COMPOSITION OF CATALYSTS FOR CONVERSION OF ETHANOL TO N-BUTANOL AND HIGHER ALCOHOLS
A method of producing a catalyst comprises forming a decomposed material comprising a decomposed hydrotalcite, a decomposed hydrocalumite, or a combination of both, combining the decomposed material with a mixture to form a catalyst mixture, and heating the catalyst mixture to convert the metal salt to a metal oxide. The mixture comprises a metal salt and a chelating agent, and the resulting metal oxide combined with the decomposed material forms the catalyst.
1 . A method for producing a higher alcohol comprising:
contacting a reactant comprising ethanol with a catalyst at a reaction temperature and pressure sufficient to produce a reaction product, wherein the catalyst comprises a decomposed hydrotalcite, a decomposed hydrocalumite, or a combination of both mixed with one or more metal oxides, wherein the reaction product comprises a higher alcohol, unreacted ethanol, and an ester;
separating the unreacted ethanol from the reaction product;
separating substantially all of the ester from the unreacted ethanol to form an ethanol recycle stream; and
recycling the ethanol recycle stream to contact the catalyst.
2 . The method of claim 1 , wherein the catalyst is formed by combining a decomposed material with a mixture to form a catalyst mixture, wherein the mixture comprises a metal salt and a chelating agent; and heating the catalyst mixture to convert the metal salt to a metal oxide, wherein the resulting metal oxide combined with the decomposed material forms the catalyst.
3 . The method of claim 1 , wherein the higher alcohol comprises a C 4 -C 13 alcohol.
4 . The method of claim 1 , wherein the higher alcohol is butanol.
5 . The method of claim 1 , wherein a conversion of ethanol to the higher alcohol is at least about 10%.
6 . The method of claim 1 , wherein a selectivity of the conversion of ethanol to the higher alcohol is at least about 90%.
7 . The method of claim 1 , wherein the one or more metal oxides comprise one or more metals selected from the group consisting of: Pd, Cu, Pt, Cr, Ni, Fe, Ru, Rh, and Co.
8 . The method of claim 1 , wherein the one or more metal oxides comprises an alkaline salt, an alkaline earth salt, or any combination thereof.
9 . The method of claim 1 , wherein the catalyst further comprises a support material.
10 . The method of claim 1 , wherein the reactant and the ethanol recycle stream are substantially free of esters.
11 . The method of claim 7 , wherein the one or more metal oxides comprise one or more metals of Pd or Cu.
12 . The method of claim 7 , wherein the one or more metal oxides comprise one or more metals of Pd.
13 . A method of producing a catalyst comprising:
decomposing material to form a decomposed hydrotalcite, a decomposed hydrocalumite, or a combination of both;
combining the decomposed material with a mixture to form a catalyst mixture, wherein the mixture comprises a metal salt; and
heating the catalyst mixture to convert the metal salt to a metal oxide, wherein the resulting metal oxide combined with the decomposed material forms the catalyst, and wherein at least one of the decomposing or the heating comprises applying heat at a temperature between 600° C. and 750° C.
14 . The method of claim 13 , wherein forming the decomposed material comprises heating a material comprising hydrotalcite, hydrocalumite, or both, to a temperature in a range of 350° C. to 800° C.
15 . The method of claim 14 , wherein heating the catalyst mixture comprises heating the material to a temperature between about 300° C. and about 800° C.
16 . The method of claim 13 , wherein the process further comprises:
mixing a second metal salt with the material prior to heating the material.
17 . The method of claim 16 , wherein the second metal salt comprises an alkaline salt, an alkaline earth salt, or any combination thereof.
18 . The method of claim 13 , wherein the metal salt comprises one or more metals selected from the group consisting of: Pd, Cu, Pt, Cr, Ni, Fe, Ru, Rh, and Co.
19 . The method of claim 13 , wherein the catalyst has a surface area of between about 20 m 2 /g to about 100 m 2 /g.
20 . The method of claim 13 , wherein the catalyst has a pore volume of between about 0.05 cm 3 /g and about 0.4 cm 3 /g.