Palladium on alumina aerogel catalyst composition and process for making same

Claim 2

A catalyst composition comprising a uniform dispersion of individual particles of metallic palladium, substantially free of clusters of said particles, on an alumina aerogel support, said composition having a BET surface area in the range of about 20 to about 700 m 2 /g, a pore volume in the range of about 1.5 to about 12 cm 3 /g, a bulk density in the range of about 0.003 to about 0.5 g/cm 3 and having a Pd°/Al 2 O 3 wgt. ratio of about 1:1000 to about 1:5.

Claim 3

The catalyst composition of claim 1 wherein said weight ratio is about 1:100 to about 1:10.

Claim 4

The catalyst composition of claim 1 wherein the metallic palladium comprises individual particles having diameters in the range of about 0.2 nm to 30 nm.

Claim 5

The catalyst composition of claim 3 wherein the alumina aerogel support has a morphology by transmission electron microscopy comprising geometric platelets substantially free of individual particles and wherein the metallic palladium consists essentially of individual particles having diameters in the range of about 2-6 nm.

Claim 6

A process of preparing the catalyst composition of claim 1 which comprises: (a) intimately contacting a solution of a hydrolyzable palladium(II) compound in an aprotic solvent with a solution or dispersion of a hydrolyzable aluminum compound in a C 1 -C 5 alcohol or mixture thereof for a time sufficient to form a mixture of said compounds, substantially free of metallic palladium; (b) intimately contacting said mixture with a solution of a C 1 -C 5 alcohol and water in an amount sufficient to hydrolyze said aluminum compound and to form a substantially uniform dispersion of metallic palladium and said hydrolyzed aluminum compound in the presence of said C 1 -C 5 alcohol mixture thereof; (c) heating said uniform dispersion in the presence of the C 1 -C 5 alcohol or mixture thereof to a temperature above the critical temperature of said alcohol or said mixture; and (d) removing said alcohol or mixture thereof under super-critical conditions to form said catalyst composition comprising a uniform dispersion of metallic palladium on an aluminum aerogel support and substantially free of palladium(II).

Claim 7

The process of claim 5 wherein in step (a) a solution of palladium(II) acetate in acetone is intimately contacted with a solution or dispersion of an aluminum C 3 -C 5 sec-alkoxide in secondary alcohol having 3-5 carbons.

Claim 8

The process of claim 6 wherein in step (a) a solution of aluminum sec-butoxide in sec-butanol is used and wherein in step (b) the C 1 -C 5 alcohol is methanol.

Claim 9

The process of claim 6 wherein in step (a) a dispersion of aluminum sec-butoxide in isopropanol is used and wherein in step (b) isopropanol is used.