Patent Application
20240226858
The present invention relates to a catalytic material comprising Ni, one or more additional metals M, and an oxidic support material comprising Si and Zr, both in oxidic form, as well as a process for preparation thereof. In addition thereto, the present invention relates to a use of the inventive catalytic material as a catalyst or catalyst component, especially in a hydrogenation reaction.
The catalytic hydrogenation of nitro group-containing compounds is known. Generally, a hydrogenation reaction is carried out either in a fixed-bed reactor or in a batch reactor. On an industrial scale, it is most usual to carry out hydrogenation reactions in the liquid phase with a suspended catalyst, the processes differing with regard to the reaction temperature, the pressure, the catalyst, the solvents and the way in which the reaction is carried out.
The catalytic materials are typically obtained by precipitation from a solution particularly containing a soluble salt of Ni at pH 7 to 10 by means of a basic compound and are processed by filtration, drying and reduction to give the catalytic material. The catalytic materials thus obtained can be used for a several hydrogenation reactions, but their catalytic activity is often unsatisfactory in many cases, since the catalytic materials still contain other components, in particular Zr and Si in oxidic form.
WO 2014/108351 A1 relates to a device of the loop-Venturi reactor type for the continuous reaction of liquids with gases. Disclosed therein are different embodiments of catalysts suitable for hydrogenation, in particular of dinitrotoluene.
EP 1163955 A1 relates to a hydrogenation catalyst for reduction of functional groups, wherein the catalyst comprises catalytically active Ni supported on a TiO2-containing carrier.
DE 3537247 A1 relates to a use of an alloy of Ni and/or Co with a modifying metal as a Raney-catalyst, in particular for the catalytic hydrogenation of aromatic dinitro compounds.
WO 00/51728 A1 relates to a hydrogenating catalyst and a method for producing the same, wherein the catalyst contains Ni on a support, is stabilized and has Ni crystallite with bimodal Ni crystallite size distribution, a Ni content of 60 to 80 weight-%, based on the total weight of the catalyst and a reduction rate of at least 70%. The catalyst is suitable for the reduction of nitro-groups of aromatics to the respective amine-group containing aromatics.
WO 00/51727 A1 relates to a catalyst, especially for hydrogenating functional groups of organic compositions in the presence of water. Said catalyst contains Ni on a carrier, is reduced and stabilized and is provided with Ni crystallites with a monomodal Ni Crystallite size distribution, a Ni content of 25 to 60 percentage by weight (in relation to the total weight of the catalyst) and a reduction degree of at least 65%.
WO 95/24964 A1 relates to nickel-containing hydrogenation catalyst essentially comprising 65 to 80% Ni calculated as Ni oxide, 10 to 25% Si, calculated as SiO2, 2 to 10% Zr, calculated as ZrO2, 0 to 10% A1, calculated as Al2O3, with the proviso that the sum of the SiO2 and Al2O3 contents is at least 15%, with the percentages by weight in relation to the total mass of the catalyst.
EP 0335222 A1 discloses a catalytic material comprising Ni, Al2O3, and ZrO2 characterized in that 20 to 90 weight-% Ni, based on the total weight of the catalytic material, and 1 to 30 weight-% Al2O3 and 0.5 to 20 weight-% ZrO2, based on the total weight of Ni, are supported on a carrier.
DE 1257753 discloses a process for preparation of a nickel- and zirconia-containing catalyst including precipitation of a carbonate and subsequent calcination.
U.S. Pat. No. 2,564,331 discloses a process for preparation of a nickel-zirconium catalyst by precipitation of carbonates from a nickel- and zirconium-containing solution.
US 2019/233364 A1 relates to a process for continuous hydrogenation of dinitrotoluene in the presence of a supported catalyst which comprises Ni and Pt in an atomic ratio of 30:70 to 70:30. Suitable support materials can comprise ZrO2, ZrO2—HfO2, SiO2—ZrO2, SiO2—ZrO2—HfO2, or mixtures thereof.
US 2012/215029 A1 relates to a process for preparing aromatic amines in the presence of a catalyst, wherein the supported catalyst can comprise Ni and Pt, whereby the Ni content can be in the range of from 60 to 80 weight-% based on the total weight of the catalyst. The support material can be in particular SiO2, ZrO2, HfO2, and a mixture of two or more thereof.
It was an object of the present invention to provide an improved catalytic material, in particular with respect to its catalytic activity. More specifically, it was an object of the present invention to provide a catalytic material exhibiting an improved activity in the hydrogenation of nitro group-containing compounds, in particular a higher selectivity towards desired amine group-containing compounds in a hydrogenation reaction of nitro group-containing compounds. Further, it was an object of the present invention to provide a catalytic material exhibiting an improved longevity and a low selectivity towards by-products, in particular when used as a catalyst or as a catalyst component in a hydrogenation reaction. In addition to that, it was an object of the present invention to provide a process for preparation of such a catalytic material and a process for the hydrogenation of nitro group-containing compounds to amine group-containing compounds. Yet further, it was an object of the present invention to provide a process for preparation of such a catalytic material.
Surprisingly, it has been found that a catalytic material can be provided in accordance with the present invention particularly being characterized in that it comprises Ni and one or more specific additional metals, wherein the Ni is supported on a specific oxidic support material. Surprisingly, said catalytic material permits for an improved catalytic activity especially in the hydrogenation of nitro group-containing compounds. Also, the catalytic material of the present invention in its oxidic form shows an excellent behavior as concerns its reducibility. Additionally, it was found that the catalytic material of the present invention further shows an improved longevity in particular when used as a catalyst or as a catalyst component in a hydrogenation reaction.
Further, a process is provided for preparing a catalytic material in accordance with the present invention.
Therefore, the present invention relates to a catalytic material for the hydrogenation of functional groups of organic compounds, preferably for the hydrogenation of nitro groups of organic compounds, more preferably for the hydrogenation of nitro groups of aromatic organic compounds,
It is preferred that the catalytic material comprises the one or more additional metals M in an amount in the range of from 0.02 to 7.5 weight-%, more preferably in the range of from 0.05 to 5 weight-%, more preferably in the range of from 0.08 to 4 weight-%, more preferably in the range of from 0.10 to 3.5 weight-%, calculated as sum of the weights of the one or more additional metals M calculated as the elements, respectively, and based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively.
It is preferred that the catalytic material exhibits an atomic ratio, Ni:M, of Ni, calculated as atomic amount of Ni comprised in the catalytic material, to the one or more additional metals M, calculated as sum of the atomic amounts of the respective additional metals M comprised in the catalytic material, in the range of from 10:1 to 2000:1, more preferably in the range of from 50:1 to 1500:1, more preferably in the range of from 71:1 to 1200:1.
It is preferred that the catalytic material exhibits an atomic ratio, Zr:M, of Zr, calculated as atomic amount of Zr comprised in the catalytic material, to the one or more additional metals M, calculated as sum of the atomic amounts of the respective additional metals M comprised in the catalytic material, in the range of from 1.0:1 to 300:1, more preferably in the range of from 5.0:1 to 150:1, more preferably in the range of from 7.0:1 to 130:1.
It is preferred that the catalytic material exhibits an atomic ratio, Si:M, of Si, calculated as atomic amount of Si comprised in the catalytic material, to the one or more additional metals M, calculated as sum of the atomic amounts of the respective additional metals M comprised in the catalytic material, in the range of from 0.5:1 to 150:1, more preferably in the range of from 2.0:1 to 75:1, more preferably in the range of from 2.5:1 to 60:1.
According to a first alternative, it is preferred that the one or more additional metals M are Re.
In the case where the one or more additional metals M are Re, it is preferred that the catalytic material comprises one or more of elemental Re, HReO4, Re2O7(OH2)2, Re2O7, ReO3, Re2O5, ReO2 and Re2O3.
Further in the case where the one or more additional metals M are Re, it is preferred that the catalytic material comprises the Re in an amount in the range of from 0.1 to 10 weight-%, more preferably in the range of from 0.5 to 7.5 weight-%, more preferably in the range of from 1 to 5 weight-%, more preferably in the range of from 1.5 to 4 weight-%, more preferably in the range of from 2 to 3.5 weight-%, calculated as sum of the weights of the one or more additional metals M calculated as the elements, respectively, and based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively.
Further in the case where the one or more additional metals M are Re, it is preferred that the catalytic material exhibits an atomic ratio, Ni:Re, of Ni, calculated as atomic amount of Ni comprised in the catalytic material, to Re, calculated as atomic amount of Re comprised in the catalytic material, in the range of from 10:1 to 150:1, more preferably in the range of from 50:1 to 100:1, more preferably in the range of from 71:1 to 79:1.
Further in the case where the one or more additional metals M are Re, it is preferred that the catalytic material exhibits an atomic ratio, Zr:Re, of Zr, calculated as atomic amount of Zr comprised in the catalytic material, to Re, calculated as atomic amount of Re comprised in the catalytic material, in the range of from 1.0:1 to 25.0:1, more preferably in the range of from 5.0:1 to 13.0:1, more preferably in the range of from 7.0:1 to 9.0:1.
Further in the case where the one or more additional metals M are Re, it is preferred that the catalytic material exhibits an atomic ratio, Si:Re, of Si, calculated as atomic amount of Si comprised in the catalytic material, to Re, calculated as atomic amount of Re comprised in the catalytic material, in the range of from 0.5:1 to 7.5:1, more preferably in the range of from 2.0:1 to 5.0:1, more preferably in the range of from 2.5:1 to 4.0:1.
According to a second alternative, it is preferred that the one or more additional metals M are selected from the group consisting of Ru, Os, Rh, Ir, Pd, and Pt, more preferably selected from the group consisting of Rh, Ir, Pd, and Pt, wherein the one or more additional metals M more preferably are Pd and/or Pt, wherein the one or more additional metals M more preferably are Pt.
In the case where the one or more additional metals M are selected from the group consisting of Ru, Os, Rh, Ir, Pd, and Pt, it is preferred that the catalytic material comprises the one or more additional metals M in an amount in the range of from 0.01 to 1 weight-%, more preferably in the range of from 0.05 to 0.5 weight-%, more preferably in the range of from 0.08 to 0.4 weight-%, more preferably in the range of from 0.1 to 0.3 weight-%, calculated as sum of the weights of the respective elements of the one or more additional metals M, calculated as sum of the weights of the one or more additional metals M calculated as the elements, respectively, and based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively.
Further in the case where the one or more additional metals M are selected from the group consisting of Ru, Os, Rh, Ir, Pd, and Pt, it is preferred that the catalytic material exhibits an atomic ratio, Ni:M, of Ni, calculated as atomic amount of Ni comprised in the catalytic material, to the one or more additional metals M, calculated as sum of the atomic amounts of the respective additional metals M comprised in the catalytic material, in the range of from 250:1 to 2000:1, more preferably in the range of from 500:1 to 1500:1, more preferably in the range of from 1000:1 to 1200:1.
Further in the case where the one or more additional metals M are selected from the group consisting of Ru, Os, Rh, Ir, Pd, and Pt, it is preferred that the catalytic material exhibits an atomic ratio, Zr:M, of Zr, calculated as atomic amount of Zr comprised in the catalytic material, to the one or more additional metals M, calculated as sum of the atomic amounts of the respective additional metals M comprised in the catalytic material, in the range of from 10:1 to 300:1, more preferably in the range of from 50:1 to 150:1, more preferably in the range of from 100:1 to 130:1.
Further in the case where the one or more additional metals M are selected from the group consisting of Ru, Os, Rh, Ir, Pd, and Pt, it is preferred that the catalytic material exhibits an atomic ratio, Si:M, of Si, calculated as atomic amount of Si comprised in the catalytic material, to the one or more additional metals M, calculated as sum of the atomic amounts of the respective additional metals M comprised in the catalytic material, in the range of from 5:1 to 150:1, more preferably in the range of from 25:1 to 75:1, more preferably in the range of from 45:1 to 60:1.
It is preferred that the catalytic material comprises from 50 to 99 weight-%, more preferably from 55 to 98 weight-%, more preferably from 60 to 97 weight-%, more preferably from 66 to 95 weight-%, more preferably from 67 to 93 weight-%, more preferably from 68 to 92 weight-%, more preferably in the range of from 69 to 91 weight-%, more preferably from 70 to 90 weight-%, of Ni, calculated as elemental Ni, and based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively.
It is preferred that the catalytic material exhibits a Ni:Zr atomic ratio in the range of from 5.0:1 to 50.0:1, more preferably in the range of from 8.6:1 to 40.0:1, more preferably in the range of from 8.8:1 to 35.5:1, more preferably in the range of from 8.9:1 to 30.0:1.
It is preferred that the catalytic material exhibits a Ni:Si atomic ratio in the range of from 10:1 to 50:1, more preferably in the range of from 15:1 to 45:1, more preferably in the range of from 19:1 to 38:1, more preferably in the range of from 21:1 to 36:1.
It is preferred that the catalytic material exhibits a Zr:Si atomic ratio in the range of from in the range of from 0.1:1 to 10:1, more preferably in the range of from 0.5:1 to 5.0:1, more preferably in the range of from 1.0:1 to 3.0:1, more preferably in the range of from 1.2:1 to 2.6:1.
It is preferred that the catalytic material comprises from 2 to 25 weight-%, more preferably from 5 to 20, more preferably from 8 to 17 weight-%, more preferably from 10 to 15 weight-%, of Zr, calculated as elemental Zr, and based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively.
It is preferred that the catalytic material comprises from 0.3 to 3.0 weight-%, more preferably from 0.7 to 2.5, more preferably from 1.0 to 2.2 weight-%, more preferably from 1.2 to 2.0 weight-%, of Si, calculated as elemental Si, and based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively.
It is preferred that from 90 to 100 weight-%, more preferably from 95 to 100 weight-%, more preferably from 99 to 100 weight-%, more preferably from 99.9 to 100 weight-%, of the oxidic support material comprising Zr in oxidic form and Si in oxidic form consists of Si, Zr, 0, and H.
It is preferred that the Ni comprised in the catalytic material is in an oxidation state of 0 or +2.
It is preferred that equal to or more than 55 atomic-%, more preferably equal to or more than 60 atomic-%, more preferably equal to or more than 65 atomic-%, more preferably equal to or more than 70 atomic-%, more preferably equal to or more than 75 atomic-%, of the Ni comprised in the catalytic material are in an oxidation state of 0, preferably determined according to Reference Example 8.
It is preferred that the catalytic material comprises particles of Ni.
In the case where the catalytic material comprises particles of Ni, it is preferred that the catalytic material exhibits a monomodal particle size distribution of the crystallites of Ni, preferably determined according to Reference Example 3.
In the case where the catalytic material exhibits a monomodal particle size distribution of the crystallites of Ni, it is preferred that the particle size distribution of the crystallites of Ni displays a maximum in the range of from 2 to 20 nm, more preferably in the range of from 3 to 15 nm, more preferably in the range of from 4 to 11 nm, more preferably in the range of from 4.5 to 10.0 nm, more preferably in the range of from 5.0 to 9.0 nm, preferably determined according to Reference Example 3.
In the case where equal to or more than 55 atomic-% of the Ni comprised in the catalytic material are in an oxidation state of 0, it is preferred that the Ni has a metallic surface area in the range of from 40 to 100 m2/g, more preferably in the range of from 50 to 90 m2/g, more preferably in the range of from 70 to 80 m2/g, preferably determined according to Reference Example 2.
It is preferred that less than 45 atomic-%, more preferably less than 40 atomic-%, more preferably less than 35 atomic-%, more preferably less than 30 atomic-%, more preferably less than 25 atomic-%, of the Ni comprised in the catalytic material are in an oxidation state of +2, wherein more preferably the Ni comprised in the catalytic material in oxidation state +2 is present in the form of NiO.
It is preferred that the catalytic material exhibits a total pore volume in the range of from 0.1 to 1.00 cm3/g, more preferably in the range of from 0.20 to 0.50 cm3/g, more preferably in the range of from 0.25 to 0.45 cm3/g, preferably determined according to Reference Example 1.
It is preferred that the catalytic material comprises from 0 to 2 weight-%, more preferably from 0 to 1 weight-%, more preferably from 0 to 0.5 weight-%, of Hf, calculated as elemental Hf, and based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively, wherein the catalytic material is more preferably essentially free of Hf, wherein the catalytic material does more preferably not comprise Hf.
It is preferred that the catalytic material comprises from 0 to 1 weight-%, more preferably from 0 to 0.5 weight-%, more preferably from 0 to 0.3 weight-%, of an alkali metal, calculated as elemental alkali metal, and based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively, wherein the catalytic material is more preferably essentially free of an alkali metal, wherein the catalytic material does more preferably not comprise an alkali metal.
In the case where the catalytic material comprises from 0 to 1 weight-% of an alkali metal, calculated as elemental alkali metal, and based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively, it is preferred that the alkali metal comprises one or more of Li, Na, and K, more preferably Na.
It is preferred that the catalytic material further comprises an element E selected from the group consisting of Mg, Ca, Zn, B, Fe, Cl, and a mixture of two or more thereof.
In the case where the catalytic material further comprises an element E selected from the group consisting of Mg, Ca, Zn, B, Fe, Cl, and a mixture of two or more thereof, it is preferred that the catalytic material comprises from 0 to 1 weight-%, more preferably from 0.001 to 0.5 weight-%, more preferably from 0.01 to 0.1 weight-%, of the element E, calculated as elemental E, based on the weight of the catalytic material.
It is preferred that the catalytic material further comprises an auxiliary agent selected from the group consisting of graphite, a polysaccharide, a sugar alcohol, a synthetic polymer, and a mixture of two or more thereof, more preferably selected from the group consisting of graphite, a sugar alcohol, a synthetic polymer, cellulose, a modified cellulose, a starch, and a mixture of two or more thererof, more preferably selected from the group consisting of graphite, a sugar alcohol, a synthetic polymer, a microcrystalline cellulose, a cellulose ether, and a mixture of two or more thereof, more preferably selected from the group consisting of graphite, sorbitol, mannitol, polyethylene glycol (PEG), polyvinylpyrrolidone (PVP), hydroxypropyl cellulose (HPC), hydroxypropyl methylcellulose (HPMC), and a mixture of two or more thereof, wherein the auxiliary agent more preferably comprises, more preferably consist of, graphite.
In the case where the catalytic material further comprises an auxiliary agent selected from the group consisting of graphite, a polysaccharide, a sugar alcohol, a synthetic polymer, and a mixture of two or more thereof, it is preferred that the catalytic material comprises the auxiliary agent in an amount in the range of from 1.0 to 5.0 weight-%, more preferably in the range of from 2.0 to 4.5 weight-%, more preferably in the range of from 2.5 to 4.0 weight-%, based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively.
It is preferred that the catalytic material is in the form of a molding.
In the case where the catalytic material is in the form of a molding, it is preferred that the catalytic material is in the form of a tablet, more preferably in the form of a tablet having a cylindrical shape or an ellipsoidal shape.
In the case where the catalytic material is in the form of a tablet, it is preferred that the tablet has a cylindrical shape, wherein the diameter is in the range of from 5 to 15 mm, more preferably in the range of from 8 to 12 mm, more preferably in the range of from 9 to 11 mm, and wherein the height is preferably in the range of from 3 to 13 mm, preferably in the range of from 6 to 10 mm, more preferably in the range of from 7 to 9 mm.
Further in the case where the catalytic material is in the form of a tablet, it is preferred that the tablet has a cylindrical shape, and wherein the tablet has a side crushing strength in the range of from 70 to 130 N, more preferably in the range of from 80 to 120 N, preferably determined according to Reference Example 4.
It is preferred that from 90 to 100 weight-%, more preferably from 95 to 100 weight-%, more preferably from 99 to 100 weight-%, more preferably from 99.9 to 100 weight-%, of the catalytic material consist of Ni, M, Si, Zr, O, H, optionally Hf, optionally an element E, optionally an alkali metal, and optionally an auxiliary agent.
Further, the present invention relates to a process for the preparation of a catalytic material according to any one of the embodiments disclosed herein, said process comprising
It is preferred that in (a) of the process the first aqueous solution is heated to a temperature in the range of from 60 to 80° C., more preferably in the range of from 65 to 75° C.
According to a first alternative, it is preferred that (b) of the process comprises
In the case where (b) of the process comprises (b.1) and (b.2), it is preferred that in (b.1) the pH is adjusted to be in the range of from 6.5 to 8.5, more preferably in the range of from 6.7 to 8.0, more preferably in the range of from 6.8 to 7.5, more preferably in the range of from 6.9 to 7.1.
Further in the case where (b) of the process comprises (b.1) and (b.2), it is preferred that in (b.1) the pH is adjusted by feeding a fifth aqueous solution comprising a source of Ni into the first aqueous solution, wherein the fifth aqueous solution more preferably has the same chemical composition as the second aqueous solution, wherein more preferably the fourth aqueous solution comprises a portion of the second aqueous solution.
According to a second alternative, it is preferred that (b) of the process comprises
It is preferred that heating in (c) of the process comprises heating of the mixture to a temperature in the range of from 55 to 90° C., more preferably in the range of from 65 to 80° C., more preferably in the range of from 70 to 75° C.
It is preferred that the source of Si in one or more of the first aqueous solution and the third aqueous solution of the process comprises one or more of a silicate, more preferably one or more of a metasilicate, an orthosilicate, and a pyrosilicate, more preferably a silicate salt, more preferably a silicate salt selected from the group consisting of alkali metal silicates and mixtures thereof, wherein the alkali metal is preferably selected from the group consisting of Li, Na, K, Rb, Cs, and mixtures of two or more thereof, more preferably from the group consisting of Li, Na, K, and mixtures of two or more thereof, wherein more preferably the alkali metal is Na and/or K, preferably Na, wherein the source of Si preferably comprises, more preferably consists of, a metasilicate, more preferably sodium silicate.
It is preferred that the concentration of the source of Si, calculated as SiO2, in the first aqueous solution of the process is in the range of from 10 to 500 mmol/l, more preferably in the range of from 30 to 250 mmol/l, more preferably in the range of from 50 to 100 mmol/l.
It is preferred that the source of Ni in the second aqueous solution and/or in the fifth aqueous solution of the process comprises one or more Ni salts, more preferably one or more Ni(II) salts, wherein the anion of the one or more Ni salts is preferably selected from the group consisting of halides, carbonate, hydrogencarbonate, sulfate, hydrogensulfate, hydroxide, nitrate, phosphate, hydogenphosphate, dihydrogenphosphate, acetate, and combinations of two or more thereof, more preferably from the group consisting of chloride, bromide, fluoride, hydrogencarbonate, hydrogensulfate, nitrate, dihydrogenphosphate, acetate, and combinations of two or more thereof,
It is preferred that the concentration of the source of Ni, calculated as NiO, in the second aqueous solution and/or in the fifth aqueous solution of the process is in the range of from 0.1 to 4 mol/l, more preferably in the range of from 0.4 to 2.5 mol/l, more preferably in the range of from 0.7 to 1.4 mol/l.
It is preferred that the ratio of the total volume of the first aqueous solution of the process to the total volume of the second aqueous solution is in the range of from 1:50 to 1:2, more preferably in the range of from 1:30 to 1:5, more preferably in the range of from 1:10 to 1:6.
It is preferred that the precipitation agent of the process comprises one or more of an inorganic base and an organic base, more preferably an inorganic base, wherein preferably the precipitation agent is selected from the group consisting of hydroxides, carbonates, aluminates, and mixtures of two or more thereof,
It is preferred that the concentration of the precipitation agent in the third aqueous solution of the process is in the range of from 1.0 to 5.0 mol/l, more preferably in the range of from 1.4 to 3.0 mol/l, more preferably in the range of from 1.8 to 2.4 mol/l.
It is preferred that the ratio of the total volume of the first aqueous solution to the total volume of the third aqueous solution of the process is in the range of from 1:70 to 5:1, more preferably in the range of from 1:15 to 3:1, more preferably in the range of from 1:2 to 2:1.
It is preferred that the concentration of the source of Zr, calculated as ZrO2, in the fourth aqueous solution of the process is in the range of from 10 to 750 mmol/l, more preferably in the range of from 20 to 600 mmol/l, more preferably in the range of from 30 to 300 mmol/l.
It is preferred that the ratio of the total volume of the first aqueous solution to the total volume of the fourth aqueous solution of the process is in the range of from 1:20 to 1:2, more preferably in the range of from 1:10 to 1:5, more preferably in the range of from 1:8 to 1:6.
It is preferred that the gas atmosphere in (d) of the process comprises a temperature in the range of from 400 to 500° C., more preferably in the range of from 440 to 460° C.
It is preferred that the process further comprises after (c) and prior to (d) one or more of
It is preferred that the gas atmosphere in one or more of (d) and (t) of the process comprises one or more of nitrogen and oxygen, more preferably air.
It is preferred that the process further comprises
In the case where the process further comprises (e) and optionally (f), it is preferred that the gas stream in (e) comprises hydrogen in an amount in the range of from 1 to 50 volume-%, based on the total volume of the gas stream, and nitrogen in an amount in the range of from 50 to 99 volume-%, based on the total volume of the gas stream.
Further in the case where the process further comprises (e) and optionally (f), it is preferred that in (e) the content of hydrogen in the gas stream is adjusted such that in (e) the temperature of the catalytic material does not exceed 425° C., wherein more preferably the temperature of the catalytic material does not exceed 385° C.
Further in the case where the process further comprises (e) and optionally (f), it is preferred that in (f) the content of oxygen in the gas stream is adjusted such that in (f) the temperature of the catalytic material does not exceed 80° C., wherein more preferably the temperature of the catalytic material does not exceed 35° C.
It is preferred that the process further comprises
In the case where the process further comprises (g) and (h), it is preferred that the auxiliary agent comprises one or more of graphite, a polysaccharide, a sugar alcohol and a synthetic polymer, more preferably one or more of graphite, a sugar alcohol, a synthetic polymer, cellulose, a modified cellulose and a starch, more preferably one or more of graphite, a sugar alcohol, a synthetic polymer, a microcrystalline cellulose, a cellulose ether, more preferably one or more of graphite, sorbitol, mannitol, polyethylene glycol (PEG), polyvinylpyrrolidone (PVP), hydroxypropyl cellulose (HPC) and hydroxypropyl methylcellulose (HPMC), more preferably graphite.
Further in the case where the process further comprises (g) and (h), it is preferred that the mixture prepared in (g) comprises the auxiliary agent in an amount in the range of from 1.0 to 5.0 weight-%, more preferably in the range of from 2.0 to 4.0 weight-%, more preferably in the range of from 2.5 to 3.5 weight-%, based on the total weight of the mixture.
Further in the case where the process further comprises (g) and (h), it is preferred that shaping in (h) comprises extruding or tableting the mixture obtained in (g), more preferably tableting the mixture obtained in (g).
Further in the case where the process further comprises (g) and (h), it is preferred that shaping in (h) comprises tableting the mixture to a tablet, more preferably to a tablet having a cylindrical shape or an ellipsoidal shape.
In the case where shaping in (h) comprises tableting the mixture to a tablet, it is preferred that tableting is performed to obtain a tablet having a cylindrical shape, wherein the diameter of the tablet is in the range of from 5 to 15 mm, more preferably in the range of from 8 to 12 mm, more preferably in the range of from 9 to 11 mm, and wherein the height is preferably in the range of from 3 to 13 mm, preferably in the range of from 6 to 10 mm, more preferably in the range of from 7 to 9 mm.
It is preferred that the process further comprises
In the case where the process further comprises (i) and optionally (k), it is preferred according to a first alternative that the one or more additional metals M are Re.
In the case where the one or more additional metals M are Re, it is preferred that the aqueous solution according to (i) of the process comprises Re in an amount in the range of from 3 to 15 weight-%, more preferably in the range of from 8 to 10 weight-%, calculated as elemental Re, based on the weight of the aqueous solution.
Further in the case where the one or more additional metals M are Re, it is preferred that the aqueous solution according to (i) comprises one or more of perrhenic acid (HReO4), Re2O7, and Re2O7(OH2)2.
In the case where the process further comprises (i) and optionally (k), it is preferred according to a second alternative that the one or more additional metals M are selected from the group consisting of Ru, Os, Rh, Ir, Pd, and Pt, more preferably selected from the group consisting of Rh, Ir, Pd, and Pt, wherein the one or more additional metals M more preferably are Pd and/or Pt, wherein the one or more additional metals M more preferably are Pt.
In the case where the one or more additional metals M are selected from the group consisting of Ru, Os, Rh, Ir, Pd, and Pt, it is preferred that the aqueous solution according to (i) comprises the one or more additional metals M in an amount in the range of from 0.1 to 1 weight-%, more preferably in the range of from 0.5 to 0.6 weight-%, calculated as sum of the weights of the respective elements of the one or more additional metals M, based on the weight of the aqueous solution.
Further in the case where the one or more additional metals M are selected from the group consisting of Ru, Os, Rh, Ir, Pd, and Pt, it is preferred that the one or more additional metals M are Pt, and wherein the aqueous solution according to (i) comprises one or more of platinum(II) nitrate, platinum(IV) nitrate, ammonium hexachloroplatinate, ammine stabilized hydroxo Pt(II) complex, tetraammineplatinum chloride, tetraammineplatinum nitrate, hexachloroplatinic acid, and potassium hexachloroplatinate.
Further in the case where the process further comprises (i) and optionally (k), it is preferred that the gas atmosphere in (k) comprises one or more of nitrogen and oxygen, preferably air.
Further in the case where the process further comprises (i) and optionally (k), it is preferred that the process further comprises
In the case where the process further comprises (m) and optionally (n), it is preferred that the gas stream in (m) comprises hydrogen in an amount in the range of from 1 to 50 volume-%, based on the total volume of the gas stream, and nitrogen in an amount in the range of from 50 to 99 volume-%, based on the total volume of the gas stream.
Further in the case where the process further comprises (m) and optionally (n), it is preferred that in (m) the content of hydrogen in the gas stream is adjusted such that in (m) the temperature of the molding does not exceed 425° C., wherein in (m) the temperature of the molding does preferably not exceed 380° C.
Further in the case where the process further comprises (m) and optionally (n), it is preferred that in (n) the content of oxygen in the gas stream is adjusted such that in (n) the temperature of the molding does not exceed 80° C., wherein in (n) the temperature of the molding does preferably not exceed 35° C.
Yet further, the present invention further relates a catalytic material obtainable or obtained by the process of any one of the embodiments disclosed herein.
Yet further, the present invention further relates to a use of the catalytic material according to any one of the embodiments disclosed herein, as a catalyst or catalyst component for a hydrogenation reaction, preferably for a hydrogenation reaction of one or more of a nitro-group containing compound, a nitrile, an aromatic, and an olefin.
Yet further, the present invention further relates a continuous process for catalytic hydrogenation of a nitro group-containing compound, the process comprising
It is preferred that the reactor provided in (I) of the continuous process is a loop reactor, preferably a loop Venturi reactor. Thus, it is preferred that a reactor is provided in (I) as disclosed in WO 2014/108351 A1. As an alternative, the reactor provided in (1) is in accordance with a reactor disclosed for the process for preparing amines as disclosed in WO 00/35852 A1.
It is preferred that in (1) of the continuous process the catalytic material is present in a fixed-bed and/or in a fluidized bed, more preferably in a fluidized bed.
It is preferred that in (1) of the continuous process the reaction zone comprises a solvent system, wherein the solvent system more preferably comprises one or more of water, and an amine-group containing compound as obtained in (II), more preferably water, more preferably de-ionized water, more preferably water, which is obtained during the hydrogenation reaction (II).
It is preferred that in (II) of the continuous process the reaction conditions comprise a temperature in the range of from 100 to 150° C., more preferably in the range of from 110 to 140° C., more preferably in the range of from 120 to 140° C.
It is preferred that in (II) of the continuous process the reaction conditions comprise a pressure in the range of from 10 to 150 bar(abs), more preferably in the range of from 15 to 50 bar(abs), more preferably in the range of from 20 to 30 bar(abs).
It is preferred that the nitro group containing compound of the continuous process comprises one or more of an aromatic nitro group-containing compound and an aliphatic nitro group-containing compound, wherein the aromatic nitro group-containing compound more preferably comprises one or more of nitrobenzene, 1,3-dinitrobenzene, 2,4-dinitrotoluene, 2,6-dinitrotoluene, 2,4,6-trinitrotoluene, 1,2-dimethyl-3-nitrobenzene, 1,2-dimethyl-4-nitrobenzene, 1,4-dimethyl-2-nitrobenzene, 1,3-dimethyl-2-nitrobenzene, 2,4-dimethyl-1 nitrobenzene, 1,3-dimethyl-5-nitrobenzene, 1-nitronaphthalene, 2-nitronaphthalene, 1,5-dinitronaphthalene und 1,8-dinitronaphthalene, 2-mononitrotoluene, 3-mononitrotoluene, 4-mononitrotoluene, 2-chloro-1,3-dinitrobenzene, 1-chloro-2,4-dinitrobenzene, o-chloronitrobenzene, m-chloronitrobenzene, p-chloronitrobenzene, 1,2-dichloro-4-nitrobenzene, 1,4-dichloro-2-nitrobenzene, 2,4-dichloro-1-nitrobenzene, 1,2-dichloro-3-nitrobenzene, 4-chloro-2-nitrotoluene, 4-chloro-3-nitrotoluene, 2-chloro-4-nitrotoluene, 2-chlor-6-nitrotoluene, o-nitroaniline, m-nitroaniline, and p-nitroaniline, preferably 2,4-dinitrotoluene or a mixture of 2,4- and 2,6-dinitrotoluene, and wherein the aliphatic nitro group-containing compound more preferably comprises one or more of tris(hydroxymethyl)nitromethane, 2-nitro-2-methyl-1,3-propanediol, 2-nitro-2-ethyl-1,3-propanediol, 2-nitro-1-butanol and 2-nitro-2-methyl-1-propanol.
It is preferred that the product stream of the continuous process comprises an amine group-containing compound, more preferably one or more of an aromatic amine group-containing compound and an aliphatic amine group-containing compound, wherein the aromatic amine group-containing compound preferably comprises one or more of aminobenzene, 1,3-diaminobenzene, 2,4-diaminotoluene, 2,6-diaminotoluene, 2,4,6-triaminotoluene, 1,2-dimethyl-3-aminobenzene, 1,2-dimethyl-4-aminobenzene, 1,4-dimethyl-2-aminobenzene, 1,3-dimethyl-2-aminobenzene, 2,4-dimethyl-1-aminobenzene, 1,3-dimethyl-5-aminobenzene, 1-aminonaphthalene, 2-aminonaphthalene, 1,5-diaminonaphthalene und 1,8-diaminonaphthalene, 2-aminotoluene, 3 aminotoluene, 4-aminotoluene, 2-chloro-1,3-diaminobenzene, 1-chloro-2,4-diaminobenzene, o-chloroaminobenzene, m-chloroaminobenzene, p-chloroaminobenzene, 1,2-dichloro-4-aminobenzene, 1,4-dichloro-2-aminobenzene, 2,4-dichloro-1-aminobenzene, 1,2-dichloro-3-aminobenzene, 4-chloro-2-aminotoluene, 4-chloro-3-aminotoluene, 2-chloro-4-aminotoluene, 2-chlor-6-aminotoluene, o-phenylenediamine, m-phenylenediamine, and p-phenylenediamine, preferably 2,4-diaminotoluene, and wherein the aliphatic amine group-containing compound preferably comprises one or more of tris(hydroxymethyl)aminomethane, 2-amino-2-methyl-1,3-propanediol, 2-amino-2-ethyl-1,3-propanediol, 2-amino-1-butanol and 2-amino-2-methyl-1-propanol.
The unit bar(abs) refers to an absolute pressure of 105 Pa and the unit Angstrom refers to a length of 10−10 m.
The present invention is further illustrated by the following set of embodiments and combinations of embodiments resulting from the dependencies and back-references as indicated. In particular, it is noted that in each instance where a range of embodiments is mentioned, for example in the context of a term such as “any one of embodiments (1) to (4)”, every embodiment in this range is meant to be explicitly disclosed for the skilled person, i.e. the wording of this term is to be understood by the skilled person as being synonymous to “any one of embodiments (1), (2), (3), and (4)”.
Further, it is explicitly noted that the following set of embodiments is not the set of claims determining the extent of protection, but represents a suitably structured part of the description directed to general and preferred aspects of the present invention.
According to an embodiment (1), the present invention relates to a catalytic material for the hydrogenation of functional groups of organic compounds, preferably for the hydrogenation of nitro groups of organic compounds, more preferably for the hydrogenation of nitro groups of aromatic organic compounds,
A preferred embodiment (2) concretizing embodiment (1) relates to said catalytic material, wherein the catalytic material comprises the one or more additional metals M in an amount in the range of from 0.02 to 7.5 weight-%, preferably in the range of from 0.05 to 5 weight-%, more preferably in the range of from 0.08 to 4 weight-%, more preferably in the range of from 0.10 to 3.5 weight-%, calculated as sum of the weights of the one or more additional metals M calculated as the elements, respectively, and based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively.
A preferred embodiment (3) concretizing embodiment (1) or (2) relates to said catalytic material, wherein the catalytic material exhibits an atomic ratio, Ni:M, of Ni, calculated as atomic amount of Ni comprised in the catalytic material, to the one or more additional metals M, calculated as sum of the atomic amounts of the respective additional metals M comprised in the catalytic material, in the range of from 10:1 to 2000:1, preferably in the range of from 50:1 to 1500:1, more preferably in the range of from 71:1 to 1200:1.
A preferred embodiment (4) concretizing any one of embodiments (1) to (3) relates to said catalytic material, wherein the catalytic material exhibits an atomic ratio, Zr:M, of Zr, calculated as atomic amount of Zr comprised in the catalytic material, to the one or more additional metals M, calculated as sum of the atomic amounts of the respective additional metals M comprised in the catalytic material, in the range of from 1.0:1 to 300:1, preferably in the range of from 5.0:1 to 150:1, more preferably in the range of from 7.0:1 to 130:1.
A preferred embodiment (5) concretizing any one of embodiments (1) to (4) relates to said catalytic material, wherein the catalytic material exhibits an atomic ratio, Si:M, of Si, calculated as atomic amount of Si comprised in the catalytic material, to the one or more additional metals M, calculated as sum of the atomic amounts of the respective additional metals M comprised in the catalytic material, in the range of from 0.5:1 to 150:1, preferably in the range of from 2.0:1 to 75:1, more preferably in the range of from 2.5:1 to 60:1.
A preferred embodiment (6) concretizing any one of embodiments (1) to (5) relates to said catalytic material, wherein the one or more additional metals M are Re.
A preferred embodiment (7) concretizing embodiment (6) relates to said catalytic material, wherein the catalytic material comprises one or more of elemental Re, HReO4, Re2O7(OH2)2, Re2O7, ReO3, Re2O5, ReO2 and Re2O3.
A preferred embodiment (8) concretizing embodiment (6) or (7) relates to said catalytic material, wherein the catalytic material comprises the Re in an amount in the range of from 0.1 to 10 weight-%, preferably in the range of from 0.5 to 7.5 weight-%, more preferably in the range of from 1 to 5 weight-%, more preferably in the range of from 1.5 to 4 weight-%, more preferably in the range of from 2 to 3.5 weight-%, calculated as sum of the weights of the one or more additional metals M calculated as the elements, respectively, and based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively.
A preferred embodiment (9) concretizing any one of embodiments (6) to (8) relates to said catalytic material, wherein the catalytic material exhibits an atomic ratio, Ni:Re, of Ni, calculated as atomic amount of Ni comprised in the catalytic material, to Re, calculated as atomic amount of Re comprised in the catalytic material, in the range of from 10:1 to 150:1, preferably in the range of from 50:1 to 100:1, more preferably in the range of from 71:1 to 79:1.
A preferred embodiment (10) concretizing any one of embodiments (6) to (9) relates to said catalytic material, wherein the catalytic material exhibits an atomic ratio, Zr:Re, of Zr, calculated as atomic amount of Zr comprised in the catalytic material, to Re, calculated as atomic amount of Re comprised in the catalytic material, in the range of from 1.0:1 to 25.0:1, preferably in the range of from 5.0:1 to 13.0:1, more preferably in the range of from 7.0:1 to 9.0:1.
A preferred embodiment (11) concretizing any one of embodiments (6) to (10) relates to said catalytic material, wherein the catalytic material exhibits an atomic ratio, Si:Re, of Si, calculated as atomic amount of Si comprised in the catalytic material, to Re, calculated as atomic amount of Re comprised in the catalytic material, in the range of from 0.5:1 to 7.5:1, preferably in the range of from 2.0:1 to 5.0:1, more preferably in the range of from 2.5:1 to 4.0:1.
A preferred embodiment (12) concretizing any one of embodiments (1) to (5) relates to said catalytic material, wherein the one or more additional metals M are selected from the group consisting of Ru, Os, Rh, Ir, Pd, and Pt, preferably selected from the group consisting of Rh, Ir, Pd, and Pt, wherein the one or more additional metals M more preferably are Pd and/or Pt, wherein the one or more additional metals M more preferably are Pt.
A preferred embodiment (13) concretizing embodiment (12) relates to said catalytic material, wherein the catalytic material comprises the one or more additional metals M in an amount in the range of from 0.01 to 1 weight-%, preferably in the range of from 0.05 to 0.5 weight-%, more preferably in the range of from 0.08 to 0.4 weight-%, more preferably in the range of from 0.1 to 0.3 weight-%, calculated as sum of the weights of the respective elements of the one or more additional metals M, calculated as sum of the weights of the one or more additional metals M calculated as the elements, respectively, and based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively.
A preferred embodiment (14) concretizing embodiment (12) or (13) relates to said catalytic material, wherein the catalytic material exhibits an atomic ratio, Ni:M, of Ni, calculated as atomic amount of Ni comprised in the catalytic material, to the one or more additional metals M, calculated as sum of the atomic amounts of the respective additional metals M comprised in the catalytic material, in the range of from 250:1 to 2000:1, preferably in the range of from 500:1 to 1500:1, more preferably in the range of from 1000:1 to 1200:1.
A preferred embodiment (15) concretizing any one of embodiments (12) to (14) relates to said catalytic material, wherein the catalytic material exhibits an atomic ratio, Zr:M, of Zr, calculated as atomic amount of Zr comprised in the catalytic material, to the one or more additional metals M, calculated as sum of the atomic amounts of the respective additional metals M comprised in the catalytic material, in the range of from 10:1 to 300:1, preferably in the range of from 50:1 to 150:1, more preferably in the range of from 100:1 to 130:1.
A preferred embodiment (16) concretizing any one of embodiments (12) to (15) relates to said catalytic material, wherein the catalytic material exhibits an atomic ratio, Si:M, of Si, calculated as atomic amount of Si comprised in the catalytic material, to the one or more additional metals M, calculated as sum of the atomic amounts of the respective additional metals M comprised in the catalytic material, in the range of from 5:1 to 150:1, preferably in the range of from 25:1 to 75:1, more preferably in the range of from 45:1 to 60:1.
A preferred embodiment (17) concretizing any one of embodiments (1) to (16) relates to said catalytic material, wherein the catalytic material comprises from 50 to 99 weight-%, preferably from 55 to 98 weight-%, more preferably from 60 to 97 weight-%, more preferably from 66 to 95 weight-%, more preferably from 67 to 93 weight-%, more preferably from 68 to 92 weight-%, more preferably in the range of from 69 to 91 weight-%, more preferably from 70 to 90 weight-%, of Ni, calculated as elemental Ni, and based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively.
A preferred embodiment (18) concretizing any one of embodiments (1) to (17) relates to said catalytic material, wherein the catalytic material exhibits a Ni:Zr atomic ratio in the range of from 5.0:1 to 50.0:1, preferably in the range of from 8.6:1 to 40.0:1, more preferably in the range of from 8.8:1 to 35.5:1, more preferably in the range of from 8.9:1 to 30.0:1.
A preferred embodiment (19) concretizing any one of embodiments (1) to (18) relates to said catalytic material, wherein the catalytic material exhibits a Ni:Si atomic ratio in the range of from 10:1 to 50:1, more preferably in the range of from 15:1 to 45:1, more preferably in the range of from 19:1 to 38:1, more preferably in the range of from 21:1 to 36:1.
A preferred embodiment (20) concretizing any one of embodiments (1) to (19) relates to said catalytic material, wherein the catalytic material exhibits a Zr:Si atomic ratio in the range of from in the range of from 0.1:1 to 10:1, more preferably in the range of from 0.5:1 to 5.0:1, more preferably in the range of from 1.0:1 to 3.0:1, more preferably in the range of from 1.2:1 to 2.6:1.
A preferred embodiment (21) concretizing any one of embodiments (1) to (20) relates to said catalytic material, wherein the catalytic material comprises from 2 to 25 weight-%, preferably from 5 to 20, more preferably from 8 to 17 weight-%, more preferably from 10 to 15 weight-%, of Zr, calculated as elemental Zr, and based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively.
A preferred embodiment (22) concretizing any one of embodiments (1) to (21) relates to said catalytic material, wherein the catalytic material comprises from 0.3 to 3.0 weight-%, preferably from 0.7 to 2.5, more preferably from 1.0 to 2.2 weight-%, more preferably from 1.2 to 2.0 weight-%, of Si, calculated as elemental Si, and based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively.
A preferred embodiment (23) concretizing any one of embodiments (1) to (22) relates to said catalytic material, wherein from 90 to 100 weight-%, preferably from 95 to 100 weight-%, more preferably from 99 to 100 weight-%, more preferably from 99.9 to 100 weight-%, of the oxidic support material comprising Zr in oxidic form and Si in oxidic form consists of Si, Zr, 0, and H.
A preferred embodiment (24) concretizing any one of embodiments (1) to (23) relates to said catalytic material, wherein the Ni is in an oxidation state of 0 or +2.
A preferred embodiment (25) concretizing any one of embodiments (1) to (24) relates to said catalytic material, wherein equal to or more than 55 atomic-%, preferably equal to or more than 60 atomic-%, more preferably equal to or more than 65 atomic-%, more preferably equal to or more than 70 atomic-%, more preferably equal to or more than 75 atomic-%, of the Ni are in an oxidation state of 0, preferably determined according to Reference Example 8.
A preferred embodiment (26) concretizing any one of embodiments (1) to (25), preferably embodiment (25), relates to said catalytic material, wherein the catalytic material comprises particles of Ni.
A preferred embodiment (27) concretizing embodiment (26) relates to said catalytic material, wherein the catalytic material exhibits a monomodal particle size distribution of the crystallites of Ni, preferably determined according to Reference Example 3.
A preferred embodiment (28) concretizing embodiment (27) relates to said catalytic material, wherein the particle size distribution of the crystallites of Ni displays a maximum in the range of from 2 to 20 nm, more preferably in the range of from 3 to 15 nm, more preferably in the range of from 4 to 11 nm, more preferably in the range of from 4.5 to 10.0 nm, more preferably in the range of from 5.0 to 9.0 nm, preferably determined according to Reference Example 3.
A preferred embodiment (29) concretizing any one of embodiments (25) to (28) relates to said catalytic material, wherein the Ni has a metallic surface area in the range of from 40 to 100 m2/g, more preferably in the range of from 50 to 90 m2/g, more preferably in the range of from 70 to 80 m2/g, preferably determined according to Reference Example 2.
A preferred embodiment (30) concretizing any one of embodiments (1) to (29) relates to said catalytic material, wherein less than 45 atomic-%, preferably less than 40 atomic-%, more preferably less than 35 atomic-%, more preferably less than 30 atomic-%, more preferably less than 25 atomic-%, of the Ni are in an oxidation state of +2, wherein more preferably the Ni in oxidation state +2 is present in the form of NiO.
A preferred embodiment (31) concretizing any one of embodiments (1) to (30) relates to said catalytic material, wherein the catalytic material exhibits a total pore volume in the range of from 0.1 to 1.00 cm3/g, preferably in the range of from 0.20 to 0.50 cm3/g, more preferably in the range of from 0.25 to 0.45 cm3/g, preferably determined according to Reference Example 1.
A preferred embodiment (32) concretizing any one of embodiments (1) to (31) relates to said catalytic material, wherein the catalytic material comprises from 0 to 2 weight-%, preferably from 0 to 1 weight-%, more preferably from 0 to 0.5 weight-%, of Hf, calculated as elemental Hf, and based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively, wherein the catalytic material is more preferably essentially free of Hf, wherein the catalytic material does more preferably not comprise Hf.
A preferred embodiment (33) concretizing any one of embodiments (1) to (32) relates to said catalytic material, wherein the catalytic material comprises from 0 to 1 weight-%, preferably from 0 to 0.5 weight-%, more preferably from 0 to 0.3 weight-%, of an alkali metal, calculated as elemental alkali metal, and based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively, wherein the catalytic material is more preferably essentially free of an alkali metal, wherein the catalytic material does more preferably not comprise an alkali metal.
A preferred embodiment (34) concretizing embodiment (33) relates to said catalytic material, wherein the alkali metal comprises one or more of Li, Na, and K, more preferably Na.
A preferred embodiment (35) concretizing any one of embodiments (1) to (34) relates to said catalytic material, wherein the catalytic material further comprises an element E selected from the group consisting of Mg, Ca, Zn, B, Fe, Cl, and a mixture of two or more thereof.
A preferred embodiment (36) concretizing embodiment (35) relates to said catalytic material, wherein the catalytic material comprises from 0 to 1 weight-%, more preferably from 0.001 to 0.5 weight-%, more preferably from 0.01 to 0.1 weight-%, of the element E, calculated as elemental E, based on the weight of the catalytic material.
A preferred embodiment (37) concretizing any one of embodiments (1) to (36) relates to said catalytic material, wherein the catalytic material further comprises an auxiliary agent selected from the group consisting of graphite, a polysaccharide, a sugar alcohol, a synthetic polymer, and a mixture of two or more thereof, preferably selected from the group consisting of graphite, a sugar alcohol, a synthetic polymer, cellulose, a modified cellulose, a starch, and a mixture of two or more thererof, more preferably selected from the group consisting of graphite, a sugar alcohol, a synthetic polymer, a microcrystalline cellulose, a cellulose ether, and a mixture of two or more thereof, more preferably selected from the group consisting of graphite, sorbitol, mannitol, polyethylene glycol (PEG), polyvinylpyrrolidone (PVP), hydroxypropyl cellulose (HPC), hydroxypropyl methylcellulose (HPMC), and a mixture of two or more thereof, wherein the auxiliary agent more preferably comprises, more preferably consist of, graphite.
A preferred embodiment (38) concretizing embodiment (37) relates to said catalytic material, wherein the catalytic material comprises the auxiliary agent in an amount in the range of from 1.0 to 5.0 weight-%, preferably in the range of from 2.0 to 4.5 weight-%, more preferably in the range of from 2.5 to 4.0 weight-%, based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively.
A preferred embodiment (39) concretizing any one of embodiments (1) to (38) relates to said catalytic material, wherein the catalytic material is in the form of a molding.
A preferred embodiment (40) concretizing embodiment (39) relates to said catalytic material, wherein the catalytic material is in the form of a tablet, more preferably in the form of a tablet having a cylindrical shape or an ellipsoidal shape.
A preferred embodiment (41) concretizing embodiment (40) relates to said catalytic material, wherein the tablet has a cylindrical shape, wherein the diameter is in the range of from 5 to 15 mm, more preferably in the range of from 8 to 12 mm, more preferably in the range of from 9 to 11 mm, and wherein the height is preferably in the range of from 3 to 13 mm, preferably in the range of from 6 to 10 mm, more preferably in the range of from 7 to 9 mm.
A preferred embodiment (42) concretizing embodiment (40) or (41) relates to said catalytic material, wherein the tablet has a cylindrical shape, and wherein the tablet has a side crushing strength in the range of from 70 to 130 N, more preferably in the range of from 80 to 120 N, preferably determined according to Reference Example 4.
A preferred embodiment (43) concretizing any one of embodiments (1) to (42) relates to said catalytic material, wherein from 90 to 100 weight-%, more preferably from 95 to 100 weight-%, more preferably from 99 to 100 weight-%, more preferably from 99.9 to 100 weight-%, of the catalytic material consist of Ni, M, Si, Zr, 0, H, optionally Hf, optionally an element E, optionally an alkali metal, and optionally an auxiliary agent.
According to an embodiment (44), the present invention further relates a process for the preparation of a catalytic material according to any one of embodiments (1) to (43), said process comprising
A preferred embodiment (45) concretizing embodiment (44) relates to said process, wherein in (a) the first aqueous solution is heated to a temperature in the range of from 60 to 80° C., more preferably in the range of from 65 to 75° C.
A preferred embodiment (46) concretizing embodiment (44) or (45) relates to said process, wherein (b) comprises
A preferred embodiment (47) concretizing embodiment (46) relates to said process, wherein in (b.1) the pH is adjusted to be in the range of from 6.5 to 8.5, more preferably in the range of from 6.7 to 8.0, more preferably in the range of from 6.8 to 7.5, more preferably in the range of from 6.9 to 7.1.
A preferred embodiment (48) concretizing embodiment (46) or (47) relates to said process, wherein in (b.1) the pH is adjusted by feeding a fifth aqueous solution comprising a source of Ni into the first aqueous solution, wherein the fifth aqueous solution more preferably has the same chemical composition as the second aqueous solution, wherein more preferably the fourth aqueous solution comprises a portion of the second aqueous solution.
A preferred embodiment (49) concretizing embodiment (44) or (45) relates to said process, wherein (b) comprises
A preferred embodiment (50) concretizing any one of embodiments (44) to (49) relates to said process, wherein heating in (c) comprises heating of the mixture to a temperature in the range of from 55 to 90° C., more preferably in the range of from 65 to 80° C., more preferably in the range of from 70 to 75° C.
A preferred embodiment (51) concretizing any one of embodiments (44) to (50) relates to said process, wherein the source of Si in one or more of the first aqueous solution and the third aqueous solution comprises one or more of a silicate, more preferably one or more of a metasilicate, an orthosilicate, and a pyrosilicate, more preferably a silicate salt, more preferably a silicate salt selected from the group consisting of alkali metal silicates and mixtures thereof, wherein the alkali metal is preferably selected from the group consisting of Li, Na, K, Rb, Cs, and mixtures of two or more thereof, more preferably from the group consisting of Li, Na, K, and mixtures of two or more thereof, wherein more preferably the alkali metal is Na and/or K, preferably Na, wherein the source of Si preferably comprises, more preferably consists of, a metasilicate, more preferably sodium silicate.
A preferred embodiment (52) concretizing any one of embodiments (44) to (51) relates to said process, wherein the concentration of the source of Si, calculated as SiO2, in the first aqueous solution is in the range of from 10 to 500 mmol/l, more preferably in the range of from 30 to 250 mmol/l, more preferably in the range of from 50 to 100 mmol/l.
A preferred embodiment (53) concretizing any one of embodiments (44) to (52) relates to said process, wherein the source of Ni in the second aqueous solution and/or in the fifth aqueous solution comprises one or more Ni salts, more preferably one or more Ni(II) salts, wherein the anion of the one or more Ni salts is preferably selected from the group consisting of halides, carbonate, hydrogencarbonate, sulfate, hydrogensulfate, hydroxide, nitrate, phosphate, hydogenphosphate, dihydrogenphosphate, acetate, and combinations of two or more thereof, more preferably from the group consisting of chloride, bromide, fluoride, hydrogencarbonate, hydrogensulfate, nitrate, dihydrogenphosphate, acetate, and combinations of two or more thereof,
A preferred embodiment (54) concretizing any one of embodiments (44) to (53) relates to said process, wherein the concentration of the source of Ni, calculated as NiO, in the second aqueous solution and/or in the fifth aqueous solution is in the range of from 0.1 to 4 mol/l, more preferably in the range of from 0.4 to 2.5 mol/l, more preferably in the range of from 0.7 to 1.4 mol/l.
A preferred embodiment (55) concretizing any one of embodiments (44) to (54) relates to said process, wherein the ratio of the total volume of the first aqueous solution to the total volume of the second aqueous solution is in the range of from 1:50 to 1:2, more preferably in the range of from 1:30 to 1:5, more preferably in the range of from 1:10 to 1:6.
A preferred embodiment (56) concretizing any one of embodiments (44) to (55) relates to said process, wherein the precipitation agent comprises one or more of an inorganic base and an organic base, more preferably an inorganic base, wherein preferably the precipitation agent is selected from the group consisting of hydroxides, carbonates, aluminates, and mixtures of two or more thereof,
A preferred embodiment (57) concretizing any one of embodiments (44) to (56) relates to said process, wherein the concentration of the precipitation agent in the third aqueous solution is in the range of from 1.0 to 5.0 mol/l, more preferably in the range of from 1.4 to 3.0 mol/l, more preferably in the range of from 1.8 to 2.4 mol/l.
A preferred embodiment (58) concretizing any one of embodiments (44) to (57) relates to said process, wherein the ratio of the total volume of the first aqueous solution to the total volume of the third aqueous solution is in the range of from 1:70 to 5:1, more preferably in the range of from 1:15 to 3:1, more preferably in the range of from 1:2 to 2:1.
A preferred embodiment (59) concretizing any one of embodiments (44) to (58) relates to said process, wherein the concentration of the source of Zr, calculated as ZrO2, in the fourth aqueous solution is in the range of from 10 to 750 mmol/l, more preferably in the range of from 20 to 600 mmol/l, more preferably in the range of from 30 to 300 mmol/l.
A preferred embodiment (60) concretizing any one of embodiments (44) to (59) relates to said process, wherein the ratio of the total volume of the first aqueous solution to the total volume of the fourth aqueous solution is in the range of from 1:20 to 1:2, more preferably in the range of from 1:10 to 1:5, more preferably in the range of from 1:8 to 1:6.
A preferred embodiment (61) concretizing any one of embodiments (44) to (60) relates to said process, wherein the gas atmosphere in (d) comprises a temperature in the range of from 400 to 500° C., more preferably in the range of from 440 to 460° C.
A preferred embodiment (62) concretizing any one of embodiments (44) to (61) relates to said process, wherein the process further comprises after (c) and prior to (d) one or more of
A preferred embodiment (63) concretizing any one of embodiments (44) to (62) relates to said process, wherein the gas atmosphere in one or more of (d) and (t) comprises one or more of nitrogen and oxygen, more preferably air.
A preferred embodiment (64) concretizing any one of embodiments (44) to (63) relates to said process, wherein the process further comprises
A preferred embodiment (65) concretizing embodiment (64) relates to said process, wherein the gas stream in (e) comprises hydrogen in an amount in the range of from 1 to 50 volume-%, based on the total volume of the gas stream, and nitrogen in an amount in the range of from 50 to 99 volume-%, based on the total volume of the gas stream.
A preferred embodiment (66) concretizing embodiment (64) or (65) relates to said process, wherein in (e) the content of hydrogen in the gas stream is adjusted such that in (e) the temperature of the catalytic material does not exceed 425° C., wherein more preferably the temperature of the catalytic material does not exceed 385° C.
A preferred embodiment (67) concretizing any one of embodiments (64) to (66) relates to said process, wherein in (f) the content of oxygen in the gas stream is adjusted such that in (f) the temperature of the catalytic material does not exceed 80° C., wherein more preferably the temperature of the catalytic material does not exceed 35° C.
A preferred embodiment (68) concretizing any one of embodiments (44) to (67) relates to said process, wherein the process further comprises
A preferred embodiment (69) concretizing embodiment (68) relates to said process, wherein the auxiliary agent comprises one or more of graphite, a polysaccharide, a sugar alcohol and a synthetic polymer, more preferably one or more of graphite, a sugar alcohol, a synthetic polymer, cellulose, a modified cellulose and a starch, more preferably one or more of graphite, a sugar alcohol, a synthetic polymer, a microcrystalline cellulose, a cellulose ether, more preferably one or more of graphite, sorbitol, mannitol, polyethylene glycol (PEG), polyvinylpyrrolidone (PVP), hydroxypropyl cellulose (HPC) and hydroxypropyl methylcellulose (HPMC), more preferably graphite.
A preferred embodiment (70) concretizing embodiment (68) or (69) relates to said process, wherein the mixture prepared in (g) comprises the auxiliary agent in an amount in the range of from 1.0 to 5.0 weight-%, preferably in the range of from 2.0 to 4.0 weight-%, more preferably in the range of from 2.5 to 3.5 weight-%, based on the total weight of the mixture.
A preferred embodiment (71) concretizing any one of embodiments (68) to (70) relates to said process, wherein shaping in (h) comprises extruding or tableting the mixture obtained in (g), more preferably tableting the mixture obtained in (g).
A preferred embodiment (72) concretizing any one of embodiments (68) to (71) relates to said process, wherein shaping in (h) comprises tableting the mixture to a tablet, more preferably to a tablet having a cylindrical shape or an ellipsoidal shape.
A preferred embodiment (73) concretizing embodiment (72) relates to said process, wherein tableting is performed to obtain a tablet having a cylindrical shape, wherein the diameter of the tablet is in the range of from 5 to 15 mm, more preferably in the range of from 8 to 12 mm, more preferably in the range of from 9 to 11 mm, and wherein the height is preferably in the range of from 3 to 13 mm, preferably in the range of from 6 to 10 mm, more preferably in the range of from 7 to 9 mm.
A preferred embodiment (74) concretizing any one of embodiments (44) to (73) relates to said process, wherein the process further comprises
A preferred embodiment (75) concretizing embodiment (74) relates to said process, wherein the one or more additional metals M are Re.
A preferred embodiment (76) concretizing embodiment (75) relates to said process, wherein the aqueous solution according to (i) comprises Re in an amount in the range of from 3 to 15 weight-%, preferably in the range of from 8 to 10 weight-%, calculated as elemental Re, based on the weight of the aqueous solution.
A preferred embodiment (77) concretizing embodiment (75) or (76) relates to said process, wherein the aqueous solution according to (i) comprises one or more of perrhenic acid (HReO4), Re2O7, and Re2O7(OH2)2.
A preferred embodiment (78) concretizing embodiment (74) relates to said process, wherein the one or more additional metals M are selected from the group consisting of Ru, Os, Rh, Ir, Pd, and Pt, preferably selected from the group consisting of Rh, Ir, Pd, and Pt, wherein the one or more additional metals M more preferably are Pd and/or Pt, wherein the one or more additional metals M more preferably are Pt.
A preferred embodiment (79) concretizing embodiment (78) relates to said process, wherein the aqueous solution according to (i) comprises the one or more additional metals M in an amount in the range of from 0.1 to 1 weight-%, preferably in the range of from 0.5 to 0.6 weight-%, calculated as sum of the weights of the respective elements of the one or more additional metals M, based on the weight of the aqueous solution.
A preferred embodiment (80) concretizing embodiment (78) or (79) relates to said process, wherein the one or more additional metals M are Pt, and wherein the aqueous solution according to (i) comprises one or more of platinum(II) nitrate, platinum(IV) nitrate, ammonium hexachloroplatinate, ammine stabilized hydroxo Pt(II) complex, tetraammineplatinum chloride, tetraammineplatinum nitrate, hexachloroplatinic acid, and potassium hexachloroplatinate.
A preferred embodiment (81) concretizing any one of embodiments (74) to (80) relates to said process, wherein the gas atmosphere in (k) comprises one or more of nitrogen and oxygen, preferably air.
A preferred embodiment (82) concretizing any one of embodiments (74) to (81) relates to said process, wherein the process further comprises
A preferred embodiment (83) concretizing embodiment (82) relates to said process, wherein the gas stream in (m) comprises hydrogen in an amount in the range of from 1 to 50 volume-%, based on the total volume of the gas stream, and nitrogen in an amount in the range of from 50 to 99 volume-%, based on the total volume of the gas stream.
A preferred embodiment (84) concretizing embodiment (82) or (83) relates to said process, wherein in (m) the content of hydrogen in the gas stream is adjusted such that in (m) the temperature of the molding does not exceed 425° C., wherein in (m) the temperature of the molding does preferably not exceed 380° C.
A preferred embodiment (85) concretizing any one of embodiments (82) to (84) relates to said process, wherein in (n) the content of oxygen in the gas stream is adjusted such that in (n) the temperature of the molding does not exceed 80° C., wherein in (n) the temperature of the molding does preferably not exceed 35° C.
According to an embodiment (86), the present invention further relates a catalytic material obtainable or obtained by the process of any one of embodiments (44) to (85).
According to an embodiment (87) the present invention further relates to a use of the catalytic material according to any one of embodiments (1) to (43) and (86), as a catalyst or catalyst component for a hydrogenation reaction, preferably for a hydrogenation reaction of one or more of a nitro-group containing compound, a nitrile, an aromatic, and an olefin.
According to an embodiment (88), the present invention further relates a continuous process for catalytic hydrogenation of a nitro group-containing compound, the process comprising
A preferred embodiment (89) concretizing embodiment (88) relates to said continuous process, wherein the reactor provided in (1) is a loop reactor, preferably a loop Venturi reactor. Thus, it is preferred that a reactor is provided in (1) as disclosed in WO 2014/108351 A1. As an alternative, the reactor provided in (1) is in accordance with a reactor disclosed for the process for preparing amines as disclosed in WO 00/35852 A1.
A preferred embodiment (90) concretizing embodiment (88) or (89) relates to said continuous process, wherein in (1) the catalytic material is present in a fixed-bed and/or in a fluidized bed, more preferably in a fluidized bed.
A preferred embodiment (91) concretizing any one of embodiments (88) to (90) relates to said process, wherein in (1) the reaction zone comprises a solvent system, wherein the solvent system more preferably comprises one or more of water, and an amine-group containing compound as obtained in (II), more preferably water, more preferably de-ionized water, more preferably water, which is obtained during the hydrogenation reaction (II).
A preferred embodiment (92) concretizing any one of embodiments (88) to (91) relates to said process, wherein in (II) the reaction conditions comprise a temperature in the range of from 100 to 150° C., more preferably in the range of from 110 to 140° C., more preferably in the range of from 120 to 140° C.
A preferred embodiment (93) concretizing any one of embodiments (88) to (92) relates to said process, wherein in (II) the reaction conditions comprise a pressure in the range of from 10 to 150 bar(abs), more preferably in the range of from 15 to 50 bar(abs), more preferably in the range of from 20 to 30 bar(abs).
A preferred embodiment (94) concretizing any one of embodiments (88) to (93) relates to said process, wherein the nitro group containing compound comprises one or more of an aromatic nitro group-containing compound and an aliphatic nitro group-containing compound, wherein the aromatic nitro group-containing compound more preferably comprises one or more of nitrobenzene, 1,3-dinitrobenzene, 2,4-dinitrotoluene, 2,6-dinitrotoluene, 2,4,6-trinitrotoluene, 1,2-dimethyl-3-nitrobenzene, 1,2-dimethyl-4-nitrobenzene, 1,4-dimethyl-2-nitrobenzene, 1,3-dimethyl-2-nitrobenzene, 2,4-dimethyl-1 nitrobenzene, 1,3-dimethyl-5-nitrobenzene, 1-nitronaphthalene, 2-nitronaphthalene, 1,5-dinitronaphthalene und 1,8-dinitronaphthalene, 2-mononitrotoluene, 3-mononitrotoluene, 4-mononitrotoluene, 2-chloro-1,3-dinitrobenzene, 1-chloro-2,4-dinitrobenzene, o-chloronitrobenzene, m-chloronitrobenzene, p-chloronitrobenzene, 1,2-dichloro-4-nitrobenzene, 1,4-dichloro-2-nitrobenzene, 2,4-dichloro-1-nitrobenzene, 1,2-dichloro-3-nitrobenzene, 4-chloro-2-nitrotoluene, 4-chloro-3-nitrotoluene, 2-chloro-4-nitrotoluene, 2-chlor-6-nitrotoluene, o-nitroaniline, m-nitroaniline, and p-nitroaniline, preferably 2,4-dinitrotoluene or a mixture of 2,4- and 2,6-dinitrotoluene, and wherein the aliphatic nitro group-containing compound more preferably comprises one or more of tris(hydroxymethyl)nitromethane, 2-nitro-2-methyl-1,3-propanediol, 2-nitro-2-ethyl-1,3-propanediol, 2-nitro-1-butanol and 2-nitro-2-methyl-1-propanol.
A preferred embodiment (95) concretizing any one of embodiments (88) to (93) relates to said process, wherein the product stream comprises an amine group-containing compound, more preferably one or more of an aromatic amine group-containing compound and an aliphatic amine group-containing compound, wherein the aromatic amine group-containing compound preferably comprises one or more of aminobenzene, 1,3-diaminobenzene, 2,4-diaminotoluene, 2,6-diaminotoluene, 2,4,6-triaminotoluene, 1,2-dimethyl-3-aminobenzene, 1,2-dimethyl-4-aminobenzene, 1,4-dimethyl-2-aminobenzene, 1,3-dimethyl-2-aminobenzene, 2,4-dimethyl-1-aminobenzene, 1,3-dimethyl-5-aminobenzene, 1-aminonaphthalene, 2-aminonaphthalene, 1,5-diaminonaphthalene und 1,8-diaminonaphthalene, 2-aminotoluene, 3 aminotoluene, 4-aminotoluene, 2-chloro-1,3-diaminobenzene, 1-chloro-2,4-diaminobenzene, o-chloroaminobenzene, m-chloroaminobenzene, p-chloroaminobenzene, 1,2-dichloro-4-aminobenzene, 1,4-dichloro-2-aminobenzene, 2,4-dichloro-1-aminobenzene, 1,2-dichloro-3-aminobenzene, 4-chloro-2-aminotoluene, 4-chloro-3-aminotoluene, 2-chloro-4-aminotoluene, 2-chlor-6-aminotoluene, o-phenylenediamine, m-phenylenediamine, and p-phenylenediamine, preferably 2,4-diaminotoluene, and wherein the aliphatic amine group-containing compound preferably comprises one or more of tris(hydroxymethyl)aminomethane, 2-amino-2-methyl-1,3-propanediol, 2-amino-2-ethyl-1,3-propanediol, 2-amino-1-butanol and 2-amino-2-methyl-1-propanol.
The present invention is further illustrated by the following examples, comparative examples, and reference examples.
The total pore volume and the average pore diameter were determined via intrusion mercury porosimetry according to standard ASTM D 4284-12.
The measurement of the metallic surface area of a sample was done using a Micromeritics AutoChem 2950 HP Chemisorption Analyzer. 100 mg of a sample were used. The sample was treated with hydrogen at a temperature of 300° C. for 1 h before measuring the amount of desorbed hydrogen. The amount of desorbed hydrogen was measured over a temperature range from −68 to 752° C. The Ni metallic surface area was calculated from the total amount of desorbed hydrogen. The calculation was done considering a calibration sample with a known Ni surface area.
The average crystallite size of Ni was measured by XRD methods applying the Scherrer equation In particular, the crystallite size was determined using X-ray diffraction by fitting the diffracted reflection width. The software used was TOPAS 6. Instrumental contribution to reflection broadening was considered during the fitting routine using the fundamental parameter approach as described in TOPAS 6 Users Manual (Bruker AXS GmbH, Ostliche Rheinbrückenstr. 49, D76187 Karlsruhe). This led to a reliable separation of the instrumental from the sample broadening. The sample contribution was determined using a single Lorentzian profile function that is defined by the following equation I.
The entire diffraction pattern was used to model the crystallite size. Data was collected on a Bruker D8 Advance diffractometer using Cu-radiation. It was measured in Bragg-Brentano geometry from 2°-70° (20), using a step size of 0.02°(2θ).
The side crushing strength was determined with a Universal Hardness Testing Machine Zwick cLine Z010 (item no. 1006326) according to ASTM D 4179 using a crosshead speed of 14 mm/min and a cylindric indenter tool with 12.2 mm diameter.
The pH value was determined using a pH Meter F20 from Mettler Toledo according to the respective operating instructions of October 2015.
The particle size was determined with an apparatus of Retsch Typ AS 200 control using a set of sieves according to DIN/ISO 3310-1.
A weighed sample of catalytic material was covered with an overlayer of about 5 mm of deionized water in a glass funnel equipped with a tap, the deionized water was allowed to act for about 15 minutes. Then, the deionized water was dripped off for 5 minutes and after that the catalyst was weighed back.
The reduction degree was determined according to the method disclosed by C. R. Hubbard and R. L. Snyder in “RIR—Measurement and Use in Quantitative XRD” in Powder Diffraction, volume 3, Issue 2, June 1988, pages 74-77.
In particular, the data evaluation (Rietveld refinement) of the data was performed with the TOPAS version 6 (Bruker AXS GmbH) software. The phase composition was as follows: NiO, Ni, very fine crystalline (<5 nm) to amorphous ZrO2, graphite, and amorphous SiO2. NiO and Ni were refined with structural data. ZrO2, amorphous SiO2 as well as graphite were fitted with single peak and not considered in the calculation. The absolute error of the weight percentages of Ni and NiO was <1% (error value). The data for the error originated from the minimization routine in the TOPAS software. The subsurface was fitted with a first-order polynomial, and the sample height error was refined.
500 g deionized water are filled in a vessel. 15 g of a water glass-containing solution (containing 2.3 g of Si calculated as SiO2) are added thereto under stirring. Separately, a metal-containing solution was prepared under stirring by providing 400 g of a nickel nitrate-solution (containing 56 g of Ni calculated as NiO), adding 100 g of a zirconyl nitrate-solution (containing 10 g of Zr calculated as ZrO2) and 500 g of de-ionized water thereto. Further, a sodium carbonate-solution was prepared separately by dissolving 200 g of sodium carbonate in 1000 g de-ionized water.
The water glass-containing solution was heated in the vessel to a temperature of 70° C. Then, the metal-containing solution was slowly introduced. When a pH of 7 was reached, introduction of the sodium carbonate-solution was started such that the pH of the reaction mixture in the vessel remained constant at a value of 7.0. After about 1 hour, addition of the metal-containing solution and of the sodium carbonate-solution was complete and the resulting mixture was stirred at 70° C. for one hour. Then, the resulting suspension was cooled to room temperature, filtered and the resulting solids washed with de-ionized water until the conductivity of the washing water was less than 100 microS.
The resulting solids were dried overnight in air at a temperature of 120° C. and then calcined at 450° C. for two hours in air to obtain a catalytic material comprising Ni in oxidic form supported on an oxidic support comprising Zr in oxidic form and Si in oxidic form.
A sample of the calcined catalytic material was further calcined at 900° C. The resulting catalytic material had a NiO content of 81.7 weight-% (corresponding to 64.3 weight-% Ni), a ZrO2 content of 13.7 weight-%, a SiO2 content of 3.1 weight-%, a HfO2 content of 0.3 weight-%, and a Na2O content of 0.2 weight.-%. Thus, the resulting catalytic material exhibited a Ni:Zr atomic ratio of 9.8:1, a Ni:Si atomic ratio of 21.5:1, and a Zr:Si atomic ratio of 2.2:1.
The rest of the calcined catalytic material was milled and subsequently mixed with 3 weight-% of graphite. The resulting powder was shaped into tablets having a geometry of 10 mm*8 mm. The side crushing strength of the resulting tablets was in the range of from 80 to 120 N.
The resulting tablets had a NiO content of 80.0 weight-%, a ZrO2 content of 13.4 weight-%, a SiO2 content of 3.0 weight-%, a HfO2 content of 0.3 weight-%, a Na2O content of 0.2 weight-%, and a C content of 3 weight-%. Further, the tablets had a water uptake of 0.32 ml/g.
The tablets obtained from Reference Example 9 were subjected to reduction conditions by treating them in a hydrogen and nitrogen containing stream and at a maximum temperature of 380° C. To this effect, reduction conditions were applied comprising a gas stream containing 1 volume-% of hydrogen and 99 volume-% of nitrogen and a temperature of 350° C. Then, the hydrogen content of the gas stream was increased up to 50 volume-% of the gas stream under the provision that the temperature did not exceed 380° C.
Then, the tablets were cooled to room temperature in a stream of nitrogen. Subsequently, the tablets were treated in a stream of nitrogen and oxygen for passivation of the surface to obtain a reduced catalytic material. The composition of the stream was adjusted such that the temperature of the tablets did not exceed 35° C. by controlling the concentration of oxygen therein. At the beginning of the reduction process, the concentration of oxygen was 0.1 volume-% and then slowly increased up to 10 volume-%.
The resulting reduced catalytic material had a reduction degree in the range of from 79 to 81% determined according to Reference Example 8 and an average Ni particle size of 8 nm, determined according to Reference Example 3.
Based on a reduction degree of 80% of the Ni contained in the catalytic material and based on 100 weight-% of the sum of the weights of Ni calculated as the element, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively, it can be postulated that the resulting reduced catalytic material had a Ni content of 79.3 weight-%, a Zr content of 12.5 weight-%, and a Si content of 1.8 weight-%.
The tablets obtained from Reference Example 9 were subjected to a treatment with perrhenic acid (HReO4) for an impregnation with Re. To this effect, 300 g of said tablets were impregnated with 90 g of an aqueous solution of perrhenic acid (HReO4) comprising 8.9 weight-% Re, calculated as elemental Re (corresponding to a Re content of 8 g). The resulting Re-impregnated tablets were dried at 120° C. in air.
The Re-impregnated tablets were then subjected to reduction conditions by treating them in a hydrogen and nitrogen containing stream and at a maximum temperature of 380° C. To this effect, reduction conditions were applied comprising a gas stream containing 1 volume-% of hydrogen and 99 volume-% of nitrogen and a temperature of 350° C. Then, the hydrogen content of the gas stream was increased up to 50 volume-% of the gas stream under the provision that the temperature did not exceed 380° C.
Then, the reduced Re-impregnated tablets were cooled to room temperature in a stream of nitrogen. Subsequently, the reduced Re-impregnated tablets were treated in a stream of nitrogen and oxygen for passivation of the surface to obtain a reduced catalytic material. The composition of the stream was adjusted such that the temperature of the tablets did not exceed 35° C. by controlling the concentration of oxygen therein. At the beginning of the reduction process, the concentration of oxygen was 0.1 volume-% and then slowly increased up to 10 volume-%.
The resulting catalytic material, the reduced Re-impregnated tablets, had a reduction degree in the range of from 79 to 81% determined according to Reference Example 8. The resulting reduced Re-impregnated tablets had a Ni content of 70.7 weight-%, a Re content of 3.0 weight-%, a ZrO2 content of 15.1 weight-%, a SiO2 content of 3.4 weight-%, a Hf content of 0.3 weight-%, a Na content of 0.2 weight-%, and a C content of 3.4 weight-%.
Calculated based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively, the resulting catalytic material had a Ni content of 76.7 weight-%, a Re content of 3.3 weight-%, a Zr content of 12.1 weight-%, and a Si content of 1.7 weight-%.
Further, the resulting catalytic material exhibited a Ni:Re atomic ratio of 74.6:1, a Zr:Re atomic ratio of 7.6:1, a Si:Re atomic ratio of 3.5:1, a Ni:Zr atomic ratio of 9.8:1, a Ni:Si atomic ratio of 21.5:1, and a Zr:Si atomic ratio of 2.2:1.
The tablets obtained from Reference Example 9 were subjected to a treatment with platinum nitrate (Pt(NO3)2) for an impregnation with Pt. To this effect, 300 g of said tablets were impregnated with 90 g of an aqueous solution of platinum nitrate (Pt(NO3)2) comprising 0.55 weight-% Pt, calculated as elemental Pt (corresponding to a Pt content of 0.5 g). The resulting Pt-impregnated tablets were dried at 120° C. in air.
The Pt-impregnated tablets were then subjected to reduction conditions by treating them in a hydrogen and nitrogen containing stream and at a maximum temperature of 380° C. To this effect, reduction conditions were applied comprising a gas stream containing 1 volume-% of hydrogen and 99 volume-% of nitrogen and a temperature of 350° C. Then, the hydrogen content of the gas stream was increased up to 50 volume-% of the gas stream under the provision that the temperature did not exceed 380° C.
Then, the reduced Pt-impregnated tablets were cooled to room temperature in a stream of nitrogen. Subsequently, the reduced Pt-impregnated tablets were treated in a stream of nitrogen and oxygen for passivation of the surface to obtain a reduced catalytic material. The composition of the stream was adjusted such that the temperature of the tablets did not exceed 35° C. by controlling the concentration of oxygen therein. At the beginning of the reduction process, the concentration of oxygen was 0.1 volume-% and then slowly increased up to 10 volume-%.
The resulting catalytic material, the reduced Pt-impregnated tablets, had a reduction degree in the range of from 79 to 81% determined according to Reference Example 8.
The resulting reduced Pt-impregnated tablets had a Ni content of 72.8 weight-%, a Pt content of 0.2 weight-%, a ZrO2 content of 15.5 weight-%, a SiO2 content of 3.5 weight-%, a Hf content of 0.3 weight-%, a Na content of 0.2 weight-%, and a C content of 3.5 weight-%.
Calculated based on 100 weight-% of the sum of the weights of Ni and of the one or more additional metals M calculated as the elements, respectively, and of Zr and Si calculated as the oxides ZrO2 and SiO2, respectively, the resulting catalytic material had a Ni content of 79.1 weight-%, a Pt content of 0.2 weight-%, a Zr content of 12.4 weight-%, and a Si content of 1.8 weight-%.
Thus, the resulting Pt-impregnated tablets exhibited a Ni:Pt atomic ratio of 1157:1, a Zr:Pt atomic ratio of 117:1, a Si:Pt atomic ratio of 54:1, a Ni:Zr atomic ratio of 9.8:1, a Ni:Si atomic ratio of 21.5:1, and a Zr:Si atomic ratio of 2.2:1.
A sample of a catalytic material was crushed under an inert gas atmosphere to particles having a particles size of smaller than 250 μm determined according to Reference Example 6. The obtained particles were suspended in water for handling in air.
As a testing unit a loop reactor (German: “Schlaufenreaktor”; for details of a loop reactor see also WO 00/35852 A1 and WO 2014/108351 A1) was used which comprised in one part an internal circulation flow having a volume of 5.6 l and in another part a tube reactor having a total volume 4.4 l. The internal circulation flow was driven by a propulsion jet (external circulation flow consisting of a product-containing solution and suspended catalytic material). The whole testing unit was thermostatized with thermal oil for dissipating heat.
2,4-dinitrotoluene was introduced close to the propulsion jet. Hydrogen was introduced into the vapour space above the internal circulation flow whereby the hydrogen feed was adjusted by pressure to ensure an adequate feed of hydrogen replacing the consumed hydrogen as quickly as possible. The formed product mixture was removed as output via a membrane which held back the catalytic material such that the amount of liquids in the reactor part comprising the internal circulation flow was kept constant. The output was analyzed periodically. A constant amount of gaseous matter was removed at the top of the vapour space such that no accumulation of gaseous by-products or impurities could occur.
The reactor was loaded with 140+/−2 g (calculated as material in dried form) of a catalytic material suspended in water. Further, the reaction conditions comprised a temperature of 135+/−2° C., a pressure of 25+/−1 bar, an external circulation flow of 450+/−50 kg/h and a 2,4-dinitrotoluene dosing rate of 1+/−0.05 kg/h. The results of the tests are noted in following table 1. The reaction progress was determined after 100 h, 200 h, and 300 h time on stream via the selectivity in % towards 2,4-toluenediamine, low boiling compounds and high boiling compounds (2,4-toluenediamine is abbreviated as TDA, low boiling compounds are abbreviated as LB and high boiling compounds are abbreviated as HB).
It can be gathered from the results that the catalytic materials according to the present invention achieve a higher TDA selectivity after 100 h as well as after 200 h time on stream. In particular, the selectivity towards TDA was 0.3-1.6% higher in comparison to the selectivity achieved by the catalytic materials according to Comparative Example 1. Further, the selectivity towards byproducts was comparatively lower for the catalytic materials according to the present invention. In particular, the selectivity towards high boiling compounds (compounds having a higher retention time compared to TDA isomers) was lower for the catalytic materials according to the present invention compared to the catalytic materials of Comparative Example 1. Further, the selectivity towards low boiling compounds (compounds having a lower retention time compared to TDA isomers) was lower for the catalytic materials according to the present invention after 200 h time on stream compared with the catalytic material according to Comparative Example 1.
| Number | Date | Country | Kind |
|---|---|---|---|
| 21172385.3 | May 2021 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/062163 | 5/5/2022 | WO |
