Catalyst and method of manufacture
A method for making a solid material which is useful as a heterogeneous catalyst including the steps of: forming at least one copper oxide suspension comprising solid particles of copper oxide in a liquid; forming at least one carrier suspension comprising solid particles of a carrier material in a liquid; combining the copper oxide suspension and the carrier suspension; subjecting the combined suspensions to mechanical energy; separating the suspension liquid from the solid particles in the combined suspension; and subjecting the solid material to a thermal decomposition step. A catalyst made by the method has a BET surface area greater than 150 m 2 /g, a particle size distribution in which D 50 is in the range from 25-35 μm, and wherein the D 50 after 60 minutes ultrasound treatment is at least 30% of the original value.
1. A solid particulate catalyst comprising copper oxide and a solid carrier material, wherein said solid particulate catalyst is in the form of a powder having a BET surface area greater than 150 m 2 /g, a particle size distribution in which D 50 is in the range from 25-35 μm, and wherein the D 50 after 60 minutes ultrasound treatment is at least 30% of the original value.
2. A solid particulate catalyst according to claim 1 which is obtainable by the preparation method of comprising the steps of:
(a) forming at least one copper oxide suspension comprising solid particles of copper oxide in a liquid;
(b) forming at least one carrier suspension comprising solid particles of a carrier material in a liquid;
(c) combining the copper oxide suspension and the carrier suspension;
d) subjecting the combined suspensions to mechanical energy;
(e) separating the suspension liquid from the solid particles in the combined suspension; and
(f) subjecting the separated solid particles to a thermal decomposition step.
3. A solid particulate catalyst according to any claim 1 , wherein the carrier material comprises a metal oxide.
4. A solid particulate catalyst according to claim 3 , wherein the carrier material comprises silica-alumina, silica, alumina, zirconia or titania.
5. A method for making the solid particulate catalyst of claim 1 which is useful as a heterogeneous catalyst comprising the steps of:
(a) forming at least one copper oxide suspension comprising solid particles of copper oxide in a liquid;
(b) forming at least one carrier suspension comprising solid particles of a carrier material in a liquid;
(c) combining the copper oxide suspension and the carrier suspension;
(d) subjecting the combined suspensions to mechanical energy;
(e) separating the suspension liquid from the solid particles in the combined suspension; and
(f) subjecting the separated solid particles to a thermal decomposition step.
6. A method according to claim 5 consisting essentially of steps (a)-(f).
7. A method according to claim 5 , wherein the material comprises from 5% to 90% by weight of copper oxide.
8. A method according to claim 5 , wherein step (d) comprises subjecting the combined suspensions to a milling or grinding process.
9. A method according to claim 5 , wherein in step (d) the mechanical energy applied to the combined suspensions is greater than 500 W/liter.
10. A method according to claim 5 , wherein the carrier material comprises a metal oxide.
11. A method according to claim 10 , wherein the carrier material comprises silica-alumina, silica, alumina, zirconia or titania.
12. A process for carrying out a chemical reaction selected from the type of reaction including hydrogenation, hydrogenolysis, amination and dehydrogenation, comprising adding a solid particulate catalyst according to claim 1 to a reaction mixture.
13. The process according to claim 12 , wherein the reaction is for hydrogenation of carbonyl groups.
14. The process according to claim 13 , wherein the reaction is for the production of a fatty alcohol.