Coprecipitated copper-nickel-silica catalysts, preparation and use thereof

Claim 2

A calcined, coprecipitated copper-nickel-silica catalyst of high activity for hydrogenating organic compounds with hydrogen at temperatures ranging from about 75° C. to about 300° C. when the catalyst is activated with a gaseous reductant at temperatures ranging from about 75° C. to about 400° C., said catalyst being characterized as capable of having a reduced nickel surface area ranging from about 55 to about 100 m 2 /g as determined by hydrogen chemisorption, after reduction at 400° C. and a B.E.T. total surface area ranging from about 150 to about 300 m 2 /g, said catalyst being further characterized as capable of being activated in the presence of a gaseous reductant at temperatures ranging from about 80° C. to about 250° C., wherein the amount of copper in the catalyst ranges from about 2 wt.% to about 10 wt.% and the amount of nickel in the catalyst ranges from about 25 wt.% to about 50 wt.%, said wt.% of copper and nickel based on the total weight of the catalyst, said catalyst having been prepared by the process comprising: (a) preparing an aqueous mixture containing nickel, copper and silicate ions and solid porous carrier particles under conditions of dilution such that the amount of dissolved nickel in said aqueous mixture is below 0.60 moles/liter; (b) heating the aqueous mixture; (c) adding a precipitating agent to coprecipitate the dissolved copper, nickel and silicate ions with the solid porous carrier particles; and (d) drying said coprecipitated catalyst and calcining it at a temperature ranging from 300° to 450° C.

Claim 3

The catalyst in accordance with claim 1 wherein the catalyst contains about 0.1 wt. % or less sodium based on the total weight of the active catalyst.

Claim 4

The catalyst in accordance with claim 1 wherein the porous solid particulate support is a member selected from the group consisting of kieselguhr, infusorial, diatomaceous, siliceous earth, silica and alumina.

Claim 5

The catalyst in accordance with claim 1 wherein the porous solid particulate support is kieselguhr.

Claim 6

The catalyst in accordance with claim 4 wherein the concentration of the porous solid particles ranges from about 10 wt. % to about 70 wt. % of the total silica in the catalyst.

Claim 7

The catalyst in accordance with claim 5 wherein the concentration of the porous solid particles ranges from about 30 wt. % to about 50 wt. % based on the total silica in the catalyst.

Claim 8

The catalyst in accordance with claim 1 wherein the catalyst has been reduced to an active state.

Claim 9

A calcined, coprecipitated copper-nickel-silica catalyst of high activity for hydrogenation of reducible organic compounds with hydrogen at temperatures ranging from about 75° C. to about 300° C. when the catalyst is activated with a gaseous reductant at temperatures ranging from about 75° C. to about 400° C., said catalyst being characterized as containing discrete porous-silica particles, capable of having a nickel surface area ranging from about 55 to about 100 m 2 /g as determined by hydrogen chemisorption, after reduction at 400° C. and a total surface area ranging from about 150 to about 300 m 2 /g, said catalyst being further characterized as capable of being activated in the presence of a gaseous reductant at temperatures ranging from about 80° C. to about 250° C., wherein the amount of copper in the catalyst ranges from about 2 wt.% to about 10 wt.%, the amount of nickel in the catalyst ranges from about 25 wt.% to about 50 wt.%, said wt.% of copper and nickel based on the total weight of the catalyst, and the catalyst contains about 0.1 wt.% or less sodium based on the total weight of the catalyst, and wherein the concentration of said porous silica support ranges from about 30 wt.% to about 50 wt.% of the total silica in the catalyst, said catalyst having been prepared by the process comprising: (a) uniformly comingling a first aqueous solution containing silicate anions and solid porous carrier particles with a second solution containing nickel and copper cations under conditions of dilution such that the amount of dissolved nickel in the comingled reaction solution is below 0.60 moles/liter; (b) heating the comingled reaction mixture; (c) adding a precipitating agent to coprecipitate the copper, nickel and silicate ions onto said solid porous carrier particles; and (d) drying said coprecipitated catalyst and calcining it at a temperature ranging from 300° to 450° C.

Claim 10

A calcined, coprecipitated copper-nickel-silica catalyst of high activity for hydrogenation of reducible organic compounds with hydrogen at temperatures ranging from about 75° C. to about 300° C. when the catalyst is activated with a gaseous reductant at temperatures ranging from about 75° C. to about 400° C., said catalyst being characterized as containing discrete porous-silica particles, capable of having a nickel surface area ranging from about 55 to about 100 m 2 /g as determined by hydrogen chemisorption, after reduction at 400° C. and a total surface area ranging from about 150 to about 300 m 2 /g, said catalyst being further characterized as capable of being activated in the presence of a gaseous reductant at temperatures ranging from about 80° C. to about 250° C., wherein the amount of copper in the catalyst ranges from about 2 wt.% to about 10 wt.%, the amount of nickel in the catalyst ranges from about 25 wt.% to about 50 wt.%, said wt.% of copper and nickel based on the total weight of the catalyst, and the catalyst contains about 0.1 wt.% or less sodium based on the total weight of the catalyst, and wherein the concentration of said porous silica support ranges from about 30 wt.% to about 50 wt.% of the total silica in the catalyst, said catalyst having been prepared by the process comprising: (a) uniformly comingling a first aqueous solution containing silicate anions and solid porous carrier particles with a second solution containing nickel and copper cations under conditions of dilution such that the amount of dissolved nickel in the comingled reaction solution is below 0.60 moles/liter; (b) heating the comingled reaction mixture; (c) adding a precipitating agent to coprecipitate the copper, nickel and silicate ions onto said solid porous carrier particles; and (d) drying said coprecipitated catalyst and calcining it at a temperature ranging from 300° to 450° C.

Claim 11

The catalyst of claim 8 wherein said catalyst has been reduced to an active state.

Claim 12

A process for making a calcined, coprecipitated copper-nickel-silica catalyst comprising the steps: (a) uniformly comingling a first aqueous solution containing anions and solid porous carrier particles with a second solution containing nickel and copper cations under conditions of dilution such that the amount of dissolved nickel in the comingled reaction solution is below 0.60 moles/liter; (b) heating the comingled reaction mixture; (c) adding a precipitating agent to coprecipitate the copper, nickel and silicate ions onto said porous solid porous carrier particles; and (d) drying said coprecipitated catalyst and calcining it at a temperature ranging from 300° to 450° C. to thereby obtain a catalyst having a B.E.T. total surface area ranging from about 150 to about 300 m 2 /g.

Claim 13

A process for making a calcined, coprecipitated copper-nickel-silica catalyst comprising the steps: (a) uniformly comingling a first aqueous solution containing anions and solid porous carrier particles with a second solution containing nickel and copper cations under conditions of dilution such that the amount of dissolved nickel in the comingled reaction solution is below 0.60 moles/liter; (b) heating the comingled reaction mixture; (c) adding a precipitating agent to coprecipitate the copper, nickel and silicate ions onto said porous solid porous carrier particles; and (d) drying said coprecipitated catalyst and calcining it at a temperature ranging from 300° to 450° C. to thereby obtain a catalyst having a B.E.T. total surface area ranging from about 150 to about 300 m 2 /g.

Claim 14

The process of claim 10 wherein the catalyst is capable of having a reduced nickel surface area ranging from about 55 to about 100 m 2 /g as determined by hydrogen chemisorption, after reduction at 400° C.

Claim 15

The process of claim 10 wherein the amount of copper in the catalyst ranges from about 2 to about 10 wt.% based on the total weight of the catalyst.

Claim 16

The process of claim 10 wherein the precipitating agent is ammonium bicarbonate.

Claim 17

The process of claim 10 including the step of reducing said catalyst at a temperature ranging from 75° C. to 400° C.

Claim 18

The process of claim 14 including the step of reducing said catalyst at a temperature ranging from 80° to 250° C.

Claim 19

The process of claim 14 wherein the amount of nickel metal in the copper-nickel solution ranges from 5 to 60 grams/liter and the amount of copper ranges from 0.2 to 12 grams/liter.

Claim 20

A process for preparing a copper-nickel-silica catalyst comprising the steps: (a) uniformly comingling a first aqueous solution containing silicate anions and solid porous carrier particles with a second solution containing nickel and copper cations under conditions of dilution such that the amount of dissolved nickel in the comingled solution is below 0.60 moles/liter; (b) heating the comingled reaction mixture; (c) adding a water soluble alkaline precipitating agent to coprecipitate the copper, nickel and silicate ions onto said solid porous carrier particles; (d) drying said coprecipitated catalyst and calcining it at a temperature ranging from 300° to 450° C.; (e) reducing said calcined and coprecipitated catalyst at a temperature ranging from 75° C. to 400° C. to thereby obtain an activated catalyst having a B.E.T. total surface area ranging from about 150 to about 300 m 2 /g and a nickel surface area ranging from about 55 to about 100 m 2 /g as determined by hydrogen chemisorption, after reduction at 400° C.

Claim 21

A process for preparing a copper-nickel-silica catalyst comprising the steps: (a) uniformly comingling a first aqueous solution containing silicate anions and solid porous carrier particles with a second solution containing nickel and copper cations under conditions of dilution such that the amount of dissolved nickel in the comingled solution is below 0.60 moles/liter; (b) heating the comingled reaction mixture; (c) adding a water soluble alkaline precipitating agent to coprecipitate the copper, nickel and silicate ions onto said solid porous carrier particles; (d) drying said coprecipitated catalyst and calcining it at a temperature ranging from 300° to 450° C.; (e) reducing said calcined and coprecipitated catalyst at a temperature ranging from 75° C. to 400° C. to thereby obtain an activated catalyst having a B.E.T. total surface area ranging from about 150 to about 300 m 2 /g and a nickel surface area ranging from about 55 to about 100 m 2 /g as determined by hydrogen chemisorption, after reduction at 400° C.

Claim 22

The process of claim 17 wherein the amount of nickel in the copper-nickel solution ranges from 5 to 60 grams/liter and the amount of copper ranges from 0.2 to 12 grams/liter.

Claim 23

The process of claim 17 wherein the precipitating agent is ammonium bicarbonate.

Claim 24

The catalyst produced by the process in accordance with claim 17.

Claim 25

The catalyst in accordance with claim 1 which has been reduced with a reductant to an active state at temperatures ranging from about 80° C. to about 250° C.

Claim 26

The catalyst in accordance with claim 8 which has been reduced with a reductant to an active state at temperatures ranging from about 80° C. to about 250° C.

Claim 27

A calcined and activated coprecipitated copper-nickel-silica catalyst of high activity for hydrogenation of reducible organic compounds, said catalyst being characterized as having a reduced nickel surface area ranging from about 55 to about 100 m 2 /g as determined by hydrogen chemisorption, after reduction at 400° C. and a B.E.T. total surface area ranging from about 150 to about 300 m 2 /g, wherein the catalyst contains about 0.1 wt.% or less sodium based on the total weight of the active catalyst and the amount of copper in the catalyst ranges from about 2 wt.% to about 10 wt.% and the amount of nickel in the catalyst ranges from about 25 wt.% to about 50 wt.%, said wt.% of copper and nickel based on the total weight of the catalyst, said catalyst having been prepared by the process comprising: (a) uniformly comingling a first aqueous solution containing silicate anions and solid porous carrier particles comprising kieselguhr with a second solution containing nickel and copper cations under conditions of dilution such that the amount of dissolved nickel in the comingled reaction solution is below 0.60 moles/liter; (b) heating the comingled reaction mixture; (c) adding a precipitating agent to coprecipitate the copper, nickel and silicate ions said solid porous carrier kieselguhr particles; (d) drying said coprecipitated catalyst and calcining it at a temperature ranging from 300° to 450° C.; and (e) reducing the calcined catalyst with a gaseous reductant at temperatures ranging from about 75° C. to about 400° C. until said catalyst has been activated by the reduction.

Claim 28

A calcined and activated coprecipitated copper-nickel-silica catalyst of high activity for hydrogenation of reducible organic compounds, said catalyst being characterized as having a reduced nickel surface area ranging from about 55 to about 100 m 2 /g as determined by hydrogen chemisorption, after reduction at 400° C. and a B.E.T. total surface area ranging from about 150 to about 300 m 2 /g, wherein the catalyst contains about 0.1 wt.% or less sodium based on the total weight of the active catalyst and the amount of copper in the catalyst ranges from about 2 wt.% to about 10 wt.% and the amount of nickel in the catalyst ranges from about 25 wt.% to about 50 wt.%, said wt.% of copper and nickel based on the total weight of the catalyst, said catalyst having been prepared by the process comprising: (a) uniformly comingling a first aqueous solution containing silicate anions and solid porous carrier particles comprising kieselguhr with a second solution containing nickel and copper cations under conditions of dilution such that the amount of dissolved nickel in the comingled reaction solution is below 0.60 moles/liter; (b) heating the comingled reaction mixture; (c) adding a precipitating agent to coprecipitate the copper, nickel and silicate ions said solid porous carrier kieselguhr particles; (d) drying said coprecipitated catalyst and calcining it at a temperature ranging from 300° to 450° C.; and (e) reducing the calcined catalyst with a gaseous reductant at temperatures ranging from about 75° C. to about 400° C. until said catalyst has been activated by the reduction.

Claim 29

The catalyst in accordance with claim 23 wherein the concentration of the kieselguhr ranges from about 10 wt.% to about 70 wt.% of the total silica in the catalyst.

Claim 30

The catalyst in accordance with claim 23 wherein the concentration of the kieselguhr ranges from about 30 wt.% to about 50 wt.% based on the total silica in the catalyst.

Claim 31

The catalyst in accordance with claims 23 or 24 which has been reduced with a reductant to an active state at temperatures ranging from about 80° C. to about 250° C.

Claim 32

The process in accordance with claim 17 wherein the catalyst is reduced at a temperature ranging from 80° C. to about 250° C.