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CN112076762B - 制备新戊二醇用催化剂 - Google Patents

制备新戊二醇用催化剂 Download PDF

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CN112076762B
CN112076762B CN202011075540.8A CN202011075540A CN112076762B CN 112076762 B CN112076762 B CN 112076762B CN 202011075540 A CN202011075540 A CN 202011075540A CN 112076762 B CN112076762 B CN 112076762B
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oxide
neopentyl glycol
aluminum
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CN112076762A (zh
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卢文新
刘佳
张大洲
胡媛
夏吴
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Shanghai Yituan Technology Co ltd
China Wuhuan Engineering Co Ltd
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Abstract

本发明公开了一种制备新戊二醇用催化剂,解决了现有催化剂存在的催化活性和稳定性有待进一步提高的问题。所述催化剂由氧化铜、氧化锌、氧化铝、以及氧化银和/或氧化镓组成,其中所述氧化铝为θ‑Al2O3晶型的氧化铝。本发明催化剂原料成本低、催化剂活性高、稳定性好、运行时间长。

Description

制备新戊二醇用催化剂
技术领域
本发明涉及催化剂,具体的说是一种加氢制备新戊二醇(NPG)用催化剂。
背景技术
新戊二醇是一种重要的化学中间体。其主要用于生产不饱和树脂、聚酯粉末涂料、无油醇酸树脂、聚氨酯泡沫塑料、弹性体的增塑剂、合成增塑剂、表面活性剂、绝缘材料、印刷油墨、阻聚剂、合成航空润滑油油品添加剂等。另外,在医药行业也有所应用。同时,新戊二醇还是优良的溶剂,可用于芳烃和环烷基碳氢化合物的选择分离。
新戊二醇在工业上通常有歧化法和缩合加氢法两种工艺。歧化法使用过量的强碱性催化剂如氢氧化钠、氢氧化钾或氢氧化钙等,使异丁醛与甲醛水溶液发生醇醛缩合反应生成羟基新戊醛(HPA),羟基新戊醛再与过量的甲醛在强碱性条件下发生交叉卡尼扎罗反应生成新戊二醇,甲醛被氧化生成甲酸,甲酸与碱中和生成甲酸盐。该方法形成大量副产物甲酸盐,新戊二醇品质不高,污染大,碱性催化剂和甲醛消耗高。缩合加氢法是合成新戊二醇的主流工艺,甲醛和异丁醛在有机胺催化剂作用下合成羟基新戊醛,然后羟基新戊醛加氢得到最终产物新戊二醇,该方法是一种先进的环保型工艺,催化剂可以循环利用,污染少,甲醛消耗低,新戊二醇品质高。
羟基新戊醛加氢制新戊二醇催化剂是缩合加氢工艺工业化的主要难点之一。羟基新戊醛加氢催化剂主要有镍基、铜基和贵金属催化剂,与镍基、贵金属催化剂相比,铜基催化剂用于HPA加氢反应具有活性和选择性高、成本低等优势。公开报道的羟基新戊醛加氢催化剂多以铜基催化剂为主。
US3808280采用三乙胺为缩合催化剂制备得到HPA,加氢制备新戊二醇的催化剂中含有钴、铜、锰、镍其中的一种,其加氢压力高达1500-4000磅/平方英寸,其压力较高,所以设备要求和成本都会相应的增加。
专利CN201210227352.1中采用铜基催化剂(Cuo为47.52wt%,ZnO为14.26wt%,Al2O3为33.11wt%,ZrO2为4.27wt%,Re207为0.91wt%)应用于羟基新戊醛加氢制新戊二醇反应中,在羟基新戊醛为13.5wt%,新戊二醇1wt%,1115酯含量9wt%,异丁醛含量0.3wt%,其他杂质1.5wt%,水含量74.7wt%下,进行加氢反应,羟基新戊醛转化率100%,NPG选择性近100%。但催化剂采用贵金属Re,成本过高,而且专利中只报道了该催化剂为1000小时稳定性数据。
专利CN201110187555.8、CN201110187553.9、CN201110187537.X采用Cu-Zn-Al或Cu-Zn-Al-Mn催化剂进行羟基新戊醛加氢反应,两段加氢可使羟基新戊醛转化率为100%,新戊二醇选择性高于97%。专利CN200910201434.7中报道了其催化剂寿命超过2000小时,但1800小时左右催化剂寿命已明显下降。
由于羟基新戊醛热稳定性差,其加氢反应在液相条件下进行时,由于液体浸泡、溶胀等原因会使催化剂的实际使用强度大幅下降,导致催化剂在液相加氢体系容易破碎、粉化,造成反应器堵塞,威胁工业装置稳定运行,影响催化剂寿命。在现有专利中,羟基新戊醛加氢制新戊二醇催化剂运行时间最长为1800h,没有更长的运行时间的报道。
发明内容
本发明的目的是为了解决上述技术问题,提供一种原料成本低、催化剂活性高、稳定性好、运行时间长的加氢制备新戊二醇(NPG)用催化剂。
本发明所述催化剂由氧化铜、氧化锌、氧化铝、以及氧化银和/或氧化镓组成,其中所述氧化铝为θ-Al2O3晶型的氧化铝。
所述催化剂由15-40wt%氧化铜、10-35wt%氧化锌、20-40wt%氧化铝,0-10wt%氧化银和/或氧化镓组成,合计100%。
所述催化剂由氧化铜25-40wt%,氧化锌15-20wt%,氧化铝30-40wt%,氧化银和/或氧化镓1-5wt%,合计100%。
所述θ-Al2O3晶型的氧化铝的制备方法并不特别限定,优选采用以下方法制备:以铝酸钠水溶液为原料,通入CO2反应后分离制得湃铝石,然后将湃铝石焙烧后得到。
所述催化剂是由铜、锌、铝、银和/或镓的氧化物通过共沉淀法沉积在氧化铝上形成包覆结构。
所述共沉淀法为:将铜、锌、银和/或镓的盐(优选为硝酸盐)制成金属盐溶液,将θ-Al2O3晶型的氧化铝加入到沉淀剂溶液中得到沉淀剂-载体悬浊溶液;将所述金属盐溶液滴加至所述沉淀剂-载体悬浊溶液中,并在30-95℃进行反应,反应结束后在60-70℃保温老化1-2小时,得到混合物的悬浊液;将混合物的悬浊液进行离心分离得到固液两相,固相用去离子水洗涤至电导率小于1000us/cm,再进行造粒、干燥、焙烧得到催化剂。
所述沉淀剂为碳酸钠、碳酸钾、碳酸氢铵、碳酸铵、氢氧化钠、氢氧化钾、柠檬酸中的至少一种,优选为碳酸钠、碳酸铵、柠檬酸。
针对背景技术中所述的技术问题,发明人对铜基催化剂的各组份进行深入分析,选用氧化铜、氧化锌、氧化铝、以及氧化银或氧化镓作为催化剂的组成,其中氧化铝特别选用了特定晶型氧化铝--θ-Al2O3晶型。
基于传统认识,在360百科中记载的已经证实氧化铝有α、β、γ、δ、η、θ、κ和χ等十一种晶体,其中θ-Al2O3晶型氧化铝由于其比表面相对较小,孔道欠发达,通常认为不适用于作为催化剂,现有文献报导的催化剂常见使用的多为η和γ型氧化铝,经过大量研究后发现,η和γ型氧化铝制得的催化剂在新戊二醇的催化反应中,其稳定性始终无法到达要求,进一步分析发现,η和γ型氧化铝表面较强的酸性位促进了醛类及中间体的聚合,形成的包覆物阻止了催化剂表面活性位的进一步反应,继而引起催化剂失活;由此联想到的常见中性载体如二氧化硅、活性炭等也在反应中活性极低,同样不具备应用性。
为解决上述技术问题,发明人克服了常规认识,特别选用θ-Al2O3晶型氧化铝,研究发现θ-Al2O3晶型氧化铝的具有活性适中、耐结焦、寿命长的特点。用于新戊二醇的催化反应时,θ-Al2O3晶型氧化铝意外的表现出优秀的催化剂活性与选择性,载体接近于中性,能够有效降低结焦几率,显著提高了催化剂抗毒及抗失活能力,使得催化剂可连续运行4000小时以上而未见明显失活。
所述θ-Al2O3晶型氧化铝可通过预制备得到,在后续催化剂制备的共沉淀法中,θ-Al2O3晶型氧化铝直接加入到沉淀剂溶液中得到沉淀剂-载体悬浊溶液,然后再与其它的金属盐溶液反应进行共沉淀,最终制得的催化剂中所含氧化铝皆为θ-Al2O3晶型氧化铝。
进一步的,本发明催化剂在Cu-Zn-Al的基础上还添加了氧化银和/或氧化镓,其中加入氧化银可以有效调整催化剂表面加氢活性,对于改善催化剂选择性有显著效果;或者加入氧化镓可以进一步抑制催化剂表面结焦性,能够提高催化剂寿命。所述氧化银和/或氧化镓的添加量为0-10wt%,更为优选为1-5wt%,过多会增加催化剂成本,过少会降低催化剂选择性或稳定性。
有益效果:
本发明催化剂在铜基催化剂的基础上,克服了技术人员的偏见,限定使用θ-Al2O3晶型氧化铝,降低成本的同时,有效提高了催化剂选择性、抗毒及抗失活能力,其NPG选择性可以达到98.6%以上,催化剂可连续运行4000小时以上而未见明显失活,技术效果显著。
附图说明
图1为theta(θ)晶型氧化铝的催化剂XRD谱图。
图2为实施例1的稳定性评价图。
具体实施方式
θ-Al2O3晶型氧化铝的制备:
配置250mL 2.4mol/L的铝酸钠水溶液并将之倒入反应器中,将之密闭、抽真空处理并水浴加热至40℃,开启搅拌、缓慢通入二氧化碳并最终保持二氧化碳压力为1MPa,期间,溶液中发生如下反应:
2NaAlO2+CO2+3H2O——2Al(OH)3+Na2CO3
NaAlO2+2H2O——Al(OH)3+NaOH
Na2CO3+2CO2+2Al(OH)3——2NaAl(CO3)(OH)2+H2O
2NaOH+CO2——Na2CO3+H2O
反应母液持续搅拌48小时,反应结束时测其母液pH为10。随后将反应生成的白色沉淀物取出,用除盐水洗涤过滤三次以上以除去其中残留的碱性物质,将该混合物摊薄置于烘箱中120℃干燥过夜,得到混合物。对该混合物进行X–射线粉末衍射(XRD)、热重–差示扫描量热(TG–DSC)及傅里叶红外(FT–IR)表征,结果说明该物质为结晶态湃铝石;
将得到的结晶态湃铝石在1000℃下焙烧6小时,获得θ-Al2O3晶型氧化铝,相关催化剂XRD谱图与标准谱图结果对比见图1。
下述实施例1-4中所述的θ-Al2O3晶型氧化铝可以市购或者是采用上述方法制备得到的θ-Al2O3晶型氧化铝。
催化剂实施例1
将9.1g Cu(NO3)2·3H2O,11.3g Zn(NO3)2·6H2O,0.7g AgNO3,1.4g Ga(NO3)3溶解在500ml水中,配置成金属盐溶液A;称量16.9g碳酸钠并溶解于100ml水中,向其中加入3gθ-Al2O3粉末,剧烈搅拌形成沉淀剂-载体悬浊溶液B;机械搅拌状态下,控制水浴60℃将A溶液缓慢滴加至B溶液中,反应生成白色沉淀,滴加完毕后在60-70℃下继续搅拌老化1-2小时,得到相应混合物的悬浊液;固相用去离子水洗涤至电导率小于1000us/cm,再进行造粒、干燥、焙烧得到催化剂。所述催化剂含31wt%氧化铜、31wt%氧化锌、30wt%氧化铝,3wt%氧化银、5wt%氧化镓,其中氧化铝为θ-Al2O3晶型。
将实施例1中催化剂在80℃、2.0MPa、原料重时空速为1.0h-1、氢醛比为5的反应条件下进行稳定性评价,相关结果图2。本发明催化剂可稳定运行4500小时以上。
催化剂实施例2
合成方法与实施例2基本相同,区别在于A、B溶液配比不同。将4.5g Cu(NO3)2·3H2O,13.2g Zn(NO3)2·6H2O,0.7g AgNO3,1.4g Ga(NO3)3溶解在500ml水中,配置成金属盐溶液A;称量14.1g碳酸钠并溶解于100ml水中,向其中加入4g θ-Al2O3粉末,剧烈搅拌形成沉淀剂-载体悬浊溶液B。所述催化剂含15wt%氧化铜、35wt%氧化锌、40wt%氧化铝,3.5wt%氧化银、5wt%氧化镓。
催化剂实施例3
合成方法与实施例2基本相同,区别在于A、B溶液配比不同。将9.1g Cu(NO3)2·3H2O,11.3g Zn(NO3)2·6H2O,1.3g AgNO3溶解在500ml水中,配置成金属盐溶液A;称量16.1g碳酸钠并溶解于100ml水中,向其中加入3g θ-Al2O3粉末,剧烈搅拌形成沉淀剂-载体悬浊溶液B。所述催化剂含32wt%氧化铜、31wt%氧化锌、31wt%氧化铝,5.6wt%氧化银。
催化剂实施例4
合成方法与实施例2基本相同,区别在于A、B溶液配比不同。将12.1g Cu(NO3)2·3H2O,9.4g Zn(NO3)2·6H2O,2.7g Ga(NO3)3溶解在500ml水中,配置成金属盐溶液A;称量14.1g碳酸钠并溶解于100ml水中,向其中加入2.5g θ-Al2O3粉末,剧烈搅拌形成沉淀剂-载体悬浊溶液B。所述催化剂含40wt%氧化铜、25wt%氧化锌、25wt%氧化铝,10wt%氧化镓。
催化剂实施例5
合成方法与实施例2基本相同,区别在于A、B溶液配比不同。将9.1g Cu(NO3)2·3H2O,11.3g Zn(NO3)2·6H2O溶解在500ml水中,配置成金属盐溶液A;称量12.9g碳酸钠并溶解于100ml水中,向其中加入1.5g θ-Al2O3粉末,剧烈搅拌形成沉淀剂-载体悬浊溶液B。所述催化剂含40wt%氧化铜、40wt%氧化锌、20wt%氧化铝。
对比例1
将9.1g Cu(NO3)2·3H2O,11.3g Zn(NO3)2·6H2O,30.0g Al(NO3)3·9H20,0.7gAgNO3,1.4g Ga(NO3)3溶解在500ml水中,配置成金属盐溶液A;称量24.5g碳酸钠并溶解于100ml水中,形成沉淀剂溶液B;机械搅拌状态下,控制水浴60℃将A溶液缓慢滴加至B溶液中,反应生成白色沉淀,滴加完毕后在60℃下继续搅拌老化2小时,得到相应混合物的悬浊液;
将相应混合物的悬浊液进行离心分离得到固液两相,固体用去离子水洗涤至电导率小于1000us/cm,将固体滤出物置于120℃干燥过夜、450℃焙烧4小时得到催化剂。
所述催化剂含31wt%氧化铜、31wt%氧化锌、30wt%氧化铝,3wt%氧化银、5wt%氧化镓,其中氧化铝为η和γ型两种晶型氧化铝的混合。
对比例2
将9.1g Cu(NO3)2·3H2O,11.3g Zn(NO3)2·6H2O,30.0g Al(NO3)3·9H20,0.7gAgNO3,1.4g Ga(NO3)3溶解在500ml水中,配置成金属盐溶液A;称量24.5g碳酸钠并溶解于100ml水中,形成沉淀剂溶液B;机械搅拌状态下,控制水浴60℃将A溶液缓慢滴加至B溶液中,反应生成白色沉淀,滴加完毕后在60-70℃下继续搅拌老化2小时,得到相应混合物的悬浊液;
将相应混合物的悬浊液进行离心分离得到固液两相,固体用去离子水洗涤至电导率小于1000us/cm,将固体滤出物置于120℃干燥过夜、1200℃焙烧4小时得到催化剂。
所述催化剂含31wt%氧化铜、31wt%氧化锌、30wt%氧化铝,3wt%氧化银、5wt%氧化镓,其中氧化铝为α晶型氧化铝。
将实施例1-5和对比例1和2制备的催化剂装于固定床反应管中,在氢气流中300℃下还原2小时,降至反应温度,通入反应原料液进行反应,相关评价数据见表1。
表1实施例催化剂反应结果
Figure BDA0002716524780000101

Claims (5)

1.一种制备新戊二醇用催化剂,其特征在于,所述催化剂由氧化铜、氧化锌、氧化铝、以及氧化银和/或氧化镓组成,其中所述氧化铝为θ-Al2O3晶型的氧化铝;
所述催化剂是通过共沉淀法将由铜、锌、铝、银和/或镓的氧化物沉积在氧化铝上形成包覆结构;
所述共沉淀法为:将铜、锌、银和/或镓的盐制成金属盐溶液,将θ-Al2O3晶型的氧化铝加入到沉淀剂溶液中得到沉淀剂-载体悬浊溶液;将所述金属盐溶液滴加至所述沉淀剂-载体悬浊溶液中,并在30-95℃进行反应,反应结束后在60-70℃保温老化1-2小时,得到混合物的悬浊液;将混合物的悬浊液进行离心分离得到固液两相,固相用去离子水洗涤至电导率小于1000us/cm,再进行造粒、干燥、焙烧得到催化剂。
2.如权利要求1所述制备新戊二醇用催化剂,其特征在于,所述催化剂由15-40wt%氧化铜、10-35wt%氧化锌、20-40wt%氧化铝,1-10wt%氧化银和/或氧化镓组成,合计100%。
3.如权利要求2所述制备新戊二醇用催化剂,其特征在于,所述催化剂由氧化铜25-40wt%,氧化锌15-20wt%,氧化铝30-40wt%,氧化银和/或氧化镓1-5wt%,合计100%。
4.如权利要求1-3任一项所述的制备新戊二醇用催化剂,其特征在于,所述θ-Al2O3晶型的氧化铝采用以下方法制备:以铝酸钠水溶液为原料,通入CO2反应后分离制得湃铝石,然后将湃铝石焙烧后得到。
5.如权利要求1所述的制备新戊二醇用催化剂,其特征在于,所述沉淀剂为碳酸钠、碳酸钾、碳酸氢铵、碳酸铵、氢氧化钠、氢氧化钾中的至少一种。
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