Extruded Cu—Al—Mn hydrogenation catalyst
First Claim
1. A shaped catalyst body, comprising Cu in an amount in the range of 20-43 wt %, Al in an amount in the range of 20-40 wt %, and Mn in an amount in the range of 1-10 wt %, based on the total weight of the shaped catalyst body,wherein the shaped catalyst body has a pore volume in the range from 250 to 700 mm3/g, determined by mercury intrusion to DIN 66133, andwherein the shaped catalyst body has a monomodal pore radius distribution and wherein 50% or more of the pore volume is formed by pores having a pore radius in the range from 7 to 40 nm, the pore radius distribution and the pore volume being determined by mercury intrusion to DIN 66133, andwherein the shaped catalyst body in reduced form has a Cu metal surface, based on the amount of Cu in the shaped catalyst body, in the range from 20 m2/gCu to 60 m2/gCu, determined by N2O pulse chemisorption, andwherein the shaped catalyst body has a bulk density in the range from 300 to 800 g/L, determined to DIN ISO 903, andwherein the shaped catalyst body is in the form of an calcined extrudate and has a side crushing strength, based on the length of the extrudates, in the range from 5 to 40 N/mm, the side crushing strength being determined to DIN EN 1094-5,the shaped catalyst body being made by a process comprising(a) providing a copper, manganese and aluminum-containing dried precipitate,(b) forming a mixture of the dry precipitate of (a) with an aluminum-containing binder selected from the group consisting of boehmite and pseudoboehmite, the aluminum-containing binder being peptized by treatment with acid,(c) extruding the mixture obtained in (b), to provide an extrudate, and(d) calcining the extrudate obtained in (c), at a temperature in the range from 300 to 750°
- C. to give a calcined extrudate.
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Abstract
The invention relates to Cu—Al—Mn shaped catalyst bodies in extruded form, and to a process for their preparation. The shaped catalyst body is suitable for the hydrogenation of organic compounds containing a carbonyl function, in particular for the hydrogenation of aldehydes, ketones and carboxylic acids and/or their esters. In particular, the shaped catalyst body is suitable for the hydrogenation of fatty acids or their esters, such as fatty acid methyl esters, to form the corresponding alcohols and dicarboxylic acid anhydrides, such as maleic anhydride, or esters of di-acids and di-alcohols, such as butane diol.
43 Citations
19 Claims
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1. A shaped catalyst body, comprising Cu in an amount in the range of 20-43 wt %, Al in an amount in the range of 20-40 wt %, and Mn in an amount in the range of 1-10 wt %, based on the total weight of the shaped catalyst body,
wherein the shaped catalyst body has a pore volume in the range from 250 to 700 mm3/g, determined by mercury intrusion to DIN 66133, and wherein the shaped catalyst body has a monomodal pore radius distribution and wherein 50% or more of the pore volume is formed by pores having a pore radius in the range from 7 to 40 nm, the pore radius distribution and the pore volume being determined by mercury intrusion to DIN 66133, and wherein the shaped catalyst body in reduced form has a Cu metal surface, based on the amount of Cu in the shaped catalyst body, in the range from 20 m2/gCu to 60 m2/gCu, determined by N2O pulse chemisorption, and wherein the shaped catalyst body has a bulk density in the range from 300 to 800 g/L, determined to DIN ISO 903, and wherein the shaped catalyst body is in the form of an calcined extrudate and has a side crushing strength, based on the length of the extrudates, in the range from 5 to 40 N/mm, the side crushing strength being determined to DIN EN 1094-5, the shaped catalyst body being made by a process comprising (a) providing a copper, manganese and aluminum-containing dried precipitate, (b) forming a mixture of the dry precipitate of (a) with an aluminum-containing binder selected from the group consisting of boehmite and pseudoboehmite, the aluminum-containing binder being peptized by treatment with acid, (c) extruding the mixture obtained in (b), to provide an extrudate, and (d) calcining the extrudate obtained in (c), at a temperature in the range from 300 to 750° - C. to give a calcined extrudate.
- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A shaped catalyst body, comprising Cu in an amount in the range of 24-42 wt %, Al in an amount in the range of 25-34 wt %, and Mn in an amount in the range of 2-8 wt %, based on the total weight of the shaped catalyst body,
wherein the shaped catalyst body has a pore volume in the range from 250 to 700 mm3/g, determined by mercury intrusion to DIN 66133, and wherein the shaped catalyst body has a monomodal pore radius distribution and wherein 50% or more of the pore volume is formed by pores having a pore radius in the range from 7 to 40 nm, the pore radius distribution and the pore volume being determined by mercury intrusion to DIN 66133, and wherein the shaped catalyst body is in the form of a calcined extrudate and has a side crushing strength, based on the length of the extrudates, in the range from 5 to 40 N/mm, the side crushing strength being determined to DIN EN 1094-5.
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19. A shaped catalyst body in extruded form, comprising Cu in an amount in the range of 20-43 wt %, Al in an amount in the range of 20-40 wt %, and Mn in an amount in the range of 1-10 wt %, based on the total weight of the shaped catalyst body in extruded form,
wherein the shaped catalyst body has a pore volume in the range from 250 to 700 mm3/g, determined by mercury intrusion to DIN 66133, and wherein the shaped catalyst body is in the form of a calcined extrudate and has a side crushing strength, based on the length of the extrudates, in the range from 5 to 40 N/mm, the side crushing strength being determined to DIN EN 1094-5, and wherein the shaped catalyst body has a monomodal pore radius distribution and wherein 50% or more of the pore volume is formed by pores having a pore radius in the range from 7 to 40 nm, the pore radius distribution and the pore volume being determined by mercury intrusion to DIN 66133, and wherein the shaped catalyst body is obtained by a process comprising: -
(a) combining (i) at least one aqueous solution of copper compounds, aluminum compounds, manganese compounds, and optionally transition metal compounds and (ii) at least one aqueous carbonate-containing solution to form a precipitate, isolating the precipitate, optionally washing the isolated precipitate, and drying the isolated precipitate to give a dried precipitate, (b1) calcining dried precipitate obtained in step (a) at a temperature in the range from 250°
C. to 900°
C. to give a calcined precipitate,(b2) mixing dried, uncalcined precipitate obtained in step (a) with calcined precipitate obtained in step (b1) in a weight ratio of dried precipitate to calcined precipitate in the range from 2;
98 to 98;
2, to give a mixture, and(b3) forming a mixture of the mixture obtained in step (b2) with an aluminum-containing binder selected from the group consisting of boehmite and pseudoboehmite, the aluminum-containing binder being peptized by treatment with acid, (c) extruding the mixture obtained in step (b), to give an extrudate, and (d) calcining the extrudate obtained in step (c), at a temperature in the range from 300 to 750°
C. to give the calcined extrudate.
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Specification