Method of fabricating a catalytic structure

• US 7,592,291 B2
• Filed: 03/21/2007
• Issued: 09/22/2009
• Est. Priority Date: 08/15/2006
• Status: Active Grant

• Current Assignee: Battelle Energy Alliance LLC (Battelle Memorial Institute)
• Original Assignee: Battelle Energy Alliance LLC (Battelle Memorial Institute)
• Inventors: Rollins, Harry W., Petkovic, Lucia M., Ginosar, Daniel M.
• Primary Examiner(s): Vanoy; Timothy C
• Assistant Examiner(s): BERNS, DANIEL J
• Application Number:
  US11/688,930
• Publication Number:
  US 20080045400A1
• Time in Patent Office: 916 Days
• Field of Search: 502/8, 502/343, 502/345
• US Class Current: 502/343
• CPC Class Codes: B01J 29/005 Mixtures of molecular sieves comprising at least one molecular sieve which is not an aluminosilicate zeolite, e.g. from groups B01J29/03 - B01J29/049 or B01J29/82 - B01J29/89
• CPC Class Codes: B01J 29/035 Microporous crystalline materials not having base exchange properties, such as silica polymorphs, e.g. silicalites
• CPC Class Codes: B01J 29/041 Mesoporous materials having base exchange properties, e.g. Si/Al-MCM-41
• CPC Class Codes: B01J 29/061 containing metallic elements added to the zeolite
• CPC Class Codes: B01J 29/072 Iron group metals or copper
• CPC Class Codes: B01J 29/40 of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
• CPC Class Codes: B01J 29/46 Iron group metals or copper
• CPC Class Codes: B01J 29/80 Mixtures of different zeolites
• CPC Class Codes: B01J 37/0018 Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat)
• CPC Class Codes: C07C 1/20 starting from organic compounds containing only oxygen atoms as heteroatoms
• CPC Class Codes: C07C 11/02 Alkenes
• CPC Class Codes: C07C 2529/46 Iron group metals or copper
• CPC Class Codes: C07C 2529/84 Aluminophosphates containing other elements, e.g. metals, boron
• CPC Class Codes: C07C 2529/85 Silicoaluminophosphates (SAPO compounds)
• CPC Class Codes: C10G 2/33 characterised by the catalyst used

Abstract

A precursor to a catalytic structure comprising zinc oxide and copper oxide. The zinc oxide has a sheet-like morphology or a spherical morphology and the copper oxide comprises particles of copper oxide. The copper oxide is reduced to copper, producing the catalytic structure. The catalytic structure is fabricated by a hydrothermal process. A reaction mixture comprising a zinc salt, a copper salt, a hydroxyl ion source, and a structure-directing agent is formed. The reaction mixture is heated under confined volume conditions to produce the precursor. The copper oxide in the precursor is reduced to copper. A method of hydrogenating a carbon oxide using the catalytic structure is also disclosed, as is a system that includes the catalytic structure.

Claims

1. A method of fabricating a catalytic structure, comprising:

heating reaction mixture comprising a zinc salt, a copper salt, a hydroxyl ion source, and a structure-directing agent in a closed vessel to produce a precursor comprising zinc oxide and copper oxide, the zinc oxide having a sheet-like morphology or a spherical morphology.

2. The method of claim 1, wherein heating a reaction mixture comprising a zinc salt, a copper salt, a hydroxyl ion source, and a structure-directing agent in a closed vessel comprises selecting the zinc salt from a compound selected from the group consisting of a zinc alkoxide, zinc acetate, zinc carbonate, zinc carbonate hydroxide, zinc citrate, zinc lactate, zinc nitrate, zinc oxalate, zinc stearate, zinc sulfate, and combinations thereof.

3. The method of claim 1, wherein heating a reaction mixture comprising a zinc salt, a copper salt, a hydroxyl ion source, and a structure-directing agent in a closed vessel comprises selecting the copper salt from a compound selected from the group consisting of copper acetate, copper acetate monohydrate, copper acetate hydrate, copper carbonate, copper formate hydrate, copper gluconate, copper hydroxide, copper methoxide, copper nitrate, copper nitrate hydrate, copper tartrate hydrate, and combinations thereof.

4. The method of claim 1, wherein heating a reaction mixture comprising a zinc salt, a copper salt, a hydroxyl ion source, and a structure-directing agent in a closed vessel comprises selecting the hydroxyl ion source from a compound selected from the group consisting of hexamethylenetetramine, ammonium hydroxide, ethylene diamine, triethanolamine, ammonia, hydrazine, and combinations thereof.

5. The method of claim 1, wherein heating a reaction mixture comprising a zinc salt, a copper salt, a hydroxyl ion source, and a structure-directing agent in a closed vessel comprises selecting the structure-directing agent from a compound selected from the group consisting of sodium citrate, potassium citrate, citric acid, poly(vinyl alcohol), poly(vinyl pyrrolidone), and combinations thereof.

6. The method of claim 1, wherein heating a reaction mixture comprising a zinc salt, a copper salt, a hydroxyl ion source, and a structure-directing agent in a closed vessel comprises heating a reaction mixture comprising zinc nitrate, copper nitrate, hexamethylenetetramine, and sodium citrate.

7. The method of claim 1, wherein heating a reaction mixture comprising a zinc salt, a copper salt, a hydroxyl ion source, and a structure-directing agent in a closed vessel comprises forming a reaction mixture comprising between about 0.01 M and about 1 M of the zinc salt, between about 0.01 M and about 1 M of the copper salt, between about 0.02 M and about 2 M of the hydroxyl ion source, and between about 0.05 mM and about 0.5 M of the surface-directing agent.

8. The method of claim 1, wherein heating a reaction mixture comprising a zinc salt, a copper salt, a hydroxyl ion source, and a structure-directing agent in a closed vessel comprises heating the reaction mixture to a temperature between about 80°

C. and about 200°

C.

9. The method of claim 1, wherein heating a reaction mixture comprising a zinc salt, a copper salt, a hydroxyl ion source, and a structure-directing agent in a closed vessel comprises heating the reaction mixture to a temperature between about 95°

C. and about 120°

C.

10. The method of claim 1, wherein heating a reaction mixture comprising a zinc salt, a copper salt, a hydroxyl ion source, and a structure-directing agent in a closed vessel comprises heating the reaction mixture for between about 1 hour and about 4 hours.

11. The method of claim 1, wherein heating a reaction mixture comprising a zinc salt, a copper salt, a hydroxyl ion source, and a structure-directing agent in a closed vessel comprises producing a mixture of zinc- and copper-containing precipitates comprising zinc oxide and copper oxide.

12. The method of claim 11, further comprising drying the mixture of zinc- and copper-containing precipitates at a temperature between about 80°

C. and about 550°

C.

13. The method of claim 1, further comprising reducing the copper oxide.

14. The method of claim 13, wherein reducing the copper oxide comprises forming a catalytic structure comprising copper metal and zinc oxide, wherein the zinc oxide has a sheet-like morphology or a spherical morphology.

15. The method of claim 14, wherein the catalytic structure further comprises at least one of at least one promoter and at least one additional catalytic material.

16. The method of claim 13, wherein reducing the copper oxide comprises forming a catalytic structure consisting essentially of copper metal and zinc oxide.

17. The method of claim 13, wherein reducing the copper oxide comprises forming a catalytic structure consisting of copper metal and zinc oxide.

18. A method of fabricating a catalytic structure, comprising:

heating a reaction mixture consisting of a zinc salt, a copper salt, a hydroxyl ion source, and at least one of sodium citrate, potassium citrate, citric acid, poly(vinyl alcohol), and poly(vinyl pyrrolidine) in a closed vessel to produce a precursor comprising zinc oxide and copper oxide.

19. The method of claim 18, wherein heating a reaction mixture consisting of a zinc salt, a copper salt, a hydroxyl ion source, and at least one of sodium citrate, potassium citrate, citric acid, poly(vinyl alcohol), and poly(vinyl pyrrolidine) in a closed vessel comprises selecting the zinc salt from a compound selected from the group consisting of a zinc alkoxide, zinc acetate, zinc carbonate, zinc carbonate hydroxide, zinc citrate, zinc lactate, zinc nitrate, zinc oxalate, zinc stearate, and zinc sulfate, and combinations thereof.

20. The method of claim 18, wherein heating a reaction mixture consisting of a zinc salt, a copper salt, a hydroxyl ion source, and at least one of sodium citrate, potassium citrate, citric acid, poly(vinyl alcohol), and poly(vinyl pyrrolidine) in a closed vessel comprises selecting the copper salt from a compound selected from the group consisting of copper acetate, copper acetate monohydrate, copper acetate hydrate, copper carbonate, copper formate hydrate, copper gluconate, copper hydroxide, copper methoxide, copper nitrate, copper nitrate hydrate, and copper tartrate hydrate, and combinations thereof.

21. The method of claim 18, wherein heating a reaction mixture consisting of a zinc salt, a copper salt, a hydroxyl ion source, and at least one of sodium citrate, potassium citrate, citric acid, poly(vinyl alcohol), and poly(vinyl pyrrolidine) in a closed vessel comprises selecting the hydroxyl ion source from a compound selected from the group consisting of hexamethylenetetramine, ammonium hydroxide, ethylene diamine, triethanolamine, ammonia, and hydrazine, and combinations thereof.

22. The method of claim 18, wherein heating a reaction mixture consisting of a zinc salt, a copper salt, a hydroxyl ion source, and at least one of sodium citrate, potassium citrate, citric acid, poly(vinyl alcohol), and poly(vinyl pyrrolidine) in a closed vessel comprises heating a reaction mixture consisting of zinc nitrate, copper nitrate, hexamethylenetetramine, and sodium citrate.