METHOD FOR PRODUCE SUPPORTED METAL CATALYTIC CONVERTERS WITH A GRAIN-SHAPED ACTIVATED CARBON USED AS CATALYTIC CONVERTER SUPPORT

Description

[0001] The present invention relates to the technical field of catalytically active systems or the technical field of catalysts or catalytically active components applied to support materials and thus in particular to the technical field of supported catalysts, as they can be used in particular for heterogeneous catalysis.

[0002] In particular, the present invention relates to a process for producing a catalyst system comprising at least one catalytically active component in the form of a supported catalyst.

[0003] Furthermore, the present invention relates to a catalyst system obtainable on the basis of the process according to the invention and further to a catalyst system as such which comprises at least one catalytically active component applied to a catalyst support, in particular at least one catalytically active component fixed to a catalyst support.

[0004] The present invention also relates to the use of the catalyst system according to the invention as a catalyst or as a catalyst support. Furthermore, the present invention relates to the use of the catalyst system according to the invention for chemical catalysis. Furthermore, the present invention equally relates to the use of the catalyst system according to the invention for catalyzing chemical processes and reactions, such as hydrogenation reactions or the like.

[0005] Furthermore, the present invention also relates to the use of the catalyst system according to the invention for the production of filters and filter materials, as well as for sorption storage for gases or liquids, and for use in or as gas sensors or in fuel cells. Furthermore, the present invention also relates to the use of the catalyst system according to the invention for sorption applications, as well as for gas purification or gas processing, and furthermore for the removal of pollutants or environmentally harmful, harmful to health, or toxic substances or gases. The present invention also relates to the use of the catalyst system according to the invention for the processing or provision of clean room atmospheres or the like.

[0006] The present invention further relates to protective materials produced using the catalyst system according to the invention or comprising the catalyst system according to the invention. The present invention further relates to filters produced using the catalyst system according to the invention or comprising the catalyst system according to the invention.

[0007] A catalyst is generally understood to be a material or substance that is capable of increasing the reaction rate of a chemical reaction by lowering the activation energy without being consumed itself.

[0008] In the current state of the art, catalysts are of great technical and commercial importance, for example, in important catalytic processes such as the contact process for the production of sulfuric acid, the catalytic process for methanol production, the Haber-Bosch process for the industrial production of ammonia, and the Ostwald process for the large-scale production of nitric acid by oxidation of ammonia. Furthermore, catalysts are used in the synthesis of fine and specialty chemicals, in the synthesis of natural products, and in the production of active pharmaceutical ingredients. In particular, catalysts are also used in catalytic hydrogenation processes.

[0009] Against this background, there is a high demand in the state of the art for specific and high-performance catalysts for use in chemical catalysis, particularly since the targeted use of catalysts allows chemical reactions to occur more quickly or with less energy consumption. In this respect, too, the use of catalysts in chemical reactions is of great commercial importance: It is estimated that around 80% of all chemical products have a catalytic stage in the underlying manufacturing or value chain. Furthermore, catalysts also play a key role in environmental protection, particularly with regard to exhaust gas aftertreatment in industry, for example in industrial power generation and in the treatment of exhaust gases from (passenger) road transport.

[0010] In principle, catalysts can be used in the form of homogeneous or heterogeneous catalysts, whereby in the case of homogeneous catalysts or catalysts used in homogeneous catalysis, the reactants underlying the reaction to be catalyzed on the one hand and the catalyst on the other hand are present in the same phase, whereas in the case of heterogeneous catalysts or catalysts used in heterogeneous catalysis, the reactants to be reacted on the one hand and the catalyst on the other hand are present in different phases, for example as a solid in relation to the catalyst and as a liquid or gas in relation to the reactants.

[0011] The advantages associated with the use of heterogeneous catalysts lie in the fact that improved separation or isolation of the catalyst from the reaction mixture is sometimes possible, along with the fundamental possibility of recycling the catalyst used or reprocessing deactivated or inactive catalysts. Particularly in industrial processes, a heterogeneous catalyst is often present as a solid or as a so-called contact catalyst, while the reactants or reactants are used in the form of gases or liquids. For example, the aforementioned industrially established processes are processes in which the catalyst is used as a solid.

[0012] InWith regard to heterogeneous catalysts or catalysts in solid form, metals or metal-containing compounds, such as metal salts or metal oxides, are often used as catalysts. Such catalysts can be used, for example, in bulk or in a form in which the catalyst or the underlying catalytically active component is present on a support system or is bound or fixed to it. Such catalyst systems in which the catalytically active component is present on a support are generally referred to as supported catalysts.

[0013] The use of supported catalysts is associated with the fundamental advantage that larger surfaces or larger contact areas with the reactants to be converted can be realized, which generally leads to an increase in the efficiency or to the use of reduced amounts of catalyst with an associated cost advantage.

[0014] In addition, the use of support systems or supported catalysts generally offers the advantage that the underlying catalysts can be more easily removed or separated from the reaction medium and generally recycled. Especially with catalysts used in bulk or in the same phase as the reactants, separation after the reaction or conversion of the reactants is difficult or associated with high losses of catalyst mass, which generally reduces economic efficiency and fundamentally complicates recycling of the catalysts used.

[0015] For supported catalyst systems or supported catalysts, the use of compact or porous support structures is generally considered in the prior art. The use of so-called compact catalysts is particularly disadvantageous in that an efficient surface enlargement cannot be achieved, and thus catalytic activity can only be provided at the relatively small geometric surface area. In contrast, porous solids used as catalyst supports have larger (internal) surface areas, which, as previously mentioned, is associated with increased efficiency or higher catalytic activity even with lower loading of active components (i.e., catalytically active metals, such as precious metals).

[0016] For example, crystalline porous solids from the zeolite family are used as catalyst supports, particularly in the petrochemical and refinery industries for processing or refining crude oil. Zeolites generally have uniform pore sizes and diameters, which allows for a certain degree of selective reaction control by matching the size to the reactants. Furthermore, the use of silica, molecular sieves, metal oxides such as aluminum oxides, or even ceramics and activated carbons as catalyst support systems is generally known in the prior art.

[0017] In principle, such carrier systems are also used to enable a permanent or elution-stable fixation of particularly cost-intensive catalysts in order to reduce the loss thereof during use or to enable corresponding recyclability, as mentioned above, or recovery of the catalyst system as a whole.

[0018] With regard to the use of activated carbon as a support material for catalysts, particularly for obtaining so-called activated carbon-supported catalysts, in particular activated carbon-supported precious metal catalysts, the state of the art generally uses corresponding activated carbons in finely divided or powdered form (powdered carbon) or in the form of a finely ground powder, with the corresponding particle sizes being in the lower µm range. By using finely divided activated carbon as a support system, the aim is generally to reduce limitations in the underlying mass transport with regard to the catalyzed target reaction, in particular by shortening diffusion or penetration distances into the pore structure of the activated carbon-based support material.However, the use of powdered activated carbon with small particle sizes as a catalyst support is associated with the central disadvantage that optimal application properties cannot be achieved overall. For example, the use of finely divided activated carbon, particularly in discontinuous applications, leads to impaired properties due to the low porosity of the filter cake or the high density of the bed of the underlying material, for example during the separation or removal of the catalyst or catalyst system after use. It should also be emphasized that the separation or removal of the catalyst or catalyst system is an indispensable or absolutely necessary process step in discontinuous catalytic processes.

[0019] In addition, such activated carbons often have a pore system that is not optimally developed with regard to the binding of the catalyst and the transport processes of reactants and products, which can impair the overall catalytic performance.

[0020] Under operating conditions, particularly in continuous catalysis processes (i.e., catalyzed reaction processes) using powdered or finely divided activated carbon or pulverized carbon in the reaction chamber, a high pressure drop occurs due to the sometimes excessive compaction of the catalyst system. This is often accompanied by a reduced flow rate for the reaction mixture containing the corresponding reactants passing through the catalyst system. Excessive compaction can also result from insufficient abrasion hardness of the catalysts or the corresponding support materials used.

[0021] Furthermore, the application properties of activated carbon-supported catalyst systems are often suboptimal in that the finely divided catalyst system, particularly in a liquid medium containing the reactants, tends to form sludge or become excessively dense. This is accompanied by the risk of clogging the reaction device or an excessive reduction in the flow or filtration rate, which is detrimental to the overall catalytic conversion. Excessive densification of the catalyst system can also result in "dead zones" in the underlying device or apparatus, in which a significantly reduced conversion of reactants occurs.

[0022] In this context, the formation of sludge-filled areas is particularly relevant in discontinuous applications. In continuous catalytic applications, in which the catalyst systems are filled, for example, into corresponding reaction chambers, such as cartridge systems, and then a particularly continuous flow of a medium containing the educts or reactants occurs, equally high pressure drops result with correspondingly lower flow rates through the catalyst system. In addition, complex filtration or retention devices, which are prone to clogging, are often required to prevent the catalyst from being carried away or flushed out of the continuously flowing reaction system.

[0023] As a result, it can be stated that catalyst systems based on powdered or finely divided activated carbon as a carrier material do not always have sufficient or satisfactory properties with regard to their application.

[0024] To mitigate the disadvantages associated with small particle sizes, attempts have been made in the prior art to use catalyst supports based on particulate activated carbon, with starting materials for the activated carbon based on coconut shells, charcoal, wood (e.g., wood waste, peat, hard coal, or the like) generally being considered. While these activated carbons used as catalyst supports, which can generally be in chip or granular form, generally lead to a certain improvement in application properties, particularly with regard to separation time in discontinuous applications, such activated carbons often exhibit insufficient mechanical stability, which is accompanied by high abrasion of the support material under operating conditions, for example, due to sometimes intensive stirring processes during the catalytic conversion.The low abrasion resistance of such activated carbons then leads to fine particles due to the corresponding comminution or grinding processes, accompanied by a high loss of catalytically active substance and the aforementioned disadvantages with regard to system clogging or compaction, etc. Furthermore, such activated carbons often lack optimally developed pore systems.

[0025] In addition, the prior art concepts for providing catalyst systems based on activated carbon as a support material are also disadvantageous in that optimal loading or fixation of the catalyst on the support material is often not possible, which on the one hand leads to the catalyst quantities applied to the support being small and on the other hand to the fact that under application conditions a release or leaching (elution) of the catalyst from the support material is often observed, whereby the washed-out catalyst quantities are lost, which is disadvantageous in terms of process technology and not least for cost reasons.

[0026] In particular, the activated carbons used in the prior art, e.g., those based on coconut shells, often exhibit only a low affinity for the catalyst to be applied or fixed. This—without wishing to be limited to this theory—is also due to the fact that the underlying activated carbons are often hydrophobic with regard to their pore surface or often do not contain a sufficient amount of, in particular, polar functional groups to bind the catalyst (which is particularly the case with polymer-based activated carbons, especially PBSACs). However, this is detrimental to the overall loading or equipping with a catalyst, also with regard to the permanent fixation of the catalyst to the support system.The high loss of catalyst for the underlying catalyst system is equally accompanied by a reduction in the reactant conversion in the underlying catalytic reactions, which also worsens the economic efficiency of the catalyst systems used.

[0027] Since conventional activated carbon has a non-polar or hydrophobic surface and consequently has no significant affinity for catalysts or catalytically active components that are to be applied or fixed and used for the reactive or catalytic treatment of the activated carbon, it is necessary to use a large excess of catalyst substance during production or treatment of the activated carbon with the catalyst in order to ensure a certain loading of the activated carbon, or it is necessary to create surface centers (i.e., centers for the attachment of the catalytically active components) in advance. In particular, the catalysts generally adhere only via purely physical interactions and can therefore be at least partially removed or washed out (e.g., by elution processes or the like), particularly upon contact with liquids.

[0028] In principle, with regard to heterogeneous catalysts using activated carbon as a support material according to the known concepts of the prior art, there is sometimes the disadvantage that, in particular as a result of a suboptimal pore system of the support material, in particular with regard to the underlying pore sizes and their distribution, or their proportions in the total pore volume, the transport or diffusion processes for reactants or products are not optimal, which is accompanied by reduced conversions and a suboptimal space / time yield, for example because reactants are not optimally transported to the underlying catalytic center or resulting products are not optimally transported away from the catalyst system.

[0029] In this context, heterogeneous catalysis in a porous structure as a catalyst support, such as activated carbon, can be divided into seven sub-steps, including corresponding transport steps for reactants or products, each of which can be rate-limiting. Fig. 4 and the following related explanations.

[0030] A suboptimal formation of the pore system of the support material thus sometimes permanently impairs the conversion or the space / time yield, since transport processes within the system are insufficient and overall limiting with regard to the catalytic activity.

[0031] Furthermore, the conversion or the space / time yield may also be reduced because the catalytically active centers as such are not optimally formed or the support material is only insufficiently equipped with a catalytically active component, which may equally be caused by a pore system of the catalyst support that is not optimally formed in this regard.

[0032] In addition, the catalyst systems known in the prior art sometimes have the disadvantage that high pressure losses result during use, particularly in a fixed bed or the like, and often there is also high dust formation with associated material loss, in particular as a result of the underlying catalyst systems not always having sufficient hardness or abrasion resistance.

[0033] DE 20 2014 101 137 U1 relates to a catalyst system comprising at least one catalytically active component applied to a catalyst support. The catalyst system is said to be obtainable by a process in which an activated carbon used as a catalyst support is first subjected to oxidation. The activated carbon thus obtained is then treated with the catalytically active component, optionally followed by a reduction of the catalyst system thus obtained.

[0034] Furthermore, DE 20 2016 100 320 U1 relates to an activated carbon with an increased meso- and / or macropore volume fraction, preferably with an increased mesopore volume fraction, wherein the activated carbon is obtainable by a process for its production. The process comprises sulfonating a polymeric organic starting material by contacting it with a sulfonating agent and subsequently allowing the sulfonating agent to act on and react with the starting material, wherein the sulfonation is to occur with simultaneous volume expansion of the starting material. The process further comprises carbonizing the resulting sulfonated starting material and subsequent activation to obtain the activated carbon.

[0035] Gelder et al., "A Study of Nitrobenzene Hydrogenation over Palladium / Carbon Catalysts", Catalysis Letters, Vol. 84, Nos. 3-4, pages 205 to 208, December 2002, concerns investigations into nitrobenzene hydrogenation over palladium / carbon catalysts using activated carbon as a support.

[0036] DE 29 36 362 C2 relates to a process for producing a palladium-carbon catalyst, wherein the palladium is deposited by reduction onto carbon suspended in an organic solvent as a catalyst support. In this context, the palladium is to be deposited as a metal on the suspended support. Powdered activated carbon, carbon black, or graphite is used as the carbon support. However, the catalysts described are sometimes associated with the disadvantages described above, particularly with regard to the separation or recovery of the catalyst, especially in discontinuous catalytic processes, as well as its application properties in continuous catalytic processes, particularly with regard to pressure loss or flow velocity.

[0037] In summary, it can be stated that the catalyst systems known in the prior art based on conventional activated carbons or powdered activated carbons as the support material used have both production- and application-specific disadvantages, in particular with regard to the loading with a catalytically active component and its fixation on the material on the one hand, and with regard to the use of the underlying systems in continuous and discontinuous catalysis applications on the other.

[0038] Against this background, it is therefore an object of the present invention to provide catalyst systems or supported catalysts which have at least one catalytically active component, as well as a corresponding production process, wherein the previously described disadvantages of the prior art are to be at least largely avoided or at least mitigated.

[0039] In particular, the present invention aims to provide a catalyst system comprising at least one catalytically active component or a supported catalyst comprising at least one catalytically active component, which has both production- and application-specific advantages. In this regard, a corresponding process for producing the catalyst system is also to be provided.

[0040] An object underlying the present invention is also to be seen in particular in the fact that, within the scope of the present invention, an overall high-performance catalyst system is to be provided which, with high durability and stability, enables high conversions and thus high space / time yields, while at the same time ensuring high recyclability and stability of the system provided.

[0041] In particular, the invention aims to provide such a catalyst system which enables a high or efficient loading with the catalyst component or a catalytically active component, while at the same time ensuring a permanent and consistent loading or equipment with the catalyst component.

[0042] Furthermore, the invention also aims to provide such a catalyst system which, in the context of its application, in particular in chemical catalysis, preferably on an industrial scale, both in discontinuous and continuous catalytic applications, has improved properties, in particular with regard to its catalytic performance as well as the separation or recovery or recycling of the system (in particular in discontinuous processes) and, in addition, also has improved properties with regard to ensuring a low or adjustable pressure loss and high or adjustable flow rates (in particular in continuous catalytic processes), wherein overall optimized process times and increased catalytic activity are also to be provided.

[0043] In particular, the present invention also aims to provide such a catalyst system which, in addition to its high catalytic activity, also has excellent mechanical properties, in particular with regard to the abrasion resistance and bursting pressure of the underlying particulate structures.

[0044] Likewise, the systems according to the invention should also be able to be tailored or individually designed or equipped with regard to the respective application or use case.

[0045] In addition, the present invention aims to provide an efficient process on the basis of which the catalyst system according to the invention with at least one catalytically active component can be obtained.

[0046] As the applicant has now discovered in a completely surprising manner, the above-mentioned problem underlying the present invention can be solved in an unexpected manner by providing, within the scope of the present invention, a specific process for producing a specific catalyst system and a corresponding catalyst system as such.

[0047] In this context, according to the invention, a special activated carbon is used as a catalyst carrier, which, in addition to its spherical design or shape, has a specially designed pore system, namely with high meso- and Macropore volume fraction of the total pore volume of the activated carbon, so that according to the invention an activated carbon with high meso- andMacroporosity (with a simultaneously defined proportion of micropores) is used. Furthermore, the activated carbon used according to the invention has a specific BET surface area with a specific ratio of total pore volume to specific BET surface area.

[0048] In addition, the process according to the invention is purposefully directed or aimed at a targeted oxidation, in particular surface oxidation (i.e. oxidation in particular also of the inner surface of the catalyst support), of the activated carbon subsequently used as a catalyst support, for the purposes of setting a specific oxygen content, in particular surface oxygen content, and with the formation of a specific hydrophilicity, wherein such a specific activated carbon is then equipped with a catalytically active component or a related precursor, followed by a reduction to obtain the catalyst system according to the invention.

[0049] In other words, according to the invention, a special catalyst system or a supported catalyst is provided with at least one catalytically active component applied to a catalyst support, wherein the catalyst support is in the form of a very specially designed granular or spherical activated carbon with a special porosity, in particular with regard to the formation of a high meso- and Macroporosity (i.e. with a high proportion of meso- and macropores in the total pore volume with a simultaneously defined proportion of micropores), and wherein the application of the catalytically active component to the activated carbon takes place in oxidized form of the activated carbon (ie, onto the oxidized activated carbon), followed by a further reduction of the underlying system (ie, the active centers or the active components) to obtain the catalyst system according to the invention. In addition to the high meso- andIn addition to macroporosity, the activated carbon used as a catalyst support also has a defined microporosity (ie a defined proportion of micropores in the total pore volume), although generally in a smaller size than the meso- and Macropore volume is subordinate but sufficient for catalysis.

[0050] Surprisingly, this provides a catalyst system according to the invention or a supported catalyst which, due to the improved transport and diffusion properties for reactants and products caused by the special pore system and an improved loading with the catalytically active component, exhibits outstanding catalytic properties, accompanied by high catalytic conversions and high space / time yields when used in catalytic processes. The catalyst system according to the invention also exhibits a high degree of dispersion and an optimized crystallite size of the catalytically active component, which can be used as a parameter or measure of the catalytic performance.

[0051] The catalyst system provided according to the invention is particularly suitable for use in the field of chemical catalysis, especially on a (large-scale) industrial scale. Furthermore, the catalyst system according to the invention is particularly suitable for corresponding filter applications for removing, for example, pollutants and toxic substances from a medium containing these substances. In particular, the catalyst systems according to the invention are also suitable for use in or for protective materials, especially for the civilian or military sector, especially protective materials for NBC use.

[0052] In particular, due to the spherical design or spherical shape, the outstanding mechanical properties of the catalyst support as well as the adjustable or specially designed meso- andMacroporosity (with simultaneously defined microporosity), the catalyst systems according to the invention are particularly important for continuous catalysis, whereby also with regard to discontinuous catalysis, disadvantages of the prior art are overcome, which are associated, for example, with conventional powder catalysts or the like, as explained above.

[0053] To achieve the above-described problem, the present invention proposes - according to a first Aspect of the present invention - the inventive method for producing a catalyst system comprising at least one catalytically active component according to the invention according to claim 1. Further, particularly advantageous embodiments of the inventive method are the subject of the relevant process subclaims.

[0054] Another object of the present invention - according to a second Another aspect of the present invention is the catalyst system according to the invention or the supported catalyst according to the invention, wherein the catalyst system or the supported catalyst comprises at least one catalytically active component and wherein a special granular activated carbon is used as the catalyst support, according to the relevant independent patent claim relating to the catalyst system according to the invention. Further, particularly advantageous embodiments of the catalyst system according to the invention are the subject of the relevant subclaim.

[0055] Yet another object of the present invention - according to a third Aspect of the present invention - are the uses according to the invention as set out in the relevant independent use claims.

[0056] Furthermore, further objects of the present invention are - according to a fourth Aspect of the present invention - the protective materials according to the invention, in particular for the civil or military sector, in particular protective clothing, according to the relevant independent claim.

[0057] Furthermore, further objects of the present invention are - according to a five t en Aspect of the present invention - also filters, in particular for removing harmful, odorous and toxic substances of all kinds, according to the relevant independent claim.

[0058] It goes without saying that in the following description of the present invention, such configurations, embodiments, advantages, examples or the like which are explained below - for the purpose of avoiding unnecessary repetition - only with regard to a single aspect of the invention, naturally also apply accordingly with regard to the other aspects of the invention, without the need for express mention.

[0059] In addition, all values ​​or parameter specifications or the like mentioned below can generally be determined using standardized or explicitly specified determination methods or, alternatively, using determination or measurement methods that are familiar to a person skilled in the art.

[0060] Furthermore, it should be noted that with all relative or percentage quantities listed below, especially those based on weight, these quantities must be selected or combined by the person skilled in the art within the scope of the present invention in such a way that the total – optionally including other components or ingredients, in particular as defined below – always amounts to 100% or 100% by weight. However, this is self-evident to the person skilled in the art.

[0061] With that in mind, the present invention will be described in more detail below.

[0062] According to the first Aspect of the present invention thus relates to a process for the preparation of a catalyst system comprising at least one catalytically active component in the form of a supported catalyst, preferably for use in heterogeneous catalysis, wherein at least one catalytically active component is applied and / or fixed to a catalyst support, wherein the catalytically active component comprises and / or consists of at least one metal, wherein the metal is selected from the group consisting of Cu, Ag, Au, Zn, Hg, Sn, Ce, Ti, Zr, V, Nb, Cr, Mo, W, Mn, Fe, Bi, Ru, Os, Co, Rh, Re, Ir, Ni, Pd and Pt, wherein the process comprises the following steps in the sequence (a) to (d) specified below: (a) providing and / or producing a spherical activated carbon used as a catalyst support (= starting activated carbon), wherein the activated carbon (i.e. the starting activated carbon) (i) has a total pore volume V total according to Gurvich in the range from 0.8 cm 3 / g to 3.9 cm 3 / g, wherein at least 50% of the total pore volume according to Gurvich of the activated carbon is represented by pores with pore diameters of at least 2 nm, in particular by pores with pore diameters in the range of 2 nm to 500 nm,preferably by meso- and macropores, and (ii) has a specific BET surface area S BET in the range from 1,000 m 2 < / g to 3,000 m 2 < / g, but with the proviso that the ratio Q of total pore volume V total according to Gurvich to specific BET surface area S BET according to the equation Q = V total / S BET is at least 0.5 10 -9 < m; then (b) oxidation, in particular surface oxidation, of the activated carbon provided and / or produced in process step (a), with the proviso that the oxidized, in particular surface-oxidized, activated carbon has an oxygen content, in particular surface oxygen content, determined by means of X-ray photoelectron spectroscopy (XPS or ESCA), of at least 4 atomic%, based on the total elemental composition of the oxidized activated carbon, and / or with the proviso that the oxidized, in particular surface-oxidized, activated carbon has a hydrophilicity, determined as water vapor adsorption behavior,such that at a partial pressure p / p 0 of 0.6, at least 30% of the maximum water vapor saturation loading of the activated carbon is reached; then (c) equipping, in particular loading and / or coating and / or impregnation, the activated carbon oxidized in process step (b), in particular surface-oxidized, with the catalytically active component, in particular with at least one precursor of the catalytically active component; then (d) reducing (i.e. on the one hand, surface reduction, in particular of the previously oxidized activated carbon and / or on the other hand, in particular reducing the catalytically active component or the relevant precursor, preferably of the metal or metal compound underlying the catalytically active component, preferably for the purpose of catalyst activation) the oxidized carbon obtained in process step (c) and equipped with the catalytically active component, in particular with the precursor of the catalytically active component,in particular surface-oxidized, activated carbon, in particular for converting the precursor of the catalytically active component into the catalytically active component, so that the catalyst system comprising at least one catalytically active component is obtained; wherein in process step (d) the reduction is carried out as a gas phase reduction, wherein in process step (d) the reduction is carried out at a temperature in the range from 115 °C to 160 °C; wherein in process step (d) the catalyst system is obtained, wherein the catalyst system has at least one catalytically active component applied and / or fixed to a catalyst support, wherein the catalytically active component comprises and / or consists of at least one metal, and wherein the catalyst support is in the form of activated carbon, wherein the catalyst support is in the form of a spherical activated carbon; and wherein the catalyst system has an activity,determined as the percentage degree of dispersion of the catalytically active component on the catalyst support, measured by chemisorption using the dynamic flow method according to DIN 66136-3:2007-01, in the range of 15% to 90%; and wherein the catalyst system has the catalytically active component with an average crystallite size, determined according to DIN 66136, of at most 80 Å (Angstroms).

[0063] A fundamental idea of ​​the present invention is therefore, as stated above, to be seen in particular in the fact that a very special activated carbon is used as a catalyst support for receiving or equipping it with the catalytically active component, wherein the activated carbon used according to the invention is used on the one hand in granular or spherical form and on the other hand with a defined porosity, in particular with regard to a high meso- and macroporosity with a simultaneously defined proportion (i.e. in a subordinate amount compared to the meso- and macropores, but sufficient for catalysis) of micropores, wherein in addition an oxidation treatment or a surface oxidation of the activated carbon is carried out in a targeted manner before equipping it with the catalytically active component.In this context, the applicant has equally found, quite surprisingly, that the use of an activated carbon with defined porosity, as mentioned above, provides overall improved catalytic properties of the resulting catalyst system, in particular with regard to high conversions with simultaneously high catalytic activity and correspondingly high space / time yields in the underlying catalytic conversions or reactions.

[0064] Without wishing to limit ourselves to this theory, the use of a special activated carbon with high meso- and Macropore proportion with a simultaneously defined proportion of micropores, in particular the transport or diffusion processes of the reactants or products underlying the catalytic reaction.

[0065] Products are sustainably improved, while at the same time ensuring high accessibility and optimised formation of the catalytically active component incorporated into the catalyst carrier.

[0066] In this context, the invention is particularly such that the kinetics of the underlying catalysis are improved overall, in particular with regard to improved transport or diffusion processes within the pore system and in the region of the boundary layer of the catalyst support, while at the same time there is high accessibility to the catalytically active component or the catalytic centers for the reactants to be converted.

[0067] According to the invention, an overall improved catalyst system is provided, which exhibits very good efficiency with regard to catalytic activity, due to the special coordination and design of the pore system of the activated carbon used as a catalyst support. In this regard, the targeted and purposeful (surface) oxidation of the activated carbon used as a catalyst support prior to treatment with the catalytically active component is also of great importance, as this improves the binding or loading of the catalytically active component or the related precursor, also with regard to the formation of catalytic centers with defined (metal) dispersion and crystallite size, as explained in more detail below.

[0068] A further central advantage of the present invention is that the activated carbons used according to the invention have a high mechanical stability and resistance, accompanied by low abrasion when used in catalytic processes, so that a correspondingly high durability of the catalytic system according to the invention is provided while at the same time being highly recyclable.

[0069] Through the targeted use of granular or spherical activated carbon, i.e. activated carbon with a special shape, the application properties of the catalyst system according to the invention are further improved, also with regard to the use of the catalyst system provided according to the invention in discontinuous and continuous catalytic applications. This is because the special shape, in particular based on discrete spheres, results in improved bed porosity for discontinuous applications, which both prevents sludge formation in the reaction system and significantly improves the separation or recovery of the catalyst from the reaction system. Secondly, the improved bed properties of the catalyst system according to the invention lead to lower pressure drops and, at the same time, high accessibility of the catalyst system for reactants or catalysts to be converted.Reactants, so that using the catalyst system according to the invention, high flow rates can also be achieved with respect to a medium containing the reactants or educts to be converted.

[0070] The activated carbon (spherical carbon) used according to the invention in granular form, and especially in spherical form, also has a number of advantages, particularly compared to other forms of activated carbon, such as powdered, chipped, and coal, or the like, with regard to improved flowability, abrasion resistance, and freedom from dust. This also leads to high mechanical strength and durability, along with long service lives of the underlying systems. Consequently, wear during use is also reduced, leading to increased service life.

[0071] As explained below, by specifically adjusting the particle size or diameter of the underlying spherical activated carbon, tailor-made catalytic systems can be provided with optimized application properties, particularly with regard to the recovery of the catalyst system, the flow behavior, or the pressure drop, while simultaneously further improving the catalytic activity of the catalyst system according to the invention. In particular, by specifying the particle size, the pressure drop or the flow rate can be adjusted or changed, so that optimized systems can be provided even with a specific application in mind.

[0072] Within the scope of the present invention, particularly extremely abrasion-resistant or mechanically stable spherical activated carbons are used for the catalyst support used, as provided in particular by the special activated carbons based on organic polymers, in particular based on sulfonated organic polymers, defined below. It is entirely surprising within the scope of the present invention that any sulfur content present in the activated carbon, which may amount to, for example, up to 0.1 wt. %, based on the activated carbon, is not detrimental to the catalytic function of the catalyst system according to the invention or does not lead to any adverse impairment of the catalytic activity and, in particular, does not lead to so-called catalyst poisoning.

[0073] Furthermore, within the scope of the present invention, as a result of the (surface) oxidation of the activated carbon used prior to equipping it with the catalytically active component, it has surprisingly been possible to ensure a high and at the same time permanent or stable loading of the activated carbon used as support material with the catalytically active component, which leads to a significantly increased catalytic activity with simultaneously improved stability of the catalyst system according to the invention, in particular since leaching or detachment of the catalytically active component from the support material is reduced or avoided in the application case.

[0074] Without wishing to be bound by this theory, the targeted oxidation or surface oxidation of the activated carbon leads to the formation of special oxygen-containing functional groups on the activated carbon used according to the invention or in its pore system, namely in the micro-, meso-, and macropores, thereby increasing the affinity of the activated carbon for the catalytically active component used according to the invention. As a result of the oxidation or surface oxidation treatment of the activated carbon carried out according to the invention before treatment with the catalytically active component, a less hydrophobic or a more hydrophilic surface of the activated carbon is generated or provided, or special functional groups are generated or provided on the surface of the activated carbon or in the pore system of the activated carbon, which significantly improves the incorporation of the catalytically active component in a completely surprising way.

[0075] In this context, it is equally surprising that the catalyst system according to the invention based on spherical activated carbon with a defined particle shape or particle size, which is subjected to oxidation before being loaded with the catalytically active component, also exhibits significantly improved catalytic activity compared to powdered activated carbons. In this context, it is completely surprising that, with regard to the catalyst system according to the invention, there are no significant restrictions or limitations with regard to mass transport, in particular with regard to the underlying educts or reactants, in the pore system of the activated carbon, which is also attributable in particular to the defined pore structure, as stated below, of the activated carbons used according to the invention. In this context, it has proven particularly advantageous according to the invention if a meso- andmacroporous activated carbon, in particular with a defined, albeit subordinate, proportion of micropores, is used as a catalyst support for the catalyst system according to the invention.

[0076] In particular, it is entirely surprising that the catalyst system provided according to the invention exhibits high catalytic activity even with relatively large particle sizes, particularly compared to powdered coal. In this context, the interaction of the measures according to the invention—without wishing to be limited to this theory—has made it possible, on the one hand, to enable a particularly uniform and high loading of the activated carbon with the catalytically active component and, on the other hand, to reduce mass transport and diffusion limitations in the catalyst system that are detrimental to catalytic activity.

[0077] Within the scope of the inventive concept, in particular due to the special coordination of the carrier system on the one hand and the catalytically active component on the other hand, blockage of the pore system underlying the activated carbon by the catalytically active component - for example due to an excessive crystal size during the crystallization of metal salts - is at least substantially prevented, which further improves the performance of the catalyst system provided according to the invention.

[0078] According to the invention, it has thus been possible for the first time to provide, on the basis of the process according to the invention, a very special catalyst system with a very special activated carbon as support material, which is equipped in a targeted manner with at least one catalytically active component, wherein the catalyst system has significant advantages and improved properties compared to systems of the prior art and is suitable for both discontinuous and continuous catalytic applications.

[0079] The catalyst system according to the invention provided by the process according to the invention exhibits both improved mechanical and improved catalytic properties, accompanied by reduced process times and a high recovery rate with reduced time expenditure and excellent recycling of the underlying catalyst or catalytically active component. Furthermore, as previously stated, the catalyst system according to the invention exhibits improved flow properties with low pressure loss, particularly when used in the form of (loose) beds.

[0080] Furthermore, the catalyst system according to the invention, which is provided on the basis of the process according to the invention, is also suitable for use in or as filter(s) or filter material(s), in particular for rendering harmful or toxic substances or the like harmless.

[0081] The catalyst system provided on the basis of the process according to the invention thus combines excellent mechanical properties on the one hand with excellent catalytic properties on the other.

[0082] Based on the process according to the invention, the activated carbon used as support material is effectively equipped with at least one catalytically active component to obtain the catalyst system according to the invention.

[0083] The term "catalyst system," as used in the invention and synonymously also referred to as "supported catalyst," is to be understood very broadly according to the invention and refers in particular to a functional unit based on at least one catalytically active component on the one hand and a support material on the other, wherein the catalytic properties can be attributed significantly to the catalytically active component, which for this purpose comprises or consists of at least one metal. In this context, the invention particularly provides that the activated carbon used is provided with the catalytically active component, in particular in the form of a finish or loading or coating or impregnation, in particular based on fixing the catalytically active component to the underlying catalyst support, to obtain the catalyst system according to the invention.

[0084] Furthermore, the terms "finishing" or "loading" or "coating" or "impregnation" as used according to the invention refer in particular to such a finishing of the activated carbon used as a support material with the catalytically active component, according to which the outer and / or inner surface structure of the activated carbon used, including the relevant pores, in particular micro-, meso- and / or macropores, are at least partially and / or sectionally in contact with the catalytically active component or are provided or equipped with it. In this case, the catalytically active component - without wishing to be limited to this theory - forms a catalytic structure orchemisorptive properties that functionally complement the physisorptive properties of the activated carbon, so that the catalyst system provided on the basis of the process according to the invention fundamentally combines both chemisorptive and physisorptive properties in one and the same material. In particular, the catalytically active component can be bound to the activated carbon surface physisorptively and / or chemisorptively, whereby the properties of the catalytically active centers or the catalytically active component can depend in particular on the surface properties of the activated carbon, the catalytically active component itself, and / or the reduction conditions. The catalytically active component is present in or on the activated carbon, in particular, in particulate or crystalline form.

[0085] Furthermore, with regard to the term "spherical," synonymously also referred to as "spherical," as used for the activated carbon used as a carrier material according to the invention, this term is to be understood very broadly and, according to a preferred embodiment of the present invention, relates in particular to an at least substantially ideal spherical or spherical shape of the activated carbon, but also to shapes or physical configurations of the activated carbon used that deviate from the spherical shape, such as a formation of the activated carbon in the shape of a (rotational) ellipsoid or the like. Furthermore, the term "spherical" also encompasses spherical or ellipsoidal shapes of the activated carbon in which the activated carbon may have protrusions or indentations, dents, depressions, cracks, or the like. Thus, the invention primarily focuses on the use of a spherical activated carbon, a spherical activated carbon, or a spherical activated carbon.

[0086] With regard to the term "surface oxidation," as used in the invention, this refers in particular to the oxidation of those surfaces of the activated carbon used as the starting material that are in contact with the environment, particularly containing the oxidizing agent, or that are, so to speak, accessible from the outside to the oxidizing agent used in the invention. This also includes, in particular, the pore system of the activated carbon in the form of macro-, meso-, and micropores.

[0087] What furthermore the invention-based Ratio (quotient; Q) of total pore volume (V total ), in particular total pore volume according to Gurvich, to specific BET surface area (S BET ), in particular according to the equation Q = V total - S BETAs far as is concerned, the underlying value in this regard serves to further characterise the pore system of the activated carbon used as a catalyst support according to the invention, in particular in that the porosity or the pore system of the activated carbon is further characterised and defined on the basis of the quotient Q, namely in particular in that for the activated carbon used as a catalyst support according to the invention, a high proportion of meso- and macropores in the total pore volume with a defined proportion of micropores. In particular, the underlying quotient describes the high meso- andMacroporosity of the activated carbon used according to the invention. In this context, the quotient Q can also be used as a measure of the improved kinetics in heterogeneous catalysis when using the catalyst system according to the invention due to the specially designed activated carbon, or of the improved catalytic activity. Thus, as a result of the specially designed pore system of the activated carbon, further characterized by the quotient, there is an overall improvement in the rate-determining steps of the kinetics underlying heterogeneous catalysis, for example, with regard to the improved diffusion behavior of reactants or products and the accessibility of the catalytically active component.The quotient Q thus also further reflects the properties of the catalyst system according to the invention provided in the context of the process according to the invention, in particular with regard to its improved catalytic performance.

[0088] With regard to the activated carbon used as a catalyst support or the associated activated carbon particles as such, the parameters listed are determined using standardized or explicitly specified determination procedures or methods familiar to the person skilled in the art. In particular, the parameters relating to the characterization of porosity or pore size distribution and other adsorption properties are generally derived, unless otherwise stated, from the corresponding nitrogen sorption isotherms of the activated carbon in question or the measured products.

[0089] In the context of the present invention, the term "micropores" refers to pores with pore diameters of less than 2 nm, whereas the term "mesopore" refers to pores with pore diameters in the range from 2 nm (i.e. 2 nm inclusive) to 50 nm inclusive, and the term "macropores" refers to pores with pore diameters of more than 50 nm (i.e. > 50 nm) and in particular up to 500 nm inclusive.

[0090] The provision or production of the activated carbon used as catalyst support as stated in process step (a) is described in more detail below: According to the invention, it can be provided in particular that the activated carbon provided or produced in process step (a) (ie starting activated carbon) has a total pore volume V total according to Gurvich in the range from 0.9 cm 3 < / g to 3.4 cm 3 < / g, in particular in the range from 1 cm 3 < / g to 2.9 cm 3 < / g, preferably in the range from 1.1 cm 3 < / g to 2.4 cm 3 < / g, more preferably in the range from 1.2 cm 3 < / g to 1.9 cm 3 < / g, particularly preferably in the range from 1.5 cm 3 < / g to 1.9 cm 3 < / g.

[0091] As stated above, the invention relates in particular to an activated carbon used as a catalyst support, which has a high meso- andmacroporosity. In this context, it can be provided according to the invention that 50% to 90%, in particular 52.5% to 87.5%, preferably 55% to 85%, preferably 57.5% to 82.5%, particularly preferably 60% to 80%, of the total pore volume according to Gurvich of the activated carbon provided and / or produced in process step (a) (ie starting activated carbon) is represented by pores with pore diameters of at least 2 nm, in particular by pores with pore diameters in the range of 2 nm to 500 nm, preferably by meso- and Macropores are formed.

[0092] In addition, the activated carbon provided or produced in process step (a) can equally have a defined, subordinate microporosity which is sufficient for catalysis, wherein in general relatively small proportions of the total pore volume are present in relation to the micropores (and in particular to an extent sufficient for catalysis): Thus, according to the invention, it can be provided in particular that 2.5 to 50%, in particular 5% to 50%, preferably 10 to 50%, particularly preferably 12.5% ​​to 47.5%, particularly preferably 15% to 45%, very particularly preferably 17.5% to 42.5%, further preferably 20% to 40%, of the total pore volume according to Gurvich of the activated carbon provided and / or produced in process step (a) (ie starting activated carbon) are formed by pores with pore diameters of less than 2 nm, preferably by micropores.

[0093] Furthermore, it can be provided according to the invention that the activated carbon provided or produced in process step (a) (ie starting activated carbon) has a total pore volume V total according to Gurvich in the range from 0.8 cm 3 / g to 3.9 cm 3 / g, in particular in the range from 0.9 cm 3 / g to 3.4 cm 3 / g, preferably in the range from 1 cm 3 / g to 2.9 cm 3 / g, preferably in the range from 1.1 cm 3 / g to 2.4 cm 3 / g, particularly preferably in the range from 1.2 cm 3 / g to 1.9 cm 3 / g, very particularly preferably in the range from 1.5 cm 3 / g to 1.9 cm 3 / g, where 50% to 90%, in particular 52.5% to 87.5%, preferably 55% to 85%, preferably 57.5% to 82.5%, particularly preferably 60% to 80%, of the total pore volume according to Gurvich of the activated carbon is formed by pores with pore diameters of at least 2 nm, in particular by pores with pore diameters in the range from 2 nm to 500 nm, preferably by meso- and macropores.

[0094] In addition, it can be provided according to the invention that the activated carbon provided or produced in process step (a) (ie starting activated carbon) has a total pore volume V total according to Gurvich in the range from 0.8 cm 3 / g to 3.9 cm 3 / g, in particular in the range from 0.9 cm 3 / g to 3.4 cm 3 / g, preferably in the range from 1 cm 3 / g to 2.9 cm 3 / g, preferably in the range from 1.1 cm 3 / g to 2.4 cm 3 / g, particularly preferably in the range from 1.2 cm 3 / g to 1.9 cm 3 / g, very particularly preferably in the range from 1.5 cm 3 / g to 1.9 cm 3 / g, where 2.5 to 50%, in particular 5% to 50%, preferably 10 to 50%, particularly preferably 12.5% ​​to 47.5%, particularly preferably 15% to 45%, very particularly preferably 17.5% to 42.5%, further preferably 20% to 40%, of the total pore volume according to Gurvich of the activated carbon provided and / or produced in process step (a) (ieStarting activated carbon) are formed by pores with pore diameters of less than 2 nm, in particular by micropores.

[0095] As for the determination of total pore volume according to Gurvich, this is a measurement / determination method that is well known to those skilled in the art. For further details regarding the determination of total pore volume according to Gurvich, reference can be made, for example, to L. Gurvich (1915), J. Phys. Chem. Soc. Soot. 47 , 805, and on p. Lowell et al.,Characterization of Porous Solids and Powders: Surface Area Pore Size and Density, Kluwer Academic Publishers, Article Technology Series, pages 111 ff. In particular, the pore volume of the activated carbon can be determined on the basis of the Gurvich rule according to the formula VP = W a / ρ l, where W a is the adsorbed amount of an underlying adsorbate and ρ l is the density of the adsorbate used (see also formula (8.20) according to page 111, chapter 8.4.) by S. Lowell et al.).

[0096] Furthermore, the activated carbon provided or produced in process step (a) (ie starting activated carbon) can have a specific BET surface area S BET in the range from 1,100 m 2 < / g to 2,600 m 2 < / g, in particular in the range from 1,200 m 2 < / g to 2,400 m 2 < / g, preferably in the range from 1,300 m 2 < / g to 2,200 m 2 < / g, more preferably in the range from 1,350 m 2 < / g to 1,950 m 2 < / g, particularly preferably in the range from 1,375 m 2 < / g to 1,900 m 2 < / g.

[0097] The determination of the specific surface area according to BET is generally known to those skilled in the art, so no further details are required. All BET surface area data refer to the determination according to ASTM D6556-04. Within the scope of the present invention, the so-called MultiPoint BET determination method (MP-BET) is used to determine the BET surface area in a partial pressure range p / p 0 of 0.05 to 0.1 – generally and unless expressly stated otherwise below.

[0098] For further details on the determination of the BET surface area and the BET method, reference can be made to the aforementioned ASTM D6556-04 as well as to Römpp Chemielexikon, 10th edition, Georg Thieme Verlag, Stuttgart / New York, keyword: "BET method", including the literature cited therein, and to Winnacker-Küchler (3rd edition), volume 7, pages 93 ff., as well as to Z. Anal. Chem. 238, pages 187 to 193 (1968).

[0099] The formation of a defined pore system with high meso- and Macropore volume or proportion, as described here, also leads to improved transport and diffusion properties for the reactants or products underlying the catalytic reaction, in particular due to the high meso- andMacropore content. At the same time, the catalyst system provided also offers improved catalytic properties due to the fact that catalytic active centers can form, particularly in smaller pores, such as micropores.

[0100] As a result of the balanced and coordinated pore distribution with the underlying defined hierarchical pore system with high meso- and A macropore volume and a micropore volume sufficient for catalysis or catalytic activity thus provide overall improved properties with regard to the kinetics of heterogeneous catalysis. In this context, the aforementioned properties of the activated carbon used in process step (a) (i.e., the starting activated carbon) are directly reflected in the catalyst system according to the invention obtained in process step (d).

[0101] In this context, it can be provided according to the invention in particular that for the activated carbon provided or produced in process step (a) (ie starting activated carbon), the ratio Q of total pore volume V total according to Gurvich to specific BET surface area S BET according to the equation Q = V total / S BET in the range from 0.5 10 -9< m to 1.9 10 -9< m, in particular in the range from 0.55 10 -9< m to 1.9 10 -9< m, preferably in the range from 0.6 10 -9< m to 1.8 10 -9< m, preferably in the range from 0.65 10 -9< m to 1.7 10 -9< m, particularly preferably in the range from 0.65 10 -9< m to 1.6 10 -9< m, very particularly preferably in the range from 0.7 10 -9< m to 1.5 · 10 -9< m, more preferably in the range of 0.75 · 10 -9< m to 1.4 · 10 -9< m, even more preferably in the range of 0.8 · 10 -9< m to 1.3 · 10 -9< m.

[0102] The aforementioned lower limits still ensure good coverage of the activated carbon with the catalytically active component, while simultaneously ensuring good mass transfer and thus high conversion rates in the underlying catalysis. Furthermore, the aforementioned upper limits still ensure a sufficient micropore volume, which is particularly associated with the formation of a correspondingly high number of active sites or centers with regard to catalytic activity, including the catalytically active component.

[0103] According to the invention, it can be provided in particular that the activated carbon provided or produced in process step (a) (ie starting activated carbon) has a specific BET surface area S BET in the range from 1,000 m 2 < / g to 3,000 m 2 < / g, in particular in the range from 1,100 m 2 < / g to 2,600 m 2 < / g, preferably in the range from 1,200 m 2 < / g to 2,400 m 2 < / g, more preferably in the range from 1,300 m 2 < / g to 2,200 m 2 < / g, particularly preferably in the range from 1,350 m 2 < / g to 1,950 m 2 < / g, very particularly preferably in the range from 1,375 m 2 < / g to 1.900 m 2 < / g, wherein the ratio (quotient; Q) of total pore volume V total according to Gurvich to specific BET surface area S BET according to the equation Q = V total / S BET in the range from 0.5 10 -9< m to 1.9 10 -9< m, in particular in the range from 0.55 10 -9< m to 1.9 10 -9< m, preferably in the range from 0.6 10 -9< m to 1.8 10 -9< m, preferably in the range from 0.65 10 -9< m to 1.7 10 -9< m, particularly preferably in the range from 0.65 10 -9< m to 1.6 10 -9< m, very particularly preferably in the range from 0.7 10 -9< m to 1.5 10 -9< m, further preferably in the range of 0.75 · 10 -9< m to 1.4 · 10 -9< m, more preferably in the range of 0.8 · 10 -9< m to 1.3 · 10 -9< m.

[0104] Furthermore, it has proven advantageous in the context of the present invention if the activated carbon provided and / or produced in process step (a) (ie starting activated carbon) has an average pore diameter of at least 15 nm or if the activated carbon has an average pore diameter of at most 100 nm.

[0105] In particular, the activated carbon provided and / or produced in process step (a) (ie starting activated carbon) can have an average pore diameter in the range from 15 nm to 100 nm, in particular in the range from 16 nm to 90 nm, preferably in the range from 17 nm to 85 nm, more preferably in the range from 18 nm to 80 nm, particularly preferably in the range from 20 nm to 70 nm, very particularly preferably in the range from 22 nm to 60 nm, further preferably in the range from 25 nm to 50 nm.

[0106] The determination of the textural properties of the meso- and macroporous activated carbon used according to the invention, or the determination of the textural properties in the meso- and macropore range, can be carried out by mercury intrusion, particularly with regard to the mean pore diameter. Due to the method, an evaluation range in the range of 0.01 µm to 20 µm is recorded with regard to the pore diameter.

[0107] In general, the mean pore diameter can also be determined from the quotient of four times the volume of a liquid absorbed or adsorbed by the activated carbon (adsorbate) with completely filled pores (V total ) on the one hand and the BET surface area (BET) on the other hand (pore diameter d = 4 · V total / BET). In this regard, reference can be made to the corresponding statements according to RW Magee(loc. cit.), in particular to the formula representation (15) on page 71 of the reference in question.

[0108] Furthermore, it is advantageous according to the invention if the activated carbon provided and / or produced in process step (a) (ie starting activated carbon) is spherical or if the activated carbon provided and / or produced in process step (a) is used in the form of a spherical activated carbon.

[0109] The special shape of the activated carbon is also associated with better flow properties in the context of its catalytic application based on the catalyst system according to the invention, which further improves the transport of reactants and products.

[0110] As far as the spherical activated carbon is concerned, this is particularly associated with improved properties, for example when using the catalyst system according to the invention in fixed bed reactors or the like.

[0111] According to the invention, the activated carbon provided and / or produced in process step (a) (i.e. starting activated carbon) can have a particle size, in particular a particle diameter, in the range from 60 µm to 1,000 µm, in particular in the range from 70 µm to 800 µm, preferably in the range from 80 µm to 600 µm, more preferably in the range from 100 µm to 400 µm, particularly preferably in the range from 150 µm to 375 µm, very particularly preferably in the range from 175 µm to 250 µm. In this context, at least 80% by weight, in particular at least 90% by weight, preferably at least 95% by weight, of the activated carbon particles, in particular activated carbon particles, can have particle sizes, in particular particle diameters, in the aforementioned ranges.

[0112] In general, the activated carbon provided or produced in process step (a) (ie starting activated carbon) can have an average particle size (D50), in particular an average particle diameter (D50), in the range from 60 µm to 900 µm, in particular in the range from 75 µm to 750 µm, preferably in the range from 85 µm to 550 µm, preferably in the range from 110 µm to 375 µm, particularly preferably in the range from 175 µm to 350 µm, very particularly preferably in the range from 185 µm to 225 µm.

[0113] The corresponding particle sizes or diameters can be determined, in particular, using the method according to ASTM D2862-97 / 04. In addition, the aforementioned sizes can be determined using methods based on sieve analysis, X-ray diffraction, laser diffractometry, or the like. The respective determination methods are well known to the person skilled in the art, so no further explanation is required in this regard.

[0114] In addition, the activated carbon provided and / or produced in process step (a) (ie starting activated carbon) can have an abrasion resistance ( ball pan hardness) and / or abrasion hardness of at least 90%, in particular at least 95%, preferably at least 97%, preferably at least 98%, particularly preferably at least 99%, very particularly preferably at least 99.5%, further preferably at least 99.8%. The abrasion resistance can generally be determined according to ASTM D3802-05. Thus, the activated carbon used according to the invention is further characterized by excellent mechanical properties, which is also reflected in the high abrasion resistance. The high mechanical strength of the activated carbon used according to the invention leads to low abrasion when using the resulting catalyst system according to the invention, which is particularly advantageous with regard to the service life and service life.The excellent mechanical properties and low abrasion also result in further advantages with regard to the production of the catalyst system according to the process of the invention, particularly with regard to the avoidance of abrasion or the like during the respective process steps. The high mechanical strength of the activated carbon and thus also of the catalyst system according to the invention leads to only minimal abrasion during application in catalysis, which is particularly advantageous with regard to the service life and the avoidance of sludge formation due to abrasion or the like.

[0115] The high mechanical stability of the activated carbon used according to the invention is also reflected in a high compressive and / or bursting strength (weight load capacity per activated carbon grain). In this context, the activated carbon provided or produced in process step (a) (i.e., starting activated carbon) can have a compressive and / or bursting strength (weight load capacity) per activated carbon grain, in particular per activated carbon bead, of at least 5 Newtons, in particular at least 10 Newtons, preferably at least 15 Newtons, more preferably at least 20 Newtons, and particularly preferably at least 22.5 Newtons. In particular, the activated carbon provided or produced in process step (a) (ie starting activated carbon) can have a compressive and / or bursting strength (weight load capacity) per activated carbon grain, in particular per activated carbon bead, in the range from 5 to 50 Newtons, in particular 10 to 45 Newtons, preferably 15 to 40 Newtons, preferably 17.5 to 35 Newtons.The determination of the compressive or bursting strength can be carried out in a manner known per se to the person skilled in the art, in particular by determining the compressive or bursting strength of individual particles by applying force using a stamp until the respective particle bursts.

[0116] The activated carbon provided or produced in process step (a) (ie starting activated carbon) can further have a tapped or tamped density in the range from 100 g / l to 1,500 g / l, in particular 125 g / l to 1,000 g / l, preferably 150 g / l to 800 g / l, more preferably 200 g / l to 600 g / l, particularly preferably 225 g / l to 500 g / l, very particularly preferably 250 g / l to 400 g / l, further preferably 255 g / l to 395 g / l. In particular, the activated carbon provided or produced in process step (a) (ie starting activated carbon) can also have a bulk density ( bulk density) in the range from 150 g / l to 1,000 g / l, in particular from 250 g / l to 700 g / l, preferably from 300 g / l to 600 g / l, more preferably from 300 g / l to 550 g / l. The tapped density can be determined in particular according to DIN 53194. The bulk density can be determined in particular according to ASTM B527-93 / 00.

[0117] In addition, the activated carbon provided or produced in process step (a) (i.e., starting activated carbon) can have a butane adsorption of at least 35%, in particular at least 40%, preferably at least 45%, preferably at least 47.5%, and / or wherein the activated carbon has a butane adsorption in the range from 35% to 90%, in particular in the range from 40% to 85%, preferably in the range from 45% to 80%, preferably in the range from 47.5% to 75%. The butane adsorption can be determined in particular according to ASTM D5742-95 / 00.

[0118] Furthermore, the activated carbon provided and / or produced in process step (a) (ie starting activated carbon) can have an iodine number of at least 1,250 mg / g, in particular at least 1,300 mg / g, preferably at least 1,400 mg / g, more preferably at least 1,425 mg / g, and / or wherein the activated carbon provided and / or produced in process step (a) has an iodine number in the range from 1,250 mg / g to 2,100 mg / g, in particular in the range from 1,300 mg / g to 2,000 mg / g, preferably in the range from 1,400 mg / g to 1,900 mg / g, more preferably in the range from 1,425 mg / g to 1,850 mg / g. The iodine number can be determined in particular according to ASTM D4607-94 / 99. The iodine number can be considered a measure of the available surface area, which is predominantly provided by small mesopores; the above-mentioned iodine number values ​​show that the activated carbons used according to the invention can, in particular, have a high mesoporosity.

[0119] Furthermore, the activated carbon provided or produced in process step (a) (ie starting activated carbon) can have a methylene blue value of at least 17 ml, in particular at least 18 ml, preferably at least 19 ml, preferably at least 19.5 ml, and / or wherein the activated carbon provided and / or produced in process step (a) has a methylene blue value in the range from 17 ml to 65 ml, in particular in the range from 18 ml to 55 ml, preferably in the range from 19 ml to 50 ml, preferably in the range from 19.5 ml to 47.5 ml.

[0120] In particular, the activated carbon provided or produced in process step (a) (ie starting activated carbon) can have a molasses number of at least 255, in particular at least 310, preferably at least 375, preferably at least 510, and / or wherein the activated carbon provided and / or produced in process step (a) has a molasses number in the range from 255 to 1,500, in particular in the range from 310 to 1,400, preferably in the range from 375 to 1,300, preferably in the range from 510 to 1,250.

[0121] Due to the high meso- andDue to its macroporosity, the activated carbon according to the invention thus exhibits equally high methylene blue and molasses adsorption numbers, which together can be considered a measure of the available surface area provided predominantly by mesopores and macropores. Thus, the methylene blue number or methylene blue adsorption, which describes the amount of methylene blue adsorbed per defined amount of adsorbents under defined conditions (i.e., the volume or number of milliliters (ml) of a methylene blue standard solution decolorized by a defined amount of dry and powdered adsorbents), tends to refer to smaller mesopores and provides an indication of the adsorption capacity of the activated carbon according to the invention with respect to molecules of a comparable size to methylene blue.Furthermore, the molasses number is a measure of meso- and macroporosity and indicates the amount of adsorbent required to decolorize a standard molasses solution. Thus, the molasses number provides an indication of the adsorption capacity of the activated carbon according to the invention with respect to molecules of a comparable size to molasses (generally sugar beet molasses). Together, the methylene blue and molasses numbers can thus be used as a measure of meso- and macroporosity. and Macroporosity, in particular mesoporosity, of the activated carbon according to the invention.

[0122] The dimensionless molasses number can be determined either by the Norit method (Norit NV, Amersfoort, Netherlands, Norit standard method NSTM 2.19 Molasses Number (Europe)") or alternatively according to the PACS method (PACS = Professional Analytical and Consulting Services Inc., Coraopolis Pennsylvania, USA). In the context of the present invention, the values ​​for the molasses number are determined according to the PACS method. When determining the molasses number according to the Norit or PACS method, the amount of powdered activated carbon required to decolorize a standard molasses solution is determined. The determination is carried out photometrically, with the molasses standard solution being adjusted against a standardized activated carbon with a molasses number of 245 and / or 350. For further details in this regard, reference can be made to the two aforementioned regulations.

[0123] The methylene blue value can be determined according to the method according to CEFIC (Conseil Européen des Fédérations des l'Industrie Chimique, Avenue Louise 250, Bte 71, B - 1050 Brussels, November 1986, European Council of Chemical Manufacturers' Federations, Test methods for activated carbons, section 2.4 "Methylene blue value", pages 27 / 28).

[0124] The methylene blue value according to the aforementioned CEFIC method is thus defined as the number of ml of a methylene blue standard solution that is decolorized by 0.1 g of dry, powdered activated carbon. This method requires a glass vessel with a ground-glass stopper, a filter, and a methylene blue standard solution, which is prepared as follows: A quantity of 1,200 mg of pure methylene blue dye (corresponding to approximately 1.5 g of methylene blue according to DAB VI [German Pharmacopoeia, 6th edition] or equivalent) is dissolved in water in a 1,000 ml volumetric flask, and the solution is allowed to stand for several hours or overnight. To check, 5.0 ml of the solution is made up to 1.0 l with 0.25% (by volume) acetic acid in a volumetric flask, and then the absorbance is measured at 620 nm and 1 cm path length, which must be (0.840 ± 0.010).If the absorbance is higher, dilute with the calculated amount of water; if lower, discard the solution and prepare a new one. To prepare the sample, the activated carbon is pulverized (< 0.1 mm) and then dried at 150 °C to constant weight. Exactly 0.1 g of the spherical carbon is mixed with 25 ml (5 ml) of the methylene blue standard solution in a ground-glass flask (a preliminary test is carried out to determine whether an initial addition of 25 ml of methylene blue standard solution with 5 ml additions or an initial addition of 5 ml of methylene blue standard solution with 1 ml additions is acceptable). Shake until decolorization occurs. Then add another 5 ml (1 ml) of the methylene blue standard solution and shake until decolorization occurs. The addition of methylene blue standard solution is repeated in 5 ml amounts (1 ml amounts) as long as decolorization occurs within 5 minutes.The total volume of the test solution decolorized by the sample is recorded. The test is repeated to confirm the results. The volume of methylene blue standard solution in ml that is just decolorized is the methylene blue value of the activated carbon. It should be noted in this context that the methylene blue dye must not be dried, as it is heat-sensitive; instead, the water content must be corrected purely mathematically.

[0125] According to the invention, the activated carbon provided or produced in process step (a) (ie starting activated carbon) can additionally have a weight-related adsorbed N 2 volume V ads (gew), determined at a partial pressure p / p 0 of 0.25, of at least 250 cm 3 < / g, in particular at least 300 cm 3 < / g, preferably at least 350 cm 3 < / g, more preferably at least 375 cm 3 < / g. In this context, the activated carbon provided and / or produced in process step (a) can have a weight-related adsorbed N 2 volume V ads (gew), determined at a partial pressure p / p 0 of 0.25, in the range from 250 cm 3 < / g to 850 cm 3 < / g, in particular in the range from 300 cm 3 < / g to 700 cm 3 < / g, preferably in the range from 350 cm 3 < / g to 650 cm 3 < / g, more preferably in the range from 375 cm 3 < / g to 625 cm 3 < / g.

[0126] In general, the activated carbon provided and / or produced in process step (a) (ie starting activated carbon) can have a volume-related adsorbed N2 volume Vads (vol.), determined at a partial pressure p / p0 of 0.25, of at least 50 cm 3 < / cm 3 < , in particular at least 100 cm 3 < / cm 3 < , preferably at least 110 cm 3 < / cm 3 <. In this regard, it can be provided in particular that the activated carbon provided or produced in process step (a) has a volume-related adsorbed N2 volume Vads (vol.), determined at a partial pressure p / p0 of 0.25, in the range from 50 cm 3 < / cm 3 < to 300 cm 3 < / cm 3 <, in particular in the range from 80 cm 3 < / cm 3 < to 275 cm 3 < / cm 3 <, preferably in the range from 90 cm 3 < / cm 3 < to 250 cm 3 < / cm 3 <, more preferably in the range from 95 cm 3 < / cm 3 < to 225 cm 3 < / cm 3 <.

[0127] Likewise, it can be provided according to the invention that the activated carbon provided or produced in process step (a) (ie starting activated carbon) has a weight-related adsorbed N 2 volume V ads (wt.), determined at a partial pressure p / p 0 of 0.995, of at least 300 cm 3 < / g, in particular at least 450 cm 3 < / g, preferably at least 475 cm 3 < / g. In particular, the activated carbon provided or produced in process step (a) can have a weight-related adsorbed N 2 volume V ads (wt.), determined at a partial pressure p / p 0 of 0.995, in the range from 300 cm 3 < / g to 2,300 cm 3 < / g, in particular in the range from 400 cm 3 < / g to 2,200 cm 3 < / g, preferably in the range from 450 cm 3 < / g to 2,100 cm 3 < / g, more preferably in the range from 475 cm 3 < / g to 2,100 cm 3 < / g.

[0128] In addition, the activated carbon provided or produced in process step (a) (ie starting activated carbon) can have a volume-related adsorbed N 2 volume V ads (vol.), determined at a partial pressure p / p 0 of 0.995, of at least 200 cm 3 < / cm 3 <, in particular at least 250 cm 3 < / cm 3 <, preferably at least 275 cm 3 < / cm 3 <, more preferably at least 295 cm 3 < / cm 3 <. According to the invention, it can also be provided that the activated carbon provided or produced in process step (a) has a volume-related adsorbed N 2 volume V ads (vol.), determined at a partial pressure p / p 0 of 0.995, in the range from 200 cm 3 < / cm 3 < to 500 cm 3 < / cm 3 <, in particular in the range from 250 cm 3 < / cm 3 < to 400 cm 3 < / cm 3 <, preferably in the range from 275 cm 3 < / cm 3 < to 380 cm 3 < / cm 3 <, more preferably in the range from 295 cm 3 < / cm 3 < to 375 cm 3 < / cm 3 <.

[0129] Consequently, the weight and volume-related volume V ads (N 2 ) of the activated carbon according to the invention is very large at different partial pressures p / p 0 , which is equally to be regarded as evidence of the excellent adsorption properties, along with the excellent suitability as a catalyst support, of the activated carbon used according to the invention.

[0130] According to the invention, the activated carbon provided or produced in process step (a) (ie starting activated carbon) can have a fractal dimension of the open porosity in the range from 2.6 to 2.99, in particular 2.7 to 2.95, preferably 2.8 to 2.95, and / or wherein the activated carbon has a fractal dimension of the open porosity of at least 2.7, in particular at least 2.8, preferably at least 2.85, preferably at least 2.9. The fractal dimension of the open porosity represents a measure of the microroughness of the inner surface of the activated carbon. For further details in this regard, in particular regarding the determination of the fractal dimension of the activated carbons used according to the invention, reference can be made to the documents DE 102 54 241 A1, WO 2004 / 046033 A1, EP 1 562 855 B1 and to US 2006 / 148645 A1 belonging to the same patent family, in particular to Example 4 cited in the respective documents.The aforementioned fractal dimensions lead to further improved catalytic properties of the catalyst system produced by the process according to the invention.

[0131] According to the invention, the activated carbon provided and / or produced in process step (a) (ie starting activated carbon) can be an activated carbon which is obtainable by carbonization and subsequent activation of an organic polymer-based starting material, in particular in the form of a polymer-based, preferably spherical (PBSAC) activated carbon. P olymer- b ased S pherical A ctivated C arbon ) .

[0132] Activated carbon in the form of PBSAC is particularly characterized by defined pore properties, a defined shape and high mechanical stability.

[0133] In particular, the starting material of the activated carbon provided or produced in process step (a) (ie starting activated carbon) can be used in the form of a spherical starting material and / or wherein the starting material of the activated carbon provided and / or produced in process step (a) can be used in granular form and / or in spherical form, preferably in spherical form.

[0134] In addition, the starting material of the activated carbon provided or produced in process step (a) (i.e. starting activated carbon) can have a particle size, in particular a particle diameter, in the range from 60 µm to 1,000 µm, in particular in the range from 70 µm to 800 µm, preferably in the range from 80 µm to 600 µm, more preferably in the range from 100 µm to 400 µm, particularly preferably in the range from 150 µm to 375 µm, very particularly preferably in the range from 175 µm to 250 µm. In this context, it can be provided according to the invention in particular that at least 80 wt.%, in particular at least 90 wt.%, preferably at least 95 wt.%, of the particles of the starting material have particle sizes, in particular particle diameters, in the aforementioned ranges.

[0135] In addition, the starting material of the activated carbon provided or produced in process step (a) (ie starting activated carbon) can have an average particle size (D50), in particular an average particle diameter (D50), in the range from 60 µm to 900 µm, in particular in the range from 75 µm to 750 µm, preferably in the range from 85 µm to 550 µm, preferably in the range from 110 µm to 375 µm, particularly preferably in the range from 175 µm to 350 µm, very particularly preferably in the range from 185 µm to 225 µm.

[0136] In particular, a starting material based on ion exchange resin precursors can be used as the starting material for the activated carbon provided and / or produced in process step (a) (ie starting activated carbon).

[0137] Furthermore, a starting material based on organic polymers, in particular based on divinylbenzene-crosslinked polystyrene, preferably based on styrene / divinylbenzene copolymers, can be used as the starting material for the activated carbon provided and / or produced in process step (a) (i.e., starting activated carbon). In this regard, the content of divinylbenzene in the starting material can be in the range from 0.1 wt.% to 25 wt.%, in particular in the range from 0.5 wt.% to 20 wt.%, preferably in the range from 1 wt.% to 15 wt.%, more preferably in the range from 2 wt.% to 10 wt.%, based on the starting material. With regard to the specifically used starting materials, reference can be made to the further explanations of the exemplary embodiments.

[0138] According to the invention, it can be provided in particular that the activated carbon provided and / or produced in process step (a) (ie starting activated carbon) is obtainable by: (i) carbonization of a polymeric organic sulfonated (sulfonic acid group-containing) starting material, in particular a particulate, preferably spherical, polymeric organic sulfonated starting material; then (ii) activation of the carbonizate (carbonized starting material) obtained in step (i), in particular to obtain the activated carbon, in particular activated carbon as defined in any of the preceding claims.

[0139] In this context, it may also be provided that, prior to process step (i) of carbonization, a process step of sulfonating the polymeric organic starting material is carried out, in particular by contacting the starting material with at least one sulfonating agent. In this context, the sulfonating agent can be used in liquid form.

[0140] In particular, sulfur trioxide (SO 3 ), especially in the form of oleum and / or preferably concentrated sulfuric acid, can be used as the sulfonating agent. However, according to the invention, an already sulfonated material can also be used.

[0141] In general, within the scope of the present invention, in the aforementioned process step (i), the carbonization can be carried out at temperatures in the range from 100 °C to 1,200 °C, in particular in the range from 120 °C to 1,100 °C, preferably in the range from 140 °C to 1,000 °C, preferably in the range from 150 °C to 950 °C.

[0142] In this context, according to the invention, it can be provided that in process step (i) the carbonization is carried out in several stages, in particular in two stages, preferably using a temperature gradient and / or a temperature profile. In this regard, the first stage can be carried out at temperatures in the range from 100 °C to 600 °C, in particular in the range from 120 °C to 590 °C, preferably in the range from 140 °C to 570 °C, more preferably at temperatures in the range from 150 °C to 550 °C. In addition, the second stage can be carried out at temperatures in the range from 500 °C to 1,200 °C, in particular in the range from 510 °C to 1,100 °C, preferably in the range from 530 °C to 1,000 °C, preferably at temperatures in the range from 550 °C to 950 °C.

[0143] According to the invention, in process step (i) the carbonization can be carried out for a period of time in the range from 0.1 h to 20 h, in particular in the range from 0.5 h to 15 h, preferably in the range from 1 h to 10 h, more preferably in the range from 1.5 h to 8 h, particularly preferably in the range from 2 h to 6 h.

[0144] Within the scope of the process according to the invention, in process step (i) the carbonization can be carried out in particular in such a way that chemical groups, in particular strongly acidic chemical groups, preferably sulfonic acid groups, are thermally decomposed or split off from the, in particular, sulfonated starting material, in particular with the formation of free radicals or with the formation of crosslinks, preferably in such a way that in particular carbonization begins or thermal decomposition of the starting material occurs, preferably with crosslinking of the polymers of the starting material and / or with the formation of carbon. In addition, in process step (i) the carbonization can be carried out in such a way that in particular after the thermal decomposition or the splitting off of the chemical groups, in particular the strongly acidic chemical groups, preferably the sulfonic acid groups, a particularly further orin particular complete carbonization of the starting material takes place.

[0145] For example, in process step (i), the thermal decomposition or cleavage of the chemical groups, in particular the strongly acidic chemical groups, preferably the sulfonic acid groups, can occur in the first stage of carbonization. Furthermore, in process step (i), the further and / or complete carbonization of the starting material is carried out or occurs in the second stage.

[0146] In general, process step (i) can be carried out under an inert atmosphere, in particular a nitrogen atmosphere, or at most under a slightly oxidizing atmosphere. According to the invention, it may optionally be provided that, in process step (i), water, in particular in the form of steam and / or an inert gas / steam mixture, preferably a nitrogen / steam mixture, is added to the carbonization atmosphere, in particular the inert atmosphere, during carbonization.

[0147] Furthermore, with regard to process step (ii), the activation can be carried out at temperatures in the range of 500 to 1,200 °C, in particular in the range of 800 °C to 1,100 °C, preferably in the range of 850 °C to 1,000 °C, preferably in the range of 900 to 975 °C. Furthermore, in process step (ii), the activation can be carried out for a period of time in the range of 0.5 h to 20 h, in particular in the range of 1 h to 15 h, preferably in the range of 2 h to 10 h.

[0148] In general, in process step (ii) the activation can be carried out in the presence of at least one activating gas, in particular oxygen, preferably in the form of air, water vapor and / or carbon dioxide or mixtures of these activating gases, and / or in the presence of an inert gas / water vapor mixture, preferably nitrogen / water vapor mixture, and / or in the presence of in particular pure carbon dioxide or an inert gas / carbon dioxide mixture, in particular a nitrogen / carbon dioxide mixture.

[0149] The basic principle of the activation provided according to the invention in process step (ii) consists in particular in selectively and specifically degrading or burning off a portion of the carbon generated during carbonization under suitable conditions, whereby the pore system can be further developed or specifically adjusted and, so to speak, finalized.

[0150] As far as the activated carbon provided or produced in process step (a) is concerned, it is generally commercially available in the specificities specified here, in particular from Blücher GmbH. Furthermore, for further details on the activated carbon provided or produced according to the invention in process step (a), in particular with regard to the carbonization and activation process steps, reference can be made to international patent application WO 98 / 07655 A1 and to the patent applications DE 196 53 238 A1, DE 196 50 414 A1, EP 0 952 960 A1, and US Pat. No. 6,300,276 B1 belonging to the same patent family, the respective disclosures of which are hereby incorporated by reference in their entirety.Furthermore, reference may be made to DE 43 04 026 A1 and to US Pat. No. 6,184,177 B1, which belongs to the same patent family, the respective disclosures of which are hereby incorporated in their entirety by reference. Reference may also be made to the international patent application WO 2017 / 097447 A1 and the parallel patent applications DE 10 2016 101 215 A1, EP 3 362 407 A1, and US 2019 / 177170 A1, the respective disclosures of which are hereby incorporated in their entirety by reference.

[0151] In the following, process step (b) with the oxidation of the activated carbon is described in more detail: In general, it can be provided within the scope of the present invention that the activated carbon oxidized in process step (b), in particular surface-oxidized, has an oxygen content, in particular surface oxygen content, determined by means of X-ray photoelectron spectroscopy [XPS (= X - R ay P hotoelectron S pectroscopy ) or ESCA (= E lectron S pectroscopy for C hemical A nalysis )] , in the range of 4 atomic% to 20 atomic%, in particular in the range of 5 atomic% to 20 atomic%, preferably in the range of 5.5 atomic% to 18 atomic%, more preferably in the range of 6 atomic% to 15 atomic%, particularly preferably in the range of 7 atomic% to 12.5 atomic%, based on the total elemental composition of the oxidized activated carbon.

[0152] According to the invention, it can be provided in particular that the activated carbon oxidized, in particular surface-oxidized, in process step (b) has an oxygen content, in particular surface oxygen content, determined by means of X-ray photoelectron spectroscopy (XPS or ESCA), of at least 5 atom%, preferably at least 5.5 atom%, more preferably at least 6 atom%, particularly preferably at least 7 atom%, based on the total elemental composition of the oxidized activated carbon.

[0153] According to the invention, it can be provided in particular that the activated carbon oxidized, in particular surface-oxidized, in process step (b) has an oxygen content, in particular surface oxygen content, determined by means of X-ray photoelectron spectroscopy (XPS or ESCA), of at most 20 atom%, preferably at most 18 atom%, more preferably at most 15 atom%, particularly preferably at most 12.5 atom%, based on the total element composition of the oxidized activated carbon.

[0154] In this context, it is preferred according to the invention if the elements other than oxygen of the activated carbon oxidized, in particular surface-oxidized, in process step (b) are formed at least substantially by carbon. In this context, the activated carbon oxidized, in particular surface-oxidized, in process step (b) may at most contain traces of oxygen and elements other than carbon, in particular nitrogen, sulfur, and / or chlorine, preferably in an amount of at most 2 atomic%, in particular at most 1.5 atomic%, preferably at most 1 atomic%, based on the total elemental composition of the oxidized activated carbon and calculated as the sum of the elements other than oxygen and carbon.

[0155] Without wishing to be limited or committed to this theory, on the basis of the process according to the invention with the (surface) oxidation carried out, an oxidized layer results, in a sense, in particular on the (pore) surface of the activated carbon, which generally has the oxygen-containing functional groups listed below.

[0156] The subsequent equipping with the catalytically active component after the surface oxidation then takes place - equally without wishing to be limited or committed to this theory - particularly in the area of ​​the oxidized (boundary) layer, whereby the oxygen-containing functional group increases the affinity and in particular also the interaction with the catalytically active component or functions, as it were, as binding or anchoring sites for the catalytically active component used according to the invention.

[0157] By equipping the activated carbon with the catalytically active component following the oxidation, the catalyst system according to the invention is thus provided as such with catalytic or reactive surfaces within the scope of the process according to the invention.

[0158] Regarding the previously stated ranges for the oxygen content of the activated carbon oxidized in process step (b), the stated lower limit ensures that sufficient binding sites are still available for the catalytically active component or its precursor. The stated upper limit further ensures that the carbon content in the oxidized activated carbon is still sufficiently high to form a stable framework, along with appropriate mechanical stability and the presence of a still defined pore system, particularly with regard to the corresponding total pore volume according to Gurvich and the specific BET surface area.

[0159] As previously mentioned, as a result of the targeted and purposeful oxidation treatment in process step (b), a relatively hydrophilic activated carbon is obtained, so that on this basis the equipment with the catalytically active component or its precursor is improved.

[0160] Against this background, the following can be said about the hydrophilicity of activated carbon: In particular, the activated carbon oxidized, in particular surface-oxidized, in process step (b) can have a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p 0 of 0.6, at least 35%, in particular at least 40%, preferably at least 50%, more preferably at least 60%, of the maximum water vapor saturation loading of the activated carbon is achieved. In addition, the activated carbon oxidized, in particular surface-oxidized, in process step (b) can have a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p 0 of 0.6, at most 100%, in particular at most 99%, preferably at most 98%, more preferably at most 95%, particularly preferably at most 90%, of the maximum water vapor saturation loading of the activated carbon is achieved.Furthermore, the activated carbon oxidized, in particular surface-oxidized, in process step (b) can have a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p 0 of 0.6, 30% to 100%, in particular 35% to 99%, preferably 40% to 98%, more preferably 50% to 95%, particularly preferably 60% to 90%, of the maximum water vapor saturation loading of the activated carbon is achieved. In particular, the activated carbon oxidized, in particular surface-oxidized, in process step (b) can have a hydrophilicity, determined as water vapor adsorption behavior, such that in a partial pressure range p / p 0 of 0.1 to 0.6, at least 30%, in particular at least 35%, preferably at least 40%, preferably at least 50%, particularly preferably at least 60%, of the maximum water vapor saturation loading of the activated carbon is achieved.According to the invention, the activated carbon oxidized, in particular surface-oxidized, in process step (b) can have a hydrophilicity, determined as water vapor adsorption behavior, such that in a partial pressure range p / p 0 of 0.1 to 0.6, at most 100%, in particular at most 99%, preferably at most 98%, preferably at most 95%, particularly preferably at most 90%, of the maximum water vapor saturation loading of the activated carbon is reached. Furthermore, the activated carbon oxidized, in particular surface-oxidized, in process step (b) can have a hydrophilicity, determined as water vapor adsorption behavior, such that in a partial pressure range p / p 0 of 0.1 to 0.6, 30% to 100%, in particular 35% to 99%, preferably 40% to 98%, more preferably 50% to 95%, particularly preferably 60% to 90%, of the maximum water vapor saturation loading of the activated carbon is achieved.

[0161] In addition, the following can be stated specifically with regard to the hydrophilicity of the activated carbon oxidized in process step (b): Thus, with regard to the activated carbon oxidized in process step (b), within the scope of the present invention, the oxidation, in particular surface oxidation, of the activated carbon provided or produced in process step (a) takes place in process step (b) with the proviso that the oxidized, in particular surface-oxidized, activated carbon has a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p 0 of 0.6 at least 30% of the maximum water vapor adsorption capacity of the activated carbon is exhausted or used.In particular, the activated carbon oxidized, in particular surface-oxidized, in process step (b) can have a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p 0 of 0.6 at least 30%, in particular at least 35%, preferably at least 40%, more preferably at least 50%, particularly preferably at least 60%, of the maximum water vapor adsorption capacity of the activated carbon is exhausted and / or utilized. In addition, the activated carbon oxidized, in particular surface-oxidized, in process step (b) can have a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p 0 of 0.6, at most 100%, in particular at most 99%, preferably at most 98%, more preferably at most 95%, particularly preferably at most 90%, of the maximum water vapor adsorption capacity of the activated carbon is exhausted and / or used. Likewise, the activated carbon oxidized, in particular surface-oxidized, in process step (b) can have a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p 0 of 0.6, 30% to 100%, in particular 35% to 99%, preferably 40% to 98%, preferably 50% to 95%, particularly preferably 60% to 90%, of the maximum water vapor adsorption capacity of the activated carbon is exhausted and / or used.In addition, the activated carbon oxidized, in particular surface-oxidized, in process step (b) can have a hydrophilicity, determined as water vapor adsorption behavior, such that in a partial pressure range p / p 0 of 0.1 to 0.6 at least at least 30%, in particular at least 35%, preferably at least 40%, more preferably at least 50%, particularly preferably at least 60%, of the maximum water vapor adsorption capacity of the activated carbon is exhausted and / or used. In particular, it can be provided according to the invention that the activated carbon oxidized, in particular surface-oxidized, in process step (b) has a hydrophilicity, determined as water vapor adsorption behavior, such that in a partial pressure range p / p 0 of 0.1 to 0.6 at most 100%, in particular at most 99%, preferably at most 98%, more preferably at most 95%, particularly preferably at most 90%, of the maximum water vapor adsorption capacity of the activated carbon is exhausted and / or used.According to the invention, the activated carbon oxidized, in particular surface-oxidized, in process step (b) can have a hydrophilicity, determined as water vapor adsorption behavior, such that in a partial pressure range p / p 0 of 0.1 to 0.6, 30% to 100%, in particular 35% to 99%, preferably 40% to 98%, more preferably 50% to 95%, particularly preferably 60% to 90%, of the maximum water vapor adsorption capacity of the activated carbon is exhausted and / or utilized.

[0162] In addition, the activated carbon oxidized in process step (b) can also have the following properties with regard to hydrophilicity: Furthermore, the activated carbon oxidized, in particular surface-oxidized, in process step (b) can have a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p 0 of 0.6, the amount of water vapor adsorbed by the activated carbon (H 2 O volume) V ads(H 2 O), based on the weight of the activated carbon, is at least 200 cm 3 < / g, in particular at least 250 cm 3 < / g, preferably at least 300 cm 3 < / g, more preferably at least 325 cm 3 < / g, particularly preferably at least 350 cm 3 < / g. In addition, the activated carbon oxidized in process step (b), in particular surface-oxidized, can have a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p 0 of 0.6, the amount of water vapor (H 2 O volume) V ads(H2O) adsorbed by the activated carbon, based on the weight of the activated carbon, is at most 1.000 cm 3 < / g, in particular at most 900 cm 3 < / g, preferably at most 800 cm 3 < / g, more preferably at most 700 cm 3 < / g, particularly preferably at most 600 cm 3 < / g. According to the invention, it can be provided in particular that the activated carbon oxidized, in particular surface-oxidized, in process step (b) has a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p 0 of 0.6 the amount of water vapor adsorbed by the activated carbon (H 2 O volume) V ads(H 2 O), based on the weight of the activated carbon, is in the range from 200 cm 3 < / g to 1,000 cm 3 < / g, in particular 250 cm 3 < / g to 900 cm 3 < / g, preferably 300 cm 3 < / g to 800 cm 3 < / g, more preferably 325 cm 3 < / g to 700 cm 3 < / g, particularly preferably 350 cm 3 < / g to 600 cm 3 < / g.

[0163] The above-mentioned values ​​of the water vapor adsorption behavior relate in particular to the underlying water vapor adsorption isotherm of the activated carbon obtained according to the invention in process step (b).

[0164] As far as the determination of water vapor adsorption behavior is concerned, this is carried out in the context of the present invention on the basis of DIN 66135-1, with water or water vapor being used as the underlying adsorptive or adsorbate. In this context, the water vapor adsorption behavior is determined statically volumetrically at a temperature of 25 °C (298 Kelvin). The pressure-dependent volume of adsorbed water or adsorbed water vapor V ads (STP) underlying the water vapor adsorption behavior is determined at different or variable ambient pressures p / p 0 in the range from 0.0 to 1.0, where p 0 represents the pressure under standard conditions (1,013.25 hPa). The water vapor adsorption behavior used according to the invention refers to the adsorption isotherm of the underlying activated carbon.

[0165] For further information and explanations on water vapor adsorption, please refer to the dissertation by M. Neitsch, "Water vapor and n-butane adsorption on activated carbon - mechanism, equilibrium and dynamics of 1-component and coadsorption", Faculty of Mechanical, Process and Energy Engineering, Technical University of Freiberg, The entire relevant content of which, in particular with regard to the statements on the adsorption of water vapor or water on activated carbon, is hereby incorporated in its entirety by reference.

[0166] The water vapor adsorption behavior, as previously specified, acts as a measure of the hydrophilicity or hydrophobicity of the activated carbon used according to the invention, in that, based on the previously stated values, such activated carbon is obtained in process step (b) and used in the subsequent process steps, which is overall polar or hydrophilic (ie in comparison to the starting activated carbon used) and which can therefore be described as hydrophilic in general terms.

[0167] According to the invention, the oxidation, in particular surface oxidation, of the activated carbon in process step (b) can also be carried out such that the oxidized, in particular surface-oxidized, activated carbon obtained in this way has a content of oxygen-containing groups, calculated and / or expressed as the content of volatile constituents ("fB") and based on the dry weight of the oxidized activated carbon, of at least 1 wt.%, in particular at least 2 wt.%, preferably at least 3 wt.%, preferably at least 4 wt.% and / or in the range from 1 wt.% to 30 wt.%, in particular 1.5 wt.% to 25 wt.%, preferably 2 wt.% to 20 wt.%, preferably 3 wt.% to 15 wt.%. In this context, the content of oxygen-containing functional groups can be adjusted by temperature and / or duration and / or type and / or concentration of oxidizing agent.

[0168] In this context, the oxidation of the activated carbon can also be tailored within the scope of the process according to the invention, also with regard to the optimization of the subsequent treatment with the catalytically active component.

[0169] Within the scope of the process according to the invention, the oxygen content of the activated carbon oxidized on its surface can be significantly increased compared to the starting activated carbon used – which generally has an oxygen content of less than 1 wt. %, expressed as the volatile content ("fB") and based on the dry weight of the starting activated carbon. The stated oxygen content refers in particular to the activated carbon oxidized in process step (b) before carrying out the subsequent reduction according to process step (d). The volatile content ("fB") generally functions as a measure of the oxidation and thus refers in particular to the surface oxides formed by the oxidation. In particular, the volatile content can be determined based on ISO 562:1981.In particular, the volatile content ("fB") of a previously dried activated carbon oxidized on its surface can be determined by heating it to 900 °C for a period of 7 minutes under inert conditions.

[0170] By purposefully forming and adjusting the content of oxygen-containing functional groups, the absorption amount of the catalytically active component or the corresponding precursor used subsequently, particularly in process step (c), can be specified or influenced. In this context, the skilled person is always able to select the relevant properties and coordinate them in such a way that the desired loading with the catalytically active component results within the meaning of the present invention.

[0171] In general, oxidation can be carried out in a gas atmosphere or by wet chemical means (especially when using acids).

[0172] According to the invention, in process step (b), the oxidation, in particular surface oxidation, of the activated carbon can be carried out using at least one oxidizing agent. The oxidizing agent can be selected from the group consisting of oxygen, ozone, inorganic or organic oxides and peroxides, in particular hydrogen peroxide, inorganic or organic acids and peracids, in particular mineral acids, and combinations thereof.

[0173] In particular, the oxidizing agent is selected from the group of oxygen, hydrogen peroxide (H 2 O 2 ), nitrogen oxides (preferably NO and / or NO 2 ), hydrochloric acid (HCl), nitric acid (HNO 3 ), sulfuric acid (H 2 SO 4 ), perchloric acid (HClO 4 ), phosphoric acid (H 3 PO 4 ) and combinations thereof.

[0174] Furthermore, the oxidizing agent is preferably selected from the group of oxygen (O 2 ), hydrochloric acid (HCl), nitric acid (HNO 3 ), sulfuric acid (H 2 SO 4 ), perchloric acid (HClO 4 ), phosphoric acid (H 3 PO 4 ), hydrogen peroxide (H 2 O 2 ) and combinations thereof, particularly preferably from the group of oxygen (O 2 ), hydrochloric acid (HCl) and nitric acid (HNO 3 ) and combinations thereof, very particularly preferably from the group of oxygen (O 2 ) and nitric acid (HNO 3 ) and combinations thereof.

[0175] With regard to the use of oxygen, atmospheric oxygen or synthetic air can be used in particular.

[0176] In general, within the scope of the present invention, in process step (b), the oxidation, in particular surface oxidation, of the activated carbon can be carried out with heating, in particular wherein the surface oxidation can be carried out at temperatures such that a reaction of the oxidizing agent with the activated carbon occurs with the formation of oxygen-containing functional groups on the surface of the activated carbon. The oxidation, in particular surface oxidation, of the activated carbon can be carried out at a temperature in the range from -20 °C to 1,000 °C, in particular in the range from 0 °C to 800 °C, preferably in the range from 5 °C to 700 °C, more preferably in the range from 10 °C to 600 °C, particularly preferably in the range from 20 °C to 550 °C. In this context, the oxidation, in particular surface oxidation, of the activated carbon can also be carried out for a period of up to 48 hours, in particular up to 24 hours, preferably up to 12 hours.According to the invention, the oxidation, in particular surface oxidation, of the activated carbon can be carried out, for example, for a period of time in the range from 1 minute to 1,000 minutes, in particular in the range from 5 minutes to 800 minutes, preferably in the range from 10 minutes to 600 minutes.

[0177] According to the invention, the oxidation, in particular surface oxidation, of the activated carbon can be carried out with the formation of a hydrophilic surface of the activated carbon. The oxidation, in particular surface oxidation, of the activated carbon can be carried out with the formation of oxygen-containing functional groups on the surface of the activated carbon. Furthermore, the oxidation, in particular surface oxidation, of the activated carbon can lead to the formation of oxygen-containing functional groups, in particular on the surface of the activated carbon. In this context, the oxygen-containing functional groups can be selected from acidic and basic oxygen-containing functional groups and combinations thereof, in particular acidic and basic surface oxides.In particular, the oxygen-containing functional groups can be selected from hydroxyl, carboxyl, carbonyl, anhydride, lactone, quinone, pyrone, chromene and ether groups and combinations thereof, in particular from the group of hydroxyl, carboxyl, carbonyl and ether groups and combinations thereof.

[0178] According to a first embodiment of the present invention, in process step (b), the oxidation, in particular surface oxidation, of the activated carbon can be carried out using an oxidizing agent in the form of oxygen (O 2 ). Thus, in process step (b), the oxidation, in particular surface oxidation, can be carried out using oxygen (O 2 ) as the oxidizing agent. In this context, the oxidation, in particular surface oxidation, of the activated carbon can be carried out at a temperature in the range from 100 °C to 1,000 °C, in particular in the range from 200 °C to 800 °C, preferably in the range from 300 °C to 700 °C, more preferably in the range from 350 °C to 600 °C, particularly preferably in the range from 400 °C to 550 °C.In particular, the oxidation, in particular surface oxidation, of the activated carbon can be carried out for a period of up to 10 hours, in particular up to 8 hours, preferably up to 6 hours, wherein the oxidation, in particular surface oxidation, of the activated carbon is carried out for a period of time in the range of 30 minutes to 1,000 minutes, in particular in the range of 60 minutes to 800 minutes, preferably in the range of 100 minutes to 600 minutes. In this regard, the procedure can be carried out in particular within the framework of air oxidation or oxidation in a gas atmosphere.

[0179] In contrast, according to a further embodiment of the invention, the procedure can also be such that in process step (b), the oxidation, in particular surface oxidation, of the activated carbon is carried out using an oxidizing agent, wherein the oxidizing agent is a mineral acid, such as nitric acid (HNO 3 ). In this regard, a wet-chemical process can be used, in particular. In this context, it can thus be provided according to the invention that in process step (b), the oxidation, in particular surface oxidation, is carried out using a mineral acid, in particular nitric acid (HNO 3 ), as the oxidizing agent.In this regard, the oxidation, in particular surface oxidation, of the activated carbon can be carried out at a temperature in the range from -20 °C to 250 °C, in particular in the range from 0 °C to 200 °C, preferably in the range from 5 °C to 175 °C, more preferably in the range from 10 °C to 150 °C, particularly preferably in the range from 15 °C to 125 °C. In addition, the oxidation, in particular surface oxidation, of the activated carbon can be carried out for a period of up to 6 hours, in particular up to 5 hours, preferably up to 4 hours. Likewise, the oxidation, in particular surface oxidation, of the activated carbon can be carried out for a period of time in the range from 5 minutes to 500 minutes, in particular in the range from 10 minutes to 400 minutes, preferably in the range from 20 minutes to 300 minutes.

[0180] According to this embodiment of the present invention, the mineral acid, in particular nitric acid (HNO 3 ), can be a 10% (vol%) to 75%, in particular 15% to 60%, preferably 20% to 55%, preferably about 25%, particularly preferably about 50%, acid.

[0181] In addition, it can be provided according to the invention that in process step (b) following the oxidation, in particular surface oxidation, and in particular before process step (c), a purification and / or drying of the oxidized activated carbon takes place. The purification can take place by means of at least one washing process in a liquid, in particular water. In addition, the drying can take place by heating the oxidized, in particular surface-oxidized, activated carbon, in particular to temperatures in the range from 40 °C to 200 °C, in particular 50 °C to 150 °C, preferably 60 °C to 120 °C. In particular, the drying can be carried out under reduced (air) pressure and / or in a vacuum and / or in particular wherein the drying takes place at an (air) pressure in the range from 0.01 Pa to 100 Pa, in particular 0.1 Pa to 10 Pa.

[0182] In the following, process step (c) with the equipping of the previously oxidized activated carbon with the catalytically active component or with the relevant precursor is described in more detail: In general, in process step (c), the equipping of the activated carbon oxidized in process step (b), in particular surface-oxidized, or the catalyst support can be carried out by applying and / or contacting, preferably fixing, the catalytically active component on the catalyst support.

[0183] In general, the catalytically active component may comprise or consist of at least one metal, in particular in the form of a metal compound, preferably in the form of an ionic metal compound, and / or in particular in elemental form.

[0184] According to the invention, the catalytically active component comprises at least one metal selected from the group consisting of Cu, Ag, Au, Zn, Hg, Sn, Ce, Ti, Zr, V, Nb, Cr, Mo, W, Mn, Fe, Bi, Ru, Os, Co, Rh, Re, Ir, Ni, Pd, and Pt, in particular Fe, Bi, V, Cu, Pb, Zn, Ag, Sn, Pd, Pt, Ru, and Ni, preferably Fe, Bi, V, Cu, Pt, Ru, and Pb, preferably Pd, Pt, and Ru, particularly preferably Pd and Pt. The catalytically active component can be used in process step (c), in particular in the form of a precursor.

[0185] In particular, the invention may provide that the precursor of the catalytically active component is designed or constructed in such a way that the precursor is converted or transformed into the catalytically active component by the reduction carried out in process step (d). In particular, the precursor of the catalytically active component may represent or be formed from an oxidized form of the catalytically active component.

[0186] In general, the precursor of the catalytically active component may comprise at least one metal compound which is soluble and / or dissociable, preferably in a particularly aqueous and / or particularly water-based solvent and / or dispersant, preferably based on at least one previously defined metal.

[0187] In addition, the precursor of the catalytically active component may comprise at least one inorganic or organic metal compound, preferably based on at least one previously defined metal, in particular a metal salt or metal oxide, preferably a metal salt.

[0188] In particular, the precursor of the catalytically active component may comprise at least one organic or inorganic metal salt, preferably based on at least one previously defined metal, wherein the salt is selected from the group of halide salts, hydroxides, amines, sulfates, sulfides, sulfites, nitrates, nitrites, phosphates, phosphides, phosphites, carbamates, alcoholates and carboxylic acid salts, in particular halide salts, nitrates, hydroxides and carboxylic acid salts.

[0189] In addition, the precursor of the catalytically active component may comprise at least one metal halide, preferably based on at least one previously defined metal, in particular a fluoride, chloride, bromide or iodide, preferably chloride, and / or at least one carboxylic acid salt of a metal, preferably based on at least one previously defined metal, in particular acetate.

[0190] In general, the precursor of the catalytically active component may comprise at least one metal compound selected from the group of palladium chloride, palladium nitrate, hexachloroplatinic acid, platinum nitrate, tetraaminoplatinic dihydroxide, ruthenium chloride, copper chloride, iron chloride, vanadium chloride and lead chloride, in particular palladium chloride, palladium nitrate, hexachloroplatinic acid, platinum nitrate and tetraaminoplatinic dihydroxide.

[0191] In particular, the precursor may comprise or consist of palladium chloride, palladium nitrate, hexachloroplatinic acid, platinum nitrate and / or tetraamine platinum dihydroxide.

[0192] According to the invention, H 2 PdCl 4 and / or Pd(NO 3 ) 2 can preferably be used as precursor (palladium precursor). According to the invention, H 2 (PtCl e ), (NH 3 ) 4 Pt(OH) 2 and / or Pt(NO 3 ) 2 can equally preferably be used as precursor (platinum precursor).

[0193] In particular, the precursor of the catalytically active component can be used in the form of a particularly aqueous and / or particularly water-based solution and / or in dispersion form (dispersion), in particular for the purposes of finishing and / or loading and / or coating and / or impregnating the oxidized, in particular surface-oxidized, activated carbon.

[0194] In this context, the solution or dispersion form (dispersion) may comprise water as a solvent or dispersant. Furthermore, the solution or dispersion form (dispersion) may contain at least one organic or inorganic acid or base, preferably hydrochloric acid.

[0195] In addition, the precursor of the catalytically active component can be present in the solution or dispersion form (dispersion) at least substantially crystal- and / or crystallite-free. In particular, the precursor of the catalytically active component can be at least substantially dissolved, in particular at least substantially dissociated, in the solution or dispersion form (dispersion).

[0196] In general, the solution or dispersion form (dispersion) can contain the precursor of the catalytically active component in amounts ranging from 0.01 wt.% to 80 wt.%, in particular 0.1 wt.% to 60 wt.%, preferably 1 wt.% to 50 wt.%, more preferably 2 wt.% to 40 wt.%, based on the solution and / or dispersion form (dispersion) and calculated as metal.

[0197] The term "solution" or "dispersion form (dispersion)", as used in this context within the scope of the present invention, is to be understood in particular to mean that, at the underlying amounts or concentrations, the precursor of the catalytically active component is at least substantially completely dissolved, dissociated or dispersed in the underlying solvent or dispersant. For example, within the scope of the present invention, for the purposes of equipping or loading the activated carbon with the catalytically active component, it can be provided that the activated carbon used according to the invention is immersed or soaked with or in a corresponding solution or dispersion (of the precursor) of the catalytically active component. In this way, the invention ensures in particular that the underlying solution orDispersion form (dispersion) at least substantially fills the entire pore system of the activated carbon, which leads to a homogeneous loading of the activated carbon with the catalytically active component.

[0198] In general, according to the invention, in process step (c), the equipping of the oxidized, in particular surface-oxidized, activated carbon with the catalytically active component, in particular with the precursor of the catalytically active component, can comprise applying and / or contacting, preferably fixing, the oxidized, in particular surface-oxidized, activated carbon with the catalytically active component, in particular with the precursor of the catalytically active component. In particular, the applying or contacting, preferably the fixing, can be carried out by immersing and / or impregnating and / or wetting and / or covering and / or coating and / or applying and / or spraying the oxidized, in particular surface-oxidized, activated carbon in or with the catalytically active component, in particular in or with the precursor of the catalytically active component.The application and / or contacting can be carried out with the introduction of energy, in particular by shaking and / or ultrasound. In this context, the catalytically active component, in particular the precursor of the catalytically active component, can be used in the form of a solution and / or dispersion, as previously mentioned.

[0199] In addition, it can be provided, in particular following the application and / or contacting and / or in particular for the purposes of equipping the oxidized, in particular surface-oxidized, activated carbon with the catalytically active component, in particular with the precursor of the catalytically active component, that excess amounts of catalytically active component, in particular excess amounts of the precursor of the catalytically active component, preferably excess amounts of solution and / or dispersion form (dispersion) of the catalytically active component, preferably excess amounts of solution and / or dispersion form (dispersion) of the precursor of the catalytically active component, are removed and / or separated from the activated carbon or the catalyst system.

[0200] In this context, the resulting activated carbon can be purified and / or dried, particularly following the application or contacting and / or particularly for the purpose of equipping the oxidized, in particular surface-oxidized, activated carbon with the catalytically active component, in particular with the precursor of the catalytically active component. In this context, the purification or drying can be carried out by means of at least one washing process in a liquid, in particular water. In addition, the purification or drying can be carried out by heating the activated carbon equipped with the catalytic component, in particular to temperatures in the range from 40 °C to 200 °C, in particular 50 °C to 150 °C, preferably 60 °C to 120 °C. In addition, the purification or drying can be carried out under reduced (air) pressure and / or in a vacuum.In addition, the purification and / or drying can be carried out at an (air) pressure in the range of 100 Pa to 0.01 Pa, in particular 10 Pa to 0.1 Pa. The removal of solvent or dispersant or the drying of the activated carbon leads in particular to the formation of a dried or particulate form of the precursor of the catalytically active component, which is then present in particular in crystalline form on or at the surfaces of the activated carbon used as a catalyst support.

[0201] In general, within the scope of the process according to the invention, it is provided that in process step (c), both the outer and inner surfaces, in particular the micro-, meso-, and / or macropores, of the oxidized, in particular surface-oxidized, activated carbon are equipped with the catalytically active component, in particular loaded and / or coated and / or impregnated, particularly in the form of the corresponding precursor. This allows a high loading of the catalytically active component to be achieved.

[0202] Process step (d) with the reduction of the oxidized, in particular surface-oxidized, activated carbon obtained in process step (c) and equipped with the catalytically active component, in particular with the precursor of the catalytically active component, is described in more detail below: As regards the reduction carried out according to the invention in process step (d) of the oxidized, in particular surface-oxidized, activated carbon obtained in process step (c) and equipped with the catalytically active component, in particular with the precursor of the catalytically active component, this leads - without wishing to be limited to this theory - on the one hand in particular to an at least partial reduction of the catalytically active component incorporated or applied in the activated carbon or of the relevant precursor. In particular, in this way the catalytically active component or the relevant precursor orthe underlying metal compound or the underlying metal is reduced, in particular if the catalytically active component or the relevant precursor is present in oxidized form or in the form of salts, ions, or the like. The reduction treatment can thus generally also be carried out against the background of catalyst activation and / or conversion of the catalyst or the catalytically active component or the relevant precursor into an active form, in particular by changing and / or reducing the oxidation number of the metal of the catalytically active component. The reduction treatment can thus be carried out in particular against the background of the activation of the catalytically active component or the relevant precursor.

[0203] The reduction treatment according to process step (d) can be carried out in particular with regard to a metal, in particular noble metal, of the catalytically active component or the relevant precursor, which, for example, when equipping the activated carbon with the catalytically active component or the relevant precursor in process step (c), is not used or present in the oxidation state zero or in the form of a compound, in particular in the form of a salt, in such a way that a corresponding conversion of the metal or noble metal into the elemental form or into the oxidation state zero takes place, in particular so that in this way a catalyst activation or a conversion into the catalytically active form is realized or carried out.

[0204] Furthermore, the reduction treatment according to process step (d) can - without wishing to be limited to this theory - lead to at least partial removal or reduction of the functional groups, in particular oxygen-containing ones, on the surface of the activated carbon or the corresponding pore system of the activated carbon (surface reduction). In process step (d), a surface reduction of the oxidized activated carbon equipped with the catalytically active component or the corresponding precursor can thus be carried out. This allows a neutral surface or a neutralization of the catalyst support or the corresponding activated carbon and thus of the catalyst system to be achieved.

[0205] The catalyst system according to the invention or the activated carbon treated in this way consequently also has, in particular, a reduced intrinsic reaction as a result of the reduced content of functional groups on the relevant surface associated with the reduction treatment, which is beneficial to the catalytic property overall.

[0206] Likewise - without wishing to be limited to this theory - based on the reduction treatment carried out, the hydrophilicity of the activated carbon and thus of the catalyst system as a whole is reduced or the content of polar groups is reduced, which overall improves the penetration or diffusion behavior of, in particular, hydrophobic or apolar reactants or products resulting from the catalytic reaction.

[0207] In general, in process step (d) the reduction is carried out as a gas phase reduction.

[0208] In particular, it can be provided according to the invention that in process step (d) the reduction is carried out at a temperature in the range from 120 °C to 150 °C, more preferably in the range from 130 °C to 145 °C.

[0209] According to the invention, in process step (d) the reduction can be carried out for a period of time in the range from 0.05 h to 48 h, in particular in the range from 0.1 h to 36 h, preferably in the range from 0.5 h to 24 h, preferably in the range from 1 h to 12 h.

[0210] The reduction treatment using a gaseous reducing agent will now be described in more detail, this embodiment being preferred according to the invention. In this context, it can be provided according to the invention that in process step (d) the reduction of the catalyst system takes place using at least one gaseous reducing agent, in particular gaseous reducing agent, preferably hydrogen. In this regard, in process step (d) the reduction can take place in an atmosphere containing the reducing agent, in particular hydrogen, in particular an inert atmosphere, preferably a nitrogen atmosphere. In this context, the atmosphere can contain the reducing agent, in particular hydrogen, in amounts in the range from 0.1 vol.% to 20 vol.%, in particular in the range from 0.5 vol.% to 10 vol.%, preferably in the range from 2 vol.% to 8 vol.%, based on the volume of the atmosphere.Furthermore, in process step (d), the reduction can be carried out at a temperature in the range from 50 °C to 300 °C, in particular in the range from 100 °C to 250 °C, preferably in the range from 110 °C to 200 °C, more preferably in the range from 115 °C to 160 °C, particularly preferably in the range from 120 °C to 150 °C, most preferably in the range from 130 °C to 145 °C. Furthermore, in process step (d), the reduction can be carried out at a volume flow of the atmosphere containing the reducing agent in the range from 5 l / h to 1,000 l / h, in particular in the range from 10 l / h to 500 l / h, preferably in the range from 50 l / h to 300 l / h. According to the invention, it can also be provided in this context that in process step (d) the reduction is carried out using a gaseous reducing agent for a period in the range from 0.1 h to 36 h, in particular in the range from 0.2 h to 24 h, preferably in the range from 0.5 h to 12 h.

[0211] In the context of the present invention, the reduction carried out in process step (d) is thus carried out using at least one gaseous reducing agent.

[0212] Overall, in or after carrying out process step (d), in particular such a catalyst system according to the invention is obtained as is described or defined below in the second aspect of the present invention, so that the statements there apply accordingly to the present aspect.

[0213] Overall, in process step (d), a catalyst system according to the invention can be obtained, wherein the catalyst system comprises at least one catalytically active component applied and / or fixed to a catalyst support, wherein the catalytically active component comprises and / or consists of at least one metal, and wherein the catalyst support is in the form of and / or based on activated carbon, wherein the catalyst support is in the form of a spherical activated carbon, wherein the activated carbon (ie the activated carbon forming the catalyst support) (i) has a total pore volume V total according to Gurvich in the range from 0.8 cm 3 / g to 3.9 cm 3 / g, wherein at least 50% of the total pore volume according to Gurvich is formed by pores with pore diameters of at least 2 nm, in particular by pores with pore diameters in the range from 2 nm to 500 nm, preferably by mesopores and macropores, and (ii) has a specific BET surface area S BET in the range from 1,000 m 2 / g to 3,000 m 2 / g, but with the proviso that the ratio (quotient; Q) of total pore volume V total according to Gurvich to specific BET surface area S BET according to the equation Q = V total / S BET is at least 0.5 10 -9 < m.

[0214] In the context of the present invention, the catalyst system is obtained in process step (d), wherein the catalyst system comprises at least one catalytically active component applied or fixed to a catalyst support, wherein the catalytically active component comprises and / or consists of at least one metal and wherein the catalyst support is in the form of or based on activated carbon, wherein the catalyst support is in the form of a spherical activated carbon.

[0215] According to the invention, the catalyst system has an activity, determined as the percentage degree of dispersion (degree of dispersion D, metal dispersity) of the catalytically active component, in particular of the metal of the catalytically active component, on the catalyst support, measured by chemisorption using the dynamic flow method according to DIN 66136-3:2007-01, in the range from 15% to 90%, in particular in the range from 20% to 80%, preferably in the range from 25% to 70%, preferably in the range from 28% to 60%.

[0216] The catalyst system comprises the catalytically active component, in particular the metal of the catalytically active component, with an average crystallite size (average crystallite size d Me ), determined according to DIN 66136, of at most 80 Å (Angstroms), in particular at most 70 Å, preferably at most 60 Å, preferably at most 58 Å, particularly preferably at most 45 Å, very particularly preferably at most 40 Å, even more preferably at most 38 Å, and / or in the range from 5 Å (Angstroms) to 80 Å, in particular in the range from 7 Å to 70 Å, preferably in the range from 10 Å to 60 Å, preferably in the range from 15 Å to 58 Å, particularly preferably in the range from 17 Å to 45 Å, very particularly preferably in the range from 18 Å to 40 Å, more preferably in the range of 20 Å to 38 Å.

[0217] In this context, it is therefore generally provided according to the invention that the catalyst system obtained in process step (d) has an activity, determined as the percentage degree of dispersion of the catalytically active component, in particular of the metal of the catalytically active component, on the catalyst support, measured by chemisorption using the dynamic flow method according to DIN 66136-3:2007-01, in the range from 15% to 90%, in particular in the range from 20% to 80%, preferably in the range from 25% to 70%, preferably in the range from 28% to 60%.

[0218] In this context, it can also be provided within the scope of the present invention that the catalyst system obtained in process step (d) contains the catalytically active component, in particular the metal of the catalytically active component, with an average crystallite size, preferably determined according to DIN 66136, of at most 70 Å (Angstroms), preferably at most 60 Å, preferably at most 58 Å, particularly preferably at most 45 Å, very particularly preferably at most 40 Å, even more preferably at most 38 Å, and / or in the range from 5 Å (Angstroms) to 80 Å, in particular in the range from 7 Å to 70 Å, preferably in the range from 10 Å to 60 Å, preferably in the range from 15 Å to 58 Å, particularly preferably in the range from 17 Å to 45 Å, very particularly preferably in the range from 18 Å to 40 Å, more preferably in the range of 20 Å to 38 Å.

[0219] According to the invention, it is thus possible in particular to obtain a catalyst system according to the invention which, in addition to a defined percentage degree of dispersion of the catalytically active component or the relevant metal, also has a defined crystallite size with regard to the catalytically active component or the relevant metal, wherein the above-mentioned properties of the specific percentage degree of dispersion and the specific crystallite size characterise the excellent catalytic properties of the catalyst system according to the invention, in particular with regard to the provision of large catalytically active surfaces with optimal equipment or coating of the pore system of the activated carbon with the catalytically active component.

[0220] The degree of dispersion of the catalytically active component or the metal dispersion thus also describes the catalytic activity of the catalyst system or the supported catalyst according to the invention. In particular, the catalytic activity is also characterized by the dispersion of the catalytically active component or the metal of the catalytically active component on the catalyst support material, given that the surface atoms of the catalytically active component significantly participate in the catalytic conversion or enable it. According to the invention, the term "degree of dispersion" (also referred to as "degree of dispersion D") is used synonymously with the term "metal dispersity" or "metal dispersity D". The percentage degree of dispersion is based in particular on the ratio of the atoms or atoms actually located on the surface.molecules of the catalytically active component to the theoretically possible size of the atoms or molecules of the catalytically active component located on the surface. In other words, the percentage degree of dispersion describes in particular the ratio of the number of surface atoms or molecules of the catalytically active component (as can be determined, for example, by means of chemisorption of a measuring gas using the atoms or molecules of the catalytically active component accessible to the measuring gas) to the total number of atoms or molecules of the catalytically active component (i.e. to the theoretically present or used total number of atoms or molecules of the catalytically active component or to the total number of atoms or molecules of the catalytically active component present in the catalyst support). The determination can be carried out in particular by means of chemisorption. In particular, carbon monoxide (CO) can be used as the measuring gas.The degree of dispersion or metal dispersity can thus be measured in particular by means of carbon monoxide chemisorption.

[0221] The percentage degree of dispersion (D) of the catalytically active component, in particular of the metal of the catalytically active component, on the catalyst support or the activated carbon can be calculated in particular on the basis of the following formula (I): D = n m ⋅ M W ⋅ x ⋅ 100

[0222] The mean crystallite size (synonymously also referred to as mean crystallite size d Me) can be calculated in particular on the basis of the following formula (II): d Me = f ⋅ W S ME ⋅ ρ Me

[0223] With regard to the formulas (I) and (II) given above, the following symbols apply: Formula symbols designation Unit D: Percentage degree of dispersion or percentage metal dispersity D % nm : Monolayer capacity mol / kg M: Molar mass of the metal or the catalytically active component kg / mol W: Metal content or proportion of the catalytically active component in the catalyst (mass fraction based on the sample mass) x: Stoichiometry factor of chemisorption d Me : Average crystallite size of the metal or the catalytically active component m f: Form factor for calculating the average crystallite size of the metal or the catalytically active component S Me : Specific surface area of ​​the metal or the catalytically active component m 2 < / kg ρ Me : Density of the metal kg / m 3

[0224] As far as the average crystallite size specified in the invention is concerned, this also characterizes the catalytic activity, particularly in light of the improved accessibility of the catalytically active component for reactants to be converted. In particular, the average crystallite sizes specified in the invention also exhibit an optimized ratio of the surface area of ​​the catalytically active component forming the crystallites to the corresponding volume, which likewise leads to an improvement in catalytic activity.

[0225] In particular, according to the invention, the average degree of dispersion on the one hand and the average crystallite size on the other hand interact with each other with regard to the overall improved catalytic activity provided and reinforce each other beyond the sum of the respective individual effects, so that in this respect there is also a synergistic effect with regard to the improved catalytic activity of the catalyst systems according to the invention, in particular also with regard to higher conversions or an improved space / time yield.

[0226] On the basis of the process according to the invention, the amount or content of catalytically active component can be specifically adjusted or tailored with respect to the catalyst system according to the invention, so that the catalytic activity of the resulting catalyst system according to the invention can also be specifically specified.

[0227] Thus, according to the invention, the catalyst system obtained in process step (d) may comprise the catalytically active component in amounts of at least 0.05 wt. %, in particular at least 0.1 wt. %, preferably at least 0.2 wt. %, preferably at least 0.5 wt. %, particularly preferably at least 0.6 wt. %, very particularly preferably at least 1 wt. %, further preferably at least 1.5 wt. %, calculated as metal and based on the total weight of the catalyst system. These lower limits ensure the provision of a defined catalytic activity.

[0228] In addition, according to the invention, it can be provided in particular that the catalyst system obtained in process step (d) comprises the catalytically active component in amounts of at most 25 wt. %, in particular at most 20 wt. %, preferably at most 15 wt. %, more preferably at most 10 wt. %, particularly preferably at most 8 wt. %, most preferably at most 7 wt. %, calculated as metal and based on the total weight of the catalyst system. This upper limit ensures, in particular, good accessibility to the catalytically active component, and in particular, pore clogging is avoided.

[0229] In this context, within the scope of the present invention, it may in particular be such that the catalyst system obtained in process step (d) comprises the catalytically active component in amounts in the range from 0.05 wt.% to 25 wt.%, in particular in the range from 0.1 wt.% to 25 wt.%, preferably in the range from 0.2 wt.% to 20 wt.%, preferably in the range from 0.5 wt.% to 15 wt.%, particularly preferably in the range from 0.6 wt.% to 10 wt.%, very particularly preferably in the range from 1 wt.% to 8 wt.%, further preferably in the range from 1.5 wt.% to 7 wt.%, calculated as metal and based on the total weight of the catalyst system.

[0230] Furthermore, the catalytically active component of the catalyst system according to the invention obtained in process step (d) can behave as follows: In particular, the catalytically active component of the catalyst system obtained in process step (d) can comprise or consist of at least one metal, in particular in the form of a metal compound, preferably in the form of an ionic metal compound, and / or in particular in elemental form.

[0231] According to the invention, the catalytically active component of the catalyst system obtained in process step (d) comprises at least one metal selected from the group consisting of Cu, Ag, Au, Zn, Hg, Sn, Ce, Ti, Zr, V, Nb, Cr, Mo, W, Mn, Fe, Bi, Ru, Os, Co, Rh, Re, Ir, Ni, Pd and Pt, in particular Fe, Bi, V, Cu, Pb, Zn, Ag, Sn, Pd, Pt, Ru and Ni, preferably Fe, Bi, V, Cu, Pt, Ru and Pb, preferably Pd, Pt and Ru, particularly preferably Pd and Pt.

[0232] This is because the aforementioned metals achieve particularly high catalytic activities with regard to underlying catalytic processes, such as hydrogenation reactions or the like.

[0233] As far as the activated carbon present in the catalyst system is concerned, it can be based on activated carbons of the following type, whereby the relevant properties equally lead to an improved performance of the catalyst system according to the invention (for example through improved equipment with or formation of the catalytically active component): Thus, the ((surface-)reduced) activated carbon of the catalyst system obtained in process step (d) (i.e. the activated carbon forming the catalyst support) may have been oxidized, in particular on its surface, before the catalytically active component is applied and / or fixed, in particular wherein the oxidation, in particular surface oxidation, of the activated carbon has been carried out using and / or in the presence of at least one oxidizing agent. In this regard, reference can also be made to the above statements, in particular regarding process step (c). Likewise, within the scope of the present invention, it may in particular be the case that the activated carbon has been reduced, in particular on its surface, after being equipped with the catalytically active component, in particular wherein the reduction of the activated carbon has been carried out using and / or in the presence of at least one reducing agent.In particular, the activated carbon, in particular after being equipped with the catalytically active component and / or after the reduction has been carried out, is a reduced, in particular surface-reduced, activated carbon. In particular, according to the invention, the precursor of the catalytically active component is converted into the active form or into the catalytically active component during the reduction treatment, in particular wherein the underlying metal component is converted into the elemental form. In addition, the activated carbon (iethe activated carbon forming the catalyst support) can be obtainable by carbonization and subsequent activation of a starting material based on organic polymers, followed by an oxidation (treatment), wherein the oxidation (treatment) takes place before the equipment with the catalytically active component, and followed by a reduction (treatment), wherein the reduction (treatment) takes place after the equipment with the catalytically active component. In this regard, reference can also be made to the above statements. Likewise, the activated carbon (i.e. the activated carbon forming the catalyst support) can be an activated carbon which is based on an activated carbon which is obtainable by carbonization and subsequent activation of an organic polymer-based starting material, and / or which is based on an activated carbon in the form of a polymer-based, preferably spherical, activated carbon (PBSAC or. P olymer- b ased S pherical A ctivated C arbon). In addition, the activated carbon of the catalyst system obtained in process step (d) (i.e. the activated carbon forming the catalyst support) can be an activated carbon derived from or based on a starting material described herein (cf. also claim 21). In particular, the activated carbon of the catalyst system obtained in process step (d) can be an activated carbon derived from or based on an activated carbon obtained according to the production process for the activated carbon described herein (cf. claims 22 to 25) or according to the oxidation process described herein according to process step (b) (cf. also claims 30 to 34).

[0234] Furthermore, in the present case, it may also be the case that the catalytically active component of the resulting catalyst system according to the invention is designed in such a way that it is based on or originates from a precursor of the catalytically active component which is reduced in particular in process step (d).

[0235] In particular, within the scope of the present invention, the catalyst system obtained in process step (d) may be a catalyst system which is reduced, in particular, at its surface (which includes, in particular, a corresponding oxidation of the catalyst support and thus of the activated carbon in question as well as of the catalytically active component or the precursor in question).

[0236] Furthermore, for further explanations of the catalyst system according to the invention obtained in process step (d), reference can be made to the following explanations according to the second aspect of the present invention with the catalyst system, the relevant explanations applying accordingly.

[0237] As regards the present first aspect of the present invention, the present invention also relates to a process for producing a catalyst system comprising at least one catalytically active component in the form of a supported catalyst, preferably for use in heterogeneous catalysis, in particular a process as defined herein,

[0238] wherein at least one catalytically active component is applied and / or fixed to a catalyst support, wherein the catalytically active component comprises and / or consists of at least one metal, wherein the metal is selected from the group consisting of Cu, Ag, Au, Zn, Hg, Sn, Ce, Ti, Zr, V, Nb, Cr, Mo, W, Mn, Fe, Bi, Ru, Os, Co, Rh, Re, Ir, Ni, Pd and Pt, wherein the process comprises the following steps in the sequence (a) to (d) specified below: (a) Providing and / or producing a spherical activated carbon used as a catalyst support (= starting activated carbon), wherein the activated carbon (i.e. starting activated carbon) (i) has a total pore volume V total according to Gurvich in the range from 0.8 cm 3 / g to 3.9 cm 3 / g, wherein at least 50% of the total pore volume according to Gurvich of the activated carbon is formed by pores with pore diameters of at least 2 nm, in particular by pores with pore diameters in the range from 2 nm to 500 nm, preferably by mesopores and macropores, (ii) has a specific BET surface area S BET in the range from 1,000 m 2 / g to 3,000 m 2 / g, but with the proviso that the ratio Q of total pore volume V total according to Gurvich to specific BET surface area S BET according to the equation Q = V total / S BET is at least 0.5 · 10 -9< m, and (iii) an average pore diameter in the range of 15 nm to 100 nm, in particular in the range of 16 nm to 90 nm,preferably in the range from 17 nm to 85 nm, preferably in the range from 18 nm to 80 nm, particularly preferably in the range from 20 nm to 70 nm, very particularly preferably in the range from 22 nm to 60 nm, further preferably in the range from 25 nm to 50 nm; then (b) oxidation, in particular surface oxidation, of the activated carbon provided and / or produced in process step (a) with the proviso that the oxidized, in particular surface-oxidized, activated carbon has an oxygen content, in particular surface oxygen content, determined by means of X-ray photoelectron spectroscopy (XPS or ESCA), of at least 4 atom%, based on the total elemental composition of the oxidized activated carbon, and / or with the proviso that the oxidized, in particular surface-oxidized, activated carbon has a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p 0 of 0,6 at least 30% of the maximum water vapor saturation loading of the activated carbon is reached; then (c) equipping, in particular loading and / or coating and / or impregnating, the activated carbon oxidized, in particular surface-oxidized, in process step (b) with the catalytically active component, in particular with at least one precursor of the catalytically active component; then (d) reducing the oxidized, in particular surface-oxidized, activated carbon obtained in process step (c) and equipped with the catalytically active component, in particular with the precursor of the catalytically active component, in particular to convert the precursor of the catalytically active component into the catalytically active component, so that the catalyst system comprising at least one catalytically active component is obtained; wherein in process step (d) the reduction is carried out as a gas phase reduction,wherein in process step (d) the reduction is carried out at a temperature in the range from 115 °C to 160 °C; wherein in process step (d) the catalyst system is obtained, wherein the catalyst system comprises at least one catalytically active component applied and / or fixed to a catalyst support, wherein the catalytically active component comprises and / or consists of at least one metal, and wherein the catalyst support is in the form of activated carbon, wherein the catalyst support is in the form of a spherical activated carbon; and wherein the catalyst system has an activity, determined as the percentage degree of dispersion of the catalytically active component on the catalyst support, measured by chemisorption using the dynamic flow method according to DIN 66136-3:2007-01, in the range from 15% to 90%; and wherein the catalyst system comprises the catalytically active component with an average crystallite size, determined according to DIN 66136,of not more than 80 Å (Angstroms).

[0239] In this context, the present invention also relates, according to the present first aspect, to a process for producing a catalyst system comprising at least one catalytically active component in the form of a supported catalyst, preferably for use in heterogeneous catalysis, in particular as defined above, wherein at least one catalytically active component is applied and / or fixed to a catalyst support, wherein the catalytically active component comprises and / or consists of at least one metal, wherein the metal is selected from the group consisting of Cu, Ag, Au, Zn, Hg, Sn, Ce, Ti, Zr, V, Nb, Cr, Mo, W, Mn, Fe, Bi, Ru, Os, Co, Rh, Re, Ir, Ni, Pd and Pt, wherein the process comprises the following steps in the sequence (a) to (d) specified below: (a) Providing and / or producing a spherical activated carbon used as a catalyst support (= starting activated carbon), wherein the activated carbon (i.e. starting activated carbon) (i) has a total pore volume (V total ), in particular a total pore volume according to Gurvich, in the range from 0.8 cm 3 / g to 3.9 cm 3 / g, wherein at least 50% of the total pore volume, in particular the total pore volume according to Gurvich, the activated carbon through pores with pore diameters of at least 2 nm,in particular by pores with pore diameters in the range from 2 nm to 500 nm, preferably by mesopores and macropores, (ii) has a specific BET surface area S BET in the range from 1,000 m 2 / g to 3,000 m 2 / g, but with the proviso that the ratio Q of total pore volume V total according to Gurvich to specific BET surface area S BET according to the equation Q = V total / S BET is at least 0.5 10 -9 < m, (iii) an average pore diameter in the range from 15 nm to 100 nm, in particular in the range from 16 nm to 90 nm, preferably in the range from 17 nm to 85 nm, preferably in the range from 18 nm to 80 nm, particularly preferably in the range from 20 nm to 70 nm, very particularly preferably in the range from 22 nm to 60 nm, further preferably in the range from 25 nm to 50 nm, and (iv) a particle size, in particular a particle diameter, in the range from 60 µm to 1,000 µm, in particular in the range from 70 µm to 800 µm,preferably in the range from 80 µm to 600 µm, preferably in the range from 100 µm to 400 µm, particularly preferably in the range from 150 µm to 375 µm, very particularly preferably in the range from 175 µm to 250 µm, in particular wherein at least 80% by weight, in particular at least 90% by weight, preferably at least 95% by weight, of the activated carbon particles, in particular activated carbon particles, have particle sizes, in particular particle diameters, in the aforementioned ranges; and / or an average particle size (D50), in particular an average particle diameter (D50), in the range from 60 µm to 900 µm, in particular in the range from 75 µm to 750 µm, preferably in the range from 85 µm to 550 µm, preferably in the range from 110 µm to 375 µm, particularly preferably in the range from 175 µm to 350 µm, very particularly preferably in the range from 185 µm to 225 µm; then (b) oxidation, in particular surface oxidation,the activated carbon provided and / or produced in process step (a), with the proviso that the oxidized, in particular surface-oxidized, activated carbon has an oxygen content, in particular surface oxygen content, determined by X-ray photoelectron spectroscopy (XPS or ESCA), of at least 4 atomic%, based on the total elemental composition of the oxidized activated carbon, and / or with the proviso that the oxidized, in particular surface-oxidized, activated carbon has a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p 0 of 0.6, at least 30% of the maximum water vapor saturation loading of the activated carbon is achieved; then (c) finishing, in particular loading and / or coating and / or impregnation, of the activated carbon oxidized, in particular surface-oxidized, in process step (b) with the catalytically active component,in particular with at least one precursor of the catalytically active component; then (d) reducing the oxidized, in particular surface-oxidized, activated carbon obtained in process step (c) and equipped with the catalytically active component, in particular with the precursor of the catalytically active component, in particular to convert the precursor of the catalytically active component into the catalytically active component, so that the catalyst system comprising at least one catalytically active component, in particular the supported catalyst, is obtained; wherein in process step (d) the reduction is carried out as a gas-phase reduction, wherein in process step (d) the reduction is carried out at a temperature in the range of 115 °C to 160 °C; wherein in process step (d) the catalyst system is obtained, wherein the catalyst system comprises at least one catalytically active component applied and / or fixed to a catalyst support,wherein the catalytically active component comprises and / or consists of at least one metal, and wherein the catalyst support is in the form of activated carbon, wherein the catalyst support is in the form of a spherical activated carbon; and wherein the catalyst system has an activity, determined as the percentage degree of dispersion of the catalytically active component on the catalyst support, measured by chemisorption using the dynamic flow method according to DIN 66136-3:2007-01, in the range from 15% to 90%; and wherein the catalyst system has the catalytically active component with an average crystallite size, determined according to DIN 66136, of at most 80 Å (Angstroms).

[0240] In particular, according to the first aspect of the present invention, the present invention also relates to a process for producing a catalyst system comprising at least one catalytically active component in the form of a supported catalyst, preferably for use in heterogeneous catalysis, in particular processes as defined herein, wherein at least one catalytically active component is applied and / or fixed to a catalyst support, wherein the catalytically active component comprises and / or consists of at least one metal, wherein the metal is selected from the group consisting of Cu, Ag, Au, Zn, Hg, Sn, Ce, Ti, Zr, V, Nb, Cr, Mo, W, Mn, Fe, Bi, Ru, Os, Co, Rh, Re, Ir, Ni, Pd and Pt, wherein the process comprises the following steps in the sequence (a) to (d) specified below: (a) Providing and / or producing a spherical activated carbon used as a catalyst support (= starting activated carbon), wherein the activated carbon (ieStarting activated carbon) (i) has a total pore volume V total according to Gurvich in the range from 0.8 cm 3 / g to 3.9 cm 3 / g, wherein at least 50% of the total pore volume, in particular the total pore volume according to Gurvich, of the activated carbon is formed by pores with pore diameters of at least 2 nm, in particular by pores with pore diameters in the range from 2 nm to 500 nm, preferably by mesopores and macropores, (ii) a specific BET surface area S BET in the range from 1,000 m 2 / g to 3.000 m 2 < / g, but with the proviso that the ratio Q of total pore volume V total according to Gurvich to specific BET surface area S BET according to the equation Q = V total / S BET is at least 0.5 10 -9 < m, and (iii) has an average pore diameter in the range from 15 nm to 100 nm, in particular in the range from 16 nm to 90 nm, preferably in the range from 17 nm to 85 nm, more preferably in the range from 18 nm to 80 nm, particularly preferably in the range from 20 nm to 70 nm, very particularly preferably in the range from 22 nm to 60 nm, further preferably in the range from 25 nm to 50 nm, (iv) a particle size, in particular a particle diameter, in the range from 60 µm to 1.000 µm, in particular in the range from 70 µm to 800 µm, preferably in the range from 80 µm to 600 µm, preferably in the range from 100 µm to 400 µm, particularly preferably in the range from 150 µm to 375 µm, very particularly preferably in the range from 175 µm to 250 µm, in particular wherein at least 80% by weight, in particular at least 90% by weight, preferably at least 95% by weight, of the activated carbon particles, in particular activated carbon particles, have particle sizes, in particular particle diameters, in the aforementioned ranges; and / or an average particle size (D50), in particular an average particle diameter (D50), in the range from 60 µm to 900 µm, in particular in the range from 75 µm to 750 µm, preferably in the range from 85 µm to 550 µm, more preferably in the range from 110 µm to 375 µm, particularly preferably in the range from 175 µm to 350 µm, very particularly preferably in the range from 185 µm to 225 µm, (v) optionally an abrasion resistance (. ball pan hardness) and / or abrasion hardness of at least 90%, in particular at least 95%, preferably at least 97%, preferably at least 98%, particularly preferably at least 99%, very particularly preferably at least 99.5%, further preferably at least 99.8%, (vi) optionally has a tapped or tamped density in the range from 100 g / l to 1,500 g / l, in particular 125 g / l to 1,000 g / l, preferably 150 g / l to 800 g / l, preferably 200 g / l to 600 g / l, particularly preferably 225 g / l to 500 g / l, very particularly preferably 250 g / l to 400 g / l, further preferably 255 g / l to 395 g / l, and / or a bulk density ( bulk density) in the range from 150 g / l to 1,000 g / l, in particular from 250 g / l to 700 g / l, preferably from 300 g / l to 600 g / l, preferably from 300 g / l to 550 g / l, (vii) optionally has a butane adsorption in the range from 35% to 90%, in particular in the range from 40% to 85%, preferably in the range from 45% to 80%, preferably in the range from 47.5% to 75%, (viii) optionally has an iodine number in the range from 1,250 mg / g to 2,100 mg / g, in particular in the range from 1,300 mg / g to 2,000 mg / g, preferably in the range from 1,400 mg / g to 1,900 mg / g, preferably in the range from 1,425 mg / g to 1,850 mg / g, (ix) optionally has a methylene blue value in the range from 17 ml to 65 ml, in particular in the range from 18 ml to 55 ml, preferably in the range from 19 ml to 50 ml, preferably in the range from 19.5 ml to 47.5 ml, (x) optionally has a molasses number in the range from 255 to 1,500, in particular in the range from 310 to 1,400, preferably in the range from 375 to 1,300,preferably in the range from 510 to 1,250, (xi) optionally has a weight-related adsorbed N 2 volume V ads (gew), determined at a partial pressure p / p 0 of 0.25, in the range from 250 cm 3 / g to 850 cm 3 / g, in particular in the range from 300 cm 3 / g to 700 cm 3 / g, preferably in the range from 350 cm 3 / g to 650 cm 3 / g, preferably in the range from 375 cm 3 / g to 625 cm 3 / g, (xii) optionally has a volume-related adsorbed N 2 volume V ads (vol.), determined at a partial pressure p / p 0 of 0.25, in the range from 50 cm 3 / cm 3 to 300 cm 3 / cm 3 , in particular in the range from 80 cm 3 < / cm 3 < to 275 cm 3 < / cm 3 < , preferably in the range from 90 cm 3 < / cm 3 < to 250 cm 3 < / cm 3 < , preferably in the range from 95 cm 3 < / cm 3 < to 225 cm 3 < / cm 3 < , (xiii) optionally a weight-related adsorbed N 2 volume V ads (wt.) , determined at a partial pressure p / p 0 of 0.995, in the range from 300 cm 3 < / g to 2300 cm 3 < / g,in particular in the range from 400 cm 3 / g to 2,200 cm 3 / g, preferably in the range from 450 cm 3 / g to 2,100 cm 3 / g, preferably in the range from 475 cm 3 / g to 2,100 cm 3 / g, (xiv) optionally a volume-related adsorbed N 2 volume V ads (vol.), determined at a partial pressure p / p 0 of 0.995, in the range from 200 cm 3 / cm 3 to 500 cm 3 / cm 3 , in particular in the range from 250 cm 3 / cm 3 to 400 cm 3 / cm 3 , preferably in the range from 275 cm 3 / cm 3 to 380 cm 3 / cm 3 , preferably in the range from 295 cm 3 / cm 3< to 375 cm 3< / cm 3< , and (xv) optionally has a fractal dimension of the open porosity in the range of 2.6 to 2.99, in particular 2.7 to 2.95, preferably 2.8 to 2.95, and / or wherein the activated carbon has a fractal dimension of the open porosity of at least 2.7, in particular at least 2.8, preferably at least 2.85, preferably at least 2.9; then (b) oxidation, in particular surface oxidation,the activated carbon provided and / or produced in process step (a), with the proviso that the oxidized, in particular surface-oxidized, activated carbon has an oxygen content, in particular surface oxygen content, determined by X-ray photoelectron spectroscopy (XPS or ESCA), of at least 4 atomic%, based on the total elemental composition of the oxidized activated carbon, and / or with the proviso that the oxidized, in particular surface-oxidized, activated carbon has a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p 0 of 0.6, at least 30% of the maximum water vapor saturation loading of the activated carbon is achieved; then (c) finishing, in particular loading and / or coating and / or impregnation, of the activated carbon oxidized, in particular surface-oxidized, in process step (b) with the catalytically active component,in particular with at least one precursor of the catalytically active component; then (d) reducing the oxidized, in particular surface-oxidized, activated carbon obtained in process step (c) and equipped with the catalytically active component, in particular with the precursor of the catalytically active component, in particular to convert the precursor of the catalytically active component into the catalytically active component, so that the catalyst system comprising at least one catalytically active component, in particular the supported catalyst, is obtained; wherein in process step (d) the reduction is carried out as a gas-phase reduction, wherein in process step (d) the reduction is carried out at a temperature in the range of 115 °C to 160 °C; wherein in process step (d) the catalyst system is obtained, wherein the catalyst system comprises at least one catalytically active component applied and / or fixed to a catalyst support,wherein the catalytically active component comprises and / or consists of at least one metal, and wherein the catalyst support is in the form of activated carbon, wherein the catalyst support is in the form of a spherical activated carbon; and wherein the catalyst system has an activity, determined as the percentage degree of dispersion of the catalytically active component on the catalyst support, measured by chemisorption using the dynamic flow method according to DIN 66136-3:2007-01, in the range from 15% to 90%; and wherein the catalyst system has the catalytically active component with an average crystallite size, determined according to DIN 66136, of at most 80 Å (Angstroms).

[0241] In addition, according to the first aspect of the present invention, the present invention further also relates to a process for producing a catalyst system comprising at least one catalytically active component in the form of a supported catalyst, preferably for use in heterogeneous catalysis, in particular processes as defined above, wherein at least one catalytically active component is applied and / or fixed to a catalyst support, wherein the catalytically active component comprises and / or consists of at least one metal, wherein the metal is selected from the group consisting of Cu, Ag, Au, Zn, Hg, Sn, Ce, Ti, Zr, V, Nb, Cr, Mo, W, Mn, Fe, Bi, Ru, Os, Co, Rh, Re, Ir, Ni, Pd and Pt, wherein the process comprises the following steps in the sequence (a) to (d) specified below: (a) Providing and / or producing a spherical activated carbon used as a catalyst support (= starting activated carbon), wherein the activated carbon (ieStarting activated carbon) (i) has a total pore volume V total according to Gurvich in the range from 0.8 cm 3 / g to 3.9 cm 3 / g, wherein at least 50% of the total pore volume, in particular the total pore volume according to Gurvich, of the activated carbon is formed by pores with pore diameters of at least 2 nm, in particular by pores with pore diameters in the range from 2 nm to 500 nm, preferably by mesopores and macropores, (ii) a specific BET surface area S BET in the range from 1,000 m 2 / g to 3.000 m 2 < / g, but with the proviso that the ratio Q of total pore volume V total according to Gurvich to specific BET surface area S BET according to the equation Q = V total / S BET is at least 0.5 10 -9 < m, and (iii) has an average pore diameter in the range from 15 nm to 100 nm, in particular in the range from 16 nm to 90 nm, preferably in the range from 17 nm to 85 nm, more preferably in the range from 18 nm to 80 nm, particularly preferably in the range from 20 nm to 70 nm, very particularly preferably in the range from 22 nm to 60 nm, further preferably in the range from 25 nm to 50 nm, (iv) a particle size, in particular a particle diameter, in the range from 60 µm to 1.000 µm, in particular in the range from 70 µm to 800 µm, preferably in the range from 80 µm to 600 µm, preferably in the range from 100 µm to 400 µm, particularly preferably in the range from 150 µm to 375 µm, very particularly preferably in the range from 175 µm to 250 µm, in particular wherein at least 80% by weight, in particular at least 90% by weight, preferably at least 95% by weight, of the activated carbon particles, in particular activated carbon particles, have particle sizes, in particular particle diameters, in the aforementioned ranges; and / or an average particle size (D50), in particular an average particle diameter (D50), in the range from 60 µm to 900 µm, in particular in the range from 75 µm to 750 µm, preferably in the range from 85 µm to 550 µm, more preferably in the range from 110 µm to 375 µm, particularly preferably in the range from 175 µm to 350 µm, very particularly preferably in the range from 185 µm to 225 µm, (v) an abrasion resistance (. ball pan hardness) and / or abrasion hardness of at least 90%, in particular at least 95%, preferably at least 97%, preferably at least 98%, particularly preferably at least 99%, very particularly preferably at least 99.5%, further preferably at least 99.8%, (vi) a tapped or tamped density in the range from 100 g / l to 1,500 g / l, in particular 125 g / l to 1,000 g / l, preferably 150 g / l to 800 g / l, preferably 200 g / l to 600 g / l, particularly preferably 225 g / l to 500 g / l, very particularly preferably 250 g / l to 400 g / l, further preferably 255 g / l to 395 g / l, and / or a bulk density ( bulk density) in the range from 150 g / l to 1,000 g / l, in particular from 250 g / l to 700 g / l, preferably 300 g / l to 600 g / l, preferably 300 g / l to 550 g / l, (vii) a butane adsorption in the range from 35% to 90%, in particular in the range from 40% to 85%, preferably in the range from 45% to 80%, preferably in the range from 47.5% to 75%, (viii) an iodine number in the range from 1,250 mg / g to 2,100 mg / g, in particular in the range from 1,300 mg / g to 2,000 mg / g, preferably in the range from 1,400 mg / g to 1,900 mg / g, preferably in the range from 1,425 mg / g to 1,850 mg / g, (ix) has a methylene blue value in the range from 17 ml to 65 ml, in particular in the range from 18 ml to 55 ml, preferably in the range from 19 ml to 50 ml, more preferably in the range from 19.5 ml to 47.5 ml, (x) has a molasses number in the range from 255 to 1,500, in particular in the range from 310 to 1,400, preferably in the range from 375 to 1,300, more preferably in the range from 510 to 1,250,(xi) a weight-related adsorbed N 2 volume V ads (gew), determined at a partial pressure p / p 0 of 0.25, in the range from 250 cm 3 / g to 850 cm 3 / g, in particular in the range from 300 cm 3 / g to 700 cm 3 / g, preferably in the range from 350 cm 3 / g to 650 cm 3 / g, preferably in the range from 375 cm 3 / g to 625 cm 3 / g, (xii) a volume-related adsorbed N 2 volume V ads (vol.), determined at a partial pressure p / p 0 of 0.25, in the range from 50 cm 3 / cm 3 to 300 cm 3 / cm 3 , in particular in the range from 80 cm 3 / cm 3 to 275 cm 3 < / cm 3 < , preferably in the range from 90 cm 3 < / cm 3 < to 250 cm 3 < / cm 3 < , preferably in the range from 95 cm 3 < / cm 3 < to 225 cm 3 < / cm 3 < , (xiii) a weight-related adsorbed N 2 volume V ads (wt.) , determined at a partial pressure p / p 0 of 0.995, in the range from 300 cm 3 < / g to 2,300 cm 3 < / g, in particular in the range from 400 cm 3 < / g to 2,200 cm 3 < / g,preferably in the range from 450 cm 3 < / g to 2,100 cm 3 < / g, more preferably in the range from 475 cm 3 < / g to 2,100 cm 3 < / g, (xiv) a volume-related adsorbed N 2 volume V ads (vol.), determined at a partial pressure p / p 0 of 0.995, in the range from 200 cm 3 < / cm 3 < to 500 cm 3 < / cm 3 <, in particular in the range from 250 cm 3 < / cm 3 < to 400 cm 3 < / cm 3 <, preferably in the range from 275 cm 3 < / cm 3 < to 380 cm 3 < / cm 3 <, preferably in the range from 295 cm 3 < / cm 3 < to 375 cm 3 < / cm 3 <, and (xv) a fractal dimension of the open porosity in the range of 2.6 to 2.99, in particular 2.7 to 2.95, preferably 2.8 to 2.95, and / or wherein the activated carbon has a fractal dimension of the open porosity of at least 2.7, in particular at least 2.8, preferably at least 2.85, preferably at least 2.9; then (b) oxidation, in particular surface oxidation, of the activated carbon provided and / or produced in process step (a) with the proviso,that the oxidized, in particular surface-oxidized, activated carbon has an oxygen content, in particular surface oxygen content, determined by X-ray photoelectron spectroscopy (XPS or ESCA), of at least 4 atomic%, based on the total elemental composition of the oxidized activated carbon, and / or with the proviso that the oxidized, in particular surface-oxidized, activated carbon has a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p 0 of 0.6, at least 30% of the maximum water vapor saturation loading of the activated carbon is reached; then (c) finishing, in particular loading and / or coating and / or impregnation, of the activated carbon oxidized in process step (b), in particular surface-oxidized, with the catalytically active component, in particular with at least one precursor of the catalytically active component; then (d) reducing the amount of the catalytically active component obtained in process step (c),oxidized, in particular surface-oxidized, activated carbon equipped with the catalytically active component, in particular with the precursor of the catalytically active component, in particular for converting the precursor of the catalytically active component into the catalytically active component, so that the catalyst system comprising at least one catalytically active component, in particular the supported catalyst, is obtained; wherein in process step (d) the reduction is carried out as a gas-phase reduction, wherein in process step (d) the reduction is carried out at a temperature in the range from 115 °C to 160 °C; wherein in process step (d) the catalyst system is obtained, wherein the catalyst system comprises at least one catalytically active component applied and / or fixed to a catalyst support,wherein the catalytically active component comprises and / or consists of at least one metal, and wherein the catalyst support is in the form of activated carbon, wherein the catalyst support is in the form of a spherical activated carbon; and wherein the catalyst system has an activity, determined as the percentage degree of dispersion of the catalytically active component on the catalyst support, measured by chemisorption using the dynamic flow method according to DIN 66136-3:2007-01, in the range from 15% to 90%; and wherein the catalyst system has the catalytically active component with an average crystallite size, determined according to DIN 66136, of at most 80 Å (Angstroms).

[0242] Overall, within the scope of the present invention, an efficient process for producing a catalyst system according to the invention with high catalytic performance is provided, wherein, with a simultaneous simplified process control, a catalyst system is provided which can be specifically adjusted or tailored, in particular with regard to its catalytic activity, and which overall has a high catalytic activity, as demonstrated in particular by the average degree of dispersion and the average crystallite size of the catalytically active component.

[0243] The provision of the high-performance catalyst system according to the invention is ensured by the targeted sequencing and coordination of the respective process steps, as defined above. The use of a special activated carbon as a catalyst support with a defined pore system and the implementation of a specific oxidation process are also of great importance, particularly with regard to providing a higher loading of the catalytically active component and better accessibility to reactants and products.

[0244] The process according to the invention and the catalyst system obtainable thereby are thus associated with a multitude of advantages and special properties, as already mentioned above. Due to the outstanding catalytic properties of the catalyst system according to the invention obtained by the process according to the invention, a broad range of applications is possible, ensuring correspondingly high catalytic conversions and high space / time yields when used for catalytic applications.

[0245] With regard to the method according to the invention, reference can also be made to the statements on the further aspects of the present invention, which apply accordingly in the present case.

[0246] Another object of the present invention - according to a second Another aspect of the present invention is also the catalyst system according to the invention in the form of a supported catalyst, preferably for use in heterogeneous catalysis, wherein the catalyst system according to the invention or the supported catalyst in question is obtainable or obtained according to the process according to the invention described above.

[0247] In this context, the invention according to the second aspect relates in particular to the catalyst system as defined above, wherein the catalyst system comprises at least one catalytically active component applied and / or fixed to a catalyst support, wherein the catalytically active component comprises and / or consists of at least one metal, wherein the metal is selected from the group consisting of Cu, Ag, Au, Zn, Hg, Sn, Ce, Ti, Zr, V, Nb, Cr, Mo, W, Mn, Fe, Bi, Ru, Os, Co, Rh, Re, Ir, Ni, Pd and Pt, and wherein the catalyst support is in the form of activated carbon, wherein the catalyst support is in the form of a spherical activated carbon, wherein the activated carbon (ie the activated carbon forming the catalyst support) (i) has a total pore volume V total according to Gurvich in the range from 0.8 cm 3 / g to 3.9 cm 3 / g, wherein at least 50% of the total pore volume, in particular the total pore volume according to Gurvich, is formed by pores with Pore ​​diameters of at least 2 nm, in particular by pores with pore diameters in the range of 2 nm to 500 nm, preferably by meso- and macropores,are formed, and (ii) has a specific BET surface area S BET in the range from 1,000 m 2 < / g to 3,000 m 2 < / g, but with the proviso that the ratio Q of total pore volume V total according to Gurvich to specific BET surface area S BET according to the equation Q = V total / S BET is at least 0.5 10 -9 < m; and wherein the catalyst system has an activity, determined as the percentage degree of dispersion of the catalytically active component, in particular of the metal of the catalytically active component, on the catalyst support, measured by chemisorption using the dynamic flow method according to DIN 66136-3:2007-01, in the range from 15% to 90%, in particular in the range from 20% to 80%, preferably in the range from 25% to 70%, preferably in the range from 28% to 60%; and wherein the catalyst system comprises the catalytically active component with an average crystallite size, determined according to DIN 66136, of at most 80 Å (Angstroms), in particular at most 70 Å,preferably at most 60 Å, preferably at most 58 Å, particularly preferably at most 45 Å, very particularly preferably at most 40 Å, even more preferably at most 38 Å, and / or in the range from 5 Å (Angstroms) to 80 Å, in particular in the range from 7 Å to 70 Å, preferably in the range from 10 Å to 60 Å, preferably in the range from 15 Å to 58 Å, particularly preferably in the range from 17 Å to 45 Å, very particularly preferably in the range from 18 Å to 40 Å, even more preferably in the range from 20 Å to 38 Å.

[0248] The catalyst system according to the invention is thus characterized by a defined percentage degree of dispersion and a defined average crystallite size of the underlying catalytically active component, resulting in excellent catalytic properties overall. Furthermore, the use of a special activated carbon as a catalyst support with a defined pore system improves the transport properties with regard to reactants and products resulting from the catalytic reaction, resulting in extremely efficient catalyst systems overall, including with regard to providing high conversions with simultaneous high space / time yield for use in heterogeneous catalysis.

[0249] According to the invention, it is provided that the catalyst system according to the invention has an activity, determined as the percentage degree of dispersion of the catalytically active component, in particular of the metal of the catalytically active component, on the catalyst support, measured by chemisorption using a dynamic flow method according to DIN 66136-3:2007-01, in the range from 15% to 90%, in particular in the range from 20% to 80%, preferably in the range from 25% to 70%, preferably in the range from 28% to 60%.

[0250] In addition, it is provided according to the invention that the catalyst system contains the catalytically active component, in particular the metal of the catalytically active component, with an average crystallite size, determined according to DIN 66136, of at most 80 Å (Angstroms), in particular at most 70 Å, preferably at most 60 Å, preferably at most 58 Å, particularly preferably at most 45 Å, very particularly preferably at most 40 Å, even more preferably at most 38 Å, and / or in the range from 5 Å (Angstroms) to 80 Å, in particular in the range from 7 Å to 70 Å, preferably in the range from 10 Å to 60 Å, preferably in the range from 15 Å to 58 Å, particularly preferably in the range from 17 Å to 45 Å, very particularly preferably in the range from 18 Å to 40 Å, even more preferably in the range of 20 Å to 38 Å.

[0251] Furthermore, the catalyst system according to the invention contains defined amounts of catalytically active components, so that the catalytic activity can also be specifically specified. In particular, this also ensures high overall catalytic activity with simultaneous good accessibility of the catalytically active component.

[0252] Thus, according to the invention, it can be provided that the catalyst system comprises the catalytically active component in amounts of at least 0.05 wt.%, in particular at least 0.1 wt.%, preferably at least 0.2 wt.%, preferably at least 0.5 wt.%, particularly preferably at least 0.6 wt.%, very particularly preferably at least 1 wt.%, further preferably at least 1.5 wt.%, calculated as metal and based on the total weight of the catalyst system.

[0253] In particular, the catalyst system may comprise the catalytically active component in amounts of at most 25 wt.%, in particular at most 20 wt.%, preferably at most 15 wt.%, more preferably at most 10 wt.%, particularly preferably at most 8 wt.%, very particularly preferably at most 7 wt.%, calculated as metal and based on the total weight of the catalyst system.

[0254] Thus, according to the invention, it can be provided overall that the catalyst system comprises the catalytically active component in amounts in the range from 0.05 wt.% to 25 wt.%, in particular in the range from 0.1 wt.% to 25 wt.%, preferably in the range from 0.2 wt.% to 20 wt.%, preferably in the range from 0.5 wt.% to 15 wt.%, particularly preferably in the range from 0.6 wt.% to 10 wt.%, very particularly preferably in the range from 1 wt.% to 8 wt.%, further preferably in the range from 1.5 wt.% to 7 wt.%, calculated as metal and based on the total weight of the catalyst system.

[0255] As far as the catalyst system according to the invention is further concerned, the catalytically active component can comprise or consist of at least one metal, in particular in the form of a metal compound, preferably in the form of an ionic metal compound, and / or in particular in elemental form.

[0256] In this context, the invention provides that the catalytically active component comprises at least one metal selected from the group consisting of Cu, Ag, Au, Zn, Hg, Sn, Ce, Ti, Zr, V, Nb, Cr, Mo, W, Mn, Fe, Bi, Ru, Os, Co, Rh, Re, Ir, Ni, Pd and Pt, in particular Fe, Bi, V, Cu, Pb, Zn, Ag, Sn, Pd, Pt, Ru and Ni, preferably Fe, Bi, V, Cu, Pt, Ru and Pb, preferably Pd, Pt and Ru, particularly preferably Pd and Pt. Particularly high catalytic activities can be provided with the aforementioned metals.

[0257] With regard to the catalyst system according to the invention, it is also particularly the case that both the outer and the inner surfaces, in particular the micro-, meso- and / or macropores, of the activated carbon are equipped with the catalytically active component.

[0258] As stated above, it is particularly provided within the scope of the present invention that the catalyst system has an activity, determined as the percentage degree of dispersion of the catalytically active component, in particular of the metal of the catalytically active component, on the catalyst support, measured by chemisorption using a dynamic flow method according to DIN 66136-3:2007-01, in the range from 15% to 90%, in particular in the range from 20% to 80%, preferably in the range from 25% to 70%, preferably in the range from 28% to 60%.

[0259] According to the invention, it is provided that the catalyst system contains the catalytically active component with an average crystallite size, determined according to DIN 66136, of at most 80 Å (Angstroms), in particular at most 70 Å, preferably at most 60 Å, preferably at most 58 Å, particularly preferably at most 45 Å, very particularly preferably at most 40 Å, even more preferably at most 38 Å, and / or in the range from 5 Å (Angstroms) to 80 Å, in particular in the range from 7 Å to 70 Å, preferably in the range from 10 Å to 60 Å, preferably in the range from 15 Å to 58 Å, particularly preferably in the range from 17 Å to 45 Å, very particularly preferably in the range from 18 Å to 40 Å, even more preferably in the range from 20 Å to 38 Å.

[0260] According to the invention, the activated carbon (i.e., the activated carbon forming the catalyst support) is based on an activated carbon which has been oxidized, in particular surface-oxidized, before the application and / or fixing of the catalytically active component and which has been reduced, in particular at its surface, after the application and / or fixing of the catalytically active component. This achieves, as previously stated, particularly good equipping with the catalytically active component for the catalyst system according to the invention. In particular, correspondingly good degrees of dispersion and crystallite sizes are achieved, so that such an activated carbon is reflected in the improved properties of the resulting product in the form of the catalyst system according to the invention.As previously mentioned, the reduction can also reduce the content of oxygen-containing functional groups and the hydrophilicity of the activated carbon, which can be particularly advantageous with regard to the transport properties of reactants or products in the activated carbon system as a catalyst support.

[0261] In general, it can also be provided according to the invention that the activated carbon (ie the activated carbon forming the catalyst support) is based on an activated carbon which is obtainable by carbonization and subsequent activation of a starting material based on organic polymers, followed by an oxidation (treatment), wherein the oxidation (treatment) has been carried out before the application and / or fixing of the catalytically active component, and followed by a reduction (treatment), wherein the reduction (treatment) has been carried out after the application and / or fixing of the catalytically active component.

[0262] In particular, the activated carbon (ie the activated carbon forming the catalyst support) can be based on an activated carbon which is obtainable by carbonization and subsequent activation of an organic polymer-based starting material, or which is in the form of a polymer-based, preferably spherical (PBSAC or P olymer- b ased S pherical A ctivated C arbon ) is present.

[0263] Such activated carbons exhibit particularly defined properties with regard to their pore system. Furthermore, they are activated carbons with high mechanical stability, which, for example, is associated with high abrasion resistance and similar properties.

[0264] In general, the activated carbon can be an activated carbon derived from or based on a previously described starting material. In particular, the activated carbon can be an activated carbon derived from or based on an activated carbon obtained by a previously described production process.

[0265] In addition, the catalyst system can be a particularly surface-reduced catalyst system.

[0266] Further properties of the activated carbon forming the catalyst support of the catalyst system according to the invention are given below: In particular, the activated carbon can have a defined total pore volume: Thus, the activated carbon (ie the activated carbon forming the catalyst support) can have a total pore volume V total according to Gurvich in the range from 0.9 cm 3 < / g to 3.4 cm 3 < / g, in particular in the range from 1 cm 3 < / g to 2.9 cm 3 < / g, preferably in the range from 1.1 cm 3 < / g to 2.4 cm 3 < / g, more preferably in the range from 1.2 cm 3 < / g to 1.9 cm 3 < / g, particularly preferably in the range from 1.5 cm 3 < / g to 1.9 cm 3 < / g. In addition, in this context, it can be such that 50% to 90%, in particular 52.5% to 87.5%, preferably 55% to 85%, preferably 57.5% to 82.5%, particularly preferably 60% to 80%, of the total pore volume, in particular the total pore volume according to Gurvich, of the activated carbon (iethe activated carbon forming the catalyst support) are formed by pores with pore diameters of at least 2 nm, in particular by pores with pore diameters in the range from 2 nm to 500 nm, preferably by mesopores and macropores. In addition, the activated carbon (iethe activated carbon forming the catalyst support) have a total pore volume V total according to Gurvich in the range from 0.8 cm 3 < / g to 3.9 cm 3 < / g, in particular in the range from 0.9 cm 3 < / g to 3.4 cm 3 < / g, preferably in the range from 1 cm 3 < / g to 2.9 cm 3 < / g, preferably in the range from 1.1 cm 3 < / g to 2.4 cm 3 < / g, particularly preferably in the range from 1.2 cm 3 < / g to 1.9 cm 3 < / g, very particularly preferably in the range from 1.5 cm 3 < / g to 1.9 cm 3 < / g, where 50% to 90%, in particular 52.5% to 87.5%, preferably 55% to 85%, preferably 57.5% to 82.5%, particularly preferably 60% to 80%, of the Total pore volume, in particular the total pore volume according to Gurvich, of the activated carbon is formed by pores with pore diameters of at least 2 nm, in particular by pores with pore diameters in the range from 2 nm to 500 nm, preferably by meso- and macropores.

[0267] In addition, the activated carbon forming the catalyst support can also have the following properties: In particular, the activated carbon (ie the activated carbon forming the catalyst support) can have a specific BET surface area S BET in the range from 1,100 m 2 / g to 2,600 m 2 / g, in particular in the range from 1,200 m 2 / g to 2,400 m 2 / g, preferably in the range from 1,300 m 2 / g to 2,200 m 2 / g, preferably in the range from 1,350 m 2 / g to 1,950 m 2 / g, particularly preferably in the range from 1,375 m 2 / g to 1,900 m 2 / g. Furthermore, for the activated carbon (iethe activated carbon forming the catalyst support) the ratio (Q) of total pore volume V total according to Gurvich to specific BET surface area S BET according to the equation Q = V total / S BET in the range from 0.5 10 -9< m to 1.9 10 -9< m, in particular in the range from 0.55 - 10 -9< m to 1.9 10 -9< m, preferably in the range from 0.6 10 -9< m to 1.8 10 -9< m, preferably in the range from 0.65 10 -9< m to 1.7 10 -9< m, particularly preferably in the range from 0.65 10 -9< m to 1.6 10 -9< m, very particularly preferably in the range from 0.7 - 10 -9< m to 1.5 10 -9< m, further preferably in the range of 0.75 10 -9< m to 1.4 10 -9< m, even more preferably in the range from 0.8 10 -9< m to 1.3 10 -9< m. In addition, the activated carbon (ie the activated carbon forming the catalyst support) can have a specific BET surface area S SET in the range from 1,000 m 2< / g to 3,000 m 2< / g, in particular in the range from 1,100 m 2< / g to 2,600 m 2< / g, preferably in the range from 1.200 m 2 < / g to 2,400 m 2 < / g, preferably in the range from 1,300 m 2 < / g to 2,200 m 2 < / g, particularly preferably in the range from 1,350 m 2 < / g to 1,950 m 2 < / g, very particularly preferably in the range from 1,375 m 2 < / g to 1,900 m 2 < / g, wherein the ratio (Q) of total pore volume V total according to Gurvich to specific BET surface area S BET according to the equation Q = V total / S BET in the range from 0.5 10 -9 < m to 1.9 10 -9 < m, in particular in the range from 0.55 - 10 -9 < m to 1.9 10 -9 < m, preferably in the range from 0.6 10 -9 < m to 1.8 - 10 -9< m, preferably in the range from 0.65 10 -9< m to 1.7 10 -9< m, particularly preferably in the range from 0.65 10 -9< m to 1.6 10 -9< m, very particularly preferably in the range from 0.7 10 -9< m to 1.5 10 -9< m, further preferably in the range from 0.75 10 -9< m to 1.4 10 -9< m, even more preferably in the range from 0.8 10 -9< m to 1.3 10 -9< m.

[0268] Furthermore, the activated carbon used as a catalyst support can also have the following properties: Thus, the activated carbon (i.e. the activated carbon forming the catalyst support) can have an average pore diameter of at least 15 nm and / or an average pore diameter of at most 100 nm. In this context, the activated carbon (i.e. the activated carbon forming the catalyst support) can have an average pore diameter in the range from 15 nm to 100 nm, in particular in the range from 16 nm to 90 nm, preferably in the range from 17 nm to 85 nm, more preferably in the range from 18 nm to 80 nm, particularly preferably in the range from 20 nm to 70 nm, very particularly preferably in the range from 22 nm to 60 nm, further preferably in the range from 25 nm to 50 nm. In the context of the present invention, the activated carbon (i.e. the activated carbon forming the catalyst support) can be spherical. In particular, the activated carbon can be used in the form of a spherical activated carbon. In addition, the activated carbon (i.e.the activated carbon forming the catalyst support) have a particle size, in particular a particle diameter, in the range from 60 µm to 1,000 µm, in particular in the range from 70 µm to 800 µm, preferably in the range from 80 µm to 600 µm, preferably in the range from 100 µm to 400 µm, particularly preferably in the range from 150 µm to 375 µm, very particularly preferably in the range from 175 µm to 250 µm. In particular, it can be provided in this context that at least 80 wt.%, in particular at least 90 wt.%, preferably at least 95 wt.%, of the activated carbon particles, in particular activated carbon particles, have particle sizes, in particular particle diameters, in the aforementioned ranges. In particular, the activated carbon (iethe activated carbon forming the catalyst support) has an average particle size (D50), in particular an average particle diameter (D50), in the range from 60 µm to 900 µm, in particular in the range from 75 µm to 750 µm, preferably in the range from 85 µm to 550 µm, more preferably in the range from 110 µm to 375 µm, particularly preferably in the range from 175 µm to 350 µm, very particularly preferably in the range from 185 µm to 225 µm. In addition, the activated carbon (ie the activated carbon forming the catalyst support) can have an abrasion resistance (. ball pan hardness) and / or abrasion hardness of at least 90%, in particular at least 95%, preferably at least 97%, preferably at least 98%, particularly preferably at least 99%, very particularly preferably at least 99.5%, further preferably at least 99.8%. In addition, the activated carbon (ie the activated carbon forming the catalyst support) can have a compressive and / or bursting strength (weight load capacity) per activated carbon grain, in particular per activated carbon bead, of at least 5 Newtons, in particular at least 10 Newtons, preferably at least 15 Newtons, preferably at least 20 Newtons, particularly preferably at least 22.5 Newtons. In particular, the activated carbon (ie the activated carbon forming the catalyst support) can have a compressive and / or bursting strength (weight load capacity) per activated carbon grain, in particular per activated carbon bead, in the range from 5 to 50 Newtons, in particular 10 to 45 Newtons, preferably 15 to 40 Newtons, preferably 17.5 to 35 Newtons.Likewise, the activated carbon (i.e. the activated carbon forming the catalyst support) can have a tapped or tamped density in the range from 100 g / l to 1,500 g / l, in particular 125 g / l to 1,000 g / l, preferably 150 g / l to 800 g / l, more preferably 200 g / l to 600 g / l, particularly preferably 225 g / l to 500 g / l, very particularly preferably 250 g / l to 400 g / l, further preferably 255 g / l to 395 g / l. In addition, the activated carbon (i.e. the activated carbon forming the catalyst support) can have a bulk density (. bulk density ) in the range from 150 g / l to 1,000 g / l, in particular from 250 g / l to 700 g / l, preferably 300 g / l to 600 g / l, more preferably 300 g / l to 550 g / l.

[0269] Going further, the activated carbon forming the catalyst support can have the following properties: Thus, the activated carbon (ie the activated carbon forming the catalyst support) can have a butane adsorption of at least 35%, in particular at least 40%, preferably at least 45%, preferably at least 47.5%, and / or wherein the activated carbon has a butane adsorption in the range from 35% to 90%, in particular in the range from 40% to 85%, preferably in the range from 45% to 80%, preferably in the range from 47.5% to 75%. In addition, the activated carbon (ie the activated carbon forming the catalyst support) can have an iodine number of at least 1,250 mg / g, in particular at least 1,300 mg / g, preferably at least 1,400 mg / g, preferably at least 1,425 mg / g, and / or wherein the activated carbon has an iodine number in the range from 1,250 mg / g to 2,100 mg / g, in particular in the range from 1,300 mg / g to 2,000 mg / g, preferably in the range from 1,400 mg / g to 1,900 mg / g, preferably in the range from 1,425 mg / g to 1,850 mg / g. Furthermore, the activated carbon (iethe activated carbon forming the catalyst support) has a methylene blue value of at least 17 ml, in particular at least 18 ml, preferably at least 19 ml, preferably at least 19.5 ml, and / or wherein the activated carbon has a methylene blue value in the range from 17 ml to 65 ml, in particular in the range from 18 ml to 55 ml, preferably in the range from 19 ml to 50 ml, preferably in the range from 19.5 ml to 47.5 ml. In addition, the activated carbon (ie the activated carbon forming the catalyst support) can have a molasses number of at least 255, in particular at least 310, preferably at least 375, preferably at least 510, and / or wherein the activated carbon has a molasses number in the range from 255 to 1,500, in particular in the range from 310 to 1,400, preferably in the range from 375 to 1,300, preferably in the range from 510 to 1,250. In addition, the activated carbon (iethe activated carbon forming the catalyst support) has a methylene blue value of at least 17 ml, in particular at least 18 ml, preferably at least 19 ml, more preferably at least 20 ml. Furthermore, activated carbon can have a methylene blue value in the range from 17 ml to 65 ml, in particular in the range from 18 ml to 55 ml, preferably in the range from 19 ml to 50 ml, more preferably in the range from 20 ml to 47.5 ml. In addition, the activated carbon (ie the activated carbon forming the catalyst support) can have a weight-related adsorbed N 2 volume V ads (gew), determined at a partial pressure p / p 0 of 0.25, of at least 250 cm 3 < / g, in particular at least 300 cm 3 < / g, preferably at least 350 cm 3 < / g, more preferably at least 375 cm 3 < / g.In this context, the activated carbon can have a weight-related adsorbed N 2 volume V ads (gew), determined at a partial pressure p / p 0 of 0.25, in the range from 250 cm 3 < / g to 850 cm 3 < / g, in particular in the range from 300 cm 3 < / g to 700 cm 3 < / g, preferably in the range from 350 cm 3 < / g to 650 cm 3 < / g, more preferably in the range from 375 cm 3 < / g to 625 cm 3 < / g. Likewise, the activated carbon (ie the activated carbon forming the catalyst support) may have a volume-related adsorbed N 2 volume V ads (vol.), determined at a partial pressure p / p 0 of 0.25, of at least 50 cm 3 / cm 3 , in particular at least 100 cm 3 / cm 3 , preferably at least 110 cm 3 / cm 3 . In this context, the activated carbon may have a volume-related adsorbed N 2 volume V ads (vol.), determined at a partial pressure p / p 0 of 0.25, in the range from 50 cm 3< / cm 3< to 300 cm 3< / cm 3< , in particular in the range from 80 cm 3< / cm 3< to 275 cm 3< / cm 3< , preferably in the range from 90 cm 3< / cm 3< to 250 cm 3< / cm 3< , more preferably in the range from 95 cm 3< / cm 3< to 225 cm 3< / cm 3< . In addition, the activated carbon (ie the activated carbon forming the catalyst support) can have a weight-related adsorbed N 2 volume V ads (wt.), determined at a partial pressure p / p 0 of 0.995, of at least 300 cm 3 < / g, in particular at least 450 cm 3 < / g, preferably at least 475 cm 3 < / g. In this context, the activated carbon can have a weight-related adsorbed N 2 volume V ads (wt.), determined at a partial pressure p / p 0 of 0.995, in the range from 300 cm 3 / g to 2,300 cm 3 / g, in particular in the range from 400 cm 3 / g to 2,200 cm 3 / g, preferably in the range from 450 cm 3 / g to 2,100 cm 3 / g, more preferably in the range from 475 cm 3 / g to 2.100 cm 3 < / g. In particular, the activated carbon (ie the activated carbon forming the catalyst support) can have a volume-related adsorbed N 2 volume V ads (vol.), determined at a partial pressure p / p 0 of 0.995, of at least 200 cm 3 < / cm 3 <, in particular at least 250 cm 3 < / cm 3 <, preferably at least 275 cm 3 < / cm 3 <, more preferably at least 295 cm 3 < / cm 3 <. In this context, the activated carbon can have a volume-related adsorbed N 2 volume V ads (vol.), determined at a partial pressure p / p 0 of 0.995, in the range from 200 cm 3 < / cm 3 < to 500 cm 3 < / cm 3 <, in particular in the range from 250 cm 3 < / cm 3 < to 400 cm 3 < / cm 3 <, preferably in the range from 275 cm 3 < / cm 3 < to 380 cm 3 < / cm 3 <, preferably in the range from 295 cm 3 < / cm 3 < to 375 cm 3 < / cm 3 <. Furthermore, as regards the activated carbon used according to the invention, the activated carbon (iethe activated carbon forming the catalyst support) has a fractal dimension of the open porosity in the range from 2.6 to 2.99, in particular 2.7 to 2.95, preferably 2.8 to 2.95, and / or wherein the activated carbon has a fractal dimension of the open porosity of at least 2.7, in particular at least 2.8, preferably at least 2.85, preferably at least 2.9.

[0270] Within the scope of the present invention, a high-performance catalyst system is thus provided which has overall improved catalytic properties, as mentioned above. For this reason, the catalyst systems according to the invention also lead, for example, to a significant reduction in the process time underlying catalysis, particularly with regard to discontinuous catalysis processes, with correspondingly long service or operating times, also due to the excellent mechanical stability of the catalyst system according to the invention. Furthermore, the use of the catalyst system according to the invention is accompanied by simplified dosing and significantly lower cleaning effort for the underlying equipment, minimized material losses, and generally simplified handling.Furthermore, the catalyst systems according to the invention can be easily reused or recycled after appropriate reactivation of the catalyst. In particular, the defined pore system of the activated carbon used as a support material according to the invention leads to a significant improvement in activity, both with regard to improving the transport processes of reactants or products and with regard to the equipment with the catalytically active component. The properties of the catalyst system according to the invention are of great importance overall, also given the cost-intensive nature of catalysts, since the catalyst systems according to the invention can be associated with considerable cost savings due to their properties.

[0271] The catalyst system according to the invention is not only suitable for use in discontinuous processes but also outstandingly suitable for use in continuous catalytic applications, wherein the catalyst systems according to the invention can, for example, be filled into corresponding reaction vessels or reactors and continuously flowed through with a medium containing educts or reactants, wherein only low pressure losses can be realized with correspondingly high flow rates during use.

[0272] The catalyst system according to the invention has a broad range of applications: In addition to its use in catalysis, in particular on a (large-scale) industrial scale, the catalyst system according to the invention is also suitable for (ad-)sorptive applications, for example for the removal of toxic substances such as pollutants or toxins, particularly due to its combined properties of chemisorption on the one hand and physisorption on the other.

[0273] Due to the particularly spherical shape, the outstanding mechanical properties of the underlying activated carbon material in the form of PBSAC and the present controllable adjustment of the porosity, in particular with regard to the provision of high meso- and macroporosity, the catalyst systems according to the invention are of great importance in particular for continuous catalysis (ie for the continuous reaction control in catalysis).

[0274] The catalyst systems according to the invention are, in particular, supported noble metal catalysts or metal catalysts supported on activated carbon. As previously mentioned, the basis for these are, in particular, polymer-based spherical high-performance adsorbents, which can generally consist of more than 99 wt. % carbon, with the activated carbon serving as the catalyst support. As previously described with regard to the process according to the invention, the catalyst support is pretreated by an oxidative process (before treatment with the catalytically active component). The proportions of volatile constituents can vary within a range from 0.1 wt. % to 15 wt. %. With regard to the process according to the invention described above, in a further processing step, the catalyst support can be loaded, preferably using various impregnation technologies, with noble metals as the catalytically active component.The impregnation level can vary, for example, within a range of 0.05 wt.% to 20 wt.%. After immobilizing the catalytically active component or the corresponding noble metal ions on the surface of the catalyst support, the metal ions can be converted in a reductive step. The reduction, which can also lead to a surface reduction of the activated carbon, takes place in the gas phase. On this basis, the previously described catalyst systems according to the invention can thus be obtained.

[0275] With regard to the design of the catalyst system according to the invention according to the present aspect, reference can also be made to the statements relating to the further aspects of the invention, which apply accordingly.

[0276] Another object of the present invention - according to a third Another aspect of the present invention is the inventive uses of the catalyst system according to the invention: Thus, the catalyst system according to the invention can be used in particular as a catalyst or catalyst support. Furthermore, the catalyst system according to the invention can be used in particular for chemical catalysis, in particular for heterogeneous catalysis, and / or for discontinuous catalysis or for continuous catalysis (i.e., continuous reaction control in catalysis).

[0277] Likewise, the catalyst system according to the invention can be used to catalyze chemical processes and reactions, in particular hydrogenation reactions or oligomerization and polymerization reactions, preferably of olefins. The catalyst system according to the invention can preferably be used to catalyze hydrogenation reactions. The catalyst system according to the invention can be used in particular for the hydrogenation of various functional groups. For example, the catalyst system according to the invention can be used for the catalytic conversion or reaction of nitro groups to amine groups. Furthermore, the catalyst system according to the invention can be used for the deprotection of protective groups.

[0278] Furthermore, the catalyst system according to the present aspect can also be used for the production of filters and filter materials, in particular for the removal of pollutants, odors and toxins, in particular from air and / or gas streams, such as ABC protective mask filters, odor filters, surface filters, air filters, in particular filters for room air purification, adsorptive support structures and filters for the medical sector.

[0279] In addition, the catalyst system according to the invention can be used as a sorption storage for gases or liquids.

[0280] Likewise, the catalyst system can be used in or as gas sensors or in fuel cells.

[0281] In addition, the catalyst system according to the invention can be used for sorptive applications, in particular adsorptive or chemisorptive applications, preferably chemisorptive applications, in particular as a preferably reactive and / or catalytic adsorbent.

[0282] Furthermore, the catalyst system according to the invention can be used for gas purification and / or gas processing.

[0283] Furthermore, the catalyst system according to the invention can be used for the removal of pollutants, in particular gaseous pollutants, or of environmentally harmful, harmful to health or toxic substances or gases.

[0284] Furthermore, the catalyst system according to the invention can be used for the preparation and / or provision of clean room atmospheres, in particular for the electrical industry, in particular for semiconductor or chip production.

[0285] Furthermore, the present invention relates - according to a fourth Aspect of the present invention - protective materials, in particular for the civil or military sector, in particular protective clothing, such as protective suits, protective gloves, protective footwear, protective socks, head protection clothing, and protective covers, preferably all of the aforementioned protective materials for ABC use, which are produced using the catalyst system according to the invention or which have the catalyst system according to the invention.

[0286] Furthermore, further objects of the present invention are - according to a fifth Aspect of the present invention - Filters, in particular for removing pollutants, odors and toxic substances of all kinds, in particular from air or gas streams, such as ABC protective mask filters, odor filters, surface filters, air filters, in particular filters for room air purification, adsorption-capable and / or chemisorption-capable support structures and filters for the medical sector, produced using the previously defined catalyst system according to the invention or comprising the previously defined catalyst system according to the invention.

[0287] With regard to the filters according to the invention, the catalyst system used can be self-supporting or, in particular, in the form of a loose bed. Furthermore, the catalyst system can be applied to a support material.

[0288] As regards the statements relating to the third to fifth aspects of the present invention, reference can also be made in this regard to the further statements relating to the first and second aspects of the present invention, the relevant statements applying accordingly.

[0289] The present invention is also described with reference to further drawings and figures, wherein the relevant statements apply to all aspects of the invention and are in no way limiting. Regarding the drawings and figures, reference can also be made to the following statements in the exemplary embodiments.

[0290] In the figure representations shows: Fig. 1: a diagrammatic representation of the nitrogen isotherms of various catalyst supports or activated carbons used in this case for the determination of porosity; Fig. 2: a diagrammatic representation of the mercury intrusion curves of various catalyst supports or activated carbons used in this case for the further determination of porosity; Fig. 3: a diagrammatic representation of the values ​​determined for various catalyst systems for the dispersion and the crystallite size of the catalytically active component or the relevant metal (5 wt.% palladium catalyst); Fig. 4: a schematic representation of the kinetics underlying heterogeneous catalysis based on sub-steps, with the first step (1) the diffusion of reactants (E) to the surface of the catalyst (K) through the stationary boundary layer (G); with the second step (2) the diffusion of the reactants (E) into the pores of the catalyst (K) to the catalytically active center orto the catalytically active component; with the third step (3) the adsorption of the reactants (E) at the active center; with the fourth step (4) the reaction of the reactants (E) at the active center to obtain the corresponding products (P); with the fifth step (5) the desorption of the products (P) from the active center; with the sixth step (6) the diffusion of the products (P) through the pore system of the catalyst (K) and with the seventh step (7) the diffusion of the products (P) through the boundary layer (G) into the outer region and the removal of the products (P); Fig. 5 a schematic representation of a process sequence according to the invention according to an embodiment of the present invention [with EP = noble metal precursor, TR = PBSAC support, TV = support pretreatment (e.g. oxidation with mineral acids or air oxidation), I = impregnation (e.g. immersion impregnation orSpray impregnation), W = washing, T = drying, R = reduction (gas phase reduction), Kat = catalyst, KatR = catalyst reactivation, MR = metal recovery]; Fig. 6 a schematic representation of a device used for heterogeneous catalysis, in particular hydrogenation, based on a fixed bed reactor; Fig. 7A a reaction underlying the hydrogenation of cinnamic acid using the catalyst system according to the invention; Fig. 7B a diagram showing the time course of the catalytic conversion (hydrogenation) of cinnamic acid as starting material by means of various catalyst systems according to the invention using activated carbon as catalyst support with a high meso- and macropore proportion in the total pore volume of the activated carbon (meso- . andmacroporous activated carbon); Fig. 7C a diagram showing the time course of the catalytic conversion (hydrogenation) of cinnamic acid by means of various catalyst systems using activated carbon as catalyst support with a high micropore content in the total pore volume of the respective activated carbon (microporous activated carbon).

[0291] Further embodiments, modifications and variations as well as advantages of the present invention will be readily apparent and achievable to a person skilled in the art upon reading the description, without departing from the scope of the present invention.

[0292] The following embodiments serve only to illustrate the present invention, but without limiting the present invention thereto. EXAMPLES OF IMPLEMENTATION: 1. Introduction:

[0293] The use of special polymer-based spherical activated carbons (spherical or spherical PBSAC) with defined porosity, particularly with regard to high meso- or macroporosity with a simultaneously defined micropore content, as catalyst support material offers the advantage, within the scope of the inventive concept, of enabling, on the one hand, optimal transport processes for reactants / products and, on the other hand, optimal equipping of the activated carbon with catalytically active components. This results in an overall high catalytic activity for the inventive catalyst systems, particularly associated with high conversions and high space / time yields. Furthermore, the preferred spherical shape allows for the lowest pressure drops to be achieved compared to adsorbents of the same size but different shape.In addition, due to the low dust content and high mechanical strength of the PBSAC, the probability of metal-laden dust or fragments being carried out in the product flow during application in the fixed bed is minimized. 2. Production of catalyst supports a) Highly microporous catalyst supports (not according to the invention)

[0294] The polymer-based spherical activated carbons (PBSAC) are produced in a three-stage batch process. The process includes a sulfonation step for thermal stabilization of the polymeric raw material, a carbonization step for removing volatile components, and an activation step for forming the internal pore system using water as the oxidant. A rotary tube reactor is used for these necessary process steps. The reactor is indirectly heated electrically in a rotary kiln.

[0295] The raw material or starting material for the production of the highly microporous PBSAC is a cross-linked styrene-divinylbenzene polymer (gel type in the H +< form) from Lanxess (Lewapol D60). It is polystyrene with 4 wt.% divinylbenzene as a cross-linker. The polymer raw material already possesses a spherical morphology, which is transferred to the resulting PBSAC. The raw material exhibits a particle diameter distribution in the range of 0.08 mm to 0.7 mm.

[0296] Sulfonation is the step of stabilizing the polymer for subsequent carbonization. For this purpose, the polystyrene is treated with a mixture of oleum (fuming sulfuric acid, 25% free SO 3 ) and sulfuric acid (96 vol%) in a mass ratio of 2:1 at room temperature and heated to the sulfonation temperature of 423 K.

[0297] In the second step of activated carbon production, carbonization, volatile components are removed in a temperature range from 423 K to 1223 K. Carbonization can be divided into two steps. In the temperature range up to 823 K, other volatile components, particularly water and sulfur compounds, are removed. In the temperature range up to 1223 K, primarily hydrocarbons and hydrogen are removed (390 min activation time). Particle shape and diameter no longer change after carbonization and correspond to those of the resulting PBSAC.

[0298] In the third step of activated carbon production, namely activation, the carbonizate is activated at about 1223 K in a water vapor atmosphere (120 kg of liquid water and two standard cubic meters of nitrogen per hour). b) Meso- and macroporous catalyst support (according to the invention)

[0299] The production of meso- and macroporous PBSACs is carried out analogously to the process steps described above in Section 2.a). Lewapol D60 from Lanxess is also used as the raw material or starting material for the production of meso- / macroporous PBSACs. However, the sulfonation of the cross-linked styrene-divinylbenzene polymer is carried out exclusively with sulfuric acid (96 vol%). The ratio of polymer to sulfonating agent is kept constant. The catalyst support is activated for 450 min. The resulting PBSACs exhibit an increased mesopore content of greater than 25%. The textural data can be found in Table 1. c) Meso- and macroporous catalyst supports based on macroporous sulfonated ion exchangers with high macroporosity (according to the invention)

[0300] The production of PBSACs based on macroporous ion exchangers follows the process steps described in Section 2.a). A sulfonated cross-linked styrene-divinylbenzene polymer (H +< form) from Finex Oy (Finex CS16GC) is used as the raw material or starting material for the production of PBSACs based on macroporous ion exchangers. Since the acidic, macroporous ion exchangers are already protected, the sulfonation step can be omitted (150 min activation time). The resulting PBSACs exhibit a high mesopore content and a defined proportion of macropores. The textural data can be found in Table 1. Alternatively, corresponding unsulfonated raw materials or starting materials can be used. In this case, for example, a cross-linked styrene-divinylbenzene polymer from Finex Oy can be used (Finex PS08G).The sulfonation can be carried out in accordance with the instructions in section 2.a). 3. Characterization of the catalyst supports or catalyst systems a) Nitrogen isotherms for determining textural data in the micropore range

[0301] To determine the textural data of the catalyst supports, nitrogen isotherms are recorded on the various catalyst supports. This is done using a Quadrasorb from Quantachrome. The specific internal surface area is determined using a Brunauer-Emmett-Teller (BET) mathematical model. The total pore volume is calculated using the Gurvich rule, and the micropore volume is determined using the carbon black method.

[0302] To prepare for the measurement, the catalyst supports are pretreated at 200 °C in vacuum, particularly to remove any adsorbed molecules. b) Mercury intrusion to determine textural data in the meso- and macropore range

[0303] The samples are dried for 2 hours at 150 °C in a drying cabinet and then measured using a Quantachrome Poremaster-60GT. To convert the pressure into pore size, the literature value for the mercury-to-carbon contact angle (155°) is used. c) Determination of the elemental composition of the catalyst supports using photoelectron spectroscopy (XPS)

[0304] The samples are analyzed without pretreatment using photoelectron spectroscopy (ESCA / XPS). For XPS analysis, measurements are performed using a Thermo VG Scientific K-Alpha X-ray analyzer. Monochromatic AlKα X-rays are used for excitation (typically ~75 W, 400 µm spot size). The transmission function and energy level are determined on copper, silver, and gold reference samples according to ISO 15472:2001 and ISO 21270:2004. The following settings are used for spectral measurements: overview spectra with a pass energy of 80 eV, high-resolution spectra with 30 eV. Quantitative information on the surface composition is calculated using Scofield factors based on overview measurements, assuming that the analyzed volume is homogeneous. The error can be estimated at approximately 10%. d) Determination of the degree of dispersion and size of the active centers by means of CO chemisorption (determination of the specific metal surface area or dispersion and the crystallite size of the catalytically active component)

[0305] Determination of monolayer capacity, degree of dispersion, active surface according to DIN 66136-1, DIN 66136-3: flow method (dynamic), measuring gases e.g. H 2 , CO, CO 2 ; planned test program: H 2 treatment 10 K / min to 80 °C, 4 h isothermal; CO titration at 50 °C, then TPR 5 Kmin-1 to 250 °C with 5% H 2 / Ar; finally CO titration at 50 °C.

[0306] In particular, the following procedure can be followed: Normative basis: DIN 66136-1 (basic principles) and DIN 66136-2 (volumetric method)

[0307] The following steps are recommended or carried out for sample preparation and reduction of the sample surface: (i) Evacuation at 100 °C for 30 min; (ii) Oxygen flow at 100 °C for 5 min; (iii) Oxygen flow and temperature increase at 10 °C / min to 350 °C; (iv) Oxygen flow at 350 °C for 30 min; (v) Evacuation at 350 °C for 15 min; (vi) Evacuation at 100 °C for 15 min; (vii) Hydrogen flow at 100 °C for 5 min; (viii) Hydrogen flow and temperature increase at 10 °C / min to 350 °C; (ix) Hydrogen flow at 350 °C for 120 min; (x) Evacuation at 350 °C for 30 min; (xi) Evacuation at 100 °C for 15 min

[0308] Subsequently, a CO isotherm is measured at 40 °C using a static-volumetric method to determine the active metal surface or metal dispersion.

[0309] The first isotherm measured after step (xi) can represent a superposition of both strongly and weakly chemisorbed gas fractions ( Combined chemisorptionIf it is necessary to distinguish between the two components, the following procedure is recommended or should be used: After the last isotherm point has been measured, the measuring cell can be evacuated at the analysis temperature (40 °C) for 60 minutes. This removes the weakly bound component, while the strongly chemisorbed component remains on the sample surface. A subsequent repetition of the isotherm measurement allows the weakly chemisorbed component to be determined (weak chemisorption). The difference between the two isotherms yields the amount of strongly chemisorbed CO.

[0310] Assuming that a CO molecule chemisorbs on exactly one surface-exposed metal atom (palladium atom) of the catalytically active component (stoichiometry = 1), the number of surface-exposed palladium atoms or metal atoms can be deduced from the amount of chemisorbed CO.

[0311] This makes it possible to specify the size of the active metal surface in m 2< per g (m 2< / g) (sample mass).

[0312] Using the metal loading ( Loading ) of the sample, known as mass of palladium in g / g sample, further characteristics or properties can be calculated: Active metal surface area in m² / g (metal); metal dispersity in %; and mean crystallite diameter of the metal clusters.

[0313] The same procedure can be followed for other metals. 4. Properties of the catalyst supports

[0314] The properties of the respective catalyst supports differ largely in terms of their textural characteristics. To determine the textural data, nitrogen isotherms of the respective PBSACs were recorded. The results obtained in this regard are presented in Figure 1where the respective value "200 µm" in the legend refers to the mean particle diameter of the activated carbon tested. The diagram representation according to Figure 1 shows the nitrogen adsorption V ads as a function of the relative pressure p / p 0 for the activated carbons investigated.

[0315] A characteristic of highly microporous materials is a sharp rise in the isotherm, associated with a high volume uptake of nitrogen, at low relative pressures. The isotherm runs as in Figure 1 As shown, the isotherm is almost flat in the wider relative pressure range and does not exhibit a pronounced hysteresis loop. The isotherm of the material "200 µm_micro l" (catalyst support or activated carbon A1, not according to the invention) exhibits such a curve, so that the material in question can be described as highly microporous. Furthermore, the proportion of micropore volume to the total volume is very high at 89%.

[0316] The isotherm of the material "200 µm_meso / macro I" (catalyst support or activated carbon B1, according to the invention) shows Figure 1 a sharp increase at a relative pressure of 0.75. Furthermore, the isotherm exhibits a pronounced hysteresis loop. These two properties, along with the micropore fraction of only 61%, demonstrate the high mesopore and macropore fraction, respectively.

[0317] When using macroporous ion exchangers to produce PBSAC, part of the polymer's macroporosity is transferred to the resulting activated carbon. This can be seen from the nitrogen isotherm of the material "200 µm_meso / macro II" (catalyst support or activated carbon B2, according to the invention); only at a relative pressure of 0.85 does the isotherm, and thus the nitrogen uptake, increase significantly ( Figure 1A pronounced hysteresis loop and the micropore volume share of only 25% demonstrate the presence of pores larger than 2 nm and thus of meso- and macropores.

[0318] The characterization of pores larger than 2 nm can be achieved by mercury intrusion. Figure 2 shows the mercury intrusion curves of the catalyst supports. The diagram representation according to Figure 2 shows the mercury intrusion dVp / dlog (dp) for the underlying pore diameter dp of the activated carbons investigated.

[0319] This clearly shows that the microporous catalyst support or activated carbon A1 ("200 µm_micro I") has no pore volume above 2 nm. The meso- / macroporous catalyst support or activated carbon B1 ("200 µm_meso / macro I") exhibits a significant pore volume in the range of 10 nm to 20 nm. The further meso- / macroporous catalyst support or activated carbon B2 ("200 µm_meso / macro II") also exhibits a very large proportion of mesopores and a significant proportion of macropores. The textural data can be found in Table 2.

[0320] The chemical composition and the resulting high purity of the activated carbons in the form of PBSAC are maintained and comparable in all cases. The high mechanical stability of the activated carbons in the form of PBSAC is also maintained, even with high porosity and a high proportion of pores larger than 2 nm (cf. "200 µm_meso / macro I" (B1) and "200 µm_meso / macro II" (B2)). The high mechanical stability is demonstrated by the high abrasion hardness of the materials of over 98% (cf. Table 1).

[0321] The following Table 1 illustrates the corresponding properties of the activated carbons and catalyst supports investigated. Table 1: Properties of the catalyst supports. A1 200 µm micro I* B1 200 µm meso / macro I B2 200 µm meso / macro II C1 Activated Carbon 1 ** C2 Activated Carbon 2 ** Ratio (Quotient Q) V total / S BET 0,44·10 -9< 0,85·10 -9< 1,24·10 -9< 0,45·10 -9< 0,57·10 -9< Specific surface area (BET) / m 2< g -1< 1.747 1.881 1.478 1.162 1.074 Pore ​​volume (Gurvich) / cm 3< g -1< 0,76 1,59 1,84 0,52 0,61 Micropore volume / % 89 38 25 90 69 Iodine value (CEFIC) / mg g -1< 1.650 1.652 1.441 - - Tap density / g L -1< 562 319 282 - - Abrasion hardness / % 99,8 99,9 98,8 - - Pore ​​volume per 1000 m 2< Surface area / cm 3< 0,43 0,85 1,24 0,48 0,57 * A1: not according to the invention ** C1, C2: commercially available coconut shell-based activated carbons; (not according to the invention) Table 2: Textural properties (Hg intrusion, evaluation range 0.01 µm to 20 µm) A1 200 µm micro I* B1 200 µm meso / macro I B2 200 µm meso / macro II Specific pore volume / cm 3< g -1< 0,005 0,81 1,17 Average pore diameter / nm 1,8 29 36

[0322] In a corresponding manner, further catalyst supports or activated carbons are provided, namely the non-inventive catalyst supports or activated carbons A2 (200 µm micro II; average particle diameter 200 µm) and A3 (370 µm micro III; average particle diameter 370 µm), which are essentially comparable to the catalyst support A1 with regard to their respective properties in the form of the parameters listed in Tables 1 and 2. In addition, further catalyst supports or activated carbons are provided, namely the catalyst supports B3 ("370 µm meso / macro III"; average particle diameter 370 µm) and B4 ("470 µm meso / macro III"; average particle diameter 470 µm) used according to the invention, which are essentially comparable to the catalyst supports B1 and B2, respectively, with regard to their other properties in the form of the parameters listed in Tables 1 and 2. 5. Oxidative pretreatment of the catalyst supports

[0323] The oxidative pretreatment of the materials in the form of catalyst supports or activated carbons serves to create oxygen centers on the surface of the respective PBSAC. These then interact with the metal ions in the salt solution. Due to the electrostatic interaction of the surface oxides with the metal ions, the latter are immobilized on the surface and preferentially migrate into the pores of the PBSAC rather than remaining in the supernatant solution. a) Oxidation with oxygen

[0324] For the oxidation of PBSAC, synthetic air is passed through a heatable, gas-tight quartz glass reactor. For surface modification, typically 250 g of PBSAC is placed in the quartz glass tube, the tube is installed in the furnace, and all gas connections are connected. Typically, the furnace is heated to the reaction temperature with a ramp of 10 K min -1. The reaction temperature lies within a range of 350 °C to 550 °C. The reaction time varies between 120 min and 600 min. b) Oxidation with mineral acids and hydrogen peroxide

[0325] Oxidation with mineral acids is carried out using wet chemical methods. The mineral acids used are primarily hydrochloric acid (HCl), nitric acid (HNO 3 ), and sulfuric acid (H 2 SO 4 ). Perchloric acid (HClO 4 ), phosphoric acid (H 3 PO 4 ), and hydrogen peroxide (H 2 O 2 ) are also used. These acids are used across the entire concentration range at temperatures from 20 °C to 100 °C.

[0326] Typically, 500 g of a polymer-based spherical adsorbent is stirred with 1000 g of mineral acid for 30 to 240 min. Excess mineral acid is then decanted, and the oxidized base adsorbent is washed with distilled water and dried. c) Properties of the oxidized catalyst supports

[0327] The structural properties are not significantly altered by the surface modification, or at most only to a very small extent. The properties of the oxidized catalyst supports used or analyzed according to the invention can be found in Table 3. The mechanical stability of the oxidized catalyst supports is maintained with very high abrasion hardness. The surface oxides can be characterized by determining the volatile components. The materials are heated at 900 °C for 7 minutes, as per ISO 562-1981, and the weight loss is then determined gravimetrically.

[0328] However, this method does not yet reveal the nature of the oxygen species on the surface of the PBSAC. To determine this, photoelectron spectra of the respective catalyst supports are recorded. From these spectra, the elemental compositions can be determined. These can be found in Table 4. It can be seen that the values ​​from the determination of the volatile components correlate with the atomic composition determined by photoelectron spectroscopy. The lowest oxygen content, 4.0 atomic %, was found in the sample oxidized with hydrochloric acid (90 min). The oxidation of the catalyst support with 50 vol% nitric acid resulted in the highest oxygen content on the surface, 11.8 atomic %. Table 3: Properties of the oxidized catalyst supports or activated carbons Description acid Quantity / mL Content / Vol.-% T / °C volatile components / % QS V tot / cm 3< g -1< QS Meso / Macro / % HS Vol. ads. / cm 3< g -1< Fraction % Abrasion / % Tap density / gL -1< Oxidation with 37% hydrochloric acid [70 °C] 688 37 70 2,8 0,79 14,6 784 1,1 100,0 545 Oxidation with 37% hydrochloric acid [70 °C] 688 37 70 3,1 0,78 14,9 794 1,5 99,8 546 Oxidation with 25% nitric acid [70 °C] 600 25 70 11,4 0,73 14,5 723 0,3 100,0 583 Oxidation with 50% nitric acid [70 °C] 600 50 70 13,3 0,72 14,9 736 1,3 99,9 583 Air oxidation 450 °C / 240 min 450 7,1 0,87 15,8 839 4,1 100,0 533 Air oxidation 500 °C / 240 min 500 7,0 0,85 17,5 865 0,6 100,0 535 Table 4: Elemental compositions from overview spectra (data in atomic percent) sample C O N S Cl Oxidation with 37 vol% hydrochloric acid, 180 min 94,9 4,2 0,0 0,7 0,2 Oxidation with 25 vol% nitric acid 87,9 10,4 1,2 0,5 0,0 Oxidation with 50 vol% nitric acid 86,7 11,8 1,1 0,5 0,0 Oxidation with 37 vol% hydrochloric acid, 90 min 95,1 4,0 0,0 0,7 0,2 Air oxidation 450 °C 92,0 7,9 0,0 0,2 0,0 Air oxidation 500 °C 91,5 8,4 0,0 0,1 0,0

[0329] To characterize the oxygen species, the bonding fractions were also determined from the high-resolution oxygen spectra. These can be found in Table 5. It is evident that over half of the oxygen species are present on the surface in the form of alcohol oxygen. Approximately 35% to 40% of the oxygen atoms are bound to the surface in the form of carbonyl oxygen. The differently oxidized catalyst supports differ only slightly from one another in terms of the proportions of oxygen species. Table 5: Bonding fractions from high-resolution oxygen spectra sample O1 O2 O3 O total Oxidation with 37 vol% hydrochloric acid, 180 min 38 53 10 4,2 Oxidation with 25 vol% nitric acid 40 52 8 10,4 Oxidation with 25 vol% nitric acid 40 52 8 11,8 Oxidation with 37 vol% hydrochloric acid, 90 min 39 52 10 4,0 Air oxidation 450 °C 35 51 13 7,9 Air oxidation 500 °C 38 51 11 8,4 O1: carbonyl oxygen (RC=O / R-CO=O*); O2: alcohol oxygen (R-OH / ROR / R-CO-O*); O3: pee-pee* 6. Impregnation of the catalyst supports

[0330] The oxidized catalyst supports or activated carbons are equipped with a catalytically active component or a corresponding precursor as follows to obtain corresponding impregnated catalyst systems. a) Palladium loading of the PBSAC

[0331] Water and an acid solution (HCl, HNO 3 ) are placed in a round-bottomed flask. A palladium precursor (typically H 2 PdCl 4 , Pd(NO 3 ) 2 ) is then added. The cloudy suspension is stirred vigorously with a magnetic stirrer for at least 30 min until a clear, brownish solution is obtained. The oxidized catalyst support is quickly added with vigorous stirring, as described above. The system is stirred at low speed (50 rpm) for 24 h. The solid is then removed using a Buchner funnel and suction flask. The catalyst is then thoroughly rinsed with ultrapure water. For drying, the material is transferred to a drying cabinet and dried at 80 °C for 12 h. b) Platinum loading of spherical adsorbents

[0332] Water and an acid solution (HCl, HNO3) are placed in a round-bottomed flask. A platinum precursor (typically H2[PtCl6], (NH3)4Pt(OH)2, Pt(NO3)2) is then added. The cloudy suspension is stirred vigorously with a magnetic stirrer for at least 30 min until a clear, brownish solution is obtained. The oxidized catalyst support is quickly added with vigorous stirring. The system is stirred at low speed (50 rpm) for 24 h. The solid is then removed using a Buchner funnel and suction flask. The catalyst is then thoroughly rinsed with ultrapure water. For drying, the material is transferred to a drying cabinet and dried at 80 °C for 12 h. 7. Reduction of catalysts or to maintain the catalyst systems

[0333] The above-mentioned impregnated catalyst systems are treated as follows by reduction to obtain corresponding catalyst systems. a) Gas phase reduction

[0334] The gas phase reduction of the catalyst material is carried out in a horizontal, heatable flow tube with 5 vol% hydrogen in nitrogen at a temperature of 50 °C to 300 °C for 1 h to 10 h. b) Liquid phase reduction (comparison)

[0335] The liquid-phase reduction is preceded by fixation of the active component with potassium hydroxide (KOH). The base is added at room temperature in a stoichiometric amount to the impregnation solution. Potassium formate (KHCOO) is then added in a 10-fold stoichiometric excess, and the solution is left to stand for 1 to 5 hours at 50 °C to 120 °C. 8. Properties of palladium catalysts

[0336] Depending on the selected reduction method and the reaction parameters, the size and distribution of the metallic active centers can be controlled. The degree of dispersion can be adjusted between 15% and 35%. The cluster sizes of the metal centers vary between 33 Å and 76 Å. This can also be achieved by Figure 3 which shows the determined values ​​for the metal dispersion (MD) and metal crystallite size (KG) of 5 wt% palladium catalysts (based on catalyst supports B1 and B4 respectively). Figure 3 also shows that at the reduction temperature T red2 optimized according to the invention (in this case 140 °C) compared to the Figure 3At the reduction temperature T red1 (here 80 °C), referred to according to the invention (and thus expressly forming part of the invention) as the so-called standard temperature, further improved properties with regard to metal dispersion and average crystallite size result, which correspondingly also leads to a further improved catalytic performance of the catalyst systems according to the invention. The same applies to platinum and ruthenium catalysts. 9. General information on hydrogenation in a fixed-bed reactor

[0337] The catalyst systems according to the invention can be used particularly on an industrial scale, for example, for catalyzing hydrogenation reactions. Hydrogenations are among the standard reactions in industrial chemistry and are used both in large-scale processes, such as the petrochemical industry, e.g., for the desulfurization of petroleum fractions, and as synthesis steps for fine chemicals. In addition to unsaturated compounds, other groups of substances are also hydrogenated, such as aldehydes and ketones to alcohols, and nitro compounds and nitriles to amines. In most hydrogenations, the reactant is in the liquid phase; only low-boiling substances such as butyraldehydes from hydroformylation are hydrogenated in the gas phase.

[0338] For example, nickel and certain precious metals such as platinum, ruthenium, and palladium are used as hydrogenation catalysts, usually in the form of supported catalysts. They are either suspended as fine-grained material in the reaction liquid or used as a fixed bed. In the latter case, trickle-bed reactors (" trickle bed reactor "), i.e. fixed-bed reactors whose catalyst packing is sprinkled with the reaction liquid. The size of the catalyst bodies (spheres, cylinders, extrudates, etc.) can, for example, be between 1 and 7 mm.

[0339] A corresponding hydrogenation device is Figure 6which can also be used to describe a process control example: The reactant A is fed into the tubular reactor (a) from above and flows through the reactor with the catalyst bed in cocurrent or countercurrent with the hydrogen H 2 . In terms of volume, the gas phase represents the main phase compared to the liquid phase and flows around the catalyst bed wetted with the liquid phase. However, only reactors operating in cocurrent flow find widespread technical application. The flow is driven by gravity or external pressure. The reactor is provided with a double jacket for temperature control. The hydrogenated product B is withdrawn at its lower end and finally degassed in the separator (b). Residual gas RG can be discharged via device (c).

[0340] In a trickle-bed reactor, conversion and selectivity depend not only on the reaction kinetics, pressure, and temperature, but also on the hydrodynamics of the reactor. Hydrodynamics have a significant influence on the liquid distribution within the reactor and directly impact the catalyst utilization rate. Uneven liquid distribution can lead to incomplete wetting of the catalyst bed, which can negatively impact the catalyst utilization rate.

[0341] Furthermore, non-optimized technical parameters, such as the ratio of reactor height to diameter and the ratio of the reactor interior to the catalyst particle diameter, can impair the wetting of the catalyst bed. To prevent these effects from non-wetted reactor interior and / or catalyst areas, the design of the liquid distributor and adherence to the appropriate size ratios are of particular importance.

[0342] Therefore, when designing trickle bed reactors, parameters such as the Liquid Holdup(a measure of the liquid present in the entire catalyst bed), the pressure drop across the bed, the distribution of the gas and liquid phases, or the mass and heat transfer coefficients. The industrial reactors used are between 5 and 30 m high; in these, the catalyst bed is present either in several or in a single bed. The diameter of the reactor is limited by the uniform distribution of the liquid across the reactor cross-section and usually does not exceed a value of 4 to 5 m. Thus, the ratio of height to diameter of the reactor (Hr / Di) is generally between 5 and 25. The trickle bed reactors used on a laboratory scale have a diameter of 0.03 to 0.2 m and can reach a length of several meters.At these scales, the ratio of the reactor's internal diameter to the catalyst's diameter (Di / dk) cannot be neglected and should be above a value of Di / dk = 10 (usually Di / dk > 15). If this ratio is not met, the difference in the structure of the packing near the reactor wall compared to the core of the packing can lead to surface penetration of the liquid, which is then reflected in lower conversions. In industrially used reactors, the ratio of the reactor's internal diameter to the catalyst's diameter is usually between 100 and 1000 to reliably exclude the effects of surface penetration of the liquid.

[0343] Conventional trickle bed reactors with a diameter of 0.2 m or more are generally less suitable for the production of fine chemicals due to the required minimum throughput. With the development of MiniplantHowever, thanks to technology, it has become possible to operate continuous processes even at very low throughputs (1 kg / h and below). Miniplants have so far been used primarily in process development. However, they are also suitable for production, particularly for the manufacture of small product batches of consistent quality, such as fine chemicals and pharmaceutical and crop protection active ingredients.

[0344] For further information, please refer in particular to the following literature: Technische Chemie, Manfred Baerns, et al., 2nd edition, Wiley-VCH Verlag & Co. KGaA, 2013; chapter "Three-Phase Trickle-Bed Reactors", Ullmann's Encyclopedia of Industrial Chemistry, Vol. 7 Online Ed., 2008; and chapter "Reactor Types and Their Industrial Application", Ullmann's Encyclopedia of Industrial Chemistry, Vol. 7 Online Ed., 2008. 10. Catalytic testing (hydrogenation of cinnamic acid)

[0345] The catalytic performance of the catalyst systems according to the invention, even in comparison to systems not according to the invention, can be investigated by means of hydrogenations or catalytically controlled hydrogenation reactions, such as the hydrogenation of cinnamic acid as the reactant to hydrocinnamic acid as the product. Reference can also be made to Figure 7A be referred to.

[0346] A 100 mL three-necked flask equipped with a stir bar, a N2 inlet, and a H2 inlet is charged with cinnamic acid (1) (2 g, 13.5 mmol) and 144 mg of catalyst. The three-necked flask is sealed with a rubber septum, evacuated, and refilled with nitrogen (three times). Ethyl acetate (14 mL) is added, and the mixture is stirred (700 rpm) until the reactant is completely dissolved. The flask is evacuated and refilled with hydrogen (three times). Samples are taken periodically after 1 h, 2 h, 3 h, 5 h, 7 h, 10 h, and 16 h and analyzed by gas chromatography coupled to a mass spectrometer. Catalyst systems based on catalyst supports A1, A2 and A3 (not according to the invention) as well as catalyst systems based on catalyst supports B1, B2 and B3 (according to the invention) are investigated.

[0347] The results are in the Figures 7B and 7CThe figures show the catalytic conversion (hydrogenation) of cinnamic acid as the reactant or starting material with the amount of cinnamic acid over time (determined by GC-MS; % area), with 100% of the unreacted cinnamic acid present as the starting material at time t = 0.

[0348] Figure 7B shows the results for the catalyst systems according to the invention based on the catalyst supports B1, B2 and B3 (where for t = 4 h the upper line shows the catalyst system B3, the middle line shows the catalyst system B1 and the lower line shows the catalyst system B2). Figure 7C shows the results for the non-inventive catalyst systems based on the catalyst supports A1, A2 and A3 (where for t = 7 h the upper line shows the catalyst system A3, and the lower lines show the catalyst systems A1 and A2 respectively).

[0349] A comparison of the Figures 7B and 7CThe curves shown demonstrate the significantly higher catalytic performance of the catalyst systems according to the invention based on catalyst supports B1, B2, and B3 compared to the non-inventive systems based on catalyst supports A1, A2, and A3. Thus, the conversion or hydrogenation of the starting material in the form of cinnamic acid is completed significantly more quickly in the systems according to the invention than in the non-inventive systems, so that higher conversion rates are achieved for the systems according to the invention.

[0350] The catalyst systems according to the invention based on catalyst supports B1, B2, and B3 thus exhibit a higher overall catalytic performance, particularly associated with higher conversions and an improved space / time yield. The same applies to corresponding platinum or ruthenium catalyst systems.

[0351] As mentioned above, the special pore system with the high meso- and Macroporosity of the activated carbon used as a catalyst support is of great importance, especially with regard to improving the transport processes for reactants and products.

[0352] Furthermore, the overall equipment with the catalytically active component is improved in the catalyst systems according to the invention, also due to the special process for producing the catalyst systems according to the invention, which involves the targeted and purposeful oxidation of the activated carbon before loading with the catalytically active component or the related precursor, followed by a reduction to obtain the catalyst system. In particular, the special pore structure of the activated carbon, as described in particular in the form of the special ratio (quotient Q) of total pore volume to specific BET surface area, leads to the improved properties with regard to the catalytic activity of the catalyst systems according to the invention.

[0353] In particular, the totality of the measures according to the invention in their specific combination, as previously stated, in their targeted and purposeful combination leads to the advantages and properties of the catalyst systems according to the invention.

[0354] As a result, the underlying investigations show overall that the catalyst systems obtained by the process according to the invention have significantly improved properties compared to systems of the prior art.

Claims

1. Method for preparing a catalyst system comprising at least one catalytically active component in the form of a supported catalyst, preferentially for use in heterogeneous catalysis, wherein at least one catalytically active component is applied and / or fixed to a catalyst support, wherein the catalytically active component comprises and / or consists of at least one metal, wherein the metal is selected from the group of Cu, Ag, Au, Zn, Hg, Sn, Ce, Ti, Zr, V, Nb, Cr, Mo, W, Mn, Fe, Bi, Ru, Os, Co, Rh, Re, Ir, Ni, Pd and Pt, wherein the method comprises the following steps in the sequence (a) to (d) specified below: (a) providing and / or preparing a spherical activated carbon (=starting activated carbon) used as catalyst support, wherein the activated carbon (i.e. the starting activated carbon) (i) has a total pore volume Vtotal according to Gurvich in the range of from 0.8 cm3 / g to 3.9 cm3 / g, wherein at least 50 % of the total pore volume according to Gurvich of the activated carbon is formed by pores having pore diameters of at least 2 nm, especially by pores having pore diameters in the range from 2 nm to 500 nm, preferentially by meso- and macropores, and (ii) has a specific BET surface area SBET in the range from 1,000 m2 / g to 3,000 m2 / g, however, with the proviso that the ratio Q of total pore volume Vtotal according to Gurvich to specific BET surface area SBET according to the equation Q=Vtotal / SBET is at least 0.5 · 10-9 m; then (b) oxidation, especially surface oxidation, of the activated carbon provided and / or prepared in process step (a), with the proviso that the oxidized, especially surface-oxidized, activated carbon has an oxygen content, especially surface oxygen content, determined by means of X-ray photoelectron spectroscopy (XPS or ESCA), of at least 4 atom %, based on the total element composition of the oxidized activated carbon, and / or with the proviso that the oxidized, especially surface-oxidized, activated carbon has a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p0 of 0.6 at least 30 % of the maximum water vapor saturation loading of the activated carbon is achieved; then (c) equipping, especially loading and / or coating and / or impregnating, of the activated carbon oxidized, especially surface-oxidized, in process step (b) with the catalytically active component, especially with at least one precursor of the catalytically active component; then (d) reducing the oxidized, especially surface-oxidized, activated carbon obtained in process step (c) and equipped with the catalytically active component, especially with the precursor of the catalytically active component, especially for converting the precursor of the catalytically active component into the catalytically active component, so that the catalyst system comprising at least one catalytically active component is obtained; wherein in process step (d) the reduction is carried out as a gas phase reduction, wherein in process step (d) the reduction is carried out at a temperature in the range of from 115 °C to 160 °C; wherein in process step (d) the catalyst system is obtained, wherein the catalyst system comprises at least one catalytically active component applied and / or fixed to a catalyst support, wherein the catalytically active component comprises and / or consists of at least one metal and wherein the catalyst support is formed in the form of activated carbon, wherein the catalyst support is present in the form of a spherical activated carbon; and wherein the catalyst system has an activity, determined as a percentage degree of dispersion of the catalytically active component on the catalyst support, measured by chemisorption by means of dynamic flow method according to DIN 66136-3:2007-01, in the range of from 15 % to 90 %; and wherein the catalyst system comprises the catalytically active component with an average crystallite size, determined according to DIN 66136, of at most 80 Å (Angstrom).

2. The method according to claim 1, wherein the activated carbon (i.e. starting activated carbon) provided and / or prepared in process step (a) has a total pore volume Vtotal according to Gurvich in the range of from 0.8 cm3 / g to 3.9 cm3 / g, especially in the range of from 0.9 cm3 / g to 3.4 cm3 / g, preferentially in the range of from 1 cm3 / g to 2.9 cm3 / g, preferably in the range of from 1.1 cm3 / g to 2.4 cm3 / g, more preferably in the range of from 1.2 cm3 / g to 1.9 cm3 / g, even more preferably in the range of from 1.5 cm3 / g to 1.9 cm3 / g, wherein 50 % to 90 %, especially 52.5 % to 87.5 %, preferentially 55 % to 85 %, preferably 57.5 % to 82.5 %, more preferably 60 % to 80 %, of the total pore volume according to Gurvich of the activated carbon is formed by pores having pore diameters of at least 2 nm, especially by pores having pore diameters in the range of from 2 nm to 500 nm, preferentially by meso- and macropores; and / or wherein the activated carbon (i.e. starting activated carbon) provided and / or prepared in process step (a) has a specific BET surface area SBET in the range of from 1,100 m2 / g to 2,600 m2 / g, especially in the range of from 1,200 m2 / g to 2,400 m2 / g, preferentially in the range of from 1,300 m2 / g to 2,200 m2 / g, preferably in the range of from 1,350 m2 / g to 1,950 m2 / g, more preferably in the range of from 1,375 m2 / g to 1,900 m2 / g; and / or wherein for the activated carbon (i.e. starting activated carbon) provided and / or prepared in process step (a) the ratio Q of total pore volume Vtotal according to Gurvich to specific BET surface area SBET, according to the equation Q=Vtotal / SBET, is in the range of from 0.5 · 10-9 m to 1.9 · 10-9 m, especially in the range of from 0.55 · 10-9 m to 1.9 · 10-9 m, preferentially in the range of from 0.6 · 10-9 m to 1.8 · 10-9 m, preferably in the range of from 0.65 · 10-9 m to 1.7 · 10-9 m, more preferably in the range of from 0.65 · 10-9 m to 1.6 · 10-9 m, even more preferably in the range of from 0.7 · 10-9 m to 1.5 · 10-9 m, further preferably in the range of from 0.75 · 10-9 m to 1.4 · 10-9 m, even further preferably in the range of from 0.8 · 10-9 m to 1.3 · 10-9 m.

3. The method according to claim 1 or 2, wherein the activated carbon oxidized, especially surface-oxidized, in process step (b) has an oxygen content, especially surface oxygen content, determined by means of X-ray photoelectron spectroscopy (XPS or ESCA), in the range of from 4 atom % to 20 atom %, especially in the range of from 5 atom % to 20 atom %, preferentially in the range of from 5.5 atom % to 18 atom %, preferably in the range of from 6 atom % to 15 atom %, more preferably in the range of from 7 atom % to 12.5 atom %, based on the total element composition of the oxidized activated carbon, especially wherein the elements other than oxygen of the activated carbon oxidized, especially surface-oxidized, in process step (b) are formed at least substantially by carbon, especially wherein the activated carbon oxidized, especially surface-oxidized, in process step (b) comprises at most traces of elements other than oxygen and carbon, especially nitrogen, sulfur and / or chlorine, preferably in an amount of at most 2 atom %, especially at most 1.5 atom %, preferably at most 1 atom %, based on the total element composition of the oxidized activated carbon and calculated as the sum of the elements other than oxygen and carbon.

4. The method according to any of the preceding claims, wherein the activated carbon oxidized, especially surface-oxidized, in process step (b) has a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p0 of 0.6 at least 35 %, especially at least 40 %, preferentially at least 50 %, preferably at least 60 %, of the maximum water vapor saturation loading of the activated carbon is achieved; and / or wherein the activated carbon oxidized, especially surface-oxidized, in process step (b) has a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p0 of 0.6 at most 100 %, especially at most 99 %, preferentially at most 98 %, preferably at most 95 %, more preferably at most 90 %, of the maximum water vapor saturation loading of the activated carbon is achieved; and / or wherein the activated carbon oxidized, especially surface-oxidized, in process step (b) has a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p0 of 0.6 30 % to 100 %, especially 35 % to 99 %, preferentially 40 % to 98 %, preferably 50 % to 95 %, more preferably 60 % to 90 %, of the maximum water vapor saturation loading of the activated carbon is achieved; and / or wherein the activated carbon oxidized, especially surface-oxidized, in process step (b) has a hydrophilicity, determined as water vapor adsorption behavior, such that in a partial pressure range p / p0 of 0.1 to 0.6 at least 30 %, especially at least 35 %, preferentially at least 40 %, preferably at least 50 %, more preferably at least 60 %, of the maximum water vapor saturation loading of the activated carbon is achieved; and / or wherein the activated carbon oxidized, especially surface-oxidized, in process step (b) has a hydrophilicity, determined as water vapor adsorption behavior, such that in a partial pressure range p / p0 of 0.1 to 0.6 at most 100 %, especially at most 99 %, preferentially at most 98 %, preferably at most 95 %, more preferably at most 90 %, of the maximum water vapor saturation loading of the activated carbon is achieved; and / or wherein the activated carbon oxidized, especially surface-oxidized, in process step (b) has a hydrophilicity, determined as water vapor adsorption behavior, such that in a partial pressure range p / p0 of 0.1 to 0.6 30 % to 100 %, especially 35 % to 99 %, preferentially 40 % to 98 %, preferably 50 % to 95 %, more preferably 60 % to 90 %, of the maximum water vapor saturation loading of the activated carbon is achieved.

5. The method according to any of the preceding claims, wherein in process step (b) the oxidation, especially surface oxidation, of the activated carbon provided and / or prepared in process step (a) takes place with the proviso that the oxidized, especially surface-oxidized, activated carbon has a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p0 of 0.6 at least 30 % of the maximum water vapor adsorption capacity of the activated carbon is exhausted and / or utilized; and / or wherein the activated carbon oxidized, especially surface-oxidized, in process step (b) has a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p0 of 0.6 at least 30 %, especially at least 35 %, preferentially at least 40 %, preferably at least 50 %, more preferably at least 60 %, of the maximum water vapor adsorption capacity of the activated carbon is exhausted and / or utilized; and / or wherein the activated carbon oxidized, especially surface-oxidized, in process step (b) has a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p0 of 0.6 at most 100 %, especially at most 99 %, preferentially at most 98 %, preferably at most 95 %, more preferably at most 90 %, of the maximum water vapor adsorption capacity of the activated carbon is exhausted and / or utilized; and / or wherein the activated carbon oxidized, especially surface-oxidized, in process step (b) has a hydrophilicity, determined as water vapor adsorption behavior, such that at a partial pressure p / p0 of 0.6 30 % to 100 %, especially 35 % to 99 %, preferentially 40 % to 98 %, preferably 50 % to 95 %, more preferably 60 % to 90 %, of the maximum water vapor adsorption capacity of the activated carbon is exhausted and / or utilized; and / or wherein the activated carbon oxidized, especially surface-oxidized, in process step (b) has a hydrophilicity, determined as water vapor adsorption behavior, such that in a partial pressure range p / p0 of 0.1 to 0.6 at least 30 %, especially at least 35 %, preferentially at least 40 %, preferably at least 50 %, more preferably at least 60 %, of the maximum water vapor adsorption capacity of the activated carbon is exhausted and / or utilized; and / or wherein the activated carbon oxidized, especially surface-oxidized, in process step (b) has a hydrophilicity, determined as water vapor adsorption behavior, such that in a partial pressure range p / p0 of 0.1 to 0.6 at most 100 %, especially at most 99 %, preferentially at most 98 %, preferably at most 95 %, more preferably at most 90 %, of the maximum water vapor adsorption capacity of the activated carbon is exhausted and / or utilized; and / or wherein the activated carbon oxidized, especially surface-oxidized, in process step (b) has a hydrophilicity, determined as water vapor adsorption behavior, such that in a partial pressure range p / p0 of 0.1 to 0.6 30 % to 100 %, especially 35 % to 99 %, preferentially 40 % to 98 %, preferably 50 % to 95 %, more preferably 60 % to 90 %, of the maximum water vapor adsorption capacity of the activated carbon is exhausted and / or utilized.

6. The method according to any of the preceding claims, wherein the catalytically active component comprises at least one metal selected from the group of Fe, Bi, V, Cu, Pb, Zn, Ag, Sn, Pd, Pt, Ru and Ni, preferentially Fe, Bi, V, Cu, Pt, Ru and Pb, preferably Pd, Pt and Ru, more preferably Pd and Pt; and / or wherein the precursor of the catalytically active component is formed and / or constituted such that the precursor is converted and / or transformed into the catalytically active component by the reduction carried out in process step (d); and / or wherein the precursor of the catalytically active component is an oxidized form of the catalytically active component or is formed therefrom.

7. The method according to any of the preceding claims, wherein in process step (c) the equipping of the oxidized, especially surface-oxidized, activated carbon with the catalytically active component, especially with the precursor of the catalytically active component, comprises an application and / or contacting, preferentially a fixing, of the oxidized, especially surface-oxidized, activated carbon with the catalytically active component, especially with the precursor of the catalytically active component, especially wherein the application and / or contacting, preferentially the fixing, is carried out by dipping and / or soaking and / or wetting and / or covering and / or coating and / or spraying on and / or spraying the oxidized, especially surface-oxidized, activated carbon in and / or with the catalytically active component, especially in and / or with the precursor of the catalytically active component, especially wherein the application and / or contacting is carried out with energy input, especially by means of shaking and / or by means of ultrasound input, and / or especially wherein the catalytically active component, especially the precursor of the catalytically active component, is used in the form of a solution and / or in dispersion form (dispersion), especially as defined in claim 39; and / or wherein especially subsequent to the application and / or contacting and / or especially for the purposes of equipping the oxidized, especially surface-oxidized, activated carbon with the catalytically active component, especially with the precursor of the catalytically active component, excess amounts of catalytically active component, especially excess amounts of the precursor of the catalytically active component, preferentially excess amounts of solution and / or dispersion form (dispersion) of the catalytically active component, preferentially excess amounts of solution and / or dispersion form (dispersion) of the precursor of the catalytically active component, are removed and / or separated from the activated carbon and / or the catalyst system; and / or wherein especially subsequent to the application and / or contacting and / or especially for the purposes of equipping the oxidized, especially surface-oxidized, activated carbon with the catalytically active component, especially with the precursor of the catalytically active component, a purification and / or drying of the activated carbon obtained is carried out, especially wherein the purification and / or drying is carried out by means of at least one washing operation in a liquid, especially water, and / or especially wherein the purification and / or drying is carried out by heating the activated carbon equipped with the catalytic component, especially to temperatures in the range of from 40 °C to 200 °C, especially 50 °C to 150 °C, preferentially 60 °C to 120 °C, and / or especially wherein the purification and / or drying is carried out under reduced (air) pressure and / or in a vacuum, and / or especially wherein the purification and / or drying is carried out at an (air) pressure in the range of from 100 Pa to 0.01 Pa, especially 10 Pa to 0.1 Pa.

8. The method according to any of the preceding claims, wherein in process step (d) the reduction is carried out at a temperature in the range of from 120 °C to 150 °C, more preferably in the range of from 130 °C to 145 °C; and / or wherein in process step (d) the reduction is carried out for a period in the range of from 0.05 h to 48 h, especially in the range of from 0.1 h to 36 h, preferentially in the range of from 0.5 h to 24 h, preferably in the range of from 1 h to 12 h.

9. The method according to any of the preceding claims, wherein the catalyst system has an activity, determined as a percentage degree of dispersion of the catalytically active component on the catalyst support, measured by chemisorption by means of dynamic flow method according to DIN 66136-3:2007-01, in the range of from 20 % to 80 %, preferentially in the range of from 25 % to 70 %, preferably in the range of from 28 % to 60 %; and / or wherein the catalyst system comprises the catalytically active component with an average crystallite size, determined according to DIN 66136, of at most 70 Å, preferentially at most 60 Å, preferably at most 58 Å, more preferably at most 45 Å, most preferably at most 40 Å, even more preferably at most 38 Å, and / or in the range of from 5 Å (Angstrom) to 80 Å, especially in the range of from 7 Å to 70 Å, preferentially in the range of from 10 Å to 60 Å, preferably in the range of from 15 Å to 58 Å, more preferably in the range of from 17 Å to 45 Å, most preferably in the range of from 18 Å to 40 Å, even more preferably in the range of from 20 Å to 38 Å.

10. A catalyst system in the form of a supported catalyst, preferentially for use in heterogeneous catalysis, obtainable and / or obtained according to a method according to any of the preceding claims.

11. The catalyst system according to claim 10, wherein the catalyst system comprises at least one catalytically active component applied and / or fixed to a catalyst support, wherein the catalytically active component comprises and / or consists of at least one metal, wherein the metal is selected from the group of Cu, Ag, Au, Zn, Hg, Sn, Ce, Ti, Zr, V, Nb, Cr, Mo, W, Mn, Fe, Bi, Ru, Os, Co, Rh, Re, Ir, Ni, Pd and Pt, and wherein the catalyst support is formed in the form of activated carbon, wherein the catalyst support is present in the form of a spherical activated carbon, wherein the activated carbon (i.e. the activated carbon forming the catalyst support) (i) has a total pore volume Vtotal according to Gurvich in the range of from 0.8 cm3 / g to 3.9 cm3 / g, wherein at least 50 % of the total pore volume according to Gurvich is formed by pores having pore diameters of at least 2 nm, especially by pores having pore diameters in the range of from 2 nm to 500 nm, preferentially by meso- and macropores, and (ii) has a specific BET surface area SBET in the range of from 1,000 m2 / g to 3,000 m2 / g, however, with the proviso that the ratio Q of total pore volume Vtotal according to Gurvich to specific BET surface area SBET according to the equation Q=Vtotal / SBET is at least 0.5 · 10-9 m; and wherein the catalyst system has an activity, determined as a percentage degree of dispersion of the catalytically active component on the catalyst support, measured by chemisorption by means of dynamic flow method according to DIN 66136-3:2007-01, in the range of from 15 % to 90 %; and wherein the catalyst system comprises the catalytically active component with an average crystallite size, determined according to DIN 66136, of at most 80 Å (Angstrom).

12. Use of a catalyst system according to claim 10 or 11, as a catalyst or catalyst support; or for the chemical catalysis, especially for the heterogeneous catalysis, and / or for the discontinuous or continuous catalysis; or for the catalysis of chemical processes and reactions, especially hydrogenation reactions or oligomerization and polymerization reactions, preferentially of olefins, preferably hydrogenation reactions.

13. Use of a catalyst system according to claim 10 or 11, for the production of filters and filter materials, especially for the removal of noxious, odorous and toxic substances, especially from air and / or gas streams, such as ABC protective mask filters, odor filters, surface filters, air filters, especially filters for room air purification, adsorption-capable support structures and filters for the medical sector; or as adsorption reservoirs for gases or liquids; or in or as gas sensors or in fuel cells; or for sorptive applications, especially adsorptive and / or chemisorptive applications, preferentially chemisorptive applications, especially as preferentially reactive and / or catalytic adsorbent; or for gas purification and / or gas treatment; or for the removal of noxious substances, especially gaseous noxious substances, or of environmentally harmful, health-harmful or toxic substances or gases and / or for the treatment and / or provision of clean room atmospheres, especially for the electrical industry, especially for semiconductor or chip production.

14. Protective materials, especially for the civil or military sector, especially protective clothing, such as protective suits, protective gloves, protective footwear, protective socks, protective head protection, as well as protective coverings, preferentially all aforementioned protective materials for ABC use, prepared using a catalyst system according to claim 10 or 11 and / or comprising a catalyst system according to claim 10 or 11.

15. A filter, especially for the removal of noxious, odorous and toxic substances of all kinds, especially from air and / or gas streams, such as ABC protective mask filters, odor filters, surface filters, air filters, especially filters for room air purification, adsorption-capable and / or chemisorption-capable support structures and filters for the medical sector, prepared using a catalyst system according to claim 10 or 11 and / or comprising a catalyst system according to claim 10 or 11.