Manganese oxide-stabilized zirconia catalyst support materials
View Patent ↗The present disclosure relates generally to catalyst support materials, catalysts and methods for using them, such as methods for converting sugars, sugar alcohols, glycerol, and bio-renewable organic acids to commercially-valuable chemicals and intermediates. One aspect of the invention is catalyst support material including ZrO 2 and one or more oxides of manganese (MnO x ), the catalyst support material being at least about 50 wt % ZrO 2 and MnO x . In certain embodiments, the weight ratio of ZrO 2 to MnO x is within the range of about 1:1 to about 30:1; and/or the catalyst support material is substantially free of any binder, extrusion aid or additional stabilizing agent.
1. A catalyst material comprising
a catalyst support material comprising ZrO 2 and one or more oxides of manganese (MnO x ), the catalyst support material containing about 1 wt % to about 20 wt % of MnO x , the total amount of ZrO 2 and MnO x being at least about 85 wt % of the catalyst support material, and
a catalyst metal disposed on the catalyst support material.
2. A catalyst material according to claim 1 , wherein the the total amount of ZrO 2 and MnO x in the catalyst support material is at least about 95 wt %.
3. A catalyst material according to claim 1 , wherein the weight ratio of ZrO 2 to MnO x in the catalyst support material is within the range of about 5:1 to about 25:1.
4. A catalyst material according to claim 1 , wherein the catalyst support material further comprises one or more oxides of yttrium and/or lanthanum, wherein the molar ratio of the ZrO 2 to the oxides of yttrium and/or lanthanum is within the range of about 10:1 to about 100:1.
5. A catalyst material according to claim 1 , wherein the catalyst support material has a pore volume within the range of about 0.1 to about 0.5 cm 3 /g.
6. A catalyst material according to claim 1 , wherein the catalyst support material has a surface area within the range of about 10 to about 400 m 2 g.
7. A catalyst material according to claim 1 , wherein the catalyst support material has crush strength within the range of about 45 N/cm to about 222 N/cm.
8. A catalyst material according to claim 1 , wherein the catalyst support material is substantially free of any binder, extrusion aid or additional stabilizing agent.
9. A catalyst material according to claim, wherein the catalyst support material comprises 1 wt. % to 10 wt. % nickel oxide.
10. A catalyst material according to claim 1 , wherein at least about 80 wt % of the ZrO 2 is in a tetragonal phase, and less than about 20 wt % of the ZrO 2 is in a monoclinic phase.
11. A catalyst material according to claim 1 , wherein the ZrO 2 is in an amorphous phase.
12. A method for making a catalyst material according to claim 1 , comprising extruding a zirconia/manganese oxide precursor material in the absence of any binder, extruding aid or additional stabilizing agent.
13. A catalyst material comprising a catalyst support material according to claim 1 , and a catalyst disposed on the catalyst support material, wherein the catalyst metal comprises Ni, Cu, Co, Fe, Ru, Rh, Pd, Ag, Re, Os, Ir, Pt, Au, Bi, Sb, or a combination thereof.
14. A method for conducting a catalytic reaction comprising contacting one or more reactants with a catalyst material according to claim 1 , wherein at least one of the reactants is in the aqueous phase, and wherein the reaction is conducted at a temperature within the range of 50 ° C. to 325 ° C., and a pressure within the range of about 10 bar to about 250 bar.
15. A method for converting a sugar, sugar alcohol or glycerol into a polyol or an alcohol comprising a shorter carbon-chain backbone, the method comprising contacting the sugar, sugar alcohol or glycerol with a catalyst material according to claim 1 and hydrogen.
16. A method according to claim 15 , wherein the reaction is conducted at a temperature within the range of 50 ° C. to 325 ° C., and a pressure within the range of about 10 bar to about 250 bar.
17. A method according to claim 15 , wherein converting the sugar, sugar alcohol or glycerol is achieved with at least 40% efficiency, and a total carbon atom selectivity of at least 70 mol %.
18. A method of hydrogenating an organic acid, the method comprising contacting organic acid with a catalyst material according to claim 13 and hydrogen.
19. A method according to claim 15 , wherein the catalyst metal comprises Ni, Cu, Co, Fe, Ru, Rh, Pd, Ag, Re, Os, Ir, Pt, Au, Bi, Sb, or a combination thereof.
20. A method according to claim 15 , wherein the catalyst metal is NiCu, NiSb, Ni, Cu, Ru, or NiCuBi.
21. A method according to claim 18 , wherein the catalyst metal comprises Ni, Cu, Co, Fe, Ru, Rh, Pd, Ag, Re, Os, Ir, Pt, Au, Bi, Sb, or a combination thereof.
22. A catalyst material comprising a catalyst support material according to claim 1 , wherein the catalyst metal NiCu, NiSb, Ni, Cu, Ru, or NiCuBi.
23. A catalyst material comprising a catalyst support material according to claim 1 , wherein the catalyst support material contains about 1 wt % to about 15 wt % of MnO x .