WO2012171892A1 - Process for the manufacture of hydrogen peroxide - Google Patents
Process for the manufacture of hydrogen peroxide Download PDFInfo
- Publication number
- WO2012171892A1 WO2012171892A1 PCT/EP2012/061067 EP2012061067W WO2012171892A1 WO 2012171892 A1 WO2012171892 A1 WO 2012171892A1 EP 2012061067 W EP2012061067 W EP 2012061067W WO 2012171892 A1 WO2012171892 A1 WO 2012171892A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- equal
- process according
- weight
- hydrogen peroxide
- catalyst support
- Prior art date
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- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 title claims abstract description 72
- 238000000034 method Methods 0.000 title claims abstract description 49
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 14
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 claims abstract description 81
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 claims abstract description 73
- 239000003054 catalyst Substances 0.000 claims abstract description 73
- 239000010931 gold Substances 0.000 claims abstract description 55
- 229910052697 platinum Inorganic materials 0.000 claims abstract description 40
- 229910052737 gold Inorganic materials 0.000 claims abstract description 37
- 229910052763 palladium Inorganic materials 0.000 claims abstract description 30
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims abstract description 27
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims abstract description 22
- 239000001301 oxygen Substances 0.000 claims abstract description 22
- 229910052760 oxygen Inorganic materials 0.000 claims abstract description 22
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims abstract description 20
- 230000015572 biosynthetic process Effects 0.000 claims abstract description 19
- 239000001257 hydrogen Substances 0.000 claims abstract description 18
- 229910052739 hydrogen Inorganic materials 0.000 claims abstract description 18
- 238000003786 synthesis reaction Methods 0.000 claims abstract description 17
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 claims description 18
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 17
- 229910000422 cerium(IV) oxide Inorganic materials 0.000 claims description 15
- 229910000510 noble metal Inorganic materials 0.000 claims description 13
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 12
- 229910001868 water Inorganic materials 0.000 claims description 12
- CPELXLSAUQHCOX-UHFFFAOYSA-M Bromide Chemical compound [Br-] CPELXLSAUQHCOX-UHFFFAOYSA-M 0.000 claims description 11
- 229910052751 metal Inorganic materials 0.000 claims description 11
- 239000002184 metal Substances 0.000 claims description 11
- 235000011007 phosphoric acid Nutrition 0.000 claims description 9
- 229910052799 carbon Inorganic materials 0.000 claims description 7
- 239000000203 mixture Substances 0.000 claims description 6
- 239000007788 liquid Substances 0.000 claims description 5
- 150000007522 mineralic acids Chemical class 0.000 claims description 5
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 4
- 150000002739 metals Chemical class 0.000 claims description 4
- 239000002904 solvent Substances 0.000 claims description 4
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 claims description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N ZrO2 Inorganic materials O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N titanium dioxide Inorganic materials O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 2
- 239000010457 zeolite Substances 0.000 claims description 2
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 15
- 238000006243 chemical reaction Methods 0.000 description 12
- 238000005984 hydrogenation reaction Methods 0.000 description 12
- CPELXLSAUQHCOX-UHFFFAOYSA-N Hydrogen bromide Chemical compound Br CPELXLSAUQHCOX-UHFFFAOYSA-N 0.000 description 11
- CETPSERCERDGAM-UHFFFAOYSA-N ceric oxide Chemical compound O=[Ce]=O CETPSERCERDGAM-UHFFFAOYSA-N 0.000 description 10
- 239000012429 reaction media Substances 0.000 description 9
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 8
- 230000000694 effects Effects 0.000 description 7
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 5
- 229910000042 hydrogen bromide Inorganic materials 0.000 description 5
- 238000002360 preparation method Methods 0.000 description 5
- 230000002829 reductive effect Effects 0.000 description 5
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 4
- 239000002253 acid Substances 0.000 description 4
- 239000003570 air Substances 0.000 description 4
- 229910002092 carbon dioxide Inorganic materials 0.000 description 4
- 239000003638 chemical reducing agent Substances 0.000 description 4
- 229910052757 nitrogen Inorganic materials 0.000 description 4
- 239000003960 organic solvent Substances 0.000 description 4
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 3
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 3
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 3
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 3
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 3
- DNIAPMSPPWPWGF-UHFFFAOYSA-N Propylene glycol Chemical compound CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 description 3
- 238000000151 deposition Methods 0.000 description 3
- 230000008021 deposition Effects 0.000 description 3
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 description 3
- 238000002474 experimental method Methods 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 229910017604 nitric acid Inorganic materials 0.000 description 3
- 238000006722 reduction reaction Methods 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 241000282326 Felis catus Species 0.000 description 2
- OAKJQQAXSVQMHS-UHFFFAOYSA-N Hydrazine Chemical compound NN OAKJQQAXSVQMHS-UHFFFAOYSA-N 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 2
- 239000012018 catalyst precursor Substances 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- SIPUZPBQZHNSDW-UHFFFAOYSA-N diisobutylaluminium hydride Substances CC(C)C[Al]CC(C)C SIPUZPBQZHNSDW-UHFFFAOYSA-N 0.000 description 2
- 239000006185 dispersion Substances 0.000 description 2
- 238000004070 electrodeposition Methods 0.000 description 2
- 230000002708 enhancing effect Effects 0.000 description 2
- 229910002804 graphite Inorganic materials 0.000 description 2
- 239000010439 graphite Substances 0.000 description 2
- 238000001465 metallisation Methods 0.000 description 2
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 description 2
- IOLCXVTUBQKXJR-UHFFFAOYSA-M potassium bromide Chemical compound [K+].[Br-] IOLCXVTUBQKXJR-UHFFFAOYSA-M 0.000 description 2
- 239000002243 precursor Substances 0.000 description 2
- 239000012279 sodium borohydride Substances 0.000 description 2
- 229910000033 sodium borohydride Inorganic materials 0.000 description 2
- JHJLBTNAGRQEKS-UHFFFAOYSA-M sodium bromide Chemical compound [Na+].[Br-] JHJLBTNAGRQEKS-UHFFFAOYSA-M 0.000 description 2
- 239000001509 sodium citrate Substances 0.000 description 2
- 239000011949 solid catalyst Substances 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 230000006641 stabilisation Effects 0.000 description 2
- 238000003756 stirring Methods 0.000 description 2
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 description 1
- 229910017356 Fe2C Inorganic materials 0.000 description 1
- 229910010084 LiAlH4 Inorganic materials 0.000 description 1
- 229910002666 PdCl2 Inorganic materials 0.000 description 1
- 229910019032 PtCl2 Inorganic materials 0.000 description 1
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 description 1
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 1
- 239000004280 Sodium formate Substances 0.000 description 1
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 1
- 229910021626 Tin(II) chloride Inorganic materials 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- PYKYMHQGRFAEBM-UHFFFAOYSA-N anthraquinone Natural products CCC(=O)c1c(O)c2C(=O)C3C(C=CC=C3O)C(=O)c2cc1CC(=O)OC PYKYMHQGRFAEBM-UHFFFAOYSA-N 0.000 description 1
- 150000004056 anthraquinones Chemical class 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- AZWXAPCAJCYGIA-UHFFFAOYSA-N bis(2-methylpropyl)alumane Chemical compound CC(C)C[AlH]CC(C)C AZWXAPCAJCYGIA-UHFFFAOYSA-N 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 238000006555 catalytic reaction Methods 0.000 description 1
- 238000005119 centrifugation Methods 0.000 description 1
- OZECDDHOAMNMQI-UHFFFAOYSA-H cerium(3+);trisulfate Chemical compound [Ce+3].[Ce+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O OZECDDHOAMNMQI-UHFFFAOYSA-H 0.000 description 1
- 229910000355 cerium(IV) sulfate Inorganic materials 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000001246 colloidal dispersion Methods 0.000 description 1
- 238000010908 decantation Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- SZXQTJUDPRGNJN-UHFFFAOYSA-N dipropylene glycol Chemical compound OCCCOCCCO SZXQTJUDPRGNJN-UHFFFAOYSA-N 0.000 description 1
- 239000002526 disodium citrate Substances 0.000 description 1
- 235000019262 disodium citrate Nutrition 0.000 description 1
- CEYULKASIQJZGP-UHFFFAOYSA-L disodium;2-(carboxymethyl)-2-hydroxybutanedioate Chemical compound [Na+].[Na+].[O-]C(=O)CC(O)(C(=O)O)CC([O-])=O CEYULKASIQJZGP-UHFFFAOYSA-L 0.000 description 1
- 239000002270 dispersing agent Substances 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 239000002360 explosive Substances 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 235000019253 formic acid Nutrition 0.000 description 1
- 229910021397 glassy carbon Inorganic materials 0.000 description 1
- 150000002334 glycols Chemical class 0.000 description 1
- 229910000856 hastalloy Inorganic materials 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 229910052741 iridium Inorganic materials 0.000 description 1
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 description 1
- LNQCJIZJBYZCME-UHFFFAOYSA-N iron(2+);1,10-phenanthroline Chemical compound [Fe+2].C1=CN=C2C3=NC=CC=C3C=CC2=C1.C1=CN=C2C3=NC=CC=C3C=CC2=C1.C1=CN=C2C3=NC=CC=C3C=CC2=C1 LNQCJIZJBYZCME-UHFFFAOYSA-N 0.000 description 1
- 238000011031 large-scale manufacturing process Methods 0.000 description 1
- 230000000670 limiting effect Effects 0.000 description 1
- 239000012280 lithium aluminium hydride Substances 0.000 description 1
- 229910000103 lithium hydride Inorganic materials 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910021645 metal ion Inorganic materials 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 239000003863 metallic catalyst Substances 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 239000002048 multi walled nanotube Substances 0.000 description 1
- 229910052762 osmium Inorganic materials 0.000 description 1
- SYQBFIAQOQZEGI-UHFFFAOYSA-N osmium atom Chemical compound [Os] SYQBFIAQOQZEGI-UHFFFAOYSA-N 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- -1 palladium metals Chemical class 0.000 description 1
- PIBWKRNGBLPSSY-UHFFFAOYSA-L palladium(II) chloride Chemical compound Cl[Pd]Cl PIBWKRNGBLPSSY-UHFFFAOYSA-L 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 229910052702 rhenium Inorganic materials 0.000 description 1
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 description 1
- 229910052703 rhodium Inorganic materials 0.000 description 1
- 239000010948 rhodium Substances 0.000 description 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 1
- 229910052707 ruthenium Inorganic materials 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- 239000002109 single walled nanotube Substances 0.000 description 1
- NLJMYIDDQXHKNR-UHFFFAOYSA-K sodium citrate Chemical compound O.O.[Na+].[Na+].[Na+].[O-]C(=O)CC(O)(CC([O-])=O)C([O-])=O NLJMYIDDQXHKNR-UHFFFAOYSA-K 0.000 description 1
- 235000011083 sodium citrates Nutrition 0.000 description 1
- HLBBKKJFGFRGMU-UHFFFAOYSA-M sodium formate Chemical compound [Na+].[O-]C=O HLBBKKJFGFRGMU-UHFFFAOYSA-M 0.000 description 1
- 235000019254 sodium formate Nutrition 0.000 description 1
- 229910000104 sodium hydride Inorganic materials 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 239000001117 sulphuric acid Substances 0.000 description 1
- 235000011149 sulphuric acid Nutrition 0.000 description 1
- AXZWODMDQAVCJE-UHFFFAOYSA-L tin(II) chloride (anhydrous) Chemical compound [Cl-].[Cl-].[Sn+2] AXZWODMDQAVCJE-UHFFFAOYSA-L 0.000 description 1
- 238000004448 titration Methods 0.000 description 1
- HRXKRNGNAMMEHJ-UHFFFAOYSA-K trisodium citrate Chemical compound [Na+].[Na+].[Na+].[O-]C(=O)CC(O)(CC([O-])=O)C([O-])=O HRXKRNGNAMMEHJ-UHFFFAOYSA-K 0.000 description 1
- 229940038773 trisodium citrate Drugs 0.000 description 1
- 235000019263 trisodium citrate Nutrition 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B15/00—Peroxides; Peroxyhydrates; Peroxyacids or salts thereof; Superoxides; Ozonides
- C01B15/01—Hydrogen peroxide
- C01B15/029—Preparation from hydrogen and oxygen
-
- 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
- B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
- B01J21/18—Carbon
-
- 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
- B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
- B01J23/48—Silver or gold
- B01J23/52—Gold
-
- 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
- B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
- B01J23/54—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
- B01J23/56—Platinum group metals
- B01J23/63—Platinum group metals with rare earths or actinides
-
- 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
- B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
- B01J23/54—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
- B01J23/56—Platinum group metals
- B01J23/64—Platinum group metals with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
- B01J23/648—Vanadium, niobium or tantalum or polonium
- B01J23/6484—Niobium
-
- 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
- B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
- B01J23/54—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
- B01J23/66—Silver or gold
-
- 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
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/40—Catalysts, in general, characterised by their form or physical properties characterised by dimensions, e.g. grain size
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/02—Impregnation, coating or precipitation
- B01J37/0201—Impregnation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/16—Reducing
Definitions
- the present invention relates to a process for the manufacture of hydrogen peroxide.
- it relates to the manufacture of hydrogen peroxide by direct synthesis from reacting hydrogen and oxygen.
- the purpose of the present invention is to provide an improved process for the formation of hydrogen peroxide by direct synthesis.
- the purpose of the present invention is to provide a process exhibiting an increased 3 ⁇ 4(3 ⁇ 4 productivity and/or a reduced hydrogenation activity (i.e. to avoid hydrogenation of H2O2 into H2O) and/or an increased selectivity to 3 ⁇ 4(3 ⁇ 4.
- the present invention therefore relates to a process for the manufacture of hydrogen peroxide by direct synthesis comprising converting hydrogen and oxygen to hydrogen peroxide in the presence of a heterogeneous supported catalyst comprising at least gold, palladium and platinum as catalytically active component, wherein the weight ratios palladium to platinum (Pd/Pt) and gold to platinum (Au/Pt) are both equal to or higher than 1 :1, and wherein gold is present in an amount of at least 0.2% by weight, preferably at least 0.3% by weight of the catalyst support.
- a heterogeneous supported catalyst comprising at least gold, palladium and platinum as catalytically active component, wherein the weight ratios palladium to platinum (Pd/Pt) and gold to platinum (Au/Pt) are both equal to or higher than 1 :1, and wherein gold is present in an amount of at least 0.2% by weight, preferably at least 0.3% by weight of the catalyst support.
- one of the essential features of the present invention resides in the use of supported catalysts comprising at least gold, palladium and platinum, wherein the Au/Pt and Pd/Pt weight ratios are both equal to or higher than 1 : 1 , in particular higher than 1 :1.
- the Au/Pt and Pd/Pt weight ratios may vary widely, but are typically, independently of one another (preferably both), higher than 1 :1, equal to or higher than 1.2: 1, with preference equal to or higher than 1.5:1, with particular preference equal to or higher than 2: 1, with higher preference equal to or higher than 4:1, with especial preference equal to or higher then 6:1, for example equal to or higher than 8:1.
- the Au/Pt and Pd/Pt weight ratios are commonly equal to or lower than 500:1, very often equal to or lower than 100: 1, frequently equal to or lower than 50:1, for example equal to or lower then 25:1.
- the (Au+Pd)/Pt weight ratio is from 2.5:1 to 100:1, especially from 3:1 to 75:1, particularly from 4:1 to 50:1, more particularly from 10:1 to 40: 1, such as from 5:1 to 40:1, most particularly from 15:1 to 30:1, such as from 7:1 to 30:1.
- the Pd/Au weight ratio is typically equal to or lower than 50:1, preferably equal to or lower than 40:1, more preferably equal to or lower than 30:1, most preferably equal to or lower than 25:1, such as equal to or lower than 5:1, 4:1, 3:1 or 2:1.
- the Pd/Au weight ratio is generally equal to or higher than 1 :3, often equal to or higher than 1 :2.5, more often equal to or higher than 1:2, most often equal to or higher thanl:1.5.
- a Pd/Au weight ratio about 1 :1 may for instance give good results.
- the catalysts used in the process of the present invention generally comprise a total amount of noble metals from 1 to 30 % by weight of the catalyst support, especially from 2 to 20 wt%, more especially from 4 to 10 wt%.
- the palladium metal is in general present in an amount equal to or higher than 0.05% by weight of the catalyst support, preferably equal to or higher than 0.1 wt%, more preferably equal to or higher than 0.2 wt%, such as equal to or higher than 0.3 wt%, equal to or higher than 0.4 wt%, equal to or higher than 0.5 wt%, equal to or higher than 0.6 wt%, equal to or higher than 0.7 wt% or equal to or higher than about 1 wt%.
- the gold metal is in general present in an amount equal to or higher than 0.3 wt% of the catalyst support, preferably equal to or higher than 0.4 wt%, more preferably equal to or higher than 0.5 wt%, most preferably equal to or higher than 0.6 wt%, with higher preference equal to or higher than 0.7 wt%, with highest preference equal to or higher than 0.8 wt%, for instance equal to or higher than about 1 wt%.
- the gold and palladium metals are commonly present each, independently of one another, in an amount equal to or lower than 9.5% by weight of the catalyst support, especially equal to or lower than 8 wt%, particularly equal to or lower than 5 wt%.
- the total amount of gold and palladium is commonly from 0.25 to 9.9% by weight of the catalyst support, in particular from 0.5 to 7.5 wt%, more particularly from 1 to 5 wt%.
- the platinum is usually present in a total amount from 0.001 to 1 % by weight of the catalyst support, preferably from 0.05 to 0.8 wt%, such as from 0.05 to 0.5 wt%, more preferably from 0.1 to 0.7 wt%, such as from 0.1 to 0.3 wt%.
- the catalysts used in the process of the present invention are in general trimetallic catalysts comprising gold, palladium and platinum.
- the catalysts of the present invention may further comprise at least one additional noble metal, for instance at least one additional noble metal selected from the group consisting of silver, rhodium, iridium, ruthenium, osmium, and rhenium.
- Said additional noble metal may for example be present in an amount from 0 to 1 % by weight of the catalyst support.
- the catalyst support to or in which the at least three noble metals present as catalytically active component are bound may be any type of support known in the art.
- Said catalyst support may for example be selected from the group consisting of carbon supports, oxide supports, and silicate supports, in particular from carbon supports, AI2O 3 , T1O2, CeC>2, Zr0 2 , Fe2C>3, S1O2, silica-alumina and zeolites or any mixture thereof.
- Suitable carbon supports are for instance graphite, carbon black, glassy carbon, activated carbon, highly oriented pyrolytic graphite (HOPG), single-walled and multi-walled carbon nanotubes, especially activated carbon.
- the support may be porous or non-porous, preferably porous.
- Said catalyst support may be used directly to deposit the catalytically active component, or may first be pretreated, prior to noble metal deposition.
- An example of pretreatment is acid washing of the support that may be carried out using a mineral acid such as hydrochloric acid or nitric acid.
- a mineral acid such as hydrochloric acid or nitric acid.
- the acid is dilute nitric acid, and supports are treated for example for 3 hours at ambient temperature.
- Deposition of gold, palladium and platinum onto the catalyst support to manufacture the catalyst may be performed by any method known in the art, especially starting from metallic gold, palladium and platinum, and/or starting from gold, palladium and platinum precursors.
- the noble metals present as catalytically active component may be deposited onto the catalyst support in the form of metal oxides or metal ions by any method known in the art, to form a catalyst precursor, for instance by incipient wetness method.
- the at least three noble metals i.e. gold, palladium and platinum, may be deposited simultaneously or sequentially, conveniently simultaneously.
- the catalyst precursor is then transformed into the corresponding metals via at least one of a heat treatment, chemical reduction in the presence of a reducing agent, or electrochemical reduction (electrodeposition). Heat treatment is typically conducted at a temperature from 250 to 600°C, preferably from 300 to 500°C, more preferably from 350 to 450°C, for example around 400°C.
- Heat treatment may be conducted under any type of atmosphere such as oxygen or oxygen containing atmosphere, reducing atmosphere, or inert atmosphere, for instance under oxygen, air, nitrogen, argon, hydrogen or mixtures thereof.
- atmosphere such as oxygen or oxygen containing atmosphere, reducing atmosphere, or inert atmosphere, for instance under oxygen, air, nitrogen, argon, hydrogen or mixtures thereof.
- Chemical reduction reactions and electrodeposition are well known in the art.
- Suitable reducing agents are known in the art and may for instance be selected from the group consisting of H 2 , NaH, LiH, LiAlH 4 , NaBH 4 , CaH 2 , SnCl 2 ,
- DIBAL-H diisobutylaluminium hydride
- the noble metals may be deposited onto the catalyst support by direct deposition of metallic gold, palladium and platinum, used in the form of a dispersion in an aqueous or organic medium, generally in the form of an aqueous dispersion, advantageously in the form of a colloidal dispersion.
- the respective amounts and weight ratios of gold, palladium and platinum may of course be adapted to the nature of the catalyst support and reaction conditions.
- Any suitable additive may also be further added to the medium during the preparation of the catalyst, for instance in at least one of the mediums comprising the noble metals and/or noble metal precursors.
- Suitable additives are for instance dispersants, stabilizers and templating agents.
- the supported catalyst may be recovered by any suitable separation method, such as filtration, decantation and/or centrifugation. Said supported catalyst may further be washed and dried, for instance at about 50 to 100°C, under air or under protective atmosphere, typically under air. The supported catalyst may also be further heat treated and/or reduced.
- the process of the present invention may be conducted in any type of suitable reactor known in the art, especially in a stirred reactor, for example into an autoclave equipped with stirring means, a loop reactor or a tube reactor.
- the catalyst may be present into the reactor as a fixed bed or as a fluid bed.
- the present process is usually conducted at a temperature equal to or higher than -10°C, often equal to or higher than 0°C, more often equal to or higher than 1°C.
- the process is typically conducted at a temperature equal to or lower than 90°C, in particular equal to or lower than 50°C, more particularly equal to or lower than 30°C.
- the process may be carried out a temperature between 1 and 50°C, especially between 2 and 20 °C,
- An inert gas such as carbon dioxide, nitrogen, helium or argon may also be present with oxygen and/or hydrogen gas, or the oxygen and/or hydrogen gas may be first saturated with water vapor.
- the hydrogen to oxygen molar ratio is in general from 10:1 to 1:100, with preference from 5:1 to 1:50, with higher preference from 1 :1 to 1 : 15, for example around 1 :7.
- the total pressure into the reactor (as measured at 20°C) is in general from 0.1 to 20 MPa, preferably from 1 to 10 MPa, more preferably from higher than 1 to 6 MPa, for instance around 4 to 5 MPa.
- duration of the reaction between oxygen and hydrogen may vary widely and may be adapted to the reaction conditions. Suitable durations are for instance from 0.5 to 400 minutes, particularly from 1 to 360 minutes, more particularly from 2 to 300 minutes, such as from 1 to 120 minutes or from 2 to 60 minutes.
- the hydrogen and oxygen are commonly reacted in the presence of a liquid such as water, organic solvents and mixtures thereof.
- a liquid such as water, organic solvents and mixtures thereof.
- suitable organic solvents are water miscible solvents such as methanol, ethanol, isopropyl alcohol, acetone and glycols such as ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol etc.
- the reaction medium may further comprise any other additional components which may contribute to a desired result or avoid an undesired result.
- bromide ions preferably in the form of hydrogen bromide (HBr), sodium bromide or potassium bromide, most preferably HBr, may be added. It has surprisingly been found that bromide ions reduce the tendency for 3 ⁇ 40 formation at higher temperatures, causing an increase in yield due to decreased decomposition (thus stabilisation) of the 3 ⁇ 4(3 ⁇ 4.
- the amount of bromide ions added calculated as HBr can be between 0.1 to 30 mg/kg of the reaction medium, more preferably between 5 and 20 mg/kg of the reaction medium and most preferably around 10 mg/kg of the reaction medium.
- an inorganic acid may also induce a stabilisation of the hydrogen peroxide formed.
- Preferred inorganic acids are sulphuric acid, nitric acid, hydrochloric acid and ortho-phosphoric acid.
- the amount of inorganic acid can be between 0.01 and 0.5 M, more preferably between 0.02 and 0.2 M and most preferable around 0.06 M.
- ortho-phosphoric acid is added at a concentration of 0.06 M. Bets results with respect to yield and selectivity are obtained by adding both, bromide ions and an inorganic acid to the reaction medium, in particular HBr and ortho-phosphoric acid.
- the process of the present invention may be carried out batchwise, for instance in an autoclave, but it can also be operated in a continuous or semi- continuous mode.
- the process according to the invention is advantageous in that it has demonstrated improved yields (3 ⁇ 4(3 ⁇ 4 productivity) and/or higher selectivity towards the preparation of hydrogen peroxide by direct reaction of hydrogen and oxygen and/or reduced hydrogenation activity (i.e. hydrogenation of 3 ⁇ 4(3 ⁇ 4 into 3 ⁇ 40).
- the process of the present invention is also environmentally friendly, especially as it can be used without organic solvents, especially without non- environmentally friendly solvents. It can also be operated under mild operating conditions, with a reduced energy usage.
- the process of the present invention is especially suitable for on-site / on-demand production of hydrogen peroxide, among others due the small size of the production devices.
- the present invention also relates to hydrogen peroxide obtainable by the process described above.
- the present invention also relates to a supported catalyst suitable for hydrogen peroxide direct synthesis obtained by reacting hydrogen and oxygen, said catalyst comprising a catalyst support and at least gold, palladium and platinum as catalytically active component, wherein the weight ratios Pd/Pt and Au/Pt are both equal to or higher than 1 : 1 and wherein the amount of gold is equal to or higher than 0.2% by weight, preferably equal to or higher than 0.3% by weight of the catalyst support.
- a supported catalyst suitable for hydrogen peroxide direct synthesis obtained by reacting hydrogen and oxygen said catalyst comprising a catalyst support and at least gold, palladium and platinum as catalytically active component, wherein the weight ratios Pd/Pt and Au/Pt are both equal to or higher than 1 : 1 and wherein the amount of gold is equal to or higher than 0.2% by weight, preferably equal to or higher than 0.3% by weight of the catalyst support.
- the (Au+Pd)/Pt, Pd/Au, Au/Pt and Pd/Pt weight ratios are as defined above.
- the catalysts according to the present invention exhibit surprisingly a long life and recyclability, while allowing the preparation of 3 ⁇ 4(3 ⁇ 4 by direct synthesis with an improved productivity and/or decreased hydrogenation activity (and so increase the total selectivity to hydrogen peroxide).
- the present invention also relates to the use of such supported catalysts for the direct synthesis of hydrogen peroxide.
- the catalysts were prepared by impregnation of suitable support materials : CeC> 2 ( ⁇ 5 micron particulate (99.9% purity) from Aldrich), ⁇ (3 ⁇ 4 (mainly anatase, P25 from Degussa), Zr(3 ⁇ 4 ( ⁇ 5 micron particulate (99%+ purity) from Aldrich), Nb 2 0 5 (99.99% metal basis, from Aldrich) carbon (G60 activated carbon from Aldrich), and S1O 2 (SBA-15 commercially available from Claytec Inc. and from Acros Organics).
- suitable support materials CeC> 2 ( ⁇ 5 micron particulate (99.9% purity) from Aldrich), ⁇ (3 ⁇ 4 (mainly anatase, P25 from Degussa), Zr(3 ⁇ 4 ( ⁇ 5 micron particulate (99%+ purity) from Aldrich), Nb 2 0 5 (99.99% metal basis, from Aldrich) carbon (G60 activated carbon from Aldrich), and S1O 2 (S
- HAuCi 4 .3H 2 0 Johnson Matthey
- PtCl 2 Johnson Matthey
- H2Q2 direct synthesis and hydrogenation - batch tests
- Catalyst testing was performed using a Parr Instruments stainless steel autoclave with a nominal volume of 50 ml and a maximum working pressure of 14 MPa.
- the autoclave was equipped with an overhead stirrer (0 - 2000 rpm) and provision for measurement of temperature and pressure.
- Hydrogen peroxide hydrogenation was carried out using the conditions described for the direct synthesis with the addition of 4wt% H 2 0 2 ( 50wt%, Aldrich) to the solvent in place of water (0.68g H 2 0 2 , 2.22g H 2 0 and 5.9g MeOH)The experiment is carried out in the absence of 25%0 2 /CC> 2 .
- the wt% of H 2 O 2 hydrogenated was determined by titrating aliquots of the fresh solution and the solution after reaction with acidified Ce(S0 4 )2 (0.0288 M) in the presence of two drops of ferroin indicator.
- the reactor is cooled to 5°C and the working pressure is at 50 bars (obtained by introduction of nitrogen).
- the reactor is flushed all the time of the reaction with the mix of gases:
- Liquid samples are taken to measure hydrogen peroxide and water concentration. Hydrogen peroxide is measured by redox titration with cerium sulfate.
- the selectivity is calculated following the fomula:
- Hydrogenation activity denoted as moles H 2 0 2 destroyed per kg catalyst per hour, based on 4wt% starting [H 2 0 2 ]. Number in brackets denoted at percent H 2 0 2 destroyed during experiment.
- Table 2 illustrates the comparison between a trimetallic catalyst and a classical bimetallic catalyst (Pd and Au) on active carbon. Those trials have been performed in semi-continuous configuration with addition of bromide ions and ortho-phosphoric acid.
- trimetalic catalyst enhances the selectivity of the reaction to hydrogen peroxide and decreases the final concentration of water in the reaction medium.
- Table 3 illustrates the importance of the addition of bromide in the reaction medium for enhancing the selectivity of the reaction. Those trials have been performed in semi-continuous configuration with addition of ortho- phosphoric acid.
- Table 4 illustrates the importance of using the right bromide content in the reaction medium for enhancing the selectivity and the conversion rate of the reaction. Those trials have been performed in semi-continuous configuration with addition of bromide and ortho-phosphoric acid. Table 4
- Table 5 illustrates the use of catalyst prepared on several supports (CeC>2 or C) and with different ratio Au/Pt and Pd/Pt. Those trials have been performed in semi-continuous configuration with addition of bromide and ortho- phosphoric acid.
- Catalyst A Catalyst B Catalyst C
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Abstract
Process for the manufacture of hydrogen peroxide by direct synthesis comprising converting hydrogen and oxygen to hydrogen peroxide in the presence of a heterogeneous supported catalyst comprising at least gold, palladium and platinum as catalytically active component, wherein the weight ratios Pd/Pt and Au/Pt are both equal to or higher than 1:1 and wherein the amount of gold is equal to or higher than 0.2% by weight of the catalyst support.
Description
Process for the manufacture of hydrogen peroxide
This application claims priority to European application No 11170357.5 filed on June 17, 2011, the whole content of this application being incorporated herein by reference for all purposes.
The present invention relates to a process for the manufacture of hydrogen peroxide. In particular, it relates to the manufacture of hydrogen peroxide by direct synthesis from reacting hydrogen and oxygen.
The standard large scale production method for hydrogen peroxide involves the use of anthraquinone as an intermediate. Such process requires very large amounts of organic solvents and thus cannot be considered as strictly environmentally friendly. Such process is also energy-consuming. And last but not least, such process typically requires huge plants, which is not compatible with on-site and on-demand production. There has thus been considerable study over the last years to develop alternative processes for the manufacture of hydrogen peroxide.
In particular, there were attempts to develop processes based on direct oxidation of hydrogen by oxygen, even if such processes imply the use of potentially explosive mixtures of hydrogen and oxygen. For instance, patent US 3,361,533 published in 1968 discloses a process for the manufacture of hydrogen peroxide by contacting hydrogen and oxygen with a solid catalyst in a liquid medium, the solid catalyst containing conveniently palladium either alone or alloyed or mixed with a minor proportion of one or more other metals, especially gold or platinum. Similarly, a more recent example is US 6,958,138 Bl, published in 2005, which discloses direct manufacture of hydrogen peroxide from hydrogen and oxygen in the presence of supported single-, bi- or multi- metal catalysts, said multi-metal catalysts consisting of a majority metal and several minority metals. Another example is given by international patent application WO 2007/007075 which discloses the use of supported Au/Pd bimetallic catalysts for the direct synthesis of ¾(¾, the catalyst support having been acid washed prior to metal deposition.
Further bi-metallic catalysts for the direct synthesis of hydrogen peroxide are disclosed in US 6,387,346, US 2006/0252947, US 2005/0201925 and by G. Bernardotto, et al. in Applied Catalysis A: General 358 (2009) 129-135.
Despite all these efforts, there still remains a need for an improved and commercially viable catalyst as well as to an improved and commercially viable direct reaction process for the direct synthesis of hydrogen peroxide.
The purpose of the present invention is to provide an improved process for the formation of hydrogen peroxide by direct synthesis. In particular, the purpose of the present invention is to provide a process exhibiting an increased ¾(¾ productivity and/or a reduced hydrogenation activity (i.e. to avoid hydrogenation of H2O2 into H2O) and/or an increased selectivity to ¾(¾.
The present invention therefore relates to a process for the manufacture of hydrogen peroxide by direct synthesis comprising converting hydrogen and oxygen to hydrogen peroxide in the presence of a heterogeneous supported catalyst comprising at least gold, palladium and platinum as catalytically active component, wherein the weight ratios palladium to platinum (Pd/Pt) and gold to platinum (Au/Pt) are both equal to or higher than 1 :1, and wherein gold is present in an amount of at least 0.2% by weight, preferably at least 0.3% by weight of the catalyst support.
Indeed, it has been surprisingly found that reacting hydrogen and oxygen in the presence of a supported catalyst comprising at least palladium, gold, and platinum in afore-said ratios and amounts allows the preparation of hydrogen peroxide with an increased productivity and/or a reduced hydrogenation activity and/or increased selectivity to hydrogen peroxide.
Thus, one of the essential features of the present invention resides in the use of supported catalysts comprising at least gold, palladium and platinum, wherein the Au/Pt and Pd/Pt weight ratios are both equal to or higher than 1 : 1 , in particular higher than 1 :1. The Au/Pt and Pd/Pt weight ratios may vary widely, but are typically, independently of one another (preferably both), higher than 1 :1, equal to or higher than 1.2: 1, with preference equal to or higher than 1.5:1, with particular preference equal to or higher than 2: 1, with higher preference equal to or higher than 4:1, with especial preference equal to or higher then 6:1, for example equal to or higher than 8:1. The Au/Pt and Pd/Pt weight ratios are commonly equal to or lower than 500:1, very often equal to or lower than 100: 1, frequently equal to or lower than 50:1, for example equal to or lower then 25:1.
Usually, in the process of the present invention, the (Au+Pd)/Pt weight ratio is from 2.5:1 to 100:1, especially from 3:1 to 75:1, particularly from 4:1 to 50:1, more particularly from 10:1 to 40: 1, such as from 5:1 to 40:1, most particularly from 15:1 to 30:1, such as from 7:1 to 30:1.
In the process of the invention, the Pd/Au weight ratio is typically equal to or lower than 50:1, preferably equal to or lower than 40:1, more preferably equal to or lower than 30:1, most preferably equal to or lower than 25:1, such as equal to or lower than 5:1, 4:1, 3:1 or 2:1. The Pd/Au weight ratio is generally equal to or higher than 1 :3, often equal to or higher than 1 :2.5, more often equal to or higher than 1:2, most often equal to or higher thanl:1.5. A Pd/Au weight ratio about 1 :1 may for instance give good results.
The catalysts used in the process of the present invention generally comprise a total amount of noble metals from 1 to 30 % by weight of the catalyst support, especially from 2 to 20 wt%, more especially from 4 to 10 wt%. In such catalysts, the palladium metal is in general present in an amount equal to or higher than 0.05% by weight of the catalyst support, preferably equal to or higher than 0.1 wt%, more preferably equal to or higher than 0.2 wt%, such as equal to or higher than 0.3 wt%, equal to or higher than 0.4 wt%, equal to or higher than 0.5 wt%, equal to or higher than 0.6 wt%, equal to or higher than 0.7 wt% or equal to or higher than about 1 wt%. The gold metal is in general present in an amount equal to or higher than 0.3 wt% of the catalyst support, preferably equal to or higher than 0.4 wt%, more preferably equal to or higher than 0.5 wt%, most preferably equal to or higher than 0.6 wt%, with higher preference equal to or higher than 0.7 wt%, with highest preference equal to or higher than 0.8 wt%, for instance equal to or higher than about 1 wt%. The gold and palladium metals are commonly present each, independently of one another, in an amount equal to or lower than 9.5% by weight of the catalyst support, especially equal to or lower than 8 wt%, particularly equal to or lower than 5 wt%. The total amount of gold and palladium is commonly from 0.25 to 9.9% by weight of the catalyst support, in particular from 0.5 to 7.5 wt%, more particularly from 1 to 5 wt%. The platinum is usually present in a total amount from 0.001 to 1 % by weight of the catalyst support, preferably from 0.05 to 0.8 wt%, such as from 0.05 to 0.5 wt%, more preferably from 0.1 to 0.7 wt%, such as from 0.1 to 0.3 wt%.
The catalysts used in the process of the present invention are in general trimetallic catalysts comprising gold, palladium and platinum. Anyway, the catalysts of the present invention may further comprise at least one additional noble metal, for instance at least one additional noble metal selected from the group consisting of silver, rhodium, iridium, ruthenium, osmium, and rhenium.
Said additional noble metal may for example be present in an amount from 0 to 1 % by weight of the catalyst support.
In the process of the present invention, the catalyst support to or in which the at least three noble metals present as catalytically active component are bound may be any type of support known in the art. Said catalyst support may for example be selected from the group consisting of carbon supports, oxide supports, and silicate supports, in particular from carbon supports, AI2O3, T1O2, CeC>2, Zr02, Fe2C>3, S1O2, silica-alumina and zeolites or any mixture thereof. Suitable carbon supports are for instance graphite, carbon black, glassy carbon, activated carbon, highly oriented pyrolytic graphite (HOPG), single-walled and multi-walled carbon nanotubes, especially activated carbon. The support may be porous or non-porous, preferably porous. Said catalyst support may be used directly to deposit the catalytically active component, or may first be pretreated, prior to noble metal deposition. An example of pretreatment is acid washing of the support that may be carried out using a mineral acid such as hydrochloric acid or nitric acid. Preferably the acid is dilute nitric acid, and supports are treated for example for 3 hours at ambient temperature.
Deposition of gold, palladium and platinum onto the catalyst support to manufacture the catalyst may be performed by any method known in the art, especially starting from metallic gold, palladium and platinum, and/or starting from gold, palladium and platinum precursors.
In a first specific embodiment of the present invention, the noble metals present as catalytically active component may be deposited onto the catalyst support in the form of metal oxides or metal ions by any method known in the art, to form a catalyst precursor, for instance by incipient wetness method. The at least three noble metals, i.e. gold, palladium and platinum, may be deposited simultaneously or sequentially, conveniently simultaneously. The catalyst precursor is then transformed into the corresponding metals via at least one of a heat treatment, chemical reduction in the presence of a reducing agent, or electrochemical reduction (electrodeposition). Heat treatment is typically conducted at a temperature from 250 to 600°C, preferably from 300 to 500°C, more preferably from 350 to 450°C, for example around 400°C. Heat treatment may be conducted under any type of atmosphere such as oxygen or oxygen containing atmosphere, reducing atmosphere, or inert atmosphere, for instance under oxygen, air, nitrogen, argon, hydrogen or mixtures thereof. Chemical reduction reactions and electrodeposition are well known in the art. Suitable
reducing agents are known in the art and may for instance be selected from the group consisting of H2, NaH, LiH, LiAlH4, NaBH4, CaH2, SnCl2,
diisobutylaluminium hydride (DIBAL-H), sodium citrate, disodium citrate, trisodium citrate, sodium formate, formic acid, and hydrazine, commonly H2 or NaBH4.
In a second specific embodiment of the present invention, the noble metals may be deposited onto the catalyst support by direct deposition of metallic gold, palladium and platinum, used in the form of a dispersion in an aqueous or organic medium, generally in the form of an aqueous dispersion, advantageously in the form of a colloidal dispersion.
It is also possible to combine both the first and second specific
embodiments described above.
In the process of the present invention, the respective amounts and weight ratios of gold, palladium and platinum may of course be adapted to the nature of the catalyst support and reaction conditions.
Any suitable additive may also be further added to the medium during the preparation of the catalyst, for instance in at least one of the mediums comprising the noble metals and/or noble metal precursors. Suitable additives are for instance dispersants, stabilizers and templating agents.
After deposition of the gold and palladium onto the catalyst support, the supported catalyst may be recovered by any suitable separation method, such as filtration, decantation and/or centrifugation. Said supported catalyst may further be washed and dried, for instance at about 50 to 100°C, under air or under protective atmosphere, typically under air. The supported catalyst may also be further heat treated and/or reduced.
The process of the present invention may be conducted in any type of suitable reactor known in the art, especially in a stirred reactor, for example into an autoclave equipped with stirring means, a loop reactor or a tube reactor. The catalyst may be present into the reactor as a fixed bed or as a fluid bed.
The present process is usually conducted at a temperature equal to or higher than -10°C, often equal to or higher than 0°C, more often equal to or higher than 1°C. The process is typically conducted at a temperature equal to or lower than 90°C, in particular equal to or lower than 50°C, more particularly equal to or lower than 30°C. For instance, the process may be carried out a temperature between 1 and 50°C, especially between 2 and 20 °C,
advantageously between 2 and 10°C.
An inert gas such as carbon dioxide, nitrogen, helium or argon may also be present with oxygen and/or hydrogen gas, or the oxygen and/or hydrogen gas may be first saturated with water vapor. The hydrogen to oxygen molar ratio is in general from 10:1 to 1:100, with preference from 5:1 to 1:50, with higher preference from 1 :1 to 1 : 15, for example around 1 :7.
The total pressure into the reactor (as measured at 20°C) is in general from 0.1 to 20 MPa, preferably from 1 to 10 MPa, more preferably from higher than 1 to 6 MPa, for instance around 4 to 5 MPa.
The duration of the reaction between oxygen and hydrogen may vary widely and may be adapted to the reaction conditions. Suitable durations are for instance from 0.5 to 400 minutes, particularly from 1 to 360 minutes, more particularly from 2 to 300 minutes, such as from 1 to 120 minutes or from 2 to 60 minutes.
In the present invention the hydrogen and oxygen are commonly reacted in the presence of a liquid such as water, organic solvents and mixtures thereof. Especially suitable organic solvents are water miscible solvents such as methanol, ethanol, isopropyl alcohol, acetone and glycols such as ethylene glycol, propylene glycol, diethylene glycol, dipropylene glycol etc.
In a certain embodiment of the present invention the reaction medium may further comprise any other additional components which may contribute to a desired result or avoid an undesired result. For example, bromide ions, preferably in the form of hydrogen bromide (HBr), sodium bromide or potassium bromide, most preferably HBr, may be added. It has surprisingly been found that bromide ions reduce the tendency for ¾0 formation at higher temperatures, causing an increase in yield due to decreased decomposition (thus stabilisation) of the ¾(¾. The amount of bromide ions added calculated as HBr can be between 0.1 to 30 mg/kg of the reaction medium, more preferably between 5 and 20 mg/kg of the reaction medium and most preferably around 10 mg/kg of the reaction medium.
In a further embodiment it has surprisingly been found that the addition of an inorganic acid may also induce a stabilisation of the hydrogen peroxide formed. Preferred inorganic acids are sulphuric acid, nitric acid, hydrochloric acid and ortho-phosphoric acid. The amount of inorganic acid can be between 0.01 and 0.5 M, more preferably between 0.02 and 0.2 M and most preferable around 0.06 M. In a preferred embodiment, ortho-phosphoric acid is added at a concentration of 0.06 M.
Bets results with respect to yield and selectivity are obtained by adding both, bromide ions and an inorganic acid to the reaction medium, in particular HBr and ortho-phosphoric acid.
The process of the present invention may be carried out batchwise, for instance in an autoclave, but it can also be operated in a continuous or semi- continuous mode.
The process according to the invention is advantageous in that it has demonstrated improved yields (¾(¾ productivity) and/or higher selectivity towards the preparation of hydrogen peroxide by direct reaction of hydrogen and oxygen and/or reduced hydrogenation activity (i.e. hydrogenation of ¾(¾ into ¾0). The process of the present invention is also environmentally friendly, especially as it can be used without organic solvents, especially without non- environmentally friendly solvents. It can also be operated under mild operating conditions, with a reduced energy usage. The process of the present invention is especially suitable for on-site / on-demand production of hydrogen peroxide, among others due the small size of the production devices.
The present invention also relates to hydrogen peroxide obtainable by the process described above.
In view of the above, the present invention also relates to a supported catalyst suitable for hydrogen peroxide direct synthesis obtained by reacting hydrogen and oxygen, said catalyst comprising a catalyst support and at least gold, palladium and platinum as catalytically active component, wherein the weight ratios Pd/Pt and Au/Pt are both equal to or higher than 1 : 1 and wherein the amount of gold is equal to or higher than 0.2% by weight, preferably equal to or higher than 0.3% by weight of the catalyst support. In a preferred
embodiment, in said supported catalyst, the (Au+Pd)/Pt, Pd/Au, Au/Pt and Pd/Pt weight ratios are as defined above.
The catalysts according to the present invention exhibit surprisingly a long life and recyclability, while allowing the preparation of ¾(¾ by direct synthesis with an improved productivity and/or decreased hydrogenation activity (and so increase the total selectivity to hydrogen peroxide).
The present invention also relates to the use of such supported catalysts for the direct synthesis of hydrogen peroxide.
Should the disclosure of any patents, patent applications, and publications which are incorporated herein by reference conflict with the description of the
present application to the extent that it may render a term unclear, the present description shall take precedence.
The present invention is further illustrated below without limiting the scope thereto.
Examples
Except otherwise mentioned, examples were conducted according to the following procedures.
Preparation of the catalysts
The catalysts were prepared by impregnation of suitable support materials : CeC>2 (<5 micron particulate (99.9% purity) from Aldrich), Τί(¾ (mainly anatase, P25 from Degussa), Zr(¾ (<5 micron particulate (99%+ purity) from Aldrich), Nb205 (99.99% metal basis, from Aldrich) carbon (G60 activated carbon from Aldrich), and S1O2 (SBA-15 commercially available from Claytec Inc. and from Acros Organics).
An incipient wetness method using aqueous solutions of PdCl2 (Johnson
Matthey), HAuCi4.3H20 (Johnson Matthey) and/or PtCl2 (Johnson Matthey) was employed. The paste formed was ground and dried at 80 °C or 110 °C for 16 hours and calcined in static air, typically at 400°C for 3 hours.
H2Q2 direct synthesis and hydrogenation - batch tests
Catalyst testing was performed using a Parr Instruments stainless steel autoclave with a nominal volume of 50 ml and a maximum working pressure of 14 MPa. The autoclave was equipped with an overhead stirrer (0 - 2000 rpm) and provision for measurement of temperature and pressure.
For the synthesis of hydrogen peroxide 10 mg of the supported catalyst were charged in an autoclave containing 5.6 g methanol and 2.9 g water. The autoclave was purged three times with CO2 (3 MPa) and then filled with 5% H2/CO2 and 25% O2/CO2 to give a hydrogen to oxygen ratio of 1 :2, at a total pressure of 3.7 MPa at 20 °C. The reaction medium was cooled down to 2°C and stirring (1200 rpm) was started on reaching the desired temperature (2°C).
Experiments were carried out for 30 min.
Hydrogen peroxide hydrogenation was carried out using the conditions described for the direct synthesis with the addition of 4wt% H202 ( 50wt%, Aldrich) to the solvent in place of water (0.68g H202, 2.22g H20 and 5.9g MeOH)The experiment is carried out in the absence of 25%02/CC>2. The wt% of H2O2 hydrogenated was determined by titrating aliquots of the fresh solution and
the solution after reaction with acidified Ce(S04)2 (0.0288 M) in the presence of two drops of ferroin indicator.
H?Q? direct synthesis and hydrogenation - semi-continuous tests
In a 380 cc Hastelloy B22 reactor, methanol (150 g), Hydrogen bromide
(lOppm), 0.06M ortho-phosphoric acid and catalyst (0.36 g) are introduced.
The reactor is cooled to 5°C and the working pressure is at 50 bars (obtained by introduction of nitrogen).
The reactor is flushed all the time of the reaction with the mix of gases:
Hydrogen (3.6% Mol) / Oxygen (25.0% Mol) / Nitrogen (71.4% Mol). The total flow is 2567 mlN/min. The oxygen / hydrogen ration is 7.2: 1.
When the gas phase out is stable (GC on line), the mechanical stirrer is started at 1500 rpm.
GC on line analyzes every 10 minutes the gas phase out.
Liquid samples are taken to measure hydrogen peroxide and water concentration. Hydrogen peroxide is measured by redox titration with cerium sulfate.
Water is measure by Karl-Fisher.
The selectivity is calculated following the fomula:
Selectivity in H202 (%) = N mol H202 formed / (N mol H202 formed + N mol water formed)
Reference Examples 1-4 and Examples 5-10 (Au/Pd/Pt on CeQ2):
Table 1 below illustrates hydrogen peroxide productivity and
hydrogenation activity for various catalytic active components based on Au, Pd and/or Pt on Ce02 support. Those trials have been performed in batch configuration and without any addition of bromide or inorganic acidity.
Table 1
Ex. Catalyst Productivity* Hydrogenation
(molH202/kg- Activity * cat/h) (molH202/kg- cat/h)
1 2.50%Au-2.50%Pd/CeO2 68 145 (7%)
2 2.50% Au-2.50%Pt/CeO2 20 109 (5%)
3 2.50%Pd-2.50%Pt/CeO2 138 182 (9%)
4 4.80%Pd-0.20%Pt/CeO2 125 192 (9%)
5 0.83%Au-3.33%Pd-0.83%Pt/CeO2 138 66 (3%)
6 2.475 %Au-2.475%Pd-0.05%Pt/CeO2 63 46 (2%)
7 2.45%Au-2.45%Pd-0.10%Pt/CeO2 109 76 (4%)
8 2.00% Au-2.00%Pd- 1.00%Pt/CeO2 115 93 (5%)
9 2.3%Au-2.5%Pd-0.2%Pt/CeO2 155 94 (5%)
10 2.5%Au-2.3%Pd-0.2%Pt/CeO2 86 11 (0.5%)
Productivity denoted as moles H202 produced per kg catalyst per hour
Hydrogenation activity denoted as moles H202 destroyed per kg catalyst per hour, based on 4wt% starting [H202]. Number in brackets denoted at percent H202 destroyed during experiment.
Examples 11 and 12: Au/Pd/Pt on C
Table 2 below illustrates the comparison between a trimetallic catalyst and a classical bimetallic catalyst (Pd and Au) on active carbon. Those trials have been performed in semi-continuous configuration with addition of bromide ions and ortho-phosphoric acid.
Table 2
As clearly demonstrate in this example, the use of a trimetalic catalyst enhances the selectivity of the reaction to hydrogen peroxide and decreases the final concentration of water in the reaction medium.
Examples 13 and 14: Au/Pd/Pt on Ce02
Table 3 below illustrates the importance of the addition of bromide in the reaction medium for enhancing the selectivity of the reaction. Those trials have been performed in semi-continuous configuration with addition of ortho- phosphoric acid.
Table 3
Examples 15 and 16: Au/Pd/Pt on C
Table 4 below illustrates the importance of using the right bromide content in the reaction medium for enhancing the selectivity and the conversion rate of the reaction. Those trials have been performed in semi-continuous configuration with addition of bromide and ortho-phosphoric acid.
Table 4
Examples 17 to 19: Au/Pd/Pt on several supports
Table 5 below illustrates the use of catalyst prepared on several supports (CeC>2 or C) and with different ratio Au/Pt and Pd/Pt. Those trials have been performed in semi-continuous configuration with addition of bromide and ortho- phosphoric acid.
Table 5
Catalyst A Catalyst B Catalyst C
Au, %Wt 2.40 4.60 3.75
Catalyst Pd, %Wt 2.40 0.20 0.63
Pt, %Wt 0.20 0.20 0.63
Support C Ce02 Ce02
Methanol g 149.51 151.16 150.04
Claims
1. Process for the manufacture of hydrogen peroxide by direct synthesis comprising converting hydrogen and oxygen to hydrogen peroxide in the presence of a heterogeneous supported catalyst comprising at least gold, palladium and platinum as catalytically active component, wherein the weight ratios Pd/Pt and Au/Pt are both equal to or higher than 1 : 1 and wherein the amount of gold is equal to or higher than 0.2% by weight of the catalyst support.
2. Process according to claim 1, wherein the amount of gold is equal to or higher than 0.3% by weight of the catalyst support.
3. Process according to claim 1 or 2, wherein the weight ratios Pd/ Pt and Au/Pt are, independently of one another, higher than 1 :1, equal to or higher than 1.2:1, with preference equal to or higher than 1.5:1, with particular preference equal to or higher than 2:1, with higher preference equal to or higher than 4: 1, with especial preference equal to or higher than 6:1, for example equal to or higher than 8:1.
4. Process according to claim 1, wherein the (Au+Pd)/Pt weight ratio is from 2.5:1 to 100: 1, especially from 3: 1 to 75:1, particularly from 4:1 to 50:1, more particularly from 5:1 to 40:1, most particularly from 7:1 to 30: 1.
5. Process according to anyone of claims 1 to 4, wherein the Pd/Au weight ratio is equal to or lower than 50: 1, preferably equal to or lower than 40:1, more preferably equal to or lower than 30:1, most preferably equal to or lower than 25 : 1.
6. Process according to anyone of claims 1 to 5, wherein the Pd/Au weight ratio is equal to or higher than 1:3, particularly equal to or higher than
1 :2.5, more particularly equal to or higher than 1 :2, most particularly equal to or higher thanl: 1.5.
7. Process according to anyone of claims 1 to 6, wherein the at least three noble metals are present in a total amount of from 1 to 10 % by weight of the catalyst support, especially in an amount from 2 to 8 wt%.
8. Process according to anyone of claims 1 to 7, wherein the gold and palladium are present in a total amount from 0.25 to 9.9% by weight of the catalyst support, in particular from 0.5 to 7.5 wt%, more particularly from 1 to 5 wt%.
9. Process according to anyone of claims 1 to 8, wherein the platinum is present in a total amount from 0.001 to 1 % by weight of the catalyst support, preferably from 0.05 to 0.8 wt%, more preferably from 0.1 to 0.7 wt%.
10. Process according to anyone of claims 1 to 9, wherein the catalytically active component is in the form of the corresponding metals obtained by reduction
11. Process according to anyone of claims 1 to 10, wherein the noble metals are bound to or in a catalyst support, said catalyst support being selected from the group consisting of carbon supports, oxidic supports, and silicate supports; in particular from activated carbon, AI2O3, Ti02, Ce02, Zr02, Fe2(¾, Si02, silica-alumina and zeolites or any mixture thereof.
12. Process according to anyone of claims 1 to 11, conducted in the presence of a liquid, preferably in the presence of an aqueous liquid water, more preferably in the presence of water and of a water-miscible solvent.
13. Process according to anyone of claims 1 to 12, conducted in the presence of bromide ions and/or an inorganic acid, preferably in the presence of HBr and ortho-phosphoric acid.
14. Hydrogen peroxide obtainable by the process of any one of claims 1 to
13.
15. A supported catalyst for hydrogen peroxide direct synthesis, which comprises a catalyst support and at least gold, palladium and platinum as catalytically active component, wherein the weight ratios Pd/Pt and Au/Pt are both equal to or higher than 1 : 1 and wherein the amount of gold is equal to or higher than 0.2% by weight of the catalyst support.
16. A supported catalyst according to claim 15, wherein Pd/Pt and Au/Pt weight ratios are each higher than 1:1, and wherein Pd/Au weight ratio is from 1 :3 to 50:1, preferably from 1:2.5 to 40:1, more preferably from 1 :2 to 25:1.
17. Use of a catalyst according to claim 15 or 16 for the direct synthesis of hydrogen peroxide.
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Cited By (3)
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CN110395696A (en) * | 2019-07-26 | 2019-11-01 | 四川轻化工大学 | Method for synthesizing hydrogen peroxide by catalyzing formic acid based on palladium-based bimetal |
EP3574996A1 (en) * | 2018-06-01 | 2019-12-04 | Korea Institute of Science and Technology | Catalyst containing au-pt alloy, method for preparing thereof and methods for synthesizing of hydrogen peroxide using the same |
WO2024137909A1 (en) * | 2022-12-23 | 2024-06-27 | Shell Usa, Inc. | Gold-containing catalyst for removal of hydrogen in oxygen-rich streams |
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EP3574996A1 (en) * | 2018-06-01 | 2019-12-04 | Korea Institute of Science and Technology | Catalyst containing au-pt alloy, method for preparing thereof and methods for synthesizing of hydrogen peroxide using the same |
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WO2024137909A1 (en) * | 2022-12-23 | 2024-06-27 | Shell Usa, Inc. | Gold-containing catalyst for removal of hydrogen in oxygen-rich streams |
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