WO2007142727A1 - Supported polyoxometalates, process for their preparation and use in oxidation of alkanes - Google Patents

Supported polyoxometalates, process for their preparation and use in oxidation of alkanes Download PDF

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WO2007142727A1
WO2007142727A1 PCT/US2007/008153 US2007008153W WO2007142727A1 WO 2007142727 A1 WO2007142727 A1 WO 2007142727A1 US 2007008153 W US2007008153 W US 2007008153W WO 2007142727 A1 WO2007142727 A1 WO 2007142727A1
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polyoxometalates
supported
polyoxometalate
group
organic substrate
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PCT/US2007/008153
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French (fr)
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Ryan M. Richards
Ulrich Kortz
Lihua Bi
Kake Zhu
Andreas Suchopar
Lifang Chen
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Exxonmobil Chemical Patents, Inc.
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Publication of WO2007142727A1 publication Critical patent/WO2007142727A1/en

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J27/00Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
    • B01J27/14Phosphorus; Compounds thereof
    • B01J27/186Phosphorus; Compounds thereof with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • B01J27/188Phosphorus; Compounds thereof with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium with chromium, molybdenum, tungsten or polonium
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/54Catalysts 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
    • B01J23/56Platinum group metals
    • B01J23/64Platinum group metals with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • B01J23/652Chromium, molybdenum or tungsten
    • B01J23/6527Tungsten
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/70Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
    • B01J23/76Catalysts 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
    • B01J23/84Catalysts 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
    • B01J23/85Chromium, molybdenum or tungsten
    • B01J23/888Tungsten
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01GCOMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
    • C01G1/00Methods of preparing compounds of metals not covered by subclasses C01B, C01C, C01D, or C01F, in general
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01GCOMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
    • C01G41/00Compounds of tungsten
    • C01G41/006Compounds containing, besides tungsten, two or more other elements, with the exception of oxygen or hydrogen
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01GCOMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
    • C01G49/00Compounds of iron
    • C01G49/009Compounds containing, besides iron, two or more other elements, with the exception of oxygen or hydrogen
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01GCOMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
    • C01G53/00Compounds of nickel
    • C01G53/006Compounds containing, besides nickel, two or more other elements, with the exception of oxygen or hydrogen
    • CCHEMISTRY; METALLURGY
    • C01INORGANIC CHEMISTRY
    • C01PINDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
    • C01P2002/00Crystal-structural characteristics
    • C01P2002/50Solid solutions
    • C01P2002/52Solid solutions containing elements as dopants

Definitions

  • This invention is directed to supported polyoxymeta- 20 lates, a process for their preparation and their use for the catalytic oxidation of organic molecules.
  • Polyoxometalates are a unique class of molecular metal-oxygen clusters. They consist of a polyhedral cage structure or framework bearing a negative charge and centrally located heteroatom(s) surrounded by the cage framework. The negative charge is balanced by
  • heteroatoms include Group Illa-VIa elements such as phosphorus, antimony, silicon, selenium and boron.
  • the framework of polyoxometalates is usually comprised of edge- or corner-shared MO ⁇ octahedra, where M
  • the addenda metal is substantially limited to a few metals including Group Vb or VIb transition metals in their highest oxidation state (e.g. V 5+ , Nb 5+ , Ta 5+ , •
  • a major subclass of polyoxometalates is constituted by Keggin type POMs .
  • These polyoxoanions generally consists of 12 framework metals and 40 oxygen atoms sym- metrically arranged around a central atom X and thus can be represented by the formula X n Mi 2 0 4 o (8 ⁇ n) ⁇ - If the central atom X is a heteroatom with a lone pair of electrons (e.g. As 111 , Sb 111 ), the formation of such closed Keggin units is not allowed. In fact, most of these POMs consist of dimeric adducts of incomplete (lacunary) Keggin fragments joined together by extra framework or heteroatoms.
  • POMs and in particular TMSPs Due to their size, shape, charge density and redox- active nature, POMs and in particular TMSPs have at- tracted continuously growing attention in the area of oxidation catalysis .
  • Cavani et al disclose the oxidation of isobutane to methacrylic acid (Topics in Catalysis 2003, 23, 141-152) and Kamat et al. describe the epoxidation of various olefins using hydrogen peroxide and a silicotungstate compound (Science 2003, 300, 964-966) . Further, WO 03/028881 discloses a process for the selective oxidative dehy- drogenation of alkanes to produce olefins using certain polyoxometalate catalysts.
  • Additional references of interest include:
  • EP1080784 EP 1078687; EP1077082; EP0771781; EP1059276;
  • polyoxometalates showing an improved catalytic performance in oxidation reactions of organic substrates and in particular attaining high conversions when used for the selective oxidation of alkanes.
  • This invention relates to supported polyoxometalates represented by the formula
  • A represents a cation
  • n is the number of cations
  • m is the charge of the polyoxoanion
  • M is a transition metal
  • X is an element selected from the group consisting of As, Sb, Bi, Se and Te.
  • polyoxometalate is supported on a solid support selected from the group consisting of AI2O3, MgO, TiO 2 , ZrO 2 , SiO 2 , mesoporous silica, active carbon, diatomite, clays, zeolites, polyoxometalate salts and mixtures thereof, with the proviso that the polyoxometalate salt supports are different from the supported polyoxometalates defined by the above formula.
  • Figure 1 is a graph illustrating the recycling of Cata- lyst in Example 9.
  • Figure 2 is a graph illustrating the kinetics of oxidation of n-hexadecane using SBA-15-APTS-Se2W 18 Fe 4 catalysts
  • Figure 3 is a graph illustrating the temperature dependence of n-hexadecane oxidation.
  • Figure 4 is a graph illustrating selectivities of dif- ferent POM 1 S loaded on SBA-15-apts.
  • A represents a cation
  • n is the number of cations
  • m is the charge of the polyoxoanion
  • M is a transition metal
  • X is an element selected from the group consisting of As, Sb, Bi, Se and Te,
  • polyoxometalate is supported on a solid support selected from the group consisting of Al 2 O 3 , MgO, TiO 2 , ZrO 2 , SiO 2 , mesoporous silica, active carbon, diatomite, clays, zeolites, polyoxometalate salts and mixtures thereof, with the proviso that the polyoxometalate salt supports are different from the supported polyoxometalates defined by the above formula .
  • polyoxometalates according to the invention can be prepared according to the method disclosed in Kortz et al., Inorg. Chem. 2002, 41, 783, and have been found to exist as a dimeric assembly, i.e. four octahedral transition metal centers hold together two trilacunary (B- /J-XW 9 O 33 ) Keggin fragments.
  • the invention also includes solvates of the present POMs.
  • a solvate is an association of solvent molecules with a polyoxometalate.
  • water is associated with the POMs, as the POMs are usually synthesized in water. However, this water can be gradually removed by heating the solid POMs .
  • the cation A can be a Group Ia, Ha, IHb, IVb, Vb, VIb, VIIb, VIIIb, Ib, lib, Ilia, IVa, Va or Via metal or an organic cation.
  • A is selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, magnesium, calcium, strontium, barium, titanium, vanadium, chromium, lanthanum, lanthanide metal, actinide metal, manganese, iron, cobalt, nickel, copper, zinc, ruthenium, palladium, platinum, tin, an- timony, tellurium, phosphonium such as tetraalkylphos- phonium, ammonium, guanidinium, tetraalkylammonium, protonated aliphatic amines, protonated aromatic amines and combinations thereof. More preferably, A is selected from sodium, potassium, cesium and combinations thereof.
  • the number n of cations is dependent on the nature of cation (s) A, namely its/their valence, and the negative charge m of the polyanion which preferably has to be balanced.
  • the overall charge of all cations A is equal to the charge of the polyanion.
  • the charge m of the polyanion is dependent on the oxidation states of the metal M and the heteroatom X.
  • m depends on the oxidation state of the atoms present in the polyanion, e.g., it follows from the oxidation states of W (+6), O (-2), a given heteroatom X (such as +3 for Sb, Bi and As or +4 for Se and Te) , and the transition metal, M (ranging from +2 to +5) .
  • m is 2 or 4 or 6 or 8 or 10.
  • n is 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10.
  • the metal M of the polyoxometalates according to the invention is selected from the entire block of transition metals of the Periodic Table of the Elements.
  • M is selected from the group consisting of first row transition metals (e.g. Fe, Cr, Mn, Co, Ni, Cu, Zn), Cd, Hg and combinations thereof.
  • the oxidation state of M comprised in the present polyoxometalates can range from +11 to +V and preferably is +III for Fe and Cr and +11 for all other incorporated transition metals.
  • the heteroatom X is selected from the group consisting of As, Sb, Bi, Se and Te.
  • the polyoxometalates of the invention are further characterized in that they are supported on a solid sup- port.
  • porous supports having high surface areas which have been described in the prior art for supporting heteropolyacids used in acid-catalyzed reactions, are also useful in this, invention (see: Haber et al., Applied Catalysis A 2003, 256, 141-152; Kozhev- nikov et al . , Catalysis Letters 1995, 30, 241-252; Koz- hevnikov et al . , Journal of Molecular Catalysis A 1996, 114, 287-298; Wu et al., Ind. Eng . Chem. Res. 1996, 35, 2546) .
  • the solid support is selected from the group consisting of AI 2 O 3 , MgO, Ti ⁇ 2, Zr ⁇ 2, SiO 2 , mesoporous silica, active carbon, diatomite, clays including layered aluminosilicates (e.g. bentonite) , zeolites such as mesoporous zeolite crystallites described in A. Boisen et al . , Chem. Commun . 2003, 8, 958-959 and Y. Tao et al., Langmuir 2005, 21, 2, 504-507, and poly- oxometalate salts.
  • the support is selected from the group consisting of AI 2 O 3 , MgO, ZrO 2 , SiO 2 and mesoporous silica which can be defined as silica having a pore size between 2 and 50 nm.
  • mesoporous silica examples include SBA-15, MCM-41, and MCM-48.
  • SBA-15 is used as mesoporous silica which can be prepared according to Zhao et al., Science 279, 1998, 548.
  • a metal oxide such as MgO or AI 2 O 3
  • this material is in the form of an aerogel, i.e.
  • the metal oxide aerogels can be characterized by a BET surface of 50 to 1000 m 2 /g, a pore volume of 0.1 to 2.0 cm 3 /g and/or a pore size of 0.5 to 20 nm each determined by nitrogen phy- sisorption analysis.
  • polyoxometalate salt is used as solid support, this polyoxometalate salt is different from the supported polyoxometalate according to the invention and is not represented by the above formula (A n ) m+ [M 4 (H 2 O) 1 0 (XW 9 ⁇ 33) 2 ] m ⁇ .
  • Suitable polyoxometalate salt supports are known from the prior art, e.g. EP 1 078 687, EP 1 059 276, US 6,043,184 and WO 00/09262, and are preferably wide pore salts having the formula
  • C is a cation selected from potassium, rubidium, cesium, magnesium, calcium, strontium, barium, transition metal, actinide metal, lanthanide metal, metal oxy ion, ammonium, tetraalkylammonium, pyridin- ium, quinolinium, protonated aromatic amines, proto- nated aliphatic amines or mixtures thereof;
  • X' is an element selected from Groups 3-16 elements; M' is molybdenum, tungsten or a combination thereof; M 1 is va- nadium; M 2 is a transition metal different from M' and M 1 such as zinc; a is the number of cations, z is the charge of C (typically 1, 2, 3, 4, 5 or 6); k is from 1 to 5; p is from 5 to 20; q is from 0 to 3; x is from 0 to 6; y is from 18 to 62; and e is the charge of the polyanion.
  • suitable polyoxometalate salt supports include CS 3 (PMOi 2 O 40 Jf Cs 4 (PM ⁇ nVO 40 ) , Cs 5 (PMOIOV 2 O 40 ) , Cs 6 (PMo 9 V 3 O 40 ) , Cs 3 (PW 12 O 40 ) , Cs 4 (PW 11 VO 40 ) , Cs 5 (PW 10 V 2 O 40 ) and Cs 6 (PW 9 V 3 O 40 ) .
  • a support containing hydroxy groups on its surface such as SiO 2 or SBA-15 is used, then it is preferred to support the polyoxometalate on a surface which has been modified with an amine compound of formula
  • R 1 is alkyl, preferably C 1 -C 4 alkyl, (preferably methyl, ethyl, propyl or butyl and all isomers thereof)
  • Y is carbon or silicon, preferably silicon (in this instance Y is NOT yttrium) x is 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 or 12, preferably 1, 2, 3, 4, 5 or 6, and R 2 is hydrogen, alkyl or aryl, preferably hydrogen .
  • a preferred amine compound used is aminopropyltriethoxysilane (APTS) .
  • the present invention is further directed to a process for preparing polyoxometalates according to the invention comprising
  • step (b) stirring and optionally heating the mixture of step (a) , (C) optionally filtering the mixture of step
  • step (a) the solid support is mixed with a solution of the polyoxometalate .
  • the solvent used for this solution is preferably selected from the group consisting of water, acetonitrile, acetone, dimethylformamide, 1,4-dioxane, 1, 2-dichloroethane and mixtures thereof. It is particularly preferred to dissolve the polyoxometalate in water.
  • the solvent used is preferably less polar than water. In general, the longer the alkyl chain, the less polar the solvent should be. For example, if cation A is tetrabutylammonium, acetonitrile is preferably used as solvent.
  • step (b) the mixture of step (a) is stirred.
  • the mixture is stirred for 1 minute to 10 hours, preferably from 5 to 10 h.
  • the mixture can be heated to a temperature of 50 to 100 0 C depending on the thermal stability of the polyoxometalate, preferably about 70 to 90 0 C, preferably about 75 to 85°C, preferably of about 80 0 C.
  • the mixture of step (b) can be filtered in step (c) , before the supported polyoxometalate is recovered in step (d) . In case a filtration has actually taken place in step (c) , the product is recovered by washing and drying the filtered solid of step (c) .
  • step (d) can be performed using techniques known in the art and is preferably carried out at a temperature of 30 to 100 0 C under ambient or reduced pressure.
  • the polyoxometalate is supported on aerogels of MgO or AI 2 O 3 by mixing the aerogel with a water solution of the POM, stirring the mixture at a temperature of 50 to 100 0 C, preferably about 70 to 90 0 C, preferably about 75 to 85°C, preferably of about 80 0 C and drying the mixture.
  • a mixture of the support and a POM solution in water is stirred for 1 minute to 10 hours, preferably 5 to 10 h and filtered. Then, the filtered solid is washed with water and dried at temperature of 50 to 100 0 C, preferably 75 to 100 0 C, preferably of about 95 "C.
  • the polyoxometalate can be supported by incipient wetness impregnation techniques.
  • the pore volume of the support is determined first and then the POM is dissolved in the same volume (or from 75% of the volume to 500% of the volume, preferably from 100% to 400% of the volume, particularly from 200 to 300% of the volume) of a solvent such as water, acetonitrile and ethanol to form a solution. Afterwards the support is impregnated with this solution and the mixture is dried.
  • the supported POMs according to the invention typically have POM loading levels on the support of up to 40 wt . % or even more. Accordingly, POM loading levels on the support of 1 to 40 wt.%, particularly 5 to 30 wt.%, and more particularly 5 to 20 wt.% are in general suitable. POM loading levels can be determined by Inductively Coupled Plasma Mass Spectrometry (ICP) analysis or X-ray photoelectron spectroscopy (XPS) as described in the Examples section. In the event the values from the ICP and XPS differ, the ICP shall control.
  • ICP Inductively Coupled Plasma Mass Spectrometry
  • XPS X-ray photoelectron spectroscopy
  • the present invention is also directed to the use of polyoxometalates according to the invention as catalyst for the oxidation of organic substrates.
  • the invention also includes a process for oxidizing organic substrates, wherein a supported polyoxometalate or a mixture of two or more supported polyoxometalates according to the invention is contacted with an organic substrate in the presence of a suitable oxidizing agent.
  • polyoxometalates according to the invention for catalyzing oxidation reactions of organic substrates as well as the process according to the inven- tion for oxidizing organic substrates can be further characterized by the following features.
  • the organic substrate can be selected from the group consisting of saturated and unsaturated hydrocarbons and unsubstituted and substituted aromatic hydrocarbons and mixtures thereof.
  • branched or un- branched alkanes and alkenes having carbon numbers from Cl to C20, preferably from Cl to C6, as well as cycloalkanes, e.g. cyclohexane and adamantane, or combinations thereof are used as organic substrate.
  • Exam- pies of suitable organic substrates are methane, ethane, propane, butane, isobutane, pentane, isopentane, neopentane, hexane, ethylene, propylene, ⁇ -butylene, cis- ⁇ -butylene, trans- ⁇ -butylene, isobutylene, n- pentylene, isopentylene, cyclohexane, adamantane, cyclooctadiene, benzene, toluene, o-xylene, m-xylene, p-xylene, mesitylene, durene, hexamethylbenzene, naphthalene, anthracene, phenantrene and mixtures thereof.
  • oxygen donors such as molecular oxygen, peroxides (e.g. H 2 O 2 , t- (C 4 H 9 )OOH) or peracids (e.g. CH 3 COOOH) can be used as oxidizing agent.
  • the oxidizing agent is an oxygen containing atmosphere.
  • the oxygen containing atmos- phere is air and is constantly passed through the hydrocarbon (such as an alkane or alkene) at a pressure of 0.01 to 100 bar, preferably 10 to 70 bar.
  • a free radical generator such as tert- butyl hydroperoxide is added to the oxidation reac- t . ion.
  • the oxidation of organic substrates occurs in the absence of solvent of diluent.
  • the POM's described herein specifically SBA-15-apts-Fe 4 Se2Wi 8 , are exceptionally good catalysts (Fig. 4 and Table 3A) for solvent-free aerobic oxidation of n-hexadecane.
  • preffered oxidation reactions occur in the presenece of less than 10 wt% solvent and diluent, preferably less than 5 wt% solvent and diluent, preferably less than 1 wt% solvent and diluent, preferably in the absence of solvent and dilunet (e.g. 0 wt% solvent or diluent), based upon the weight of reactants .
  • the oxidation of the organic substrate is preferably carried out at a temperature of 30 to 600 0 C, preferably 75 to 250 0 C, preferably 130 to 180 0 C.
  • the oxidation is carried out at a temperature of 100 0 C or more, alternately 110 0 C or more, alternately 120 °C or more, alternately 130 0 C or more, alternately 140 0 C or more, alternately 150 °C or more, alternately 160 0 C or more, alternately 170 °C or more, alternately 180 0 C or more, alternately 190 °C or more, alternately 200 0 C or more, alternately 210 0 C or more, alternately 220 0 C or more .
  • the present supported catalysts have turned out to show an increased activity compared to the corresponding non-supported polyoxometalates .
  • the conversion of the alkane feed is typically increased by a factor of at least 2, preferably of at least 5, and more pref- erably of at least 10.
  • the present supported polyoxometalates can be converted (e.g. by calcination) to mixed metal oxide catalysts in a highly reproducible manner. Consequently, the polyoxometalates according to the invention can also be used as a precursor for mixed metal oxide catalysts such as so- called Mitsubishi-type catalysts which are particularly useful for the oxidation of hydrocarbons such as propane .
  • Another useful aspect of this invention is that the supported polyoxometalates described herein can be recycled and used multiple times for the oxidation of organic molecules.
  • the supported POM produced herein can be collected by filtration after an oxidation reaction, washed at 25°C or more with a suitable solvent such as a nonpolar or polar organic solvent or water or mix- tures thereof.
  • a suitable solvent such as a nonpolar or polar organic solvent or water or mix- tures thereof.
  • Nonpolar solvents comprise species such as C3 - C16 branched or linear alkanes as well as aromatic compounds such as benzene, methylbenzenes or sty- rene .
  • Polar organic solvents comprise linear or branched C2 or higher alcohols or ketones or phenols. Acetone is a particularly useful solvent.
  • the washed supported POM is then optionally dried under heat (typically more than 100 0 C, alternately 125°C or more, alternately 150°C or more) to remove the washing agent for 30 minutes to 48 hours, typically for 1 to 24 hours, more typically for 2 to 10 hours, more typically 3 to 5 hours. If rapid drying is desired reduced pressure may be applied.
  • heat typically more than 100 0 C, alternately 125°C or more, alternately 150°C or more
  • the catalyst can be recycled in situ, e.g. without removal from its reactor vessel .
  • supported POMs can be recycled after flu- idized bed service in a dedicated regenerator and in an oxidizing atmosphere.
  • the recycled supported POMs may be used on fresh or- ganic molecules (such as hexadecane) or on recycled organic molecules from a recycle stream.
  • the supported polyoxometalates may be recycled and used again under the same or different reaction conditions.
  • the supported POMs are recycled at least 1 time, preferably at least 4 times, preferably at least 8 times, preferably at least 12 times, preferably at least 100 times. Under certain conditions, such as fluidized bed application, the catalyst may undergo more than 1000 cycles.
  • this invention relates to a process to oxidize organic substrates comprising contacting a first organic substrate with the polyoxometalates described herein, thereafter re- covering the polyoxometalates, contacting the polyoxometalates with a suitable solvent at a temperature of 25°C or more and optional drying of the washed poly- oxometalate to obtain a recycled polyoxometalate, thereafter contacting the recycled polyoxometalate with a second organic substrate, which may be the same or different than the first organic substrate, this process may be repeated many times, preferably at least 4 times, preferably at least 8 times, preferably at least 12 times, preferably at least 100 times.
  • the POM's described herein are immobilized on a support (such as 3- aminopropyltriethoxysilane (apts) modified SBA-15) to form efficient heterogeneous catalysts for long (C8 and above, preferably ClO and bove, more preferably C12 and above) chain n-alkane oxidation using air as the oxidant in a solvent-free system through a classical free radical chain autoxidation mechanism.
  • a support such as 3- aminopropyltriethoxysilane (apts) modified SBA-15
  • the catalysts described herein are also readily recyclable by filtration without any loss of activity. This invention further relates to:
  • A represents a cation
  • n is the number of cations
  • m is the charge of the polyoxoanion
  • M is a transition metal
  • X is an element selected from the group consisting of As, Sb, Bi, Se and Te,
  • polyoxornetalate is supported on a solid support selected from the group consisting of Al 2 O 3 , MgO, TiO 2 , ZrO 2 , SiO 2 , mesoporous silica, active carbon, diatomite, clays, zeolites, polyoxometalate salts and mixtures thereof, with the proviso that the polyoxometalate salt supports are different from the supported polyoxometalates defined by the above formula .
  • A is selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, magnesium, calcium, strontium, barium, titanium, vanadium, chromium, lanthanum, lanthanide metal, actinide metal, manganese, iron, cobalt, nickel, copper, zinc, ruthenium, palladium, platinum, tin, antimony, tellurium, phosphonium, ammonium, guanidinium, tetraalkylammonium, protonated aliphatic amines, protonated aromatic amines and combinations thereof.
  • Y is carbon or silicon, preferably silicon x is an integer from 0 to 12, preferably 1 to 6, and
  • R 2 is hydrogen, alkyl or aryl, preferably hydro- gen.
  • step (b) stirring and optionally heating the mixture of step (a) ,
  • step (c) optionally filtering the mixture of step (b) , and
  • step (a) is selected from the group consisting of water, acetonitrile, acetone, dimethylformamide, 1,4-dioxane, 1, 2-dichloroethane and combinations thereof.
  • step (b) the mixture is heated to a temperature of 50/ to 100 0 C, preferably of about 80 0 C. 10. Process according to any one of paragraphs 7 to 9, wherein in step (d) the supported polyoxometalate is recovered by evaporating the solvent of the mixture of step (b) or washing and drying the filtered solid of step (c) .
  • Process for oxidizing organic substrates comprising contacting supported polyoxometalates according to any one of paragraphs 1 to 6 or prepared according to any one of paragraphs 7 to 10 with an organic substrate in the presence of an oxidizing agent.
  • a process to oxidize organic substrates comprising contacting a first organic substrate with the polyoxometalates of paragraphs 1 to 7 , thereafter recovering the polyoxometalates, contacting the polyoxometalates with a suitable solvent at a temperature of 25°C or more and optional drying of the washed polyoxometalate to obtain a recycled polyoxome- talate, thereafter contacting the recycled polyoxometalate with a second organic substrate, which may be the same or different than the first organic substrate (preferably this process is repeated at least 4 times, preferably at least 8 times, preferably at least 12 times, ⁇ preferably at least 100 times).
  • Example 2 For the synthesis of the corresponding Cr, Mn, Co, Ni, Zn, Cd and Hg derivatives, Example 2 was repeated except that appropriate amounts of the respective metal salts were used instead of FeCl 3 -6H 2 O (see Kortz et al., Inorg. Chem. 2002, 41, 783) . For example, 0.80 g of CrCl 3 -6H 2 O and 0.71 g of CoCl 2 -6H 2 O, respectively, were used.
  • Mg(OCHa) 2 containing 10 wt. % Mg.
  • This solution was diluted with 300 mL of toluene and then 4 mL of water mixed with methanol (between 5-20 mL) was added slowly over 30 min.
  • the powder collected after pressure release was calcined at 500 0 C for 4 h to give MgO aerogel.
  • SBA-15 was synthesized in acidic conditions using the tri-block copolymer, poly (ethylene oxide) - poly (propylene oxide) -poly (ethylene oxide)
  • EO20PO70EO20 (BASF)
  • TEOS tetraethyl or- thosilicate
  • the solid products were filtered and calcined at 550 0 C for 4 h to give 0.6 g of SBA-15.
  • the supports prepared according to Examples 3 to 5 have been characterized by XRD, nitrogen adsorption- desorption and TEM analysis.
  • XRD analysis was conducted using a Siemens Diffractometer D5000 with Cu Ka
  • the surface area of AI 2 O 3 and MgO aerogels can be influenced by the manner in which the water is introduced during aerogel preparation, e.g. dropwise or at once.
  • 0.2 g of a polyoxometalate salt prepared according to Examples 1 or 2 was dissolved in 200 mL of water. 0.5 g of MgO or AI 2 O 3 was added and the mixture was stirred at 80 0 C to dryness.
  • the polyoxometalate salt was dissolved in acetonitrile instead of water.
  • modified silica 0.5 g was mixed with 100 ml of water, and HCl (2 M) was added to adjust the pH to about 2. Then, 0.1 g of polyoxometalate prepared according to Example 1 or 2 was added and the mixture was stirred for 8 hours . The solids were filtered and washed with water three times. The product was kept in an oven at 100 0 C for 4 hours.
  • the supported polyoxometalates prepared according to Examples 6 and 7 were characterized by ICP analysis using a Varian Vista MPX.
  • the samples were prepared using microwave digestion by dissolving 10 mg of the supported POM in a mixture of HNO 3 (6 ml), HCl (6 ml), HF (1 ml) and H 2 O 2 (3 ml) .
  • 6 ml of boric acid (5%) was added and a second run was performed.
  • the quantification was done by ICP-OES using calibration curves made between 0 and 50 ppm from standards with known amounts of the respective elements. All tests were conducted twice using a 20 mg sample in the second test. The final volume for each sample was 100 ml.
  • the catalysts according to the invention typically have POM loading levels between about 8 and 33 % by weight.
  • the application of POMs on SBA-15 modified with aminopropyltriethoxysilane appears to give the highest POM loadings.
  • the product distribution was determined by gas chromatographic analysis.
  • the composition of the product prepared by a supported poly- oxometalate according to the invention was as follows:
  • n-hexadecane about 75.0 %
  • C 10 -Ci 6 ketones about 12.2 %
  • Ci 6 alcohols about 3.5 %
  • Ce-Ci 3 acids about 2.7 %
  • gamma-lactones about 1.2 %.
  • Catalysts according to the invention were mainly selective to Cio ⁇ Ci 6 ketones and in particular Ci ⁇ ketones. Some combustion of hydrocarbon took place as evidenced by the formation of lower carbon chain carboxylic acids .
  • Figure 4 compares certain experiments from Table 3 marked with a caret ( ⁇ ) with regard to selectivity for ketones and alcohols (produced ketones alcohol/reacted n-hexadecane) and n-hexadecane conversion (reacted n- hexadecane/introduced n-hexadecane) .
  • FIG. 2 reports four experiments with Se 2 Wi 8 Fe 4 -SBA-15- apts. The experiments were run as described in Example 8, except that:
  • Example 8 In order to rule out the contribution of homogeneous catalysis a hot filtration experiment was performed. Thus, the reaction according to Example 8 was conducted in the presence of the SBA-15-APTS-Se 2 W 18 Fe 4 catalyst, the supernatant was hot-filtered off and 0.5 ml of the reaction solution was transferred into 5 ml fresh hexadecane substrate at 150 0 C under constant flow of air. The catalyst-free solution was then left running for 4 hours, but no further reaction took place (see fig. 2(d)) .
  • Example 10 Temperature dependence of hexadecane oxida- tion

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Abstract

The invention relates to supported polyoxometalates represented by the formula (An)m+ [M4 (H2O) 10 (XW9O33) 2] m- or solvates thereof, wherein A represents a cation, n is the numbe of cations, m is the charge of the poly-oxoanion, M is a transition metal, and X is an element selected from the group consisting of As, Sb, Bi, Se and Te, characterized in that the polyoxometalate is supported on a solid support selected from the group consisting of Al2O3, MgO, TiO2, ZrO2, SiO2, mesoporous silica, active carbon, diatomite, clays, zeolites, polyoxometalate salts and mixtures thereof, with the proviso that the polyoxometalate salt supports are different from the supported polyoxometalates defined by the above formula, a process for their preparation and their use for the catalytic oxidation of organic molecules.

Description

SUPPORTED POLYOXOMETALATES, PROCESS FOR THEIR PREPARATION AND USE IN OXIDATION OF ALKANES
10
PRIORITY CLAIM
This application is a continuation-in-part of and 15 claims priority to USSN 11/443,683, filed May 31. 2006.
Field of the Invention
This invention is directed to supported polyoxymeta- 20 lates, a process for their preparation and their use for the catalytic oxidation of organic molecules.
Background of the Invention
25 Polyoxometalates (POMs) are a unique class of molecular metal-oxygen clusters. They consist of a polyhedral cage structure or framework bearing a negative charge and centrally located heteroatom(s) surrounded by the cage framework. The negative charge is balanced by
30 cations that are external to the cage. Generally, suitable heteroatoms include Group Illa-VIa elements such as phosphorus, antimony, silicon, selenium and boron. The framework of polyoxometalates is usually comprised of edge- or corner-shared MOβ octahedra, where M
35 represents a transition metal (addenda) . Due to appropriate cation radius and good π-electron acceptor properties, the addenda metal is substantially limited to a few metals including Group Vb or VIb transition metals in their highest oxidation state (e.g. V5+, Nb5+, Ta5+,
Figure imgf000003_0001
• A major subclass of polyoxometalates is constituted by Keggin type POMs . These polyoxoanions generally consists of 12 framework metals and 40 oxygen atoms sym- metrically arranged around a central atom X and thus can be represented by the formula XnMi204o(8~n)~- If the central atom X is a heteroatom with a lone pair of electrons (e.g. As111, Sb111), the formation of such closed Keggin units is not allowed. In fact, most of these POMs consist of dimeric adducts of incomplete (lacunary) Keggin fragments joined together by extra framework or heteroatoms.
For example, Krebs et al . (Chem. Eur. J. 1997, 3, 1232; Inorg. Chem. 1999, 38, 2688) describe the dimeric structural type [ (WO2) 4 (OH) 2 (P-XW9O33) 2] 12~ (X = SbIIX, Bi111) . Moreover, the authors were also able to substitute the two external tungsten atoms by first-row transition metals resulting in transition metal substituted polyoxometalates (TMSPs) represented by the formula [(WO2) 2M2(H2O) 6 (P-XW9O33) 2](14-2n)- (X = Sb111, Mn+ = Mn2+, Fe3+, Co2+, Ni2+; X = Bi1", Mn+ = Fe3+, Co2+, Ni2+, Cu2+, Zn2+) .
Moreover, Kortz et al . report on tetrasubstituted dimeric polyoxotungstates which consist of two [•β- XW9O33]11" (n = 9, X = As111, Sb111; n = 8, X = SeIV, TeIV) moieties linked by four Fe3+ ions having terminal H2O ligands (Inorg. Chem. 2002, 41, 783) . These authors were also able to substitute the iron centers in this structure by a large number of other 1st, 2nd and 3'rd row transition metals (e.g. Mn2+, Co2+, Ni2+, Cd2+, Hg2+) .
Due to their size, shape, charge density and redox- active nature, POMs and in particular TMSPs have at- tracted continuously growing attention in the area of oxidation catalysis .
Several oxidation reactions of organic substrates using polyoxometalates are described in the literature. For instance, Neumann et al . describe the oxidation of al- kenes and cycloalkanes using a ruthenium-substituted sandwich type polyoxometalate and hydrogen peroxide or molecular oxygen as an oxygen donor (Angew. Chem. Int. Ed. Engl. 1995, 34, 1587; Inorg. Chem. 1995, 34, 5753; and J. Am. Chem. Soc . 1998, 120, 11969). In addition, they report on the epoxidation of chiral allylic alcohols (J. Org. Chem. 2003, 68, 1721-1728). Cavani et al . disclose the oxidation of isobutane to methacrylic acid (Topics in Catalysis 2003, 23, 141-152) and Kamat et al. describe the epoxidation of various olefins using hydrogen peroxide and a silicotungstate compound (Science 2003, 300, 964-966) . Further, WO 03/028881 discloses a process for the selective oxidative dehy- drogenation of alkanes to produce olefins using certain polyoxometalate catalysts.
Additional references of interest include:
Pope et al., JACS 1992, 114, 2932-2938; Finke et al . , Inorg. Chem. 2005; Li et al., Chinese J. Chem. 2004, 22(8), 874-876; Sousa et al . , Chem. Comm. 2004, 23, 2656-2657; Haber et al . , Applied Catal . A2003, 256(1- 2), 141-152; Cavani et al . , Topics in Catalysis 2003, 23(1-4), 119-124; Hill et al., JACS 2003, 125(11), 3194-3195; Krebs et al . , Polyoxometallate Chemistry 2001, 89-99; Burns et al., J. MoI. Catal. A2002, 184(1- 2), 451-464, Ratiu et al., Polyhedron 2002, 21(4), 353- 358; Cavani et al . , Catal. Letters 2001, 71(1-2), 99- 105; Villanneau et al., JCS Dalton Trans. Inorg. Chem. 1999, 3, 421-426; Server-Carrio et al . , JACS 1999, 121(5), 977-984; Katsoulis et al., EP95-308486, - A -
19951127 (Dow Corning Corp.); Yonehara et al . , JP 2003-
349996, 20031008 (Nippon Shokubai Co.); US2004/0210086;
US 6,809,219; US 6,743,748; US 6,710,207; US 6,664,408;
US 6,610,864; US2003/0187297 ; US2003/0171604 ; US2003/0144550; US2003/0109740; US2003/0036473;
US2003/0017561; US 6,518,216; US2002/0165405;
US2002/0142914; US 6,455,735; US2002/0091275; US
6,387,841; US 6,169,202; US 6,114,274; US 6,060,419; US
6,043,184; US 6,022,986; US 5,990,348; US 5,928,382; US 5,714,429; US 5,705,685; US 5,684,216; US 5,629,459; US
5,616,815; US 4,634,502; EP 1080784; EP 1213280;
EP1205474; EP1380340; EP0966323; EP1205474; EP1201636;
EP1080784; EP 1078687; EP1077082; EP0771781; EP1059276;
EP0704240; EP0955284; EP0771781; EP0713847; EP0713723; EP0704240; EPO683153; WO2005/023747; WO2003/039745;
WO2000/009262 and DE10055173.
However, with respect to the catalytic performance of polyoxometalates in oxidation reactions and in particu- lar in the selective oxidation of alkanes no satisfactory results have been reported up to now.
Therefore, it is the object of the present invention to provide polyoxometalates showing an improved catalytic performance in oxidation reactions of organic substrates and in particular attaining high conversions when used for the selective oxidation of alkanes.
Summary of the Invention
This invention relates to supported polyoxometalates represented by the formula
(An) m+ [M4 ( H2O) 10 (XW9O33 J 2] 111"
or solvates thereof , wherein A represents a cation, n is the number of cations, m is the charge of the polyoxoanion, M is a transition metal, and X is an element selected from the group consisting of As, Sb, Bi, Se and Te.
wherein that the polyoxometalate is supported on a solid support selected from the group consisting of AI2O3, MgO, TiO2, ZrO2, SiO2, mesoporous silica, active carbon, diatomite, clays, zeolites, polyoxometalate salts and mixtures thereof, with the proviso that the polyoxometalate salt supports are different from the supported polyoxometalates defined by the above formula.
Brief Description of the Figures
Figure 1 is a graph illustrating the recycling of Cata- lyst in Example 9.
Figure 2 is a graph illustrating the kinetics of oxidation of n-hexadecane using SBA-15-APTS-Se2W18Fe4 catalysts
Figure 3 is a graph illustrating the temperature dependence of n-hexadecane oxidation.
Figure 4 is a graph illustrating selectivities of dif- ferent POM 1S loaded on SBA-15-apts.
Detailed Description of the Invention
The CAS numbering scheme for the Periodic Table Groups is used as published in CHEMICAL AND ENGINEERING NEWS, 63(5) , 27 (1985) . The object described above is achieved by supported polyoxometalates represented by the formula
(An) m+ [M4 (H2O)10 (XW9O33) 2]m~
or solvates thereof, wherein
A represents a cation, n is the number of cations, m is the charge of the polyoxoanion, M is a transition metal, and
X is an element selected from the group consisting of As, Sb, Bi, Se and Te,
characterized in that the polyoxometalate is supported on a solid support selected from the group consisting of Al2O3, MgO, TiO2, ZrO2, SiO2, mesoporous silica, active carbon, diatomite, clays, zeolites, polyoxometalate salts and mixtures thereof, with the proviso that the polyoxometalate salt supports are different from the supported polyoxometalates defined by the above formula .
The polyoxometalates according to the invention can be prepared according to the method disclosed in Kortz et al., Inorg. Chem. 2002, 41, 783, and have been found to exist as a dimeric assembly, i.e. four octahedral transition metal centers hold together two trilacunary (B- /J-XW9O33) Keggin fragments.
The invention also includes solvates of the present POMs. A solvate is an association of solvent molecules with a polyoxometalate. Preferably, water is associated with the POMs, as the POMs are usually synthesized in water. However, this water can be gradually removed by heating the solid POMs . The cation A can be a Group Ia, Ha, IHb, IVb, Vb, VIb, VIIb, VIIIb, Ib, lib, Ilia, IVa, Va or Via metal or an organic cation. Preferably, A is selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, magnesium, calcium, strontium, barium, titanium, vanadium, chromium, lanthanum, lanthanide metal, actinide metal, manganese, iron, cobalt, nickel, copper, zinc, ruthenium, palladium, platinum, tin, an- timony, tellurium, phosphonium such as tetraalkylphos- phonium, ammonium, guanidinium, tetraalkylammonium, protonated aliphatic amines, protonated aromatic amines and combinations thereof. More preferably, A is selected from sodium, potassium, cesium and combinations thereof.
The number n of cations is dependent on the nature of cation (s) A, namely its/their valence, and the negative charge m of the polyanion which preferably has to be balanced. Typically, the overall charge of all cations A is equal to the charge of the polyanion. In turn, the charge m of the polyanion is dependent on the oxidation states of the metal M and the heteroatom X. m depends on the oxidation state of the atoms present in the polyanion, e.g., it follows from the oxidation states of W (+6), O (-2), a given heteroatom X (such as +3 for Sb, Bi and As or +4 for Se and Te) , and the transition metal, M (ranging from +2 to +5) . In some embodiments, m is 2 or 4 or 6 or 8 or 10. In some embodiments, n is 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10.
The metal M of the polyoxometalates according to the invention is selected from the entire block of transition metals of the Periodic Table of the Elements. Preferably, M is selected from the group consisting of first row transition metals (e.g. Fe, Cr, Mn, Co, Ni, Cu, Zn), Cd, Hg and combinations thereof. The oxidation state of M comprised in the present polyoxometalates can range from +11 to +V and preferably is +III for Fe and Cr and +11 for all other incorporated transition metals.
The heteroatom X is selected from the group consisting of As, Sb, Bi, Se and Te.
Specific embodiments of polyoxometalates according to the above formula are given in the examples.
The polyoxometalates of the invention are further characterized in that they are supported on a solid sup- port. Generally, porous supports having high surface areas which have been described in the prior art for supporting heteropolyacids used in acid-catalyzed reactions, are also useful in this, invention (see: Haber et al., Applied Catalysis A 2003, 256, 141-152; Kozhev- nikov et al . , Catalysis Letters 1995, 30, 241-252; Koz- hevnikov et al . , Journal of Molecular Catalysis A 1996, 114, 287-298; Wu et al., Ind. Eng . Chem. Res. 1996, 35, 2546) . The solid support is selected from the group consisting of AI2O3, MgO, Tiθ2, Zrθ2, SiO2, mesoporous silica, active carbon, diatomite, clays including layered aluminosilicates (e.g. bentonite) , zeolites such as mesoporous zeolite crystallites described in A. Boisen et al . , Chem. Commun . 2003, 8, 958-959 and Y. Tao et al., Langmuir 2005, 21, 2, 504-507, and poly- oxometalate salts. Preferably, the support is selected from the group consisting of AI2O3, MgO, ZrO2, SiO2 and mesoporous silica which can be defined as silica having a pore size between 2 and 50 nm. Examples of mesoporous silica are SBA-15, MCM-41, and MCM-48. In particular, SBA-15 is used as mesoporous silica which can be prepared according to Zhao et al., Science 279, 1998, 548. Further, if a metal oxide such as MgO or AI2O3 is used as support, it is preferred that this material is in the form of an aerogel, i.e. a material having a relatively low density and high porosity as a consequence of the method of preparation. The metal oxide aerogels can be characterized by a BET surface of 50 to 1000 m2/g, a pore volume of 0.1 to 2.0 cm3/g and/or a pore size of 0.5 to 20 nm each determined by nitrogen phy- sisorption analysis.
If a polyoxometalate salt is used as solid support, this polyoxometalate salt is different from the supported polyoxometalate according to the invention and is not represented by the above formula (An) m+ [M4 (H2O) 10 (XW9θ33)2]m~. Suitable polyoxometalate salt supports are known from the prior art, e.g. EP 1 078 687, EP 1 059 276, US 6,043,184 and WO 00/09262, and are preferably wide pore salts having the formula
(CaH(e_a2) ) e+ (X' kM' p-xM^M^Oy) e",
wherein C is a cation selected from potassium, rubidium, cesium, magnesium, calcium, strontium, barium, transition metal, actinide metal, lanthanide metal, metal oxy ion, ammonium, tetraalkylammonium, pyridin- ium, quinolinium, protonated aromatic amines, proto- nated aliphatic amines or mixtures thereof; X' is an element selected from Groups 3-16 elements; M' is molybdenum, tungsten or a combination thereof; M1 is va- nadium; M2 is a transition metal different from M' and M1 such as zinc; a is the number of cations, z is the charge of C (typically 1, 2, 3, 4, 5 or 6); k is from 1 to 5; p is from 5 to 20; q is from 0 to 3; x is from 0 to 6; y is from 18 to 62; and e is the charge of the polyanion. Examples of suitable polyoxometalate salt supports include CS3(PMOi2O40Jf Cs4 (PMθnVO40) , Cs5 (PMOIOV2O40) , Cs6 (PMo9V3O40) , Cs3 (PW12O40) , Cs4 (PW11VO40) , Cs5(PW10V2O40) and Cs6(PW9V3O40) .
If a support containing hydroxy groups on its surface such as SiO2 or SBA-15 is used, then it is preferred to support the polyoxometalate on a surface which has been modified with an amine compound of formula
(R1O)3Y (CH2) XNR2 2,
wherein
R1 is alkyl, preferably C1-C4 alkyl, (preferably methyl, ethyl, propyl or butyl and all isomers thereof)
Y is carbon or silicon, preferably silicon (in this instance Y is NOT yttrium) x is 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 or 12, preferably 1, 2, 3, 4, 5 or 6, and R2 is hydrogen, alkyl or aryl, preferably hydrogen .
In particular, a preferred amine compound used is aminopropyltriethoxysilane (APTS) .
Such a modification causes the hydroxy groups on the surface of the support to react with the alkoxy group of the amine compound resulting in the formation of support-amine compound-bonds and thus in the immobili- zation of the amine compound on the support. Therefore, after acidification ammonium cations covalently bound to the support are obtained which can electrostatically interact with the polyanions of the POMs to be immobilized. The present invention is further directed to a process for preparing polyoxometalates according to the invention comprising
(a) mixing the solid support with a solution of (An) m+ [M4 (H2O) io (XW9O33) 2]m" (where A, n, m, M, and X are as defined above) ,
(b) stirring and optionally heating the mixture of step (a) , (C) optionally filtering the mixture of step
(b) , and
(d) recovering the supported polyoxometa- late.
In step (a), the solid support is mixed with a solution of the polyoxometalate . The solvent used for this solution is preferably selected from the group consisting of water, acetonitrile, acetone, dimethylformamide, 1,4-dioxane, 1, 2-dichloroethane and mixtures thereof. It is particularly preferred to dissolve the polyoxometalate in water. However, in case cation A is tetraal- kylammonium, the solvent used is preferably less polar than water. In general, the longer the alkyl chain, the less polar the solvent should be. For example, if cation A is tetrabutylammonium, acetonitrile is preferably used as solvent.
In step (b) , the mixture of step (a) is stirred. Preferably, the mixture is stirred for 1 minute to 10 hours, preferably from 5 to 10 h. Additionally, during stirring the mixture can be heated to a temperature of 50 to 100 0C depending on the thermal stability of the polyoxometalate, preferably about 70 to 900C, preferably about 75 to 85°C, preferably of about 80 0C. Optionally, the mixture of step (b) can be filtered in step (c) , before the supported polyoxometalate is recovered in step (d) . In case a filtration has actually taken place in step (c) , the product is recovered by washing and drying the filtered solid of step (c) . If the reaction mixture has not been filtered, then the supported POM is typically recovered by evaporating the solvent of mixture (b) and drying the obtained solid. Usually, the drying of step (d) can be performed using techniques known in the art and is preferably carried out at a temperature of 30 to 100 0C under ambient or reduced pressure.
In one embodiment of the invention, the polyoxometalate is supported on aerogels of MgO or AI2O3 by mixing the aerogel with a water solution of the POM, stirring the mixture at a temperature of 50 to 100 0C, preferably about 70 to 900C, preferably about 75 to 85°C, preferably of about 80 0C and drying the mixture.
For supporting POMs on modified SiO2 or SBA-15 such as APTS-modified SiO∑ or SBA-15, a mixture of the support and a POM solution in water is stirred for 1 minute to 10 hours, preferably 5 to 10 h and filtered. Then, the filtered solid is washed with water and dried at temperature of 50 to 100 0C, preferably 75 to 1000C, preferably of about 95 "C.
In addition, the polyoxometalate can be supported by incipient wetness impregnation techniques. In this method, the pore volume of the support is determined first and then the POM is dissolved in the same volume (or from 75% of the volume to 500% of the volume, preferably from 100% to 400% of the volume, particularly from 200 to 300% of the volume) of a solvent such as water, acetonitrile and ethanol to form a solution. Afterwards the support is impregnated with this solution and the mixture is dried.
It has been found that the supported POMs according to the invention typically have POM loading levels on the support of up to 40 wt . % or even more. Accordingly, POM loading levels on the support of 1 to 40 wt.%, particularly 5 to 30 wt.%, and more particularly 5 to 20 wt.% are in general suitable. POM loading levels can be determined by Inductively Coupled Plasma Mass Spectrometry (ICP) analysis or X-ray photoelectron spectroscopy (XPS) as described in the Examples section. In the event the values from the ICP and XPS differ, the ICP shall control.
The present invention is also directed to the use of polyoxometalates according to the invention as catalyst for the oxidation of organic substrates.
In a further aspect, the invention also includes a process for oxidizing organic substrates, wherein a supported polyoxometalate or a mixture of two or more supported polyoxometalates according to the invention is contacted with an organic substrate in the presence of a suitable oxidizing agent.
The use of the polyoxometalates according to the invention for catalyzing oxidation reactions of organic substrates as well as the process according to the inven- tion for oxidizing organic substrates can be further characterized by the following features.
The organic substrate can be selected from the group consisting of saturated and unsaturated hydrocarbons and unsubstituted and substituted aromatic hydrocarbons and mixtures thereof. Advantageously, branched or un- branched alkanes and alkenes having carbon numbers from Cl to C20, preferably from Cl to C6, as well as cycloalkanes, e.g. cyclohexane and adamantane, or combinations thereof are used as organic substrate. Exam- pies of suitable organic substrates are methane, ethane, propane, butane, isobutane, pentane, isopentane, neopentane, hexane, ethylene, propylene, α-butylene, cis-β-butylene, trans-β-butylene, isobutylene, n- pentylene, isopentylene, cyclohexane, adamantane, cyclooctadiene, benzene, toluene, o-xylene, m-xylene, p-xylene, mesitylene, durene, hexamethylbenzene, naphthalene, anthracene, phenantrene and mixtures thereof.
Commonly, suitable oxygen donors such as molecular oxygen, peroxides (e.g. H2O2, t- (C4H9)OOH) or peracids (e.g. CH3COOOH) can be used as oxidizing agent. Preferably, the oxidizing agent is an oxygen containing atmosphere. In particular, the oxygen containing atmos- phere is air and is constantly passed through the hydrocarbon (such as an alkane or alkene) at a pressure of 0.01 to 100 bar, preferably 10 to 70 bar. In useful embodiments a free radical generator (such as tert- butyl hydroperoxide) is added to the oxidation reac- t.ion. It has been noted that tert-butyl hydroperoxide caused increased conversion, particularly over longer time periods. Likewise the addition of a radical scavenger during the oxidation reaction has been shown to terminate the reaction and profoundly affect the prod- uct distribution.
Without being bound by theory, it is beleived that the the oxidation of organic substrates (such as n- hexadecane) proceeds via a free-radical autoxidation mechanism. This is suggested by (i) an induction period of about two hours seen in n-hexadecane conversion versus time plots, (ii) the indication that the induction period is diminished by prior addition of traces of free-radical initiators (such as tert-butyl hydroperoxide (TBHP) ) , which greatly increases both the rate and degree of conversion of n-hexadecane while still retaining a high preference for the three desired products, and (iii) the observation that addition of small quantities of a free-radical scavenger (such as 3, 5-tertbutyl-4-hydroxytoluene) essentially terminates the reaction and profoundly affects the product distribution .
In another embodiment, the oxidation of organic substrates occurs in the absence of solvent of diluent. Advantageously, the POM's described herein, specifically SBA-15-apts-Fe4Se2Wi8, are exceptionally good catalysts (Fig. 4 and Table 3A) for solvent-free aerobic oxidation of n-hexadecane. Thus preffered oxidation reactions occur in the presenece of less than 10 wt% solvent and diluent, preferably less than 5 wt% solvent and diluent, preferably less than 1 wt% solvent and diluent, preferably in the absence of solvent and dilunet (e.g. 0 wt% solvent or diluent), based upon the weight of reactants .
Moreover, in some embodiments, the oxidation of the organic substrate is preferably carried out at a temperature of 30 to 6000C, preferably 75 to 2500C, preferably 130 to 180 0C. In a particularly useful embodiment the oxidation is carried out at a temperature of 1000C or more, alternately 110 0C or more, alternately 120 °C or more, alternately 130 0C or more, alternately 140 0C or more, alternately 150 °C or more, alternately 160 0C or more, alternately 170 °C or more, alternately 180 0C or more, alternately 190 °C or more, alternately 200 0C or more, alternately 2100C or more, alternately 2200C or more .
It has been found that supporting of the present dimeric POMs on a solid support yields heterogeneous catalysts for selectively oxidizing organic substrates. Generally, a number of reaction products such as ethers, esters, alcohols, ketones, aldehydes, epoxides, lactones, paraffins and acids can be obtained in cer- tain selectivities and high conversions of the organic substrate using the supported POMs of the present invention. In particular, it has been found that the catalysts are mainly selective to internal ketones if an unbranched-chain alkane is used as feed material. Thus, the present use as well as the present process are particularly suitable for the selective oxidation of alkanes and especially for synthesizing ketones. Preferably, more than 10 % by weight (more preferably more than 15 wt%, more preferably more than 20 wt%)of the alkane feed material is converted into ketones and in particular into the ketone corresponding to the employed alkane.
Moreover, the present supported catalysts have turned out to show an increased activity compared to the corresponding non-supported polyoxometalates . Depending on the polyoxometalate and support used, the conversion of the alkane feed is typically increased by a factor of at least 2, preferably of at least 5, and more pref- erably of at least 10.
Due to their definite stoichiometry, the present supported polyoxometalates can be converted (e.g. by calcination) to mixed metal oxide catalysts in a highly reproducible manner. Consequently, the polyoxometalates according to the invention can also be used as a precursor for mixed metal oxide catalysts such as so- called Mitsubishi-type catalysts which are particularly useful for the oxidation of hydrocarbons such as propane .
Another useful aspect of this invention is that the supported polyoxometalates described herein can be recycled and used multiple times for the oxidation of organic molecules.
For example the supported POM produced herein can be collected by filtration after an oxidation reaction, washed at 25°C or more with a suitable solvent such as a nonpolar or polar organic solvent or water or mix- tures thereof. Nonpolar solvents comprise species such as C3 - C16 branched or linear alkanes as well as aromatic compounds such as benzene, methylbenzenes or sty- rene . Polar organic solvents comprise linear or branched C2 or higher alcohols or ketones or phenols. Acetone is a particularly useful solvent. The washed supported POM is then optionally dried under heat (typically more than 1000C, alternately 125°C or more, alternately 150°C or more) to remove the washing agent for 30 minutes to 48 hours, typically for 1 to 24 hours, more typically for 2 to 10 hours, more typically 3 to 5 hours. If rapid drying is desired reduced pressure may be applied.
Alternatively if in a fixed bed application the catalyst can be recycled in situ, e.g. without removal from its reactor vessel .
Alternatively supported POMs can be recycled after flu- idized bed service in a dedicated regenerator and in an oxidizing atmosphere. The recycled supported POMs may be used on fresh or- ganic molecules (such as hexadecane) or on recycled organic molecules from a recycle stream. Advantageously, the supported polyoxometalates may be recycled and used again under the same or different reaction conditions. Typically the supported POMs are recycled at least 1 time, preferably at least 4 times, preferably at least 8 times, preferably at least 12 times, preferably at least 100 times. Under certain conditions, such as fluidized bed application, the catalyst may undergo more than 1000 cycles.
Thus, in a particularly useful embodiment, this invention relates to a process to oxidize organic substrates comprising contacting a first organic substrate with the polyoxometalates described herein, thereafter re- covering the polyoxometalates, contacting the polyoxometalates with a suitable solvent at a temperature of 25°C or more and optional drying of the washed poly- oxometalate to obtain a recycled polyoxometalate, thereafter contacting the recycled polyoxometalate with a second organic substrate, which may be the same or different than the first organic substrate, this process may be repeated many times, preferably at least 4 times, preferably at least 8 times, preferably at least 12 times, preferably at least 100 times.
In a preferred embodiment, the POM's described herein (such as Fe4As2Wi8, Fe4Sb2Wi8, Fe4Se2Wi8 and Fe4Te2Wi8) are immobilized on a support (such as 3- aminopropyltriethoxysilane (apts) modified SBA-15) to form efficient heterogeneous catalysts for long (C8 and above, preferably ClO and bove, more preferably C12 and above) chain n-alkane oxidation using air as the oxidant in a solvent-free system through a classical free radical chain autoxidation mechanism. The catalysts described herein are also readily recyclable by filtration without any loss of activity. This invention further relates to:
1. Supported polyoxometalates represented by the formula : (An) m+ [M4 (H2O) io (XW9O3S)2]"1" or solvates thereof, wherein
A represents a cation, n is the number of cations, m is the charge of the polyoxoanion, M is a transition metal, and
X is an element selected from the group consisting of As, Sb, Bi, Se and Te,
wherein that the polyoxornetalate is supported on a solid support selected from the group consisting of Al2O3, MgO, TiO2, ZrO2, SiO2, mesoporous silica, active carbon, diatomite, clays, zeolites, polyoxometalate salts and mixtures thereof, with the proviso that the polyoxometalate salt supports are different from the supported polyoxometalates defined by the above formula .
2. Polyoxometalates according to paragraph 1, wherein A is selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, magnesium, calcium, strontium, barium, titanium, vanadium, chromium, lanthanum, lanthanide metal, actinide metal, manganese, iron, cobalt, nickel, copper, zinc, ruthenium, palladium, platinum, tin, antimony, tellurium, phosphonium, ammonium, guanidinium, tetraalkylammonium, protonated aliphatic amines, protonated aromatic amines and combinations thereof.
3. Polyoxometalates according to paragraphs 1 or 2, wherein M is selected from Fe, Cr, Mn, Co, Ni, Cu, Zn, Cd and Hg, preferably Fe, Cr and Co. 4. Polyoxometalates according to any one of paragraphs 1 to 3, wherein the mesoporous silica is SBA-15, MCM-41 or MCM-48.
5. Polyoxometalates according to any one of para- graphs 1 to 4, wherein the solid support is SiO2 or mesoporous silica, in particular SBA-15, having a surface modified with an amine compound of formula
Figure imgf000022_0001
wherein R1 is alkyl, preferably Ci-C4 alkyl,
Y is carbon or silicon, preferably silicon x is an integer from 0 to 12, preferably 1 to 6, and
R2 is hydrogen, alkyl or aryl, preferably hydro- gen.
6. Polyoxometalates according to paragraph 5, wherein the amine compound is aminopropyltriethoxysilane.
7. Process for the preparation of polyoxometalates according to any one of paragraphs 1 to 6 comprising (a) mixing the solid support with a solution of (An) m+ [M4 (H2O)10 (XW9O33) 2]m~,
(b) stirring and optionally heating the mixture of step (a) ,
(c) optionally filtering the mixture of step (b) , and
(d) recovering the supported polyoxometa- late.
8. Process according to paragraph 7, wherein the solvent used for the solution in step (a) is selected from the group consisting of water, acetonitrile, acetone, dimethylformamide, 1,4-dioxane, 1, 2-dichloroethane and combinations thereof.
9. Process according to paragraph 7 or 8 , wherein in step (b) the mixture is heated to a temperature of 50/ to 100 0C, preferably of about 80 0C. 10. Process according to any one of paragraphs 7 to 9, wherein in step (d) the supported polyoxometalate is recovered by evaporating the solvent of the mixture of step (b) or washing and drying the filtered solid of step (c) .
11. Use of supported polyoxometalates according to any one of paragraphs 1 to 6 or prepared according to any one of paragraphs 7 to 10 as catalyst for the oxidation of organic substrates, preferably the selective oxida- tion of alkanes.
12. Process for oxidizing organic substrates comprising contacting supported polyoxometalates according to any one of paragraphs 1 to 6 or prepared according to any one of paragraphs 7 to 10 with an organic substrate in the presence of an oxidizing agent.
13. Use of supported polyoxometalates according to any one of paragraphs 1 to 6 or prepared according to any one of paragraphs 7 to 10 as a precursor for preparing mixed metal oxide catalysts. 14. Use according to paragraph 13, wherein the mixed metal oxide catalysts are Mitsubishi-type catalysts.
15. The use of paragraph 11 or process of claim 12 wherein the oxidation takes place at a temperature of 1000C or more, preferably 1200C or more, preferably 1500C or more, preferably 200 0C or more.
16. The use of paragraph 11 or process of claim 12 wherein the supported polyoxometalates is recycled, preferably at least 1 time, preferably at least 4 times, preferably at least 8 times, preferably at least 12 times, preferably at least 100 times.
17. A process to oxidize organic substrates (typically an alkane) comprising contacting a first organic substrate with the polyoxometalates of paragraphs 1 to 7 , thereafter recovering the polyoxometalates, contacting the polyoxometalates with a suitable solvent at a temperature of 25°C or more and optional drying of the washed polyoxometalate to obtain a recycled polyoxome- talate, thereafter contacting the recycled polyoxometalate with a second organic substrate, which may be the same or different than the first organic substrate (preferably this process is repeated at least 4 times, preferably at least 8 times, preferably at least 12 times, ^preferably at least 100 times).
The invention is further illustrated by the following examples.
Exaπiples
Preparation of Polyoxometalates
The POMs used in the following examples were prepared according to Kortz et al . , Inorg. Chem. 2002, 41, 783.
Example 1: Synthesis of [ Fe4 (H2O) io (XW9O33) 2] 6" (X = As and Sb)
0.97 g of FeCl3- 6H2O was dissolved in 40 mL of water. 4.0 g of Na9[Of-AsW9O33] was added. The pH of the solution was adjusted to 3.0 by addition of 4M HCl. Then the solution was heated to 90° C for Ih. After cooling to room temperature 4.0 g solid CsCl was added. This resulted in 4.1 g of Cs5Na [Fe4 (H2O) i0 (AsW9O33) 2] -nH2O (n = 5-20, yield -87%). Cs5Na [Fe4 (H2O) 10 (SbW9O33) 2] -nH20 (n = 5-20) was obtained in similar yields when using 4.0 g of Na9[O-SbW9O33] instead of Na9 [α-AsW9O33] .
For the synthesis of the corresponding Cr derivative, Example 1 was repeated except that 0.96 g of CrCl3 -6H2O was used instead of FeCl3- 6H2O. Example 2: Synthesis of [Fe4 (H2O) io (XW9O33) 2] 4 (X = Se and Te)
4.4 g of Na2WO4 -2H2O was dissolved in 40 mL of H2O and heated to about 50 0C. 0.82 g of FeCl3 -6H2O and 0.17 g of H2Seθ3 were added. The pH of the solution was adjusted to 1.0 by addition of 4M HCl. Then the solution was heated to 90° C for Ih. After cooling to room temperature 4.0 g solid CsCl was added. This resulted in 4.1 g of Cs4 [Fe4 (H2O) I0(SeW9O33) 2] -nH20 (n = 2-10, yield -57%) . Cs4 [Fe4 (H2O) io (TeW9O33) 2] -nH20 (n = 2-10) was obtained in similar yields when instead of 0.17 g of H2SeO3 0.41 g of K2TeO3 was used.
For the synthesis of the corresponding Cr, Mn, Co, Ni, Zn, Cd and Hg derivatives, Example 2 was repeated except that appropriate amounts of the respective metal salts were used instead of FeCl3 -6H2O (see Kortz et al., Inorg. Chem. 2002, 41, 783) . For example, 0.80 g of CrCl3 -6H2O and 0.71 g of CoCl2 -6H2O, respectively, were used.
The following species were prepared using the above procedures :
Cs5Na [Fe4 (H2O)10 (AsW9O33J2] (As2W18Fe4) Cs5Na [Fe4 (H2O) 10 (SbW9O33) 2] (Sb2W18Fe4) Cs4 [Fe4 (H2O) 10 (SeW9O33) 2] (Se2W18Fe4) Cs4 [Fe4 (H2O) io (TeW9O33) 2] (Te2W18Fe4)
Cs5Na [Cr4 (H2O)10 (AsW9O33) 2] (As2W18Cr4) Cs5Na [Cr4 (H2O) 10 (SbW9O33) 2] (Sb2W18Cr4) Cs4[Cr4(H2O)10(SeW9O33)Z] (Se2W18Cr4)
Cs8 [Co4 (H2O) io (SeW9O33) 2] (Se2W18Co4) Cs8 [Co4 (H2O)10 (TeW9O33)2] (Te2W18Co4) Preparation of Supports
Example 3: Preparation of AI2O3 Aerogel
0.0147 mol of aluminum triisopropoxide was dissolved in 130 mL of 2-propanol and 170 mL of toluene. 0.0444 mol of water was added while stirring. After further stirring for 14 h, the reaction mixture was heated in an autoclave to a temperature of 265 0C and a pressure of 60-100 bar {supercritical conditions) . After releasing the pressure, the solid was calcined at 500 0C for 4 h to give Al2O3 aerogel.
Example 4 : Preparation of MqO Aerogel
2.4 g of Mg ribbon was cut into small pieces and stirred with 100 mL of methanol under an argon atmosphere to form a clear solution of Mg(OCHa) 2 containing 10 wt. % Mg. This solution was diluted with 300 mL of toluene and then 4 mL of water mixed with methanol (between 5-20 mL) was added slowly over 30 min. The obtained clear gel was transferred to an autoclave and dried at supercritical conditions (T = 265 0C, p = 100- 120 bar) . The powder collected after pressure release was calcined at 500 0C for 4 h to give MgO aerogel.
Example 5: Preparation of Mesoporous Silica SBA-15
SBA-15 was synthesized in acidic conditions using the tri-block copolymer, poly (ethylene oxide) - poly (propylene oxide) -poly (ethylene oxide)
(EO20PO70EO20) (BASF), as template and tetraethyl or- thosilicate (TEOS) as a silicon source. 37.5 mL of a solution of EO20PO70EO20:2M HC1:TEOS:H2O = 2:60:4.25:15 (molar ratio) was prepared, stirred for 4 h at 40 0C, and then heated at 95 0C for 3 days. The solid products were filtered and calcined at 550 0C for 4 h to give 0.6 g of SBA-15.
The supports prepared according to Examples 3 to 5 have been characterized by XRD, nitrogen adsorption- desorption and TEM analysis. XRD analysis was conducted using a Siemens Diffractometer D5000 with Cu Ka
(λ=0.15406 nm, 40 kV, 40 mA) radiation, at a scanning speed of 0.06 deg/min. N2 adsorption-desorption iso- therms at 77 K were performed with a Quantachrome Auto- sorbl-C system, the data were analyzed by employing the BJH (Barrett-Joyner-Halenda) method. Pore volume and pore size distribution curves were obtained from the desorption branch of the isotherm. High Resolution TEM (HRTEM) images were obtained with a JEOL 200CX electron microscope operating at 200 kV.
The results of these analyses are shown in Table 1.
Table 1: Characterization of different supports
Figure imgf000027_0001
*: average pore size as determined^, b'w nitrogen phy- sisorption
Note: generally, the surface area of AI2O3 and MgO aerogels can be influenced by the manner in which the water is introduced during aerogel preparation, e.g. dropwise or at once. Application of POMs on the support
Example 6: Impregnation upon MgO and AI2O3 Aerogels
0.2 g of a polyoxometalate salt prepared according to Examples 1 or 2 was dissolved in 200 mL of water. 0.5 g of MgO or AI2O3 was added and the mixture was stirred at 80 0C to dryness.
In case tetrabutylammonium type POM salts have to be supported, the polyoxometalate salt was dissolved in acetonitrile instead of water.
Example 7; Modification of SBA-15 and POM supporting
The surface modification of SBA-15 and subsequent POM supporting is shown in the following scheme:
Figure imgf000028_0001
Stiπing, filtration
Figure imgf000028_0002
In a Schlenk tube, 1 q of mesoporous silica SBA-15 prepared according to Example 5 was heated to 130 0Q for 5 h in vacuum to remove the adsorbed water. Then, under nitrogen atmosphere 30 mL of a 1 wt . % solution of 3- aminopropyltriethoxysilane in anhydrous toluene was added to the silica. After stirring and refluxing for 5 h, the solids were filtered and washed with toluene to remove unanchored 3-aminopropyltriethoxysilane. The solids were collected and heated in an oven at 100 0C for 5 h for the condensation process to obtain the amino group modified mesoporous silica. To support POMs thereon, 0.5 g of the modified silica was mixed with 100 ml of water, and HCl (2 M) was added to adjust the pH to about 2. Then, 0.1 g of polyoxometalate prepared according to Example 1 or 2 was added and the mixture was stirred for 8 hours . The solids were filtered and washed with water three times. The product was kept in an oven at 100 0C for 4 hours.
The same modification and supporting procedure applies to SiO2 and MCM-41.
The supported polyoxometalates prepared according to Examples 6 and 7 were characterized by ICP analysis using a Varian Vista MPX. The samples were prepared using microwave digestion by dissolving 10 mg of the supported POM in a mixture of HNO3 (6 ml), HCl (6 ml), HF (1 ml) and H2O2 (3 ml) . After the first run, 6 ml of boric acid (5%) was added and a second run was performed. The quantification was done by ICP-OES using calibration curves made between 0 and 50 ppm from standards with known amounts of the respective elements. All tests were conducted twice using a 20 mg sample in the second test. The final volume for each sample was 100 ml.
Figure imgf000030_0001
It can be seen from Table 2 that the catalysts according to the invention typically have POM loading levels between about 8 and 33 % by weight. The application of POMs on SBA-15 modified with aminopropyltriethoxysilane appears to give the highest POM loadings.
Catalytic Oxidation of Alkanes
Example 8 : Oxidation of hexadecane
10 mg of the catalyst (either non-supported POM according to Examples 1 or 2 or supported POM according to Examples 6 or 7) and 5 ml of n-hexadecane were heated in a 25 ml 2-necked-round bottom flask to 1500C at con- stant air flow (30 ml/min) for 6 hours. The solution was allowed to cool to ambient temperature and samples were taken for gas chromatographic analysis and stored under inert gas (argon) .
Gas chromatographic analyses were carried out on a Var- ian GC 3900-FID using a flame-ionization detector, a HP-FFAP (J&W) column (1=50 m, ID=O.25 mm, film thickness: 0.5 μm) , a pressure of 11 psi (0.76 bar) and a make up flow of 20 ml/min (T = 600C, 10°C/min to 219°C, hold t=52 min) .
The conversion of the hexadecane feed with the tested catalysts is shown in Table 3 in terms of % by area of the hexadecane peak determined by gas chromatographic analysis. Table 3: Conversion of n-hexadecane
Figure imgf000032_0001
* see Table 3A, Λ see Figure 4. The results of Table 3 show that the supported poly- oxometalates of the invention lead to a similar or better conversion of the alkane feed than the correspond- ing non-supported POMs. However, taking into account the POM loadings of the heterogeneous catalysts, the conversion of hexadecane, i.e. the catalytic activity of the POM, is increased by a factor of about 2 to about 10 by supporting the polyoxometalates .
Furthermore, the product distribution was determined by gas chromatographic analysis. For example, the composition of the product prepared by a supported poly- oxometalate according to the invention was as follows:
n-hexadecane : about 75.0 %, C10-Ci6 ketones: about 12.2 %, Ci6 alcohols: about 3.5 %, Ce-Ci3 acids: about 2.7 %, and gamma-lactones : about 1.2 %.
Catalysts according to the invention were mainly selective to Cio~Ci6 ketones and in particular Ciβ ketones. Some combustion of hydrocarbon took place as evidenced by the formation of lower carbon chain carboxylic acids .
In some cases significantly higher alcohol selectivi- ties were observed.
The other compounds of the product mixture were found to be mainly aldehydes, paraffins, and ketones having less then 10 carbon atoms. Table 3A reports n-C16 conversion, ketone selectivity and TOF for the experiments in Table 3 marked with an asterisk ( *) . Table 3A
Figure imgf000034_0001
*n-C16 conv. (%) = reacted n-hexadecane/introduced n- hexadecane.
** Ketone sel. (%) = Selectivity of ketones = produced ketone/reacted n-hexadecane .
*** TOF = mols n-hexadecane converted per mole POM per hour .
Figure 4 compares certain experiments from Table 3 marked with a caret (Λ) with regard to selectivity for ketones and alcohols (produced ketones alcohol/reacted n-hexadecane) and n-hexadecane conversion (reacted n- hexadecane/introduced n-hexadecane) .
Figure 2 reports four experiments with Se2Wi8Fe4-SBA-15- apts. The experiments were run as described in Example 8, except that:
1. In (a) 2 mmol of 7.5% tert-butyl-peroxide (TBHP) was added at the beginning of the reaction.
2. (b) is the same example as in table 3; 3. In (c) the catalyst was pretreated by 7% H2/N2 at 2500C for 5 hours before reaction's . In (d) the solid catalyst was hot filtered after 3 hours, then the hot-filtered solution keep on the reaction (as described in Example 9);and 5. In (e) 2 mmol of 3, 5-tertbutyl-4-hydroxytolene was added at the beginning of the reaction. Example 9: Recycling
Heterogeneous catalysts often suffer extensive leaching of active metal species during reactions and eventually lose their catalytic activity. After reaction according to Example 8, an SBA-15 APTS supported Se2Wi8Fe4 solid sample was filtered off and collected, washed with acetone and dried at 100°C for 4 h and reused un- der identical conditions with fresh hexadecane substrate. The SBA-15-APTS-Se2Wi8Fe4 catalyst maintained its high catalytic activity even after four cycles (Fig. 1). n-Hexadecane conversion, ketones selectivity and TOF were essentially constant within experimental error, indicating that APTS modified SBA-15 supported Fe4Se2Wi8 could be used repeatedly. The conversion of n-hexadecane was the highest for SBA-15-apts-Fe4Se2Wi8, whereas selectivities to Ci6 ketones (about 50%) and Ci6 alcohols (about 28%) appear similar for all SBA-15- apts-Fe4X2Wi8 catalysts. For example, we found a product distribution: 7-one : 6-one : 5-one : 4-one: 3-one : 2- one = 20 : 18 : 17 : 15 : 15 : 15 , 5-ol : 4-ol : 3-ol : 2-ol 52:17:14:17 for SBA-15-apts-Fe4Se2W18. (see Fig. 1)
In order to rule out the contribution of homogeneous catalysis a hot filtration experiment was performed. Thus, the reaction according to Example 8 was conducted in the presence of the SBA-15-APTS-Se2W18Fe4 catalyst, the supernatant was hot-filtered off and 0.5 ml of the reaction solution was transferred into 5 ml fresh hexadecane substrate at 1500C under constant flow of air. The catalyst-free solution was then left running for 4 hours, but no further reaction took place (see fig. 2(d)) .
Example 10: Temperature dependence of hexadecane oxida- tion
A series of experiments were carried out with SBA-15- APTS-Sb2Wi8Cr4 at different reaction temperatures. Fresh catalyst was subjected to conditions according to Example 8 but at 25°C, 500C, 1000C, 1500C and 2000C, respectively. As shown in Fig. 3 the reaction starts to take place at temperatures exceeding 1000C.
All documents described herein are incorporated by ref- erence herein, including any priority documents and/or testing procedures, except to the extent they are inconsistent with this specification. As is apparent from the foregoing general description and the specific embodiments, while forms of the invention have been illustrated and described, various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited thereby. Likewise, the term "comprising" is considered synonymous with the term "including" for purposes of Australian law.

Claims

CLAIMS :
1. Supported polyoxometalates represented by the formula
(An)m+ [M4 (H2O) 10 (XW9O33) 2]m" or solvates thereof, wherein A represents a cation, n is the number of cations, m is the charge of the polyoxoanion, M is a transition metal, and
X is an element selected from the group consisting of As, Sb, Bi, Se and Te,
wherein the polyoxometalate is supported on a solid support selected from the group consisting of Al2O3, MgO, Tiθ2, ZrO2, SiO2, mesoporous silica, active carbon, diatomite, clays, zeolites, polyoxometalate salts and mixtures thereof, with the proviso that the polyoxometalate salt supports are different from the supported polyoxometalates defined by the above formula .
2. The Polyoxometalates of claim 1, wherein A is selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, magnesium, calcium, strontium, barium, titanium, vanadium, chromium, lanthanum, lanthanide metal, actinide metal, manganese, iron, cobalt, nickel, copper, zinc, ruthenium, palladium, platinum, tin, antimony, tellurium, phosphonium, ammonium, guanidinium, tetraalkylammonium, protonated aliphatic amines, protonated aromatic amines and combinations thereof .
3. The Polyoxometalates of claim 1 or 2, wherein M is selected from Fe, Cr, Mn, Co, Ni, Cu, Zn, Cd and Hg.
4. The Polyoxometalates of claim 1, 2 or 3, wherein M is selected from Fe, Cr and Co.
5. The Polyoxometalates of claim 1, 2, 3 or 4 wherein the solid support is Siθ2 or mesoporous silica.
6. The Polyoxometalates of claim 1, 2, 3 or 4 wherein the solid support is SBA-15, MCM-41 or MCM-48.
7. The Polyoxometalates of claim 1, 2, 3, 4, 5, or 6 wherein the solid support is SBA-15, having a surface modified with an amine compound of formula
(R1O)3Y (CH2) XNR2 2, wherein
R1 is alkyl,
Y is carbon or silicon, x is 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, or
12, and
R2 is hydrogen, alkyl or aryl .
8. The Polyoxometalates of claim 7, wherein the solid support is SBA-15 having a surface modified with aminopropyltriethoxysilane .
9. The Polyoxometalates according to any of claims 1 to 8, wherein X is As, Sb or Bi.
10. The Polyoxometalates according to any of claims 1 to 8, wherein X is Se or Te .
11. A process for the preparation of supported polyoxometalates represented by the formula (A) : (An) m+ [M4 (H2O) 10 (XW9O33 ) 2 ] m-
or solvates thereof, wherein A represents a cation, n is the number of cations, m is the charge of the polyoxoanion, M is a transition metal, and
X is an element selected from the group consisting of As, Sb, Bi, Se and Te, said process comprising
(a) mixing a solid support selected from the group consisting of AI2O3, MgO, Tiθ2, ZrO2, SiO, mesoporous silica, active carbon, diatomite, clays, zeolites, polyoxometalate salts and mixtures thereof, with a solution of
(An) m+ [M4 ( H2O) 10 (XW9O33J 2] 111" ,
(b) stirring and optionally heating the mixture of step (a) ,
(c) optionally filtering the mixture of step (b) , and
(d) recovering the supported polyoxometalate; provided that the solid supports are different from the supported polyoxometalates defined by the above formula (A) .
12. The process of claim 11, wherein the solvent used for the solution in step (a) is selected from the group consisting of water, acetonitrile, acetone, dimethylformamide, 1,4-dioxane, 1, 2-dichloroethane and combinations thereof.
13. The process of claim 11 or 12, wherein in step (b) the mixture is heated to a temperature of 50 to 100 0C.
14. The process of claim 11, 12 or 13 wherein in step
(d) the supported polyoxometalate is recovered by evaporating the solvent of the mixture of step (b) or washing and drying the filtered solid of step
(C) .
15. A process to oxidize organic substrates comprising contacting an organic substrate with the PoIy- oxometalates of any claims 1 to 10.
16. A process to oxidize organic substrates comprising contacting an organic substrate with the PoIy- oxometalates of any of claims 1 to 10 in the presence of an oxidizing agent.
17. The process of claim 15 or 16 wherein the organic substrate is an alkane.
18. A process to oxidize organic substrates comprising contacting an organic substrate with the poly- oxometalates of any of claims 1 to 10 in the presence of an oxidizing agent, wherein the oxidation takes place at a temperature of 1000C or more.
19. The process of claim 18 wherein the organic substrate is an alkane.
20. A process to oxidize organic substrates comprising contacting a first organic substrate with the polyoxometalates of any of claims 1 to 10, thereafter recovering the polyoxometalates, contacting the polyoxometalates with a suitable solvent at a temperature of 25°C or more and optionally drying of the washed polyoxometalate to obtain a recycled polyoxometalate, thereafter contacting the recy- cled polyoxometalate with a second organic substrate, which may be the same or different that the first organic substrate .
21. The process of claim 20 wherein the polyoxometalate is recycled 4 or more times.
22. The process of claim 16, 18, 20, or 21 wherein the organic substrate (s) is/are selected from the group consisting of methane, ethane, propane, butane, isobutane, pentane, isopentane, neopentane, hexane, ethylene, propylene, α-butylene, cis-β- butylene, trans-β-butylene, isobutylene, n- pentylene, isopentylene, cyclohexane, adamantane, cyclooctadiene, benzene, toluene, o-xylene, m- xylene, p-xylene, mesitylene, durene, hexamethylbenzene, naphthalene, anthracene, phenantrene and mixtures thereof.
23. Use of supported polyoxometalates according to any one of claims 1 to 10 or prepared according to any one of claims 11 to 14 as catalyst for the oxidation of organic substrates, preferably the selective oxidation of alkanes.
24. Process for oxidizing organic substrates comprising contacting supported polyoxometalates according to any one of claims 1 to 10 or prepared according to any one of claims 11 to 14 with an organic substrate in the presence of an oxidizing agent .
25. Use of supported polyoxometalates according to any one of claims 1 to 10 or prepared according to any one of claims 11 to 14 as a precursor for preparing mixed metal oxide catalysts.
26. Use according to claim 25, wherein the mixed metal oxide catalysts are Mitsubishi-type catalysts.
27. The use of claim 23, 24 25, or 26 wherein the oxidation takes place at a temperature of 1000C or more, preferably 1200C or more, preferably 1500C or more, preferably 200 0C or more.
28. The use of claim 23, 24 25, 26 or 27 wherein the supported polyoxometalates is recycled, preferably at least 1 time, preferably at least 4 times, preferably at least 8 times, preferably at least 12 times, preferably at least 100 times.
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