Catalyst composite and methods of making and using
A catalyst composite includes an agglomerate of a plurality of catalyst composite components and a binder. The catalyst composites may be useful as a catalyst in a variety of chemical processes including hydrogenation, dehydrogenation, hydrogenolysis, oxidation, reduction, alkylation, dealkylation, carbonylation, decarbonylation, coupling, isomerization, amination, deamination, or hydrodehalogenation.
1 . A catalyst composite comprising:
an agglomerate of a plurality of catalyst composite components and a binder, wherein the catalyst composite components comprise a reactive species, a support, a promoter, an ion exchange material, or a combination comprising at least one of the foregoing catalyst composite components.
2 . The catalyst composite of claim 1 , wherein at least a portion of the reactive species is disposed onto a surface of at least a potion of the support.
3 . The catalyst composite of claim 1 , wherein at least a portion of the promoter is disposed onto the surface of at least a potion of the support.
4 . The catalyst composite of claim 1 , wherein at least a portion of the ion exchange material is disposed onto the surface of at least a potion of the support.
5 . The catalyst composite of claim 1 , wherein at least a potion of the reactive species, promoter, and ion exchange material is disposed onto the surface of at least a potion of the support.
6 . The catalyst composite of claim 1 , wherein the reactive species comprises a metal or metal oxide comprising an element of Groups 3-10 and 14 of a Periodic Table of Elements.
7 . The catalyst composite of claim 6 , wherein the reactive species comprises a precious metal.
8 . The catalyst composite of claim 7 , wherein the reactive species further comprises a non-precious metal.
9 . The catalyst composite of claim 8 , wherein a molar ratio of the precious metal to the non-precious metal is about 0.3:1 to about 100:1.
10 . The catalyst composite of claim 1 , wherein the support comprises an oxide, mixed oxide, zeolite, alumina, silica, aluminosilicate, carbonate, clay, ceramic, carbon, or a combination comprising at least one of the foregoing.
11 . The catalyst composite of claim 1 , wherein the promoter comprises a composition comprising a Group 3-7 or 14 element, a Rare Earth element, or a combination comprising at least one of the foregoing elements of the Periodic Table of Elements.
12 . The catalyst composite of claim 1 , wherein the binder comprises a non-crosslinked thermoplastic polymer, crosslinked thermoplastic polymer, or a combination comprising at least one of the foregoing binder materials.
13 . The catalyst composite of claim 1 , wherein the reactive species, whether supported or unsupported, is in an amount of about 0.01 to about 99 weight percent (wt %), the support is in an amount of about 20 to about 99 wt %, the promoter, whether supported or unsupported, is in an amount of less than or equal to about 60 wt %, the ion exchange material, whether supported or unsupported, is in an amount of less than or equal to about 60 wt %, and the binder is in an amount of about 0.01 to about 25 wt % binder, and wherein the weight percent is based on the total weight of the catalyst composite.
14 . A method for making a catalyst composite comprising:
mixing a plurality of catalyst composite components with a binder to fonn a mixture, wherein the catalyst composite components comprise a reactive species, a support, a promoter, an ion exchange material, or a combination comprising at least one of the foregoing catalyst composite components; and
processing the mixture to form the catalyst composite, wherein the catalyst composite comprises an agglomerate of a plurality of catalyst composite components held together with the binder.
15 . The method of claim 14 , further comprising:
disposing at least a portion of the reactive species, promoter, ion exchange material, or a combination comprising at least a portion of at least one of the foregoing onto a surface of at least a portion of the support prior to the mixing.
16 . The method of claim 14 , further comprising grinding the plurality of catalyst composite components into fine powdered particles prior to the mixing.
17 . The method of claim 14 , further comprising disposing the mixture onto a surface of a larger support prior to processing.
18 . The method of claim 14 , further comprising activating the reactive species.
19 . The method of claim 14 , wherein the processing comprises heat and pressure treating.
20 . The method of claim 14 , further comprising:
grinding the catalyst composite into finely ground particles of catalyst composite;
disposing the finely ground particles of catalyst composite onto a surface of a larger support particle; and
processing the finely ground particles of catalyst composite disposed onto the surface of the larger support particle to form a complex catalyst composite.
21 . A method for catalyzing a chemical process, comprising:
contacting a reaction mixture with catalyst composite, wherein the catalyst composite comprises an agglomerate of a plurality of catalyst composite components and a binder, wherein the catalyst composite components comprise a reactive species, a support, a promoter, an ion exchange material, or a combination comprising at least one of the foregoing catalyst composite components; and
increasing a reaction rate for the reaction mixture to produce a product.
22 . The method of claim 21 , wherein the chemical process comprises hydrogenation, dehydrogenation, hydrogenolysis, oxidation, reduction, alkylation, dealkylation, carbonylation, decarbonylation, coupling, isomerization, amination, deamination, and hydrodehalogenation.
23 . The method of claim 21 , wherein the chemical process comprises oxidative production of a halogen oxide from an alkali metal halite solution.