Catalyst composition for producing amines by reductive amination

Abstract

A catalyst comprising a carrier component selected from alumina, silica, and combinations thereof; and an active component having a first metal, a second metal, and a third metal. The first metal is selected from a group consisting of cobalt, nickel, and copper. The second metal is selected from a group consisting of rhenium, ruthenium, chromium, zinc, sodium, calcium, magnesium, strontium, lithium, potassium, barium, cesium, lanthanum, tungsten, iron, silver, titanium, manganese, aluminum, rhodium, platinum, palladium, iridium, and combinations thereof. The third metal is niobium.

Description

86277-WO-PCT / DOW 86277 WO1CATALYST COMPOSITION FOR PRODUCING AMINES BY REDUCTIVE AMINATIONCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 718,951 filed November 11, 2024, the contents of which are incorporated in their entirety herein.TECHNICAL FIELD

[0002] Embodiments disclosed herein generally relate to a catalyst and methods for preparing the catalyst.BACKGROUND

[0003] Reductive amination is a chemical process that converts monoethanolamine (MEA) into ethyleneamines. Reductive amination of MEA may generate both desired and undesired ethyleneamine products. Examples of desired ethyleneamine products may include ethylenediamine (EDA), N-(2-aminoethyl)ethanolamine (AEEA), diethylenetriamine (DETA), piperazine (PIP), and / or N-(2-aminoethyl)piperazine (AEP), which are of high market value. Most of the EDA produced in industry is produced by continuous reaction of MEA and ammonia in the presence of hydrogen over a catalyst. During EDA production, a variety of undesired byproducts may be formed. Examples of undesired by-products may include alkylamines, which may include N-methylethylenediamine (NMEDA or methyl- EDA), N-ethylethylenediamine (NEEDA or ethyl-EDA), methylamine (MA), and ethylamine (EA). Other examples of undesired by-products during EDA production may include heavy amines such as poly alkylene polyamines, many of which may comprise greater than or equal to four nitrogen atoms in their molecular structure. Separation of undesired by-products is a present challenge. For example, in many industries, NMEDA should be less than 1000 ppm in EDA for many applications and a relatively high amount of heavy amines may be at least 10% of the total ethyleneamine product composition. In addition to undesired by-products that may be present in the effluent stream, unreacted MEA may be present in the effluent. Both increased selectivity and high MEA conversion are desired to increase desired products in the effluent stream. A present challenge in this chemical process is increasing the86277-WO-PCT / DOW 86277 WO2 selectivity of high-value ethyleneamines, such as EDA, in the reductive amination process at commercially attractive MEA conversions (>20%). Conventional catalysts produce large amounts of alkylamines and heavy amines, which present significant separation challenges and expenses.SUMMARY

[0004] The conventional catalysts used in this process often results in undesired byproducts, which may include heavy amines, alkylamines, and light alkylamines. Catalyst performance may be measured as a function of MEA conversion and EDA selectivity, of which the conventional catalyst conversion of MEA may be too low and the selectivity of EDA may be too low. Nickel is a common catalyst component used in reductive amination, but may result in relatively low selectivity of desired products, relatively high (>10%) selectivity of undesired heavy amines, and other undesired by-products. Conventional catalysts result in reaction performance where a variety of products are present in the process effluent stream, which necessitates separation of high market value products from low market value products. To reduce the amount of low market value products and to increase the amount of high market value products in the effluent stream, a catalyst capable of minimizing undesired amine products under a variety of conditions is desired. There is also a need for a catalyst capable of increased MEA conversion and increased EDA selectivity, with minimal to no metal leaching and with minimal undesired amine products. Embodiments disclosed and described herein, include catalysts comprising niobium that are suitable for reductive amination and reduce the generation of undesired byproducts. Some embodiments include a catalyst comprising greater than 0.5 wt. % niobium.

[0005] A catalyst comprising a carrier component selected from the group consisting of alumina, silica, and combinations thereof; and an active component comprising a first metal, a second metal, and a third metal, wherein the first metal is selected from the group consisting of cobalt, nickel, and copper, the second metal is selected from a group consisting of rhenium, ruthenium, chromium, zinc, sodium, calcium, magnesium, strontium, lithium, potassium, barium, cesium, lanthanum, tungsten, iron, silver, titanium, manganese, aluminum, rhodium, platinum, palladium, iridium, and combinations thereof, and the third metal is niobium. The metal contents achieved in embodiments disclosed herein cannot be achieved by conventional catalyst preparation methods.86277-WO-PCT / DOW 86277 WO3

[0006] This summary is provided to introduce a selection of concepts that are further described in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

[0007] Additional features and advantages of the described embodiments will be set forth in the detailed description that follows. The additional features and advantages of the described embodiments will be, in part, readily apparent to those skilled in the art from that description or recognized by practicing the described embodiments, including the detailed description that follows as well as the claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a scatter plot showing the MEA conversion performance of Comparative Catalyst A compared to Example Catalyst 1 over a range of temperatures at Reaction Condition 1.

[0009] FIG. 2 is a scatter plot showing the MEA conversion performance of Comparative Catalyst A compared to Example Catalyst 1 over a range of temperatures of Reaction Condition 2.

[0010] FIG. 3 is a scatter plot showing the EDA selectivity of Comparative Catalyst A compared to Example Catalyst 1 over a range of MEA conversions measured under Reaction Condition 2.DETAILED DESCRIPTION

[0011] Presently described, according to one or more embodiments, are catalysts for reductive amination, methods for producing catalysts, and methods for using catalysts. Catalysts described in this disclosure may comprise a carrier portion and an active catalyst portion.

[0012] As used in this disclosure, a “catalyst” refers to any substance that increases the rate of a specific chemical reaction. Catalysts described in this disclosure may be utilized to promote various reactions, such as, but not limited to, producing amines by reductive amination. Catalysts described in this disclosure may comprise a carrier component and an active component.86277-WO-PCT / DOW 86277 WO4

[0013] As used in this disclosure, an “effluent” generally refers to a stream that exits a system component such as a separation unit, a reactor, or reaction zone, following a separation or particular reaction, and generally has a different composition (at least proportionally) than the stream that entered the separation unit, reactor, or reaction zone.

[0014] As used in this disclosure, “product effluent” generally refers to a stream that exits a system component such as a reactor or reaction zone, following a particular reaction, and generally has a different composition (at least proportionally) than the stream that entered the reactor or reaction zone.

[0015] As used in this disclosure, “>N4” generally refers to a molecular structure comprising greater than or equal to four nitrogen atoms.

[0016] As used in this disclosure, “undesired byproducts” or “unwanted byproducts” generally refers to heavy amines, alkylamines, light alkylamines, or combinations thereof. As used in this disclosure “heavy amines” generally refers to polyalkylene polyamines or polyalkylene polyamines with molecular structures containing greater than or equal to four nitrogen atoms. As used in this disclosure “alkylamines” may refer to methylamine (MA), ethylamine (EA), N-methylethylenediamine (NMEDA), N-ethylethylenediamine (NEED A), or combinations thereof, where “light alkylamines” may specifically refer to methylamine (MA), ethylamine (EA), or combinations thereof.

[0017] As used in this disclosure, “desired products” or “wanted products” generally refers to ethyleneamine products which are of high market value. Examples of desired ethyleneamine products may include ethylenediamine (EDA), N-(2- aminoethyl)ethanolamine (AEEA), diethylenetriamine (DETA), piperazine (PIP), N-(2- aminoethyl)piperazine (AEP), and combinations thereof.

[0018] As used throughout this disclosure, “carrier component” may be selected from the group consisting of alumina, silica, and combinations thereof. Examples include, but are not limited to, kieselguhrs, diatomaceous earths, and mixed silica-aluminas. Carrier components may be used as physical carriers for other components of the catalyst and, in embodiments, may have minimal chemical effect on the other components of the catalyst.

[0019] As used throughout this disclosure, “active component” may comprise one or more metals, one or more metal oxides, or combinations thereof.

[0020] As used in this disclosure, the “reaction zone” may be defined as a zone in the reactor containing the catalysts where the reaction is initiated.86277-WO-PCT / DOW 86277 WO5

[0021] As used in this disclosure, “calcining” or “calcine” may be defined as a treatment of a solid chemical compound whereby the compound is raised to a high temperature without fusing in order to drive off volatile matter or to effect changes such as oxidation and / or thermal decomposition. Calcining may be used to remove impurities or volatile substances.

[0022] As used in this disclosure, “polyalkylene polyamines” refer to molecular structures of polyalkylene polyamines comprising four or greater nitrogen atoms, and may include, but are not limited to, triethylenetetramine (TETA), tetraethylenepentamine (TEPA), pentaethylenehexamine (PEHA), nitrilotrisethylamine (NTEA), diaminoethylpiperazine (DiAEP), piperazinoethylethylenediamine (PEEDA), 4-aminoethyltriethylenetetramine (AETETA), aminoethylpiperazinoethylethylenediamine (AEPEEDA), and / or piperazineoethyldiethylenetriamine (PEDETA).

[0023] As used in this disclosure, “space velocity” or “SV” (hr-1) may be defined as a ratio of mass flow rate (g / hr) of a feed stream to the mass of the catalyst (g) loaded in a reactor.

[0024] As used in this disclosure, “selectivity” refers to a mass-based approximation rather than conventional molar based approximation. This distinction is used to compare results with mass-based production ratios calculated by technical centers and production personnel. As used in this disclosure, selectivity may be based on converted products, excluding unreacted feed material such as the reducing agent and the amino alcohol.

[0025] As used in this disclosure, “conversion” refers specifically to the conversion of MEA on a weight basis.

[0026] As used in this disclosure, “concentration of hydrogen” may be used to refer to the concentration of hydrogen with respect to MEA, the concentration of hydrogen with respect to ammonia, and / or the concentration of hydrogen with respect to the contents of total material in the reaction zone.

[0027] In embodiments of a catalyst, the catalyst may comprise a carrier component selected from the group consisting of alumina, silica, and combinations thereof; and an active component comprising a first metal, a second metal, and a third metal, wherein the first metal is selected from the group consisting of cobalt, nickel, and copper, the second metal is selected from a group consisting of rhenium, ruthenium, chromium, zinc, sodium, calcium, magnesium, strontium, lithium, potassium, barium, cesium, lanthanum, tungsten, iron, silver, titanium, manganese, aluminum, rhodium, platinum, palladium, iridium, and combinations thereof, and the third metal is niobium. Without being bound by any particular theory,86277-WO-PCT / DOW 86277 WO6 including niobium with the first and second metals as disclosed above improves the activity and selectivity of the catalyst by increasing dispersion of the first metal compared with conventional catalysts that do not include niobium. In addition, niobium does not significantly leach from the catalyst and may extend catalyst life compared to other conventional catalysts under reaction conditions.

[0028] In embodiments, a catalyst may comprise a carrier component having from 65 wt. % to 95 wt. % alumina, based on the total weight of the carrier component. For instance, in embodiments the carrier component may comprise from 65 wt. % to 90 wt. %, from 65 wt. % to 85 wt. %, from 65 wt. % to 80 wt. %, from 65 wt. % to 75 wt. %, from 65 wt. % to 70 wt. %, from 70 wt. % to 90 wt. %, from 70 wt. % to 85 wt. %, from 70 wt. % to 80 wt. %, from 70 wt. % to 75 wt. %, from 75 wt. % to 90 wt. %, from 75 wt. % to 85 wt. %, from 75 wt. % to 80 wt. %, from 80 wt. % to 90 wt. %, from 80 wt. % to 85 wt. %, from 85 wt. % to 90 wt. %, or from 90 wt. % to 95 wt. % alumina. If the amount of alumina in the carrier component is too high, the selectivity of EDA may decrease over time and the selectivity for AEEA may increase over time; however, if the amount of alumina is too low, the total metals to be impregnated onto the carrier may be affected and may result in loss of catalyst activity or selectivity.

[0029] In embodiments, the catalyst may have a carrier component that comprises from 5 wt. % to 35 wt. % silica, based on the total weight of the carrier component. For instance, in embodiments the carrier component may comprise from 5 wt. % to 35 wt. %, from 5 wt. % to 30 wt. %, from 5 wt. % to 25 wt. %, from 5 wt. % to 20 wt. %, from 5 wt. % to 15 wt. %, from 5 wt. % to 10 wt. %, from 10 wt. % to 35 wt. %, from 10 wt. % to 30 wt. %, from 10 wt. % to 25 wt. %, from 10 wt. % to 20 wt. %, from 10 wt. % to 15 wt. %, from 15 wt. % to 35 wt. %, from 15 wt. % to 30 wt. %, from 15 wt. % to 25 wt. %, from 15 wt. % to 20 wt. %, from 20 wt. % to 35 wt. %, from 20 wt. % to 30 wt. %, from 20 wt. % to 25 wt. %, from 25 wt. % to 35 wt. %, from 25 wt. % to 30 wt. %, or from 30 wt. % to 35 wt. % silica. If the amount of silica is too high the total metals to be impregnated onto the carrier may be affected and may result in loss of catalyst activity or selectivity; however, if the amount of silica is too low, the selectivity of EDA may decrease over time and the selectivity for AEEA may increase over time.

[0030] In embodiments of a catalyst, the catalyst may comprise a carrier component selected from the group consisting of alumina, silica, and combinations thereof; and an active86277-WO-PCT / DOW 86277 WO7 component comprising a first metal, a second metal, and a third metal, wherein the first metal is selected from the group consisting of cobalt, nickel, and copper, the second metal is selected from a group consisting of rhenium, ruthenium, chromium, zinc, sodium, calcium, magnesium, strontium, lithium, potassium, barium, cesium, lanthanum, tungsten, iron, silver, titanium, manganese, aluminum, rhodium, platinum, palladium, iridium, and combinations thereof, and the third metal is niobium. In embodiments, the first metal may be nickel and the second metal may be rhenium.

[0031] In embodiments, a catalyst for producing amines by reductive amination comprises a ratio of the first metal to the second metal (based on the weight percent of each metal element to the total catalyst) may be from 1 :1 to 10:1. For instance, in embodiments the ratio may be from 1 :1 to 9:1, from 1 :1 to 8:1, from 1 :1 to 7:1, from 1 :1 to 6:1, from 1 :1 to 5:1, from 1 :1 to 4, from 1 :1 to 3:1, from 1 :1 to 2:1, from 2:1 to 10:1, from 2:1 to 9:1, from 2:1 to 8:1, from 2:1 to 7:1, from 2:1 to 6:1, from 2:1 to 5:1, from 2:1 to 4:1, from 2:1 to 3:1, from 3:1 to 10:1, from 3:1 to 9:1, from 3:1 to 8:1, from 3:1 to 7:1, from 3:1 to 6:1, from 3:1 to 5, from 3:1 to 4:1, from 4:1 to 10:1, from 4:1 to 9:1, from 4:1 to 8:1, from 4:1 to 7:1, from 4:1 to 6:1, from 4:1 to 5:1, from 5:1 to 10:1, from 5:1 to 9:1, from 5:1 to 8:1, from 5:1 to 7:1, from 5:1 to 6:1, from 6:1 to 10:1, from 6:1 to 9:1, from 6:1 to 8:1, from 6:1 to 7:1, from 7:1 to 10:1, from 7:1 to 9:1, from 7:1 to 8:1, from 8:1 to 10:1, from 8:1 to 9: 1 , or from 9:1 to 10: 1. If the ratio of nickel to rhenium is too high, activity and / or desired selectivity may be lowered; however, if the ratio of nickel to rhenium is too low, activity and / or desired selectivity may be lowered. In embodiments the first metal may be nickel and the second metal may be rhenium.

[0032] In embodiments, a catalyst for producing amines by reductive amination comprises an atomic ratio of the first metal to the second metal, wherein the ratio is an atomic ratio of the metal elements, that is from 1 :1 to 50:1. For instance, in embodiments the ratio may be from 1 :1 to 49:1, from 1 :1 to 48:1, from 1 :1 to 47:1, from 1 :1 to 46:1, from 1 :1 to 45:1, from 1 :1 to 44:1, from 1 :1 to 43:1, from 1 :1 to 42:1, from 1 :1 to 41 :1, from 1 :1 to 40:1, from 1 :1 to 39:1, from 1 :1 to 38:1, from 1 :1 to 37:1, from 1 :1 to 36:1, from 1 :1 to 35:1, from 1 :1 to 34:1, from 1 :1 to 33:1, from 1 :1 to 32:1, from 1 :1 to 31 :1, from 1 :1 to 30:1, from 1 :1 to 29:1, from 1 :1 to 28:1, from 1 :1 to 27:1, from 1 :1 to 26:1, from 1 :1 to 25:1, from 1 :1 to 24:1, from 1 :1 to 23:1, from 1 :1 to 22:1, from 1 :1 to 21 :1, from 1 :1 to 20:1, from 1 :1 to 19:1, from 1 :1 to 18:1, from 1 :1 to 17:1, from 1 :1 to 16:1, from 1 :1 to 15:1, from 1 :1 to 14:1, from 1 :1 to86277-WO-PCT / DOW 86277 WO813:1, from 1 :1 to 12:1, from 1 :1 to 11 :1, from 1 :1 to 10:1, from 1 :1 to 9:1, from 1 :1 to 8:1, from 1 :1 to 7:1, from 1 :1 to 6:1, from 1 :1 to 5:1, from 1 :1 to 4:1, from 1 :1 to 3:1, from 1 :1 to 2:1, from 1 :1 to 5:1, from 1 :1 to 4:1, from 1 :1 to 3:1, from 1 :1 to 2:1, from 2:1 to 50:1, from 2:1 to 49:1, from 2:1 to 48:1, from 2:1 to 47:1, from 2:1 to 46:1, from 2:1 to 45:1, from 2:1 to 44:1, from 2:1 to 43:1, from 2:1 to 42:1, from 2:1 to 41 :1, from 2:1 to 40:1, from 2:1 to 39:1, from 2:1 to 38:1, from 2:1 to 37:1, from 2:1 to 36:1, from 2:1 to 35:1, from 2:1 to 34:1, from 2:1 to 33:1, from 2:1 to 32:1, from 2:1 to 32:1, from 2:1 to 30:1, from 2:1 to 29:1, from 2:1 to 28:1, from 2:1 to 27:1, from 2:1 to 26:1, from 2:1 to 25:1, from 2:1 to 24:1, from 2:1 to 23:1, from 2:1 to 22:1, from 2:1 to 21 :1, from 2:1 to 20:1, from 2:1 to 19:1, from 2:1 to 18:1, from 2:1 to 17:1, from 2:1 to 16:1, from 2:1 to 15:1, from 2:1 to 14:1, from 2:1 to 13:1, from 2:1 to 12:1, from 2:1 to 11 :1, from 2:1 to 10:1, from 2:1 to 5:1, from 2:1 to 4:1, from 2:1 to 3:1, from 3:1 to 50:1, from 3:1 to 47:1, from 3:1 to 46:1, from 3:1 to 45:1, from 3:1 to 44:1, from 3:1 to 43:1, from 3:1 to 42:1, from 3:1 to 41 :1, from 3:1 to 40:1, from 3:1 to 39:1, from 3:1 to 38:1, from 3:1 to 37:1, from 3:1 to 36:1, from 3:1 to 35:1, from 3:1 to 34:1, from 3:1 to 33:1, from 3:1 to 32:1, from 3:1 to 20:1, from 3:1 to 10:1, from 3:1 to 5:1, from 3:1 to 4:1, from 4:1 to 48:1, from 4:1 to 47:1, from 4:1 to 46:1, from 4:1 to 45:1, from 4:1 to 44:1, from 4:1 to 43:1, from 4:1 to 42:1, from 4:1 to 41 :1, from 4:1 to 40:1, from 4:1 to 39:1, from 4:1 to 38:1, from 4:1 to 37:1, from 4:1 to 36:1, from 4:1 to 35:1, from 4:1 to 34:1, from 4:1 to 33:1, from 4:1 to 32:1, from 4:1 to 20:1, from 4:1 to 10:1, from 4:1 to 5:1, from 5:1 to 50:1, from 5:1 to 46:1, from 5:1 to 45:1, from 5:1 to 44:1, from 5:1 to 43:1, from 5:1 to 42:1, from 5:1 to 41 :1, from 5:1 to 40:1, from 5:1 to 39:1, from 5:1 to 38:1, from 5:1 to 37:1, from 5:1 to 36:1, from 5:1 to 35:1, from 5:1 to 34:1, from 5:1 to 33:1, from 5:1 to 32:1, from 5:1 to 20:1, from 5:1 to 10:1, from 10:1 to 50:1, from 10:1 to 47:1, from 10:1 to 46:1, from 10:1 to 45:1, from 10:1 to 44:1, from 10:1 to 43:1, from 10:1 to 42:1, from 10:1 to 41 :1, from 10:1 to 40:1, from 10:1 to 39:1, from 10:1 to 38:1, from 10:1 to 37:1, from 10:1 to 36:1, from 10:1 to 35:1, from 10:1 to 34:1, from 10:1 to 33:1, from 10:1 to 32:1, from 10:1 to 20:1, from 10:1 to 14:1, from 10:1 to 13:1, from 10:1 to 12:1, from 10:1 to 11 :1, from 11 :1 to 14:1, from 11 :1 to 13:1, from 11 :1 to 12:1, from 12:1 to 14:1, from 12:1 to 13:1, from 13:1 to 14:1, from 20:1 to 50:1, from 20:1 to 47:1, from 20:1 to 46:1, from 20:1 to 45:1, from 20:1 to 44:1, from 20:1 to 43:1, from 20:1 to 42:1, from 20:1 to 41 :1, from 20:1 to 40:1, from 20:1 to 39:1, from 20:1 to 38:1, from 20:1 to 37:1, from 20:1 to 36:1, from 20:1 to 35:1, from 20:1 to 34:1, from 20:1 to 33:1, from 20:1 to 30:1, from 30:1 to 50:1, from 30:1 to 47:1, from 30:1 to 46:1, from 30:186277-WO-PCT / DOW 86277 WO9 to 45:1, from 30:1 to 44:1, from 30:1 to 43:1, from 30:1 to 42:1, from 30:1 to 41 :1, from 30:1 to 40:1, from 30:1 to 39:1, from 30:1 to 38:1, from 30:1 to 37:1, from 30:1 to 36:1, from 30:1 to 35:1, from 30:1 to 34:1, from 30:1 to 33:1, from 40:1 to 49:1, from 40:1 to 48:1, from 40:1 to 47:1, from 40:1 to 46:1, from 40:1 to 45:1, from 40:1 to 44:1, from 40:1 to 43:1, from 40:1 to 42:1, from 40:1 to 41 :1, from 45:1 to 50:1, from 45:1 to 49:1, from 45:1 to 48:1, from 45:1 to 47:1, from 45:1 to 46:1, or from 46:1 to 50:1. As used herein, the above ratio is a ratio of metal atoms and does not include non-metal components of compounds such as, for example, oxides or salts. If the ratio of nickel to rhenium is too high, activity and / or desired selectivity may be lowered; however, if the ratio of nickel to rhenium is too low, activity and / or desired selectivity may be lowered. In embodiments the first metal may be nickel and the second metal may be rhenium.

[0033] In embodiments, a catalyst for producing amines by reductive amination comprises an atomic ratio of the first metal to the third metal, wherein the ratio is an atomic ratio of the metal elements, that is from 1 :1 to 50:1. For instance, in embodiments the ratio may be from 1 :1 to 49:1, from 1 :1 to 48:1, from 1 :1 to 47:1, from 1 :1 to 46:1, from 1 :1 to 45:1, from 1 :1 to 44:1, from 1 :1 to 43:1, from 1 :1 to 42:1, from 1 :1 to 41 :1, from 1 :1 to 40:1, from 1 :1 to 39:1, from 1 :1 to 38:1, from 1 :1 to 37:1, from 1 :1 to 36:1, from 1 :1 to 35:1, from 1 :1 to 34:1, from 1 :1 to 33:1, from 1 :1 to 32:1, from 1 :1 to 31 :1, from 1 :1 to 30:1, from 1 :1 to 29:1, from1 :1 to 28:1, from 1 :1 to 27:1, from 1 :1 to 26:1, from 1 :1 to 25:1, from 1 :1 to 24:1, from 1 :1 to 23:1, from 1 :1 to 22:1, from 1 :1 to 21 :1, from 1 :1 to 20:1, from 1 :1 to 19:1, from 1 :1 to 18:1, from 1 :1 to 17:1, from 1 :1 to 16:1, from 1 :1 to 15:1, from 1 :1 to 14:1, from 1 :1 to 13:1, from 1 :1 to 12:1, from 1 :1 to 11 :1, from 1 :1 to 10:1, from 1 :1 to 9:1, from 1 :1 to 8:1, from1 :1 to 7:1, from 1 :1 to 6:1, from 1 :1 to 5:1, from 1:1 to 4:1, from 1 :1 to 3:1, from 1 :1 to 2:1, from 1 :1 to 5:1, from 1 :1 to 4:1, from 1 :1 to 3:1, from 1 :1 to 2:1, from 2:1 to 50:1, from 2:1 to 49:1, from 2:1 to 48:1, from 2:1 to 47:1, from 2:1 to 46:1, from 2:1 to 45:1, from 2:1 to 44:1, from 2:1 to 43:1, from 2:1 to 42:1, from 2:1 to 41 :1, from 2:1 to 40:1, from 2:1 to 39:1, from 2:1 to 38:1, from 2:1 to 37:1, from 2:1 to 36:1, from 2:1 to 35:1, from 2:1 to 34:1, from2:1 to 33:1, from 2:1 to 32:1, from 2:1 to 32:1, from 2:1 to 30:1, from 2:1 to 29:1, from 2:1 to 28:1, from 2:1 to 27:1, from 2:1 to 26:1, from 2:1 to 25:1, from 2:1 to 24:1, from 2:1 to 23:1, from 2:1 to 22:1, from 2:1 to 21 :1, from 2:1 to 20:1, from 2:1 to 19:1, from 2:1 to 18:1, from 2:1 to 17:1, from 2:1 to 16:1, from 2:1 to 15:1, from 2:1 to 14:1, from 2:1 to 13:1, from2:1 to 12:1, from 2:1 to 11 :1, from 2:1 to 10:1, from 2:1 to 5:1, from 2:1 to 4:1, from 2:1 to86277-WO-PCT / DOW 86277 WO103:1, from 3:1 to 50:1, from 3:1 to 47:1, from 3:1 to 46:1, from 3:1 to 45:1, from 3:1 to 44:1, from 3:1 to 43:1, from 3:1 to 42:1, from 3:1 to 41 :1, from 3:1 to 40:1, from 3:1 to 39:1, from 3:1 to 38:1, from 3:1 to 37:1, from 3:1 to 36:1, from 3:1 to 35:1, from 3:1 to 34:1, from 3:1 to 33:1, from 3:1 to 32:1, from 3:1 to 20:1, from 3:1 to 10:1, from 3:1 to 5:1, from 3:1 to 4:1, from 4:1 to 48:1, from 4:1 to 47:1, from 4:1 to 46:1, from 4:1 to 45:1, from 4:1 to 44:1, from 4:1 to 43:1, from 4:1 to 42:1, from 4:1 to 41 :1, from 4:1 to 40:1, from 4:1 to 39:1, from 4:1 to 38:1, from 4:1 to 37:1, from 4:1 to 36:1, from 4:1 to 35:1, from 4:1 to 34:1, from 4:1 to 33:1, from 4:1 to 32:1, from 4:1 to 20:1, from 4:1 to 10:1, from 4:1 to 5:1, from 5:1 to 50:1, from 5:1 to 46:1, from 5:1 to 45:1, from 5:1 to 44:1, from 5:1 to 43:1, from 5:1 to 42:1, from 5:1 to 41 :1, from 5:1 to 40:1, from 5:1 to 39:1, from 5:1 to 38:1, from 5:1 to 37:1, from 5:1 to 36:1, from 5:1 to 35:1, from 5:1 to 34:1, from 5:1 to 33:1, from 5:1 to 32:1, from 5:1 to 20:1, from 5:1 to 10:1, from 10:1 to 50:1, from 10:1 to 47:1, from 10:1 to 46:1, from 10:1 to 45:1, from 10:1 to 44:1, from 10:1 to 43:1, from 10:1 to 42:1, from 10:1 to 41 :1, from 10:1 to 40:1, from 10:1 to 39:1, from 10:1 to 38:1, from 10:1 to 37:1, from 10:1 to 36:1, from 10:1 to 35:1, from 10:1 to 34:1, from 10:1 to 33:1, from 10:1 to 32:1, from 10:1 to 20:1, from 10:1 to 15:1, from 10:1 to 14:1, from 10:1 to 13:1, from 10:1 to 12:1, from 10:1 to 11 :1, from 11 :1 to 15:1, from 11 :1 to 14:1, from 11 :1 to 13:1, from 11 :1 to 12:1, from 12:1 to 15:1, from 12:1 to 14:1, from 12:1 to 13:1, from 13:1 to 15:1, from 13:1 to 14:1, from 14:1 to 15:1, from 20:1 to 50:1, from 20:1 to 47:1, from 20:1 to 46:1, from 20:1 to 45:1, from 20:1 to 44:1, from 20:1 to 43:1, from 20:1 to 42:1, from 20:1 to 41 :1, from 20:1 to 40:1, from 20:1 to 39:1, from 20:1 to 38:1, from 20:1 to 37:1, from 20:1 to 36:1, from 20:1 to 35:1, from 20:1 to 34:1, from 20:1 to 33:1, from 20:1 to 30:1, from 30:1 to 50:1, from 30:1 to 47:1, from 30:1 to 46:1, from 30:1 to 45:1, from 30:1 to 44:1, from 30:1 to 43:1, from 30:1 to 42:1, from 30:1 to 41 :1, from 30:1 to 40:1, from 30:1 to 39:1, from 30:1 to 38:1, from 30:1 to 37:1, from 30:1 to 36:1, from 30:1 to 35:1, from 30:1 to 34:1, from 30:1 to 33:1, from 40:1 to 49:1, from 40:1 to 48:1, from 40:1 to 47:1, from 40:1 to 46:1, from 40:1 to 45:1, from 40:1 to 44:1, from 40:1 to 43:1, from 40:1 to 42:1, from 40:1 to 41 :1, from 45:1 to 50:1, from 45:1 to 49:1, from 45:1 to 48:1, from 45:1 to 47:1, from 45:1 to 46:1, or from 46:1 to 50:1. As used herein, the above ratio is a ratio of metal atoms and does not include non-metal components of compounds such as, for example, oxides or salts. If the ratio of nickel to niobium is too high, dispersion may be poor, reducing activity and selectivity; however, if the ratio of nickel to niobium is too low, dispersion may be poor, reducing activity and selectivity. In embodiments, the first metal may be nickel.86277-WO-PCT / DOW 86277 WO11

[0034] In embodiments, a catalyst for producing amines by reductive amination comprises an atomic ratio of the second metal to the third metal, wherein the ratio is an atomic ratio of the metal elements, that is from 0.5:1 to 10:1. For example, in embodiments the ratio may be from 0.5:1 to 10 :1, from 0.5:1 to 9.6:1, from 0.5:1 to 9.2:1, from 0.5:1 to 8.9:1, from 0.5:1 to 8.5:1, from 0.5:1 to 8.1 :1, from 0.5:1 to 7.7:1, from 0.5:1 to 7.3:1, from 0.5:1 to 7:1, from 0.5:1 to 6.6:1, from 0.5:1 to 6.2:1, from 0.5:1 to 5.8:1, from 0.5:1 to 5.4:1, from 0.5:1 to 5.1 :1, from 0.5:1 to 4.7:1, from 0.5:1 to 4.3:1, from 0.5:1 to 3.9:1, from 0.5:1 to 3.5:1, from 0.5:1 to 3.2:1, from 0.5:1 to 2.8:1, from 0.5:1 to 2.4:1, from 0.5:1 to 2:1, from 0.5:1 to 1.6:1, from 0.5:1 to 1.3:1, from 0.9:1 to 10:1, from 0.9:1 to 9.6:1, from 0.9:1 to 9.2:1, from 0.9:1 to 8.9:1, from 0.9:1 to 8.5:1, from 0.9:1 to 8.1 :1, from 0.9:1 to 7.7:1, from 0.9:1 to 7.3:1, from 0.9:1 to 7:1, from 0.9:1 to 6.6:1, from 0.9:1 to 6.2:1, from 0.9:1 to 5.8:1, from 0.9:1 to 5.4:1, from 0.9:1 to 5.1 :1, from 0.9:1 to 4.7:1, from 0.9:1 to 4.3:1, from 0.9:1 to 3.9:1, from 0.9:1 to 3.5:1, from 0.9:1 to 3.2:1, from 0.9:1 to 2.8:1, from 0.9:1 to 2.4:1, from 0.9:1 to 2:1, from 0.9:1 to 1.6:1, from 1.3:1 to 10:1, from 1.3:1 to 9.6:1, from 1.3:1 to 9.2:1, from 1.3:1 to 8.9:1, from 1.3:1 to 8.5:1, from 1.3:1 to 8.1 :1, from 1.3:1 to 7.7:1, from 1.3:1 to 7.3:1, from 1.3:1 to 7:1, from 1.3:1 to 6.6:1, from 1.3:1 to 6.2:1, from 1.3:1 to 5.8:1, from 1.3:1 to 5.4:1, from 1.3:1 to 5.1 :1, from 1.3:1 to 4.7:1, from 1.3:1 to 4.3:1, from 1.3:1 to 3.9:1, from 1.3:1 to 3.5:1, from 1.3:1 to 3.2:1, from 1.3:1 to 2.8:1, from 1.3:1 to 2.4:1, from 1.3:1 to 2:1, from 1.6:1 to 10:1, from 1.6:1 to 9.6:1, from 1.6:1 to 9.2:1, from 1.6:1 to 8.9:1, from 1.6:1 to 8.5:1, from 1.6:1 to 8.1 :1, from 1.6:1 to 7.7:1, from 1.6:1 to 7.3:1, from 1.6:1 to 7:1, from 1.6:1 to 6.6:1, from 1.6:1 to 6.2:1, from 1.6:1 to 5.8:1, from 1.6:1 to 5.4:1, from 1.6:1 to 5.1 :1, from 1.6:1 to 4.7:1, from 1.6:1 to 4.3:1, from 1.6:1 to 3.9:1, from 1.6:1 to 3.5:1, from 1.6:1 to 3.2:1, from 1.6:1 to 2.8:1, from 1.6:1 to 2.4:1, from 2:1 to 10:1, from 2:1 to 9.6:1, from 2:1 to 9.2:1, from 2:1 to 8.9:1, from 2:1 to 8.5:1, from 2:1 to 8.1 :1, from 2:1 to 7.7:1, from 2:1 to 7.3:1, from 2:1 to 7:1, from 2:1 to 6.6:1, from 2:1 to 6.2:1, from 2:1 to 5.8:1, from 2:1 to 5.4:1, from 2:1 to 5.1 :1, from 2:1 to 4.7:1, from 2:1 to 4.3:1, from 2:1 to 3.9:1, from 2:1 to 3.5:1, from 2:1 to 3.2:1, from 2:1 to 2.8:1, from 2.4:1 to 10:1, from 2.4:1 to 9.6:1, from 2.4:1 to 9.2:1, from 2.4:1 to 8.9:1, from 2.4:1 to 8.5:1, from 2.4:1 to 8.1 :1, from 2.4:1 to 7.7:1, from 2.4:1 to 7.3:1, from 2.4:1 to 7:1, from 2.4:1 to 6.6:1, from 2.4:1 to 6.2:1, from 2.4:1 to 5.8:1, from 2.4:1 to 5.4:1, from 2.4:1 to 5.1 :1, from 2.4:1 to 4.7:1, from 2.4:1 to 4.3:1, from 2.4:1 to 3.9:1, from 2.4:1 to 3.5:1, from 2.4:1 to 3.2:1, from 2.8:1 to 10:1, from 2.8:1 to 9.6:1, from 2.8:1 to 9.2:1, from 2.8:1 to 8.9:1, from 2.8:1 to 8.5:1, from 2.8:1 to 8.1 :1, from 2.8:186277-WO-PCT / DOW 86277 WO12 to 7.7:1, from 2.8:1 to 7.3:1, from 2.8:1 to 7:1, from 2.8:1 to 6.6:1, from 2.8:1 to 6.2:1, from 2.8:1 to 5.8:1, from 2.8:1 to 5.4:1, from 2.8:1 to 5.1 :1, from 2.8:1 to 4.7:1, from 2.8:1 to 4.3:1, from 2.8:1 to 3.9:1, from 2.8:1 to 3.5:1, from 3.2:1 to 10:1, from 3.2:1 to 9.6:1, from 3.2:1 to 9.2:1, from 3.2:1 to 8.9:1, from 3.2:1 to 8.5:1, from 3.2:1 to 8.1 :1, from 3.2:1 to 7.7:1, from 3.2:1 to 7.3:1, from 3.2:1 to 7:1, from 3.2:1 to 6.6:1, from 3.2:1 to 6.2:1, from 3.2:1 to 5.8:1, from 3.2:1 to 5.4:1, from 3.2:1 to 5.1 :1, from 3.2:1 to 4.7:1, from 3.2:1 to 4.3:1, from 3.2:1 to 3.9:1, from 3.5:1 to 10:1, from 3.5:1 to 9.6:1, from 3.5:1 to 9.2:1, from 3.5:1 to 8.9:1, from 3.5:1 to 8.5:1, from 3.5:1 to 8.1 :1, from 3.5:1 to 7.7:1, from 3.5:1 to 7.3:1, from 3.5:1 to 7:1, from 3.5:1 to 6.6:1, from 3.5:1 to 6.2:1, from 3.5:1 to 5.8:1, from 3.5:1 to 5.4:1, from 3.5:1 to 5.1 :1, from 3.5:1 to 4.7:1, from 3.5:1 to 4.3:1, from 3.9:1 to 10:1, from 3.9:1 to 9.6:1, from 3.9:1 to 9.2:1, from 3.9:1 to 8.9:1, from 3.9:1 to 8.5:1, from 3.9:1 to 8.1 :1, from 3.9:1 to 7.7:1, from 3.9:1 to 7.3:1, from 3.9:1 to 7:1, from 3.9:1 to 6.6:1, from 3.9:1 to 6.2:1, from 3.9:1 to 5.8:1, from 3.9:1 to 5.4:1, from 3.9:1 to 5.1 :1, from 3.9:1 to 4.7:1, from 4.3:1 to 10:1, from 4.3:1 to 9.6:1, from 4.3:1 to 9.2:1, from 4.3:1 to 8.9:1, from 4.3:1 to 8.5:1, from 4.3:1 to 8.1 :1, from 4.3:1 to 7.7:1, from 4.3:1 to 7.3:1, from 4.3:1 to 7:1, from 4.3:1 to 6.6:1, from 4.3:1 to 6.2:1, from 4.3:1 to 5.8:1, from 4.3:1 to 5.4:1, from 4.3:1 to 5.1 :1, from 4.7:1 to 10:1, from 4.7:1 to 9.6:1, from 4.7:1 to 9.2:1, from 4.7:1 to 8.9:1, from 4.7:1 to 8.5:1, from 4.7:1 to 8.1 :1, from 4.7:1 to 7.7:1, from 4.7:1 to 7.3:1, from 4.7:1 to 7:1, from 4.7:1 to 6.6:1, from 4.7:1 to 6.2:1, from 4.7:1 to 5.8:1, from 4.7:1 to 5.4:1, from 5.1 :1 to 10:1, from 5.1 :1 to 9.6:1, from 5.1 :1 to 9.2:1, from 5.1 :1 to 8.9:1, from 5.1 :1 to 8.5:1, from 5.1 :1 to 8.1 :1, from 5.1 :1 to 7.7:1, from 5.1 :1 to 7.3:1, from 5.1 :1 to 7:1, from 5.1 :1 to 6.6:1, from 5.1 :1 to 6.2:1, from 5.1 :1 to 5.8:1, from 5.4:1 to 10:1, from 5.4:1 to 9.6:1, from 5.4:1 to 9.2:1, from 5.4:1 to 8.9:1, from 5.4:1 to 8.5:1, from 5.4:1 to 8.1 :1, from 5.4:1 to 7.7:1, from 5.4:1 to 7.3:1, from 5.4:1 to 7:1, from 5.4:1 to 6.6:1, from 5.4:1 to 6.2:1, from 5.8:1 to 10:1, from 5.8:1 to 9.6:1, from 5.8:1 to 9.2:1, from 5.8:1 to 8.9:1, from 5.8:1 to 8.5:1, from 5.8:1 to 8.1 :1, from 5.8:1 to 7.7:1, from 5.8:1 to 7.3:1, from 5.8:1 to 7:1, from 5.8:1 to 6.6:1, from 6.2:1 to 10:1, from 6.2:1 to 9.6:1, from 6.2:1 to 9.2:1, from 6.2:1 to 8.9:1, from 6.2:1 to 8.5:1, from 6.2:1 to 8.1 :1, from 6.2:1 to 7.7:1, from 6.2:1 to 7.3:1, from 6.2:1 to 7:1, from 6.6:1 to 10:1, from 6.6:1 to 9.6:1, from 6.6:1 to 9.2:1, from 6.6:1 to 8.9:1, from 6.6:1 to 8.5:1, from 6.6:1 to 8.1 :1, from 6.6:1 to 7.7:1, from 6.6:1 to 7.3:1, from 7:1 to 10:1, from 7:1 to 9.6:1, from 7:1 to 9.2:1, from 7:1 to 8.9:1, from 7:1 to 8.5:1, from 7:1 to 8.1 :1, from 7:1 to 7.7:1, from 7.3:1 to 10:1, from 7.3:1 to 9.6:1, from 7.3:1 to 9.2:1, from 7.3:1 to 8.9:1, from 7.3:1 to86277-WO-PCT / DOW 86277 WO138.5:1, from 7.3:1 to 8.1 :1, from 7.7:1 to 10:1, from 7.7:1 to 9.6:1, from 7.7:1 to 9.2:1, from 7.7:1 to 8.9:1, from 7.7:1 to 8.5:1, from 8.1 :1 to 10:1, from 8.1 :1 to 9.6:1, from 8.1 :1 to 9.2:1, from 8.1 :1 to 8.9:1, from 8.5:1 to 10:1, from 8.5:1 to 9.6:1, from 8.5:1 to 9.2:1, from 8.9:1 to 10:1, from 8.9:1 to 9.6:1, or from 9.2:1 to 10:1. As used herein, the above ratio is a ratio of metal atoms and does not include non-metal components of compounds such as, for example, oxides or salts. In embodiments, the second metal may be rhenium. If the ratio is too high, cost may be prohibitively high; however, if the ratio is too low activity and selectivity may be reduced

[0035] In one or more embodiments, the catalyst does not comprise boron.

[0036] In embodiments, a catalyst may have a surface area from between 20 m2 / g to 140 m2 / g. For instance, in embodiments the carrier may have a surface area from between 20 m2 / g to 140 m2 / g, 20 m2 / g to 130 m2 / g, 20 m2 / g to 120 m2 / g, 20 m2 / g to 110 m2 / g, 20 m2 / g to 100 m2 / g, 20 m2 / g to 90 m2 / g, 20 m2 / g to 80 m2 / g, 20 m2 / g to 70 m2 / g, 20 m2 / g to 60 m2 / g, 20 m2 / g to 50 m2 / g, 20 m2 / g to 40 m2 / g, 20 m2 / g to 30 m2 / g, 30 m2 / g to 140 m2 / g, 30 m2 / g to 130 m2 / g, 30 m2 / g to 120 m2 / g, 30 m2 / g to 110 m2 / g, 30 m2 / g to 100 m2 / g, 30 m2 / g to 90 m2 / g, 30 m2 / g to 80 m2 / g, 30 m2 / g to 70 m2 / g, 30 m2 / g to 60 m2 / g, 30 m2 / g to 50 m2 / g, 30 m2 / g to 40 m2 / g, 40 m2 / g to 140 m2 / g, 40 m2 / g to 130 m2 / g, 40 m2 / g to 120 m2 / g, 40 m2 / g to 110 m2 / g, 40 m2 / g to 100 m2 / g, 40 m2 / g to 90 m2 / g, 40 m2 / g to 80 m2 / g, 40 m2 / g to 70 m2 / g, 40 m2 / g to 60 m2 / g, 40 m2 / g to 50 m2 / g, 50 m2 / g to 140 m2 / g, 50 m2 / g to 130 m2 / g, 50 m2 / g to 120 m2 / g, 50 m2 / g to 110 m2 / g, 50 m2 / g to 100 m2 / g, 50 m2 / g to 90 m2 / g, 50 m2 / g to 80 m2 / g, 50 m2 / g to 70 m2 / g, 50 m2 / g to 60 m2 / g, 60 m2 / g to 140 m2 / g, 60 m2 / g to 130 m2 / g, 60 m2 / g to 120 m2 / g, 60 m2 / g to 110 m2 / g, 60 m2 / g to 100 m2 / g, 60 m2 / g to 90 m2 / g, 60 m2 / g to 80 m2 / g, 60 m2 / g to 70 m2 / g, 70 m2 / g to 140 m2 / g, 70 m2 / g to 130 m2 / g, 70 m2 / g to 120 m2 / g, 70 m2 / g to 110 m2 / g, 70 m2 / g to 100 m2 / g, 70 m2 / g to 90 m2 / g, 70 m2 / g to 80 m2 / g, 80 m2 / g to 140 m2 / g, 80 m2 / g to 130 m2 / g, 80 m2 / g to 120 m2 / g, 80 m2 / g to 110 m2 / g, 80 m2 / g to 100 m2 / g, 80 m2 / g to 90 m2 / g, 90 m2 / g to 140 m2 / g, 90 m2 / g to 130 m2 / g, 90 m2 / g to 120 m2 / g, 90 m2 / g to 110 m2 / g, 90 m2 / g to 100 m2 / g, 100 m2 / g to 140 m2 / g, 100 m2 / g to 130 m2 / g, 100 m2 / g to 120 m2 / g, 100 m2 / g to 110 m2 / g, 110 m2 / g to 140 m2 / g, 110 m2 / g to 130 m2 / g, 110 m2 / g to 120 m2 / g, 120 m2 / g to 140 m2 / g, 120 m2 / g to 130 m2 / g, or 130 m2 / g to 140 m2 / g. If the catalyst surface area is too high, fabrication may be difficult; however, if the catalyst surface area is too low, catalyst activity may be low and selectivity of EDA may be reduced.86277-WO-PCT / DOW 86277 WO14

[0037] In embodiments, a catalyst may comprise a carrier, in which the carrier may have a surface area from between 30 m2 / g to 450 m2 / g. For instance, in embodiments the carrier may have a surface area from between 30 m2 / g to 450 m2 / g, 50 m2 / g to 450 m2 / g, 100 m2 / g to 450 m2 / g, 150 m2 / g to 450 m2 / g, 200 m2 / g to 450 m2 / g, 250 m2 / g to 450 m2 / g, 300 m2 / g to 450 m2 / g, 350 m2 / g to 450 m2 / g, 400 m2 / g to 450 m2 / g, 30 m2 / g to 400 m2 / g, 50 m2 / g to 400 m2 / g, 100 m2 / g to 400 m2 / g, 150 m2 / g to 400 m2 / g, 200 m2 / g to 400 m2 / g, 250 m2 / g to 400 m2 / g, 300 m2 / g to 400 m2 / g, 350 m2 / g to 400 m2 / g, 30 m2 / g to 350 m2 / g, 50 m2 / g to 350 m2 / g, 100 m2 / g to 350 m2 / g, 150 m2 / g to 350 m2 / g, 200 m2 / g to 350 m2 / g, 250 m2 / g to 350 m2 / g, 300 m2 / g to 350 m2 / g, 30 m2 / g to 300 m2 / g, 50 m2 / g to 300 m2 / g, 100 m2 / g to 300 m2 / g, 150 m2 / g to 300 m2 / g, 200 m2 / g to 300 m2 / g, 250 m2 / g to 300 m2 / g, 30 m2 / g to 250 m2 / g, 50 m2 / g to 250 m2 / g, 100 m2 / g to 250 m2 / g, 150 m2 / g to 250 m2 / g, 200 m2 / g to 250 m2 / g, 30 m2 / g to 200 m2 / g, 50 m2 / g to 200 m2 / g, 100 m2 / g to 200 m2 / g, 150 m2 / g to 200 m2 / g, 30 m2 / g to 150 m2 / g, 50 m2 / g to 150 m2 / g, 100 m2 / g to 150 m2 / g, 30 m2 / g to 100 m2 / g, 50 m2 / g to 100 m2 / g, 30 m2 / g to 50 m2 / g. If the carrier surface area is too high, selectivity to the desired ethyleneamines may be low; however, if the carrier surface area is too low, metal dispersion may be poor and activity and selectivity of the desired ethyleneamines may be low.

[0038] In embodiments, a catalyst may comprise an active component that is from 3 wt. % to 40 wt. %, based on the total weight of the catalyst. For instance, in embodiments the catalyst may comprise from 3 wt. % to 40 wt. %, from 3 wt. % to 35 wt. %, from 3 wt. % to 30 wt. %, from 3 wt. % to 25 wt. %, from 3 wt. % to 20 wt. %, from 3 wt. % to 15 wt. %, from 3 wt. % to 10 wt. %, from 1 wt. % to 5 wt. %, from 5 wt. % to 40 wt. %, from 5 wt. % to 35 wt. %, from 5 wt. % to 30 wt. %, from 5 wt. % to 25 wt. %, from 5 wt. % to 20 wt. %, from 5 wt. % to 15 wt. %, from 5 wt. % to 10 wt. %, from 10 wt. % to 40 wt. %, from 10 wt. % to 35 wt. %, from 10 wt. % to 30 wt. %, from 10 wt. % to 25 wt. %, from 10 wt. % to 20 wt. %, from 10 wt. % to 15 wt. %, from 15 wt. % to 40 wt. %, from 15 wt. % to 35 wt. %, from 15 wt. % to 30 wt. %, from 15 wt. % to 25 wt. %, from 15 wt. % to 20 wt. %, from 20 wt. % to 40 wt. %, from 20 wt. % to 35 wt. %„ from 20 wt. % to 30 wt. %, from 20 wt. % to 25 wt. %, from 30 wt. % to 40 wt. %, from 30 wt. % to 35 wt. %, or from 35 wt. % to 40 wt. % total active component. If the active component is too high, dispersion may be poor, reducing activity and selectivity; however, if the active component is too low, activity and conversion may be reduced. In embodiments, a catalyst may comprise from 2 wt. % to 30 wt. % nickel, based on the total weight of the catalyst. For instance, in embodiments the catalyst86277-WO-PCT / DOW 86277 WO15 may comprise nickel in amounts from 2 wt. % to 30 wt. %, from 2 wt. % to 25 wt. %, from 2 wt. % to 20 wt. %, from 2 wt. % to 10 wt. %, from 2 wt. % to 5 wt. %, from 5 wt. % to 30 wt. %, from 5 wt. % to 25 wt. %, from 5 wt. % to 20 wt. %, from 5 wt. % to 15 wt. %, from 5 wt. % to 10 wt. %, from 10 wt. % to 30 wt. %, from 10 wt. % to 25 wt. %, from 10 wt. % to 20 wt. %, from 10 wt. % to 15 wt. %, from 15 wt. % to 30 wt. %, from 15 wt. % to 25 wt. %, from 15 wt. % to 20 wt. %, from 20 wt. % to 30 wt. %, from 20 wt. % to 25 wt. %, or from 25 wt. % to 30 wt. % of the total catalyst. If the amount of nickel is too high, dispersion may be poor, reducing activity and selectivity; however, if the amount of nickel is too low, catalytic activity may be reduced.

[0039] In embodiments, a catalyst may comprise from 0.5 wt. % to 5 wt. % rhenium, based on the total weight of the catalyst (active components and carrier components). For instance, in embodiments the mass of rhenium may be from 0.5 wt. % to 5.0 wt.%, from 0.5 wt. % to 4.5 wt.%, from 0.5 wt.% to 4.0 wt.%, from 0.5 wt. % to 3.5 wt.%, from 0.5 wt.% to 3.0 wt.%, from 0.5 wt.% to 2.5 wt.%, from 0.5 wt.% to 2.0 wt.%, from 0.5 wt.% to 1.5 wt. %, from 0.5 wt. % to 1.0 wt. %, from 1.0 wt. % to 5.0 wt. %, from 1.0 wt. % to 4.5 wt. %, from 1.0 wt. % to 4.0 wt. %, from 1.0 wt. % to 3.5 wt. %, from 1.0 wt. % to 3.0 wt. %, from 1.0 wt. % to 2.5 wt. %, from 1.0 wt. % to 2.0 wt. %, from 1.0 wt. % to 1.5 wt. %, from 1.5 wt.% to 5.0 wt. %, from 1.5 wt.% to 4.5 wt.%, from 1.5 wt.% to 4.0 wt.%, from 1.5 wt.% to 3.5 wt.%, from 1.5 wt.% to 3.0 wt.%, from 1.5 wt.% to 2.5 wt.%, from 1.5 wt.% to 2.0 wt.%, from 2.0 wt.% to 5.0 wt.%, from 2.0 wt.% to 4.5 wt.%, from 2.0 wt.% to 4.0 wt.%, from 2.0 wt.% to 3.5 wt.%, from 2.0 wt.% to 3.0 wt.%, from 2.0 wt.% to 2.5 wt.%, from 2.5 wt.% to 5.0 wt.%, from 2.5 wt.% to 4.5 wt.%, from 2.5 wt.% to 4.0 wt.%, from 2.5 wt.% to 3.5 wt.%, from 2.5 wt.% to 3.0 wt.%, from 3.0 wt.% to 5.0 wt.%, from 3.0 wt.% to 4.5 wt.%, from 3.0 wt.% to 4.0 wt.%, from 3.0 wt.% to 3.5 wt.%, from 3.5 wt.% to 5.0 wt.%, from 3.5 wt.% to 4.5 wt.%, from 3.5 wt.% to 4.0 wt.%, from 4.0 wt.% to 5.0 wt.%, from 4.0 wt.% to 4.5 wt.%, or from 4.5 wt.% to 5.0 wt.% based on the total mass of the catalyst. If the mass of rhenium is too high, the manufacturing cost may increase without increase in selectivity to the desired ethyleneamines; however, if the mass of rhenium is too low, the selectivity to the desired ethyleneamine may be low.

[0040] In embodiments, a catalyst may comprise from 0.5 wt. % to 5 wt. % niobium, based on the total weight of the catalyst (active components and carrier components). For instance, in embodiments the mass of niobium may be from 0.5 wt. % to 5.0 wt.%, from 0.5 wt. % to86277-WO-PCT / DOW 86277 WO164.5 wt.%, from 0.5 wt.% to 4.0 wt.%, from 0.5 wt. % to 3.5 wt.%, from 0.5 wt.% to 3.0 wt.%, from 0.5 wt.% to 2.5 wt.%, from 0.5 wt.% to 2.0 wt.%, from 0.5 wt.% to 1.5 wt. %, from 0.5 wt. % to 1.0 wt. %, from 1.0 wt. % to 5.0 wt. %, from 1.0 wt. % to 4.5 wt. %, from 1.0 wt. % to 4.0 wt. %, from 1.0 wt. % to 3.5 wt. %, from 1.0 wt. % to 3.0 wt. %, from 1.0 wt. % to 2.5 wt. %, from 1.0 wt. % to 2.0 wt. %, from 1.0 wt. % to 1.5 wt. %, from 1.5 wt.% to 5.0 wt. %, from 1.5 wt.% to 4.5 wt.%, from 1.5 wt.% to 4.0 wt.%, from 1.5 wt.% to 3.5 wt.%, from 1.5 wt.% to 3.0 wt.%, from 1.5 wt.% to 2.5 wt.%, from 1.5 wt.% to 2.0 wt.%, from 2.0 wt.% to 5.0 wt.%, from 2.0 wt.% to 4.5 wt.%, from 2.0 wt.% to 4.0 wt.%, from 2.0 wt.% to 3.5 wt.%, from 2.0 wt.% to 3.0 wt.%, from 2.0 wt.% to 2.5 wt.%, from 2.5 wt.% to 5.0 wt.%, from 2.5 wt.% to 4.5 wt.%, from 2.5 wt.% to 4.0 wt.%, from 2.5 wt.% to 3.5 wt.%, from 2.5 wt.% to 3.0 wt.%, from 3.0 wt.% to 5.0 wt.%, from 3.0 wt.% to 4.5 wt.%, from 3.0 wt.% to 4.0 wt.%, from 3.0 wt.% to 3.5 wt.%, from 3.5 wt.% to 5.0 wt.%, from 3.5 wt.% to 4.5 wt.%, from 3.5 wt.% to 4.0 wt.%, from 4.0 wt.% to 5.0 wt.%, from 4.0 wt.% to 4.5 wt.%, or from 4.5 wt.% to 5.0 wt.% based on the total mass of the catalyst. If the mass of niobium is too high, the manufacturing cost may increase without increase in selectivity to the desired ethyleneamines; however, if the mass of niobium is too low, the selectivity to the desired ethyleneamine may be low.

[0041] Heterogeneous catalyst preparation commonly comprises incipient wetness impregnation, which is the most widely used method due to preparation simplicity, low costs, and limited amount of waste. Metal loading of incipient wetness impregnation is a function of the amount of active precursor or precursors based on solvent solubility. Incipient wetness impregnation is a traditional impregnation method that impregnates a carrier with one or more metal salts, which are precursors to metal catalysts. Often, the impregnation includes contacting a carrier with an aqueous solution formed from a mixture of metal salts to form an impregnated carrier. The impregnated carrier may then be calcined and reduced by known methods. However, it was discovered that mixing an aqueous niobium-containing salt solution to a salt comprising the first metal and / or the second metal, as described herein, in aqueous solution resulted in precipitation. This precipitation for a traditional incipient wetness impregnation method is problematic and can lead to lower metal dispersions and a less than desired metal loading for the catalyst.

[0042] It was discovered that the metal contents achieved in embodiments described hereinabove could not be achieved by a traditional incipient wetness technique. In86277-WO-PCT / DOW 86277 WO17 embodiments, to obtain the desired metal content in the catalysts, the catalysts are formed by unique impregnation methods disclosed herein.

[0043] In embodiments, a method for impregnation for preparing a catalyst comprises an initial impregnation, an initial calcining, a subsequent impregnation, a subsequent calcining, a reduction, cooling, and passivating. In embodiments, the initial impregnation step comprises contacting a carrier composite with an aqueous solution comprising the third metal to form a first impregnated carrier composite. In embodiments, the initial calcining comprises calcining the first impregnated carrier composite, thereby forming a first doped carrier. In embodiments, the subsequent impregnation step comprises contacting the first doped carrier with an aqueous solution comprising the first metal and the second metal to form a second impregnated carrier composite. In embodiments, the subsequent calcining comprises calcining the second impregnated carrier composite, thereby forming the second doped carrier. In embodiments, the second doped carrier is reduced by contacting the second doped carrier with a hydrogen flow, resulting in an unpassivated catalyst. In embodiments, the unpassivated catalyst is cooled and passivated to result in a catalyst.

[0044] In embodiments, a method for impregnation for preparing a catalyst comprises an initial impregnation, an initial calcining, a subsequent impregnation, a subsequent calcining, a reduction, cooling, and passivating. In embodiments, the initial impregnation step comprises contacting a carrier composite with an aqueous solution comprising only one of the first, the second, or the third metal to form a first impregnated carrier composite. In embodiments, the initial calcining comprises calcining the first impregnated carrier composite, thereby forming a first doped carrier. In embodiments, the subsequent impregnation step comprises a second impregnation step comprising contacting the first doped carrier with an aqueous solution comprising only one of the first, the second, or the third metal, but a metal different than the metal used in the first impregnation to form a second impregnated carrier composite. In embodiments the subsequent calcining comprises calcining the second impregnated carrier composite, thereby forming a second doped carrier. In embodiments, the method further comprises an additional impregnation after the subsequent impregnation. The additional impregnation step comprises contacting the second doped carrier with an aqueous solution comprising one of the first, the second, or the third metal, but a metal different than that use in the initial impregnation and the subsequent impregnation, to form a third impregnated carrier composite. In embodiments, an additional86277-WO-PCT / DOW 86277 WO18 calcining after the additional impregnation step is performed. In embodiments, the additional calcining comprises calcining the third impregnated carrier, thereby forming a third doped carrier. In embodiments, the third doped carrier is reduced by contacting the third doped carrier with hydrogen to form an unpassivated catalyst. In embodiments, the unpassivated catalyst is cooled and passivated to result in a catalyst.

[0045] In embodiments, a method for impregnating for preparing a catalyst comprises an initial impregnation, an initial calcining, a subsequent impregnation, a subsequent calcining, a reduction, cooling, and passivating. In embodiments, the initial impregnation step comprises contacting a carrier composite with an aqueous solution comprising the first metal and the second metal to form a first impregnated carrier composite. In embodiments, the initial calcining comprises calcining the first impregnated carrier composite, thereby forming the first doped carrier. In embodiments, the subsequent impregnation step comprises contacting the first doped carrier with an aqueous solution comprising the third metal to form a second impregnated carrier composite. In embodiments, the subsequent calcining comprises calcining the first impregnated carrier composite, thereby forming the second doped carrier. In embodiments, the second doped carrier is reduced by contacting the second doped carrier with hydrogen , to form an unpassivated catalyst. In embodiments, the unpassivated catalyst is cooled and passivated to result in a catalyst.

[0046] In embodiments, the method for preparing a catalyst comprising a carrier composite preparation step, an initial impregnation step, an initial calcining step, a subsequent impregnation step, a subsequent calcining step, an additional impregnation step, an additional calcining step, a reduction step, a cooling step, and a passivation step is performed greater than once to achieve maximum metal content in the catalyst.

[0047] In embodiments, the method for preparing a catalyst comprising a carrier composite preparation step, an initial impregnation step, an initial calcining step, a subsequent impregnation step, a subsequent calcining step, a reduction step, a cooling step, and a passivation step is performed greater than once to achieve maximum metal content in the catalyst.

[0048] In embodiments, a method for preparing a catalyst comprises a drying step, wherein the drying step comprises heating a carrier to remove moisture. In embodiment, the drying method occurs prior to initial impregnation. In embodiments, the drying method occurs prior to subsequent impregnation. In embodiments, the drying method occurs prior to additional86277-WO-PCT / DOW 86277 WO19 impregnation. In embodiments, the drying method occurs prior to calcining. In embodiments, the drying step may be performed at from 70 ° C to 200 ° C, for a duration of 2 to 72 hours.

[0049] For example, in embodiments, the drying temperature may be from 70 ° C to 200 ° C, from 70 ° C to 150 ° C, from 70 ° C to 100 ° C, from 100 ° C to 200 ° C, from 100 ° C to 150 ° C, from 150 ° C to 250 ° C. For example, in embodiments, the heat treatment duration may be from 2 to 72 hours, from 5 to 50 hours, from 5 to 30 hours, from 5 to 10 hours, from 20 to 72 hours, from 20 to 50 hours, from 20 to 30 hours, from 30 to 72 hours, from 30 to 50 hours, from 50 hours to 70 hours, or from 60 hours to 70 hours.

[0050] In embodiments of each of the impregnation methods described above, the reduction is conducted by contacting a doped carrier with a hydrogen containing gas at a flow rate from 30 to 60 Standard Liters Per Hour (SLPH), at a temperature from 250 °C to 650 °C, for a duration of 0.5 to 5 hours. For example, in embodiments, the flow rate may be from 30 to 50 SLPH, from 30 to 40 SLPH, from 40 to 50 SLPH, from 40 to 60 SLPH, or from 50 to 60 SLPH. For example, in embodiments, the reducing temperature may be from 250 °C to 600 °C, from 250 °C to 400 °C, from 300 °C to 650 °C, from 300 °C to 400 °C, from 350 °C to 650, from 350 °C to 400, or from 550 °C to 650. For example, in embodiments, the reducing duration may be from 0.5 to 4 hours, from 0.5 to 3 hours, from 0.5 to 2 hours, from 0.5 to 1 hours, from 1 to 5 hours, from 1 to 4 hours, from 1 to 3 hours, from 1 to 2 hours, from 2 to 5 hours, from 2 to 4 hours, from 2 to 3 hours, from 3 to 5 hours, from 3 to 4 hours, or from 4 to 5 hours. In one or more embodiment, the doped carrier is the second doped carrier. In one or more embodiment, the doped carrier is the third doped carrier. In one or more embodiments, the hydrogen containing gas is substantially pure H2.

[0051] In embodiments of each of the impregnation methods described above, the calcining is conducted at a temperature from 300 °C to 500 ° C. For example, in embodiments, the calcining temperature may be from 300 °C to 450 °C, from 300 °C to 400 °C, or from 450 °C to 500 °C.

[0052] In embodiments an aqueous solution is formed by dissolving ammonium niobate (V) oxalate hydrate in water.

[0053] In embodiments, a catalyst may comprise a carrier component selected from the group consisting of alumina, silica, and combinations thereof; and an active component comprising a first metal, a second metal, and a third metal, wherein the first metal is selected from the group consisting of cobalt, nickel, and copper, the second metal is selected from a86277-WO-PCT / DOW 86277 WO20 group consisting of rhenium, ruthenium, chromium, zinc, sodium, calcium, magnesium, strontium, lithium, potassium, barium, cesium, lanthanum, tungsten, iron, silver, titanium, manganese, aluminum, rhodium, platinum, palladium, iridium, and combinations thereof, and the third metal is niobium.

[0054] In embodiments, a catalyst may be used in a process for producing amines by reductive amination, wherein the process may comprise introducing a feed stream, the feed stream comprising an amino alcohol and a reducing agent, and hydrogen in a reaction zone of a reactor, contacting the feed stream with the catalyst in the reaction zone, and producing a product stream comprising ethyleneamines, wherein the reducing agent is ammonia.

[0055] In embodiments, a catalyst may be used in a process for producing amines by reductive amination, wherein the process may comprise introducing a feed stream, the feed stream comprising an amino alcohol and a reducing agent, and hydrogen in a reaction zone of a reactor, contacting the feed stream with the catalyst in the reaction zone, and producing a product stream comprising ethyleneamines, wherein the amino alcohol may be monoethanolamine.

[0056] In embodiments, the catalyst may be used in a process for producing amines by reductive amination, wherein the process may comprise an overall conversion of MEA may be from 20 wt. % to 99 wt. %. For example, the overall conversion of MEA may be from 20 wt. % to 90 wt. %, from 20 wt. % to 70 wt. %, from 20 wt. % to 50 wt. %, from 20 wt. % to 30 wt. %, from 30 wt. % to 99 wt. %, from 30 wt. % to 90 wt. %, from 30 wt. % to 70 wt. %, from 30 wt. % to 50 wt. %, from 50 wt. % to 99 wt. %, from 50 wt. % to 90 wt. %, from 50 wt. % to 70 wt. %, from 70 wt. % to 99 wt. %, from 70 wt. % to 90 wt. %, or from 90 wt. % to 99 wt. %.

[0057] In embodiments, the catalyst may be used in a process for producing amines by reductive amination, wherein the process may comprise a molar ratio of reducing agent to amino alcohol from 1 :10 to 45:1. For example, the molar ratio may be from 1 :10 to 45:1, from 1 :10 to 40:1, from 1 :10 to 35:1, 1 :10 to 30:1, from 1 :10 to 25:1, from 1 :10 to 20:1, from 1 :10 to 15:1, from 1 :10 to 10:1, from 1 :10 to 5:1, from 1 :10 to 1 :1, from 1 :10 to 1 :5, 1 :5 to 45:1, from 1 :5 to 40:1, from 1 :5 to 35:1, from 1 :5 to 30:1, from 1 :5 to 25:1, from 1 :5 to 20:1, from 1 :5 to 15:1, from 1 :5 to 10:1, from 1 :5 to 5:1, from 1 :5 to 1 :1, from 1 :1 to 45:1, from 1 :1 to 40:1, from 1 :1 to 35:1, from 1 :1 to 30:1, from 1 :1 to 25:1, from 1 :1 to 20:1, from 1 :1 to 15:1, from 1 :1 to 10:1, from 1 :1 to 5:1, from 5:1 to 30:1, from 5:1 to 25:1, from 5:1 to86277-WO-PCT / DOW 86277 WO2120:1, from 5:1 to 15:1, from 5:1 to 10:1, from 10:1 to 30:1, from 10:1 to 25:1, from 10:1 to 20:1, from 10:1 to 15:1, from 15:1 to 30:1, from 15:1 to 25:1, from 15:1 to 20:1, from 20:1 to 30:1, from 20:1 to 25:1, or from 25:1 to 30:1 reducing agent to amino alcohol. If the molar ratio of the reducing agent to amino alcohol is too high, more energy may be required for the separation and recycle process of the reducing agent; however, if the molar ratio of the reducing agent to amino alcohol is too low, selectivity to desired ethyleneamines may decrease and numerous side reactions may occur.

[0058] In embodiments, the catalyst may be used in a process for producing amines by reductive amination, wherein the process may be from 750 psi to 4000 psi, from 750 psi to 3500 psi, from 750 psi to 3000 psi, from 750 psi to 2500 psi, from 750 psi to 2000 psi, from 750 psi to 1500 psi, from 750 psi to 1000 psi, from 1000 psi to 4000 psi, from 1000 psi to 3500 psi, from 1000 psi to 3000 psi, from 1000 psi to 2500 psi, from 1000 psi to 2000 psi, from 1000 psi to 1500 psi, from 1500 psi to 4000 psi, from 1500 psi to 3500 psi from 1500 psi to 3000 psi, from 1500 psi to 2500 psi, from 1500 psi to 2000 psi, from 2000 psi to 4000 psi, from 2000 psi to 3500 psi, from 2000 psi to 3000 psi, or from 2500 psi to 3000 psi. If the pressure is too high, more energy consumption may be required; however, if the pressure is too low, the catalyst may lose activity and desired reactions may not occur.

[0059] In embodiments, the catalyst may be used in a process for producing amines by reductive amination, wherein the process may be conducted at a temperature that is from 120 °C to 300 °C. For instance, in embodiments the temperature may be from 120 °C to 275 °C, from 120 °C to 250 °C, from 120 °C to 225 °C, from 120 °C to 200 °C, from 120 °C to 175 °C, from 120 °C to 150 °C, from 150 °C to 300 °C, from 150 °C to 275 °C, from 150 °C to 250 °C, from 150 °C to 225 °C, from 150 °C to 200 °C, from 150 °C to 175 °C, from 175 °C to 300 °C, from 175 °C to 275 °C, from 175 °C to 250 °C, from 175 °C to 225 °C, from 175 °C to 200 °C, from 200 °C to 300 °C, from 200 °C to 275 °C, from 200 °C to 250 °C, from 200 °C to 225 °C, from 225 °C to 300 °C, , from 225 °C to 275 °C, from 225 °C to 250 °C, from 250 °C to 300 °C, from 250 °C to 275 °C, or from 275 °C to 300 °C. If the temperature is too high, this may result in higher energy consumption and significant side reactions may occur; however, if the temperature is too low, catalyst activity and conversion may be low.

[0060] In embodiments, a catalyst may be used in a process for producing amines by reductive amination, wherein the process may comprise introducing a feed stream, the feed stream comprising an amino alcohol and a reducing agent, and hydrogen in a reaction zone86277-WO-PCT / DOW 86277 WO22 of a reactor, contacting the feed stream with the catalyst in the reaction zone, and producing a product stream comprising ethyleneamines, the feed stream further comprising water, and the mass of the water may be less than or equal to 30 wt. % of the mass of amino alcohol in the feed stream. For instance, in embodiments the mass of water may be less than or equal to 25 wt. %, 20 wt. %, 15 wt. %, or less than or equal to 10 wt. % of the mass of amino alcohol in the feed stream. If the mass of the water is too high catalyst stability and production rate may be reduced, and more wastewater may be generated.

[0061] In embodiments, a catalyst may be used in a process for producing amines by reductive amination, wherein the process may comprise introducing a feed stream, the feed stream comprising an amino alcohol and a reducing agent, and hydrogen in a reaction zone of a reactor, contacting the feed stream with the catalyst in the reaction zone, and producing a product stream comprising ethyleneamines, wherein hydrogen may be supplied to the reaction zone as a separate stream from the amino alcohol and the reducing agent.

[0062] In embodiments, a catalyst may be used in a process for producing amines by reductive amination, wherein the process may comprise introducing a feed stream, the feed stream comprising an amino alcohol and a reducing agent, and hydrogen in a reaction zone of a reactor, contacting the feed stream with the catalyst in the reaction zone, and producing a product stream comprising ethyleneamines, wherein hydrogen may be supplied to the reaction zone as a component of the feed stream, which also includes the amino alcohol and the reducing agent.

[0063] In embodiments, a catalyst may be used in a process for producing amines by reductive amination, wherein the process may comprise introducing a feed stream, the feed stream comprising an amino alcohol and a reducing agent, and hydrogen in a reaction zone of a reactor, contacting the feed stream with the catalyst in the reaction zone, and producing a product stream comprising ethyleneamines, wherein the concentration of hydrogen in the reaction zone relative to the total quantity of H2, MEA, and NH3 may be from 0.0001 mol.% to 50 mol.%. For instance, in embodiments, the concentration of hydrogen in the reaction zone relative to the total quantity of H2, MEA, and NH3 may be from 0.0001 mol.% to 45 mol.%, from 0.0001 mol.% to 40 mol.%, from 0.0001 mol.% to 35 mol.%, from 0.0001 mol.% to 30 mol.%, from 0.0001 mol.% to 25 mol.%, from 0.0001 mol.% to 20 mol.%, from 0.0001 mol.% to 15 mol.%, from 0.0001 mol.% to 10 mol.%, from 0.0001 mol.% to 5 mol.%, from 5 mol.% to 50 mol.%, from 5 mol.% to 45 mol.%, from 5 mol.% to 30 mol.%, from 5 mol.%86277-WO-PCT / DOW 86277 WO23 to 35 mol.%, from 5 mol.% to 25 mol.%, from 5 mol.% to 20 mol.%, from 5 mol.% to 15 mol.%, from 5 mol.% to 10 mol.%, from 10 mol.% to 50 mol.%, from 10 mol.% to 45 mol.%, from 10 mol.% to 40 mol.%, from 10 mol.% to 35 mol.%, from 10 mol.% to 30 mol.%, from 10 mol.% to 25 mol.%, from 10 mol.% to 20 mol.%, from 10 mol.% to 15 mol.%, from 15 mol.% to 50 mol.%, from 15 mol.% to 45 mol.%, from 15 mol.% to 40 mol.%, from 15 mol.% to 35 mol.%, from 15 mol.% to 30 mol.%, from 15 mol.% to 25 mol.%, from 15 mol.% to 20 mol.%, from 20 mol.% to 50 mol.%, from 20 mol.% to 45 mol.%, from 20 mol.% to 40 mol.%, from 20 mol.% to 35 mol.%, from 20 mol.% to 30 mol.%, from 20 mol.% to 25 mol.%, from 25 mol.% to 50 mol.%, from 25 mol.% to 45 mol.%, from 25 mol.% to 40 mol.%, from 25 mol.% to 35 mol.%, from 25 mol.% to 30 mol.%, from 30 mol.% to 50 mol.%, from 30 mol.% to 45 mol.%, from 30 mol.% to 40 mol.%, from 30 mol.% to 35 mol.%, from 35 mol.% to 50 mol.%, from 35 mol.% to 45 mol.%, from 35 mol.% to 40 mol.%, from 40 mol.% to 50 mol.%, from 40 mol.% to 45 mol.%, or from 45 mol.% to 50 mol.%. If too much hydrogen is present in the reaction zone, selectivity may be decreased. Additionally, if too little hydrogen is present in the reaction zone the catalyst may deactivate or lose activity.

[0064] In embodiments, a catalyst may be used in a process for producing amines by reductive amination, wherein the process may comprise introducing a feed stream, the feed stream comprising an amino alcohol and a reducing agent, and hydrogen in a reaction zone of a reactor, contacting the feed stream with the catalyst in the reaction zone, and producing a product stream comprising ethyleneamines, wherein the feed stream may be fed into the reaction zone at a space velocity (SV) from 0.5 hr'1to 13 hr'1. For instance, in embodiments the space velocity of the feed stream may be from 0.5 hr'1to 12 hr'1, from 0.5 hr'1to 11 hr'1, from 0.5 hr'1to 10 hr'1, from 0.5 hr'1to 9 hr'1, from 0.5 hr'1to 8 hr'1, from 0.5 hr'1to 7 hr'1, from 0.5 hr'1to 6 hr'1, from 0.5 hr'1to 5 hr'1, from 0.5 hr'1to 4 hr'1, from 0.5 hr'1to 3 hr'1, from 0.5 hr'1to 2 hr'1, from 0.5 hr'1to 1 hr'1, from 1 hr'1to 13 hr'1, from 1 hr'1to 12 hr'1, from1 hr'1to 11 hr'1, from 1 hr'1to 10 hr'1, from 1 hr'1to 9 hr'1, from 1 hr'1to 8 hr'1, from 1 hr'1to 7 hr'1, from 1 hr'1to 6 hr'1, from 1 hr'1to 5 hr'1, from 1 hr'1to 4 hr'1, from 1 hr'1to 3 hr'1, from 1 hr'1to 2 hr'1, from 2 hr'1to 13 hr'1, from 2 hr'1to 12 hr'1, from 2 hr'1to 11 hr'1, from2 hr'1to 10 hr'1, from 2 hr'1to 9 hr'1, from 2 hr'1to 8 hr'1, from 2 hr'1to 7 hr'1, from 2 hr'1to 6 hr'1, from 2 hr'1to 5 hr'1, from 2 hr'1to 4 hr'1, from 2 hr'1to 3 hr'1, from 3 hr'1to 13 hr'1, from 3 hr'1to 12 hr'1, from 3 hr'1to 11 hr'1, from 3 hr'1to 10 hr'1, from 3 hr'1to 9 hr'1, from86277-WO-PCT / DOW 86277 WO243 hr'1to 8 hr'1, from 3 hr'1to 7 hr'1, from 3 hr'1to 6 hr'1, from 3 hr'1to 5 hr'1, from 3 hr'1to 4 hr'1, from 5 hr'1to 13 hr'1, from 5 hr'1to 12 hr'1, from 5 hr'1to 11 hr'1, from 5 hr'1to 10 hr'1, from 5 hr'1to 9 hr'1, from 5 hr'1to 8 hr'1, from 5 hr'1to 7 hr'1, from 5 hr'1to 6 hr'1, from 10 hr'1to 13 hr'1, from 10 hr'1to 12 hr'1, from 10 hr'1to 11 hr'1, from 11 hr'1to 13 hr'1, from 11 hr'1to 12 hr'1, or from 12 hr'1to 13 hr'1. If the space velocity of the feed stream is too high, the conversion will be low; however, if the space velocity of the feed stream is too low, selectivity of EDA may be reduced.

[0065] In embodiments, a catalyst may comprise of one or more active components in which the one or more active components are impregnated into the carrier component.

[0066] In embodiments, a catalyst in may comprise a carrier component in which the carrier component is alumina. In another embodiment the carrier component is silica. In yet another embodiment the carrier component may comprise a mixture of alumina and silica.

[0067] In embodiments, a catalyst may be used in a process for producing amines by reductive amination, wherein the process may comprise introducing a feed stream, the feed stream comprising an amino alcohol and a reducing agent, and hydrogen in a reaction zone of a reactor, contacting the feed stream with the catalyst in the reaction zone, and producing a product stream comprising ethyleneamines, the process may comprise a selectivity of EDA in the product composition (not including unreacted MEA) from 50% to 99%. For example, selectivity of EDA may be from 50% to 95%, from 50% to 90%, from 50% to 85%, from 50% to 80%, from 50% to 75%, from 50% to 70%, from 50% to 65%, from 50% to 60%, from 50% to 55%, from 55% to 99%, from 55% to 95%, from 55% to 90%, from 55% to 85%, from 55% to 80%, from 55% to 75%, from 55% to 70%, from 55% to 65%, from 55% to 60%, from 60% to 99%, from 60% to 95%, from 60% to 90%, from 60% to 85%, from 60% to 80%, from 60% to 75%, from 60% to 70%, from 60% to 65%, from 65% to 99%, from 65% to 95%, from 65% to 90%, from 65% to 85%, from 65% to 80%, from 65% to 75%, from 65% to 70%, from 70% to 99%, from 70% to 95%, from 70% to 90%, from 70% to 85%, from 70% to 80%, from 70% to 75%, from 75% to 99%, from 75% to 95%, from 75% to 90%, from 75% to 85%, from 75% to 80%, from 80% to 99%, from 80% to 95%, from 80% to 90%, from 80% to 85%, from 85% to 99%, from 85% to 95%, from 85% to 90%, from 90% to 99%, from 90% to 95%, or from 95% to 99%.

[0068] Without intending to be bound by any particular theory, it is believed the process described herein may be used for reductive amination and producing a product having an86277-WO-PCT / DOW 86277 WO25 increased selectivity of EDA at higher MEA conversion compared to methods using conventional catalysts.EXAMPLES

[0069] The various embodiments disclosed herein will be further clarified by the following examples. The examples are illustrative in nature, and should not be understood to limit the embodiments disclosed herein.Catalyst Example 1 Preparation

[0070] Catalyst Example 1 is formed from a carrier component and an active component. A precursor salt of each respective metal was dissolved in distilled water to form an impregnation solution. In each case, the carrier was impregnated with the metal solution to incipient wetness and gently agitated until all the liquid had been adsorbed. The manufacture of Catalyst Example 1 comprises a carrier composite preparation step, a first impregnation step, a first calcining step, a second impregnation step, a second calcining step, a reduction step, a cooling step, and a passivation step. A detailed description of the catalyst preparation steps may be reviewed in patent EP 0737514 Al.CARRIER COMPONENT

[0071] The preparation of a carrier composite of this example is carried out in the manner described in patent EP 0737669 Al, which is incorporated herein by reference, in which the preparation comprises drying the carrier composite at 70 °C for 24 hr to remove excess moisture. The carrier component of the present example comprises 80 wt. % alumina and 20 wt. % silica. The carrier component of the present example is comprised of 1 / 8” diameter extrudates.ACTIVE COMPONENT

[0072] The active component of Catalyst Example 1 comprises nickel as the first metal of the active component. The second metal of the active component in Catalyst Example 1 is rhenium. The third metal of the active component in Catalyst Example 1 is niobium. In order to manufacture a catalyst comprising a carrier component and an active component, an impregnation step may be included. Each active component is impregnated into the carrier component by an impregnation step to manufacture Catalyst Example 1.First Impregnation and First Calcining

[0073] The third metal of the active component, niobium, was introduced to the carrier solution in the first impregnation step. Specifically, an aqueous solution of ammonium86277-WO-PCT / DOW 86277 WO26 niobate (V) oxalate hydrate was prepared by dissolving 5.54 g ammonium niobate (V) oxalate hydrate (product number 525839 from MilliporeSigma) in deionized water in a first vessel. A second vessel was charged with 151 g of the carrier. The contents of the first vessel was transferred to the second vessel to allow contact between the aqueous ammonium niobate (V) oxalate hydrate with the carrier to create the first impregnated carrier.

[0074] To remove residual impurities or volatile substances and promote thermal decomposition of the niobium salt from the first impregnated carrier, the first impregnated carrier was calcined by hydrothermally treating in air. The first impregnated carrier was calcined at 340 °C for 3 hours, resulting in a first doped carrier.Second Impregnation and Second Calcining

[0075] The first metal of the active component, nickel, was introduced to the carrier solution in the second impregnation step. Additionally, the second metal of the active component, rhenium, was introduced to the carrier solution in the second impregnation step. Specifically, an aqueous solution of nickel nitrate hexahydrate and ammonium perrhenate was prepared by dissolving 69.01 g nickel nitrate hexahydrate (product number 203874 from MilliporeSigma) and dissolving 5.14 g ammonium perrhenate (product number 316954 from MilliporeSigma) in deionized water in a first vessel. A second vessel was charged with the first doped carrier. The contents of the first vessel was transferred to the second vessel to allow contact between the aqueous nickel nitrate hexahydrate and the aqueous ammonium perrhenate with the first doped carrier to create a second impregnation carrier.

[0076] To remove residual impurities or volatile substances and promote thermal decomposition of the nickel and rhenium salts from the second impregnation carrier, the second impregnation carrier was calcined by hydrothermally treating in air. The second impregnation carrier was calcined at 340 °C for 3 hours, resulting in a second doped carrier.Reduction

[0077] A reduction in part of the doped metals was instigated on the second doped carrier under hydrogen flow and heat. The second doped carrier was contacted with a hydrogen flow at 340 °C. The hydrogen flowed at 41.6 SLPH for 3 hours. The reduction of the second doped carrier resulted in an unpassivated Experiment 1 catalyst.Cooling

[0078] The unpassivated Experiment 1 catalyst was cooled to below 100 °C in hydrogen. After cooling to below 100 °C, the catalyst was further cooled under nitrogen.86277-WO-PCT / DOW 86277 WO27Passivation

[0079] Catalyst passivation refers to the formation of a protective oxide layer on the active metal particles that prevent their oxidation when exposed to air, stabilizing the catalyst. The unpassivated Experiment 1 catalyst was passivated by exposing the catalyst to a mixture of oxygen and nitrogen at room temperature. Approximately 180 seem (standard cubic centimeters) of 5% O2 / N2 and 420 seem of N2 were introduced to the catalyst until the exotherm peaked and then cooled to room temperature. At no time was the exotherm allowed to exceed 70 °C.

[0080] The carrier composite preparation step, the first impregnation step, the first calcining step, the second impregnation step, the second calcining step, the reduction step, the cooling step, and the passivation step were repeated until approximately 500 g of catalyst was generated. Each series of steps using approximately 150 g carrier component will yield approximately 170 g catalyst material.

[0081] Catalyst Example 1 carrier component is 80 wt. % alumina and 20 wt. % silica. Catalyst Example 1 active components mass to the total catalyst weight (carrier component and active component) is 8.2 wt. % nickel, 2.1 wt. % rhenium, and 1.0 wt. % niobium. The Catalyst Example 1 surface area is 110 m2 / g. Catalyst Example 1 is a solid particle extrudate of 1 / 8” diameter.Comparative Catalyst Example A Preparation

[0082] Comparative Catalyst Example A comprises boron, nickel, and rhenium. Comparative Catalyst Example A comprises a carrier component and an active component. A detailed description of the catalyst preparation steps may be reviewed in patent EP 0737514 Al.

[0083] The preparation of a carrier composite of this example is carried out in the manner described in patent EP 0737669 Al. Due to the low water solubility of boric acid, higher temperature at 70 °C was used to dissolve boric acid in water. The carrier component is 80 wt. % alumina and 20 wt. % silica. The active components mass to the total catalyst weight (carrier component and active component) is 8.0 wt. % nickel, 2.1 wt. % rhenium, and 1.6 wt. % boron. The Comparative Catalyst Example A surface area is 107 m2 / g (as described in WO2001066247 A2). Comparative Catalyst Example A is a solid particle extrudates of 1 / 8” diameter.REACTION PERFORMANCE EXAMPLES86277-WO-PCT / DOW 86277 WO28

[0084] Reaction Examples 1 to 2 and Comparative Reaction Examples A to B compare the performance of each of the catalysts described herein. The results favor a mass-based approximation to selectivity rather than a molar formula often described in textbooks. This approach is used for easier comparison with mass-based production ratios calculated by technical centers and production personnel. All mass-based selectivities reported herein use the mass-based definition given below.

[0086] Similarly, conversion is presented on a weight basis, wherein conversion refers specifically to the conversion of MEA in the influent stream. Mass conversion of MEA may be calculated by the below formula., wt% of MEA in the feed-wt% of MEA in the product . > _

[0087] MEA Conversion = - - - - - - - - - x 100 wt% of MEA in the feedReaction Conditions

[0088] The main properties of effluent stream resulting from Example Catalyst 1, andComparative Example Catalyst A were characterized by gas chromatography (GC) among other techniques. For example, metal concentrations were characterized using Inductively Coupled Plasma (ICP). The reaction performances were evaluated in a 1 inch by 8 foot upflow, heterogeneous catalyst packed bed reactor with a tubular reaction zone containing the catalyst. The reactor bed is made of 0.81 inch inner diameter seamless Swagelok tubing.

[0089] For each respective run, the reactor was packed with the respective catalyst. Any material inside of the reactor was removed prior to each reaction run. Reaction Examples 1 and 2 were performed after packing a reactor with 400 g Catalyst Example 1. Comparative Reactions A and B were performed after packing the reactor with 400 g Comparative Catalyst Example A. Reaction Example 1 and Comparative Reaction Example A took place under Reaction Condition 1, which was at 1500 psig, 25 SLPH H2, 3.2 mol. % H2, 7 mL / min MEA flow, 17.4 mol / hr-kg cat MEA SV, 10 mL / min NH3, and temperatures from 161 °C to 178 °C. Reaction Example 2 and Comparative Reaction Example B took place at Reaction Condition 2, which was at 1900 psig, 29 SLPH H2, 2.7 mol. % H2, 10.3 mL / min MEA flow, 25.6 mol / hr-kg cat MEA SV, 17.1 mL / min NH3, and temperatures from 157 °C to 177 °C.

[0090] The feed material was 99 percent pure MEA (from Dow Chemical Company). The MEA was pumped in a continuous, uninterrupted flow from two 500 mL ISCO syringe pumps. The MEA feed stream passed through a pre-heater before entering the reactor. Before86277-WO-PCT / DOW 86277 WO29 entering the reactor, a separate stream of hydrogen gas and ammonia contact the MEA feed stream. The hydrogen was supplied from a 6000 psi hydrogen cylinder. The ammonia supply was supplied from 500 psi ammonia cylinders. The ammonia was pumped into the MEA stream in a continuous, uninterrupted flow from two 500 mL ISCO syringe pumps. The reductive amination reaction examples were conducted in a temperature range of 157-177 °C.Results - Conversion and Selectivity

[0091] Conversion of MEA and selectivity of EDA are measured from Reaction Example 1, Reaction Example 2, Comparative Reaction Example A, and Comparative Reaction Example B.

[0092] Catalyst performance was measured by conversion percentage of MEA and EDA selectivity under Reaction Condition 1 and Reaction Condition 2. FIG. 1 shows the MEA conversions measured from Example Catalyst 1 and Comparative Example Catalyst A at Reaction Condition 1, which was conducted at 1500 psig, 25 SLPH EE, 3.2 mol. % EE, 7 mL / min MEA flow, 17.4 mol / hr-kg cat MEA SV, 10 mL / min NE , and from 161 °C to 178 °C. The results demonstrate that the Example Catalyst 1 gave higher activities in converting MEA compared to Comparative Example Catalyst A. FIG. 2 and FIG. 3 present the MEA conversions and EDA selectivities measured over Example Catalyst 1 and Comparative Example Catalyst A under Reaction Condition 2, which was conducted at 1900 psig, 29 SLPH H2, 2.7 mol. % H2, 10.3 mL / min MEA flow, 25.6 mol / hr-kg cat MEA SV, 17.1 mL / min NH3, and from 157 °C to 177 °C. Similar to FIG. 1, FIG. 2 indicates that higher MEA conversions can be achieved over the Example Catalyst 1 than Comparative Example Catalyst A when the reactions are conducted under the same temperatures. The EDA selectivity vs MEA conversion plot, as shown in FIG. 3, demonstrates that the Example Catalyst 1 gives higher EDA selectivities compared to the Comparative Example Catalyst A under the same MEA conversions.

[0093] It will be apparent to persons of ordinary skill in the art that various modifications and variations can be made without departing from the scope disclosed herein. Since modifications, combinations, sub combinations, and variations of the disclosed embodiments, which incorporate the spirit and substance disclosed herein, may occur to persons of ordinary skill in the art, the scope disclosed herein should be construed to include everything within the scope of the appended claims and their equivalents.86277-WO-PCT / DOW 86277 WO30

[0094] For the purposes of defining the present technology, the transitional phrase “consisting of’ may be introduced in the claims as a closed preamble term limiting the scope of the claims to the recited components or steps and any naturally occurring impurities. For the purposes of defining the present technology, the transitional phrase “consisting essentially of’ may be introduced in the claims to limit the scope of one or more claims to the recited elements, components, materials, or method steps as well as any non-recited elements, components, materials, or method steps that do not materially affect the novel characteristics of the claimed subject matter. The transitional phrases “consisting of’ and “consisting essentially of’ may be interpreted to be subsets of the open-ended transitional phrases, such as “comprising” and “including,” such that any use of an open ended phrase to introduce a recitation of a series of elements, components, materials, or steps should be interpreted to also disclose recitation of the series of elements, components, materials, or steps using the closed terms “consisting of’ and “consisting essentially of.” For example, the recitation of a composition “comprising” components A, B, and C should be interpreted as also disclosing a composition “consisting of’ components A, B, and C as well as a composition “consisting essentially of’ components A, B, and C. Any quantitative value expressed in the present application may be considered to include open-ended embodiments consistent with the transitional phrases “comprising” or “including” as well as closed or partially closed embodiments consistent with the transitional phrases “consisting of’ and “consisting essentially of.”

[0095] As used in the Specification and appended Claims, the singular forms “a”, “an”, and “the” include plural references unless the context clearly indicates otherwise. The verb “comprises” and its conjugated forms should be interpreted as referring to elements, components or steps in a non-exclusive manner. The referenced elements, components or steps may be present, utilized or combined with other elements, components or steps not expressly referenced.

[0096] It should be understood that any two quantitative values assigned to a property may constitute a range of that property, and all combinations of ranges formed from all stated quantitative values of a given property are contemplated in this disclosure. The subject matter disclosed herein has been described in detail and by reference to specific embodiments. It should be understood that any detailed description of a component or feature of an embodiment does not necessarily imply that the component or feature is essential to the86277-WO-PCT / DOW 86277 WO31 particular embodiment or to any other embodiment. Further, it should be apparent to those skilled in the art that various modifications and variations can be made to the described embodiments without departing from the spirit and scope of the claimed subject matter.

Claims

86277-WO-PCT / DOW 86277 WO32CLAIMS1. A catalyst comprising: a carrier component selected from the group consisting of alumina, silica, and combinations thereof; and an active component comprising a first metal, a second metal, and a third metal, wherein the first metal is selected from the group consisting of cobalt, nickel, and copper, the second metal is selected from a group consisting of rhenium, ruthenium, chromium, zinc, sodium, calcium, magnesium, strontium, lithium, potassium, barium, cesium, lanthanum, tungsten, iron, silver, titanium, manganese, aluminum, rhodium, platinum, palladium, iridium, and combinations thereof, and the third metal is niobium.

2. The catalyst of claim 1, wherein the carrier component is a mixture of alumina and silica.

3. The catalyst of claim 1 or 2, wherein the active component is impregnated into the carrier component by incipient wetness.

4. The catalyst of any one of claims 1 to 3, wherein the active component is from 3 wt. % to 40 wt. % of the total catalyst.

5. The catalyst of any one of claims 1 to 4, wherein the first metal is nickel and the second metal is rhenium.

6. The catalyst of claim 5, wherein the total nickel content in the total catalyst is from 2 wt.% to 30 wt.% of the total catalyst.

7. The catalyst of claim 5, wherein the total nickel content in the catalyst is from 7 wt.% to 9.5 wt.% of the catalyst.86277-WO-PCT / DOW 86277 WO338. The catalyst of claim 5, wherein the total rhenium content in the total catalyst is from 0.5 wt.% to 5.0 wt.% of the total catalyst.

9. The catalyst of claim 5, wherein the total rhenium content in the catalyst is from 1.5 wt.% to 3 wt.% of the catalyst.

10. The catalyst of any one of claims 1 to 9, wherein the total niobium content in the total catalyst is from 0.5 wt.% to 5.0 wt.% of the total catalyst.

11. The catalyst of any one of claims 1 to 10, wherein an atomic ratio of rhenium to niobium is from 0.5:1 to 10:1.

12. The catalyst of any one of claims 1 to 11, wherein an atomic ratio of nickel to niobium is from 1 :1 to 50:1.

13. The catalyst of any one of claims 1 to 12, wherein an atomic ratio of nickel to rhenium is from 1 :1 to 50:1.

14. The catalyst of any one of claims 1 to 13, wherein the catalyst surface area is from 20 m2 / g to 140 m2 / g.

15. The catalyst of claim 14, wherein the catalyst surface area is from 70 m2 / g to 120 m2 / g.

16. The catalyst of any one of claims 1 to 15, wherein the carrier surface area is from 30 m2 / g to 450 m2 / g.

17. The catalyst of any one of claims 1 to 16, wherein the carrier component comprises: from 65 wt.% to 95 wt.% alumina; and from 5 wt.% to 35 wt.% silica.86277-WO-PCT / DOW 86277 WO3418. A method for preparing the catalyst of any one of claims 1 to 17, the method comprising: an initial impregnation, wherein the initial impregnation comprises a homogenous solution made from mixing one or more metal salts, wherein a metal of the one or more metal salts comprise a first metal, a second metal, a third metal, or combinations thereof a calcination step; a subsequent impregnation, wherein the subsequent impregnation comprises one or more homogenous solution made from mixing one or more metal salts, wherein the one or more metal salts comprise the first metal, the second metal, the third metal, or combinations thereof, a subsequent calcination; and a reduction, wherein at least one of the initial impregnation and the subsequent impregnation utilizes ammonium niobium (V) oxalate as a metal salt, the first metal is selected from the group consisting of cobalt, nickel, and copper, the second metal is selected from a group consisting of rhenium, ruthenium, chromium, zinc, sodium, calcium, magnesium, strontium, lithium, potassium, barium, cesium, lanthanum, tungsten, iron, silver, titanium, manganese, aluminum, rhodium, platinum, palladium, iridium, and combinations thereof, and the third metal is niobium;.

19. A method for preparing the catalyst of claim 18, wherein the initial impregnation utilizes a homogenous mixture made from mixing a metal salt comprising the first metal and a metal salt comprising the second metal, and the subsequent impregnation utilizes a homogenous solution made from a metal salt comprises the third metal.

20. A method for preparing the catalyst of claim 18, wherein the initial impregnation utilizes a homogenous solution made from a metal salt comprises the third metal, andThe subsequent impregnation utilizes a homogenous mixture made from mixing a metal salt comprising the first metal and a metal salt comprising the second metal.86277-WO-PCT / DOW 86277 WO3521. A method for preparing the catalyst of claim 18, wherein the method comprises an additional impregnation, wherein the initial impregnation utilizes a homogenous mixture made from mixing a metal salt comprising only one of the first metal, the second metal, or the third metal, the subsequent impregnation utilizes a homogenous mixture made from mixing a metal salt comprising only one of the first metal, the second metal, or the third metal that is different from the metal used in the homogenous mixture of the initial impregnation, and the additional impregnation utilizes a homogenous mixture made from mixing a metal salt comprising only one of the first metal, the second metal, or the third metal that is different from the metal used in the homogenous mixture of the initial impregnation and different from the metal used in the homogeneous mixture of the subsequent impregnation.

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