Methods for dispersal of catalyst promoters
The present invention describes improved methods of introducing promoters to catalysts. This invention provides a method for dispersal of a promoter onto a solid surface. A catalyst material and a deliquescent material can together be contacted with a gas phase comprising a solvent under conditions effective for deliquescence whereby the promoter is dispersed onto the solid surface. This invention combines practical benefits of dry-mixing with the enhanced dispersion that can be realized by solvent-based methods.
1. A method for dispersal of a promoter onto a solid surface, said method comprising:
(i) providing a catalyst material comprising a solid surface that is at least partially hydrophilic;
(ii) providing a deliquescent material comprising, in free or combined form, a promoter;
(iii) mixing said catalyst material and said deliquescent material, thereby creating a mixture; and
(iv) contacting said mixture with a gas phase comprising a solvent, under conditions effective for deliquescence, whereby said promoter is dispersed onto said solid surface.
2. The method of claim 1 , wherein said solvent is polar.
3. The method of claim 2 , wherein said solvent is water.
4. The method of claim 2 , wherein said solvent is selected from the group consisting of C 1 -C 3 alcohols, liquid amines, and polar aprotic solvents.
5. The method of claim 4 , wherein said solvent is DMF.
6. The method of claim 1 , wherein said solvent is non-polar.
7. The method of claim 6 , wherein said non-polar solvent is selected from the group consisting of hydrocarbons, ethers, and halocarbons.
8. The method of claim 1 , wherein said gas phase comprises an inert gas.
9. The method of claim 1 , wherein said gas phase comprises air.
10. A method for dispersal of a promoter onto a solid surface, said method comprising:
(i) providing a catalyst material comprising a solid surface that is at least partially hydrophilic;
(ii) providing a deliquescent material comprising, in free or combined form, a promoter;
(iii) mixing said catalyst material and said deliquescent material, thereby creating a mixture; and
(iv) contacting said mixture with a gas phase comprising a solvent, under conditions effective for deliquescence and at a temperature such that said solvent is condensable, whereby said promoter is dispersed onto said solid surface.
11. The method of claim 1 or 10 , wherein said deliquescent material is K 2 CO 3 and said promoter is potassium.
12. The method of claim 1 , wherein said catalyst material comprises a non-polar material selected from the group consisting of organic polymers, elemental carbon, and transition metal sulfides.
13. The method of claim 1 , wherein said solid surface has catalytic activity, and said promoter enhances said catalytic activity.
14. The method of claim 13 , wherein said catalytic activity causes the conversion of syngas into a mixture comprising one or more C 1 -C 4 alcohols.
15. The method of claim 14 , wherein said catalyst material comprises cobalt, molybdenum, and sulfur.
16. The method of claim 1 or 10 , wherein said promoter dispersal is substantially uniform.
17. The method of claim 1 , further comprising the step of loading a material or mixture obtained from any of steps (i)-(iv) into a reactor.
18. The method of claim 17 , wherein the promoter is dispersed before the catalyst is loaded into said reactor.
19. The method of claim 1 , further comprising use of the promoted catalyst for the conversion of syngas into at least one C 1 -C 4 alcohol.
20. The method of claim 19 , wherein at least one of said C 1 -C 4 alcohols is ethanol.
21. A method for producing at least one C 1 -C 4 alcohol, said method comprising
(i) providing a catalyst material comprising a solid surface that is at least partially hydrophilic;
(ii) providing a deliquescent material comprising, in free or combined form, a promoter;
(iii) mixing said catalyst material and said deliquescent material, thereby creating a mixture;
(iv) contacting said mixture with a gas phase comprising a solvent, under conditions effective for deliquescence, whereby said promoter is dispersed onto said solid surface, thereby generating a promoted catalyst; and
(v) contacting said promoted catalyst with syngas to produce at least one C 1 -C 4 alcohol.
22. The method of claim 21 , wherein at least one of said C 1 -C 4 alcohols is ethanol.