WO2016059431A1 - Catalyst and process - Google Patents

Catalyst and process Download PDF

Info

Publication number
WO2016059431A1
WO2016059431A1 PCT/GB2015/053090 GB2015053090W WO2016059431A1 WO 2016059431 A1 WO2016059431 A1 WO 2016059431A1 GB 2015053090 W GB2015053090 W GB 2015053090W WO 2016059431 A1 WO2016059431 A1 WO 2016059431A1
Authority
WO
WIPO (PCT)
Prior art keywords
catalyst
alumina
silica
copper
zinc
Prior art date
Application number
PCT/GB2015/053090
Other languages
French (fr)
Inventor
Gareth Headdock
Jemma Julie HINCHLIFF
Philip John Hughes
Marinus Johannes Vissenberg
Aalbert Zwijnenburg
Original Assignee
Johnson Matthey Public Limited Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Johnson Matthey Public Limited Company filed Critical Johnson Matthey Public Limited Company
Publication of WO2016059431A1 publication Critical patent/WO2016059431A1/en

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J21/00Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/12Silica and alumina
    • 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
    • B01J23/72Copper
    • 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
    • B01J23/80Catalysts 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 zinc, cadmium or mercury
    • CCHEMISTRY; METALLURGY
    • C07ORGANIC CHEMISTRY
    • C07CACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C29/00Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
    • C07C29/132Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group
    • C07C29/136Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH
    • C07C29/147Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH of carboxylic acids or derivatives thereof
    • C07C29/149Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group of >C=O containing groups, e.g. —COOH of carboxylic acids or derivatives thereof with hydrogen or hydrogen-containing gases
    • CCHEMISTRY; METALLURGY
    • C07ORGANIC CHEMISTRY
    • C07CACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C31/00Saturated compounds having hydroxy or O-metal groups bound to acyclic carbon atoms
    • C07C31/02Monohydroxylic acyclic alcohols
    • C07C31/125Monohydroxylic acyclic alcohols containing five to twenty-two carbon atoms
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02Impregnation, coating or precipitation
    • B01J37/03Precipitation; Co-precipitation

Definitions

  • the present invention concerns a catalyst containing copper and the use of such a catalyst in catalytic processes.
  • Fatty alcohols are useful feedstocks, in particular for the production of surfactants and detergents. They may be produced in a variety of ways.
  • One process yielding fatty alcohols is the hydrogenolysis of methyl esters of fatty acids (FAMEs) which are usually derived from triglycerides found in animal fats and vegetable oils.
  • FAMEs methyl esters of fatty acids
  • the hydrogenolysis or hydrogenation of FAME feedstocks using catalysts containing copper and chromium has been described in the prior art, for example in US2091800.
  • WO91/04789 describes an acid-resistant copper chromite catalyst material containing promoter metal compounds as well as colloidal silicic acid, and a process for their production and use for direct fixed-bed hydration of fatty acids to produce fatty alcohols of appropriate chain-length. It is, however, desirable to avoid the use of chromium compounds in this process so that contact with toxic chromium compounds is avoided in the manufacture and use of the catalyst and also to ensure that the products
  • US5364986 describes the production of C6-22 fatty alcohols by a process which comprises contacting a triglyceride with hydrogen in the presence of a copper-zinc catalyst and in a reaction zone.
  • catalysts of the type described in US5364986 are not resistant to the process conditions found in some commercial hydrogenolysis processes and may become weak during use, leading to a change in the structure of the catalyst bed.
  • US5475159 describes a process for the direct hydrogenation of methyl esters in the presence of a catalyst comprising a copper compound, a zinc compound and at least one compound selected from the group consisting of aluminium, zirconium, magnesium, a rare earth and mixtures thereof. It is an object of the invention to provide a catalyst and process which avoids some of the problems found in the prior art catalysts and processes.
  • a catalyst comprising copper or a compound thereof, zinc or a compound thereof and a material containing silica and alumina.
  • a process according to the invention for the hydrogenation or dehydrogenation of an organic feedstock comprises the steps of providing a feed stream comprising a hydrogenatable or dehydrogenatable organic feedstock, providing a catalyst comprising copper or a compound thereof, zinc or a compound thereof and a material containing silica and alumina and contacting said feed stream with said catalyst.
  • the process may be a hydrogenation process.
  • hydrogenation we include hydrogenation of a carbonyl group, hydrogenolysis of an ester, hydrogenolysis of a carboxylic acid, hydrogenolysis of an alcohol, especially a polyol such as glycerol, and hydrogenation of carbon monoxide to form hydrocarbon products.
  • a process, according to the invention, for producing an alcohol comprises contacting a feedstock comprising an organic aldehyde, ketone, an ester of a carboxylic acid or a carboxylic acid with hydrogen in the presence of a catalyst comprising copper or a compound thereof, zinc or a compound thereof and a material containing silica and alumina.
  • Hydrogenation processes according to the invention may comprise a process for the hydrogenation of organic aldehydes to alcohols, for example C3 - C32 alcohols, for example in the production of oxo- alcohols or glycols.
  • Alcohols formed in such processes may include short chain alcohols, e.g. containing from 3 - 10 C atoms, and longer chain alcohols, such as fatty alcohols, e.g. containing 12 - 22 C atoms.
  • Hydrogenation processes according to the invention may comprise the hydrogenation of esters, mono-, di- or tri-carboxylic acid compounds for the production of alcohols, diols or polyols, such as the production of 1 ,6-hexane diol from adipic acid for example.
  • Hydrogenolysis of an ester of a carboxylic acid or of a carboxylic acid comprises contacting an ester of a carboxylic acid and/or a carboxylic acid with hydrogen in the presence of a catalyst.
  • a dehydrogenation process of the invention may comprise the step of contacting an alcohol with a catalyst to form an aldehyde, ketone or an ester.
  • the ester of a carboxylic acid may be an ester of a fatty acid, i.e. a carboxylic acid containing from 12 to 32 C atoms.
  • the ester may be an ester of a carboxylic acid containing from 6 to 32 carbon atoms.
  • the carboxylic acid residue of the ester may contain from 6 to 32 carbon atoms.
  • the carboxylic acid residue of the ester may contain from 6 to 22 carbon atoms, for example 10 - 18 C atoms.
  • the ester may contain the residue of an alcohol containing from 1 to 32 carbon atoms.
  • the ester may be an ester of a lower alkyl alcohol, such as a methyl, ethyl or propyl ester or it may be an ester of a higher alcohol or fatty alcohol, containing from 12 to 32 C atoms.
  • the ester may comprise a wax ester, i.e. an ester of a fatty alcohol and a fatty acid.
  • the ester may contain the residue of an alcohol containing from 1 to 22 carbon atoms, for example 1 - 18 C atoms.
  • the ester may be present in a feedstock comprising a mixture of more than one ester.
  • the feedstock may further comprise other compounds such as carboxylic acids and water, for example.
  • the process may be a hydrogenation process or a hydrogenolysis process.
  • the alcohol produced in the process for the hydrogenolysis of an ester may be a fatty alcohol.
  • the alcohol may comprise an alcohol containing from 6 to 32 carbon atoms.
  • the alcohol may comprise an alcohol containing from 8 to 32 carbon atoms.
  • the alcohol produced from the ester may contain the same number of carbon atoms as the carboxylic acid residue of the ester.
  • dodecanol ( ⁇ 3 ( ⁇ 2 ) ⁇ ) may be produced by a hydrogenolysis process of the invention when the ester is methyl laurate (CH 3 (CH2)ioC(0)0-CI-l3) .
  • the process may be a liquid-phase process. The process may alternatively take place in the gas phase.
  • the process may take place in a batch reactor, such as a stirred tank or an autoclave.
  • the process may be a continuous process, wherein a liquid phase feedstock containing the organic feedstock, such as an ester of a carboxylic acid, is caused to flow through a bed of catalyst particles.
  • the liquid hourly space velocity (LHSV) may be from 0.1 to 10 hr 1 , for example from 0.1 to 3 hr 1 .
  • Hydrogen may be fed to the reactor as a gas, optionally mixed with at least one other gas such as nitrogen. Hydrogen may be dissolved in the liquid-phase feed prior to, or during, the process of feeding the liquid-phase feedstock to the reactor.
  • the hydrogen pressure may be in the range from 1 - 300 bar gauge.
  • the hydrogen pressure may be in the range from 200 - 300 barg. Alternatively a lower hydrogen pressure may be used, in the range 1 - 200 barg.
  • the reaction conditions to be used depend upon the nature of the reaction and the starting materials used.
  • the reaction may take place at a temperature of at least 120°C.
  • a suitable temperature may be within the range from 150 - 250°C.
  • the catalyst comprises copper or a compound thereof.
  • the copper is present as copper metal.
  • Catalysts in that form may be activated by treatment to convert the less active compound to the active metal by reduction.
  • the treatment conventionally involves contact with a hydrogen-containing gas at elevated temperature and may therefore be carried out in the reactor to be used for hydrogenation.
  • the catalyst contains active metallic copper although there is usually also some unreduced copper present since the reduction process is rarely 100% efficient.
  • Catalysts may be supplied in a reduced form; however such catalysts must be protected from contact with an oxygen-containing gas because they are pyrophoric.
  • the protection methods include encapsulation, e.g. in a fat or wax material, and passivation.
  • passivation When the catalyst is passivated, a proportion of the active copper metal is reacted to form passivating compounds such as an oxide or carbonate under controlled conditions.
  • passivated catalyst can then be handled and the passivating compounds can be reduced on contact with hydrogen.
  • the catalyst of the invention and used in the process of the invention therefore comprises copper metal and/or a compound of copper which is reducible to copper metal.
  • the compound of copper is preferably copper oxide.
  • the catalyst may comprise from 10 - 70% of copper, by weight, calculated as copper metal.
  • the catalyst may comprise 20 - 60% by weight of copper (calculated as copper metal).
  • the catalyst may contain 25 - 45% by weight of copper (calculated as copper metal).
  • the catalyst further comprises a compound of zinc.
  • the catalyst preferably contains 10 - 70% by weight of zinc (calculated as zinc metal).
  • the catalyst may comprise 20 - 60% by weight of zinc (calculated as zinc metal).
  • the catalyst may contain 25 - 45% by weight of zinc (calculated as zinc metal).
  • the zinc is preferably present in the catalyst as zinc oxide.
  • the catalyst may contain up to about 85% of zinc oxide, by weight.
  • the catalyst contains a material containing silica and alumina.
  • the material containing silica and alumina may be a structural promoter.
  • structural promoter we mean a material which affects, especially improves, the mechanical properties of the catalyst. The improvement in mechanical properties may have the effect of improving the activity of the catalyst in the reaction, through promotion of resistance of the catalyst to the feedstock, leading to retention of mechanical properties.
  • the material containing silica and alumina maybe a catalyst support. A catalyst support is effective in improving the distribution and form of the catalytically active metals in the finished catalyst.
  • the material containing silica and alumina may affect the catalytic properties of the catalyst.
  • the catalyst may contain from 1 to 40%, preferably 5 - 20%, by weight of the material containing silica and alumina.
  • the material containing silica and alumina may contain from 1 % to 70% of silica by weight and from 10% to 99% of alumina by weight. In some embodiments the material containing silica and alumina may contain from 1 % to 40% of silica by weight and from 60% to 99% of alumina by weight.
  • the material containing silica and alumina may contain other elements or compounds, such as magnesium, for example, which occurs in some clay minerals,
  • the alumina in the material containing silica and alumina may be in the form of a hydrated alumina, e.g.
  • a precursor to the catalyst of the invention contains a hydrated form of alumina and the catalyst formed from the precursor contains a less-hydrated form of alumina.
  • the catalyst formed from a precursor containing hydrated alumina may contain a transition alumina.
  • the transition alumina may comprise gamma, theta or delta alumina.
  • Transition aluminas are formed when a hydrated or partially hydrated alumina is heated (i.e. calcined) at a temperature in excess of about 300 °C for a time sufficient to form a transition form of alumina.
  • Calcination is normally continued for at least one hour and may take several hours.
  • materials containing silica and alumina which are suitable for use in the catalysts of the present invention or their precursors include silica-doped alumina materials and clays, e.g. kaolin, montmorillonite, attapulgite.
  • the material containing silica and alumina may contain, comprise or consist of
  • aluminosilicates species For the purpose of this patent application, we define aluminosilicates as aluminium silicates in which some of the Si 4+ ions in silicates are replaced by Al 3+ ions and in which the charge is balanced by other positive ions.
  • Zeolites are microporous crystalline aluminosilicates having an ordered pore structure.
  • the material containing silica and alumina does not consist of a zeolite.
  • the material containing silica and alumina contains, comprises or consists of aluminosilicates species, they are non-zeolitic aluminosilicates species. It is not intended that the catalyst of the invention contains a zeolite.
  • the catalyst does not comprise or contain a zeolite.
  • the catalyst used in the process of the invention may be formed from a catalyst precursor comprising a copper compound, a zinc compound and a material containing silica and alumina.
  • the formation of a catalyst for use in the invention from a catalyst precursor may include the processes of calcination, reduction, and/or shaping. Shaping processes may include tabletting, extrusion and/or granulation.
  • the catalyst may contain ingredients such as lubricants, pore-formers, pelleting aids etc. For example the catalyst may contain up to about 5% by weight of graphite as a pelleting aid.
  • the catalyst used in the invention may be made by conventional methods used in catalyst manufacturing.
  • a catalyst precursor may, for example, be made by forming a solution of a soluble compound of copper and a soluble compound of zinc and then causing the precipitation of insoluble compounds of copper and zinc by adding a precipitating agent.
  • the material containing silica and alumina may be present in the solution before the precipitation of the copper and zinc compounds.
  • the material containing silica and alumina may be mixed with the precipitated copper and zinc compounds.
  • a copper or a compound thereof, a zinc compound and the material containing silica and alumina may be mixed together to form the catalyst or a precursor thereof.
  • a precursor to the catalyst comprising the material containing silica and alumina, a copper compound and a compound of zinc may be calcined for at least 30 minutes at a temperature of at least 400 °C.
  • the calcination temperature may be at least 500 °C.
  • the catalyst may take the form of particles having a minimum dimension of 0.5 mm.
  • catalyst particles suitable for use in a fixed catalyst bed may take the form of regular shapes such as spheres, cylinders, tablets, rings, wheels, saddles, lobed cylinders or irregular shapes such as granules.
  • Such catalyst shapes may be prepared by various methods which are known to the skilled person.
  • the catalyst precursor may be shaped into the desired shape, e.g. spheres, tablets, cylinders, lobed cylinders, rings or granules, before or after a calcination step, if a calcination step is carried out.
  • the catalyst precursor may be reduced so that at least some metallic copper is formed from the copper compound.
  • Reduction may be carried out by contacting the catalyst precursor with a hydrogen- containing gas at a temperature of at least 100 °C.
  • Reduction may take place in a chemical reactor for carrying out the process of the invention.
  • Reduction of the catalyst precursor may be carried out by the manufacturer of the catalyst after the calcination step, if used.
  • Reduced catalysts may be passivated or encapsulated. Storage and transport of reduced catalysts may take place under an oxygen-free atmosphere.
  • Example 1 Preparation of a Catalyst according to the Invention A mixed aqueous solution (1 1 .5 litre) of copper nitrate and zinc nitrate and nitric acid, containing 37.5 g l of copper and 40g/l of zinc, was heated to 90 °C. An aqueous solution of sodium carbonate (20 litres, 106 g/l) was heated to 90 °C. 125 g of a silica-alumina material containing 10% silica was slurried in 11 litres of water and heated in a vessel.
  • the mixed Cu/Zn solution and Na 2 C0 3 solutions were then added to the slurry at 90°C over 30 minutes, with agitation.
  • the solids were filtered, washed with deionised water and re-slurried in deionised water.
  • the wet filter cake was formed into noodles and dried for 12 hours at 90 °C.
  • the dried solids were calcined at 590 °C for 2 hours, blended with pelleting aids and pelleted to form cylinders (3.2mm x 3.2mm) of catalyst according to the invention.
  • the dried and calcined material has a composition 45% CuO, 45% ZnO, and 10% silica-alumina, i.e. excluding water, pelleting aids etc.
  • a catalyst was made by the method described in Example 1 but using a commercial amorphous silica support instead of the silica-alumina.
  • a catalyst was made by the method described in Example 1 but using an alumina material pre- precipitated from a solution of aluminium nitrate instead of the silica-alumina.
  • a catalyst was made by the method described in Example 1 but using a silica-alumina material containing 20% silica.
  • a catalyst was made by the general method described in Example 1 in which the proportion of Cu and Zn was changed to 37.5 g/L of Cu and 17 g/L of Zn, resulting in a catalyst containing 63% CuO, 27% ZnO, and 10% of the silica-alumina, excluding water, pelleting aids etc.
  • Comparative Example 6 was a commercially available copper chromite catalyst in the form of cylinders having a particle size of 3mm diameter x 3mm length.
  • a catalyst was made by the method described in Example 1 but the dried solids formed by drying the wet filter cake were calcined at 700 °C for 2 hours instead of at 590 °C.
  • a catalyst was made by the method described in Example 1 except that the precipitation step of adding the mixed Cu/Zn solution and Na 2 C0 3 solutions to the heated slurry was carried out at 70 °C instead of 90 °C.
  • Example 9 Preparation of a Catalyst according to the Invention A catalyst was made by the method described in Example 1 except that following the addition of the mixed Cu/Zn solution and Na 2 C0 3 solutions to the heated slurry over 30 minutes, the mixture was held at 90 °C for 60 minutes prior to filtration.
  • a catalyst was made by the method described in Example 1 but the dried solids formed by drying the wet filter cake were calcined at 500 °C for 2 hours instead of at 590 °C.
  • Example 1 1 Process according to the invention
  • the catalysts were tested in a stirred batch autoclave at 100 bar hydrogen and 220 °C. 12 ml of catalyst was used each time along with 500 ml of methyl laurate as feedstock. The catalysts were reduced in the reactor, prior to the addition of the methyl laurate feed, for 10 hours at 240 °C in a flow of 5% hydrogen in nitrogen. A sample of the feedstock was taken and samples were also taken periodically throughout the duration of the reaction. After 24 hours online the reactor was cooled, depressurised and the catalyst and feedstock were discharged. The samples of the liquid reaction mixture were analysed by gas chromatography. Table 1 shows, for each reaction mixture, the % conversion (calculated from 100 - wt % of methyl ester in product mixture) and wt% of alcohol in the reaction mixture after at least 20 hours online.
  • Catalyst pellets were tested for horizontal crush strength using a commercial compression testing machine (Model CT6 available from Engineering Systems (Nottm) Ltd) to measure the force that must be applied in order to break the catalyst pellet.
  • the pellets were tested using a 50 kg load cell with flat plattens and a speed of 22 mm/minute. 20 pellets were analysed for each sample and the mean horizontal crush strength was calculated.
  • Example 13 Catalyst according to the invention
  • a catalyst was made by the method described in Example 1 but using an attapulgite clay (65% silica) as the silica-alumina material.
  • Example 1 and Example 13 were tested (separately) in a fixed bed reaction as follows.
  • a catalyst bed was formed from 80 ml of the catalyst pellets in an oil-heated, jacketed tubular reactor (22mm i.d, 850mm length), supplied with hydrogen and nitrogen gas feed and means to feed liquid methyl ester feedstock (C12 - C18 methyl ester feedstock derived from palm kernel oil) to the top of the catalyst bed.
  • the temperatures reported in this example refer to the temperature of the circulating heating oil.
  • the catalyst was reduced in the reactor in a flowing stream of 5% hydrogen in nitrogen for 18 hours as the temperature was raised to 240 °C. The temperature was then adjusted to the desired reaction temperature and allowed to equilibrate under nitrogen.
  • Example 1 and Comparative Example 6 were tested (separately) in a fixed bed reaction as follows.
  • a catalyst bed was formed from 100 ml of the catalyst pellets in an electrically heated tubular reactor (28mm i.d, 900mm length), supplied with hydrogen and nitrogen gas feed and means to feed liquid methyl ester feedstock (C12 - C18 methyl ester feedstock derived from palm kernel oil) to the top of the catalyst bed.
  • the temperature of the catalyst bed was monitored using thermocouples positioned inside a thermowell within the catalyst bed.
  • the catalyst was reduced in the reactor in a flowing stream of 2% hydrogen in nitrogen for 18 hours as the temperature was raised to 240 °C. The temperature was then adjusted to the desired reaction temperature and allowed to equilibrate under nitrogen.
  • Example 16 Use of catalysts in fixed bed hydrogenation of aldehyde
  • Example 1 , 4 and 5 were tested (separately) in a fixed bed reaction as follows.
  • a catalyst bed was formed from 250 ml of the catalyst pellets in a tubular reactor supplied with hydrogen and nitrogen gas feed and means to feed a liquid feedstock comprising a 20wt% solution of butanal in butanol to the top of the catalyst bed, with a recycle of the reaction product.
  • the catalyst was reduced in the reactor in a flowing stream of 1 % hydrogen in nitrogen for 35 hours at 210 °C.
  • the temperature was then adjusted to the desired reaction temperature and the butanal feed solution and hydrogen were fed to the catalyst bed, with partial recycle of the product stream.
  • the same reaction conditions were used for each catalyst. Samples were taken periodically. Samples of the feedstock and of the reactor outlet were analysed by gas chromatography. The results in Table 4 are from samples taken during stable operation of the process.
  • Example 17 Use of catalysts in batch hydrogenation of aldehyde
  • the catalysts from Example 1 and 6 were tested in a stirred batch autoclave at 20 bar hydrogen and 140 °C. 12 ml of catalyst was used each time along with 500 ml of a 20% (by volume) solution of butanal in butanol (i.e. 100 ml of butanal mixed with 400 ml of butanol). The catalysts were reduced in the reactor, prior to the addition of the feed, for 10 hours at 240 °C in a flow of 5% hydrogen in nitrogen. A sample of the feedstock was taken and samples were also taken periodically throughout the duration of the reaction and analysed by gas chromatography. The reaction was run until conversion reached 99.98%. The results in Table 5 show the composition of the sample taken at that final conversion.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
  • Catalysts (AREA)

Abstract

A catalyst comprising copper or a compound thereof, zinc or a compound thereof and a material containing silica and alumina is described and used in a hydrogenation or dehydrogenation process, e.g. for producing an alcohol by contacting an ester of a carboxylic acid with hydrogen in the presence of the catalyst.

Description

Catalyst and Process
The present invention concerns a catalyst containing copper and the use of such a catalyst in catalytic processes.
Fatty alcohols are useful feedstocks, in particular for the production of surfactants and detergents. They may be produced in a variety of ways. One process yielding fatty alcohols is the hydrogenolysis of methyl esters of fatty acids (FAMEs) which are usually derived from triglycerides found in animal fats and vegetable oils. The hydrogenolysis or hydrogenation of FAME feedstocks using catalysts containing copper and chromium has been described in the prior art, for example in US2091800. WO91/04789 describes an acid-resistant copper chromite catalyst material containing promoter metal compounds as well as colloidal silicic acid, and a process for their production and use for direct fixed-bed hydration of fatty acids to produce fatty alcohols of appropriate chain-length. It is, however, desirable to avoid the use of chromium compounds in this process so that contact with toxic chromium compounds is avoided in the manufacture and use of the catalyst and also to ensure that the products are free of chromium.
US5364986 describes the production of C6-22 fatty alcohols by a process which comprises contacting a triglyceride with hydrogen in the presence of a copper-zinc catalyst and in a reaction zone. We have found, however, that catalysts of the type described in US5364986 are not resistant to the process conditions found in some commercial hydrogenolysis processes and may become weak during use, leading to a change in the structure of the catalyst bed. US5475159 describes a process for the direct hydrogenation of methyl esters in the presence of a catalyst comprising a copper compound, a zinc compound and at least one compound selected from the group consisting of aluminium, zirconium, magnesium, a rare earth and mixtures thereof. It is an object of the invention to provide a catalyst and process which avoids some of the problems found in the prior art catalysts and processes.
According to the invention we provide a catalyst comprising copper or a compound thereof, zinc or a compound thereof and a material containing silica and alumina.
A process according to the invention for the hydrogenation or dehydrogenation of an organic feedstock comprises the steps of providing a feed stream comprising a hydrogenatable or dehydrogenatable organic feedstock, providing a catalyst comprising copper or a compound thereof, zinc or a compound thereof and a material containing silica and alumina and contacting said feed stream with said catalyst.
The process may be a hydrogenation process. By hydrogenation, we include hydrogenation of a carbonyl group, hydrogenolysis of an ester, hydrogenolysis of a carboxylic acid, hydrogenolysis of an alcohol, especially a polyol such as glycerol, and hydrogenation of carbon monoxide to form hydrocarbon products. A process, according to the invention, for producing an alcohol comprises contacting a feedstock comprising an organic aldehyde, ketone, an ester of a carboxylic acid or a carboxylic acid with hydrogen in the presence of a catalyst comprising copper or a compound thereof, zinc or a compound thereof and a material containing silica and alumina.
Hydrogenation processes according to the invention may comprise a process for the hydrogenation of organic aldehydes to alcohols, for example C3 - C32 alcohols, for example in the production of oxo- alcohols or glycols. Alcohols formed in such processes may include short chain alcohols, e.g. containing from 3 - 10 C atoms, and longer chain alcohols, such as fatty alcohols, e.g. containing 12 - 22 C atoms. Hydrogenation processes according to the invention may comprise the hydrogenation of esters, mono-, di- or tri-carboxylic acid compounds for the production of alcohols, diols or polyols, such as the production of 1 ,6-hexane diol from adipic acid for example. Hydrogenolysis of an ester of a carboxylic acid or of a carboxylic acid comprises contacting an ester of a carboxylic acid and/or a carboxylic acid with hydrogen in the presence of a catalyst.
A dehydrogenation process of the invention may comprise the step of contacting an alcohol with a catalyst to form an aldehyde, ketone or an ester.
According to a particular embodiment of the invention, a hydrogenolysis process, according to the invention, for producing an alcohol comprises contacting an ester of a carboxylic acid with hydrogen in the presence of a catalyst comprising copper or a compound thereof, zinc or a compound thereof and a material containing silica and alumina. The ester of a carboxylic acid may be an ester of a fatty acid, i.e. a carboxylic acid containing from 12 to 32 C atoms. The ester may be an ester of a carboxylic acid containing from 6 to 32 carbon atoms. In other words, the carboxylic acid residue of the ester may contain from 6 to 32 carbon atoms. The carboxylic acid residue of the ester may contain from 6 to 22 carbon atoms, for example 10 - 18 C atoms. The ester may contain the residue of an alcohol containing from 1 to 32 carbon atoms. For example, the ester may be an ester of a lower alkyl alcohol, such as a methyl, ethyl or propyl ester or it may be an ester of a higher alcohol or fatty alcohol, containing from 12 to 32 C atoms. The ester may comprise a wax ester, i.e. an ester of a fatty alcohol and a fatty acid. The ester may contain the residue of an alcohol containing from 1 to 22 carbon atoms, for example 1 - 18 C atoms. The ester may be present in a feedstock comprising a mixture of more than one ester. The feedstock may further comprise other compounds such as carboxylic acids and water, for example.
The process may be a hydrogenation process or a hydrogenolysis process. The alcohol produced in the process for the hydrogenolysis of an ester may be a fatty alcohol. The alcohol may comprise an alcohol containing from 6 to 32 carbon atoms. The alcohol may comprise an alcohol containing from 8 to 32 carbon atoms. The alcohol produced from the ester may contain the same number of carbon atoms as the carboxylic acid residue of the ester. For example, dodecanol (ΟΗ3(ΟΗ2)ιιΟΗ) may be produced by a hydrogenolysis process of the invention when the ester is methyl laurate (CH3(CH2)ioC(0)0-CI-l3) . The process may be a liquid-phase process. The process may alternatively take place in the gas phase. The process may take place in a batch reactor, such as a stirred tank or an autoclave. Alternatively the process may be a continuous process, wherein a liquid phase feedstock containing the organic feedstock, such as an ester of a carboxylic acid, is caused to flow through a bed of catalyst particles. The liquid hourly space velocity (LHSV) may be from 0.1 to 10 hr 1 , for example from 0.1 to 3 hr 1. Hydrogen may be fed to the reactor as a gas, optionally mixed with at least one other gas such as nitrogen. Hydrogen may be dissolved in the liquid-phase feed prior to, or during, the process of feeding the liquid-phase feedstock to the reactor. The hydrogen pressure may be in the range from 1 - 300 bar gauge. In a typical reaction, the hydrogen pressure may be in the range from 200 - 300 barg. Alternatively a lower hydrogen pressure may be used, in the range 1 - 200 barg. The reaction conditions to be used depend upon the nature of the reaction and the starting materials used. The reaction may take place at a temperature of at least 120°C. When the process of the invention is a process for the hydrogenolysis of a fatty ester, for example, a suitable temperature may be within the range from 150 - 250°C.
The catalyst comprises copper or a compound thereof. In the active form of the catalyst, the copper is present as copper metal. As the skilled person will be aware, it is common to provide catalysts in which the active metal is present as a compound which is catalytically inactive or less active than the metal. Catalysts in that form may be activated by treatment to convert the less active compound to the active metal by reduction. The treatment conventionally involves contact with a hydrogen-containing gas at elevated temperature and may therefore be carried out in the reactor to be used for hydrogenation. After activation the catalyst contains active metallic copper although there is usually also some unreduced copper present since the reduction process is rarely 100% efficient. Catalysts may be supplied in a reduced form; however such catalysts must be protected from contact with an oxygen-containing gas because they are pyrophoric. The protection methods include encapsulation, e.g. in a fat or wax material, and passivation. When the catalyst is passivated, a proportion of the active copper metal is reacted to form passivating compounds such as an oxide or carbonate under controlled conditions. The passivated catalyst can then be handled and the passivating compounds can be reduced on contact with hydrogen. The catalyst of the invention and used in the process of the invention therefore comprises copper metal and/or a compound of copper which is reducible to copper metal. The compound of copper is preferably copper oxide.
The catalyst may comprise from 10 - 70% of copper, by weight, calculated as copper metal. The catalyst may comprise 20 - 60% by weight of copper (calculated as copper metal). In particular, the catalyst may contain 25 - 45% by weight of copper (calculated as copper metal).
The catalyst further comprises a compound of zinc. The catalyst preferably contains 10 - 70% by weight of zinc (calculated as zinc metal). The catalyst may comprise 20 - 60% by weight of zinc (calculated as zinc metal). In particular, the catalyst may contain 25 - 45% by weight of zinc (calculated as zinc metal). The zinc is preferably present in the catalyst as zinc oxide. The catalyst may contain up to about 85% of zinc oxide, by weight.
The catalyst contains a material containing silica and alumina. The material containing silica and alumina may be a structural promoter. By "structural promoter" we mean a material which affects, especially improves, the mechanical properties of the catalyst. The improvement in mechanical properties may have the effect of improving the activity of the catalyst in the reaction, through promotion of resistance of the catalyst to the feedstock, leading to retention of mechanical properties. The material containing silica and alumina maybe a catalyst support. A catalyst support is effective in improving the distribution and form of the catalytically active metals in the finished catalyst. The material containing silica and alumina may affect the catalytic properties of the catalyst.
The catalyst may contain from 1 to 40%, preferably 5 - 20%, by weight of the material containing silica and alumina. The material containing silica and alumina may contain from 1 % to 70% of silica by weight and from 10% to 99% of alumina by weight. In some embodiments the material containing silica and alumina may contain from 1 % to 40% of silica by weight and from 60% to 99% of alumina by weight. The material containing silica and alumina may contain other elements or compounds, such as magnesium, for example, which occurs in some clay minerals, The alumina in the material containing silica and alumina may be in the form of a hydrated alumina, e.g. boehmite, or a transition alumina, i.e. a partially hydrated alumina such as gamma, theta or delta alumina. In one embodiment, a precursor to the catalyst of the invention contains a hydrated form of alumina and the catalyst formed from the precursor contains a less-hydrated form of alumina. The catalyst formed from a precursor containing hydrated alumina may contain a transition alumina. The transition alumina may comprise gamma, theta or delta alumina.
Transition aluminas are formed when a hydrated or partially hydrated alumina is heated (i.e. calcined) at a temperature in excess of about 300 °C for a time sufficient to form a transition form of alumina.
Calcination is normally continued for at least one hour and may take several hours. Examples of materials containing silica and alumina which are suitable for use in the catalysts of the present invention or their precursors include silica-doped alumina materials and clays, e.g. kaolin, montmorillonite, attapulgite. The material containing silica and alumina may contain, comprise or consist of
aluminosilicates species. For the purpose of this patent application, we define aluminosilicates as aluminium silicates in which some of the Si4+ ions in silicates are replaced by Al3+ ions and in which the charge is balanced by other positive ions. Zeolites are microporous crystalline aluminosilicates having an ordered pore structure. The material containing silica and alumina does not consist of a zeolite. When the material containing silica and alumina contains, comprises or consists of aluminosilicates species, they are non-zeolitic aluminosilicates species. It is not intended that the catalyst of the invention contains a zeolite. Therefore in preferred embodiments of the catalyst of the invention, the catalyst does not comprise or contain a zeolite. The catalyst used in the process of the invention may be formed from a catalyst precursor comprising a copper compound, a zinc compound and a material containing silica and alumina.
The formation of a catalyst for use in the invention from a catalyst precursor may include the processes of calcination, reduction, and/or shaping. Shaping processes may include tabletting, extrusion and/or granulation. The catalyst may contain ingredients such as lubricants, pore-formers, pelleting aids etc. For example the catalyst may contain up to about 5% by weight of graphite as a pelleting aid.
The catalyst used in the invention may be made by conventional methods used in catalyst manufacturing. A catalyst precursor may, for example, be made by forming a solution of a soluble compound of copper and a soluble compound of zinc and then causing the precipitation of insoluble compounds of copper and zinc by adding a precipitating agent. The material containing silica and alumina may be present in the solution before the precipitation of the copper and zinc compounds. Alternatively the material containing silica and alumina may be mixed with the precipitated copper and zinc compounds. As a further alternative, a copper or a compound thereof, a zinc compound and the material containing silica and alumina may be mixed together to form the catalyst or a precursor thereof.
A precursor to the catalyst comprising the material containing silica and alumina, a copper compound and a compound of zinc may be calcined for at least 30 minutes at a temperature of at least 400 °C. The calcination temperature may be at least 500 °C.
The catalyst may take the form of particles having a minimum dimension of 0.5 mm. For example, catalyst particles suitable for use in a fixed catalyst bed may take the form of regular shapes such as spheres, cylinders, tablets, rings, wheels, saddles, lobed cylinders or irregular shapes such as granules. Such catalyst shapes may be prepared by various methods which are known to the skilled person. The catalyst precursor may be shaped into the desired shape, e.g. spheres, tablets, cylinders, lobed cylinders, rings or granules, before or after a calcination step, if a calcination step is carried out.
The catalyst precursor may be reduced so that at least some metallic copper is formed from the copper compound. Reduction may be carried out by contacting the catalyst precursor with a hydrogen- containing gas at a temperature of at least 100 °C. Reduction may take place in a chemical reactor for carrying out the process of the invention. Reduction of the catalyst precursor may be carried out by the manufacturer of the catalyst after the calcination step, if used. Reduced catalysts may be passivated or encapsulated. Storage and transport of reduced catalysts may take place under an oxygen-free atmosphere.
The catalyst and process of the invention will be further described in the following examples. Example 1 : Preparation of a Catalyst according to the Invention A mixed aqueous solution (1 1 .5 litre) of copper nitrate and zinc nitrate and nitric acid, containing 37.5 g l of copper and 40g/l of zinc, was heated to 90 °C. An aqueous solution of sodium carbonate (20 litres, 106 g/l) was heated to 90 °C. 125 g of a silica-alumina material containing 10% silica was slurried in 11 litres of water and heated in a vessel. The mixed Cu/Zn solution and Na2C03 solutions were then added to the slurry at 90°C over 30 minutes, with agitation. The solids were filtered, washed with deionised water and re-slurried in deionised water. The wet filter cake was formed into noodles and dried for 12 hours at 90 °C. The dried solids were calcined at 590 °C for 2 hours, blended with pelleting aids and pelleted to form cylinders (3.2mm x 3.2mm) of catalyst according to the invention. The dried and calcined material has a composition 45% CuO, 45% ZnO, and 10% silica-alumina, i.e. excluding water, pelleting aids etc.
Comparative Example 2: Preparation of a Comparative Catalyst
A catalyst was made by the method described in Example 1 but using a commercial amorphous silica support instead of the silica-alumina.
Comparative Example 3: Preparation of a Comparative Catalyst
A catalyst was made by the method described in Example 1 but using an alumina material pre- precipitated from a solution of aluminium nitrate instead of the silica-alumina.
Example 4: Preparation of a Catalyst according to the Invention
A catalyst was made by the method described in Example 1 but using a silica-alumina material containing 20% silica.
Example 5: Preparation of a Catalyst according to the Invention
A catalyst was made by the general method described in Example 1 in which the proportion of Cu and Zn was changed to 37.5 g/L of Cu and 17 g/L of Zn, resulting in a catalyst containing 63% CuO, 27% ZnO, and 10% of the silica-alumina, excluding water, pelleting aids etc.
Comparative Example 6 was a commercially available copper chromite catalyst in the form of cylinders having a particle size of 3mm diameter x 3mm length.
Example 7: Preparation of a Catalyst according to the Invention
A catalyst was made by the method described in Example 1 but the dried solids formed by drying the wet filter cake were calcined at 700 °C for 2 hours instead of at 590 °C.
Example 8: Preparation of a Catalyst according to the Invention
A catalyst was made by the method described in Example 1 except that the precipitation step of adding the mixed Cu/Zn solution and Na2C03 solutions to the heated slurry was carried out at 70 °C instead of 90 °C.
Example 9: Preparation of a Catalyst according to the Invention A catalyst was made by the method described in Example 1 except that following the addition of the mixed Cu/Zn solution and Na2C03 solutions to the heated slurry over 30 minutes, the mixture was held at 90 °C for 60 minutes prior to filtration.
Example 10: Preparation of a Catalyst according to the Invention
A catalyst was made by the method described in Example 1 but the dried solids formed by drying the wet filter cake were calcined at 500 °C for 2 hours instead of at 590 °C.
Example 1 1 : Process according to the invention
The catalysts were tested in a stirred batch autoclave at 100 bar hydrogen and 220 °C. 12 ml of catalyst was used each time along with 500 ml of methyl laurate as feedstock. The catalysts were reduced in the reactor, prior to the addition of the methyl laurate feed, for 10 hours at 240 °C in a flow of 5% hydrogen in nitrogen. A sample of the feedstock was taken and samples were also taken periodically throughout the duration of the reaction. After 24 hours online the reactor was cooled, depressurised and the catalyst and feedstock were discharged. The samples of the liquid reaction mixture were analysed by gas chromatography. Table 1 shows, for each reaction mixture, the % conversion (calculated from 100 - wt % of methyl ester in product mixture) and wt% of alcohol in the reaction mixture after at least 20 hours online.
Example 12: Crush strength tests
Catalyst pellets were tested for horizontal crush strength using a commercial compression testing machine (Model CT6 available from Engineering Systems (Nottm) Ltd) to measure the force that must be applied in order to break the catalyst pellet. The pellets were tested using a 50 kg load cell with flat plattens and a speed of 22 mm/minute. 20 pellets were analysed for each sample and the mean horizontal crush strength was calculated.
Samples of fresh catalyst were tested, and these results are indicated in Table 1 as "initial crush strength". Samples of these catalysts were then charged to a batch autoclave and reduced in the reactor at 240 °C in a flow of 5% hydrogen in nitrogen. 500 ml of methyl laurate was charged and contacted with the catalysts at 100 bar hydrogen and 220°C for 24 hours, The reactor was then cooled, the catalyst was discharged and the crush strength measured. For each test, the percentage difference between the mean crush strength of the fresh catalyst and that of the spent catalyst was calculated to give the % strength lost during the reaction. The results are shown in Table 1 .
The results show that, although the conversion and alcohol yield is high using the catalyst of Example 3, i.e. containing an alumina material instead of silica and alumina, the catalyst pellets were found to have lost 52% of their strength during the course of the reaction. This level of strength loss from catalyst pellets in a catalyst bed is unacceptable in practice, because the load on the catalyst pellets is likely to cause them to collapse, leading to a very significant loss of void space in the bed through which the reactants can pass. Whilst the silica-containing catalysts of Example 2 are strong, the conversion and alcohol yield are very low. The catalysts of the invention provide a high conversion and yield and an acceptable retention of strength during the reaction.
Table 1
Figure imgf000009_0001
Example 13: Catalyst according to the invention
A catalyst was made by the method described in Example 1 but using an attapulgite clay (65% silica) as the silica-alumina material.
Example 14: Use of catalysts in fixed bed hydrogenolysis
The catalysts of Example 1 and Example 13 were tested (separately) in a fixed bed reaction as follows. A catalyst bed was formed from 80 ml of the catalyst pellets in an oil-heated, jacketed tubular reactor (22mm i.d, 850mm length), supplied with hydrogen and nitrogen gas feed and means to feed liquid methyl ester feedstock (C12 - C18 methyl ester feedstock derived from palm kernel oil) to the top of the catalyst bed. The temperatures reported in this example refer to the temperature of the circulating heating oil. The catalyst was reduced in the reactor in a flowing stream of 5% hydrogen in nitrogen for 18 hours as the temperature was raised to 240 °C. The temperature was then adjusted to the desired reaction temperature and allowed to equilibrate under nitrogen. The reaction was begun by starting the feed of ester and hydrogen and the reaction conditions were set as shown in Table 2. The results in Table 2 are from samples taken after the reaction had been allowed to equilibrate for 8 hours at each set of reaction conditions. A fresh catalyst sample was used for each run at each pressure. Samples of the feedstock and of the reactor outlet were analysed by gas chromatography. Table 2
Figure imgf000010_0001
Example 15: Use of catalysts in fixed bed hydrogenolysis
The catalysts of Example 1 and Comparative Example 6 were tested (separately) in a fixed bed reaction as follows. A catalyst bed was formed from 100 ml of the catalyst pellets in an electrically heated tubular reactor (28mm i.d, 900mm length), supplied with hydrogen and nitrogen gas feed and means to feed liquid methyl ester feedstock (C12 - C18 methyl ester feedstock derived from palm kernel oil) to the top of the catalyst bed. The temperature of the catalyst bed was monitored using thermocouples positioned inside a thermowell within the catalyst bed. The catalyst was reduced in the reactor in a flowing stream of 2% hydrogen in nitrogen for 18 hours as the temperature was raised to 240 °C. The temperature was then adjusted to the desired reaction temperature and allowed to equilibrate under nitrogen. The reaction was begun by starting the feed of ester and hydrogen and the reaction conditions were set as shown in Table 3. The results in Table 2 are from samples taken after the reaction had been allowed to equilibrate for 16 hours at each set of reaction conditions. Samples of the feedstock and of the reactor outlet were analysed by gas chromatography. Table 3
Figure imgf000011_0001
Example 16: Use of catalysts in fixed bed hydrogenation of aldehyde
The catalysts of Example 1 , 4 and 5 were tested (separately) in a fixed bed reaction as follows. A catalyst bed was formed from 250 ml of the catalyst pellets in a tubular reactor supplied with hydrogen and nitrogen gas feed and means to feed a liquid feedstock comprising a 20wt% solution of butanal in butanol to the top of the catalyst bed, with a recycle of the reaction product. The catalyst was reduced in the reactor in a flowing stream of 1 % hydrogen in nitrogen for 35 hours at 210 °C. The temperature was then adjusted to the desired reaction temperature and the butanal feed solution and hydrogen were fed to the catalyst bed, with partial recycle of the product stream. The same reaction conditions were used for each catalyst. Samples were taken periodically. Samples of the feedstock and of the reactor outlet were analysed by gas chromatography. The results in Table 4 are from samples taken during stable operation of the process.
Table 4
Figure imgf000011_0002
Example 17: Use of catalysts in batch hydrogenation of aldehyde
The catalysts from Example 1 and 6 were tested in a stirred batch autoclave at 20 bar hydrogen and 140 °C. 12 ml of catalyst was used each time along with 500 ml of a 20% (by volume) solution of butanal in butanol (i.e. 100 ml of butanal mixed with 400 ml of butanol). The catalysts were reduced in the reactor, prior to the addition of the feed, for 10 hours at 240 °C in a flow of 5% hydrogen in nitrogen. A sample of the feedstock was taken and samples were also taken periodically throughout the duration of the reaction and analysed by gas chromatography. The reaction was run until conversion reached 99.98%. The results in Table 5 show the composition of the sample taken at that final conversion.
Table 5
Catalyst Time to 99.98% conversion butanol di-n-butyl ether n-butyl butyrate
(minutes) (wt%) (wt%) (wt%)
1 259 92.78 0.01 0.48
6 186 94.71 0.01 0.04

Claims

Claims
1 . A catalyst comprising copper or a compound thereof, zinc or a compound thereof and a material containing silica and alumina, said material not being a zeolite.
2. A catalyst according to claim 1 wherein the zinc is present in the catalyst as zinc oxide.
3. A catalyst according to claim 1 or claim 2 containing 10 - 70% by weight of zinc, calculated as zinc metal.
4. A catalyst according to any one of the preceding claims containing 10 - 70% by weight of copper, calculated as copper metal.
5. A catalyst according to any one of the preceding claims containing 1 - 40% by weight of the
material containing silica and alumina.
6. A catalyst according to any one of the preceding claims, wherein the material containing silica and alumina contains from 1 % to 70% of silica by weight and from 10% to 99% of alumina by weight.
7. A catalyst according to any one of the preceding claims, wherein the material containing silica and alumina comprises a clay.
8. A catalyst according to any one of the preceding claims, wherein the material containing silica and alumina comprises a silica-doped alumina containing from 1 - 40% of silica.
9. A process for the hydrogenation or dehydrogenation of an organic feedstock, comprising the steps of providing a feed stream comprising a hydrogenatable or dehydrogenatable organic feedstock, providing a catalyst comprising copper or a compound thereof, zinc or a compound thereof and a material containing silica and alumina and contacting said feed stream with said catalyst.
10. A process according to claim 9, wherein said process is a process for hydrogenation of a
carbonyl group, hydrogenolysis of an ester, hydrogenolysis of a carboxylic acid, hydrogenolysis of an alcohol or hydrogenation of carbon monoxide to form hydrocarbon.
1 1 . A process according to claim 10 for producing an alcohol comprising the step of contacting an ester of a carboxylic acid with hydrogen in the presence of a catalyst according to any one of the preceding claims.
12. A process according to claim 1 1 , wherein said process is a hydrogenolysis process and said feedstock comprises an ester of a carboxylic acid containing from 6 to 32 carbon atoms.
13. A process according to claim 10 for producing an alcohol comprising the step of contacting an aldehyde with hydrogen in the presence of a catalyst according to any one of the preceding claims.
14. A process according to claim 10, wherein said process is a hydrogenation process for the
production of an alcohol from a carboxylic acid.
15. A process according to any one of claims 9 to 14, which is a continuous process, wherein a liquid phase feedstock containing said organic feedstock is caused to flow through a bed of catalyst particles and said hydrogen is either present as a gas or dissolved in said liquid phase.
16. A process according to any one of claims 9 to 15, wherein said catalyst is a catalyst according to any one of claims 1 to 8.
PCT/GB2015/053090 2014-10-17 2015-10-16 Catalyst and process WO2016059431A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB1418475.8A GB201418475D0 (en) 2014-10-17 2014-10-17 Catalyst and process
GB1418475.8 2014-10-17

Publications (1)

Publication Number Publication Date
WO2016059431A1 true WO2016059431A1 (en) 2016-04-21

Family

ID=52013170

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2015/053090 WO2016059431A1 (en) 2014-10-17 2015-10-16 Catalyst and process

Country Status (2)

Country Link
GB (2) GB201418475D0 (en)
WO (1) WO2016059431A1 (en)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108579668A (en) * 2018-04-02 2018-09-28 东营市俊源石油技术开发有限公司 A kind of raw material naphtha and alkane product deoxidation adsorbent and preparation method
CN109225242A (en) * 2018-10-16 2019-01-18 南京工业大学 Composite nano-attapulgite ceramsite ozone catalyst and preparation method and application thereof
CN109569629A (en) * 2017-09-28 2019-04-05 中国石油化工股份有限公司 The method of catalyst for acetic acid ester through hydrogenation and preparation method thereof and acetic acid ester through hydrogenation alcohol
WO2019109629A1 (en) * 2017-12-06 2019-06-13 万华化学集团股份有限公司 CATALYST FOR PREPARING α-PHENYLETHANOL BY HYDROGENATION OF ACETOPHENONE, PREPARATION METHOD THEREOF AND APPLICATION THEREOF
GB2583185A (en) * 2019-04-15 2020-10-21 Johnson Matthey Plc Copper-containing catalysts
CN115414934A (en) * 2022-07-21 2022-12-02 朱义峰 Solid copper-based catalyst, preparation method and application thereof, hydrogen storage system for storing and releasing hydrogen and method for storing and releasing hydrogen
WO2024062209A1 (en) 2022-09-23 2024-03-28 Johnson Matthey Public Limited Company Copper-containing hydrogenation catalysts for the hydrogenolysis of esters

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5151259A (en) * 1989-12-22 1992-09-29 Haldor Topsoe A/S Modified crystalline aluminosilicate and method of preparing the same
US6048820A (en) * 1997-03-11 2000-04-11 Agency Of Industrial Of Sciences And Technology Copper-based catalyst and method for production thereof
CN1883798A (en) * 2005-06-22 2006-12-27 中国石油化工股份有限公司 Catalyst for direct preparation of dimethyl ether by using synthesis gas
CN101306369A (en) * 2008-07-11 2008-11-19 西南化工研究设计院 Catalyst for synthesizing methanol and preparing process thereof
CN101565358A (en) * 2009-05-22 2009-10-28 昆明理工大学 Method for directly synthesizing dimethyl ether by CO2 of slurry reactor
CN101733124A (en) * 2009-12-07 2010-06-16 中国科学院山西煤炭化学研究所 Catalyst for fixed bed hydrogenation for continuous production of fatty alcohol, preparation method thereof and application thereof
CN101934233A (en) * 2010-09-13 2011-01-05 浙江大学 Preparation method of catalyst Cu-ZnO/HZSM-5 for directly synthesizing dimethyl ether by using synthesis gas

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130237618A1 (en) * 2010-11-19 2013-09-12 Mitsui Chemicals, Inc. Process for producing methanol
SG11201408066UA (en) * 2012-06-04 2015-03-30 Mitsui Chemicals Inc Catalyst for methanol production, method of producing the same and process of methanol production

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5151259A (en) * 1989-12-22 1992-09-29 Haldor Topsoe A/S Modified crystalline aluminosilicate and method of preparing the same
US6048820A (en) * 1997-03-11 2000-04-11 Agency Of Industrial Of Sciences And Technology Copper-based catalyst and method for production thereof
CN1883798A (en) * 2005-06-22 2006-12-27 中国石油化工股份有限公司 Catalyst for direct preparation of dimethyl ether by using synthesis gas
CN101306369A (en) * 2008-07-11 2008-11-19 西南化工研究设计院 Catalyst for synthesizing methanol and preparing process thereof
CN101565358A (en) * 2009-05-22 2009-10-28 昆明理工大学 Method for directly synthesizing dimethyl ether by CO2 of slurry reactor
CN101733124A (en) * 2009-12-07 2010-06-16 中国科学院山西煤炭化学研究所 Catalyst for fixed bed hydrogenation for continuous production of fatty alcohol, preparation method thereof and application thereof
CN101934233A (en) * 2010-09-13 2011-01-05 浙江大学 Preparation method of catalyst Cu-ZnO/HZSM-5 for directly synthesizing dimethyl ether by using synthesis gas

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN109569629A (en) * 2017-09-28 2019-04-05 中国石油化工股份有限公司 The method of catalyst for acetic acid ester through hydrogenation and preparation method thereof and acetic acid ester through hydrogenation alcohol
CN109569629B (en) * 2017-09-28 2021-11-19 中国石油化工股份有限公司 Catalyst for acetic ester hydrogenation, preparation method thereof and method for preparing alcohol by acetic ester hydrogenation
WO2019109629A1 (en) * 2017-12-06 2019-06-13 万华化学集团股份有限公司 CATALYST FOR PREPARING α-PHENYLETHANOL BY HYDROGENATION OF ACETOPHENONE, PREPARATION METHOD THEREOF AND APPLICATION THEREOF
US11167280B2 (en) 2017-12-06 2021-11-09 Wanhua Chemical Group Co., Ltd. Catalyst for preparing α-phenylethanol by hydrogenation of acetophenone, preparation method thereof and application thereof
CN108579668A (en) * 2018-04-02 2018-09-28 东营市俊源石油技术开发有限公司 A kind of raw material naphtha and alkane product deoxidation adsorbent and preparation method
CN109225242A (en) * 2018-10-16 2019-01-18 南京工业大学 Composite nano-attapulgite ceramsite ozone catalyst and preparation method and application thereof
GB2583185A (en) * 2019-04-15 2020-10-21 Johnson Matthey Plc Copper-containing catalysts
GB2583185B (en) * 2019-04-15 2022-04-06 Johnson Matthey Plc Copper-containing catalysts
CN115414934A (en) * 2022-07-21 2022-12-02 朱义峰 Solid copper-based catalyst, preparation method and application thereof, hydrogen storage system for storing and releasing hydrogen and method for storing and releasing hydrogen
WO2024062209A1 (en) 2022-09-23 2024-03-28 Johnson Matthey Public Limited Company Copper-containing hydrogenation catalysts for the hydrogenolysis of esters

Also Published As

Publication number Publication date
GB201418475D0 (en) 2014-12-03
GB201518382D0 (en) 2015-12-02
GB2535567A (en) 2016-08-24

Similar Documents

Publication Publication Date Title
WO2016059431A1 (en) Catalyst and process
KR100628855B1 (en) Catalyst and Method for Hydrogenating Carbonyl Compounds
US4982020A (en) Process for direct hydrogenation of glyceride oils
US8518851B2 (en) Catalyst for the hydrogenation of unsaturated hydrocarbons and process for its preparation
JP4020430B2 (en) HYDROGENATION MOLDED CATALYST AND METHOD FOR PRODUCTION AND USE THEREOF
JP5154015B2 (en) Process for producing fatty acid alkyl ester and glycerin
CA2883573C (en) Copper-based catalyst precursor, method for manufacturing same, and hydrogenation method
KR101062146B1 (en) Ceramic catalyst used to prepare fatty acid alkyl ester and method for preparing high purity fatty acid alkyl ester using same
WO2010133619A1 (en) Process for producing fatty alcohols by hydrogenation of fatty acid triglycerides on a copper-containing heterogeneous catalyst
CN102712559A (en) Method for producing a supported hydrogenation catalyst having increased hydrogenation activity
KR100839292B1 (en) Method for Hydrogenating Carbonyl Compounds
KR20100138860A (en) Ceramic catalyst used for manufacturing fatty acid alkyl-group ester and method thereof using same
CN106536454B (en) Method for catalytic deoxygenation of natural oils and fats
JP5179107B2 (en) Catalyst for hydrogenation
JPH0657286A (en) Production of desulfurized oils or fats or desulfurized fatty acid ester
WO2010018405A1 (en) Chemical process and catalyst
Suyenty et al. Catalyst in basic oleochemicals
JP4037393B2 (en) Method for producing alcohol
Czarnecki et al. Preparation of Fixed-Bed RANEY® Catalysts and Their Evaluation
KR100989121B1 (en) Process for the continuous hydrogenation of unsaturated fatty alkyl ester
Ladebeck et al. Copper-Based Chromium-Free Hydrogenation Catalysts
PL222393B1 (en) Method for preparing propylene glycol out of glycerine
EP2970065A1 (en) Process for the selective production of propanols by hydrogenation of glycerol

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 15784135

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 15784135

Country of ref document: EP

Kind code of ref document: A1