcohol production method that enables an intended alcohol to be produced at a high yield with high selectivity by the hydrogenation reaction of a carbonyl compound while reducing the above-described various side reactions to a sufficient degree.
- Another object of the present invention is to provide a high-activity metal-supporting catalyst including rhenium which enables an intended alcohol to be produced at a high yield with high selectivity by the hydrogenation reaction of a carbonyl compound while reducing the side reactions and a method for producing such a metal-supporting catalyst.
- the inventors of the present invention found that the above issue 3 may be addressed by using a catalyst produced by attaching rhenium and a specific second component to a carrier when an alcohol is produced by the hydrogenation reaction of a carbonyl compound and consequently made the present invention.
- first invention The summary of the first aspect of the present invention (hereinafter, referred to as “first invention”) is as follows.
- second invention The summary of the second aspect of the present invention (hereinafter, referred to as “second invention”) is as follows.
- an alcohol production method in which a carbonyl compound is reduced into an alcohol with high activity and high selectivity by using a reduction catalyst including rhenium that serves as a catalytic activity component, the catalyst further including one or more catalytic additive components selected from the group consisting of silicon, gallium, germanium, and indium and a carrier including an oxide of a metal belonging to Group 4 of the periodic table, the catalytic additive components being supported on the carrier.
- a reduction catalyst including rhenium that serves as a catalytic activity component, the catalyst further including one or more catalytic additive components selected from the group consisting of silicon, gallium, germanium, and indium and a carrier including an oxide of a metal belonging to Group 4 of the periodic table, the catalytic additive components being supported on the carrier.
- the catalyst useful for producing an alcohol is also provided.
- the term “periodic table” used herein refers to the long form of periodic table (Nomenclature of Inorganic Chemistry IUPAC recommendations 2005).
- the catalyst according to the first invention enables an increase in catalytic activity, which has been an issue for rhenium catalysts, to be achieved substantially without using noble metals belonging to Groups 8 to 10 of the periodic table.
- the catalyst according to the first Invention also makes it possible to produce an alcohol from a carbonyl compound while reducing side reactions, such as an esterification reaction of a carboxylic acid used as a raw material with an alcohol produced and a defunctionalization reaction due to the dehydration and hydrogenation of the alcohol produced, which significantly occurs particularly at a later stage of the reaction, to a high degree. It becomes also possible to, in the case where a polyvalent carboxylic acid 13 used as a raw material, produce a hydroxycarboxylic acid with high selectivity by converting a part of the carboxylic acid functional groups into alcohol functional groups.
- an alcohol production method in which a carbonyl compound is reduced into an alcohol with high activity and high selectivity by using a reduction catalyst including rhenium that serves as a catalytic activity component, the catalyst further including one or more catalytic additive components selected from the group consisting of silicon, gallium, germanium, and indium at a predetermined elemental mass ratio and a carrier, the catalytic additive components being supported on the carrier. Also provided is the catalyst useful for producing an alcohol.
- the catalyst according to the second invention enables an increase in catalytic activity, which has been an issue for rhenium catalysts, to be achieved substantially without using noble metals belonging to Groups 8 to 10 of the periodic table.
- the catalyst according to the second invention also makes it possible to produce an alcohol from a carbonyl compound while reducing side reactions, such as the esterification reaction of a carboxylic acid used as a raw material with an alcohol produced and a defunctionalization reaction due to the dehydration and hydrogenation of the alcohol produced, which significantly occurs particularly at a later stage of the reaction, to a high degree. It becomes also possible to, in the ease where a polyvalent carboxylic acid is used as a raw material, produce a hydroxycarboxylic acid with high selectivity by converting a part of the carboxylic acid functional groups into alcohol functional groups.
- catalytic components supported on a carrier e.g., rhenium; one or more elements selected from the group consisting of silicon, gallium, germanium, and indium; and optional metal elements belonging to Groups 8 to 10 of the periodic table, such as ruthenium
- a carrier e.g., rhenium; one or more elements selected from the group consisting of silicon, gallium, germanium, and indium; and optional metal elements belonging to Groups 8 to 10 of the periodic table, such as ruthenium
- a material produced by attaching the metal components to a carrier may be referred to as “metal-supporting material”.
- a catalyst, produced by reducing the metal-supporting material may be referred to as “metal-supporting catalyst”.
- the metal components supported on the carrier are the same as the metal components included in the catalyst.
- the content of the supported metal in the catalyst can be determined by publicly known analysis methods, such as inductively coupled plasma mass spectrometry (ICP-MS), inductively coupled plasma atomic emission spectrometry (ICP-AES), atomic absorption spectrometry (AAS), and X-ray fluorescence analysis (XRK).
- ICP-MS inductively coupled plasma mass spectrometry
- ICP-AES inductively coupled plasma atomic emission spectrometry
- AAS atomic absorption spectrometry
- XRK X-ray fluorescence analysis
- the quantitative analysis of the supported metal included in the catalyst is conducted using inductively coupled plasma atomic emission spectrometry, atomic absorption spectrometry, or both inductively coupled plasma atomic emission spectrometry and atomic absorption spectrometry in order to determine the metal content in the catalyst.
- the mass ratio between the metal components supported on the carrier is calculated on the basis of the metal components included in the catalyst as in the description of the method for determining the content of the supported metal in the catalyst.
- the mass ratio between the rhenium element an a the second component element can be determined using publicly known analysis methods, such as inductively coupled plasma mass spectrometry (ICP-MS), inductively coupled plasma atomic emission spectrometry (ICP-AES), atomic absorption spectrometry and X-ray fluorescence analysis (XRF), as in the description of the method for determining the content, of the supported metal in the catalyst.
- ICP-MS inductively coupled plasma mass spectrometry
- ICP-AES inductively coupled plasma atomic emission spectrometry
- XRF X-ray fluorescence analysis
- the catalyst according to the present invention can be suitably used as a hydrogenation catalyst when an alcohol is produced from a carbonyl compound.
- a carbonyl compound is defined as a compound that includes a carbon-oxygen double bond (C ⁇ O), and
- An alcohol is defined as a compound produced by converting the carbonyl compound into an alcohol functional group (OH).
- a compound produced by converting at least one of the carbon-oxygen double bonds of the carbonyl compound into an alcohol functional group is defined as an alcohol.
- a catalyst according to the first invention (hereinafter, may be referred to simply as “first catalyst”) is a metal-supporting catalyst that includes a metal component and a carrier on which the metal component is supported.
- the metal components including a first component that is rhenium arid one or more second components selected from the group consisting of silicon, gallium, germanium, and indium are supported on a carrier including an oxide of a metal belonging to Group 4 of the periodic cable.
- the first catalyst is normally produced by reducing a metal-supporting material on which the metal component is supported with a reducing gas and then performing an oxidative stabilization treatment as needed.
- the metal component supported on the metal-supporting catalyst according to the first invention includes a first component that is rhenium and one or more second components selected from the group consisting of silicon, gallium, germanium, and indium.
- the second components used in combination with rhenium are preferably one or more elements selected from the group consisting of silicon, germanium, and indium, are more preferably one or more elements that include indium end/or germanium, are further preferably one or more elements that include germanium, and are particularly preferably germanium.
- the lower limit for the mass ratio of the second component elements that are one or mere elements selected from the group consisting of silicon, gallium, germanium, and indium to the rhenium element is preferably 0.1 or more and is more preferably 0.5 or more
- the upper limit for the above mass ratio is preferably 10 or less, is more preferably 5 or less, is further preferably 3 or less, is particularly preferably 2 or less, and is most preferably 1 or less.
- Appropriately selecting the types of the second components used in combination with rhenium and/or the proportion of the second components supported on the carrier increases the catalytic activity in a hydrogenation reaction of a carbonyl compound and makes it possible to produce an alcohol while reducing side reactions, such as the esterification reaction of a carboxylic acid used as a raw material with an alcohol produced and a defunctionalization reaction due to the dehydration and hydrogenation of the alcohol produced, which significantly occurs particularly at a later stage of the reaction, to a high degree.
- Using the above metal components in combination with one another enables the first catalyst to be handled in the air atmosphere. This increases ease of operation, such as transportation and storage of the catalyst and introduction cf the catalyst to a reactor in the production of an alcohol.
- the addition of the second components enables the electronic state of rhenium, which is a catalytic activity component of the hydrogenation catalyst, to be controlled to be in a state suitable for a reduction reaction of a carbonyl functional group; the adsorptivity of reactive substrates onto the surface of the catalyst is enhanced due to the affinity of the reactive substrates tor the second components; and the orientation of adsorption of the reactive substrates on the surface of the catalyst is controlled at a high degree.
- the mass ratio of the rhenium element, to the total mass of the metal-supporting catalyst is normally 0.5% by mass or more, is preferably 1% by mass or more, is more preferably 3% by mass or snore, is normally 20% by mass or less, is preferably 10% by mass or less, and is more preferably 8% by mass or less.
- the amount of rhenium supported on the catalyst is limited to be equal to or more than the lower limit, sufficiently high catalytic activity can be achieved. This prevents, for example, an increase in the volume of the reactor used.
- the amount of rhenium supported on the catalyst is limited to be equal to or less than the upper limit, an increase in the cost of the catalyst can be limited, furthermore, in such a case, coagulation of rhenium supported on the catalyst can be reduced.
- reaction selectivity can be further increased.
- the first catalyst may further include, as needed, a third component that is a metal component other than the above metal components (i.e., rhenium and the second components) and that does not adversely affect the reactions conducted using the. first catalyst, such as a reduction reaction.
- a third component that is a metal component other than the above metal components (i.e., rhenium and the second components) and that does not adversely affect the reactions conducted using the. first catalyst, such as a reduction reaction.
- the other metal component include metal components belonging to Groups 3 to 10 of the periodic table except iron and nickel. Examples thereof include at least one metal selected from the group consisting of ruthenium, cobalt, rhodium, iridium, palladium, and platinum which are capable of catalyzing hydrogenation.
- Metals such as iron and nickel, may elute and enter the catalyst when a metal reaction container made of SS, SUS, or the like becomes corroded in the preparation oil the catalyst and/or the reaction.
- the metal in the case where the eluted metal is precipitated on the catalyst and included in the catalyst, the metal is not defined as a metal component of the first catalyst.
- the following metals may be detected in the catalyst in trace amounts at specific contents depending on the material used.
- nickel, chromium, and manganese may foe detected in addition to iron at specific contents.
- nickel chromium, and manganese may foe detected in addition to iron at specific contents.
- metals enter from SUS301 nickel and chromium may be detected in addition to iron at specific contents.
- metals enter from SUS302 nickel and chromium may be detected in addition to iron at specific contents.
- metals enter from SUS303 nickel, chromium, and molybdenum may be detected in addition to iron at specific contents.
- metals enter from SUS304 nickel and chromium may be detected in addition to iron at specific contents.
- nickel and chromium may be detected in addition to iron at specific contents.
- metals enter from SUS316 nickel, chromium, and molybdenum may be detected in addition to iron at specific contents.
- metals enter from SUS317 nickel, chromium, and molybdenum may be detected in addition to iron at specific contents.
- metals enter from SUS329J1 nickel, chromium, and molybdenum may be detected in addition to iron at specific contents.
- metals enter from SUS403 chromium may be detected in addition to iron at a specific content.
- metals enter from SUS405 chromium and aluminum may be detected in addition to iron at specific contents.
- chromium When metals enter from SUS420, chromium may be detected in addition to iron at a specific content. When metals enter from SUS430, chromium may be detected in addition to iron at a specific content. When metals enter from 8 US430LX, chromium, titanium, or niobium may be detected in addition to iron at a specific content. When metals enter from SUS630, nickel, chromium, copper, and niobium may be detected in addition to iron at specific contents.
- Examples of the metal component that belongs to a group other than Groups 8 to 10 of the periodic table include at least one metal selected from the group consisting of silver, gold, molybdenum, tungsten, aluminum, and boron.
- At least one metal selected from ruthenium, cobalt, rhodium, iridium, palladium, platinum, gold, molybdenum, and tungsten is preferable; at least one metal selected from ruthenium, cobalt, rhodium, iridium, palladium, platinum, molybdenum, arid tungsten is more preferable; at least one metal selected from ruthenium, iridium, palladium, and platinum is particularly preferable; and ruthenium is most preferable.
- the elemental mass ratio of the third component included in the first catalyst to the rhenium element is normally less than 0.2, is preferably 0.15 or less, is more preferably 0.1 or less, is further preferably less than 0.1, and is most preferably 0 in order to increase reaction selectivity and economical efficiency in terms of the costs for producing the catalyst. That is, it is preferable that the first catalyst substantially do not include any of the rare and expensive metals belonging to Groups 8 to 10 of the periodic table other than iron or nickel.
- the elemental mass ratio of the third component to the rhenium element is normally 10 or less, is preferably 5 or less, is more preferably 1 or less, and is further preferably 0.5 or less.
- the first catalyst may include compounds of one or more alkali metal elements selected from the group consisting of lithium, sodium, potassium, rubidium, and cesium; compounds of one or more alkaline-earth metal elements selected from the group consisting of magnesium, calcium, strontium, and barium; and compounds of one or more halogen elements selected from the group consisting of fluorine, chlorine, bromine, and iodine, in addition to the metal components described above.
- the ratio between the additional components and the rhenium component is nor. limited.
- the carrier used in the first invention is a carrier that includes an oxide of a metal belonging to Group 4 of the periodic table.
- an inert carrier can be used.
- the term “inert carrier” used herein refers to a carrier that does not have a catalytic activity in a hydrogenation or a carbonyl compound alone.
- the inert carrier is defined as a carrier that substantially does not include any of the metals belonging to Group 8 to 12 of the periodic table which is selected from the group consisting oi iron, ruthenium, cobalt, rhodium, iridium, nickel, palladium, platinum, copper, and zinc, chromium, and rhenium, which are metals having catalytic activity.
- a carrier that substantially does not include any cf the above metals is a carrier that does not primarily include any of the above metals. That is, the amount of the above metals included in the carrier to the total mass of the carrier is 5% by mass or less, is preferably 1% by mass or less, and is mere preferably 0.1% by mass or less.
- the content of the above metals in the carrier can be determined as in the analysis of the content of the supported metal in the catalyst, using publicly known analysis methods, such as inductively coupled plasma mass spectrometry (ICP-MS), inductively coupled plasma atomic emission spectrometry (ICP-AES), atomic absorption spectrometry (AAS), and X-ray fluorescence analysis (XRF).
- ICP-MS inductively coupled plasma mass spectrometry
- ICP-AES inductively coupled plasma atomic emission spectrometry
- AAS atomic absorption spectrometry
- XRF X-ray fluorescence analysis
- a carrier that includes an oxide of a metal belonging to Group 4 of the periodic table such as titanium oxide (titania), zirconium oxide (zirconia), or hafnium oxide, is used in order to increase catalytic activity and reaction selectivity achieved particularly when a carboxylic acid is used as a raw material and ease of regeneration of the catalyst and reduce the elution of metals.
- titanium oxide and zirconium oxide are preferable in order to increase catalytic activity and produce an intended alcohol with high selectivity.
- titanium oxide may be particularly preferable in order to readily produce carrier particles having a large specific surface area.
- the oxides of metals belonging to Group 4 of the periodic table may be used alone or in combination of two or more. In the case where the oxides of metals belonging to Group 4 of the periodic table are used in combination of two or more, the combination of the oxides arid the mixing ratio between the oxides are not limited.
- the oxides can be used in a form similar to a mixture of the individual compounds or a composite oxide.
- the carrier used in the first invention may contain a sulfate ion.
- the carrier in the case where titanium oxide is used as a carrier, it may fee preferable that the carrier contain a sulfate ion.
- using a carrier including a sulfate ion may markedly reduce a degradation reaction involved by decarboxylation and a defunctionalization reaction associated with dehydration and hydrogenation of the reaction product, that is, an alcohol, which occur simultaneously with a catalytic reaction of hydrogenation of a carbonyl compound.
- the metal components that include rhenium and the second components are supported on such a carrier, the catalytic activity of the hydrogenation catalyst may be markedly increased.
- the metal components are used in combination with the carrier, the catalyst can be handled in the air atmosphere. This increases ease of operation of the catalyst, such as transportation and storage of the catalyst and introduction of the catalyst to a reactor in the production of an alcohol.
- the functions of the catalyst are enhanced for the following reasons: when the carrier contains a sulfate ion, sulfate ions present in the surface of the carrier may form acid sites on the surface of the catalyst. Furthermore, the dispersibility of the supported metal may be increased due to the interaction between the supported metal and the sulfate ion or a substitution reaction of the supported metal with the sulfate ion which occurs when the metal components are supported on the carrier. Moreover, the electronic state of rhenium, which is a catalytic activity component of the hydrogenation catalyst, can be controlled to be in a state suitable for a reduction reaction of a carbonyl functional group. The above factors may synergistically increase the reaction selectivity of the catalyst and the activity of the catalyst.
- the mass ratio of the amount of the sulfate ion included in the carrier to the total mass of the carrier used is preferably 0.01% by mass or more, is more preferably 0.1% by mass or more, and is particularly preferably 0.2% by mass or more.
- the mass ratio of the amount of the sulfate ion to the total mass of the carrier used is preferably 10% by mass or less, Is more preferably 7% by mass or less, and is particularly preferably 5% by mass or less.
- the content of the sulfate ion in the carrier used is limited to be equal to or more than the lower limit, the advantageous effects of adding the above components are achieved at a sufficient level and high catalytic activity can be achieved, furthermore, the occurrence of the defunctionalization reaction can be further reduced.
- This limits increases in the costs for constructing reaction facilities and the costs for purifying the product and enables an economically advantageous alcohol production process to be provided.
- the carrier is not limited and may be any carrier that includes a sulfate ion.
- An appropriate commercial product may be used directly.
- the carrier may be prepared by, for example, dissolving a corresponding metal sulfate in water and subsequently performing neutralization or pyrohydrolysis, or by treating a corresponding metal hydroxide or a baked metal oxide with a sulfatizing agent and subsequently performing baking in an oxidizing atmosphere, such as the air atmosphere.
- the treatment using a sulfatizing agent is to introduce sulfate ions into the carrier.
- This treatment nay be performed in the step of producing the carrier or nay be performed after the production of the carrier.
- the sulfatizing agent include sulfuric acid, persulfuric acid, and the salts thereof.
- Sulfuric acid, a sulfuric acid salt, and a persulfuric acid salt are preferable.
- the sulfuric acid salt is not limited and may be any sulfuric acid salt capable of providing sulfate ions when dissolved.
- examples of the sulfuric acid salt include ammonium sulfate, sodium sulfate, and potassium sulfate.
- the above salts may be in the form of an anhydride or hydrate. Such salts may be preferable in some cases because they are less hazardous than acids and easy to handle.
- a preparation example of the carrier including a sulfate ion according to the first invention is described below, taking titanium oxide and zirconium oxide as an example.
- Titanium oxide containing a sulfate ion car be prepared by dissolving titanium sulfate or titanyl sulfate in water, subsequently performing neutralization at a low temperature or pyrohydrolysis, and then performing baking. Titanium oxide containing a sulfate ion can also be prepared by dissolving titanium ore in sulfuric acid, subsequently performing heating to produce metatitanic acid or titanium hydroxide, and then performing baking.
- titanium oxide containing a sulfate ion may be produced by passing dilute sulfuric acid through titanium hydroxide, which is a starting material, prepared from titanium tetraisopropoxide or the like and subsequently performing baking in the air atmosphere.
- titanium hydroxide which is a starting material, prepared from titanium tetraisopropoxide or the like and subsequently performing baking in the air atmosphere.
- a baked titanium oxide may also be used as a starting material instead of titanium hydroxide.
- a sulfuric acid salt such as ammonium 3 ulfate, may be supported on the carrier.
- the titanium oxide that has been subjected to the sulfatizing treatment is subsequently baked.
- the baking temperature is preferably 350° C. to 700° C. and is more preferably 450° C. to 600° C. It is not preferable to set the baking temperature to be excessively high because, if the baking temperature is excessively high, the sulfate ions included in the catalyst become volatilized and the surface area of the titanium oxide decreases disadvantageous.
- the amount of baking time during which the baking is performed is not limited. It is appropriate to set the baking time to about 3 hours.
- Examples of a commercial product, of the titanium oxide containing a sulfate ion include MC-50, MC-90, and MC-150 produced by Ishihara Sangyo Kaisha, Ltd., which are also described in Examples of the first Invention below.
- Zirconium oxide containing a sulfate ion can be prepared by, &.& in the preparation example of the titanium oxide, adding sulfuric acid, a sulfate, a persulfate, or the like to a starting material that is, for example, zirconium hydroxide prepared by adding ammonia wafer to an aqueous solution of a zirconium compound, such as zirconium oxychloride, zirconium oxynitrate, zirconium propoxide, or the like, and subsequently performing baking in the air atmosphere.
- a baked zirconium oxide may also be used instead of zirconium hydroxide.
- a sulfuric acid such as ammonium sulfate, may be supported on the carrier.
- the zirconium oxide that has been subjected to the sulfatizing treatment is subsequently baked.
- the baking temperature is preferably 350° C. to 700° C. and is more preferably 450° C. to 600° C. It is not preferable to set the baking temperature to be excessively high because, if the baking temperature is excessively high, the sulfate ions included in the catalyst become volatilized and the surface area of the zirconium oxide decreases disadvantageously.
- the amount of baking tine during which the baking is performed is not limited. It is appropriate to set the baking time to about 3 hours.
- the carrier is a commercial carrier
- the content of sulfate ion in the carrier has been published by the manufacturer, and the sulfate ion content falls within the above-described range of sulfate ion content specified in the first invention
- the carrier is considered to correspond to the carrier according to the first invention.
- Examples of such a commercial carrier include MC-50, MC-90, and MC-130 produced by Ishihara Sangyo Kaisha, Ltd.
- the sulfur element Component of the carrier is derived from a sulfate ion
- the content of sulfate ion in the carrier or catalyst may be determined using a publicly known high-frequency furnace combustion-infrared detection method (carbon sulfur analyzer) by combusting the catalyst in a high-frequency induction heating furnace under an oxygen atmosphere and converting the content of sulfur in the combustion gas into the mass of sulfate ion, which is determined by an infrared detection method.
- the content of the sulfate ion in the catalyst is not limited and the mass ratio of the amount of sulfate ion to the total mass of the catalyst is preferably 0.01% by mass or more, is more preferably 0.1% by mass or more, is particularly preferably 0.2% by mass or worn, is normally 10% by mass or less, is preferably 7% by mass or less, is more preferably 5% by mass or less, is particularly preferably 2% by mass or less, and is most preferably 1% by mass or less.
- the mass ratio of the amount of sulfur element to the total mass of the catalyst is preferably 0.01% by mass or more, is more preferably 0.1% by mass or more, is normally 3% by mass or less, is preferably 2% by mass or less, is more preferably 1% by mass or less, and is particularly preferably 0.6% by mass or less.
- a catalyst containing a sulfate ion or sulfur may markedly reduce a degradation reaction involved by decarboxylation and a defunctionalization reaction associated with dehydration and hydrogenation of the reaction product, that is, an alcohol, which occur simultaneously with a catalytic reaction of hydrogenation of a carbonyl compound.
- Limiting the content of sulfate ion in the catalyst to be equal to or more than the lower limit may increase catalytic activity to a sufficient degree and reduce the occurrence of the defunctionalization reaction to a sufficient degree. This limits an increase in the complexity of the process for purifying the reaction product and an increase in the purification coats and consequently enables an economically advantageous alcohol production process to be provided.
- Limiting the content of sulfate ion in the catalyst according to the present invention to be equal to or more than the lower limit also enhances the stability of the catalyst in the air atmosphere. This increases ease of operation of the catalyst, such as transportation and storage of the catalyst and introduction cf the catalyst to a reactor in the production of an alcohol. Limiting the content of the sulfate ion m the catalyst to be equal to or less than the upper limit reduces, for example, corrosion of the reactor caused by sulfate ions included in the catalyst becoming eluted during the reaction and side reactions of the target product caused by the liberated acid catalyst. This limits increases in the costs for constructing reaction facilities and the costs for purifying the target product and enables an economically advantageous alcohol production process to be provided.
- the content of the sulfate ion in the carrier or catalyst is determined by publicly known ion chromatography after the sulfate ion has been extracted from the catalyst in a pretreatment 3 tep.
- the content of the sulfur in the carrier or catalyst is determined using a publicly known high-frequency furnace combustion-infrared detection method (carbon sulfur analyzer) by combusting the catalyst in a high-frequency induction heating furnace under an oxygen atmosphere and calculating the content of sulfur in the combustion gas by an infrared detection method.
- a publicly known high-frequency furnace combustion-infrared detection method carbon sulfur analyzer
- the carrier used in the first invention is preferably composed primarily of the oxide of a metal belonging to Group 4 of the periodic table.
- the expression “composed primarily of” used herein means that the mass ratio of the oxide of a metal belonging to Group 4 of the periodic table to the total mass of the carrier is normally 50% by mass or more, is preferably 70% by mass or more, and is more preferably 90% to 100% by mass.
- the carrier used in the first invention may include a carrier component other than the oxide of a metal belonging to Group 4 of the periodic table.
- the other carrier component include one or more compounds selected from graphite, active carbon, silicon carbide, silicon nitride, aluminum nitride, boron nitride, boron oxide, aluminum oxide (alumina), silicon oxide (silica), lanthanum oxide, cerium oxide, yttrium oxide, niobium oxide, magnesium silicate, calcium silicate, magnesium aiuminate, calcium aluminate, aluminosilicate, aluminosilicophosphate, aluminophosphate, magnesium phosphate, calcium phosphate, strontium phosphate, apatite hydroxide (calcium hydroxyphosphate), apatite chloride, apatite fluoride, calcium sulfate, barium sulfate, and barium carbonate.
- the specific surface area of the carrier particles used in the first invention varies by the type of the carrier used and is not limited.
- the specific surface area of the carrier particles used in the first invention is normally 50 m 2 /g or more, is preferably 80 m 2 /g or more, is more preferably 100 m 2 /g or more, is normally 3000 m 2 /g or less, and is preferably 2000 m 2 /g or less.
- the specific surface area of the carrier particles is normally 50 m 2 /g or more, is preferably 80 m 2 /g or more, is more preferably 100 m 2 /g or more, is normally 1000 m 2 /g or less, and is preferably 800 m 2 /g or less.
- the specific surface area of the carrier particles is generally calculated from the amount of nitrogen adsorbed on the carrier particles using the BET equation.
- the shape and size of the carrier particles used in the first invention are not limited.
- the average particle size of the carrier is normally 0.1 ⁇ m or more, is preferably 3 ⁇ m or more, is more preferably 5 ⁇ m or more, is further preferably 50 ⁇ m or more, is normally 5 mm or less, and is preferably 4 mm or less.
- the particle size of the carrier is measured in accordance with Test sieving described in JIS Standard JIS Z8815 (1894).
- the volume of the carrier particle is measured, the diameter of a spherical particle having the same volume as the carrier particle is calculated, and the diameter of the spherical particle is considered the diameter of the carrier particle.
- the average particle size of the carrier falls within the above range, the activity of the catalyst per unit mass is increased, and ease of handling of the catalyst is further increased.
- the average particle size of the carrier is normally 0.1 ⁇ m or more, is preferably 1 ⁇ m or more, is more preferably 5 ⁇ m or more, is further preferably 50 ⁇ m or more, is normally i ism or less, and is preferably 2 mm or less. It is preferable to reduce the average particle size of the carrier because the smaller the average particle size of the carrier, the higher the activity of the catalyst per unit mass. However, setting the average particle size of the carrier to be excessively smaller than the above lower limit may make it difficult to separate the reaction liquid and the catalyst from each other.
- the average particle size of the carrier is normally 0.5 mm or snore and 5 mm or less, is preferably 4 mm or less, and is more preferably 3 mm or less. If the particle size of the carrier is excessively smaller than the above lower limit, it may become difficult to operate a reaction facility due to pressure difference. If the particle size of the carrier is excessively larger than the above upper limit, reaction activity may be reduced.
- a catalyst according to the second invention (hereinafter, may be referred to simply as “second catalyst”) is a metal-supporting catalyst that includes a metal component and a carrier on which the metal component is supported.
- the metal components including a first component that is rhenium and one or more second components selected from the group consisting of silicon, gallium, germanium, and indium are supported on a carrier.
- the mass ratio of the amount of the second components to the amount of rhenium is set to a predetermined value.
- the second catalyst is normally produced by reducing a metal-supporting material on which the metal component is supported with a reducing gas and then performing an oxidative stabilization treatment as needed.
- the metal component supported on the metal-supporting catalyst according to the second invention includes a first component that is rhenium and one or more second components selected from the group consisting of silicon, gallium, germanium, and indium.
- the second components used in combination with rhenium are preferably one or more elements selected from the group consisting of silicon, germanium, and indium, are more preferably one or more elements that include indium and/or germanium, are further preferably one or more elements that include germanium, and are particularly preferably germanium.
- the lower limit for the mass ratio of the second component elements that are one or more elements selected from the group consisting of silicon, gallium, germanium, and indium to the rhenium element is preferably 0.1 or more and is more preferably 0.5 or more
- the upper limit for the above mass ratio is preferably 30 or less, is more preferably 5 or less, is further preferably 3 or less, is particularly preferably 2 or less, and is most preferably 3 or less.
- Appropriately selecting the types of the second components used in combination with rhenium and/or the proportion of the second components supported on the carrier increases the catalytic activity in a hydrogenation reaction of a carbonyl compound and makes it possible to produce an alcohol while reducing side reactions, such as an esterification reaction of a carboxylic acid used as a raw material with an alcohol produced, and a defunctionalization reaction due to the dehydration and hydrogenation of the alcohol produced, which significantly occurs particularly at a later stage of the reaction, to a high degree.
- Using the above metal components in combination with one another enables the second catalyst to be handled in the air atmosphere. This increases ease of operation, such as transportation and storage of the catalyst and introduction of the catalyst to a reactor in the production of an alcohol.
- the addition of the second components enables the electronic state of rhenium, which is a catalytic activity component of the hydrogenation catalyst, to be controlled to be in a state suitable for a reduction reaction of a carbonyl functional group; the adsorptivity of reactive substrates onto the surface of the catalyst is enhanced due to the affinity of the reactive substrates for the second components; and the orientation of adsorption of the reactive substrates on the surface of the catalyst is controlled at a high degree.
- the mass ratio of the rhenium element to the total mass of the metal-supporting catalyst is normally 0.5% by mass or more, is preferably 1% by mass or more, is more preferably 3% by mass or more, is normally 20% by mass or less, is preferably 10% by mass or. less, and is more preferably 8% by mass or less.
- the amount of rhenium supported on the catalyst is limited to be equal to or more than the lower limit, sufficiently high catalytic activity can be achieved. This prevents, for example, an increase in the sire of the reactor used.
- the amount of rhenium supported on the catalyst is limited to be equal to or less than the upper limit, an increase in the cost of the catalyst can be limited.
- reaction selectivity can be further increased.
- the second catalyst may further include, as needed, a third component that is a metal component other than the above metal components (i.e., rhenium and the second components) and that does not adversely affect the reactions conducted using the second catalyst, such as a reduction reaction.
- a third component that is a metal component other than the above metal components (i.e., rhenium and the second components) and that does not adversely affect the reactions conducted using the second catalyst, such as a reduction reaction.
- the Other metal component include metal components belonging to Groups 8 to 10 of the periodic table except iron and nickel. Examples thereof include at least one metal selected from the group consisting of ruthenium, cobalt, rhodium, iridium, palladium, and platinum, which are capable of catalyzing hydrogenation.
- periodic table used herein refers to the long form of periodic table (.Nomenclature of Inorganic Chemistry IUPAC Recommendations 2005).
- Metals such as iron and nickel, may elute and enter the catalyst when a metal reaction container made of SS, SUS, or the like becomes corroded in the preparation of the catalyst and/or the reaction.
- the metal in the case where the eluted metal is precipitated on the catalyst and included in the catalyst, the metal is not defined as a metal component of the second catalyst.
- the following metals may be detected in the catalyst in trace amounts at specific contents depending on the material used.
- nickel, chromium, and manganese may be detected in addition to iron at specific contents.
- nickel chromium, and manganese may tee detected in addition to iron at specific contents.
- metals enter from SUS301 nickel and chromium may be detected in addition to iron at specific contents.
- metals enter from SUS302 nickel and chromium may be detected in addition to iron at specific contents.
- metals enter from SUS202 nickel, chromium, and molybdenum may be detected in addition to iron at specific contents.
- metals enter from SUS304 nickel and chromium may be detected in addition to iron at. specific contents.
- nickel and chromium may be detected in addition to iron at specific contents.
- metals enter from SUS316 nickel, chromium, and molybdenum may be detected in addition to iron at specific contents.
- metals enter from SUS317 nickel, chromium, and molybdenum may be detected in addition to iron at specific contents.
- metals enter from SUS329J1 nickel, chromium, and molybdenum may be detected in addition to iron at specific contents.
- metals enter from SUS403 chromium may be detected in addition to iron at a specific content.
- metals enter from SUS405 chromium and aluminum may be detected in addition to iron at specific contents.
- chromium When metals enter from SUS420, chromium may be detected in addition to iron at a specific content. When metals enter from SUS430, chromium may be detected in addition to iron at a specific content. When metals enter from SUS430LX, chromium, titanium, or niobium may be detected in addition to iron at a specific content. When metals enter from SUS630, nickel, chromium, copper, and niobium may be detected in addition to iron at specific contents.
- Examples of the metal component that belongs to a group other than Groups 8 to 10 of the periodic table include at least one metal selected from the group consisting of silver, gold, molybdenum, tungsten, aluminum, and boron.
- At least one metal selected from ruthenium, cobalt, rhodium, iridium, palladium, platinum, gold, molybdenum, and tungsten is preferable; at least one metal selected from ruthenium, cobalt, rhodium, iridium, palladium, platinum, molybdenum, and tungsten is more preferable; at least one metal selected from ruthenium, iridium, palladium, and platinum is particularly preferable; and ruthenium is most preferable.
- the elemental mass ratio of the third component included in the second catalyst to the rhenium element is normally less than 0.2, is preferably 0.15 or less, is more preferably 0.1 or less, is further preferably less than 0.1, and is most preferably 0 in order to increase reaction selectivity and economical efficiency in terns of the costs for producing the catalyst. That is, it is preferable that the second catalyst substantially do not include any of the rare and expensive metals belonging to Groups 8 to 10 of the periodic table ether than iron or nickel.
- the elemental mass ratio of the third component to the rhenium element is normally 10 or less, is preferably 5 or less, is more preferably 1 or less, and is further preferably 0.5 or less.
- the second catalyst may include compounds of one or more alkali metal elements selected from the group consisting of lithium, sodium, potassium, rubidium, and cesium; compounds of one or more alkaline-earth metal elements selected from the group consisting of magnesium, calcium, strontium, and barium; and compounds of one or mere halogen elements selected from the group consisting of fluorine, chlorine, bromine, and iodine, in addition to the metal components described above.
- the ratio between the additional components and the rhenium component is not limited.
- the carrier used in the second invention is not limited.
- an inert carrier can be used.
- the term “inert carrier” used herein refers to a carrier that does not have a catalytic activity in a hydrogenation of a carbonyl compound alone.
- the inert, carrier is defined as a carrier that substantially does not include any of the metals belonging to Group 8 to 12 of the periodic table which is selected from the group consisting of iron, ruthenium, cobalt, rhodium, iridium, nickel, palladium, platinum, copper, and zinc, chromium, and rhenium, which are metals having catalytic activity.
- a carrier that substantially does not include any of the -above metals is a carrier that does not primarily include any of the above metals. That is, the amount of the above metals included in the carrier to the total mass of the carrier is 5% by mass or less, is preferably 1% by mass or less, and is more preferably 0.1% by mass or less.
- the content of the above metals in the carrier can be determined as in the analysis of the content of the supported metal in the catalyst, using publicly known analysis methods, such as inductively coupled plasma mass spectrometry (ICP-MS), inductively coupled plasma atomic emission spectrometry (ICP-AES), atomic absorption spectrometry (AAS), and X-ray fluorescence analysis (XRF).
- ICP-MS inductively coupled plasma mass spectrometry
- ICP-AES inductively coupled plasma atomic emission spectrometry
- AAS atomic absorption spectrometry
- XRF X-ray fluorescence analysis
- the carrier according to the second invention include graphite, active carbon, silicon carbide, silicon nitride, aluminum nitride, boron nitride, boron oxide, aluminum oxide (alumina), silicon oxide (silica), titanium oxide (titania), zirconium oxide (zirconia), hafnium oxide, lanthanum oxide, cerium oxide, yttrium oxide, niobium oxide, magnesium silicate, calcium silicate, magnesium aluminate, calcium aluminate, aluminosilicate, aluminosilicophosphate, aluminophosphate, magnesium phosphate, calcium phosphate, strontium phosphate, apatite hydroxide (calcium hydroxyphosphate), apatite chloride, apatite fluoride, calcium sulfate, barium sulfate, and barium carbonate.
- a carbonaceous carrier titanium oxide, zirconium oxide, niobium oxide, and cerium oxide are preferable in order to increase catalytic, activity and reaction selectivity achieved particularly when a carboxylic acid is used as a raw material and reduce the elution of metals.
- titanium oxide, zirconium oxide, niobium oxide, and cerium oxide are preferable in order to increase case of the regeneration treatment of the catalyst.
- titanium oxide and zirconium oxide which are oxides of metals belonging to Group 4 of the periodic table, are more preferable. Titanium oxide may be particularly preferable in order to readily produce carrier particles having a large specific surface area.
- the carrier used in the second invention may contain a sulfate ion.
- the carrier in the case where titanium oxide is used as a carrier, it may be preferable that the carrier contain a sulfate ion.
- using a carrier including a sulfate ion may markedly reduce a degradation reaction involved by decarboxylation and a defunctionalization reaction associated with dehydration and hydrogenation of the reaction product, that is, an alcohol, which occur simultaneously with a catalytic reaction of hydrogenation of a carbonyl compound.
- the metal components that include rhenium and the second components are supported on such a carrier, the catalytic activity of the hydrogenation catalyst may be markedly increased.
- the metal components are used in combination with the carrier, the catalyst can be handled in the air atmosphere. This increases ease of operation of the catalyst, such as transportation and storage of the catalyst and introduction of the catalyst to a reactor in the production of an alcohol.
- the mass ratio of the amount of the sulfate ion included in the carrier to the total mass of the carrier used is preferably 0.01% by mass or more, is more preferably 0.1% by mass or more, and is particularly preferably 0.2% by mass or more.
- the mass ratio of the amount of the sulfate ion to the total mass of the carrier used is preferably 10% by mass or less, is more preferably 7% by mass or less, and is particularly preferably 5% by mass or less.
- the carrier is not limited and may be any carrier that includes a sulfate ion.
- An appropriate commercial product may be used directly.
- the carrier is composed of a metal oxide
- the carrier may be prepared by, for example, dissolving a corresponding metal sulfate in water and subsequently performing neutralization or pyrohydrolysis, or by treating a corresponding metal hydroxide or a baked metal oxide with a sulfatizing agent and subsequently performing baking in an oxidizing atmosphere, such as the air atmosphere.
- the treatment using a sulfatizing agent is to introduce sulfate ions into the carrier.
- a preparation example of the carrier including a sulfate ion according to the second invention is described below, taking titanium oxide and zirconium oxide as an example.
- Titanium oxide containing a sulfate ion can be prepared by dissolving titanium sulfate or titanyl sulfate in water, subsequently performing neutralization at a low temperature or pyrohydrolysis, and then performing baking. Titanium oxide containing a sulfate ion can also be prepared by dissolving titanium ore in sulfuric acid, subsequently performing heating to produce metatitanic acid or titanium hydroxide, and then performing baking.
- titanium oxide containing a sulfate ion may be produced by passing dilute sulfuric acid through titanium hydroxide, which is a starting material, prepared from titanium tetraisopropoxide or the like and subsequently performing baking in the air atmosphere.
- titanium hydroxide which is a starting material, prepared from titanium tetraisopropoxide or the like and subsequently performing baking in the air atmosphere.
- a baked titanium oxide may also be used as a starting material instead of titanium hydroxide.
- a sulfuric acid salt such as ammonium sulfate, may be supported on the carrier.
- the titanium oxide that has been subjected to the sulfatizing treatment is subsequently baked.
- the baking temperature is preferably 350° C. to 700° C. and is mere preferably 450° C. to 600° C. It is not preferable to set the baking temperature to be excessively high because, if the baking temperature is excessively high, the sulfate ions included in the catalyst become volatilized and the surface area of the titanium oxide decreases disadvantageously.
- the amount of baking time during which the baking is performed is not limited. It is appropriate to set the baking time to about 3 hours.
- Examples of a commercial product of the titanium oxide containing a sulfate ion include MC-30, MC-90, and MC-150 produced by Ishihara Sangyo Kaisha, Ltd., which are also described in Examples of the second invention below.
- Zirconium oxide containing a sulfate ion can be prepared by, as in the preparation example of the titanium oxide, adding sulfuric acid, a sulfate, a persulfate, or the like to a starting material that is, for example, zirconium hydroxide prepared by adding ammonia water to an aqueous solution of a zirconium compound, such as zirconium oxychloride, zirconium oxynitrate, zirconium propoxide, or the like, and subsequently performing baking in the air atmosphere.
- a baked zirconium oxide may also be used instead of zirconium hydroxide.
- a sulfuric acid such as ammonium sulfate, may be supported on the carrier.
- the zirconium oxide that has been subjected to the sulfatizing treatment is subsequently baked.
- the baking temperature is preferably 350° C. to 700° C. and is more preferably 450° C. to 600° C. It is not preferable to set the baking temperature to be excessively high because, it the baking temperature is excessively high, the sulfate ions included in the catalyst become volatilized and the surface area of. the zirconium oxide decreases disadvantageously.
- the amount of baking time during which the baking is performed is not limited. It is appropriate to set the baking time to about 3 hours.
- the sulfur element component of the carrier is derived from a sulfate ion
- the content of sulfate ion in the carrier or catalyst may be determined using a publicly known high-frequency furnace combustion-infrared detection method (carbon sulfur analyzer) by combusting the catalyst in a high-frequency induction heating furnace under an oxygen atmosphere and converting the content of sulfur in the combustion gas into the mass of sulfate ion, which is determined by an infrared detection method.
- the content of the sulfate ion ,i.n the catalyst is not limited and the mass ratio of the amount of. sulfate ion to the total mass of the catalyst is preferably 0.01% by mass or more, is more preferably 0.1% by mass or more, is particularly preferably 0.2% by mass or more, is normally 10% by mass or less, is preferably 1% by mass or leas, is more preferably 5% by mass or less, is particularly preferably 2% by mass or less, and is most preferably 1% by mass or less.
- the mass ratio of the amount of sulfur element to the total mass of the catalyst is preferably 0.01% fey mass or more, is more preferably 0.1% by mass or more, is normally 3% by mass or less, is preferably 2% by mass or less, is more preferably 1% by mass or less, and is particularly preferably 0.6% by mass or less.
- Using a catalyst containing a sulfate ion or sulfur may markedly reduce a degradation reaction involved by decarboxylation and a defunctionalization reaction associated with dehydration and hydrogenation of the reaction product, that is, an alcohol, which occur simultaneously with a catalytic reaction of hydrogenation of a carbonyl compound.
- Limiting the content of sulfate ion in the catalyst to be equal to or more than the lower limit may increase catalytic activity to a sufficient degree and reduce the occurrence of the defunctionalization reaction to a sufficient degree. This limits an increase in the complexity of the process for purifying the reaction product and an increase in the purification costs and consequently enables an economically advantageous alcohol production process to be provided.
- Limiting the content of sulfate ion in the catalyst according to the present invention to be equal to or more than the lower limit also enhance, the stability of the catalyst in the air atmosphere. This increases ease of operation of the catalyst, such as transportation and storage of the catalyst and introduction of the catalyst to a reactor in the production of an alcohol. Limiting the content of the sulfate ion in the catalyst to be equal to or less than the upper limit reduces, for example, corrosion of the reactor caused by sulfate ions included in the catalyst becoming eluted during the reaction and side reactions of the target product caused by the liberated acid catalyst. This limits increases in the costs tor constructing reaction facilities and the costs for purifying the target product and enables an economically advantageous alcohol production process to be provided.
- the content of the sulfate ion in the carrier or catalyst is determined by publicly known ion chromatography after the sulfate ion has been extracted from the catalyst in a pretreatment step.
- the content of the sulfur in the carrier or catalyst is determined using a publicly known high-frequency furnace combustion-infrared detection method (carbon sulfur analyzer) by combusting the catalyst in a high-frequency induction heating furnace under an oxygen atmosphere and calculating the content of sulfur in the combustion gas by an infrared detection method.
- a publicly known high-frequency furnace combustion-infrared detection method carbon sulfur analyzer
- the specific surface area of the carrier particles used in the second invention varies by the type of the carrier used and is not limited.
- the specific surface area of the carrier particles used in the second invention is normally 50 m 2 /g or more, is preferably 80 m 2 /g or more, is more preferably 100 m 2 /g or more, is normally 3000 m 2 /g or loss, and is preferably 2000 m 2 /g or leas.
- the specific surface area of the carrier particles is normally 50 m 2 /g or more, is preferably 80 m 2 /g or more, is more preferably 100 m 2 /g or more, is normally 1000 m 2 /g or less, and is preferably 800 m 2 /g or less.
- the .specific surface area of the carrier particles is generally calculated from the amount of nitrogen adsorbed on the carrier particles using the BET equation.
- the shape and size of the carrier particles used in the second invention are not limited.
- the average particle size of the carrier is normally 0.1 ⁇ m or more, is preferably 1 ⁇ m or more, is more preferably 5 ⁇ m or more, is further preferably 50 ⁇ m or mere, is normally 5 mm or less, and is preferably 4 mm or less.
- the particle size of the carrier is measured in accordance with Test sieving described in JIS Standard JIB Z8815 (1994).
- the volume of the carrier particle is measured, the diameter of a spherical particle having the same volume as the carrier particle is calculated, and the diameter of the spherical particle is considered the diameter of the carrier particle.
- the average particle size of the carrier falls within the above range, the activity of the catalyst per unit mass is increased, and ease of handling of the catalyst rs further increased.
- the average particle size of the carrier is normally 0.1 ⁇ m or more, is preferably 1 ⁇ m or more, is more preferably 5 ⁇ m or more, is further preferably 50 ⁇ m or more, is normally 3 ⁇ m or less, and is preferably 2 nun or less. It is preferable to reduce the average particle size of the carrier because the smaller the average particle size of the carrier, the higher the activity of the catalyst per unit mass. However, setting the average particle size of. the carrier to be excessively smaller than the above lower limit may make it difficult to separate the reaction liquid and the catalyst from each other.
- the average particle size of the carrier is normally 0.5 mm or mere and 5 mm or less, is preferably 4 mm or less, and is more preferably 3 mm or less. If the particle size of the carrier is excessively smaller than the above lower limit, it may become difficult to operate a reaction facility due to pressure difference. If the particle size of the carrier is excessively larger than the above upper limit, reaction activity may be reduced.
- this catalyst normally includes the following steps.
- metal attachment step a step in which, the metal components are attached to the carrier
- oxidative stabilization step a step in which oxidation is performed as needed subsequent to the reduction treatment, (hereinafter, this step is referred to as “oxidative stabilization step”))
- the metal attachment step is a step in which required amounts of the above-described metal components are attached to the above-described carrier in order to prepare a metal-supporting material.
- the method for attaching the metal components to the carrier is not limited, and publicly known methods can be used.
- a solution or dispersion liquid containing metal-containing compounds that are raw materials tor the metal components can be used.
- the method for attaching the metal components to the carrier is not limited. Normally, various impregnation methods may be used. Examples thereof include an adsorption method in which metal ions are caused to adsorb to the carrier in an amount equal to or less than the salutation amount of the metal ions adsorbed by using the ability of the metal ions to adsorb to the carrier; an equilibrium adsorption method in which the carrier is immersed in the solution containing an amount of metal ions which is equal to or more than the saturation amount of the metal ions adsorbed and the excess solution is removed; a pore-filling method in which the solution having the same, volume as the pores formed in the carrier is added to the carrier and the whole amount of the solution is caused to adsorb to the carrier; an incipient wetness method in which the solution is added t.o the carrier until the volume of the solution added is appropriate to the water absorption capacity of the carrier and the treatment is terminated when the surfaces of the carrier particles become uniformly wet and excess solution is not present on the surfaces of
- the pore-filling method, the incipient wetness method, the evaporation-to-dryness method, and the spray method are preferable, and the pore-filling method, the incipient wetness method, and the evaporation-to-dryness method are more preferable.
- the carrier include a sulfate ion. In such a case, it is preferable to attach the metal components to a carrier that includes an amount of sulfate ion which is 0.01% by mass or more and 10% by mass or less of the mass of the carrier.
- the metal-containing compounds used are not limited and may be selected appropriately in accordance with the attaching method used. Examples thereof include halides, such as a chloride, a bromide, and an iodide; mineral acid salts, such as a nitric acid salt and a sulfuric acid salt; metal hydroxides; metal oxides; metal-containing ammonium salts; organic-group-containing compounds, such as an acetic acid salt and a metal alkoxide; and metal complexes.
- halides, mineral acid salts, metal hydroxides, metal oxides, metal-containing ammonium salts, and organic-group-containing compounds are preferable, and halides, mineral acid salts, metal oxides, metal-containing ammonium salts, and organic-group-containing compounds are more preferable.
- the above compounds may be used alone or in combination of two or more in a required amount.
- the metal-containing compounds When the metal-containing compounds are attached to the carrier, the metal-containing compounds may be dissolved or dispersed in a solvent and the resulting solutions and dispersion liquids may be used in any of the above attaching methods.
- the type of the solvent used in this step is not limited and may be any type of solvent in which the metal-containing compounds can be dissolved or dispersed and which does not adversely affect the baking and hydrogen reduction of the metal-supporting material and the hydrogenation reaction in which this catalyst is used, which are conducted in the subsequent step.
- the solvent include ketone solvents, such as acetone, alcohol solvents, such as methanol and ethanol, ether solvents, such as tetrahydrofuran and ethylene glycol dimethyl ether, and water.
- the above solvents may be used alone or in the form of a mixed solvent.
- water is preferably used because water is inexpensive and the solubility of the raw materials, that is, the metal-containing compounds, in water is high.
- various additives may be optionally used in addition to the solvent.
- using a solution of carboxylic acid and/or a carbonyl compound may improve the dispersibility of each of the metal components on the carrier which is achieved when the metal components are attached to the carrier, as described in Japanese Unexamined Patent Application Publication No. 10-15366.
- the metal-supporting material may be dried as needed. It is preferable to subject the metal-supporting material to a .reduction treatment step after the metal-supporting material has been dried and subsequently baked as needed, for the following reason: if the metal-supporting material is subjected to the subsequent reduction treatment without being dried, the catalyst may have low reaction activity.
- the method for drying the metal-supporting material is not limited and may be any method capable of removing the solvent and the like used for attaching the metal components to the carrier. Normally, the metal-supporting material is dried in a stream of inert gas or at a reduced pressure.
- the pressure at which the metal-supporting material is dried is nor, limited. Normally, the metal-supporting material is dried at normal pressure or a reduced pressure.
- the temperature at which the metal-supporting material is dried is normally, but not limited to, 300° C. or less, is preferably 250° C. or less, is more preferably 200° C. or less, and is normally 80° C. or more.
- the metal-supporting material may be baked as needed. Baking the metal-supporting material increases the likelihood of the catalyst having a high catalytic activity and excellent reaction selectivity.
- the baking of the metal-supporting material may be performed in the air atmosphere. For example, the baking of the metal-supporting material may be performed by heating the metal-supporting material in an air stream at a predetermined temperature for a predetermined amount of time.
- the temperature at which the metal-supporting material is baked is normally, but not limited to, 100° C. or more, is preferably 250° C. or more, is more preferably 400° C. or more, is normally 1000° C. or less, is preferably 700° C. or less, and is more preferably 600° C. or less.
- the amount of time during which the metal-supporting material is baked, which varies with the baking temperature, is normally 30 minutes or more, is preferably 1 hour or more, is more preferably 2 hours or more, is normally 40 hours or less, is preferably 30 hours or less, and is more preferably 10 hours or less.
- the metal-supporting material is normally subjected to a reduction treatment using a reducing gas.
- a reduction treatment a publicly known method, such as liquid-phase reduction or a gas-phase reduction, may be used.
- the reducing gas used in the reduction treatment step is not limited and may be any gas having a reducing power.
- the reducing gas include hydrogen, methanol, and hydrazine.
- the reducing gas is preferably hydrogen.
- the hydrogen concentration in the hydrogen-containing gas is not limited.
- the hydrogen concentration in the hydrogen-containing gas may be 100% by volume.
- the hydrogen-containing gas may be diluted with an inert gas.
- inert gas used herein refers to a gas unreactive with the metal-supporting material or a hydrogen ga 3 , such as nitrogen or water vapor. Normally, nitrogen is used as an inert gas.
- the hydrogen concentration in the reducing gas (hydrogen-containing gas) diluted with an inert gas is normally 5% by volume or more, is preferably 15% by volume or more, is more preferably 30% by volume or more, and is further preferably 50% by volume or more relative to the all the gas components. It is possible to use a hydrogen-containing gas having a low hydrogen concentration at the initial stage of reduction and gradually increase the hydrogen concentration in the hydrogen-containing gas over the course of reduction.
- the amount of time required for the reduction treatment is normally 7 minutes or more, is preferably 15 minutes or more, is more preferably 30 minutes or more, is normally 40 hours or less, is preferably 30 hours or leas, and is more preferably 10 hours or less.
- the temperature at which the reduction treatment is performed is normally 130° C. or more, is preferably 200° C. or more, is more preferably 250° C. or more, is normally 700° C. or less, is preferably 600° C. or less, and is more preferably 500° C. or less. If the reduction treatment is performed at an excessively high temperature, for example the supported metal may b sintered and, consequently, the activity of the. catalyst may be reduced.
- the reducing gas may be enclosed in the reactor or may be passed through the reactor. It is preferable to pass the reducing gas through the reactor. This is because passing the reducing gas through the reactor prevents the occurrence of local hydrogen deficiency.
- water, ammonium chloride, and the like may be produced as by-products in the rector depending on the raw materials used, and the by-products may adversely affect the metal-supporting material that has not been subjected to the reduction treatment or the metal-supporting catalyst, which has been subjected to the reduction treatment. Passing the reducing gas through the reactor enables the by-products to be discharged to the outside of the reaction system.
- the amount of the reducing gas required by the reduction treatment is not limited and may be set such that the objects of the first to third inventions are achieved.
- the amount of the reducing gas required by the reduction treatment can be set appropriately in accordance with the apparatus used, the size of the reactor used for reduction, the method for passing the reducing gas through the reactor, the method for fluidizing the catalyst, and the like.
- Examples of a preferable method for performing the reduction treatment include a method in which the reducing gas is passed through the metal-supporting material with a fixed bed; a method in which the reducing gas is passed through the metal-supporting material that is disposed to stand on a tray or a belt; and a method in which the metal-supporting material is caused to fluidize and the reducing gas is passed through the fluidized metal-supporting material.
- the metal-supporting catalyst which is produced by reducing the metal-supporting material, is subjected to an oxidative stabilization treatment in order to control the oxidation state.
- an oxidative stabilization treatment enables the production of a catalyst that has excellent activity and excellent selectivity and that can be handled in the air atmosphere.
- the method .in which water is added to the metal-supporting catalyst, the method in which the metal-supporting catalyst is charged into water, and the method in which oxidative stabilization is performed using the gas having a low oxygen concentration are preferable, the method in which oxidative stabilization (slow oxidation) is performed using the gas having a low oxygen concentration (hereinafter, this method is referred to as “slow-oxidation method”) is more preferable, and a method in which oxidative stabilization is performed in a stream of the gas having a low oxygen concentration is particularly preferable.
- the initial oxygen concentration with which oxidative stabilization is performed using the gas having a low oxygen concentration is not limited.
- the oxygen concentration with which the slew oxidation is started is normally 0.2% by volume or more, is preferably 0.5% by volume or more, is normally 10% by volume or less, is preferably 8% by volume or less, and is further preferably 7% by volume or less. If the oxygen concentration is excessively lower than the lower limit, it takes a considerable amount of time to complete the oxidative stabilization and stabilization may fail to be achieved at a sufficient level. If the oxygen concentration is excessively higher than the upper limit, the temperature of the catalyst may be excessively increased and the catalyst may become deactivated.
- the gas having a low oxygen concentration is preferably prepared by diluting air with an inert gas.
- the inert, gas used for diluting air is preferably nitrogen.
- Examples of a method for performing the oxidative stabilization using the gas having a low oxygen concentration include a method in which the gas having a low oxygen concentration is passed through the catalyst with a fixed bed; a method in which the gas having a low oxygen concentration is passed through the catalyst that is disposed to stand on a tray or a belt; and a method in which the catalyst is caused to fluidize and the gas having a low oxygen concentration is passed through the fluidized catalyst.
- the method for producing this catalyst is not limited to the above-described production method and may be any method capable of producing this catalyst.
- the method for producing this catalyst nay include another publicly known step such that this catalyst can be produced.
- This catalyst is suitable as a catalyst used in the reduction reaction (hydrogenation) of a carbonyl compound.
- An alcohol can be produced by treating a carbonyl compound with this catalyst.
- the carbonyl compound that is to be subjected to the reduction reaction nay be. any carbonyl compound that is industrially readily available.
- Specific examples of the carboxylic acid and/or the carboxylic acid eater include aliphatic chain monocarboxylic acids, such as acetic acid, butyric acid, decancic acid, lauric acid, oleic acid, linoleic acid, linolenic acid, stearic acid, and palmitic acid; aliphatic cyclic monocarboxylic acids, such as cyclohexanecarboxylic acid, naphthenic acid, and cyclopentanecarboxylic acid; aliphatic polycarboxylic acids, such as oxalic acid, malonic acid, succinic acid, methylsuccinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, sebacic acid, cyclohexanedicarboxylic acid, 1,2,4-butane
- carboxylic acid halide examples include chlorides and bromides of the above carboxylic acids.
- carboxylic anhydride examples include acetic anhydride, succinic anhydride, maleic anhydride, and phthalic anhydride.
- aldehyde and the ketone examples include benzaldehyde, propionaldehyde, acetaldehyde, 3-hydroxypropionaldehyde, furfural, hydroxymethylfurfural, acetone, benzophenone, glucose, xylose, lactose, and fructose.
- the carboxylic acid and carboxylic acids constituting the carboxylic acid ester, the carboxylic acid amide, the carboxylic acid halide, and/or the carboxylic anhydride are preferably, but not limited to, chain or cyclic saturated aliphatic carboxylic acids, are more preferably carboxylic acids a portion of which excluding carboxyl groups has 20 or less carbon atoms.
- the number of the carbon atoms included in the carboxylic acids is more preferably 14 or less.
- the carboxylic acid, the carboxylic acid ester, the carboxylic anhydride, and the aldehyde are preferable, the carboxylic acid, the carboxylic acid ester, the carboxylic anhydride, and the aldehyde are more preferable, and the carboxylic acid arid the carboxylic acid ester are particularly preferable from the viewpoint of ease of availability of the raw materials.
- the carbonyl compounds that are to be subjected to the reduction reaction are not limited to the above carbonyl compounds.
- the carboxylic acid is preferably a dicarboxylic acid and is further preferably a dicarboxylic acid represented by Formula (1) below the portion of which except carboxyl groups includes 20 or less carbon atoms.
- R 1 represents an aliphatic or alicyclic hydrocarbon group that may have a substituent, the portion of the hydrocarbon group except the substituent including 1 to 20 carbon atoms)
- This catalyst enables a polyvalent carboxylic acid, such as the above dicarboxylic acid, to be converted into a corresponding hydroxycarboxylic acid, lactone, or polyhydric alcohol with high selectivity at a high yield.
- a polyvalent carboxylic acid such as the above dicarboxylic acid
- particularly preferable carbonyl compounds include carboxylic acids having a furan skeleton which are derived from biomass resources, such as furandicarboxylic acid, and aldehydes, such as hydroxymethylfurfural.
- the reduction reaction using this catalyst may be conducted in a liquid phase or gas phase, the reduction reaction using this catalyst is preferably conducted in a liquid phase.
- the reduction reaction using this catalyst in a liquid phase may be conducted without using a solvent or in the presence of a solvent, the reduction reaction using this catalyst in a liquid phase is normally conducted in the presence of a solvent.
- the solvent examples include, normally, water; lower alcohols, such as methanol and ethanol; alcohols that are the reaction products; ethers, such as tetrahydrofuran, dioxane, and ethylene glycol dimethyl ether; and hydrocarbons, such as hexane, decalin, and methylcyclohexane.
- lower alcohols such as methanol and ethanol
- alcohols that are the reaction products such as tetrahydrofuran, dioxane, and ethylene glycol dimethyl ether
- hydrocarbons such as hexane, decalin, and methylcyclohexane.
- the above solvents may be used alone or in a mixture of two or more.
- a water solvent from the viewpoints of solubility and the like.
- the amount, of the solvent used is normally, but not limited to, about 0.1 to 20 times by mass, is preferably 0.5 to 10 times by mass, and is more preferably about 1 to 10 times by mass the amount of the carbonyl compound used as a raw material.
- the reduction reaction using this catalyst is normally conducted in a pressurized hydrogen gas.
- the reaction is normally conducted at 100° C. to 300° C. and is preferably conducted at 120° C. to 250° C.
- the reaction pressure is normally 1 to 30 MPaG, .is preferably 1 to 25 MPaG, and is further preferably 5 to 25 MPaG.
- the product of the reduction reaction using this catalyst is normally recovered by solvent distillation, solvent distillation followed by extraction using an organic solvent, distillation, sublimation, crystallization, chromatography, or the like, which depends on the physical properties of the product.
- the product is liquid at handling temperature, it is preferable to recover the product, while purifying the product by distillation.
- the product is solid at handling temperature, it is preferable to recover the product while purifying the product by crystallization. It is preferable to purify the solid product by washing.
- a 0.2 M-aqueous sodium hydroxide solution was added to the sample.
- the resulting mixture was irradiated with ultrasonic wave and subsequently subjected to centrifugal separation.
- the resulting liquid was analyzed by ion chromatography in order to determine the content of sulfate ions in the sample.
- the content, of sulfur in the sample was determined in accordance with a high-frequency furnace combustion-infrared detection method (carbon sulfur analyzer) by combusting the sample in a high-frequency induction heating furnace under an oxygen atmosphere and calculating the content of sulfur in the combustion gas by an infrared detection method.
- a high-frequency furnace combustion-infrared detection method carbon sulfur analyzer
- Titanium oxide particles (Catalysis Society of Japan, Reference catalyst JRC-TIO-14 produced by Ishihara Sangyc Kaisha, Ltd.) having a specific surface area of 308 m 2 /g were added to the resulting solution. The solution was stirred at room temperature for 20 minutes. Subsequently, water was removed using an evaporator. Then, drying was performed at 100° C. for 4 hours. The resulting material was charged into a vertical baking tube. While air was passed through the tube, a baking treatment was performed at 500° C. for 3 hours. The resulting solid was charged into a vertical baking tube.
- a hydrogenation reaction was conducted as in Example I-1 with the catalyst prepared in Example I-1, except that the amount of time during which the hydrogenation reaction was conducted was changed to 18 hours.
- the molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 89.3% and 6.5%, respectively.
- the molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (1,10-decanediol and 10-hydroxydecanoic acid) was 0.017.
- a hydrogenation reaction was conducted as in Example I-1 with a catalyst prepared as in Example I-3, except that the treatment in which the surfaces of the catalyst particles were stabilized by passing a 6-volume % oxygen/nitrogen gas through the tube was not performed after the reduction treatment had been performed while a hydrogen gas was passed through the tube.
- the molar yields of 1,10-decanediol and 10-hydroxydecancic acid in the reaction were 74.7% and 2.6%, respectively.
- the molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (1,10-decanediol and 10-hydroxydecanoic acid) was 0.004.
- a 5% rhenium-5% germanium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example I-1, except that the titanium oxide particles were changed to titanium oxide particles having a specific surface area of 302 m 2 /g and a sulfate ion content of 4.8% by mass (MC-150, produced by Ishihara Sangyo Kaisha, Ltd.).
- the sulfate ion content in the catalyst was 0.63% by mass.
- the sulfur content in the catalyst was 0.57% by mass.
- a hydrogenation reaction was conducted as in Example I-1 with this catalyst. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 81.7% and 0.6%, respectively.
- the molar ratio of the by-products (I-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target, components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.006.
- a 5% rhenium-5% germanium/titanium oxide catalyst was prepared by the same method as in Example I-1. except that the titanium oxide particles were changed to titanium oxide particles having a specific surface area of 90 m 2 /g and a sulfate ion content of 3.6% by mass (MC-90, produced by Ishihara Sangyo Kaisha, Ltd.). The sulfate ion content in the catalyst was 0.30% by mass. The sulfur content in the catalyst was 0.35% by mass, A hydrogenation reaction was conducted as in Example I-1 with this catalyst. The molar yields of 1,10-decanodiol and 10-hydroxydecanoic acid in the reaction were 4.5% and 36.8%, respectively.
- the molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.011.
- Example I-1 A 5% rheniuns-5% indium/titanium, oxide catalyst, was prepared by the same catalyst preparation method as in Example I-1, except that indium(III) chloride tetrahydrate was used instead of tetraethoxygermanium(IV). Subsequently, a hydrogenation reaction was conducted as in Example I-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 9.0% and 43.5%, respectively.
- the molar, ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target, components 10-hydroxydecanoic acid and 1,10-decanediol) was 0.034.
- a 5% rheniuns-5% silicon/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example I-1, except that tetraethoxysilane(IV) was used instead of tetraethoxygermanium(IV) and ethanol was used instead of water for preparing the solution. Subsequently, a hydrogenation reaction was conducted as in Example I-1. The molar yields or 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 1.7% and 23.1%, respectively.
- the molar ratio of the by-products (1-nonanol, 3-docanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.039.
- a 5% rhenium-1% germanium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example I-1, except that the ratio between the amounts of ammonium perrhenate and tetraethoxygermanium(IV) used as metal raw materials was changed and the surfaces of the catalyst particles were not stabilized by passing the 6-volume % oxygen/nitrogen gas through the tube subsequent to the reduction treatment.
- a hydrogenation reaction was conducted as in Example I-1 with this catalyst, except that the amount of time during which the reaction was conducted was changed to 3 hours.
- the molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 38.7% and 10.8%, respectively.
- the moinr ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.009.
- a hydrogenation reaction was conducted with the catalyst prepared in Example I-3 as in Example I-1, except that the amount of time during which the reaction was conducted was changed to 3 hours.
- the molar yields of 1,10-docanediol and 10-hydroxydecanoic acid in the reaction were 35.3% and 32.9%, respectively.
- the molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydraxydecanoic acid and 1,10-decanediol) was 0.005.
- a 5% rheniuns-5% germanium-0.5% ruthenium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example I-1, except that ammonium perrbenate, tetraethoxygermanium(IV), and ruthenium(III) chloride were used as metal raw materials and the surfaces of the catalyst particles were not stabilized by passing the 6-volume % oxygen/nitrogen gas through the tube subsequent to the reduction treatment. Subsequently, a hydrogenation reaction was conducted as in Example I-1. The molar yields of 1,10-decanediol and 10-hydroxydecancic acid in the reaction were 72.0% and 3.6%, respectively.
- the molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.006.
- a 5% rhenium-5% germaniunt-5% ruthenium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example I-10, except that the ratio between the amounts of ammonium perrhenate, tetraethoxygermanium(IV), and ruthenium(III) chloride used as metal raw materials was changed. Subsequently, a hydrogenation reaction was conducted as in Example I-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 89.0% and 0.4%, respectively.
- the molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.020.
- a 5% rhenium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example I-1, except that tetraethoxygermanium was not used. Subsequently, a hydrogenation reaction was conducted as in Example I-1.
- the molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 0.1% and 21.0%, respectively.
- the molar, ratio of the by-products ( 1 -nonanol, 1 -decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (1,10-decanediol and 10-hydroxydecanoic acid) was 0.060.
- a 5% rhenium-5% palladium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example X-1, except that ammonium perrhenate and dichlorotetraamminepalladium(II) were used as metal raw materials. Subsequently, a hydrogenation reaction was conducted as in Example I-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 33.1% and 0.0%, respectively.
- the molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.325.
- a 5% rhenium-5% ruthenium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example I-3, except that ammonium perrhenate and ruthenium(III) chloride were used as metal raw materials. Subsequently, a hydrogenation reaction was conducted as in Example I-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 45.0% and 11.1%, respectively. The molar ratio of the by-products ( 1 -nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.063.
- Table 1 summarizes the results obtained in Examples I-1 to I-11 and Comparative examples I-1 to I-3.
- Titanium oxide particles (MC-150, produced by Ishih&ra Sangyo Kaisha, Ltd.>having a specific surface area of 302 m 2 /g and a sulfate ion content of 4.8% by mass were added to the resulting solution. The solution was stirred at room temperature for 20 minutes.
- a 5% rheniura-5% germanium/zirconium oxide catalyst was prepared by the same catalyst preparation method as in Example I-6, except that zirconium oxide particles having a specific surface area of 97 m 2 /g which did not include a sulfate ion was used instead of the titanium oxide particles. Subsequently, a hydrogenation reaction was conducted as in example I-8, except that a water solvent was used instead of methanol. The molar yield of 10-decanol in the reaction was 23.2% and the molar ratio of the by-products (nonane and decane) to the target component (10-decanol) was 0.001.
- the total amount of 1,10-decanediol and 10-hydroxydecanoic acid produced is used as a measure of catalytic activity because 10-hydroxydecancic acid is considered a reaction intermediate of the 1,10-decanediol product and can be derived into 1,10-decanediol when the reaction time is further prolonged.
- a comparison between the results obtained in Examples I-12 and I-13 confirms that a catalyst including a carrier composed of zirconium oxide also has the same advantageous effects as a catalyst including a carrier composed of titanium oxide. Specifically, it is confirmed that a catalyst including a zirconium oxide carrier has a catalytic activity comparable to that of a catalyst including a titanium oxide carrier in terms of catalytic activity per unit specific surface area.
- a comparison between the results obtained in Examples I-1 and I-2 confirms that reaction selectivity car. be maintained by using a catalyst that includes germanium even under high-inversion-rate reaction conditions, which have been an issue for rhenium catalysts.
- a comparison between the results obtained in Examples I-1, I-4, and I-5 confirms that the higher the sulfate ion content in the catalyst, the higher the degree of reduction in the defunctionalization reaction, the higher the reaction selectivity, and the higher the degree of increase in the catalytic activity of the hydrogenation catalyst per unit specific surface area of the carrier. The remarkable reduction in the side reactions enables the production of an alcohol with a high purity and a reduction in the costs of purification of the alcohol produced.
- Titanium oxide particles (Catalysis Society of Japan, Reference catalyst JRC-TIO-14 produced by Ishihare Sangyo Kaisha, Ltd.) having a specific surface area of 308 m 2 /g were added to the resulting solution. The solution was stirred at room temperature for 20 minutes. Subsequently, water was removed using an evaporator. Then, drying was performed at 100° C. for 4 hours. The resulting material was charged into a vertical baiting tube. While air was passed through the tube, a baking treatment was performed at 500° C. for 3 hours. The resulting solid was charged into a vertical baking tube.
- a hydrogenation reaction was conducted as in Example II-1 with the catalyst prepared in Example II-1, except that the amount of time during which the hydrogenation reaction was conducted was changed to 18 hours.
- the molar yields or 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 89.3% and 6.5%, respectively.
- the molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (1,20-decanediol and 10-hydroxydecanoic acid) was 0.017.
- a hydrogenation reaction was conducted as in Example II-1 with a catalyst prepared as in Example II-1, except that the treatment in which the surfaces of the catalyst particles were stabilized by passing a 6-volume % oxygen/nitrogen gas through the tube was not performed after the reduction treatment had been performed while a hydrogen gas was passed through the tube.
- the molar yields of 1,10-docanediol and 10-hydroxydecanoic acid in the reaction wore 74.7% and 2.6%, respectively.
- the molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (1,10-decanediol and 10-hydroxydecanoic acid) was 0.004.
- a 5% rhenium-5% germanium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example II-1, except that the titanium oxide particles were changed to titanium oxide particles having a specific surface area of 302 m 2 /g and a sulfate ion content of 4.8% by mass (MC-150, produced by Ishihara Sangyo Kaisha, Ltd.).
- the sulfate ion content in the catalyst was 0.63% by mass.
- the sulfur content in the catalyst was 0.57% by mass
- a hydrogenation reaction was conducted as in Example II-1 with this catalyst.
- the molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 81.7% and 0.6%, respectively.
- the molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.006.
- a 5% rhenium-5% germanium/titanium oxide catalyst was prepared by the same method as in Example II-1, except that the titanium oxide particles were changed to titanium oxide particles having a specific surface area of 90 m 2 /g and a sulfate ion content of 3.6% by mass (MC-90, produced by Ishihare Sangyo Kaisha, Ltd.).
- the sulfate ion content in the catalyst was 0.30% by mass.
- the sulfur content in the catalyst was 0.35% by mass.
- a hydrogenation reaction was conducted as in Example II-1 with this catalyst.
- the molar yields of 1,10-decanedioi and 10-hydroxydecanoic acid in the reaction were 4.5% and 36.8%, respectively.
- the molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxyclecanoic acid and 1,10-decanediol) was 0.011.
- a 5% rhenium-5% indium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example II-1, except, that indium(III) chloride tetrahydrate was used instead of tetraethoxygermanium(IV). Subsequently, a hydrogenation reaction was conducted as in Example II-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 9.0% and 43.5%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decaroic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.034.
- a 5% rhenium-5% silicon/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example II-1, except that tetraethoxysilane(IV) was used instead of tetraethoxygermanium(IV) and ethanol was used instead of water for preparing the solution. Subsequently, a hydrogenation reaction was conducted as in Example II-1. The molar yields of 1,10-decarediol and 10-hydroxydecanoic acid in the reaction were 1.7% and 23.1%, respectively.
- the molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.039.
- a 5% rhenium-1% germanium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example II-1, except that the ratio between the amounts of ammonium perrhenate and tetraethoxygermanium(IV) used as metal raw materials was changed and the surfaces of the catalyst particles were not stabilized by passing the 6-volume % oxygen/nitrogen gas through the tube subsequent to the reduction treatment.
- a hydrogenation reaction was conducted as in Example II-1 with this catalyst, except that the amount of time during which the reaction was conducted was changed to 3 hours.
- the molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 36.7% and 10.8%, respectively.
- a hydrogenation reaction was conducted with the catalyst prepared in Example 11 -3 as in Example II-1, except that the amount of time during which the reaction was conducted was changed to 3 hours.
- the molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 35.3% and 32.9%, respectively.
- the molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1 , 10 -decanediol) was 0.005.
- a 5% rhenium-5% germanium-5% ruthenium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example II-10, except that the ratio between the amounts of ammonium perrhenate, tetraethoxygermanium(XV) and ruthenium(III) chloride used as metal raw materials was changed. Subsequently, a hydrogenation reaction was conducted as in Example II-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction wore 39.0% and 0.4%, respectively.
- the molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.020.
- a 5% rhenium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example II-1, except chat tetraethoxygermanium was not used. Subsequently a hydrogenation reaction was conducted as in Example II-1.
- the molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 0.1% and 21.0%, respectively.
- the molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (1,10-decanediol and 10-hydroxydecanoic acid) was 0.060.
- a 5% rhenium-5% palladium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example II-1, except that ammonium perrhenate and dichlorotetraanuninepalladium(II) were used as metal raw materials. Subsequently, a hydrogenation reaction was conducted as in Example I-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid m the reaction were 33.1% and 0.0%, respectively.
- the molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.825.
- a 5% rhenium-5% ruthenium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example II-1, except that ammonium perrhenate and ruthenium (III) chloride were used as metal, raw materials. Subsequently, a hydrogenation reaction was conducted as in Example II-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 45.0% and 11.1%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanolc acid and 1,10-decanediol was 0.063.
- Table 2 summarizes the results obtained in Examples II-1 to II-11 and Comparative examples II-1 to II-3.
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Abstract
Description
- The present invention relates specifically to a catalyst useful as a catalyst for hydrogenation of a carbonyl compound and an alcohol production method in which a carbonyl compound is hydrogenated using the catalyst.
- Methods in which a carbonyl compound is hydrogenated to form a corresponding alcohol have long been known. For example, a common alcohol production method from an organic carboxylic acid is to esterify a carboxylic acid with a lower alcohol and subsequently perform reduction using an Adkins catalyst (copper chromite catalyst).
- However, the production of an alcohol with a copper catalyst, which is commonly conducted under a severe condition such as a hydrogen pressure of 200 atmospheres or more, is an uneconomical process that consumes a large amount of energy for producing an alcohol and introduces various facility restrictions. Furthermore, since a copper catalyst is not capable of directly reducing an organic carboxylic acid, a carboxylic acid needs to be converted into a carboxylic acid ester before a reduction treatment is performed. Therefore, multistage reaction processes need to be conducted in order to produce an intended alcohol. This increases the complexity of the process.
- Moreover, in the case where the above production method is used, it becomes considerably difficult to selectively produce a hydroxycarboxylic acid using, for example, a polyvalent carboxylic acid as a raw material by converting a part of the carboxylic acid functional group3 into alcohol functional groups.
- In contrast, a method in which a carboxylic acid is directly hydrogenated (reduced) in one stage and a corresponding alcohol is produced with high selectivity is an economically advantageous process. Even in the case where a polyvalent carboxylic acid is used as a raw material, it is possible to selectively produce a corresponding hydroxycarboxylic acid by appropriately controlling the reaction conditions.
- There have been proposed various metal-supporting catalysts that include a noble metal belonging to Groups 3 to 10 of the periodic table as a catalytic activity component, for use in such a process. Examples of the metal-supporting catalysts include a catalyst produced by attaching palladium and rhenium to a carrier and subsequently performing a reduction treatment with hydrogen or the like (e.g., PTL 1 and NPL 1) and a catalyst produced by attaching ruthenium and tin to a carrier and subsequently performing a reduction treatment with hydrogen or the like (e.g., PTLs 2 and 3).
- The above catalysts are suitable catalysts that have a high reaction activity and high reaction selectivity in the reduction of a carboxylic acid and/or a carboxylic acid eater. There has also beer, proposed a hydrogenation reaction of a particular carboxylic acid In which a cobalt catalyst that includes lanthanum and palladium, which is an example of the above-described catalysts, is used (e.g., PTL 4).
- On the other hand, there have also been proposed catalysts that do not include any of the expensive noble metals belonging to Groups 8 to 10 of the periodic table. For example, a catalyst including rhenium that serves as a catalytic component has been reported since a long time ago (e.g., NPL 2). There has also been proposed a tin-containing rhenium catalyst for use in a hydrogenation reaction of a particular carboxylic acid (e.g., PTL 5). Recently, there has been reported a method for selectively producing an intended alcohol under further mild conditions. In the production method, a metal-supporting catalyst including rhenium that serves as a catalytic activity component is used (e.g., NPLs 3 and 4).
- However, since catalysts including rhenium that serves as a catalytic activity component have lower catalytic activity than catalysts including a noble metal, it is common to use, as a supported metal, rhenium in combination with a noble metal belonging to Groups 8 to 10 of the periodic table or to add cobalt, which belongs to Group 9 of the periodic table, to a carrier (e.g., PTLs 6, 7, 8, and 9 and NPL 5).
- PTL 1: Japanese Unexamined Patent Application Publication No. 63-218636
- PTL 2: Japanese Unexamined Patent Application Publication No. 2000-007596
- PTL 3: Japanese Unexamined Patent Application Publication No. 2001-157841
- PTL 4: Japanese Unexamined Patent Application Publication No. 63-301845
- PTL 5: Japanese Unexamined Patent Application Publication No. 4-99753
- PTL 6: Japanese Unexamined Patent Application Publication No. 6-116182
- PTL 7: Japanese Unexamined Patent Application Publication (Translation of PCT Application) No. 2002-501817
- PTL 8: Japanese Unexamined Patent Application Publication (Translation of PCT Application) No. 2016-500697
- PTL 9: Japanese Unexamined Patent Application Publication No. 7-119187
- NFL 1: Topics in Catalysis 55 (2012) 466-473
- NPL 2: Journal of Organic Chemistry 24 (1959) 1847-1854
- NPL 3: Journal of Catalysis 328 (2015) 197-207
- NPL 4: Chemistry A European Journal 23 (2017) 1001-1006
- NPL 5: ACS Catalysis 5 (2015) 7034-7047
- A catalyst including a noble metal belonging to Groups 6 to 10 of the periodic table which serves as a catalytic activity component, which is produced using an expensive noble metal, increases the costs of production of a catalyst. In addition, such a catalyst typically causes side reactions, such as a degradation reaction that involves decarboxylation, a defunctionalization reaction associated with dehydration and hydrogenation of the reaction product, and an esterification reaction of a carboxylic acid used as a raw material with an alcohol produced. Thus, it is necessary to reduce the above side reactions.
- For example, as for a palladium metal-supporting catalyst containing rhenium, the addition of rhenium increases the rate of catalytic reaction in which succinic acid is converted into the hydride of succinic acid, that is, butanediol, as described in NPL 1. However, the above-described side reactions also occur, which reduce the productivity of the reaction product, and increase the purification costs. In addition, the catalytic activity of such a catalyst is still at an insufficient level.
- As for the catalysts that include a catalytic component, such as tin, in addition to a noble metal belonging to Groups 8 to 10 of the periodic table as proposed in PTLs 2 and 3, the addition of tin or the like increases reaction selectivity. However, the addition of such catalytic components may disadvantageously reduce catalytic activity. This results in a necessity to further use a large amount of expensive noble metal, such as platinum, and increases the costs of production or a catalyst.
- The catalyst including rhenium that serves as a principal catalytic activity component allows a highly economical process to be realized in the sense that the catalyst does not include any expensive noble metal. However, such catalysts typically have lower activity than catalysts that include a noble metal. Moreover, an esterification reaction of a carboxylic acid used as a raw material with an alcohol produced is likely to occur due to high Lewis acidity of rhenium and, particularly at a later stage of the reaction, a defunctionalization reaction may significantly occur due to the dehydration and hydrogenation of the alcohol produced. This significantly reduces the selectivity of the alcohol that is t.c be produced.
- An object of the present Invention is to provide a highly economical alcohol production method that enables an intended alcohol to be produced at a high yield with high selectivity by the hydrogenation reaction of a carbonyl compound while reducing the above-described various side reactions to a sufficient degree.
- Another object of the present invention is to provide a high-activity metal-supporting catalyst including rhenium which enables an intended alcohol to be produced at a high yield with high selectivity by the hydrogenation reaction of a carbonyl compound while reducing the side reactions and a method for producing such a metal-supporting catalyst.
- The inventors of the present invention found that the above issue3 may be addressed by using a catalyst produced by attaching rhenium and a specific second component to a carrier when an alcohol is produced by the hydrogenation reaction of a carbonyl compound and consequently made the present invention.
- The summary of the first aspect of the present invention (hereinafter, referred to as “first invention”) is as follows.
- [1-1] An alcohol production method in which an alcohol is produced from a carbonyl compound, the method comprising producing an alcohol by using a catalyst, the catalyst including a metal component including a first component that is rhenium and one or more second components selected from the group consisting of silicon, gallium, germanium, and indium and a carrier or which the metal component is supported, the carrier including an oxide of a metal belonging to Group 4 of the periodic table.
- [1-2] The alcohol production method according to [1-1], wherein the mass ratio of elements that are the second components included in the catalyst to the rhenium element included in the catalyst is 0.1 or more and 10 or less.
- [1-3] The alcohol production method according to [1-1] or [1-2], wherein the oxide of a metal belonging to Group 4 of the periodic table, the oxide being included in the catalyst, includes titanium oxide and/or zirconium oxide.
- [1-4] The alcohol production method according to any one of [1-1] to [1-3], wherein the catalyst is a catalyst prepared by a method including a step in which the metal component is attached to a carrier including a sulfate ion.
- [1-5] The alcohol production method according to [1-4], wherein the sulfate ion content in the carrier is 0.01% by mass or more and 10% by mass or less of the mass of the carrier.
- [1-6] The alcohol production method according to any one of [1-1] to [1-5], wherein the sulfate ion content in the catalyst is 0.01% by mass or more and 10% by mass or less of the mass of the catalyst.
- [1-7] A catalyst comprising a metal component including a first component that is rhenium and one or more second components selected from the group consisting of silicon, gallium, germanium, and indium, and a carrier on which the metal component is supported, the carrier including an oxide of a metal belonging to Group 4 of the periodic table.
- [1-8] The catalyst according to [1-7], wherein the mass ratio of elements that are the second components to the rhenium element is 0.1 or more and 10 or less.
- [1-9] The catalyst according to [1-7] or [1-8], wherein the oxide of a metal belonging to Group 4 of the periodic table includes titanium oxide and/or zirconium oxide.
- [1-10] The catalyst according to any one of [1-7] to [1-9], wherein the sulfate ion content in the catalyst is 0.01% by mass or more and 10% by mass or less of the mass of the catalyst.
- [1-11] The catalyst according to any one of [1-7] to [1-10], the catalyst being a catalyst used for hydrogenation of a carbonyl compound.
- The summary of the second aspect of the present invention (hereinafter, referred to as “second invention”) is as follows.
- [2-1] An alcohol production method in which an alcohol is produced from a carbonyl compound, the method comprising producing an alcohol by using a catalyst, the catalyst including a metal component including a first component that is rhenium and one or more second components selected from the group consisting of silicon, gallium, germanium, and indium and a carrier on which the metal component is supported, the mass ratio of elements that are the second components to the rhenium element being 0.1 or more and 10 or less.
- [2-2] The alcohol production method according to [2-1], wherein the second components of the catalyst include germanium.
- [2-3] The alcohol production method according to [2-1] or [2-2], wherein the mass ratio of a metallic element belonging to Groups 3 to 10 of the periodic table to the rhenium element included in the catalyst, the metallic element being other than iron or nickel, is less than 0.2.
- [2-4] The alcohol production method according to [2-3], wherein the metallic element belonging to Groups 3 to 10 of the periodic table, the metallic element being included in the catalyst, the metallic element being other than iron or nickel, includes ruthenium.
- [2-5] The alcohol production method according to any one of [2-1] to [2-4], wherein the carrier is a carbonaceous carrier or a carrier including an oxide of n metal belonging to Group 4 of the periodic table.
- [2-6] The alcohol production method according to any one of [2-1] to [2-5], wherein the catalyst is a catalyst prepared by a method including a step in which the metal component is attached to a carrier including a sulfate ion.
- [2-7] The alcohol production method according to [2-6], wherein the sulfate ion content in the carrier is 0.01% by mass or more and 10% by mass or less of the mass of the carrier.
- [2-8] The alcohol production method according to any one of [2-1] to [2-7], wherein the sulfate ion content in the catalyst is 0.01% by mass or more and 10% by mass or less of the mass of the catalyst.
- [2-9] A catalyst comprising a metal component including a first component that is rhenium and one or more second components selected from the group consisting of silicon, gallium, germanium, and indium and a carrier on which the metal component is supported, the mass ratio of elements that are the second components to the rhenium element being 0.1 or more and 10 or less.
- [2-10] The catalyst according to [2-9], wherein the second components include germanium.
- [2-11] The catalyst according to [2-9] or [2-10], wherein the mass ratio of a metallic element belonging to Groups 3 to 10 of the periodic table to the amount of the rhenium element, the metallic element being other than iron or nickel, is less than 0.2.
- [2-12] The catalyst according to [2-13], wherein the metallic element belonging to Groups 8 to 10 of the periodic table, the metallic clement being other than iron or nickel, includes ruthenium.
- [2-13] The catalyst according to any one of [2-9] to [2-12], wherein the carrier is a carbonaceous carrier or a carrier including an oxide of a metal belonging to Group 4 of the periodic table.
- [2-14] The catalyst according to any one of [2-9] to [2-13], wherein the sulfate ion content in the catalyst is 0.01% by mass or mere and 10% by mass or less.
- [2-15] The catalyst according to any one of [2-9] to [2-14], the catalyst being a catalyst used for hydrogenation of a carbonyl compound.
- [2-16] A method for producing a catalyst, the method comprising attaching a metal component including at least a first component that is rhenium and one or more second components selected from the croup consisting of silicon, gallium, germanium, and indium to a carrier including a sulfate ion, the content of the sulfate ion in the carrier being 0.01% by mass or more and 10% by mass or less of the mass of the carrier.
- According to the first invention, there is provided an alcohol production method in which a carbonyl compound is reduced into an alcohol with high activity and high selectivity by using a reduction catalyst including rhenium that serves as a catalytic activity component, the catalyst further including one or more catalytic additive components selected from the group consisting of silicon, gallium, germanium, and indium and a carrier including an oxide of a metal belonging to Group 4 of the periodic table, the catalytic additive components being supported on the carrier. Also provided is the catalyst useful for producing an alcohol. Note that the term “periodic table” used herein refers to the long form of periodic table (Nomenclature of Inorganic Chemistry IUPAC recommendations 2005).
- The catalyst according to the first invention enables an increase in catalytic activity, which has been an issue for rhenium catalysts, to be achieved substantially without using noble metals belonging to Groups 8 to 10 of the periodic table. The catalyst according to the first Invention also makes it possible to produce an alcohol from a carbonyl compound while reducing side reactions, such as an esterification reaction of a carboxylic acid used as a raw material with an alcohol produced and a defunctionalization reaction due to the dehydration and hydrogenation of the alcohol produced, which significantly occurs particularly at a later stage of the reaction, to a high degree. It becomes also possible to, in the case where a polyvalent carboxylic acid 13 used as a raw material, produce a hydroxycarboxylic acid with high selectivity by converting a part of the carboxylic acid functional groups into alcohol functional groups.
- According to the second invention, there is provided an alcohol production method in which a carbonyl compound is reduced into an alcohol with high activity and high selectivity by using a reduction catalyst including rhenium that serves as a catalytic activity component, the catalyst further including one or more catalytic additive components selected from the group consisting of silicon, gallium, germanium, and indium at a predetermined elemental mass ratio and a carrier, the catalytic additive components being supported on the carrier. Also provided is the catalyst useful for producing an alcohol.
- The catalyst according to the second invention enables an increase in catalytic activity, which has been an issue for rhenium catalysts, to be achieved substantially without using noble metals belonging to Groups 8 to 10 of the periodic table. The catalyst according to the second invention also makes it possible to produce an alcohol from a carbonyl compound while reducing side reactions, such as the esterification reaction of a carboxylic acid used as a raw material with an alcohol produced and a defunctionalization reaction due to the dehydration and hydrogenation of the alcohol produced, which significantly occurs particularly at a later stage of the reaction, to a high degree. It becomes also possible to, in the ease where a polyvalent carboxylic acid is used as a raw material, produce a hydroxycarboxylic acid with high selectivity by converting a part of the carboxylic acid functional groups into alcohol functional groups.
- Embodiments of the present, invention are described below in detail. The elements described below are merely an example (typical example) of an aspect of the present invention. The present invention is not limited by the description and may be modified within the scope of the present invention.
- In the present invention, catalytic components supported on a carrier (e.g., rhenium; one or more elements selected from the group consisting of silicon, gallium, germanium, and indium; and optional metal elements belonging to Groups 8 to 10 of the periodic table, such as ruthenium) may be referred to collectively as “metal components”.
- A material produced by attaching the metal components to a carrier may be referred to as “metal-supporting material”.
- A catalyst, produced by reducing the metal-supporting material may be referred to as “metal-supporting catalyst”.
- In the present invention, the metal components supported on the carrier are the same as the metal components included in the catalyst.
- The content of the supported metal in the catalyst can be determined by publicly known analysis methods, such as inductively coupled plasma mass spectrometry (ICP-MS), inductively coupled plasma atomic emission spectrometry (ICP-AES), atomic absorption spectrometry (AAS), and X-ray fluorescence analysis (XRK). In the case where ICP-MS, ICP-AES, and AAS are used, the sample is formed into a solution in a pretreatment conducted in combination with the analysis. The type of the analysis method used is not limited since an appropriate analysis method varies with the element subjected to the quantitative analysis, the concentration of the element, and the accuracy required for the analysis. In the present invention, the quantitative analysis of the supported metal included in the catalyst is conducted using inductively coupled plasma atomic emission spectrometry, atomic absorption spectrometry, or both inductively coupled plasma atomic emission spectrometry and atomic absorption spectrometry in order to determine the metal content in the catalyst.
- The mass ratio between the metal components supported on the carrier is calculated on the basis of the metal components included in the catalyst as in the description of the method for determining the content of the supported metal in the catalyst. The mass ratio between the rhenium element an a the second component element can be determined using publicly known analysis methods, such as inductively coupled plasma mass spectrometry (ICP-MS), inductively coupled plasma atomic emission spectrometry (ICP-AES), atomic absorption spectrometry and X-ray fluorescence analysis (XRF), as in the description of the method for determining the content, of the supported metal in the catalyst.
- In the present invention “% by weight” and “% by mass” are synonymous with each other, and “element” and “atom” are synonymous with each other.
- The catalyst according to the present invention can be suitably used as a hydrogenation catalyst when an alcohol is produced from a carbonyl compound. In the present invention, a carbonyl compound is defined as a compound that includes a carbon-oxygen double bond (C═O), and
- An alcohol is defined as a compound produced by converting the carbonyl compound into an alcohol functional group (OH).
- Therefore, in the present invention, in the case where a carbonyl compound used as a raw material includes a plurality of carbon-oxygen double bonds, a compound produced by converting at least one of the carbon-oxygen double bonds of the carbonyl compound into an alcohol functional group is defined as an alcohol.
- A catalyst according to the first invention (hereinafter, may be referred to simply as “first catalyst”) is a metal-supporting catalyst that includes a metal component and a carrier on which the metal component is supported. Specifically, the metal components including a first component that is rhenium arid one or more second components selected from the group consisting of silicon, gallium, germanium, and indium are supported on a carrier including an oxide of a metal belonging to Group 4 of the periodic cable.
- The first catalyst is normally produced by reducing a metal-supporting material on which the metal component is supported with a reducing gas and then performing an oxidative stabilization treatment as needed.
- <Metal Component>
- The metal component supported on the metal-supporting catalyst according to the first invention includes a first component that is rhenium and one or more second components selected from the group consisting of silicon, gallium, germanium, and indium. Among these, the second components used in combination with rhenium are preferably one or more elements selected from the group consisting of silicon, germanium, and indium, are more preferably one or more elements that include indium end/or germanium, are further preferably one or more elements that include germanium, and are particularly preferably germanium.
- As for the ratio between the amounts of the above essential components supported on the catalyst, the lower limit for the mass ratio of the second component elements that are one or mere elements selected from the group consisting of silicon, gallium, germanium, and indium to the rhenium element is preferably 0.1 or more and is more preferably 0.5 or more, and the upper limit for the above mass ratio is preferably 10 or less, is more preferably 5 or less, is further preferably 3 or less, is particularly preferably 2 or less, and is most preferably 1 or less.
- Appropriately selecting the types of the second components used in combination with rhenium and/or the proportion of the second components supported on the carrier increases the catalytic activity in a hydrogenation reaction of a carbonyl compound and makes it possible to produce an alcohol while reducing side reactions, such as the esterification reaction of a carboxylic acid used as a raw material with an alcohol produced and a defunctionalization reaction due to the dehydration and hydrogenation of the alcohol produced, which significantly occurs particularly at a later stage of the reaction, to a high degree. Using the above metal components in combination with one another enables the first catalyst to be handled in the air atmosphere. This increases ease of operation, such as transportation and storage of the catalyst and introduction cf the catalyst to a reactor in the production of an alcohol.
- Using the above metal components in combination with one another enables an increase in catalytic activity and an increase in reaction selectivity, which have been Considered contradictory, to be both achieved presumably for the following reasons: the addition of the second components enables the electronic state of rhenium, which is a catalytic activity component of the hydrogenation catalyst, to be controlled to be in a state suitable for a reduction reaction of a carbonyl functional group; the adsorptivity of reactive substrates onto the surface of the catalyst is enhanced due to the affinity of the reactive substrates tor the second components; and the orientation of adsorption of the reactive substrates on the surface of the catalyst is controlled at a high degree.
- Although the amount of rhenium supported on the first catalyst is not limited, the mass ratio of the rhenium element, to the total mass of the metal-supporting catalyst is normally 0.5% by mass or more, is preferably 1% by mass or more, is more preferably 3% by mass or snore, is normally 20% by mass or less, is preferably 10% by mass or less, and is more preferably 8% by mass or less. When the amount of rhenium supported on the catalyst is limited to be equal to or more than the lower limit, sufficiently high catalytic activity can be achieved. This prevents, for example, an increase in the volume of the reactor used. When the amount of rhenium supported on the catalyst is limited to be equal to or less than the upper limit, an increase in the cost of the catalyst can be limited, furthermore, in such a case, coagulation of rhenium supported on the catalyst can be reduced. This reduces the side reactions, such as a degradation reaction involved by decarboxylation, a defunctionalization reaction associated with dehydration and hydrogenation of the reaction product, and an esterifications reaction of a carboxylic acid used as a raw material with an alcohol produced, due to high Lewis acidity of rhenium. As a result, reaction selectivity can be further increased.
- The first catalyst may further include, as needed, a third component that is a metal component other than the above metal components (i.e., rhenium and the second components) and that does not adversely affect the reactions conducted using the. first catalyst, such as a reduction reaction. Examples of the other metal component include metal components belonging to Groups 3 to 10 of the periodic table except iron and nickel. Examples thereof include at least one metal selected from the group consisting of ruthenium, cobalt, rhodium, iridium, palladium, and platinum which are capable of catalyzing hydrogenation.
- Metals, such as iron and nickel, may elute and enter the catalyst when a metal reaction container made of SS, SUS, or the like becomes corroded in the preparation oil the catalyst and/or the reaction. In the first invention, in the case where the eluted metal is precipitated on the catalyst and included in the catalyst, the metal is not defined as a metal component of the first catalyst. In the case of elution from a reaction container made of SUS, in addition to iron, the following metals may be detected in the catalyst in trace amounts at specific contents depending on the material used.
- For example, when metals enter from SUS201, nickel, chromium, and manganese may foe detected in addition to iron at specific contents. When metals enter from SUS202, nickel chromium, and manganese may foe detected in addition to iron at specific contents. When metals enter from SUS301, nickel and chromium may be detected in addition to iron at specific contents. When metals enter from SUS302, nickel and chromium may be detected in addition to iron at specific contents. When metals enter from SUS303, nickel, chromium, and molybdenum may be detected in addition to iron at specific contents. When metals enter from SUS304, nickel and chromium may be detected in addition to iron at specific contents. When metals enter from SUS305, nickel and chromium may be detected in addition to iron at specific contents. When metals enter from SUS316, nickel, chromium, and molybdenum may be detected in addition to iron at specific contents. When metals enter from SUS317, nickel, chromium, and molybdenum may be detected in addition to iron at specific contents. When metals enter from SUS329J1, nickel, chromium, and molybdenum may be detected in addition to iron at specific contents. When metals enter from SUS403, chromium may be detected in addition to iron at a specific content. When metals enter from SUS405, chromium and aluminum may be detected in addition to iron at specific contents. When metals enter from SUS420, chromium may be detected in addition to iron at a specific content. When metals enter from SUS430, chromium may be detected in addition to iron at a specific content. When metals enter from 8US430LX, chromium, titanium, or niobium may be detected in addition to iron at a specific content. When metals enter from SUS630, nickel, chromium, copper, and niobium may be detected in addition to iron at specific contents.
- Examples of the metal component that belongs to a group other than Groups 8 to 10 of the periodic table include at least one metal selected from the group consisting of silver, gold, molybdenum, tungsten, aluminum, and boron.
- Among the above third components, at least one metal selected from ruthenium, cobalt, rhodium, iridium, palladium, platinum, gold, molybdenum, and tungsten is preferable; at least one metal selected from ruthenium, cobalt, rhodium, iridium, palladium, platinum, molybdenum, arid tungsten is more preferable; at least one metal selected from ruthenium, iridium, palladium, and platinum is particularly preferable; and ruthenium is most preferable.
- In the case where the third component is selected from rare and expensive metals belonging to Groups 8 to 10 of the periodic table except iron and nickel, the elemental mass ratio of the third component included in the first catalyst to the rhenium element is normally less than 0.2, is preferably 0.15 or less, is more preferably 0.1 or less, is further preferably less than 0.1, and is most preferably 0 in order to increase reaction selectivity and economical efficiency in terms of the costs for producing the catalyst. That is, it is preferable that the first catalyst substantially do not include any of the rare and expensive metals belonging to Groups 8 to 10 of the periodic table other than iron or nickel.
- In the case where the third component is selected from metals other than the noble metals belonging to Groups 8 to 10 of the periodic table, the elemental mass ratio of the third component to the rhenium element is normally 10 or less, is preferably 5 or less, is more preferably 1 or less, and is further preferably 0.5 or less. When the above additional metal components are used in an appropriate combination at adequate contents, it is possible to achieve high catalytic activity while maintaining high selectivity.
- In the case where a metal, such as iron or nickel, becomes eluted and enters the catalyst due to the corrosion of a reaction container made of SS, SUS, or the like, in the first invention, the content of iron and the contents of the above metals included at specific contents, which are determined on the basis of the type of material constituting the reaction container, are not taken into account in the calculation of the content of the metal components in the catalyst.
- In order to further increase the activity of the catalyst, reaction selectivity, and the like, the first catalyst may include compounds of one or more alkali metal elements selected from the group consisting of lithium, sodium, potassium, rubidium, and cesium; compounds of one or more alkaline-earth metal elements selected from the group consisting of magnesium, calcium, strontium, and barium; and compounds of one or more halogen elements selected from the group consisting of fluorine, chlorine, bromine, and iodine, in addition to the metal components described above. In such a case, the ratio between the additional components and the rhenium component is nor. limited.
- <Carrier>
- The carrier used in the first invention is a carrier that includes an oxide of a metal belonging to Group 4 of the periodic table. In particular, an inert carrier can be used. The term “inert carrier” used herein refers to a carrier that does not have a catalytic activity in a hydrogenation or a carbonyl compound alone. Specifically, the inert carrier is defined as a carrier that substantially does not include any of the metals belonging to Group 8 to 12 of the periodic table which is selected from the group consisting oi iron, ruthenium, cobalt, rhodium, iridium, nickel, palladium, platinum, copper, and zinc, chromium, and rhenium, which are metals having catalytic activity.
- A carrier that substantially does not include any cf the above metals is a carrier that does not primarily include any of the above metals. That is, the amount of the above metals included in the carrier to the total mass of the carrier is 5% by mass or less, is preferably 1% by mass or less, and is mere preferably 0.1% by mass or less. The content of the above metals in the carrier can be determined as in the analysis of the content of the supported metal in the catalyst, using publicly known analysis methods, such as inductively coupled plasma mass spectrometry (ICP-MS), inductively coupled plasma atomic emission spectrometry (ICP-AES), atomic absorption spectrometry (AAS), and X-ray fluorescence analysis (XRF).
- In the first invention, a carrier that includes an oxide of a metal belonging to Group 4 of the periodic table, such as titanium oxide (titania), zirconium oxide (zirconia), or hafnium oxide, is used in order to increase catalytic activity and reaction selectivity achieved particularly when a carboxylic acid is used as a raw material and ease of regeneration of the catalyst and reduce the elution of metals. Among the oxides of metals belonging to Group 4 of the periodic table, titanium oxide and zirconium oxide are preferable in order to increase catalytic activity and produce an intended alcohol with high selectivity. Among these, titanium oxide may be particularly preferable in order to readily produce carrier particles having a large specific surface area. The oxides of metals belonging to Group 4 of the periodic table may be used alone or in combination of two or more. In the case where the oxides of metals belonging to Group 4 of the periodic table are used in combination of two or more, the combination of the oxides arid the mixing ratio between the oxides are not limited. The oxides can be used in a form similar to a mixture of the individual compounds or a composite oxide.
- It may be preferable that the carrier used in the first invention contain a sulfate ion. In particular, in the case where titanium oxide is used as a carrier, it may fee preferable that the carrier contain a sulfate ion.
- In the first invention, using a carrier including a sulfate ion may markedly reduce a degradation reaction involved by decarboxylation and a defunctionalization reaction associated with dehydration and hydrogenation of the reaction product, that is, an alcohol, which occur simultaneously with a catalytic reaction of hydrogenation of a carbonyl compound. In addition, when the metal components that include rhenium and the second components are supported on such a carrier, the catalytic activity of the hydrogenation catalyst may be markedly increased. When the metal components are used in combination with the carrier, the catalyst can be handled in the air atmosphere. This increases ease of operation of the catalyst, such as transportation and storage of the catalyst and introduction of the catalyst to a reactor in the production of an alcohol.
- It is considered that the functions of the catalyst are enhanced for the following reasons: when the carrier contains a sulfate ion, sulfate ions present in the surface of the carrier may form acid sites on the surface of the catalyst. Furthermore, the dispersibility of the supported metal may be increased due to the interaction between the supported metal and the sulfate ion or a substitution reaction of the supported metal with the sulfate ion which occurs when the metal components are supported on the carrier. Moreover, the electronic state of rhenium, which is a catalytic activity component of the hydrogenation catalyst, can be controlled to be in a state suitable for a reduction reaction of a carbonyl functional group. The above factors may synergistically increase the reaction selectivity of the catalyst and the activity of the catalyst.
- The mass ratio of the amount of the sulfate ion included in the carrier to the total mass of the carrier used is preferably 0.01% by mass or more, is more preferably 0.1% by mass or more, and is particularly preferably 0.2% by mass or more. The mass ratio of the amount of the sulfate ion to the total mass of the carrier used is preferably 10% by mass or less, Is more preferably 7% by mass or less, and is particularly preferably 5% by mass or less.
- When the content of the sulfate ion in the carrier used is limited to be equal to or more than the lower limit, the advantageous effects of adding the above components are achieved at a sufficient level and high catalytic activity can be achieved, furthermore, the occurrence of the defunctionalization reaction can be further reduced. This limits an increase in the complexity of the process for purifying the reaction product and an increase in the purification costs and consequently enables an economically advantageous alcohol production process to be provided. Limiting the content of the sulfate ion in the carrier used to he equal to or less than the upper limit reduces, for example, corrosion of the reactor caused by sulfate ions included in the carrier becoming eluted during the reaction depending on the solvent used and side reactions of the target product caused by the liberated acid catalyst and therefore eliminates the need to use materials having high corrosion resistance. This limits increases in the costs for constructing reaction facilities and the costs for purifying the product and enables an economically advantageous alcohol production process to be provided.
- In the case where a carrier including a sulfate ion is used in the first invention, the carrier is not limited and may be any carrier that includes a sulfate ion. An appropriate commercial product may be used directly. In the case where the carrier is composed of a metal oxide, the carrier may be prepared by, for example, dissolving a corresponding metal sulfate in water and subsequently performing neutralization or pyrohydrolysis, or by treating a corresponding metal hydroxide or a baked metal oxide with a sulfatizing agent and subsequently performing baking in an oxidizing atmosphere, such as the air atmosphere. The treatment using a sulfatizing agent is to introduce sulfate ions into the carrier. This treatment nay be performed in the step of producing the carrier or nay be performed after the production of the carrier. Examples of the sulfatizing agent include sulfuric acid, persulfuric acid, and the salts thereof. Sulfuric acid, a sulfuric acid salt, and a persulfuric acid salt are preferable. The sulfuric acid salt is not limited and may be any sulfuric acid salt capable of providing sulfate ions when dissolved. Examples of the sulfuric acid salt include ammonium sulfate, sodium sulfate, and potassium sulfate. The same applies to the persulfuric acid salt, and examples thereof include ammonium persulfate, sodium persulfate, and potassium persulfate. The above salts may be in the form of an anhydride or hydrate. Such salts may be preferable in some cases because they are less hazardous than acids and easy to handle.
- A preparation example of the carrier including a sulfate ion according to the first invention is described below, taking titanium oxide and zirconium oxide as an example.
- Titanium oxide containing a sulfate ion car. be prepared by dissolving titanium sulfate or titanyl sulfate in water, subsequently performing neutralization at a low temperature or pyrohydrolysis, and then performing baking. Titanium oxide containing a sulfate ion can also be prepared by dissolving titanium ore in sulfuric acid, subsequently performing heating to produce metatitanic acid or titanium hydroxide, and then performing baking.
- In another case, titanium oxide containing a sulfate ion may be produced by passing dilute sulfuric acid through titanium hydroxide, which is a starting material, prepared from titanium tetraisopropoxide or the like and subsequently performing baking in the air atmosphere. Alternatively, a baked titanium oxide may also be used as a starting material instead of titanium hydroxide. Instead of passing sulfuric acid, a sulfuric acid salt, such as ammonium 3ulfate, may be supported on the carrier.
- The titanium oxide that has been subjected to the sulfatizing treatment is subsequently baked. The baking temperature is preferably 350° C. to 700° C. and is more preferably 450° C. to 600° C. It is not preferable to set the baking temperature to be excessively high because, if the baking temperature is excessively high, the sulfate ions included in the catalyst become volatilized and the surface area of the titanium oxide decreases disadvantageous. The amount of baking time during which the baking is performed is not limited. It is appropriate to set the baking time to about 3 hours.
- Examples of a commercial product, of the titanium oxide containing a sulfate ion include MC-50, MC-90, and MC-150 produced by Ishihara Sangyo Kaisha, Ltd., which are also described in Examples of the first Invention below.
- Zirconium oxide containing a sulfate ion can be prepared by, &.& in the preparation example of the titanium oxide, adding sulfuric acid, a sulfate, a persulfate, or the like to a starting material that is, for example, zirconium hydroxide prepared by adding ammonia wafer to an aqueous solution of a zirconium compound, such as zirconium oxychloride, zirconium oxynitrate, zirconium propoxide, or the like, and subsequently performing baking in the air atmosphere. Alternatively, a baked zirconium oxide may also be used instead of zirconium hydroxide. Instead of passing dilute sulfuric acid, a sulfuric acid, such as ammonium sulfate, may be supported on the carrier.
- The zirconium oxide that has been subjected to the sulfatizing treatment is subsequently baked. The baking temperature is preferably 350° C. to 700° C. and is more preferably 450° C. to 600° C. It is not preferable to set the baking temperature to be excessively high because, if the baking temperature is excessively high, the sulfate ions included in the catalyst become volatilized and the surface area of the zirconium oxide decreases disadvantageously. The amount of baking tine during which the baking is performed is not limited. It is appropriate to set the baking time to about 3 hours.
- In the case where the carrier is a commercial carrier, the content of sulfate ion in the carrier has been published by the manufacturer, and the sulfate ion content falls within the above-described range of sulfate ion content specified in the first invention, the carrier is considered to correspond to the carrier according to the first invention. Examples of such a commercial carrier include MC-50, MC-90, and MC-130 produced by Ishihara Sangyo Kaisha, Ltd.
- In the case where it is clear that the sulfur element Component of the carrier is derived from a sulfate ion, alternatively, the content of sulfate ion in the carrier or catalyst may be determined using a publicly known high-frequency furnace combustion-infrared detection method (carbon sulfur analyzer) by combusting the catalyst in a high-frequency induction heating furnace under an oxygen atmosphere and converting the content of sulfur in the combustion gas into the mass of sulfate ion, which is determined by an infrared detection method.
- In the case where the catalyst according to the first invention contains a sulfate ion, the content of the sulfate ion in the catalyst is not limited and the mass ratio of the amount of sulfate ion to the total mass of the catalyst is preferably 0.01% by mass or more, is more preferably 0.1% by mass or more, is particularly preferably 0.2% by mass or wore, is normally 10% by mass or less, is preferably 7% by mass or less, is more preferably 5% by mass or less, is particularly preferably 2% by mass or less, and is most preferably 1% by mass or less. The mass ratio of the amount of sulfur element to the total mass of the catalyst is preferably 0.01% by mass or more, is more preferably 0.1% by mass or more, is normally 3% by mass or less, is preferably 2% by mass or less, is more preferably 1% by mass or less, and is particularly preferably 0.6% by mass or less.
- Using a catalyst containing a sulfate ion or sulfur may markedly reduce a degradation reaction involved by decarboxylation and a defunctionalization reaction associated with dehydration and hydrogenation of the reaction product, that is, an alcohol, which occur simultaneously with a catalytic reaction of hydrogenation of a carbonyl compound. Limiting the content of sulfate ion in the catalyst to be equal to or more than the lower limit, may increase catalytic activity to a sufficient degree and reduce the occurrence of the defunctionalization reaction to a sufficient degree. This limits an increase in the complexity of the process for purifying the reaction product and an increase in the purification coats and consequently enables an economically advantageous alcohol production process to be provided. Limiting the content of sulfate ion in the catalyst according to the present invention to be equal to or more than the lower limit also enhances the stability of the catalyst in the air atmosphere. This increases ease of operation of the catalyst, such as transportation and storage of the catalyst and introduction cf the catalyst to a reactor in the production of an alcohol. Limiting the content of the sulfate ion m the catalyst to be equal to or less than the upper limit reduces, for example, corrosion of the reactor caused by sulfate ions included in the catalyst becoming eluted during the reaction and side reactions of the target product caused by the liberated acid catalyst. This limits increases in the costs for constructing reaction facilities and the costs for purifying the target product and enables an economically advantageous alcohol production process to be provided.
- In the first invention, the content of the sulfate ion in the carrier or catalyst is determined by publicly known ion chromatography after the sulfate ion has been extracted from the catalyst in a pretreatment 3tep.
- The content of the sulfur in the carrier or catalyst is determined using a publicly known high-frequency furnace combustion-infrared detection method (carbon sulfur analyzer) by combusting the catalyst in a high-frequency induction heating furnace under an oxygen atmosphere and calculating the content of sulfur in the combustion gas by an infrared detection method.
- The carrier used in the first invention is preferably composed primarily of the oxide of a metal belonging to Group 4 of the periodic table. The expression “composed primarily of” used herein means that the mass ratio of the oxide of a metal belonging to Group 4 of the periodic table to the total mass of the carrier is normally 50% by mass or more, is preferably 70% by mass or more, and is more preferably 90% to 100% by mass.
- The carrier used in the first invention may include a carrier component other than the oxide of a metal belonging to Group 4 of the periodic table. Examples of the other carrier component include one or more compounds selected from graphite, active carbon, silicon carbide, silicon nitride, aluminum nitride, boron nitride, boron oxide, aluminum oxide (alumina), silicon oxide (silica), lanthanum oxide, cerium oxide, yttrium oxide, niobium oxide, magnesium silicate, calcium silicate, magnesium aiuminate, calcium aluminate, aluminosilicate, aluminosilicophosphate, aluminophosphate, magnesium phosphate, calcium phosphate, strontium phosphate, apatite hydroxide (calcium hydroxyphosphate), apatite chloride, apatite fluoride, calcium sulfate, barium sulfate, and barium carbonate.
- The specific surface area of the carrier particles used in the first invention varies by the type of the carrier used and is not limited. The specific surface area of the carrier particles used in the first invention is normally 50 m2/g or more, is preferably 80 m2/g or more, is more preferably 100 m2/g or more, is normally 3000 m2/g or less, and is preferably 2000 m2/g or less. In particular, in the first invention in which the oxide of a metal belonging to Group 4 of the periodic table is used, the specific surface area of the carrier particles is normally 50 m2/g or more, is preferably 80 m2/g or more, is more preferably 100 m2/g or more, is normally 1000 m2/g or less, and is preferably 800 m2/g or less. The larger the specific surface area of the carrier particles, the higher the catalytic activity. Therefore, carrier particles having a larger specific surface area are suitably used. The specific surface area of the carrier particles is generally calculated from the amount of nitrogen adsorbed on the carrier particles using the BET equation.
- The shape and size of the carrier particles used in the first invention are not limited. When the shape of the carrier particles is converted into a spherical shape, the average particle size of the carrier is normally 0.1 μm or more, is preferably 3 μm or more, is more preferably 5 μm or more, is further preferably 50 μm or more, is normally 5 mm or less, and is preferably 4 mm or less. The particle size of the carrier is measured in accordance with Test sieving described in JIS Standard JIS Z8815 (1894). In the case where the shape of a carrier particle is not spherical, the volume of the carrier particle is measured, the diameter of a spherical particle having the same volume as the carrier particle is calculated, and the diameter of the spherical particle is considered the diameter of the carrier particle. When the average particle size of the carrier falls within the above range, the activity of the catalyst per unit mass is increased, and ease of handling of the catalyst is further increased.
- In the case where the reaction conducted using the first catalyst is a complete mixing reaction, the average particle size of the carrier is normally 0.1 μm or more, is preferably 1 μm or more, is more preferably 5 μm or more, is further preferably 50 μm or more, is normally i ism or less, and is preferably 2 mm or less. It is preferable to reduce the average particle size of the carrier because the smaller the average particle size of the carrier, the higher the activity of the catalyst per unit mass. However, setting the average particle size of the carrier to be excessively smaller than the above lower limit may make it difficult to separate the reaction liquid and the catalyst from each other.
- In the case where the reaction conducted using the first catalyst is a fixed-bed reaction, the average particle size of the carrier is normally 0.5 mm or snore and 5 mm or less, is preferably 4 mm or less, and is more preferably 3 mm or less. If the particle size of the carrier is excessively smaller than the above lower limit, it may become difficult to operate a reaction facility due to pressure difference. If the particle size of the carrier is excessively larger than the above upper limit, reaction activity may be reduced.
- A catalyst according to the second invention (hereinafter, may be referred to simply as “second catalyst”) is a metal-supporting catalyst that includes a metal component and a carrier on which the metal component is supported. Specifically, the metal components including a first component that is rhenium and one or more second components selected from the group consisting of silicon, gallium, germanium, and indium are supported on a carrier. The mass ratio of the amount of the second components to the amount of rhenium is set to a predetermined value.
- The second catalyst is normally produced by reducing a metal-supporting material on which the metal component is supported with a reducing gas and then performing an oxidative stabilization treatment as needed.
- <Metal Component>
- The metal component supported on the metal-supporting catalyst according to the second invention includes a first component that is rhenium and one or more second components selected from the group consisting of silicon, gallium, germanium, and indium. Among these, the second components used in combination with rhenium are preferably one or more elements selected from the group consisting of silicon, germanium, and indium, are more preferably one or more elements that include indium and/or germanium, are further preferably one or more elements that include germanium, and are particularly preferably germanium.
- As for the ratio between the amounts of the above essential components supported on the catalyst, the lower limit for the mass ratio of the second component elements that are one or more elements selected from the group consisting of silicon, gallium, germanium, and indium to the rhenium element is preferably 0.1 or more and is more preferably 0.5 or more, and the upper limit for the above mass ratio is preferably 30 or less, is more preferably 5 or less, is further preferably 3 or less, is particularly preferably 2 or less, and is most preferably 3 or less.
- Appropriately selecting the types of the second components used in combination with rhenium and/or the proportion of the second components supported on the carrier increases the catalytic activity in a hydrogenation reaction of a carbonyl compound and makes it possible to produce an alcohol while reducing side reactions, such as an esterification reaction of a carboxylic acid used as a raw material with an alcohol produced, and a defunctionalization reaction due to the dehydration and hydrogenation of the alcohol produced, which significantly occurs particularly at a later stage of the reaction, to a high degree. Using the above metal components in combination with one another enables the second catalyst to be handled in the air atmosphere. This increases ease of operation, such as transportation and storage of the catalyst and introduction of the catalyst to a reactor in the production of an alcohol.
- Using the above metal components in combination with each other enables an increase in catalytic activity and an increase in reaction selectivity, which have been considered contradictory, to be both achieved presumably for the following reasons: the addition of the second components enables the electronic state of rhenium, which is a catalytic activity component of the hydrogenation catalyst, to be controlled to be in a state suitable for a reduction reaction of a carbonyl functional group; the adsorptivity of reactive substrates onto the surface of the catalyst is enhanced due to the affinity of the reactive substrates for the second components; and the orientation of adsorption of the reactive substrates on the surface of the catalyst is controlled at a high degree.
- Although the amount of rhenium, supported on the second catalyst is not limited, the mass ratio of the rhenium element to the total mass of the metal-supporting catalyst is normally 0.5% by mass or more, is preferably 1% by mass or more, is more preferably 3% by mass or more, is normally 20% by mass or less, is preferably 10% by mass or. less, and is more preferably 8% by mass or less. When the amount of rhenium supported on the catalyst is limited to be equal to or more than the lower limit, sufficiently high catalytic activity can be achieved. This prevents, for example, an increase in the sire of the reactor used. When the amount of rhenium supported on the catalyst is limited to be equal to or less than the upper limit, an increase in the cost of the catalyst can be limited. Furthermore, in such a case, coagulation of rhenium supported on the catalyst can be reduced. This reduces the side reactions, such as a degradation reaction involved fey decarboxylation, a defunctionalization reaction associated with dehydration and hydrogenation of. the reaction product, and an esterification reaction of a carboxylic acid used as a raw material with an alcohol produced, due to high Lewis acidity of rhenium. As a result, reaction selectivity can be further increased.
- The second catalyst may further include, as needed, a third component that is a metal component other than the above metal components (i.e., rhenium and the second components) and that does not adversely affect the reactions conducted using the second catalyst, such as a reduction reaction. Examples of the Other metal component include metal components belonging to Groups 8 to 10 of the periodic table except iron and nickel. Examples thereof include at least one metal selected from the group consisting of ruthenium, cobalt, rhodium, iridium, palladium, and platinum, which are capable of catalyzing hydrogenation. Note that the term “periodic table” used herein refers to the long form of periodic table (.Nomenclature of Inorganic Chemistry IUPAC Recommendations 2005).
- Metals, such as iron and nickel, may elute and enter the catalyst when a metal reaction container made of SS, SUS, or the like becomes corroded in the preparation of the catalyst and/or the reaction. In the second invention, in the case where the eluted metal is precipitated on the catalyst and included in the catalyst, the metal is not defined as a metal component of the second catalyst. In the case of elution from a reaction container made of SUS, in addition to iron, the following metals may be detected in the catalyst in trace amounts at specific contents depending on the material used.
- For example, when metals enter from SUS201, nickel, chromium, and manganese may be detected in addition to iron at specific contents. When metals enter from SUS202, nickel chromium, and manganese may tee detected in addition to iron at specific contents. When metals enter from SUS301, nickel and chromium may be detected in addition to iron at specific contents. When metals enter from SUS302, nickel and chromium may be detected in addition to iron at specific contents. When metals enter from SUS202, nickel, chromium, and molybdenum may be detected in addition to iron at specific contents. When metals enter from SUS304, nickel and chromium may be detected in addition to iron at. specific contents. When metals enter from SUS305, nickel and chromium may be detected in addition to iron at specific contents. When metals enter from SUS316, nickel, chromium, and molybdenum may be detected in addition to iron at specific contents. When metals enter from SUS317, nickel, chromium, and molybdenum may be detected in addition to iron at specific contents. When metals enter from SUS329J1, nickel, chromium, and molybdenum may be detected in addition to iron at specific contents. When metals enter from SUS403, chromium may be detected in addition to iron at a specific content. When metals enter from SUS405, chromium and aluminum may be detected in addition to iron at specific contents. When metals enter from SUS420, chromium may be detected in addition to iron at a specific content. When metals enter from SUS430, chromium may be detected in addition to iron at a specific content. When metals enter from SUS430LX, chromium, titanium, or niobium may be detected in addition to iron at a specific content. When metals enter from SUS630, nickel, chromium, copper, and niobium may be detected in addition to iron at specific contents.
- Examples of the metal component that belongs to a group other than Groups 8 to 10 of the periodic table include at least one metal selected from the group consisting of silver, gold, molybdenum, tungsten, aluminum, and boron.
- Among the above third components, at least one metal selected from ruthenium, cobalt, rhodium, iridium, palladium, platinum, gold, molybdenum, and tungsten is preferable; at least one metal selected from ruthenium, cobalt, rhodium, iridium, palladium, platinum, molybdenum, and tungsten is more preferable; at least one metal selected from ruthenium, iridium, palladium, and platinum is particularly preferable; and ruthenium is most preferable.
- In the case where the third component is selected from rare and expensive metals belonging to Groups 8 to 10 of the periodic table except iron and nickel, the elemental mass ratio of the third component included in the second catalyst to the rhenium element is normally less than 0.2, is preferably 0.15 or less, is more preferably 0.1 or less, is further preferably less than 0.1, and is most preferably 0 in order to increase reaction selectivity and economical efficiency in terns of the costs for producing the catalyst. That is, it is preferable that the second catalyst substantially do not include any of the rare and expensive metals belonging to Groups 8 to 10 of the periodic table ether than iron or nickel.
- In the case where the third component is selected from metals other than the noble metals belonging to Groups 8 to 10 of the periodic table, the elemental mass ratio of the third component to the rhenium element is normally 10 or less, is preferably 5 or less, is more preferably 1 or less, and is further preferably 0.5 or less. When the above additional metal components are used in an appropriate combination at adequate contents, it rs possible to achieve high catalytic activity while maintaining high selectivity.
- In the case where a metal, such as iron or nickel, becomes eluted and enters the catalyst due to the corrosion of a reaction container made of SS, SUS, or the like, in the second invention, the content of iron and the contents of the above metals included at specific contents, which are determined on the basis of the type of material constituting the reaction container, are not taken into account in the calculation of the content of the metal components in the catalyst.
- In order to further increase the activity of the catalyst, reaction selectivity, and the like, the second catalyst may include compounds of one or more alkali metal elements selected from the group consisting of lithium, sodium, potassium, rubidium, and cesium; compounds of one or more alkaline-earth metal elements selected from the group consisting of magnesium, calcium, strontium, and barium; and compounds of one or mere halogen elements selected from the group consisting of fluorine, chlorine, bromine, and iodine, in addition to the metal components described above. In such a case, the ratio between the additional components and the rhenium component is not limited.
- <Carriar>
- The carrier used in the second invention is not limited. In particular, an inert carrier can be used. The term “inert carrier” used herein refers to a carrier that does not have a catalytic activity in a hydrogenation of a carbonyl compound alone. Specifically, the inert, carrier is defined as a carrier that substantially does not include any of the metals belonging to Group 8 to 12 of the periodic table which is selected from the group consisting of iron, ruthenium, cobalt, rhodium, iridium, nickel, palladium, platinum, copper, and zinc, chromium, and rhenium, which are metals having catalytic activity.
- In the second invention, a carrier that substantially does not include any of the -above metals is a carrier that does not primarily include any of the above metals. That is, the amount of the above metals included in the carrier to the total mass of the carrier is 5% by mass or less, is preferably 1% by mass or less, and is more preferably 0.1% by mass or less. The content of the above metals in the carrier can be determined as in the analysis of the content of the supported metal in the catalyst, using publicly known analysis methods, such as inductively coupled plasma mass spectrometry (ICP-MS), inductively coupled plasma atomic emission spectrometry (ICP-AES), atomic absorption spectrometry (AAS), and X-ray fluorescence analysis (XRF).
- Examples of the inert carrier used in the second invention includes a carrier composed primarily of an element other than the metals belonging to Groups 8 to 12 of the periodic cable, such as iron, ruthenium, cobalt, rhodium, iridium, nickel, palladium, platinum, copper, and zinc, chromium, or rhenium; a carrier composed primarily of a carbide, a nitride, an oxide, a hydroxide, a sulfuric acid salt, a carbonic acid salt, or a phosphoric acid salt of the element; and a carrier composed primarily of a mixture of the above substances. The expression “composed primarily of” used herein means that the mass ratio of the substance to the total mass of the carrier is normally 50% by mass or more, is preferably 70% by mass or more, and is more preferably 90% by mass or more.
- Specific examples of the carrier according to the second invention include graphite, active carbon, silicon carbide, silicon nitride, aluminum nitride, boron nitride, boron oxide, aluminum oxide (alumina), silicon oxide (silica), titanium oxide (titania), zirconium oxide (zirconia), hafnium oxide, lanthanum oxide, cerium oxide, yttrium oxide, niobium oxide, magnesium silicate, calcium silicate, magnesium aluminate, calcium aluminate, aluminosilicate, aluminosilicophosphate, aluminophosphate, magnesium phosphate, calcium phosphate, strontium phosphate, apatite hydroxide (calcium hydroxyphosphate), apatite chloride, apatite fluoride, calcium sulfate, barium sulfate, and barium carbonate.
- Among these, a carbonaceous carrier, titanium oxide, zirconium oxide, niobium oxide, and cerium oxide are preferable in order to increase catalytic, activity and reaction selectivity achieved particularly when a carboxylic acid is used as a raw material and reduce the elution of metals. Among the above substances, titanium oxide, zirconium oxide, niobium oxide, and cerium oxide are preferable in order to increase case of the regeneration treatment of the catalyst. Among the above substances, titanium oxide and zirconium oxide, which are oxides of metals belonging to Group 4 of the periodic table, are more preferable. Titanium oxide may be particularly preferable in order to readily produce carrier particles having a large specific surface area.
- The above carriers may be used alone or in combination of two or more. In the case where the carriers are used in combination of two or more, the combination of the carriers and the mixing ratio between the carriers are not limited. The carriers can be used in a form similar to a mixture of the individual compounds, a composite compound, or a double salt.
- The carrier may be used directly or may be subjected to a pretreatment in which the carrier particles are formed into a shape suitable for supporting the metal components thereon. For example, in the case where a carbonaceous carrier is used, the carbonaceous carrier may be subjected to a heating treatment using nitric acid before use, as described in Japanese Unexamined Patent Application Publication No. 10-71332. It is preferable to use the above method in order to enhance the dispersibility of the metal components on the carrier and thereby increase the activity of the catalyst.
- It may be preferable that the carrier used in the second invention contain a sulfate ion. In particular, in the case where titanium oxide is used as a carrier, it may be preferable that the carrier contain a sulfate ion.
- In the second invention, using a carrier including a sulfate ion may markedly reduce a degradation reaction involved by decarboxylation and a defunctionalization reaction associated with dehydration and hydrogenation of the reaction product, that is, an alcohol, which occur simultaneously with a catalytic reaction of hydrogenation of a carbonyl compound. In addition, when the metal components that include rhenium and the second components are supported on such a carrier, the catalytic activity of the hydrogenation catalyst may be markedly increased. When the metal components are used in combination with the carrier, the catalyst can be handled in the air atmosphere. This increases ease of operation of the catalyst, such as transportation and storage of the catalyst and introduction of the catalyst to a reactor in the production of an alcohol.
- It is considered that the functions of the catalyst are enhanced for the following reasons: when the carrier contains a sulfate ion, sulfate ions present in the surface of the carrier may form acid 3ites on the surface of the catalyst. Furthermore, the dispersibility of the supported metal may be increased due to the interaction between the supported metal and the sulfate ion or a substitution reaction of the supported metal with the sulfate ion which occurs when the metal components are supported on the carrier. Moreover, the electronic state of rhenium, which is a catalytic activity component oI the hydrogenation catalyst, can be controlled to be in a state suitable for a reduction reaction of a carbonyl functional group. The above factors may synergistically increase the reaction selectivity of the catalyst and the activity of the catalyst.
- The mass ratio of the amount of the sulfate ion included in the carrier to the total mass of the carrier used is preferably 0.01% by mass or more, is more preferably 0.1% by mass or more, and is particularly preferably 0.2% by mass or more. The mass ratio of the amount of the sulfate ion to the total mass of the carrier used is preferably 10% by mass or less, is more preferably 7% by mass or less, and is particularly preferably 5% by mass or less.
- When the content of the sulfate ion in the carrier used is limited to be equal to or more than the lower limit, the advantageous effects of adding the above components are achieved at. a sufficient level and high catalytic activity can be achieved. Furthermore, the occurrence of the defunctionalization reaction can be further reduced. This limits an increase in the complexity of the process for purifying the reaction product and an increase in the purification costs and consequently enables an economically advantageous alcohol production process to be provided. Limiting the content of the sulfate ion in the carrier used to be equal to or less than the upper limit reduces, for example, corrosion of the reactor caused by sulfate ions included in the carrier becoming eluted during the reaction depending on the solvent used and side reactions of the target product caused by the liberated acid catalyst and therefore eliminates the need to use materials having high corrosion resistance. This limits increases in the costs for constructing reaction facilities and the costs for purifying the product and enables an economically advantageous alcohol production process to be provided.
- In the case where a carrier, including a sulfate ion is used in the 3eccnd invention, the carrier is not limited and may be any carrier that includes a sulfate ion. An appropriate commercial product may be used directly. In the case where the carrier is composed of a metal oxide, the carrier may be prepared by, for example, dissolving a corresponding metal sulfate in water and subsequently performing neutralization or pyrohydrolysis, or by treating a corresponding metal hydroxide or a baked metal oxide with a sulfatizing agent and subsequently performing baking in an oxidizing atmosphere, such as the air atmosphere. The treatment using a sulfatizing agent is to introduce sulfate ions into the carrier. This treatment may foe performed in the step of producing the carrier or may be performed after the production of the carrier. Examples of the sulfatizing agent include sulfuric acid, persulfuric acid, and the salts thereof. Sulfuric acid, a sulfuric acid salt, and a persulfuric acid salt are preferable. The sulfuric acid salt is not limited and may be any sulfuric acid salt capable of providing sulfate ions when dissolved. Examples cf the sulfuric acid salt include ammonium sulfate, sodium sulfate, and potassium sulfate. The same applies to the persulfuric acid salt, and examples thereof include ammonium persulfate, sodium persulfate, and potassium persulfate. The above salts may be in the form of an anhydride or hydrate. Such salts may be preferable in some cases because they are Ie3s hazardous than ac.id3 and easy to handle.
- A preparation example of the carrier including a sulfate ion according to the second invention is described below, taking titanium oxide and zirconium oxide as an example.
- Titanium oxide containing a sulfate ion can be prepared by dissolving titanium sulfate or titanyl sulfate in water, subsequently performing neutralization at a low temperature or pyrohydrolysis, and then performing baking. Titanium oxide containing a sulfate ion can also be prepared by dissolving titanium ore in sulfuric acid, subsequently performing heating to produce metatitanic acid or titanium hydroxide, and then performing baking.
- In another case, titanium oxide containing a sulfate ion may be produced by passing dilute sulfuric acid through titanium hydroxide, which is a starting material, prepared from titanium tetraisopropoxide or the like and subsequently performing baking in the air atmosphere. Alternatively, a baked titanium oxide may also be used as a starting material instead of titanium hydroxide. Instead of passing sulfuric acid, a sulfuric acid salt, such as ammonium sulfate, may be supported on the carrier.
- The titanium oxide that has been subjected to the sulfatizing treatment is subsequently baked. The baking temperature is preferably 350° C. to 700° C. and is mere preferably 450° C. to 600° C. It is not preferable to set the baking temperature to be excessively high because, if the baking temperature is excessively high, the sulfate ions included in the catalyst become volatilized and the surface area of the titanium oxide decreases disadvantageously. The amount of baking time during which the baking is performed is not limited. It is appropriate to set the baking time to about 3 hours.
- Examples of a commercial product of the titanium oxide containing a sulfate ion include MC-30, MC-90, and MC-150 produced by Ishihara Sangyo Kaisha, Ltd., which are also described in Examples of the second invention below.
- Zirconium oxide containing a sulfate ion can be prepared by, as in the preparation example of the titanium oxide, adding sulfuric acid, a sulfate, a persulfate, or the like to a starting material that is, for example, zirconium hydroxide prepared by adding ammonia water to an aqueous solution of a zirconium compound, such as zirconium oxychloride, zirconium oxynitrate, zirconium propoxide, or the like, and subsequently performing baking in the air atmosphere. Alternatively, a baked zirconium oxide may also be used instead of zirconium hydroxide. Instead of passing dilute sulfuric acid, a sulfuric acid, such as ammonium sulfate, may be supported on the carrier.
- The zirconium oxide that has been subjected to the sulfatizing treatment is subsequently baked. The baking temperature is preferably 350° C. to 700° C. and is more preferably 450° C. to 600° C. It is not preferable to set the baking temperature to be excessively high because, it the baking temperature is excessively high, the sulfate ions included in the catalyst become volatilized and the surface area of. the zirconium oxide decreases disadvantageously. The amount of baking time during which the baking is performed is not limited. It is appropriate to set the baking time to about 3 hours.
- In the case where the carrier is a commercial carrier, the content of sulfate ion in the carrier has been published by the manufacturer, and the sulfate ion content falls within the above-described range of sulfate ion content specified in the second invention, the carrier is considered to correspond to the carrier according to the second invention. Examples of such a commercial carrier include MC-50, MC-90, and MC-150 produced by Ishihara Sangyo Kaisha, Ltd.
- In the case where it is clear that the sulfur element component of the carrier is derived from a sulfate ion, alternatively, the content of sulfate ion in the carrier or catalyst may be determined using a publicly known high-frequency furnace combustion-infrared detection method (carbon sulfur analyzer) by combusting the catalyst in a high-frequency induction heating furnace under an oxygen atmosphere and converting the content of sulfur in the combustion gas into the mass of sulfate ion, which is determined by an infrared detection method.
- In the case where the catalyst according to the second invention contains a sulfate ion, the content of the sulfate ion ,i.n the catalyst is not limited and the mass ratio of the amount of. sulfate ion to the total mass of the catalyst is preferably 0.01% by mass or more, is more preferably 0.1% by mass or more, is particularly preferably 0.2% by mass or more, is normally 10% by mass or less, is preferably 1% by mass or leas, is more preferably 5% by mass or less, is particularly preferably 2% by mass or less, and is most preferably 1% by mass or less. The mass ratio of the amount of sulfur element to the total mass of the catalyst is preferably 0.01% fey mass or more, is more preferably 0.1% by mass or more, is normally 3% by mass or less, is preferably 2% by mass or less, is more preferably 1% by mass or less, and is particularly preferably 0.6% by mass or less.
- Using a catalyst containing a sulfate ion or sulfur may markedly reduce a degradation reaction involved by decarboxylation and a defunctionalization reaction associated with dehydration and hydrogenation of the reaction product, that is, an alcohol, which occur simultaneously with a catalytic reaction of hydrogenation of a carbonyl compound. Limiting the content of sulfate ion in the catalyst to be equal to or more than the lower limit may increase catalytic activity to a sufficient degree and reduce the occurrence of the defunctionalization reaction to a sufficient degree. This limits an increase in the complexity of the process for purifying the reaction product and an increase in the purification costs and consequently enables an economically advantageous alcohol production process to be provided. Limiting the content of sulfate ion in the catalyst according to the present invention to be equal to or more than the lower limit also enhance, the stability of the catalyst in the air atmosphere. This increases ease of operation of the catalyst, such as transportation and storage of the catalyst and introduction of the catalyst to a reactor in the production of an alcohol. Limiting the content of the sulfate ion in the catalyst to be equal to or less than the upper limit reduces, for example, corrosion of the reactor caused by sulfate ions included in the catalyst becoming eluted during the reaction and side reactions of the target product caused by the liberated acid catalyst. This limits increases in the costs tor constructing reaction facilities and the costs for purifying the target product and enables an economically advantageous alcohol production process to be provided.
- In the second invention, the content of the sulfate ion in the carrier or catalyst is determined by publicly known ion chromatography after the sulfate ion has been extracted from the catalyst in a pretreatment step.
- The content of the sulfur in the carrier or catalyst is determined using a publicly known high-frequency furnace combustion-infrared detection method (carbon sulfur analyzer) by combusting the catalyst in a high-frequency induction heating furnace under an oxygen atmosphere and calculating the content of sulfur in the combustion gas by an infrared detection method.
- The specific surface area of the carrier particles used in the second invention varies by the type of the carrier used and is not limited. The specific surface area of the carrier particles used in the second invention is normally 50 m2/g or more, is preferably 80 m2/g or more, is more preferably 100 m2/g or more, is normally 3000 m2/g or loss, and is preferably 2000 m2/g or leas. In the case where a metal oxide is used as a carrier, the specific surface area of the carrier particles is normally 50 m2/g or more, is preferably 80 m2/g or more, is more preferably 100 m2/g or more, is normally 1000 m2/g or less, and is preferably 800 m2/g or less. The larger the specific surface area of the carrier particles, the higher the catalytic activity. Therefore, carrier particles having a larger specific surface area are suitably used. The .specific surface area of the carrier particles is generally calculated from the amount of nitrogen adsorbed on the carrier particles using the BET equation.
- The shape and size of the carrier particles used in the second invention are not limited. When the shape of the carrier particles is converted into a spherical shape, the average particle size of the carrier is normally 0.1 μm or more, is preferably 1 μm or more, is more preferably 5 μm or more, is further preferably 50 μm or mere, is normally 5 mm or less, and is preferably 4 mm or less. The particle size of the carrier is measured in accordance with Test sieving described in JIS Standard JIB Z8815 (1994). In the case where the shape of a carrier particle is not spherical, the volume of the carrier particle is measured, the diameter of a spherical particle having the same volume as the carrier particle is calculated, and the diameter of the spherical particle is considered the diameter of the carrier particle. When the average particle size of the carrier falls within the above range, the activity of the catalyst per unit mass is increased, and ease of handling of the catalyst rs further increased.
- In the case where the reaction conducted using the second catalyst is a complete mixing reaction, the average particle size of the carrier is normally 0.1 μm or more, is preferably 1 μm or more, is more preferably 5 μm or more, is further preferably 50 μm or more, is normally 3 μm or less, and is preferably 2 nun or less. It is preferable to reduce the average particle size of the carrier because the smaller the average particle size of the carrier, the higher the activity of the catalyst per unit mass. However, setting the average particle size of. the carrier to be excessively smaller than the above lower limit may make it difficult to separate the reaction liquid and the catalyst from each other.
- In the case where the reaction conducted using the second main catalyst is a fixed-bed reaction, the average particle size of the carrier is normally 0.5 mm or mere and 5 mm or less, is preferably 4 mm or less, and is more preferably 3 mm or less. If the particle size of the carrier is excessively smaller than the above lower limit, it may become difficult to operate a reaction facility due to pressure difference. If the particle size of the carrier is excessively larger than the above upper limit, reaction activity may be reduced.
- [Method for Producing This Catalyst]
- The method for producing the first catalyst and the second catalyst (hereinafter, they are referred to as “this catalyst”) normally includes the following steps.
- (i) a step in which, the metal components are attached to the carrier (hereinafter, this step is referred to as “metal attachment step”))
- (ii) a step in which the resulting metal-supporting material is subjected to a reduction treatment using a reducing gas (hereinafter, this step is referred to as “reduction treatment step”))
- (iii) a step in which oxidation is performed as needed subsequent to the reduction treatment, (hereinafter, this step is referred to as “oxidative stabilization step”))
- Each of the above steps is described below.
- <(i) Metal Attachment Step>
- The metal attachment step is a step in which required amounts of the above-described metal components are attached to the above-described carrier in order to prepare a metal-supporting material. The method for attaching the metal components to the carrier is not limited, and publicly known methods can be used. For attaching the metal components to the carrier, a solution or dispersion liquid containing metal-containing compounds that are raw materials tor the metal components can be used.
- The method for attaching the metal components to the carrier is not limited. Normally, various impregnation methods may be used. Examples thereof include an adsorption method in which metal ions are caused to adsorb to the carrier in an amount equal to or less than the salutation amount of the metal ions adsorbed by using the ability of the metal ions to adsorb to the carrier; an equilibrium adsorption method in which the carrier is immersed in the solution containing an amount of metal ions which is equal to or more than the saturation amount of the metal ions adsorbed and the excess solution is removed; a pore-filling method in which the solution having the same, volume as the pores formed in the carrier is added to the carrier and the whole amount of the solution is caused to adsorb to the carrier; an incipient wetness method in which the solution is added t.o the carrier until the volume of the solution added is appropriate to the water absorption capacity of the carrier and the treatment is terminated when the surfaces of the carrier particles become uniformly wet and excess solution is not present on the surfaces of the carrier particles; an evaporation-to-dryness method in which the carrier is impregnated with the solution and the solvent is removed by evaporation while the solution is stirred; and a spray method in which the carrier is dried and the solution is sprayed to the dried carrier. Among these, the pore-filling method, the incipient wetness method, the evaporation-to-dryness method, and the spray method are preferable, and the pore-filling method, the incipient wetness method, and the evaporation-to-dryness method are more preferable. Using the above preparation methods enables rhenium, the above-described second component, and the optional third component and the other metal components which may be added to the catalyst as needed to be supported on the carrier while being relatively uniformly dispersed on the carrier. As described in the first and second inventions above, it may be preferable that the carrier include a sulfate ion. In such a case, it is preferable to attach the metal components to a carrier that includes an amount of sulfate ion which is 0.01% by mass or more and 10% by mass or less of the mass of the carrier.
- The metal-containing compounds used are not limited and may be selected appropriately in accordance with the attaching method used. Examples thereof include halides, such as a chloride, a bromide, and an iodide; mineral acid salts, such as a nitric acid salt and a sulfuric acid salt; metal hydroxides; metal oxides; metal-containing ammonium salts; organic-group-containing compounds, such as an acetic acid salt and a metal alkoxide; and metal complexes. Among these, halides, mineral acid salts, metal hydroxides, metal oxides, metal-containing ammonium salts, and organic-group-containing compounds are preferable, and halides, mineral acid salts, metal oxides, metal-containing ammonium salts, and organic-group-containing compounds are more preferable. The above compounds may be used alone or in combination of two or more in a required amount.
- When the metal-containing compounds are attached to the carrier, the metal-containing compounds may be dissolved or dispersed in a solvent and the resulting solutions and dispersion liquids may be used in any of the above attaching methods. The type of the solvent used in this step is not limited and may be any type of solvent in which the metal-containing compounds can be dissolved or dispersed and which does not adversely affect the baking and hydrogen reduction of the metal-supporting material and the hydrogenation reaction in which this catalyst is used, which are conducted in the subsequent step. Examples of the solvent include ketone solvents, such as acetone, alcohol solvents, such as methanol and ethanol, ether solvents, such as tetrahydrofuran and ethylene glycol dimethyl ether, and water. The above solvents may be used alone or in the form of a mixed solvent. Among the above solvents, water is preferably used because water is inexpensive and the solubility of the raw materials, that is, the metal-containing compounds, in water is high.
- When the metal-containing compounds are dissolved or dispersed in the solvent, various additives may be optionally used in addition to the solvent. For example, using a solution of carboxylic acid and/or a carbonyl compound may improve the dispersibility of each of the metal components on the carrier which is achieved when the metal components are attached to the carrier, as described in Japanese Unexamined Patent Application Publication No. 10-15366.
- The metal-supporting material may be dried as needed. It is preferable to subject the metal-supporting material to a .reduction treatment step after the metal-supporting material has been dried and subsequently baked as needed, for the following reason: if the metal-supporting material is subjected to the subsequent reduction treatment without being dried, the catalyst may have low reaction activity.
- The method for drying the metal-supporting material is not limited and may be any method capable of removing the solvent and the like used for attaching the metal components to the carrier. Normally, the metal-supporting material is dried in a stream of inert gas or at a reduced pressure.
- The pressure at which the metal-supporting material is dried is nor, limited. Normally, the metal-supporting material is dried at normal pressure or a reduced pressure.
- The temperature at which the metal-supporting material is dried is normally, but not limited to, 300° C. or less, is preferably 250° C. or less, is more preferably 200° C. or less, and is normally 80° C. or more.
- After the metal-supporting material has been dried, the metal-supporting material may be baked as needed. Baking the metal-supporting material increases the likelihood of the catalyst having a high catalytic activity and excellent reaction selectivity. The baking of the metal-supporting material may be performed in the air atmosphere. For example, the baking of the metal-supporting material may be performed by heating the metal-supporting material in an air stream at a predetermined temperature for a predetermined amount of time.
- The temperature at which the metal-supporting material is baked is normally, but not limited to, 100° C. or more, is preferably 250° C. or more, is more preferably 400° C. or more, is normally 1000° C. or less, is preferably 700° C. or less, and is more preferably 600° C. or less. The amount of time during which the metal-supporting material is baked, which varies with the baking temperature, is normally 30 minutes or more, is preferably 1 hour or more, is more preferably 2 hours or more, is normally 40 hours or less, is preferably 30 hours or less, and is more preferably 10 hours or less.
- <(ii) Reduction Treatment Step>
- The metal-supporting material is normally subjected to a reduction treatment using a reducing gas. In the reduction treatment, a publicly known method, such as liquid-phase reduction or a gas-phase reduction, may be used.
- The reducing gas used in the reduction treatment step is not limited and may be any gas having a reducing power. Examples of the reducing gas include hydrogen, methanol, and hydrazine. The reducing gas is preferably hydrogen.
- In the case where a hydrogen-containing gas is used as a reducing gas, the hydrogen concentration in the hydrogen-containing gas is not limited. The hydrogen concentration in the hydrogen-containing gas may be 100% by volume. Ir. another case, the hydrogen-containing gas may be diluted with an inert gas. The term “inert gas” used herein refers to a gas unreactive with the metal-supporting material or a hydrogen ga3, such as nitrogen or water vapor. Normally, nitrogen is used as an inert gas. The hydrogen concentration in the reducing gas (hydrogen-containing gas) diluted with an inert gas is normally 5% by volume or more, is preferably 15% by volume or more, is more preferably 30% by volume or more, and is further preferably 50% by volume or more relative to the all the gas components. It is possible to use a hydrogen-containing gas having a low hydrogen concentration at the initial stage of reduction and gradually increase the hydrogen concentration in the hydrogen-containing gas over the course of reduction.
- The amount of time required for the reduction treatment, which varies with the amounts of the metal-supporting material and the like that are to be treated and the type of the apparatus or the like used, is normally 7 minutes or more, is preferably 15 minutes or more, is more preferably 30 minutes or more, is normally 40 hours or less, is preferably 30 hours or leas, and is more preferably 10 hours or less. The temperature at which the reduction treatment is performed is normally 130° C. or more, is preferably 200° C. or more, is more preferably 250° C. or more, is normally 700° C. or less, is preferably 600° C. or less, and is more preferably 500° C. or less. If the reduction treatment is performed at an excessively high temperature, for example the supported metal may b sintered and, consequently, the activity of the. catalyst may be reduced.
- In the reduction treatment, the reducing gas may be enclosed in the reactor or may be passed through the reactor. It is preferable to pass the reducing gas through the reactor. This is because passing the reducing gas through the reactor prevents the occurrence of local hydrogen deficiency. In the reduction treatment, water, ammonium chloride, and the like may be produced as by-products in the rector depending on the raw materials used, and the by-products may adversely affect the metal-supporting material that has not been subjected to the reduction treatment or the metal-supporting catalyst, which has been subjected to the reduction treatment. Passing the reducing gas through the reactor enables the by-products to be discharged to the outside of the reaction system.
- The amount of the reducing gas required by the reduction treatment is not limited and may be set such that the objects of the first to third inventions are achieved. The amount of the reducing gas required by the reduction treatment can be set appropriately in accordance with the apparatus used, the size of the reactor used for reduction, the method for passing the reducing gas through the reactor, the method for fluidizing the catalyst, and the like.
- The size of the metal-supporting catalyst, which has been subjected to the reduction treatment, is net limited and basically the same as the site of the carrier.
- Examples of a preferable method for performing the reduction treatment include a method in which the reducing gas is passed through the metal-supporting material with a fixed bed; a method in which the reducing gas is passed through the metal-supporting material that is disposed to stand on a tray or a belt; and a method in which the metal-supporting material is caused to fluidize and the reducing gas is passed through the fluidized metal-supporting material.
- <(iii) Oxidative Stabilization Step>
- In the production of this catalyst, as needed, the metal-supporting catalyst, which is produced by reducing the metal-supporting material, is subjected to an oxidative stabilization treatment in order to control the oxidation state. Performing the oxidative stabilization treatment enables the production of a catalyst that has excellent activity and excellent selectivity and that can be handled in the air atmosphere.
- The method for performing oxidative stabilization is not limited. Examples thereof include a method in which water is added to the metal-supporting catalyst, a method in which the metal-supporting catalyst is charged into water, a method in which oxidative stabilization is performed using a gas having a low oxygen concentration which is diluted with an inert gas, and a method in which stabilization is performed using carbon dioxide. Among the above methods, the method .in which water is added to the metal-supporting catalyst, the method in which the metal-supporting catalyst is charged into water, and the method in which oxidative stabilization is performed using the gas having a low oxygen concentration are preferable, the method in which oxidative stabilization (slow oxidation) is performed using the gas having a low oxygen concentration (hereinafter, this method is referred to as “slow-oxidation method”) is more preferable, and a method in which oxidative stabilization is performed in a stream of the gas having a low oxygen concentration is particularly preferable.
- The initial oxygen concentration with which oxidative stabilization is performed using the gas having a low oxygen concentration is not limited. The oxygen concentration with which the slew oxidation is started is normally 0.2% by volume or more, is preferably 0.5% by volume or more, is normally 10% by volume or less, is preferably 8% by volume or less, and is further preferably 7% by volume or less. If the oxygen concentration is excessively lower than the lower limit, it takes a considerable amount of time to complete the oxidative stabilization and stabilization may fail to be achieved at a sufficient level. If the oxygen concentration is excessively higher than the upper limit, the temperature of the catalyst may be excessively increased and the catalyst may become deactivated.
- The gas having a low oxygen concentration is preferably prepared by diluting air with an inert gas. The inert, gas used for diluting air is preferably nitrogen.
- Examples of a method for performing the oxidative stabilization using the gas having a low oxygen concentration include a method in which the gas having a low oxygen concentration is passed through the catalyst with a fixed bed; a method in which the gas having a low oxygen concentration is passed through the catalyst that is disposed to stand on a tray or a belt; and a method in which the catalyst is caused to fluidize and the gas having a low oxygen concentration is passed through the fluidized catalyst.
- The higher the dispersibility of the supported metal or. the metal-supporting catalyst, the higher the rate at which the oxidative stabilization is performed and the larger the amount of oxygen used in the reaction. Therefore, the method in which the gas having a low oxygen concentration is passed through the catalyst with a fixed bed and the method in which the catalyst is caused to fluidize and the gas having a low oxygen concentration is passed through the fluidized catalyst are preferable.
- The method for producing this catalyst is not limited to the above-described production method and may be any method capable of producing this catalyst. For example. the method for producing this catalyst nay include another publicly known step such that this catalyst can be produced.
- [Production of Alcohol With This Catalyst]
- This catalyst is suitable as a catalyst used in the reduction reaction (hydrogenation) of a carbonyl compound. An alcohol can be produced by treating a carbonyl compound with this catalyst.
- Preferable examples of the reduction reaction conducted with this catalyst include an alcohol production method which includes a step in which at least one carbonyl compound selected from the group consisting of a ketone, an aldehyde, a carboxylic acid, a carboxylic acid ester, a carboxylic acid amide, a carboxylic acid halide, and a carboxylic anhydride is reduced to produce an alcohol derived from the compound. Among the above compounds, a carboxylic acid can be directly reduced with this catalyst to form an alcohol.
- The carbonyl compound that is to be subjected to the reduction reaction nay be. any carbonyl compound that is industrially readily available. Specific examples of the carboxylic acid and/or the carboxylic acid eater include aliphatic chain monocarboxylic acids, such as acetic acid, butyric acid, decancic acid, lauric acid, oleic acid, linoleic acid, linolenic acid, stearic acid, and palmitic acid; aliphatic cyclic monocarboxylic acids, such as cyclohexanecarboxylic acid, naphthenic acid, and cyclopentanecarboxylic acid; aliphatic polycarboxylic acids, such as oxalic acid, malonic acid, succinic acid, methylsuccinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, sebacic acid, cyclohexanedicarboxylic acid, 1,2,4-butanetricarboxylic acid, 1,3,4-cyclohexanetricarboxylic acid, bicyclohexyldicarboxylic acid, and decahydronaphthalenedicarboxylic acid; aromatic carboxylic acids, such as phthalic acid, isophthalic acid, terephthalic acid, and trimesic acid; carboxylic acids including a furan skeleton, such as furancarboxylic acid and furandicarboxylic acid; carboxylic acid esters, such as methyl esters, ethyl esters, propyl esters, and butyl esters of the above carboxylic acids and esters of an alcohol produced by reducing a carboxylic acid; and lactones, such as γ-butyrolactone, δ-valerolacton(r), and ε-caprolactone.
- Specific examples of the carboxylic acid amide include methyl amides and ethyl amides of the above carboxylic acids.
- Specific examples of the carboxylic acid halide include chlorides and bromides of the above carboxylic acids.
- Specific examples of the carboxylic anhydride include acetic anhydride, succinic anhydride, maleic anhydride, and phthalic anhydride.
- Examples of the aldehyde and the ketone include benzaldehyde, propionaldehyde, acetaldehyde, 3-hydroxypropionaldehyde, furfural, hydroxymethylfurfural, acetone, benzophenone, glucose, xylose, lactose, and fructose.
- The carboxylic acid and carboxylic acids constituting the carboxylic acid ester, the carboxylic acid amide, the carboxylic acid halide, and/or the carboxylic anhydride are preferably, but not limited to, chain or cyclic saturated aliphatic carboxylic acids, are more preferably carboxylic acids a portion of which excluding carboxyl groups has 20 or less carbon atoms. The number of the carbon atoms included in the carboxylic acids is more preferably 14 or less.
- In the present invention, among the above carbonyl compounds that are to be subjected to the reduction reaction, the carboxylic acid, the carboxylic acid ester, the carboxylic anhydride, and the aldehyde are preferable, the carboxylic acid, the carboxylic acid ester, the carboxylic anhydride, and the aldehyde are more preferable, and the carboxylic acid arid the carboxylic acid ester are particularly preferable from the viewpoint of ease of availability of the raw materials. However, the carbonyl compounds that are to be subjected to the reduction reaction are not limited to the above carbonyl compounds.
- The carboxylic acid is preferably a dicarboxylic acid and is further preferably a dicarboxylic acid represented by Formula (1) below the portion of which except carboxyl groups includes 20 or less carbon atoms.
-
HOOC—R1—COOH (2) - (in Formula (1), R1 represents an aliphatic or alicyclic hydrocarbon group that may have a substituent, the portion of the hydrocarbon group except the substituent including 1 to 20 carbon atoms)
- This catalyst enables a polyvalent carboxylic acid, such as the above dicarboxylic acid, to be converted into a corresponding hydroxycarboxylic acid, lactone, or polyhydric alcohol with high selectivity at a high yield. Appropriately selecting the production conditions, 3uch as the type of catalyst used, the reaction pressure, the reaction temperature, and the amount of time the raw materials are retained, enables the ratio between the amount of the hydroxycarboxylic acid or lactone produced and the amount, of the polyhydric alcohol produced to be controlled.
- Other examples of particularly preferable carbonyl compounds include carboxylic acids having a furan skeleton which are derived from biomass resources, such as furandicarboxylic acid, and aldehydes, such as hydroxymethylfurfural.
- Although the reduction reaction using this catalyst may be conducted in a liquid phase or gas phase, the reduction reaction using this catalyst is preferably conducted in a liquid phase. Although the reduction reaction using this catalyst in a liquid phase may be conducted without using a solvent or in the presence of a solvent, the reduction reaction using this catalyst in a liquid phase is normally conducted in the presence of a solvent.
- Examples of the solvent include, normally, water; lower alcohols, such as methanol and ethanol; alcohols that are the reaction products; ethers, such as tetrahydrofuran, dioxane, and ethylene glycol dimethyl ether; and hydrocarbons, such as hexane, decalin, and methylcyclohexane. The above solvents may be used alone or in a mixture of two or more.
- In particular, in the case where a carbonyl compound is to foe reduced, it is preferable to use a water solvent from the viewpoints of solubility and the like. The amount, of the solvent used is normally, but not limited to, about 0.1 to 20 times by mass, is preferably 0.5 to 10 times by mass, and is more preferably about 1 to 10 times by mass the amount of the carbonyl compound used as a raw material.
- The reduction reaction using this catalyst is normally conducted in a pressurized hydrogen gas. The reaction is normally conducted at 100° C. to 300° C. and is preferably conducted at 120° C. to 250° C. The reaction pressure is normally 1 to 30 MPaG, .is preferably 1 to 25 MPaG, and is further preferably 5 to 25 MPaG.
- After the reaction has been terminated, the product of the reduction reaction using this catalyst is normally recovered by solvent distillation, solvent distillation followed by extraction using an organic solvent, distillation, sublimation, crystallization, chromatography, or the like, which depends on the physical properties of the product. In the case where the product is liquid at handling temperature, it is preferable to recover the product, while purifying the product by distillation. In the case where the product is solid at handling temperature, it is preferable to recover the product while purifying the product by crystallization. It is preferable to purify the solid product by washing.
- The present invention is described below further in detail with reference to Examples. The present invention is not limited by Examples below without departing from the scope of the present invention.
- (Measurement of Sulfate Ion Content)
- A 0.2 M-aqueous sodium hydroxide solution was added to the sample. The resulting mixture was irradiated with ultrasonic wave and subsequently subjected to centrifugal separation. The resulting liquid was analyzed by ion chromatography in order to determine the content of sulfate ions in the sample.
- (Measurement of Sulfur Content)
- The content, of sulfur in the sample was determined in accordance with a high-frequency furnace combustion-infrared detection method (carbon sulfur analyzer) by combusting the sample in a high-frequency induction heating furnace under an oxygen atmosphere and calculating the content of sulfur in the combustion gas by an infrared detection method.
- Ammonium perrhenate and tetraethoxygermanium(IV) were dissolved in water. Titanium oxide particles (Catalysis Society of Japan, Reference catalyst JRC-TIO-14 produced by Ishihara Sangyc Kaisha, Ltd.) having a specific surface area of 308 m2/g were added to the resulting solution. The solution was stirred at room temperature for 20 minutes. Subsequently, water was removed using an evaporator. Then, drying was performed at 100° C. for 4 hours. The resulting material was charged into a vertical baking tube. While air was passed through the tube, a baking treatment was performed at 500° C. for 3 hours. The resulting solid was charged into a vertical baking tube. While a hydrogen gas was passed through the tube, a reduction treatment was performed at 500° C. for 30 minutes. Subsequently, the temperature was reduced to 30° C. After purging with an argon gas had been performed, a 6-volume % oxygen/nitrogen gas was passed through the tube. Hereby, 5% rhenium-5% germanium/titanium oxide catalyst particles having stabilized surfaces (the ratio of the amount of rhenium supported to the total mass of the catalyst: 5 mass %, the ratio of the amount of germanium supported to the total mass of the catalyst: 5 mass % (Ge/Re=1)) were prepared. The sulfate ion contents in the titanium oxide particles (Catalysis society of Japan, Reference catalyst JRC-TIO-14) and the catalyst were 0.2% by mass and 0.14% by mass, respectively. The sulfur content in the catalyst was 0.078% by mass.
- Into a 70-mL high-pressure reactor, 100 mg of the catalyst prepared by the above method, 500 mg of sebacic acid, 2 g of water, and a stirrer chip were charged. After the reactor had been purged with nitrogen, a hydrogen gas (7 MPaG) was introduced into the reactor at room temperature. Subsequently, a hydrogenation reaction was conducted at 220° C. for 7.5 hours. The reaction pressure at 220° C. was 13 MPaG. After the reaction had beer, terminated, the temperature was reduced to room temperature and the pressure was then reduced. An analysis of the reaction liquid by gas chromatography confirmed that the molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 5.9% and 48.1%, respectively, and the molar ratio of the by-products (1-nonanol, 1-aecanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (1,10-decanediol and 10-hydroxydecancic acid) was 0.016.
- A hydrogenation reaction was conducted as in Example I-1 with the catalyst prepared in Example I-1, except that the amount of time during which the hydrogenation reaction was conducted was changed to 18 hours. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 89.3% and 6.5%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (1,10-decanediol and 10-hydroxydecanoic acid) was 0.017.
- A hydrogenation reaction was conducted as in Example I-1 with a catalyst prepared as in Example I-3, except that the treatment in which the surfaces of the catalyst particles were stabilized by passing a 6-volume % oxygen/nitrogen gas through the tube was not performed after the reduction treatment had been performed while a hydrogen gas was passed through the tube. The molar yields of 1,10-decanediol and 10-hydroxydecancic acid in the reaction were 74.7% and 2.6%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (1,10-decanediol and 10-hydroxydecanoic acid) was 0.004.
- A 5% rhenium-5% germanium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example I-1, except that the titanium oxide particles were changed to titanium oxide particles having a specific surface area of 302 m2/g and a sulfate ion content of 4.8% by mass (MC-150, produced by Ishihara Sangyo Kaisha, Ltd.). The sulfate ion content in the catalyst was 0.63% by mass. The sulfur content in the catalyst was 0.57% by mass. A hydrogenation reaction was conducted as in Example I-1 with this catalyst. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 81.7% and 0.6%, respectively. The molar ratio of the by-products (I-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target, components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.006.
- A 5% rhenium-5% germanium/titanium oxide catalyst was prepared by the same method as in Example I-1. except that the titanium oxide particles were changed to titanium oxide particles having a specific surface area of 90 m2/g and a sulfate ion content of 3.6% by mass (MC-90, produced by Ishihara Sangyo Kaisha, Ltd.). The sulfate ion content in the catalyst was 0.30% by mass. The sulfur content in the catalyst was 0.35% by mass, A hydrogenation reaction was conducted as in Example I-1 with this catalyst. The molar yields of 1,10-decanodiol and 10-hydroxydecanoic acid in the reaction were 4.5% and 36.8%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.011.
- A 5% rheniuns-5% indium/titanium, oxide catalyst, was prepared by the same catalyst preparation method as in Example I-1, except that indium(III) chloride tetrahydrate was used instead of tetraethoxygermanium(IV). Subsequently, a hydrogenation reaction was conducted as in Example I-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 9.0% and 43.5%, respectively. The molar, ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target, components 10-hydroxydecanoic acid and 1,10-decanediol) was 0.034.
- A 5% rheniuns-5% silicon/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example I-1, except that tetraethoxysilane(IV) was used instead of tetraethoxygermanium(IV) and ethanol was used instead of water for preparing the solution. Subsequently, a hydrogenation reaction was conducted as in Example I-1. The molar yields or 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 1.7% and 23.1%, respectively. The molar ratio of the by-products (1-nonanol, 3-docanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.039.
- A 5% rhenium-1% germanium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example I-1, except that the ratio between the amounts of ammonium perrhenate and tetraethoxygermanium(IV) used as metal raw materials was changed and the surfaces of the catalyst particles were not stabilized by passing the 6-volume % oxygen/nitrogen gas through the tube subsequent to the reduction treatment. A hydrogenation reaction was conducted as in Example I-1 with this catalyst, except that the amount of time during which the reaction was conducted was changed to 3 hours. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 38.7% and 10.8%, respectively. The moinr ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.009.
- A hydrogenation reaction was conducted with the catalyst prepared in Example I-3 as in Example I-1, except that the amount of time during which the reaction was conducted was changed to 3 hours. The molar yields of 1,10-docanediol and 10-hydroxydecanoic acid in the reaction were 35.3% and 32.9%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydraxydecanoic acid and 1,10-decanediol) was 0.005.
- A 5% rheniuns-5% germanium-0.5% ruthenium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example I-1, except that ammonium perrbenate, tetraethoxygermanium(IV), and ruthenium(III) chloride were used as metal raw materials and the surfaces of the catalyst particles were not stabilized by passing the 6-volume % oxygen/nitrogen gas through the tube subsequent to the reduction treatment. Subsequently, a hydrogenation reaction was conducted as in Example I-1. The molar yields of 1,10-decanediol and 10-hydroxydecancic acid in the reaction were 72.0% and 3.6%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.006.
- A 5% rhenium-5% germaniunt-5% ruthenium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example I-10, except that the ratio between the amounts of ammonium perrhenate, tetraethoxygermanium(IV), and ruthenium(III) chloride used as metal raw materials was changed. Subsequently, a hydrogenation reaction was conducted as in Example I-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 89.0% and 0.4%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.020.
- A 5% rhenium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example I-1, except that tetraethoxygermanium was not used. Subsequently, a hydrogenation reaction was conducted as in Example I-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 0.1% and 21.0%, respectively. The molar, ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (1,10-decanediol and 10-hydroxydecanoic acid) was 0.060.
- A 5% rhenium-5% palladium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example X-1, except that ammonium perrhenate and dichlorotetraamminepalladium(II) were used as metal raw materials. Subsequently, a hydrogenation reaction was conducted as in Example I-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 33.1% and 0.0%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.325.
- A 5% rhenium-5% ruthenium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example I-3, except that ammonium perrhenate and ruthenium(III) chloride were used as metal raw materials. Subsequently, a hydrogenation reaction was conducted as in Example I-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 45.0% and 11.1%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.063.
- Table 1 summarizes the results obtained in Examples I-1 to I-11 and Comparative examples I-1 to I-3.
-
TABLE 1 Reaction results Hydrogenation Yield of 1,10- Yield of 10- By-product/target reaction time decanediol hydroxydecanoic component molar Catalyst (hour) (mol %) acid (mol %) ratio Example 5%Re · 5%Ge/TiO2 7.5 5.9 48.1 0.016 I-1 Example 5%Re · 5%Ge/TiO2 18 89.3 6.5 0.017 I-2 Example 5%Re · 5%Ge/TiO2 7.5 74.7 2.6 0.004 I-3 Example 5%Re · 5%Ge/TiO2 7.5 81.7 0.6 0.006 I-4 Example 5%Re · 5%Ge/TiO2 7.5 4.5 36.8 0.011 I-5 Example 5%Re · 5%In/TiO2 7.5 9.0 43.5 0.034 I-6 Example 5%Re · 5%Si/TiO2 7.5 1.7 23.1 0.039 I-7 Example 5%Re · 1%Ge/TiO2 3 38.7 10.8 0.009 I-8 Example 5%Re · 5%Ge/TiO2 3 35.3 32.9 0.005 I-9 Example 5%Re · 5%Ge · 7.5 72.0 3.6 0.006 I-10 5%Ru/ TiO2 Example 5%Re · 5%Ge · 7.5 89.0 0.4 0.020 I-11 5%Ru/ TiO2 Comparative 5%Re/TiO2 7.5 0.1 21.0 0.060 example I-1 Comparative 5%Re · 5%Pd/TiO2 7.5 33.1 0.0 0.825 example I-2 Comparative 5%Re · 5%Ru/TiO2 7.5 45.0 11.1 0.063 example I-3 - Ammonium perrhenate and tetraethoxygexmanium(XV) were dissolved in water. Titanium oxide particles (MC-150, produced by Ishih&ra Sangyo Kaisha, Ltd.>having a specific surface area of 302 m2/g and a sulfate ion content of 4.8% by mass were added to the resulting solution. The solution was stirred at room temperature for 20 minutes.
- Subsequently, water was removed using an evaporator. Then, drying was performed at 100° C. for 4 hours. The resulting material was charged into a vertical baking tube, while air was passed through the tube, a baking treatment was performed at 500° C. for 3 hours. The resulting solid was charged into a vertical baking tube. While a hydrogen gas was passed through the tube, a reduction treatment was performed at 500° C. for 30 minutes. Hereby, a 5% rhenium-5% germanium/titanium oxide catalyst (the ratio of the amount of rhenium supported to the total mass of the catalyst: 5 mass %, the ratio of the amount of germanium supported to the total mass of the catalyst: 5 mass % (Ge/Re=1)) was prepared.
- Into a 70-mL high-pressure reactor, 70 mg of the catalyst prepared by the above method, 260 mg of decanoic acid, 1.2 mL of methanol, and a stirrer chip were charged. After the reactor had been purged with nitrogen, a hydrogen gas (7 MPaG) was introduced into the reactor at room temperature. Subsequently, a hydrogenation reaction -was conducted at 220° C. for 3 hours. The reaction pressure at 220° C. was 13 MPaG. After the reaction had been terminated, the temperature was reduced to room temperature and the pressure was then reduced. An analysis of the reaction liquid by gas chromatography confirmed that the molar yield of 10-decanol in the reaction was 76.5% and the molar ratio of the by-products (nonane and decane) to the target component (10-decanol) was 0.004.
- A 5% rheniura-5% germanium/zirconium oxide catalyst was prepared by the same catalyst preparation method as in Example I-6, except that zirconium oxide particles having a specific surface area of 97 m2/g which did not include a sulfate ion was used instead of the titanium oxide particles. Subsequently, a hydrogenation reaction was conducted as in example I-8, except that a water solvent was used instead of methanol. The molar yield of 10-decanol in the reaction was 23.2% and the molar ratio of the by-products (nonane and decane) to the target component (10-decanol) was 0.001.
- A comparison between the results obtained in Examples I-1 to I-11 and the results obtained in Comparative examples I-1 to I-3, where a catalyst including a carrier composed of titanium oxide was used, confirms that using a catalyst produced by attaching the specific second component to a catalyst including rhenium and an oxide of a metal belonging to Group 4 of the periodic table increases the total amount of 1,10-decanediol and 10-hydroxydecanoic acid produced in a hydrogenation reaction of a earboxylic acid per unit specific surface area and enhances catalytic activity. Furthermore, the occurrence of side reactions, such as a defunctionalization reaction associated with dehydration and hydrogenation, can fee markedly reduced. The advantageous effects become significant particularly when a catalyst including germanium is used. Note that, the total amount of 1,10-decanediol and 10-hydroxydecanoic acid produced is used as a measure of catalytic activity because 10-hydroxydecancic acid is considered a reaction intermediate of the 1,10-decanediol product and can be derived into 1,10-decanediol when the reaction time is further prolonged. A comparison between the results obtained in Examples I-12 and I-13 confirms that a catalyst including a carrier composed of zirconium oxide also has the same advantageous effects as a catalyst including a carrier composed of titanium oxide. Specifically, it is confirmed that a catalyst including a zirconium oxide carrier has a catalytic activity comparable to that of a catalyst including a titanium oxide carrier in terms of catalytic activity per unit specific surface area. A comparison between the results obtained in Examples I-1 and I-2 confirms that reaction selectivity car. be maintained by using a catalyst that includes germanium even under high-inversion-rate reaction conditions, which have been an issue for rhenium catalysts. In addition, a comparison between the results obtained in Examples I-1, I-4, and I-5 confirms that the higher the sulfate ion content in the catalyst, the higher the degree of reduction in the defunctionalization reaction, the higher the reaction selectivity, and the higher the degree of increase in the catalytic activity of the hydrogenation catalyst per unit specific surface area of the carrier. The remarkable reduction in the side reactions enables the production of an alcohol with a high purity and a reduction in the costs of purification of the alcohol produced.
- Ammonium perrnenate and tetraethoxygermanium(IV) were dissolved in water. Titanium oxide particles (Catalysis Society of Japan, Reference catalyst JRC-TIO-14 produced by Ishihare Sangyo Kaisha, Ltd.) having a specific surface area of 308 m2/g were added to the resulting solution. The solution was stirred at room temperature for 20 minutes. Subsequently, water was removed using an evaporator. Then, drying was performed at 100° C. for 4 hours. The resulting material was charged into a vertical baiting tube. While air was passed through the tube, a baking treatment was performed at 500° C. for 3 hours. The resulting solid was charged into a vertical baking tube. While a hydrogen gas was passed through the tube, a reduction treatment was performed at 500° C. for 30 minutes. Subsequently, the temperature was reduced to 30° C. After purging with an argon gas had been performed, a 6-volume % oxygen/nitrogen gas was passed through the tube. Hereby, 5% rhenium-5% germanium/titanium oxide catalyst particles having stabilized surfaces (the ratio of the amount of rhenium supported to the total mass of the catalyst: 5 mass %, the ratio of the amount of germanium supported to the total mass of the catalyst: 5 mass % (Ge/Re=1)) were prepared. The sulfate ion contents in the titanium oxide particles (Catalysis Society of Japan, Reference catalyst JRC-TIO-14) and the catalyst were 0.2% by mass and 0.14% by mass, respectively. The sulfur content in the catalyst was 0.078% by mass.
- Into a 70-mL high-pressure reactor, 100 mg of the catalyst prepared by the above method, 500 mg of sebacic acid, 2 g of water, and a stirrer chip were charged. After the reactor had been purged with nitrogen, a hydrogen gas (7 MPaG) was introduced into the reactor at room temperature. Subsequently, a hydrogenation reaction was conducted at 220° C. for 7.5 hours. The reaction pressure at. 220° C. was 13 MPaG. After the reaction had been terminated, the temperature was reduced to room temperature and the pressure was then reduced. An analysis of the reaction liquid by gas chromatography confirmed that the molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 5.9% and 48.1%, respectively, and the molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (1,10-decandiol and 10-hydroxydecanoic acid) was 0.016.
- A hydrogenation reaction was conducted as in Example II-1 with the catalyst prepared in Example II-1, except that the amount of time during which the hydrogenation reaction was conducted was changed to 18 hours. The molar yields or 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 89.3% and 6.5%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (1,20-decanediol and 10-hydroxydecanoic acid) was 0.017.
- A hydrogenation reaction was conducted as in Example II-1 with a catalyst prepared as in Example II-1, except that the treatment in which the surfaces of the catalyst particles were stabilized by passing a 6-volume % oxygen/nitrogen gas through the tube was not performed after the reduction treatment had been performed while a hydrogen gas was passed through the tube. The molar yields of 1,10-docanediol and 10-hydroxydecanoic acid in the reaction wore 74.7% and 2.6%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (1,10-decanediol and 10-hydroxydecanoic acid) was 0.004.
- A 5% rhenium-5% germanium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example II-1, except that the titanium oxide particles were changed to titanium oxide particles having a specific surface area of 302 m2/g and a sulfate ion content of 4.8% by mass (MC-150, produced by Ishihara Sangyo Kaisha, Ltd.). The sulfate ion content in the catalyst was 0.63% by mass. The sulfur content in the catalyst was 0.57% by mass, a hydrogenation reaction was conducted as in Example II-1 with this catalyst. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 81.7% and 0.6%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.006.
- A 5% rhenium-5% germanium/titanium oxide catalyst was prepared by the same method as in Example II-1, except that the titanium oxide particles were changed to titanium oxide particles having a specific surface area of 90 m2/g and a sulfate ion content of 3.6% by mass (MC-90, produced by Ishihare Sangyo Kaisha, Ltd.). The sulfate ion content in the catalyst was 0.30% by mass. The sulfur content in the catalyst was 0.35% by mass. A hydrogenation reaction was conducted as in Example II-1 with this catalyst. The molar yields of 1,10-decanedioi and 10-hydroxydecanoic acid in the reaction were 4.5% and 36.8%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxyclecanoic acid and 1,10-decanediol) was 0.011.
- A 5% rhenium-5% indium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example II-1, except, that indium(III) chloride tetrahydrate was used instead of tetraethoxygermanium(IV). Subsequently, a hydrogenation reaction was conducted as in Example II-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 9.0% and 43.5%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decaroic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.034.
- A 5% rhenium-5% silicon/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example II-1, except that tetraethoxysilane(IV) was used instead of tetraethoxygermanium(IV) and ethanol was used instead of water for preparing the solution. Subsequently, a hydrogenation reaction was conducted as in Example II-1. The molar yields of 1,10-decarediol and 10-hydroxydecanoic acid in the reaction were 1.7% and 23.1%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.039.
- A 5% rhenium-1% germanium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example II-1, except that the ratio between the amounts of ammonium perrhenate and tetraethoxygermanium(IV) used as metal raw materials was changed and the surfaces of the catalyst particles were not stabilized by passing the 6-volume % oxygen/nitrogen gas through the tube subsequent to the reduction treatment. A hydrogenation reaction was conducted as in Example II-1 with this catalyst, except that the amount of time during which the reaction was conducted was changed to 3 hours. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 36.7% and 10.8%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-docanediol) was 0.009.
- A hydrogenation reaction was conducted with the catalyst prepared in Example 11-3 as in Example II-1, except that the amount of time during which the reaction was conducted was changed to 3 hours. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 35.3% and 32.9%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.005.
- A 5% rhenium-5% germanitxm-0.5% ruthenium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example II-1, except that ammonium perrhenate, tetraethoxygermanium(IV), and ruthenium(III) chloride were used as metal raw materials and the surfaces of the catalyst particles w-re not stabilized by passing the 6-volume % oxygen/nitrogen gas through the tube subsequent to the reduction treatment. Subsequently, a hydrogenation reaction was conducted as in Example II-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 72.0% and 3.6%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-norsanoic acid, and 1-decanoic acid) to the target, components (10-bydroxydecanoic acid and 1,10-decanediol) was 0.006.
- A 5% rhenium-5% germanium-5% ruthenium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example II-10, except that the ratio between the amounts of ammonium perrhenate, tetraethoxygermanium(XV) and ruthenium(III) chloride used as metal raw materials was changed. Subsequently, a hydrogenation reaction was conducted as in Example II-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction wore 39.0% and 0.4%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.020.
- A 5% rhenium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example II-1, except chat tetraethoxygermanium was not used. Subsequently a hydrogenation reaction was conducted as in Example II-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 0.1% and 21.0%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (1,10-decanediol and 10-hydroxydecanoic acid) was 0.060.
- A 5% rhenium-5% palladium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example II-1, except that ammonium perrhenate and dichlorotetraanuninepalladium(II) were used as metal raw materials. Subsequently, a hydrogenation reaction was conducted as in Example I-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid m the reaction were 33.1% and 0.0%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanoic acid and 1,10-decanediol) was 0.825.
- A 5% rhenium-5% ruthenium/titanium oxide catalyst was prepared by the same catalyst preparation method as in Example II-1, except that ammonium perrhenate and ruthenium (III) chloride were used as metal, raw materials. Subsequently, a hydrogenation reaction was conducted as in Example II-1. The molar yields of 1,10-decanediol and 10-hydroxydecanoic acid in the reaction were 45.0% and 11.1%, respectively. The molar ratio of the by-products (1-nonanol, 1-decanol, 1-nonanoic acid, and 1-decanoic acid) to the target components (10-hydroxydecanolc acid and 1,10-decanediol was 0.063.
- Table 2 summarizes the results obtained in Examples II-1 to II-11 and Comparative examples II-1 to II-3.
-
TABLE 2 Reaction results Hydrogenation Yield of 1,10- Yield of 10- By-product/target reaction time decanediol hydroxydecanoic component molar Catalyst (hour) (mol %) acid (mol %) ratio Example 5%Re · 5%Ge/TiO2 7.5 5.9 48.1 0.016 II-1 Example 5%Re · 5%Ge/TiO2 18 89.3 6.5 0.017 II-2 Example 5%Re · 5%Ge/TiO2 7.5 74.7 2.6 0.004 II-3 Example 5%Re · 5%Ge/TiO2 7.5 81.7 0.6 0.006 II-4 Example 5%Re · 5%Ge/TiO2 7.5 4.5 36.8 0.011 II-5 Example 5%Re · 5%In/TiO2 7.5 9.0 43.5 0.034 II-6 Example 5%Re · 5%Si/TiO2 7.5 1.7 23.1 0.039 II-7 Example 5%Re · 1%Ge/TiO2 3 38.7 10.8 0.009 II-8 Example 5%Re · 5%Ge/TiO2 3 35.3 32.9 0.005 II-9 Example 5%Re · 5%Ge · 7.5 72.0 3.6 0.006 II-10 5%Ru/ TiO2 Example 5%Re · 5%Ge · 7.5 89.0 0.4 0.020 II-11 5%Ru/ TiO2 Comparative 5%Re/TiO2 7.5 0.1 21.0 0.060 example II-1 Comparative 5%Re · 5%Pd/TiO2 7.5 33.1 0.0 0.825 example II-2 Comparative 5%Re · 5%Ru/TiO2 7.5 45.0 11.1 0.063 example II-3 - Ammonium perrhenate and tetraethoxygermanium(IV) were dissolved in water. Titanium oxide particles (MC-150, produced by Ishihara Sangyo Kalsha, Ltd.) having a specific surface area of 302 m2/g and a sulfate ion content of 4.8% by mass were added to the resulting solution. The solution was stirred at room temperature for 20 minutes.
- Subsequently, water was removed using an evaporator. Then, drying was performed at 100° C. for 4 hours. The resulting material was charged into a vertical baking tube, while air was passed through the tube, a baking treatment was performed at 500° C. for 3 hours. The resulting solid was charged into a vertical baking tube. While a hydrogen gas was passed through the tube, a reduction treatment was performed at 500° C. for 30 minutes. Hereby, a 5% rhenium-5% germanium/titanium oxide catalyst (the ratio of the amount of rhenium supported to the total mass of the catalyst: 5 mass %, the ratio of the amount of germanium supported to the total mass of the catalyst: 5 mass % (Ge/Re=1)) was prepared.
- Into a 70-mL high-pressure reactor, 70 mg of the catalyst prepared by the above method, 260 mg of decanoic acid, 1.2 mL of methanol, and a stirrer chip were charged. After the reactor had been purged with nitrogen, a hydrogen gas (7 MPaG) was introduced into the reactor at room temperature. Subsequently, a hydrogenation reaction -was conducted at 220° C. for 3 hours. The reaction pressure at 220° C. was 13 MPaG. After the reaction had been terminated, the temperature was reduced to room temperature and the pressure was then reduced. An analysis of the reaction liquid by gas chromatography confirmed that the molar yield of 10-decanol in the reaction was 76.5% and the molar ratio of the by-products (nonane and decane) to the target component (10-decanol) was 0.004.
- A 5% rhenium-5% germanium/zirconium oxide catalyst was prepared by the same catalyst preparation method as in Example II-8, except that zirconium oxide particles having a specific surface area of 97 m2/g which did not include a sulfate ion was used instead of the titanium oxide particles. Subsequently, a hydrogenation reaction was conducted as in Example II-8, except that a water solvent was used instead of methanol. The molar yield of 10-decanol in the reaction was 23.2% and the molar ratio of the by-products (nonane and decane) to the target component (10-decanol) was 0.001.
- A comparison between the results obtained in Examples II-1, to II-3, and the results obtained in Comparative examples II-1 to II-3, where a catalyst including a carrier composed of titanium oxide was used, confirms that using a catalyst including rhenium and a specific amount of second component increases the total amount of 1,10-decanediol and 10-hydroxydecanoic acid produced in a hydrogenation reaction of a carboxylic acid per unit specific surface area and enhances catalytic activity per unit specific surface area. Furthermore, the occurrence of side reactions, such as a defunctionalization reaction associated with dehydration and hydrogenation, can be markedly reduced. The advantageous effects become significant particularly when a catalyst including germanium is used. Note chat, the total amount of 1,10-decanediol and 10-hydroxydecancic acid produced is used as a measure of catalytic activity because 10-hydroxydecanoic acid is considered a reaction intermediate of the 1,10-decanediol product and can be derived into 1,10-decanediol when the reaction times is further prolonged. A comparison between the results obtained in Examples II-12 and II-13 confirms that a catalyst including a carrier composed of zirconium oxide also has the same advantageous effects as a catalyst, including a carrier composed of titanium oxide.
- Specifically, it is confirmed that a catalyst including a zirconium oxide carrier has a catalytic activity comparable to that of a catalyst including a titanium oxide carrier in terms of catalytic activity per unit specific surface area. A comparison between the results obtained in Examples II-1 and II-2 confirms that reaction selectivity can be maintained by using a catalyst that includes germanium even under high-inversion-rate reaction conditions, which have been an issue for rhenium catalysts. In addition, a comparison between the results obtained in Examples II-1, II-4, and II-5 confirms that the higher the sulfate ion content in the catalyst, the higher the degree of reduction in the defunctionalization reaction, the higher the reaction selectivity, and the higher the degree of increase in the catalytic activity of the hydrogenation catalyst per unit specific surface area of the carrier. The remarkable reduction in the side reactions enables the production of an alcohol with a high purity and a reduction in the costs of purification of the alcohol produced.
- This catalyst is industrially useful as a catalyst for directly synthesizing an alcohol from a carbonyl compound. This catalyst enables an intended alcohol to fee produced with high activity and high selectivity and reduces increases in the costs of purification of the product and the costs of production of the catalyst. Therefore, this catalyst is industrially highly valuable.
- Although the present invention has been described in detail with reference to particular embodiments, it is apparent to a person skilled in the art that various modifications can be mace therein without departing from the spirit and scope of the present invention.
- The present application is based on Japanese Patent Application No. 2017-043988 filed on Mar. 8, 2017, and Japanese Patent Application No. 2017-102053 filed on May 2 2017, which are incorporated herein by reference in their entirety.
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