Method for preparing catalyst

• US 8,603,938 B2
• Filed: 09/10/2009
• Issued: 12/10/2013
• Est. Priority Date: 09/11/2008
• Status: Active Grant

• Current Assignee: KAO Corporation
• Original Assignee: KAO Corporation
• Inventors: Sakamoto, Toru, Mimura, Taku
• Primary Examiner(s): Hailey, Patricia L
• Application Number:
  US13/062,823
• Publication Number:
  US 20110160493A1
• Time in Patent Office: 1,552 Days
• Field of Search: 502/318, 502/319, 502/331, 502/343, 502/345, 502/346, 568/852, 568/861, 554/141, 554/146
• US Class Current: 502/318
• CPC Class Codes: B01J 23/002 Mixed oxides other than spinels, e.g. perovskite
• CPC Class Codes: B01J 23/72 Copper
• CPC Class Codes: B01J 23/745 Iron
• CPC Class Codes: B01J 23/80 with zinc, cadmium or mercury
• CPC Class Codes: B01J 23/868 copper and chromium
• CPC Class Codes: B01J 23/94 of catalysts comprising metals, oxides or hydroxides of the iron group metals or copper
• CPC Class Codes: B01J 2523/00 Constitutive chemical elements of heterogeneous catalysts
• CPC Class Codes: B01J 2523/17 Copper
• CPC Class Codes: B01J 2523/25 Barium
• CPC Class Codes: B01J 2523/27 Zinc
• CPC Class Codes: B01J 2523/47 Titanium
• 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 37/06 Washing B01J37/0009, B01J37/0018 take precedence
• CPC Class Codes: B01J 37/16 Reducing
• CPC Class Codes: B01J 37/18 with gases containing free hydrogen
• CPC Class Codes: C07C 29/149 with hydrogen or hydrogen-containing gases
• CPC Class Codes: C07C 31/125 containing five to twenty-two carbon atoms
• CPC Class Codes: Y02P 20/584 Recycling of catalysts

Abstract

The present invention provides the method for preparing a catalyst including the following steps 1 and 2, and the method for producing an alcohol including preparing a catalyst by the method and subjecting a carboxylic acid or a carboxylic acid ester to catalytic reduction with hydrogen in the presence of the prepared catalyst:

• • step 1: immersing a molded precursor of a catalyst containing metal oxide in a solvent,
  • step 2: supplying hydrogen gas or a mixture of hydrogen gas with an inert gas to a catalyst layer in the presence of a solvent to reduce the catalyst precursor prepared in the step 1.

Claims

1. A method for preparing a catalyst, comprising the following steps 1 and 2:

step 1;

immersing a molded precursor of a catalyst containing a metal oxide in a solvent and preventing dry spots from generating on a surface of the molded precursor,

step 2;

supplying hydrogen gas or a mixture of hydrogen gas with an inert gas to a catalyst layer in the presence of a solvent to reduce the catalyst precursor prepared in the step 1.

2. The method for preparing a catalyst according to claim 1, wherein the solvent is at least one selected from the group consisting of glyceride oils, fatty acid esters, aliphatic alcohols, and hydrocarbons.

3. The method for preparing a catalyst according to claim 1, wherein the catalyst is a copper-containing hydrogenation catalyst.

4. The method for preparing a catalyst according to claim 3, wherein the copper-containing hydrogenation catalyst is at least one selected from the group consisting of copper-chromium oxide, copper-zinc oxide, copper-iron oxide, copper-aluminum oxide and copper-silica oxide.

5. The method for preparing a catalyst according to any of claim 1 or 2, wherein the catalyst precursor is immersed in the solvent for 0.5 to 50 hours.

6. A method for producing an alcohol, comprising preparing a catalyst by the method according to claim 1 or 2, and subjecting a carboxylic or a carboxylic acid ester to a catalytic reduction with hydrogen in the presence of the prepared catalyst.

7. The method for preparing a catalyst according to any of claim 1 or 2, in which step 1 is conducted in a fixed-bed reactor and step 2 is conducted while flowing the solvent and supplying the gas.

8. The method for preparing a catalyst according to claim 7, wherein step 1 comprises filling the fixed-bed reactor with a molded precursor containing a metal oxide, then supplying the solvent, immersing the molded precursor with the solvent and removing the solvent from the reactor.