Extruded Cu-Al-Mn Catalyst for Hydrogenation
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Solution Overview
Problem
Conventional catalysts in tablet form have high mechanical stability but restricted pore volume, limiting reaction accessibility, while extrudate catalysts have lower stability and performance issues due to binder effects.
Innovation Solution
The development of Cu—Al—Mn catalyst bodies in extruded form, using specific binders to create stable shapes with high pore volume, comprising copper, aluminum, and manganese, processed through precipitation, drying, mixing with aluminum-containing binders, extrusion, and calcination, to achieve enhanced stability and activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If catalysts are produced in tablet form with high compression, then mechanical stability is improved, but pore volume is reduced and access to active centers is restricted
Solution Approach 1:
The invention changes the processing parameters from high-compression tableting to extrusion at lower compression pressures. This parameter change allows the catalyst to maintain mechanical stability through the extrusion process while preserving significantly higher pore volume (0.35-1.0 cm³/g) compared to tableted catalysts, thereby resolving the contradiction between strength and pore volume.
Solution Approach 2:
The invention replaces the tableting mechanical process with an extrusion process. Instead of compressing powder into tablets under high pressure, the slurry is forced through a die to form cylindrical extrudates. This substitution of the mechanical forming method inherently preserves pore structure while providing adequate mechanical strength for industrial use.
2Volume of stationary object
If extrudate form is used to increase pore volume, then access to active centers is improved, but mechanical stability decreases
Solution Approach 1:
The invention uses composite material formulation combining copper chromite active phase with specific binders (alumina, silica, titania) and structural promoters. This composite approach allows the extrudate to achieve both high pore volume (0.35-1.0 cm³/g) and adequate mechanical stability (side crushing strength ≥ 5 N/mm) simultaneously, resolving the contradiction between pore accessibility and mechanical strength.
Solution Approach 2:
The invention optimizes extrusion parameters including slurry composition, water content, extrusion pressure, and drying conditions. By carefully controlling these parameters, the extrudates achieve sufficient mechanical strength without compromising the high pore volume structure, thus resolving the stability-pore volume contradiction.
3Shape
If conventional binders are used in extrudates, then shaped bodies can be formed, but catalyst performance is adversely affected
Solution Approach 1:
The invention extracts or removes conventional organic binders that adversely affect catalyst performance. Instead, it uses inorganic binder materials (alumina, silica, titania) that do not interfere with catalytic activity. This extraction of harmful binder components while maintaining shaped body formation capability resolves the contradiction between shape integrity and catalyst performance.
Solution Approach 2:
The invention introduces inorganic binder materials as intermediary substances that serve dual functions: providing structural integrity for shaped body formation and maintaining catalytic performance. These inorganic binders act as mediators between the requirement for shaped catalyst bodies and the need for high catalyst activity, resolving the performance-shape contradiction.
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
The Cu—Al—Mn catalyst bodies exhibit higher pore volume and comparable stability to conventional tablets, with improved activity and selectivity in hydrogenation reactions, such as fatty acid ester conversion to alcohols, while maintaining mechanical stability.
Implementation Method 1
combining (i) at least one aqueous solution of copper compounds, aluminum compounds, manganese compounds, and optionally transition metal compounds and (ii) at least one aqueous carbonate-containing solution to form a precipitate
Implementation Method 2
calcining the extrudate obtained in step (c), at a temperature in the range from 300 to 750° C., preferably in the range from 600° C. to 750° C., more particularly at about 750° C., to give an extruded shaped body
Implementation Method 3
The shaped catalyst bodies are suitable for hydrogenating organic compounds which contain a carbonyl function, more particularly for hydrogenating aldehydes, ketones, and also carboxylic acids and/or their esters
Data Source
AI summary
The invention relates to Cu—Al—Mn shaped catalyst bodies in extruded form, and to a process for their preparation. The shaped catalyst body is suitable for the hydrogenation of organic compounds containing a carbonyl function, in particular for the hydrogenation of aldehydes, ketones and carboxylic acids and/or their esters. In particular, the shaped catalyst body is suitable for the hydrogenation of fatty acids or their esters, such as fatty acid methyl esters, to form the corresponding alcohols and dicarboxylic acid anhydrides, such as maleic anhydride, or esters of di-acids and di-alcohols, such as butane diol.