Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
  • B01J23/70—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
  • B01J23/85—Chromium, molybdenum or tungsten
  • B01J23/88—Molybdenum
  • B01J23/883—Molybdenum and nickel
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • 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
  • 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
• • 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
  • C07C31/18—Polyhydroxylic acyclic alcohols
  • C07C31/20—Dihydroxylic alcohols
  • C07C31/205—1,3-Propanediol; 1,2-Propanediol

Definitions

• the present invention relates to the manufacture of 1, 3-propanediol .
• the present invention relates to an improved catalyst for hydrogenating 3- hydroxypropanal to 1, 3-propanediol which exhibits prolonged catalyst life in the hydrogenation reaction environment.
• the present invention relates to an improved process for preparing 1,3- propanediol from 3-hydroxypropanal .
• 1, 3-propanediol a chemical intermediate in the preparation of polyesters, can be prepared by hydrogenation of 3-hydroxypropanal in agueous solution.
• Selective hydrogenation of 3-hydroxypropanal to 1,3- propanediol is complicated by the high reactivity of 3- hydroxypropanal and the relatively low solubility of hydrogen in aqueous solution.
• a catalyst composition comprising, in solid particulate form, (a) an active nickel component in which the nickel constitutes from 25 to 60 wt% of the catalyst composition; (b) a molybdenum component in which the molybdenum constitutes from 5 to 20 wt% of the catalyst composition; and (c) from 10 to 50 wt%, based on the weight of the catalyst composition of a binder material comprising at least one of oxides of silicon and silicates and oxides of zinc, aluminium, zirconium, magnesium and calcium, each of said aluminium, calcium and zinc present in an amount no greater than 2 wt%, based on the weight of the catalyst composition.
• a process for preparing 1, 3-propanediol comprising (a) contacting, in an aqueous reaction mixture at a temperature of at least 30°C, 3-hydroxypropanal and hydrogen in the presence of a solid particulate catalyst composition comprising (i) an active nickel component in which the nickel constitutes from 25 to 60 wt% of the catalyst composition; (ii) a molybdenum component in which the molybdenum constitutes from 5 to 20 wt% of the catalyst composition; and (iii) from 10 to 50 wt% of a binder material selected from at least one of oxides of silicon and silicates and oxides of zinc, aluminium, zirconium, magnesium and calcium, each of said aluminium, calcium and zinc present in an amount no greater than 2 wt%, based on the weight of the catalyst composition, to produce an aqueous product mixture comprising 1, 3-propanediol; and (b) recovering the 1, 3-propanediol from the
• FIG. 1 is a plot of catalyst activity over time for a 3-hydroxypropanal hydrogenation catalyst according to the invention.
• FIG. 2 is a plot of catalyst activity over time for a 3-hydroxypropanal hydrogenation catalyst according to the invention.
• FIG. 3 is a plot of catalyst activity over time for a conventional nickel hydrogen catalyst.
• FIG. 4 is a plot of catalyst activity over time for a 3-hydroxypropanal hydrogen catalyst according to the invention .
• the hydrogenation catalyst contains, as the major active component, from 25 to 60 wt% nickel (as Ni ) , preferably from 25 to 45 wt% .
• the nickel in the active catalyst is predominantly in reduced form.
• the catalyst contains 5 to 20 wt% molybdenum (as Mo°) , preferably 6 to 16 wt% .
• the molybdenum is present in the catalyst in both metal and oxide form.
• the molybdenum has a binding function and is also an activity promoter.
• the binder portion of the catalyst acts as a "glue" to hold the separate components together and to provide crush resistance from the pressure drop across the catalyst bed.
• the binder constitutes 10 to 50 wt% of the catalyst and is made up of oxides of silicon, and silicates and oxides of zinc, zirconium, calcium, magnesium and/or aluminium.
• the catalyst will contain from 30 to 70, preferably 35 to 55, wt% silicon; from 0 to 2, preferably 0 to 1, wt% zinc; and from 0 to 2 wt% aluminium.
• the binder will contain not more than 2 wt% calcium, and will preferably contain 0-1 wt% calcium.
• a preferred embodiment of the catalyst contains essentially no zinc or calcium.
• the preferred catalyst composition for hydrogenation of 3-hydroxypropanal to 1, 3-propanediol in aqueous solution contains about 35 wt% nickel and about 8-12 wt% molybdenum, with the balance binder material as described above.
• the catalyst can be prepared by any procedure that incorporates the active nickel component, the molybdenum component and the binder material in a solid bulk form.
• catalyst preparation involves mixing nickel oxide, the binder material such as attapulgus clay, and molybdenum trioxide powder into a homogeneous powder.
• a solution of colloidal silica in sufficient water to form an extrudable mixture is stirred into the solid mixture.
• the wet mixture is then extruded through a die plate with 0.10-0.18 cm (0.040-0.070 in.) diameter holes.
• the extrudates are dried at 100-125°C for a time sufficient to reduce the moisture content to less than about 5 wt% .
• the dried extrudates are then calcined in air at 450-550°C for at least about 3 hours until the desired strength is developed.
• the catalyst Prior to use, the catalyst is reduced under hydrogen gas at a temperature within the range of 350 to 450°C for a time sufficient for reduction of at least 60% of the nickel. If the reduced catalyst is not used immediately, it is cooled to ambient and stored under a protective medium such as 1, 3-propanediol until used.
• a protective medium such as 1, 3-propanediol until used.
• the catalyst is in particulate form, with particle size and shape such as to provide sufficient catalyst activity dependent upon other process variables such as flow rate and pressure.
• the preferred catalyst particles are less than 0.32 cm (1/8 in.) in diameter (across the width of the particle cross-section) , preferably 0.08-0.16 cm (1/16-1/32 in.), to provide an optimum balance of geometric surface area and crush resistance.
• the preferred catalyst shapes for longest catalyst bed life are trilobal and cylindrical.
• the catalyst will preferably exhibit an activity of at least 10 h _1 /catalyst volume fraction, preferably at least 20, in the selective hydrogenation of 3- hydroxypropanal to 1 , 3-propanediol .
• the catalyst has improved stability in the reaction environment and good physical integrity over the catalyst active life.
• Hydrogenation of the 3-hydroxypropanal to 1,3- propanediol can be carried out in aqueous solution at an temperature of at least 30°C, generally within the range of 50 to 175°C, under a positive hydrogen pressure of at least 689 kPa (100 psig) , generally within the range of 1379-13790 kPa (200 to 2000 psig) .
• Hydrogenation of HPA to PDO is disclosed in US-5786524.
• the invention hydrogenation process is designed particularly for use in a process for preparing 1,3- propanediol by the hydroformylation of ethylene oxide, as described for example in US-A-5463145 and US-A- 3687981 or from acrolein, as described in US-A-5093537.
• 3-hydroxypropanal is an intermediate product which is hydrogenated in aqueous solution to 1, 3-propanediol .
• ethylene oxide is hydroformylated (reacted with carbon monoxide and hydrogen) at a temperature within the range of 50 to 140°C and a CO/H 2 pressure within the range of 3447-34474 kPa (500 to 5000 psig), preferably 60 to 90°C and 6895-24132 kPa (1000 to 3500 psig), in the presence of a suitable hydroformylation catalyst such as cobalt or rhodium carbonyl to produce a hydroformylation product mixture containing 3-hydroxypropanal, 1,3- propanediol and hydroformylation reaction by-products.
• a suitable hydroformylation catalyst such as cobalt or rhodium carbonyl
• the 3-hydroxypropanal component is removed by extraction into water and passed to a hydrogenation reaction vessel in the form of an aqueous solution having a 3- hydroxypropanal concentration less than 15 wt%, preferably less than 10 wt%, based on the weight of the aqueous solution.
• the hydrogenation of 3-hydroxypropanal to 1, 3-propanediol is carried out as described above to form a hydrogenation product mixture containing 1,3- propanediol as the major product, which is recovered by suitable means such as distillation.
• a 3.79 litre (one-gallon) plough-type mixer is charged with 730 parts of technical grade nickel calcium silicate (93-97% NiCaSiA10 x ) , 125 parts of Microcel E (0.8 solids) and 125 parts bentonite clay (0.8 solids) and mixed for 2 minutes.
• a solution containing 600 parts of deionized water and 16-20 parts of molybdenum from ammonium molybdate solution is stirred into the mixture, and mixing is continued for 5-10 minutes.
• the wet mix is then extruded through a die plate with 0.15-0.18 cm (0.06 in to 0.07in) diameter holes of trilobe form.
• the extrusions are dried overnight at 100-125°C.
• the dried intermediate is then reduced with hydrogen at 445-455°C to a reduced nickel content of about 90%, based on total nickel.
• a 3.79 litre (one-gallon) plough-type mixer was charged with 750 parts of technical-grade nickel oxide (93 - 97% NiO) , 498 parts of Attagel-30 attapulgus clay (0.8 solids), and 185 parts of molybdenum trioxide powder (Mo0 3 ) and mixed for 2-3 minutes.
• a solution of 796 parts Nalco 2327, a colloidal silica sol (available from Nalco Chemical Company) was added to the dry blend with stirring. Stirring was continued for 5 minutes. About 60 parts of additional deionized water was added to the mixer and stirring was continued for another 5 minutes.
• the wet mix was then extruded through a single celcon tri-insert which contained holes 0.10 cm (0.040 inch) in diameter.
• the extrudates were dried at 110°C, then sized/screened and calcined in air at 500°C for about 3 hours in a stationary ceramic sagger.
• the extrudates were then reduced with hydrogen at 420-430°C to a reduced nickel content of 90%, based on total nickel.
• a one-gallon plow-type mixer was charged with 735 parts of technical-grade nickel oxide (93 - 97% NiO) , 355 parts Attagel 30 attapulgus clay (0.8 solids) and 286 parts of molybdenum trioxide powder (Mo0 3 ) and mixed for 2 minutes.
• a solution of 795 parts of Nalco 2327 colloidal silica in 225 parts deionized water was added to the solid mixture with stirring, and the stirring was continued for 10 minutes.
• the wet mix was then extruded through a die plate with 0.10-0.18 cm (0.040-0.070 in) diameter holes. The extrudates were dried overnight at 100-125°C.
• the heat of reaction was removed by heat exchange in the recirculation loop. Pressure was maintained by continuous addition of hydrogen to replace consumed gas . Samples of feed and product were periodically taken and the concentration of 3-hydroxypropanal was determined. Assuming a first-order reaction rate with respect to 3- hydroxypropanal concentration, an apparent reaction rate constant was calculated for each feed/product pair of 3- hydroxypropanal concentrations. The activity of the catalyst to hydrogenate 3-hydroxypropanal was calculated as the reaction rate constant, expressed in units of volume of liquid/volume of catalyst particles/time. The reaction rates of catalysts A to D were measured over a period of about 30 days.
• Catalyst C is a standard, off-the-shelf nickel hydrogenation catalyst containing a relatively low molybdenum content (1.8 wt%) .
• Catalysts A, B and D are invention catalysts designed for more stable hydrogenation of 3- hydroxypropanal in aqueous solution. Results are shown in Figures 1 to 4 and in Table 1.

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• Chemical & Material Sciences (AREA)
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• Chemical Kinetics & Catalysis (AREA)
• Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
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• Low-Molecular Organic Synthesis Reactions Using Catalysts (AREA)
• Investigating Or Analysing Materials By Optical Means (AREA)

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