Catalyst extrudates based on copper oxide and their use for hydrogenating carbonyl compounds

• US 7,807,603 B2
• Filed: 12/04/2004
• Issued: 10/05/2010
• Est. Priority Date: 12/09/2003
• Status: Expired due to Fees

• Current Assignee: BASF AG (BASF SE)
• Original Assignee: BASF AG (BASF SE)
• Inventors: Schubert, Olga, Windecker, Gunther, Weck, Alexander, Hesse, Michael, Pinkos, Rolf, Schlitter, Stephan, Borchers, Sabine, Roesch, Markus
• Primary Examiner(s): Nguyen; Cam N
• Application Number:
  US10/580,950
• Publication Number:
  US 20070117719A1
• Time in Patent Office: 2,131 Days
• Field of Search: 502/244, 502/324, 502/331, 502/345, 502/346, 502/349, 502/350, 502/355, 502/415, 502/439, 502/263, 502/351, 502/407
• US Class Current: 502/346
• CPC Class Codes: B01J 21/04 Alumina
• CPC Class Codes: B01J 23/72 Copper
• CPC Class Codes: B01J 23/94 of catalysts comprising metals, oxides or hydroxides of the iron group metals or copper
• CPC Class Codes: B01J 35/30 characterised by their physical properties
• CPC Class Codes: B01J 35/615 100-500 m2/g
• CPC Class Codes: B01J 35/633 less than 0.5 ml/g
• CPC Class Codes: B01J 35/66 Pore distribution
• CPC Class Codes: B01J 37/0009 Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
• CPC Class Codes: B01J 37/18 with gases containing free hydrogen
• CPC Class Codes: B01J 38/10 using elemental hydrogen
• CPC Class Codes: B01J 38/12 Treating with free oxygen-containing gas
• CPC Class Codes: C07C 29/149 with hydrogen or hydrogen-containing gases
• CPC Class Codes: C07D 315/00 Heterocyclic compounds containing rings having one oxygen atom as the only ring hetero atom according to more than one of groups C07D303/00 - C07D313/00
• CPC Class Codes: Y02P 20/584 Recycling of catalysts

Abstract

The invention relates to a catalyst provided in the form of an extrudate, which contains 5 to 85% by weight of copper oxide and comprises, in the active material and as binders, the same oxidic carrier material. The invention also relates to the use of the catalyst for hydrogenating carbonyl compounds.

Claims

1. A shaped catalyst body having a macroscopically uniform structure and comprising:

from 5 to 85% by weight of copper oxide as an active component and

Al₂O₃ as oxidic support material and as binder, wherein

a) the shaped catalyst body has a pore volume of greater than 0.15 ml/g in the pore diameter range from 10 nm to 100 nm, and

b) the oxidic support material in the shaped body is present both in finely disperse form and also to a proportion by volume of from 1 to 95% by volume of the shaped body in particulate form and is predominantly present as X-ray-amorphous material.

2. The shaped catalyst body according to claim 1, which is an extrudate.

3. The shaped catalyst body according to claim 2, wherein said extrudate is in the form of a cylindrical extrudate, a star extrudate, a ribbed extrudate, a trilobed extrudate, a hollow extrudate, or a honeycombed extrudate.

4. The shaped catalyst body according to claim 3, wherein the diameter of said extrudate is from 0.5 to 10 mm.

5. The shaped catalyst body according to claim 1, wherein the active component additionally includes aluminum oxide and the oxidic support material additionally includes aluminum oxide.

6. The shaped catalyst body according to claim 1, wherein the shaped body has a pore volume of greater than 0.30 ml/g in the pore diameter range from 10 nm to 100 nm.

7. The shaped catalyst body according to claim 1, wherein a BET surface area of said copper oxide is from 10 to 400 m²/g.

8. The shaped catalyst body according to claim 1, wherein said Al₂O₃ is present in an amount ranging from 15 to 95% by weight.

9. The shaped catalyst body according to claim 1, wherein the oxidic support material further comprises at least one of titanium oxide, zirconium oxide, silicon oxide, and manganese oxide.

10. A process for producing a shaped catalyst body according to claim 1, comprising mixing an active component comprising from 10 to 98% by weight of copper oxide and an oxidic support material with a binder comprising the same support material or a precursor thereof and shaping the same to form shaped bodies.

11. The process according to claim 10, wherein from 10 to 98% by weight of the oxidic support material in the catalyst comes from the binder used.

12. A process for the hydrogenation of carbonyl compounds, comprising phase hydrogenating a carbonyl compound in the presence of the shaped catalyst body according to claim 1.

13. A process for gas-phase hydrogenation of maleic anhydride comprising gas-phase hydrogenating maleic anhydride in the presence of the shaped catalyst body according to claim 1.

14. A shaped catalyst body having a macroscopically uniform structure and consisting essentially of:

a catalytically active composition containing 5 to 85% by weight of copper oxide and Al₂O₃ in a fine dispersion, and

Al₂O₃ in particulate form as a binder.

15. The shaped catalyst body according to claim 14, which that has a pore volume of greater than 0.15 ml/g for pore diameters in the range 10 nm to 100 nm.

16. The shaped catalyst body according to claim 15, wherein the binder has a particle size greater than about 2 μ

m or a particle volume greater than about 4 μ

m³.

17. The shaped catalyst body according to claim 16, wherein the proportion of the particulate form of Al₂O₃ ranges from 1 to 95% by volume.

18. The shaped catalyst body according to claim 17, wherein the particulate proportion of Al₂O₃ is predominantly present as X-ray-amorphous material.

19. The shaped catalyst body according to claim 14, which is prepared by a process comprising:

admixing metal salts to form a suspension containing copper oxide and Al₂O₃,

recovering a catalytically active composition containing CuO and Al₂O₃,

admixing the catalytically active composition containing CuO and Al₂O₃ with a binder that comprises Al₂O₃ or precursor thereof,

extruding the admixture to form an extrudate, and

calcining the extrudate at a temperature ranging from 300°

C. to 800°

C.

20. The shaped catalyst body according to claim 19, comprising admixing the catalytically active composition containing CuO and Al₂O₃ with a boehmite binder.