Pd/SiO2 Hydrogenation catalyst suitable for H2 O2 manufacture

Claim 2

A catalyst consisting essentially of amorphous silica particles having deposited thereon about 0.05-5 percent by weight based on the weight of silica of at least one oxide, hydroxide or carbonate of a metal selected from zirconium, thorium, hafnium, cerium, and titanium and about 0.1-10 percent by weight based on the weight of silica of palladium metal; the metal oxide, hydroxide or carbonate being deposited before or simultaneously with the palladium metal in the form of its oxide, hydroxide or carbonate.

Claim 3

The catalyst of claim 1 wherein the amorphous silica particles have a particle size in the range of about 10-300 microns and a surface area of about 20-600 m 2 /g.

Claim 4

The catalyst of claim 1 or claim 2 wherein the metal oxide, hydroxide or carbonate concentration is about 0.1-2 percent by weight.

Claim 5

The catalyst of claim 1 or claim 2 wherein the palladium concentration is about 0.2-5 percent by weight and the amorphous silica particles are silica gel particles having an average particle size distribution in the range of about 50-200 microns and a surface area in the range of about 100-350 m 2 /g.

Claim 6

A process for preparing a supported palladium catalyst comprising (1) mixing a water-soluble palladium salt, amorphous silica particles and at least one water-soluble salt of a metal selected from zirconium, thorium, hafnium, cerium, titanium and aluminum, in an aqueous medium at a pH less than 4, the amount of said metal salt being sufficient to cause at least a major portion of the palladium present in solution to attach to the surface of the amorphous silica particles when the palladium salt is subsequently precipitated as an oxide, hydroxide or carbonate of palladium by the addition of base; and (2) adding a base to said mixture raising the pH of the aqueous medium to above about 4 causing the metal and palladium to deposit onto the silica particles as their hydroxides, oxides or carbonates.

Claim 7

A process for preparing a supported palladium catalyst comprising (1) mixing a water-soluble palladium salt, amorphous silica particles and at least one water-soluble salt of a metal selected from zirconium, thorium, hafnium, cerium, titanium and aluminum, in an aqueous medium at a pH less than 4, the amount of said metal salt being sufficient to cause at least a major portion of the palladium present in solution to attach to the surface of the amorphous silica particles when the palladium salt is subsequently precipitated as an oxide, hydroxide or carbonate of palladium by the addition of base; and (2) adding a base to said mixture raising the pH of the aqueous medium to above about 4 causing the metal and palladium to deposit onto the silica particles as their hydroxides, oxides or carbonates.

Claim 8

The process of claim 5 wherein the added base is an alkali metal carbonate, the temperature of addition is in the range of about 50-150° C., the pH is raised to pH 5-8 and the depositied palladium hydroxide, oxide or carbonate is reduced to palladium metal.

Claim 9

The process of claim 5 wherein the amorphous silica particles have an average particle size distribution in the range of about 100-300 microns and a surface area in the range of about 20-600 m 2 /g.

Claim 10

The process of claim 5, claim 6 or claim 7 wherein the salt of zirconium, thorium, hafnium, cerium, titanium or aluminum is a nitrate, sulfate, halide or oxyhalide.

Claim 11

The process of claim 5 wherein the surface of the silica particles is iron-free.

Claim 12

The process of claim 5, claim 6 or claim 7 wherein the deposited palladium hydroxide, oxide or carbonate is reduced by adding to the mixture a reducing agent selected from the group consisting of hydrogen, formaldehyde, and hydrazine and the resulting catalyst is removed and washed with water.

Claim 13

The process of claim 5 or claim 6 wherein the amorphous silica particles are silica gel particles having a surface area of about 100-350 m 2 /g and the metal salt is a nitrate, chloride or oxychloride added at a concentration of about 0.05-5 percent by weight of the silica gel.

Claim 14

A process for preparing a supported palladium catalyst comprising (1) adding to an aqueous slurry of about 5-30 percent by weight silica gel particles having an average particle size distribution in the range of about 10-300 microns and a surface area of about 20-600 m 2 /g, about 0.1-10 percent by weight, based on silica, of Na 2 PdCl 4 or PdCl 2 in dilute HCl and one of the following, based on the weight of silica: (a) about 0.3-1 percent zirconium oxychloride, (b) about 0.5-1.5 percent thorium nitrate, (c) about 0.2-0.8 percent titanium tetrachloride, (d) about 0.4-1.5 percent cerium nitrate hexahydrate, or (e) about 0.3-1.4 percent aluminum chlorhydroxide; (2) heating the slurry to a temperature in the range of about 75°-100° C.; (3) gradually adding to the heated slurry an alkali metal carbonate in an amount sufficient to raise the slurry pH to a pH in the range of about 5-8; and (4) adding formaldehyde in an amount sufficient to reduce the palladium content to palladium metal.

Claim 15

A process for preparing a supported palladium catalyst comprising (1) adding to an aqueous slurry of about 5-30 percent by weight silica gel particles having an average particle size distribution in the range of about 10-300 microns and a surface area of about 20-600 m 2 /g, about 0.1-10 percent by weight, based on silica, of Na 2 PdCl 4 or PdCl 2 in dilute HCl and one of the following, based on the weight of silica: (a) about 0.3-1 percent zirconium oxychloride, (b) about 0.5-1.5 percent thorium nitrate, (c) about 0.2-0.8 percent titanium tetrachloride, (d) about 0.4-1.5 percent cerium nitrate hexahydrate, or (e) about 0.3-1.4 percent aluminum chlorhydroxide; (2) heating the slurry to a temperature in the range of about 75°-100° C.; (3) gradually adding to the heated slurry an alkali metal carbonate in an amount sufficient to raise the slurry pH to a pH in the range of about 5-8; and (4) adding formaldehyde in an amount sufficient to reduce the palladium content to palladium metal.

Claim 16

The process of claim 12 wherein the alkali metal carbonate is at least one of sodium carbonate and potassium carbonate.

Claim 17

The process of claim 12 wherein the silica gel particles have a surface area in the range of about 100-350 m 2 g.

Claim 18

The process of claim 12 or claim 14 wherein the palladium added is PdCl 2 in dilute HCl at a pH of about 1.5-2.5.

Claim 19

The process of claim 12 wherein the concentration of (a), (b), (c), (d) or (e) is: (a) about 0.5-0.6 percent, (b) about 0.8-1 percent, (c) about 0.3-0.4 percent, (d) about 0.7-0.9 percent or (e) about 0.6-0.8 percent.