Copper Catalyst Liquid Phase Reduction Velocity Control
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Solution Overview
Problem
Conventional methods for preparing copper-containing hydrogenation catalysts face challenges in achieving high catalytic activity without degrading solvent purity, particularly due to limitations in reduction temperature and catalyst deactivation.
Innovation Solution
A method involving liquid phase reduction of a molded copper-containing catalyst precursor using hydrogen gas or a hydrogen-inert gas mixture at 50 to 150°C, with a controlled reduction velocity of 1.2% to 2.0% by weight/hour, in the presence of a solvent that prevents solvent impurity and maintains catalyst activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid phase reduction is conducted at high temperature (above 150°C) to increase catalytic activity, then catalytic activity improves, but solvent purity decreases due to generation of ester wax and hydrocarbon by-products
Solution Approach 1:
The invention changes the reduction temperature parameter to a specific range (50-150°C, preferably 70-130°C) and controls the reduction velocity parameter (1.2-2.0% by weight/hour) to achieve optimal balance between catalytic activity and solvent purity. This parameter optimization resolves the contradiction by finding the sweet spot where catalytic activity is sufficiently high while solvent degradation is minimized.
Solution Approach 2:
The invention dynamically controls the reduction velocity during the reduction process, adjusting it to maintain within 1.2-2.0% by weight/hour. This dynamic control allows the system to adapt the reduction rate to prevent excessive temperature effects that would degrade solvent purity, while still achieving high catalytic activity through controlled progression.
2Ease of manufacture
If gas phase reduction is used to activate the catalyst, then the process is simple and well-established, but the activation time is excessively long (4-14 days) reducing productivity
Solution Approach 1:
The invention transitions from gas phase reduction to liquid phase reduction, using liquid hydrogen or hydrogen-containing liquid mixture as the reducing agent. This hydraulic approach enables much faster reduction kinetics compared to gas phase, reducing activation time from 4-14 days to just 0.5-5 hours while maintaining process control and simplicity.
Solution Approach 2:
The invention utilizes the phase transition aspect by employing liquid phase hydrogen instead of gas phase hydrogen for the reduction process. The liquid phase provides better contact and faster reaction kinetics with the copper-containing catalyst precursor, dramatically accelerating the activation process while maintaining ease of operation.
3Productivity
If reduction velocity is increased to reduce activation time, then productivity improves, but catalyst deactivation occurs due to water and fatty acid formation
Solution Approach 1:
The invention optimizes the reduction velocity parameter to a specific range (1.2-2.0% by weight/hour) that prevents catalyst deactivation. This controlled parameter change ensures that reduction proceeds fast enough for practical productivity (0.5-5 hours) but slow enough to avoid excessive water and fatty acid formation that would deactivate the catalyst.
Solution Approach 2:
The invention implements feedback control by monitoring the reduction progress and adjusting the reduction velocity to maintain within the optimal range. This feedback mechanism prevents catalyst deactivation by detecting when reduction is approaching completion and preventing excessive reduction conditions that would generate deactivating by-products.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the preparation of a copper-containing hydrogenation catalyst with high activity and long lifespan, producing high-quality alcohols at a low cost without compromising solvent purity, thus enhancing industrial productivity.
Implementation Method 1
reducing a molded precursor of the copper-containing hydrogenation catalyst by supplying hydrogen gas or a mixture of hydrogen gas with an inert gas
Implementation Method 2
subjecting a carboxylic acid or a carboxylic acid ester to catalytic reduction with hydrogen in the presence of the prepared copper-containing hydrogenation catalyst
Data Source
AI summary
The present invention provides a method of preparing the copper-containing hydrogenation catalyst having high activity by liquid phase reduction without decreasing purity of the solvent and a method for efficiently producing an alcohol. The present invention provides the method of preparing the copper-containing hydrogenation catalyst, including reducing a molded precursor of the copper-containing hydrogenation catalyst by supplying hydrogen gas or a mixture of hydrogen gas with an inert gas at a temperature of 50 to 150°C in the presence of a solvent to obtain the copper-containing hydrogenation catalyst, wherein the reduction is conducted at an average reduction velocity of the copper-containing hydrogenation catalyst of not more than 3.0% by weight/hour. The present invention also provides the method of producing an alcohol, including preparing the copper-containing hydrogenation catalyst by the method of preparation, and subjecting a carboxylic acid or a carboxylic acid ester to catalytic reduction with hydrogen in the presence of the prepared copper-containing hydrogenation catalyst.