CN115551824A

CN115551824A - Process for the hydrogenolysis of glycerol

Info

Publication number: CN115551824A
Application number: CN202180032846.1A
Authority: CN
Inventors: J·特里安; A·J·英格拉姆
Original assignee: Archer Daniels Midland Co
Current assignee: Archer Daniels Midland Co
Priority date: 2020-05-18
Filing date: 2021-05-18
Publication date: 2022-12-30
Also published as: WO2021236586A1; EP4153550A1; BR112022022606A2; JP2023526927A

Abstract

A process for the catalytic hydrogenolysis of glycerol to produce propylene glycol and/or ethylene glycol is described.

Description

Process for the hydrogenolysis of glycerol

Technical Field

The present invention generally relates to a process for the catalytic hydrogenolysis of glycerol to produce propylene glycol and/or ethylene glycol.

Background

Carbon is a material that can be deployed as a catalyst support or adsorbent. The most commonly used carbon-based supports for chemical catalytic reactions are those having a high specific surface area (e.g. more than 500 m) ² Per g) of activated carbon. Preparation of activated carbonIt is desirable to activate carbonaceous materials (e.g., charcoal, wood, coconut shells, or carbon black from petroleum) by chemical activation (such as contact with an acid at elevated temperatures) or steam activation. Both activation methods produce a large number of micropores and thus a high surface area. Depending on the source of the carbonaceous material, the resulting activated carbon may have a high residual content of inorganic ash and sulfur, and may have oxygen-or nitrogen-containing functional groups on the surface. Activated carbon is considered to have an optimal support structure for catalyst applications because it allows a good dispersion of catalytically active components on the catalyst surface and allows chemical reagents to be efficiently adsorbed and reacted on the catalyst surface.

In recent years, there has been increasing interest in using bio-renewable materials as feedstocks to replace or supplement crude oil. See, for example, klass, biomass for Renewable Energy, fuels, and Chemicals, academic Press,1998. This publication and all other publications cited herein are incorporated by reference. One of the major challenges for converting biologically renewable resources such as carbohydrates (e.g., glucose derived from starch, cellulose, or sucrose) into current commodity and specialty chemicals is the selective removal of oxygen atoms from the carbohydrates. Methods for converting carbon-oxygen single bonds to carbon-hydrogen bonds are known. See, for example, U.S. patent No. 8,669,397, which describes a process for converting glucose to adipic acid via a glucaric acid intermediate. One of the challenging problems associated with the catalytic conversion reactions of highly functional biorenewable derived molecules and intermediates is achieving the high levels of catalytic activity, selectivity and stability required for commercial applications. Highly functional biorenewable derived molecules and intermediates derived from carbohydrates (e.g. glucose and glucaric acid) are non-volatile for catalytic activity and selectivity and must therefore be processed in solution in the liquid phase. When compared to gas phase catalytic processes, liquid phase catalytic processes are known to suffer from lower throughput due to slower liquid-solid (and gas-liquid-solid) diffusion rates than gas-solid diffusion rates.

Another challenging problem associated with the catalytic conversion reactions of highly functional biorenewable derived molecules and intermediates is the utilization of chemically aggressive reaction conditions. For example, U.S. Pat. No. 8,669,397 describes a catalytic conversion step carried out at elevated temperatures in the presence of polar solvents (e.g., water and acetic acid). In general, the dissociation of non-volatile, highly functional molecules (e.g., glucose and glucaric acid) requires polar solvents, and productive and low cost catalytic conversion steps for commercial applications require high temperatures. Thus, one of the important challenges associated with the catalytic conversion of highly functional biorenewable derived molecules and intermediates is catalyst stability. Long-term catalyst stability is essential for commercial production, which means that the catalyst must be stable, productive, and selective for a long period of time under the reaction conditions.

Challenges associated with the development of shaped catalysts for industrial use, especially in the conversion reactions of biorenewable derived molecules and intermediates, are a) high productivity and selectivity at industrial scale consistent with economically viable catalysts, b) mechanical and chemical stability of the shaped catalyst support and c) retention of the catalytically active component by the support and avoidance of permeation of the catalytically active component into the polar solvent reaction medium. There remains a need for industrially scalable, highly active, selective and stable catalyst supports and catalyst compositions that can meet these challenges.

Disclosure of Invention

Briefly, in various aspects, the present invention relates to a process for the hydrogenolysis of glycerol. Some methods include feeding a feed composition comprising glycerol to a reaction zone and reacting the glycerol with hydrogen in the reaction zone in the presence of a catalyst composition as described herein (e.g., comprising a shaped porous carbon product) to form a reaction product comprising propylene glycol and/or ethylene glycol. Other processes for the hydrogenolysis of glycerol include feeding a feed composition comprising glycerol to a reaction zone and reacting the glycerol with hydrogen in the presence of a catalyst composition in the reaction zone to form a reaction product comprising propylene glycol and/or ethylene glycol, wherein the catalyst composition comprises a catalytically active ingredient comprising a metal selected from the group consisting of chromium, cobalt, nickel, copper, zinc, ruthenium, rhodium, palladium, silver, rhenium, osmium, iridium, platinum, gold, and any combination thereof, and a catalyst support comprising a shaped porous carbon product comprising carbon black.

Other objects and features will be in part apparent and in part pointed out hereinafter.

Brief description of the drawings

FIG. 1 provides scanning electron microscope images of the cross section of catalyst extrudate samples made with Monarch700 carbon black.

Figure 2 provides an enlarged view of one catalyst extrudate cross-section of figure 1.

FIG. 3 shows a plot of the cumulative pore volume (%) of crude Monarch700 carbon black material as a function of average pore diameter.

FIG. 4 shows a plot of cumulative pore volume (%) of fresh catalyst extrudates containing Monarch700 carbon black material as a function of average pore diameter.

FIG. 5 shows a plot of cumulative pore volume (%) of catalyst extrudates containing Monarch700 carbon black material as a function of average pore diameter after 350 hours of use.

FIG. 6 shows a plot of cumulative pore volume (%) as a function of average pore diameter for extrudates utilizing Monarch700 carbon black and glucose/hydroxyethylcellulose binder.

Figure 7 shows a plot of cumulative pore volume (%) as a function of average pore diameter for extrudates utilizing Sid Richardson SC159 carbon black and glucose/hydroxyethylcellulose binder.

Figure 8 shows a plot of cumulative pore volume (%) as a function of average pore diameter for extrudates utilizing Sid Richardson SC159 carbon black and glucose/hydroxyethylcellulose binder exposed to oxygen at 300 ℃ for 3 hours.

Figure 9 shows a plot of cumulative pore volume (%) as a function of average pore diameter for extrudates using the ash 5368 carbon black and glucose/hydroxyethylcellulose binder.

FIG. 10 shows a plot of the cumulative pore volume (%) of activated carbon extrudates of Sud Chemie G32H-N-75 as a function of the average pore diameter.

FIG. 11 shows a plot of cumulative pore volume (%) of activated carbon extrudates of Donau Superglass K4-35 as a function of average pore diameter.

Figure 12 shows the pore size distribution of extrudates using Sid Richardson SC159 carbon black and glucose/hydroxyethylcellulose binder as measured by mercury porosimetry.

FIG. 13 shows a plot of pore diameter versus pore volume for carbon black extrudates.

FIG. 14 shows an SEM image of Ni-Re on a carbon black extrudate catalyst (no nitric acid added).

FIG. 15 shows the results of EDX analysis of Ni-Re on the carbon black extrudate catalyst shown in FIG. 14.

FIG. 16 shows an SEM image of Ni-Re on a carbon black extrudate catalyst (with addition of nitric acid).

FIG. 17 shows the results of EDX analysis of Ni-Re on the carbon black extrudate catalyst shown in FIG. 16.

Detailed Description

The present invention generally relates to shaped porous carbon products and methods for making these products. For example, the shaped porous carbon product may be used as a catalyst support, chromatographic support material, filtration medium, adsorbent, and the like. The invention also relates to catalyst compositions comprising these shaped porous carbon products, methods of making the catalyst compositions, and various methods of using the shaped porous carbon products and catalyst compositions.

The present invention provides a shaped porous carbon product having high mechanical strength and being resistant to chipping and abrasion during use. Moreover, the shaped porous carbon products have excellent chemical stability towards reaction solvents (e.g. acids and other polar solvents) even at high temperatures. The shaped porous carbon product is highly suitable for liquid phase catalytic reactions by providing efficient mass transfer of compounds having a relatively large molecular volume to and from the surface of the support.

The invention also provides a method for preparing a shaped porous carbon product. The shaped porous carbon product can be made from inexpensive and readily available materials, thus advantageously increasing process economics. Moreover, the disclosed method is suitable for preparing durable, high mechanical strength shaped porous carbon products using water soluble organic binders. These methods avoid the use of organic solvents that require special handling and storage.

The invention further provides catalyst compositions comprising the shaped porous carbon products as catalyst supports and methods for preparing these catalyst compositions. The shaped porous carbon product exhibits a high degree of retention of the catalytically active component of the catalyst composition, which advantageously avoids or reduces the amount of penetration of the catalytically active material into the liquid phase reaction medium. Furthermore, the catalyst composition has a high stability required for commercial product manufacture.

Also, for example, the present invention provides methods of using the shaped porous carbon products and catalyst compositions for conversion reactions of biorenewable derived molecules and intermediates for commercial applications (e.g., selective oxidation of glucose to glucaric acid) or for applications requiring adsorption of compounds having a relatively large molecular volume. It has been surprisingly found that the shaped porous carbon product exhibits excellent mechanical strength (e.g., mechanical part crush strength and/or radial part crush strength) and that the use of a catalyst composition comprising the shaped porous carbon product of the present invention unexpectedly provides higher productivity, selectivity and/or yield in certain reactions when compared to similar catalyst compositions having different catalyst support materials.

Shaped porous carbon product and method of making

The shaped porous carbon products of the present invention can be prepared with carbon black. Carbon black materials include various sub-types including acetylene black, conductive carbon black, channel black, furnace black, lamp black, and thermal black. The main processes used to make carbon black are the furnace process and the thermal cracking process. Typically, carbon black is produced by depositing solid carbon particles in the gas phase formed by combustion or thermal cracking of petroleum products. Carbon black materials are characterized by particles having diameters in the nanometer range (typically about 5 to about 500 nm). These materials also have much lower surface area, a greater amount of mesopores (mesopores), and lower ash and sulfur content than activated carbon. Carbon black materials are used commercially in many applications such as fillers, pigments, reinforcements, and viscosity modifiers. However, due to their extremely low surface area, carbon black materials generally cannot be used as supports for chemical catalytic reactions or adsorbents. Low surface area carbon black materials are preferably not considered support structures for catalytic applications because low surface area is considered to be detrimental to effective dispersion of the catalytically active components resulting in poor catalytic activity.

As described above, activated carbon is considered to have an optimum support structure for catalytic applications because it allows a catalytically active component to be well dispersed on the surface of a catalyst and allows a chemical agent to be effectively adsorbed and reacted on the surface of the catalyst. Conversely, this limits the use of carbon black as a catalyst support. In order to use carbon black as a support for chemical catalytic reactions, several groups have reported methods for modifying carbon black materials. The reported modifications are centered on methods for increasing the surface area of the carbon black material. U.S. Pat. No. 6,337,302 describes a process for making "almost useless" carbon black as an activated carbon for commercial applications. U.S. Pat. No. 3,329,626 describes surface area of 40 to 150m by steam activation ² Per gram of carbon black material converted to a surface area of up to about 1200m ² A method of activating carbon per gram.

Despite these teachings, it has been unexpectedly discovered that certain carbon black materials having a particular combination of characteristics (e.g., surface area, pore volume, and pore diameter) are effective for shaped porous carbon catalyst supports for catalytic reactions, including liquid and mixed phase reaction media. The shaped porous carbon products of the present invention can be formed into a mechanically strong, chemically stable, durable form that can reduce resistance to liquid and gas flow, withstand desired process conditions, and provide long-term stable catalytic operation. These shaped porous carbon products provide high productivity and high selectivity during long continuous flow operations under demanding reaction conditions, including liquid phase reactions, in which the catalyst composition is exposed to reaction solvents such as acids and water at elevated temperatures.

Carbon black may constitute a majority of the shaped porous carbon product of the present invention. Thus, the carbon black content in the shaped porous carbon product is at least about 35 wt% or more, such as at least about 40 wt%, at least about 45 wt%, at least about 50 wt%, at least about 55 wt%, at least about 60 wt%, at least about 65 wt%, or at least about 70 wt%. In various embodiments, the carbon black content in the shaped porous carbon product is from about 35 wt% to about 80 wt%, from about 35 wt% to about 75 wt%, from about 40 wt% to about 80 wt%, or from about 40 wt% to about 75 wt%.

Typically, the carbon black material used to prepare the shaped porous carbon products of the present invention has a BET specific surface area in the range of about 20m ² G to about 500m ² (ii) in terms of/g. In various embodiments, the carbon black has a BET specific surface area in the range of about 20m ² G to about 350m ² G, about 20m ² G to about 250m ² G, about 20m ² G to about 225m ² G, about 20m ² G to about 200m ² G, about 20m ² A/g to about 175m ² G, about 20m ² G to about 150m ² G, about 20m ² A/g to about 125m ² G, about 20m ² G to about 100m ² G, about 25m ² G to about 500m ² A,/g, about 25m ² G to about 350m ² A,/g, about 25m ² G to about 250m ² G, about 25m ² G to about 225m ² A,/g, about 25m ² G to about 200m ² A,/g, about 25m ² A/g to about 175m ² A,/g, about 25m ² G to about 150m ² G, about 25m ² G to about 125m ² G, about 25m ² G to about 100m ² G, about 30m ² G to about 500m ² G, about 30m ² G to about 350m ² G, about 30m ² G to about 250m ² G, about 30m ² G to about 225m ² G, about 30m ² G to about 200m ² G, about 30m ² A/g to about 175m ² G, about 30m ² G to about 150m ² G, about 30m ² A/g to about 125m ² In g, or about 30m ² G to about 100m ² (ii) in terms of/g. The specific surface area of the carbon black material is determined from the nitrogen adsorption data using Brunauer, emmett and Teller (BET) theory. See J.Am.chem.Soc.1938,60,309-331 and ASTM test methods ASTM 3663, D6556, or D4567 for total and external surface area measurements by nitrogen adsorptionStandard Test Methods for quantity and External Surface Area Measurements by Nitrogen addition and are incorporated herein by reference.

The average pore diameter of the carbon black material is typically greater than about 5nm, greater than about 10nm, greater than about 12nm, or greater than about 14nm. In some embodiments, the carbon black material used to prepare the shaped porous carbon product has an average pore diameter in the range of from about 5nm to about 100nm, from about 5nm to about 70nm or more, from about 5nm to about 50nm, from about 5nm to about 25nm, from about 10nm to about 100nm, from about 10nm to about 70nm or more, from about 10nm to about 50nm, or from about 10nm to about 25nm. Such pore diameters allow reactant molecules having a large molecular volume (e.g., biorenewable derived molecules having a 6-carbon atom architecture) to be efficiently transported back and forth to the pore structure of the catalytically active surface, thereby enabling increased activity.

The specific pore volume of the carbon black material used to prepare the shaped porous carbon products of the present invention is generally greater than about 0.1cm ³ Per gram, greater than about 0.2cm ³ Per gram, or greater than about 0.3cm ³ (ii) in terms of/g. The specific pore volume of the carbon black material may range from about 0.1cm ³ G to about 1cm ³ G, about 0.1cm ³ G to about 0.9cm ³ G, about 0.1cm ³ G to about 0.8cm ³ G, about 0.1cm ³ G to about 0.7cm ³ G, about 0.1cm ³ G to about 0.6cm ³ Per g, about 0.1cm ³ G to about 0.5cm ³ Per g, about 0.2cm ³ G to about 1cm ³ Per g, about 0.2cm ³ G to about 0.9cm ³ G, about 0.2cm ³ G to about 0.8cm ³ G, about 0.2cm ³ G to about 0.7cm ³ G, about 0.2cm ³ G to about 0.6cm ³ G, about 0.2cm ³ G to about 0.5cm ³ Per g, about 0.3cm ³ G to about 1cm ³ Per g, about 0.3cm ³ G to about 0.9cm ³ Per g, about 0.3cm ³ G to about 0.8cm ³ Per g, about 0.3cm ³ G to about 0.7cm ³ Per g, about 0.3cm ³ G to about 0.6cm ³ In g, or about 0.3cm ³ G to about 0.5cm ³ (ii) in terms of/g. Carbon black materials having these specific pore volumes provide sufficient uniform wetting and good dispersion of the catalytically active component while allowing for uniform wettingA volume of sufficient contact between the reactant molecules and the catalytically active surface. The average pore diameter and pore volume were determined according to the procedure described below: barrett, L.G.Joyner, P.P.Halenda, J.Am.chem.Soc.1951,73,373-380 (BJH Method), and ASTM D4222-03 (2008) Standard Test Method for Determination of Nitrogen addition and resolution applications of Catalysts and Catalysts Carriers by dynamic Volumetric Measurements, incorporated herein by reference.

Certain carbon black materials are known to be electrically conductive. Thus, in various embodiments, the shaped porous carbon product comprises a conductive carbon black and in some embodiments, the shaped porous carbon product is conductive. In other embodiments, the shaped porous carbon product comprises a non-conductive carbon black. In further embodiments, the shaped porous carbon product comprises a non-conductive carbon black, wherein the shaped porous carbon product does not have a conductivity suitable for a conductive electrode. In certain embodiments, the shaped porous carbon product comprises less than about 50%, less than about 40%, less than about 30%, less than about 20%, less than about 10%, less than about 5%, or less than about 1% of conductive carbon black based on the total weight of carbon black in the shaped porous carbon product and/or the total weight of carbon black used to prepare the shaped porous carbon product. In some embodiments, the shaped porous carbon product comprises carbon black consisting of or consisting essentially of non-conductive carbon black. In some embodiments, the carbon black comprises silica-bound or alumina-bound carbon black. In certain embodiments, the shaped porous carbon product may further comprise graphite and/or metal oxides (e.g., alumina, silica, titania, etc.).

Shaped porous carbon products containing carbon black can be made by various methods such as dry extrusion, drop casting, injection molding, 3D printing, extrusion, and other pelletizing and pelletizing methods. For example, dry powder extrusion involves extruding carbon black particles in a press (e.g., a hot or cold isostatic press or calender). Other granulation and pelletization methods include tumbling carbon black particles and contacting the particles with a spray containing a binder.

Various methods of making shaped porous carbon products include mixing water, carbon black, and a binder to form a carbon black mixture; shaping the carbon black mixture to produce a shaped carbon black composite; heating the shaped carbon black composite to carbonize the binder into a water-insoluble state and produce a shaped porous carbon product. In various methods of making shaped porous carbon products, a binder solution may be prepared by mixing water and a binder prior to mixing with carbon black. Generally, in the binder, the binder solution and the carbon black mixture are relatively concentrated. For example, the water content of the carbon black mixture is generally not more than about 80 wt.%, not more than about 55 wt.%, not more than about 40 wt.%, or not more than about 25 wt.%. In various embodiments, the water content of the carbon black mixture may be from about 5 wt% to about 70 wt%, from about 5 wt% to about 55 wt%, from about 5 wt% to about 40 wt%, or from about 5 wt% to about 25 wt%. The viscosity of the binder solution can vary, for example, depending on the binder content and can be readily adjusted to suit a particular forming process by varying the relative amounts of the solid and liquid components. For example, the viscosity of the aqueous solution can be varied by adjusting the amount of binder used and the type of binder used. In various methods, water and binder may also be mixed and heated to form a binder solution. In some cases, heating may increase the amount of binder that may be incorporated into the binder solution and/or the carbon black mixture (e.g., by increasing the solubility of the binder). For example, the water and binder may be heated to a temperature of at least about 50 ℃, at least about 60 ℃, or at least about 70 ℃. In various embodiments, the water and binder may be heated to a temperature of from about 50 ℃ to about 95 ℃, from about 50 ℃ to about 90 ℃, or from about 60 ℃ to about 85 ℃.

After mixing and heating to form the binder solution, the binder solution may be cooled if necessary and then mixed with carbon black, or then formed into a shaped carbon black composite.

A method of making the shaped porous carbon product of the invention includes mixing carbon black particles with a solution containing a binder to produce a slurry; shaping the slurry (e.g., by extrusion molding) to produce a shaped carbon black composite, and heating or pyrolyzing the shaped carbon black composite to carbonize the binder to produce a shaped porous carbon product.

In the various methods of making the shaped porous carbon products of the invention described herein, a binder solution or binder is thoroughly mixed with water and blended with carbon black to produce a carbon black mixture (e.g., slurry or paste). The weight ratio of binder to carbon black in the carbon black mixture is typically at least about 1. The binder to carbon black weight ratio in the carbon black mixture can also be from about 1 to about 3, from about 1 to about 1, from about 1 to about 3 to about 1, from about 1 to about 1. Typically, the carbon black content in the carbon black mixture is at least about 35 wt% or more, such as at least about 40 wt%, at least about 45 wt%, at least about 50 wt%, at least about 55 wt%, at least about 60 wt%, at least about 65 wt%, or at least about 70 wt% on a dry weight basis. In various embodiments, the carbon black content in the carbon black mixture is from about 35 wt.% to about 80 wt.%, from about 35 wt.% to about 75 wt.%, from about 40 wt.% to about 80 wt.%, or from about 40 wt.% to about 75 wt.%, on a dry weight basis. Moreover, the binder content in the carbon black mixture is typically at least about 10 wt.%, at least about 20 wt.%, at least about 25 wt.%, at least about 30 wt.%, at least about 35 wt.%, at least about 40 wt.%, or at least 45 wt.% on a dry weight basis. In the various methods described herein for preparing the shaped porous carbon products of the present invention, the binder content in the carbon black mixture is from about 10 wt% to about 50 wt%, from about 10 wt% to about 45 wt%, from about 15 wt% to about 50 wt%, from about 20 wt% to about 50 wt%, or from about 20 wt% to about 45 wt% on a dry weight basis.

Various methods of making the shaped porous carbon product can also include extrusion or kneading of the carbon black mixture. Extrusion pressing or kneading the carbon black mixture makes the mixture compact and can reduce the water content of the mixture. The extrusion pressing or kneading of water, carbon black and a binder (carbon black mixture) may be performed simultaneously with the mixing of water, carbon black and a binder. For example, one method of mixing water, carbon black and a binder and simultaneously extruding the resulting carbon black mixture may be performed using a hybrid mill.

After mixing the carbon black and the binder, the resulting carbon black mixture is formed into a shaped carbon black composite structure having a desired shape and size by the following forming techniques: such as extrusion, pelletizing, pastillation, cold or hot isostatic pressing, calendering, injection molding, 3D printing, drip casting, or other known methods of producing molded structures. Forming methods such as cold isostatic pressing or cold isostatic pressing and 3D printing may or may not require a binder.

Generally, the shaped porous carbon product can be shaped and graded for use in known industrial reactor types, such as stirred tank reactors based on batch slurries, continuous slurries, fixed bed reactors, ebullating bed reactors, and other known industrial reactor types. The shaped porous carbon product can be shaped into a variety of shapes including spherical, bead, cylindrical, granular, multilobal, annular, star, broken cylinder (rippled cylinder), triple, alpha, wheel, and the like. Furthermore, the shaped porous carbon product can be shaped into amorphous, non-geometric, and random as well as asymmetric shapes, such as high flow rings (hiflow rings) as well as conical and alpha rings. The average diameter of the shaped porous carbon product is typically at least about 50 μm (0.05 mm), at least about 500 μm (0.5 mm), at least about 1,000 μm (1 mm), or at least about 10,000 μm (10 mm) or more to accommodate processing requirements.

For extrusion molding, the following pressures are typically applied to the carbon black mixture: at least about 100kPa (1 bar), or between about 100kPa (1 bar) and about 10,000kPa (100 bar), between 500kPa (5 bar) and 5,000kPa (50 bar), or between 1,000kPa (10 bar) and 3,000kPa (30 bar).

In the drip casting method, a carbon black mixture containing carbon black particles and a binder is dispensed in the form of droplets into a casting bath to shape a shaped carbon black composite, and then the shaped carbon black composite is separated from the casting bath. Droplets of a carbon black mixture of a particular diameter can be dispensed through a graded nozzle and dropped into a bath to produce solidified spherical carbon black composites having various diameters. In various embodiments of this method, the binder comprises alginate (or alginate in combination with another carbohydrate binder described herein) that can be dispensed into a bath containing an agent that causes solidification (e.g., an ionic salt, such as a calcium salt), as described in U.S. patent No. 5,472,648, the entire contents of which are incorporated herein by reference. The droplets are then allowed to remain substantially free in the ionic solution until the desired degree of solidification and coagulation is achieved. Alternatively, the drip irrigation casting bath used may be, for example, an oil bath or a bath that causes freeze drying. When an oil bath is utilized, the oil temperature is high enough to thermally cure the binder (e.g., convert the binder into a three-dimensional gel). When a freeze drying bath is utilized, the resulting beads are typically dried by vacuum treatment. The shaped carbon black composites produced by these drip casting processes are subsequently pyrolyzed.

As described in more detail below, other ingredients may be added to the carbon black mixture to aid in the molding process (e.g., lubricants, compatibilizers, etc.) or to provide other benefits. In various embodiments, the carbon black mixture further comprises a forming adjuvant. For example, the forming adjuvant may comprise a lubricant. Suitable forming adjuvants include, for example, lignin or lignin derivatives.

In addition, pore formers may be mixed with the carbon black and binder to modify and obtain the desired porosity characteristics of the shaped porous carbon product. Other methods of altering the porosity of the shaped porous carbon product include mixing two or more different carbon black starting materials (e.g., carbon blacks having different shapes and/or sizes, whose irregular packing results in a multi-modal pore size distribution, or carbon blacks from different sources/suppliers), or mixing carbon black powder carbons. Other methods of altering the porosity of the shaped porous carbon product include multiple heat treatments and/or multiple mixing (e.g., pyrolyzing a shaped carbon black composite of carbon powder and binder, followed by mixing with fresh carbon black powder and binder, and pyrolyzing the resulting composite).

In various methods of making shaped porous carbon products, after a carbon black mixture (e.g., slurry or paste) is processed into a shaped carbon black composite, the composite can be dried to dehydrate the composite. Drying can be accomplished by heating the composite at atmospheric pressure and typically at a temperature of from about room temperature (e.g., about 20 ℃) to about 150 ℃, from about 40 ℃ to about 120 ℃, or from about 60 ℃ to about 120 ℃. Other drying methods may be utilized, including vacuum drying, freeze drying, and dehumidification. When using certain manufacturing methods for shaping (e.g. pastillation, extrusion), a drying step may not be required.

In various methods of making a shaped porous carbon product, a shaped carbon black composite is heat treated in an inert (e.g., inert nitrogen atmosphere), oxidizing or reducing atmosphere (e.g., by extrusion, pelletizing, briquetting, cold or hot isostatic pressing, calendering, injection molding, 3D printing, drip casting, and other shaping methods) to carbonize at least a portion of the binder into a water insoluble state and produce a shaped porous carbon product. The heat treatment is generally carried out at the following temperatures: about 250 ℃ to about 1,000 ℃, about 300 ℃ to about 900 ℃, about 300 ℃ to about 850 ℃, about 300 ℃ to about 800 ℃, about 350 ℃ to about 850 ℃, about 350 ℃ to about 800 ℃, about 350 ℃ to about 700 ℃, about 400 ℃ to about 850 ℃, or about 400 ℃ to about 800 ℃. In some cases and depending on the binder used, it has been determined that lower carbonization temperatures can result in slow bleeding of residual binder from the shaped porous carbon product, which reduces mechanical strength over prolonged use in catalytic reactions. In general, the heat treatment is carried out at a higher carbonization temperature within the above range in order to secure long-term stability. In some cases, the resulting shaped porous carbon product can be washed after heat treatment to remove impurities.

According to various production methods, the shaped porous carbon product of the present invention contains a binder or a carbonized product thereof in addition to carbon black. Various references, including U.S. Pat. No. 3,978,000, describe the use of acetone soluble organic polymers and thermosetting resins as binders for shaped carbon supports. However, the use of flammable organic solvents and expensive thermosetting resins is undesirable or uneconomical for the mass production of shaped porous carbon products.

The high mechanical strength shaped porous carbon product of the present invention can be made using an effective binder. The use of an effective binder provides a durable shaped porous carbon product capable of withstanding the conditions prevailing in a continuous liquid phase flow environment, such as a liquid phase that may contain water or biologically renewably-derived molecular or intermediate conversion reactions of an acidic medium. In such cases, the shaped porous carbon product is mechanically and chemically stable to enable long term operation without significant loss of catalytic performance. Moreover, the use of an effective binder provides a durable shaped porous carbon product that can withstand high temperatures.

Applicants have found that readily available water soluble organic compounds are suitable binders for preparing shaped porous carbon products of high mechanical strength. A binder as used herein is considered to be water soluble if it has a solubility of at least about 1% by weight, preferably at least about 2% by weight, at 50 ℃. Aqueous organic binder solutions are highly suitable for commercial manufacturing processes. Organic binders dissolved in aqueous solution are well mixed and dispersed when in contact with the carbon black material. These adhesives also avoid safety and handling issues associated with the use of large quantities of organic solvents that may be flammable and require special storage and handling. Moreover, these adhesives are relatively inexpensive compared to expensive polymer-based adhesives. Thus, in various embodiments, the carbon black mixture is free of water-immiscible solvents.

In various embodiments, the water-soluble organic binder comprises a carbohydrate or derivative thereof, which may be monomeric or oligomeric or polymeric carbohydrates (also referred to as sugars, oligosaccharides and polysaccharides). Also included are derivatives of carbohydrates (in monomeric or oligomeric or polymeric form) in which one or more functional groups bound to the carbohydrate may be displaced or derivatized. Such derivatives may be acidic or charged carbohydrates, such as alginic acid or alginate, or pectin, or aldonic, uronic, xylonic or xylonic acids (or oligomers or polymers or salts thereof). Other derivatives include sugar alcohols and polymeric forms thereof (e.g., sorbitol, mannitol, xylitol or polyols derived from carbohydrates). The carbohydrate binder may be used in the following form: a syrup, such as molasses or corn syrup, or a soluble starch, or a soluble gum, or a modified version thereof.

In various embodiments, the water-soluble organic binder comprises a saccharide selected from the group consisting of: monosaccharides, disaccharides, oligosaccharides, derivatives thereof, and any combinations thereof. In these and other embodiments, the water-soluble organic binder comprises: (i) a saccharide selected from the group consisting of: monosaccharides, disaccharides, oligosaccharides, derivatives thereof, and any combination thereof, and (ii) polymeric carbohydrates, derivatives of polymeric carbohydrates, or non-carbohydrate synthetic polymers, or any combination thereof. (i) The weight ratio of saccharide to (ii) polymeric carbohydrate, derivative of polymeric carbohydrate, or non-carbohydrate synthetic polymer, or combination thereof, can be from about 5.

In various embodiments, the water-soluble organic binder comprises a monosaccharide. For example, the monosaccharide may be selected from the group consisting of: glucose, fructose, hydrates thereof, syrups thereof (e.g., corn syrup, molasses, etc.), and combinations thereof. In further embodiments, the water-soluble organic binder comprises a disaccharide. Disaccharides include, for example, maltose, sucrose, syrups thereof, and combinations thereof.

As noted, the binder may comprise a polymeric carbohydrate, a derivative of a polymeric carbohydrate, or a non-carbohydrate synthetic polymer, or any combination thereof. In various embodiments, the binder comprises a polymeric carbohydrate, a derivative of a polymeric carbohydrate, or any combination thereof. The polymeric carbohydrate or derivative of the polymeric carbohydrate may include a cellulose compound. Cellulose compounds include, for example, methyl cellulose, ethyl methyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, methyl hydroxyethyl cellulose, ethyl hydroxyethyl cellulose, hydroxypropyl methyl cellulose, carboxymethyl cellulose, and mixtures thereof.

Further, the polymeric carbohydrate or derivative of a polymeric carbohydrate may be selected from the group consisting of: alginic acid, pectin, aldonic acids, aldaric acids, uronic acids, alditols, and salts, oligomers and polymers thereof. The polymeric carbohydrate or derivative of a polymeric carbohydrate may also include starch or a soluble gum.

In various embodiments, the water-soluble organic binder comprises a cellulose compound. In another embodiment, the binder comprises an acidic polysaccharide, such as alginic acid, pectin or a salt thereof. In other embodiments, the binder comprises a soluble cellulose, such as an alkyl cellulose (e.g., hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxyethyl methyl cellulose, hydroxypropyl methyl cellulose, and carboxymethyl cellulose).

In various embodiments, the binder comprises a non-carbohydrate synthetic polymer. Water-soluble polymers or copolymers can be used as binders. For example, polyacrylic acid, polyvinyl alcohol, polyvinyl pyrrolidone, polyvinyl acetate, polyacrylates, polyethers derived therefrom (e.g., polyethylene glycol, and the like) and copolymers (which may be block copolymers containing water insoluble block monomers and water soluble block monomers), and blends thereof. In some cases, the water-soluble copolymer can be a block copolymer comprising a water-soluble polymer block and a second polymer block (e.g., polystyrene) that can be hydrophobic and suitable for carbonization. In another embodiment, a dispersion of the polymer in water is used as binder, i.e. a water-insoluble polymer dispersed in water (with the aid of a surfactant), such as a commercial polyvinyl alcohol, polyacrylonitrile, acrylonitrile-butadiene-styrene copolymer, phenolic polymer or lignin polymer dispersion. There are also copolymers consisting of water-soluble branches (e.g. polyacrylic acid) and hydrophobic branches (e.g. polymaleic anhydride, polystyrene) which enable the copolymer to be water-soluble and carbonize the hydrophobic branches upon pyrolysis without depolymerisation. The carbohydrate or derivative thereof, the water-soluble polymer and the polymer dispersion in water may be used in various combinations.

As described above, the water-soluble organic binder that can be used in combination with the saccharide binder includes water-soluble cellulose and starch (e.g., hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxyethyl methyl cellulose, hydroxypropyl methyl cellulose, carboxymethyl cellulose), water-soluble alcohols (e.g., sorbitol, xylitol, polyvinyl alcohol), water-soluble acetals (e.g., polyvinyl butyral), water-soluble acids (e.g., stearic acid, citric acid, alginic acid, aldonic acid, aldaric acid, uronic acid, xylonic acid, or xylaric acid (or oligomers thereof, or polymers or salts or esters thereof), polyvinyl acrylic acid (or salts or esters thereof)). In some embodiments, the combination of water-soluble organic binders comprises a cellulosic compound and a monosaccharide. In certain embodiments, the cellulosic compound comprises hydroxyethyl cellulose, or methyl cellulose, and the monosaccharide comprises glucose, fructose, or a hydrate thereof (e.g., glucose). In particular, a combination comprises glucose and hydroxyethyl cellulose which provides enhanced mechanical strength to the shaped porous carbon product, particularly when processed at high carbonization temperatures. In other embodiments, the combination of water-soluble organic binders comprises a monosaccharide and a water-soluble alcohol such as sorbitol, mannitol, xylitol, or polyvinyl alcohol. In other embodiments, the combination of water-soluble organic binders comprises a monosaccharide and a water-soluble acid such as stearic acid, pectin, alginic acid, or polyacrylic acid (or salts thereof). In further embodiments, the combination of water-soluble organic binders comprises a monosaccharide and a water-soluble ester such as a polyacrylate or a polyacetate. In other embodiments, the combination of water-soluble organic binders comprises a monosaccharide and a water-soluble acetal such as polyacetal (e.g., polyvinyl butyral).

Other water soluble compounds may be used in combination with the carbohydrate or polymeric binder. Combining a carbohydrate or other binder with other water-soluble organic compounds of choice can provide benefits to the preparation and characteristics of the resulting shaped porous carbon product. For example, water-soluble organic compounds, e.g. stearic acid or stearates, e.g. Zr or NH ₄ The stearate may provide lubricity during the forming process. Wetting agents (such as the GLYDOL series commercially available from Zschimmer and Schwarz) may be added.

The pore former may also be added in combination with a binder (or binders). The pore former is typically added to occupy a specific molecular volume within the formulation so that after shaping and heat treatment, the pore former is pyrolysed to leave pores of a specific volume and diameter within the shaped product. The presence of such pores may be beneficial for performance. For example, when used as a catalyst support, the presence of such pores can result in more efficient diffusion back and forth (of reactants and products) to the catalytically active surface. More efficient access of reactants and products can lead to improved catalyst productivity and selectivity. Typically, the porogen is an oligomer (e.g., a dimer, trimer of higher oligomers) or polymer in nature. Water-soluble organic compounds, such as water-soluble linear and branched polymers and crosslinked polymers, are suitable for use as porogens. Polyacrylates (e.g., weakly cross-linked polyacrylates known as superabsorbents), polyvinyl alcohols, polyvinyl acetates, polyesters, polyethers, or copolymers thereof (which may be block copolymers) may be used as porogens. In some cases, the water-soluble copolymer can be a block copolymer comprising a water-soluble polymer block and a second polymer block (e.g., polystyrene) that can be hydrophobic and suitable for carbonization. In another embodiment, a dispersion of the polymer in water is used as binder, i.e. a water-insoluble polymer dispersed in water (with the aid of surfactants), such as commercial polyvinyl alcohol, polyacrylonitrile, acrylonitrile-butadiene-styrene copolymer, phenolic polymer dispersions. There are also copolymers consisting of water-soluble branches (for example polyacrylic acid) and hydrophobic branches (for example polymaleic anhydride, polystyrene) which enable the copolymer to be water-soluble and to carbonize the hydrophobic branches without depolymerisation on pyrolysis. The dispersions of carbohydrates or their derivatives (disaccharides, oligosaccharides, polysaccharides, such as sucrose, maltose, trehalose (trihalose), starch, cellobiose, cellulose), water-soluble polymers and polymers in water can be used together in any combination as pore formers to obtain shaped porous carbon black products having the desired pore size and volume characteristics described herein.

Gels (e.g., pre-gelled superabsorbents) or water-insoluble incompressible solids (e.g., polystyrene microspheres, lignin, phenolic polymers) or swellable pore formers such as in the form of EXPANSEL microspheres commercially available from Akzo Nobel pump and Performance (Sundsvall, sweden) may also be added. The molecular weight of the oligomer or polymer can also be selected to tailor the desired pore size and volume characteristics of the shaped carbon products of the invention. For example, the desired shaped carbon product may have a monomodal, bi-modal or multi-modal pore size distribution as a result of the addition of the pore former. To illustrate, a bi-or multi-modal pore size distribution may consist of a high percentage of pores between 10 and 100nm and pores greater than 100 nm. This pore structure can provide performance advantages. For example, the presence of such a pore size distribution can result in more efficient diffusion back and forth through larger pores (transport pores) to the catalytically active surface, which resides in pores between 10 and 100nm in size. More efficient access of reactants and products can lead to increased catalyst productivity, selectivity, and/or yield.

After heat treating the shaped carbon black composite, the resulting shaped porous carbon product comprises carbon black and a carbonized binder. More generally, the shaped porous carbon product may comprise carbon agglomerates. Without being bound by any particular theory, it is believed that the carbon agglomerates comprise carbon agglomerates or particles that are at least partially physically bound or entangled by the carbonized binder. Also, without being bound by any particular theory, the resulting agglomerates may comprise a chemical combination of the carbonized binder and the carbon agglomerates or particles.

The carbonized binder comprises the carbonized product of the water soluble organic binder described herein. Carbonizing the binder during the preparation of the shaped porous carbon product can result in a reduced weight of the shaped carbon black composite formed therefrom. Thus, in various embodiments, the carbonized binder content of the shaped porous carbon product is from about 10 wt.% to about 50 wt.%, from about 20 wt.% to about 50 wt.%, from about 25 wt.% to about 40 wt.%, or from about 25 wt.% to about 35 wt.% (e.g., 30 wt.%).

Generally, the specific surface area (BET surface area), average pore diameter, and specific pore volume of the shaped porous carbon product correspond to the specific surface area, average pore diameter, and specific pore volume of the carbon black material used to prepare the product. However, the method of preparation can result in a reduction or increase (e.g., by about 10% -50% or 10% -30%) in these properties of the product as compared to the carbon black material. In various embodiments, the shaped porous carbon productThe specific surface area of the material is about 20m ² G to about 500m ² G, about 20m ² G to about 350m ² G, about 20m ² G to about 250m ² G, about 20m ² G to about 225m ² G, about 20m ² G to about 200m ² G, about 20m ² A/g to about 175m ² G, about 20m ² G to about 150m ² G, about 20m ² G to about 125m ² In terms of/g, or about 20m ² G to about 100m ² A,/g, about 25m ² G to about 500m ² A,/g, about 25m ² G to about 350m ² A,/g, about 25m ² G to about 250m ² A,/g, about 25m ² G to about 225m ² A,/g, about 25m ² G to about 200m ² G, about 25m ² G to about 175m ² G, about 25m ² G to about 150m ² A,/g, about 25m ² A/g to about 125m ² G, about 25m ² G to about 100m ² G, about 30m ² G to about 500m ² G, about 30m ² G to about 350m ² G, about 30m ² G to about 250m ² G, about 30m ² G to about 225m ² G, about 30m ² G to about 200m ² G, about 30m ² G to about 175m ² G, about 30m ² G to about 150m ² G, about 30m ² A/g to about 125m ² In g, or about 30m ² G to about 100m ² (iv) g. The specific surface area of the shaped porous carbon product was determined from the nitrogen adsorption data using Brunauer, emmett and Teller. See J.am.chem.Soc.1938,60,309-331 and ASTM Test Methods D3663, D6556 or D4567 for a method described in Standard Test Methods for Surface Area Measurements by Nitrogen Adsorption.

The average pore diameter of the shaped porous carbon product is typically greater than about 5nm, greater than about 10nm, greater than about 12nm, or greater than about 14nm. In some embodiments, the shaped porous carbon product has a mean pore diameter of from about 5nm to about 100nm, from about 5nm to about 70nm, from about 5nm to about 50nm, from about 5nm to about 25nm, from about 10nm to about 100nm, from about 10nm to about 70nm, from about 10nm to about 50nm, or from about 10nm to about 25nm. Furthermore, the shaped porous carbon product of the invention has a specific pore volume of pores with a diameter of 1.7nm to 100nmThe product (as measured by the BJH method) is typically greater than about 0.1cm ³ A/g, greater than about 0.2cm ³ In g, or greater than about 0.3cm ³ (iv) g. In various embodiments, the shaped porous carbon product has a specific pore volume (as measured by the BJH method) of pores having a diameter of 1.7nm to 100nm of about 0.1cm ³ G to about 1.5cm ³ G, about 0.1cm ³ G to about 0.9cm ³ G, about 0.1cm ³ G to about 0.8cm ³ G, about 0.1cm ³ G to about 0.7cm ³ Per g, about 0.1cm ³ G to about 0.6cm ³ Per g, about 0.1cm ³ G to about 0.5cm ³ G, about 0.2cm ³ G to about 1cm ³ Per g, about 0.2cm ³ G to about 0.9cm ³ Per g, about 0.2cm ³ G to about 0.8cm ³ G, about 0.2cm ³ G to about 0.7cm ³ Per g, about 0.2cm ³ G to about 0.6cm ³ G, about 0.2cm ³ G to about 0.5cm ³ G, about 0.3cm ³ G to about 1cm ³ G, about 0.3cm ³ G to about 0.9cm ³ Per g, about 0.3cm ³ G to about 0.8cm ³ G, about 0.3cm ³ G to about 0.7cm ³ G, about 0.3cm ³ G to about 0.6cm ³ In g, or about 0.3cm ³ G to about 0.5cm ³ (iv) g. The average pore diameter and specific pore volume were determined according to the procedure described in: barrett, L.G.Joyner, P.P.Halenda, J.Am.Chem.Soc.1951,73,373-380 (BJH Method), and ASTM D4222-03 (2008) Standard Test Method for Determination of Nitrogen addition and removal isomers of Catalysts and Catalysts Carriers by Static Volumetric Measurements measures, which are incorporated herein by reference.

It is observed that the size of the specific surface area is generally proportional to the concentration of micropores in the structure of the shaped porous carbon product. In particular, the shaped porous carbon product typically has a low concentration of pores having an average diameter of less than 1.7 nm. Typically, pores having an average diameter of less than 1.7nm constitute no more than about 10%, no more than about 5%, no more than about 4%, no more than about 3%, or no more than about 2.5% of the pore volume of the shaped porous carbon product. Similarly, in various embodiments, no peak in the pore size distribution of the shaped porous carbon product below about 10nm or about 5nm was observed. For example, the shaped porous carbon product can have a pore size distribution such that a peak of the distribution is at a diameter of greater than about 5nm, greater than about 7.5nm, greater than about 10nm, greater than about 12.5nm, greater than about 15nm, or greater than about 20 nm. Moreover, the shaped porous carbon product has a pore size distribution such that a peak of the distribution is at a diameter of less than about 100nm, less than about 90nm, less than about 80nm, or less than about 70 nm.

Furthermore, the shaped porous carbon product advantageously has a high concentration of mesopores between about 10nm and about 100nm, between about 20nm and about 100nm, or between about 10nm and about 50 nm. Thus, in various embodiments, at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, at least about 95% of the pore volume of the shaped porous carbon product, as measured by the BJH method on the basis of pores having a diameter of 1.7nm to 100nm, is attributable to pores having a mean pore diameter of about 10nm to about 100 nm. For example, from about 50% to about 99%, from about 50% to about 95%, from about 50% to about 90%, from about 50% to about 80%, from about 60% to about 99%, from about 60% to about 95%, from about 60% to about 90%, from about 60% to about 80%, from about 70% to about 99%, from about 70% to about 95%, from about 70% to about 90%, from about 70% to about 80%, from about 80% to about 99%, from about 80% to about 95%, from about 80% to about 90%, or from about 90% to about 99% of the pore volume of the shaped porous carbon product as measured by the BJH method on the basis of pores having a diameter from 1.7nm to 100nm is attributable to pores having a mean pore diameter from about 10nm to about 100 nm. Also, in various embodiments, at least about 35%, at least about 40%, at least about 45%, or at least about 50% of the pore volume of the shaped porous carbon product, as measured by the BJH method on the basis of pores having a diameter of 1.7nm to 100nm, is attributable to pores having a mean pore diameter of from about 20nm to about 90nm, or from about 10nm to about 50 nm. For example, from about 35% to about 80%, from about 35% to about 75%, from about 35% to about 65%, from about 40% to about 80%, from about 40% to about 75%, or from about 40% to about 70% of the pore volume of the shaped porous carbon product as measured by the BJH method on the basis of pores having a diameter of from 1.7nm to 100nm is attributable to pores having a mean pore diameter of from about 20nm to about 90nm or from about 10nm to about 50 nm.

Typically, the shaped porous carbon product has a relatively low concentration of pores of less than 10nm, less than 5nm, or less than 3 nm. For example, no more than about 10%, no more than about 5%, or no more than about 1% of the pore volume of the shaped porous carbon product, as measured by the BJH method on the basis of pores having a diameter from 1.7nm to 100nm, is attributable to pores having a mean pore diameter of less than 10nm, less than 5nm, or less than 3 nm. In various embodiments, from about 0.1% to about 10%, from about 0.1% to about 5%, from about 0.1% to about 1%, from about 1% to about 10%, or from about 1% to about 5% of the pore volume of the shaped porous carbon product as measured by the BJH method based on pores having a diameter from 1.7nm to 100nm is attributable to pores having a mean pore diameter of less than 10nm, less than 5nm, or less than 3 nm.

The shaped porous carbon products described herein are high mechanical strength and stable. Crush strength represents the solid's resistance to compression and is an important characteristic of the shaped porous carbon products described herein for industrial use. Instruments for measuring the crushing strength of a component of individual solid particles typically include a load cell that measures the force gradually applied to the solid during the advancement of the piston. The applied force is increased until the solid breaks up and disintegrates into small fragments and eventually a powder. The corresponding value of the breaking force is defined as the crushing strength of the part and is usually the average of a number of samples. Standard protocols for measuring crush strength are known in the art. For example, the mechanical strength of the shaped porous carbon product can be measured by the part crush strength test protocol described in ASTM D4179 or ASTM D6175, which are incorporated herein by reference. Some of these testing methods are reported to be limited to particles of a defined size range, geometry, or manufacturing method. However, the crush strength of irregularly shaped particles and particles of different sizes and manufactures can still be suitably measured by these and similar test methods.

In various embodiments, the shaped porous carbon product prepared according to the present invention has a radial part crush strength greater than about 4.4N/mm (1 lb/mm), greater than about 8.8N/mm (2 lb/mm), or greater than about 13.3N/mm (3 lb/mm). In certain embodiments, the shaped porous carbon product has a radial part crush strength of from about 4.4N/mm (1 lb/mm) to about 88N/mm (20 lb/mm), from about 4.4N/mm (1 lb/mm) to about 66N/mm (15 lb/mm), or from about 8.8N/mm (2 lb/mm) to about 44N/mm (10 lb/mm). In radial component crush strength measurements, the measured force is relative to the dimension of the solid perpendicular to the applied load, which can typically range from about 0.5mm to about 20mm, from about 1mm to about 10mm, or from about 1.5mm to 5mm. For the irregularly shaped porous carbon products, the radial component crush strength was measured by applying a load perpendicularly to the longest dimension of the solid.

Mechanical part crush strength can also be reported based on amorphous porous carbon product size units (e.g., typically for spherical solids or solids having roughly equal transverse dimensions). The shaped porous carbon products prepared according to the present invention typically have a part crush strength greater than about 22N (5 lb), greater than about 36N (8 lb), or greater than about 44N (10 lb). In various embodiments, the part crush strength of the shaped porous carbon product can be from about 22N (5 lb) to about 88N (20 lb), from about 22N (5 lb) to about 66N (15 lb), or from about 33N (7.5 lb) to about 66N (15 lb).

In addition to crush strength, the shaped porous carbon product also has desirable wear and abrasion resistance characteristics. There are several test methods suitable for determining the attrition and abrasion resistance of shaped porous carbon products and catalysts produced in accordance with the present invention. These methods are a measure of the tendency of a material to produce fines during transportation, handling and production use.

One such Method is the Attrition index, determined according to ASTM D4058-96 (Standard Test Method for the addition and subtraction of Catalyst and Catalyst Carriers), which is a measure of the wear and Abrasion resistance of a material (e.g., extrudate or Catalyst particles) due to repeated contact of the particles with a hard surface in a designated rotating Test bucket, which is incorporated herein by reference. This test method is generally applicable to tablets, extrudates, spheres, granules, pellets and irregular shaped particles typically having at least one dimension greater than about 1/16 inch (1.6 mm) and less than about 3/4 inch (19 mm), although abrasion measurements can also be made on larger sized materials. Variable and constant speed rotating drum abrasion testers designed according to ASTM D4058-96 are readily available. Typically, the material to be tested is placed in a rotating test drum and tumbled at about 55 to about 65RPM for about 35 minutes. The material was then removed from the test drum and screened on a 20 mesh screen. The weight percent of the original material sample remaining on the 20 mesh screen is referred to as the "percent remaining". The shaped porous carbon products (e.g., extrudates) and catalysts prepared therefrom typically have a rotating drum attrition index as measured in accordance with ASTM D4058-96 or similar test method such that the percent residue is greater than about 85 wt.%, greater than about 90 wt.%, greater than about 92 wt.%, greater than about 95 wt.%, greater than about 97 wt.%, or greater than about 99 wt.%. Results with a residual percentage greater than about 97% indicate a material with excellent mechanical stability and durable structure that is particularly desirable for industrial applications.

The attrition loss (ABL) is an alternative measure of the attrition resistance of the shaped porous carbon product (e.g., extrudate) and the catalyst prepared therefrom. As with the attrition index, the results of this test method can be used as a measure of fines generated during handling, transportation and use of the material. The amount of wear is a measure of the wear resistance of a material due to the vigorous horizontal agitation of particles in the 30 mesh screen. Typically, the material to be tested is first placed on a 20 mesh screen and gently shaken side-to-side at least about 20 times to remove dust. The dedusted samples were weighed and then transferred to a clean 30 mesh screen stacked above a clean screen frame for collection of fines. The resulting stack is then assembled on a vibratory screening machine (e.g., RO-Tap RX-29 vibratory screening machine from W.S. Tyler Industrial Group, mentor, OH) to form a complete stack of screens, which are securely covered and vibrated for about 30 minutes. The collected fines were weighed and divided by the weight of the dust-removed sample to obtain the amount of sample attrition expressed as a weight percentage. The horizontal stirred screen abrasion loss of the shaped porous carbon products (e.g., extrudates) and catalysts made therefrom is generally less than about 5 wt.%, less than about 3 wt.%, less than about 2 wt.%, less than about 1 wt.%, less than about 0.5 wt.%, less than about 0.2 wt.%, less than about 0.1 wt.%, less than about 0.05 wt.%, or less than about 0.03 wt.%. A wear of less than about 2% results which is particularly desirable for industrial applications.

Shaped porous carbon product of the invention and method for producing the shaped porous carbon productThe methods of (a) include various combinations of features described herein. For example, in various embodiments, a shaped porous carbon product comprises (a) carbon black and (b) a carbonized binder comprising a carbonized product of a water-soluble organic binder, wherein the shaped porous carbon product has a BET specific surface area of about 20m ² G to about 500m ² G or about 25m ² G to about 250m ² Per gram, average pore diameter greater than about 10nm, and specific pore volume greater than about 0.1cm ³ (ii)/g, the radial component crush strength is greater than about 4.4N/mm (1 lb/mm) and the carbon black content is at least about 35 wt%. In other embodiments, the shaped porous carbon product comprises carbon agglomerates, wherein the shaped porous carbon product has a mean diameter of at least about 50 μm and a BET specific surface area of about 20m ² G to about 500m ² In the range of/g or about 25m ² G to about 250m ² A mean pore diameter of greater than about 10nm and a specific pore volume of greater than about 0.1cm ³ A/g and a radial component crush strength greater than about 4.4N/mm (1 lb/mm).

The shaped porous carbon products of the present invention can also have a low sulfur content. For example, the sulfur content of the shaped porous carbon product can be no more than about 1 wt% or no more than about 0.1 wt%.

The characteristics and properties including carbon black type, binder type, specific surface area, specific pore volume, average pore diameter, crush strength, abrasion and wear resistance, and carbon black content may be independently adjusted or modified within the ranges described herein. Moreover, the shaped porous carbon product can be further defined in terms of the characteristics described herein.

For example, the shaped porous carbon product may comprise (a) carbon black and (b) a carbonized binder comprising a carbonized product of a water-soluble organic binder, and wherein the shaped porous carbon product has a BET specific surface area of about 20m ² G to about 500m ² Per gram, average pore diameter greater than about 5nm, and specific pore volume greater than about 0.1cm ³ (ii)/g, the radial component crush strength is greater than about 4.4N/mm (1 lb/mm), the carbon black content is at least about 35 wt%, and the carbonized binder content is from about 20 wt% to about 50 wt%.

In other embodiments, the shaped porous carbon product of the inventionComprising (a) carbon black and (b) a carbonising binder comprising the carbonising product of a water-soluble organic binder, wherein the shaped porous carbon product has a BET specific surface area of about 20m ² G to about 500m ² G or about 25m ² G to about 250m ² A mean pore diameter of greater than about 10nm and a specific pore volume of greater than about 0.1cm ³ (ii)/g, and a radial component crush strength greater than about 4.4N/mm (1 lb/mm), and a carbon black content of at least about 35 wt%, and wherein the shaped porous carbon product has a pore volume measured on the basis of pores having a diameter of 1.7nm to 100nm and at least about 35% of the pore volume is attributable to pores having a mean pore diameter of about 10nm to about 50 nm.

Another shaped porous carbon product of the invention comprises carbon agglomerates, wherein the shaped porous carbon product has a mean diameter of at least about 50 μm and a BET specific surface area of about 20m ² G to about 500m ² In the range of/g or about 25m ² G to about 250m ² A mean pore diameter of greater than about 10nm and a specific pore volume of greater than about 0.1cm ³ (ii)/g, and a radial part crush strength greater than about 4.4N/mm (1 lb/mm), and wherein the shaped porous carbon product has a pore volume measured on the basis of pores having a diameter of 1.7nm to 100nm and at least about 35% of the pore volume is attributable to pores having a mean pore diameter of about 10nm to about 50 nm.

The methods of the present invention comprise various combinations of features, characteristics and method steps described herein. For example, various methods for preparing a shaped porous carbon product include mixing water and a water-soluble organic binder and heating to form a binder solution, wherein the water and the binder are heated to a temperature of at least about 50 ℃, and wherein the binder comprises: (i) a saccharide selected from the group consisting of: a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof, and (ii) a polymeric carbohydrate, a derivative of a polymeric carbohydrate, or a non-carbohydrate synthetic polymer, or any combination thereof; mixing carbon black particles with a binder solution to produce a carbon black mixture; shaping the carbon black mixture to produce a shaped carbon black composite; and heating the shaped carbon black composite to carbonize the binder into a water-insoluble state and produce a shaped porous carbon product.

Other methods for preparing shaped porous carbon products include mixing water, carbon black, and a water-soluble organic binder to form a carbon black mixture, wherein the binder comprises: (i) a saccharide selected from the group consisting of: monosaccharides, disaccharides, oligosaccharides, derivatives thereof, and any combination thereof, and (ii) polymeric carbohydrates, derivatives of polymeric carbohydrates, or non-carbohydrate synthetic polymers, or any combination thereof; shaping the carbon black mixture to produce a shaped carbon black composite; and heating the shaped carbon black composite to carbonize the binder into a water-insoluble state and produce a shaped porous carbon product.

Additional methods include mixing water, carbon black, and a binder to form a carbon black mixture, wherein the binder comprises a saccharide selected from the group consisting of: a monosaccharide, disaccharide, oligosaccharide, derivative thereof, or any combination thereof, and wherein the weight ratio of binder to carbon black in the carbon black mixture is at least about 1; shaping the carbon black mixture to produce a shaped carbon black composite; and heating the shaped carbon black composite to carbonize the binder into a water-insoluble state and produce a shaped porous carbon product.

Other methods include mixing water, carbon black, and a binder to form a carbon black mixture, wherein the binder comprises a saccharide selected from the group consisting of: a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, or any combination thereof, and wherein the water content of the carbon black mixture is no more than about 80 wt.%, no more than about 55 wt.%, no more than about 40 wt.%, or no more than about 25 wt.%; shaping the carbon black mixture to produce a shaped carbon black composite; and heating the shaped carbon black composite to carbonize the binder into a water-insoluble state and produce a shaped porous carbon product.

Another method of preparing a shaped porous carbon product by extrusion molding preferably comprises mixing carbon black particles with an aqueous solution containing a water-soluble organic binder compound to produce a carbon black mixture(ii) the water-soluble organic binder compound is selected from the group consisting of: monosaccharides, disaccharides, oligosaccharides, polysaccharides, and combinations thereof, wherein the carbon black mixture comprises at least about 40 weight percent carbon black and at least about 40 weight percent binder on a dry weight basis; shaping the carbon black mixture at a pressure of at least 500kPa (5 bar) to produce a shaped carbon black composite; drying the shaped carbon black material at a temperature of about room temperature (e.g., about 20 ℃) to about 150 ℃; and in an oxidizing, inert, or reducing atmosphere (e.g. inert N) ₂ Atmosphere) to a temperature between about 250 ℃ and about 800 ℃ to carbonize the binder into a water-insoluble state and produce a shaped porous carbon product, wherein the shaped porous carbon product has an average diameter of at least about 50 μm and a BET specific surface area of about 20m ² G to about 500m ² In the range of/g or about 25m ² G to about 250m ² A mean pore diameter of greater than about 10nm and a specific pore volume of greater than about 0.1cm ³ A/g and a radial crush strength greater than about 4.4N/mm (1 lb/mm). Typically, the water-soluble organic binder compound is selected from the group consisting of: monosaccharides, oligosaccharides, polysaccharides, and combinations thereof. The carbon black content of the shaped porous carbon product can be at least about 35 wt% or as described herein. Also in some embodiments, the shaped porous carbon product has a pore volume measured on the basis of pores having a diameter of from 1.7nm to 100nm and at least about 35% of said pore volume is attributable to pores having a mean pore diameter of from about 10nm to about 50 nm. The carbon black mixture may optionally be heated during a forming step (e.g., extrusion, pelletizing, briquetting, cold or hot isostatic pressing, calendering, injection molding, 3D printing, drip casting, or other methods) to facilitate forming into a desired shape.

Additional shaped porous carbon products and methods of making of the present invention include any combination of features described herein and wherein the above features are independently substituted or added to the above embodiments.

The shaped porous carbon black product can also be wash coated or dip coated onto other materials to make structured composites. The shaped porous carbon black product (at least micron size) may be inHeterogeneous phase-separated composites (e.g. carbon-ZrO) ₂ Composite or carbon domains based on large pore (mm size) ceramic foams) and domains on layered or structured materials, such as carbon black washcoated on inert supports, such as steatite, plastic or glass beads.

The shaped porous carbon black products of the present invention may be further heat treated or chemically treated to alter the physical and chemical characteristics of the shaped porous carbon black products. For example, chemical treatment (e.g., oxidation) can produce a more hydrophilic surface, which can facilitate preparation of the catalyst (improved wettability and dispersibility). Oxidation processes are known in the art, see, e.g., U.S. Pat. nos. 7,922,805 and 6,471,763. In other embodiments, the shaped porous carbon black product is surface treated using methods known for attaching functional groups to carbon-based substrates. See, for example, WO2002/018929, WO97/47691, WO99/23174, WO99/31175, WO99/51690, WO2000/022051, and WO99/63007, all of which are incorporated herein by reference. The functional group can be an ionizable group such that when the shaped porous carbon black product is subjected to ionizing conditions, the functional group comprises an anionic portion or a cationic portion. This embodiment is applicable when the shaped porous carbon black product is used as a separation medium in chromatography columns and other separation devices.

Catalyst composition and preparation method

Aspects of the invention also relate to catalyst compositions comprising the shaped porous carbon product as a catalyst support and methods of making the catalyst compositions. The shaped porous carbon product of the invention provides for efficient dispersion and immobilization of the catalytically active component or precursor thereof to the surface of the carbon product. The catalyst compositions of the present invention are suitable for use in long term continuous flow operating phase reactions under desired reaction conditions (e.g., liquid phase reactions in which a shaped porous carbon product is exposed to a reaction solvent, such as an acid and water, at elevated temperatures). The catalyst compositions containing the shaped porous carbon products of the invention exhibit the operational stability necessary for commercial applications.

Generally, the catalyst composition of the invention comprises a shaped porous carbon product as catalyst support and a catalytically active component or precursor thereof at the surface (external and/or internal surface) of said support. In various catalyst compositions of the invention, the catalytically active component or precursor thereof comprises a metal at the surface of the shaped porous carbon product. In these and other embodiments, the metal comprises at least one metal selected from groups IV, V, VI, VII, VIII, IX, X, XI, XII, and XIII. Some preferred metals include cobalt, nickel, copper, zinc, iron, vanadium, molybdenum, manganese, barium, ruthenium, rhodium, rhenium, palladium, silver, osmium, iridium, platinum, gold, and combinations thereof. In various embodiments, the metal comprises at least one d-block metal. Some preferred d-block metals are selected from the group consisting of: cobalt, nickel, copper, zinc, iron, ruthenium, rhodium, palladium, silver, osmium, iridium, platinum, gold, and combinations thereof. Typically, the metal at the surface of the catalyst support may comprise from about 0.1% to about 50%, from about 0.1% to about 25%, from about 0.1% to about 10%, from about 0.1% to about 5%, from about 0.25% to about 50%, from about 0.25% to about 25%, from about 0.25% to about 10%, from about 0.25% to about 5%, from about 1% to about 50%, from about 1% to about 25%, from about 1% to about 10%, from about 1% to about 5%, from about 5% to about 50%, from about 5% to about 25%, or from about 5% to about 10% of the total weight of the catalyst.

Generally, the metal can be present in various forms (e.g., elemental, metal oxide, metal hydroxide, metal ion, metallate, polyanion, oligomer, or colloidal, etc.). Typically, however, the metal is reduced to the elemental form in the reactor either during preparation of the catalyst composition or in situ under the reaction conditions.

The metal may be deposited on the surface of the shaped porous carbon product according to procedures known in the art including, but not limited to, incipient wetness impregnation, ion exchange, deposition-precipitation, coating, and vacuum impregnation. When two or more metals are deposited on the same support, the two or more metals may be deposited sequentially or simultaneously. Multiple impregnation steps may also be utilized (e.g., impregnating the same metal twice under different conditions to increase the overall loading of metal or to adjust the metal distribution throughout the enclosure). In various embodiments, for the oxidation catalyst, the metal deposited on the shaped porous carbon product forms an outer shell that at least partially covers the surface of the carbon product. In other words, the metal deposited on the shaped porous carbon product covers the outer surface of the carbon product. In various embodiments, the metal infiltrates the surface pores of the shaped porous carbon product to form an outer shell ("eggshell") having a thickness of from about 10 μm to about 400 μm, or from about 50 μm to about 150 μm (e.g., about 100 μm). In certain embodiments, the shell may be created subsurface to create a catalytically active metal-containing subsurface region ("egg yolk") of 10 μm to about 400 μm. For each metal, there may also be a structured housing characterized by a different distribution of metals throughout the housing.

In other embodiments, the metal may be deposited on the carbon black particles prior to shaping the shaped porous carbon product. Thus, in these embodiments, the carbon black mixture may also include a metal, such as a d-block metal. Some preferred d-block metals are selected from the group consisting of: cobalt, nickel, copper, zinc, iron, ruthenium, rhodium, palladium, silver, osmium, iridium, platinum, gold, and combinations thereof. In various embodiments, the metal comprises at least one metal selected from groups IV, V, VI, VII, VIII, IX, X, XI, XII, and XIII. Preferred metals include cobalt, nickel, copper, zinc, iron, vanadium, molybdenum, manganese, barium, ruthenium, rhodium, rhenium, palladium, silver, osmium, iridium, platinum, gold, and combinations thereof. Typically, the metal may comprise from about 0.1% to about 50%, from about 0.1% to about 25%, from about 0.1% to about 10%, from about 0.1% to about 5%, from about 0.25% to about 50%, from about 0.25% to about 25%, from about 0.25% to about 10%, from about 0.25% to about 5%, from about 1% to about 50%, from about 1% to about 25%, from about 1% to about 10%, from about 1% to about 5%, from about 5% to about 50%, from about 5% to about 25%, or from about 5% to about 10%. For example, when the metal used is a noble metal, the metal content can be from about 0.25% to about 10% of the total weight of the shaped porous carbon product. Alternatively, when the metal used is a non-noble metal, the metal content can be from about 0.1% to about 50% of the total weight of the shaped porous carbon product.

In various embodiments, the catalyst composition is dried after metal deposition, for example, optionally at a temperature of at least about 50 ℃, more typically at least about 120 ℃ by at least about 1An hour, more typically 3 hours or more. Alternatively, drying may be carried out in a continuous or staged manner, with separate temperature controlled zones (e.g., 60 ℃,80 ℃ and 120 ℃) being utilized. Typically, drying is initiated below the boiling point of the solvent (e.g., 60 ℃) followed by an increase in temperature. In these and other embodiments, the catalyst is dried under sub-atmospheric or atmospheric conditions. In various embodiments, after drying, the catalyst is reduced (e.g., by N at 350 ℃ c.) ₂ Medium make 5% H ₂ Flow for 3 hours). Also, in these and other embodiments, for example, the catalyst is calcined at a temperature of at least about 200 ℃ for a period of time (e.g., at least about 3 hours).

In some embodiments, the catalyst composition of the invention is prepared by depositing the catalytically active component or precursor thereof (e.g., directly onto the surface of the shaped porous carbon product) after shaping the shaped porous carbon product. The catalyst composition of the invention can be prepared by contacting the shaped porous carbon product with a soluble metal complex or a composition of soluble metal complexes. The heterogeneous mixture of solids and liquids may then be stirred, mixed and/or shaken to increase the uniformity of dispersion of the catalyst, which in turn allows for more uniform deposition of the metal on the support surface after removal of the liquid. After deposition, the metal complex on the shaped porous carbon product is heated and treated with a reducing agent such as a hydrogen-containing gas (e.g., shaping gas 5% H) ₂ And 95% N ₂ ) And (4) reducing. The temperature at which heating is carried out typically ranges from about 150 ℃ to about 600 ℃, from about 200 ℃ to about 500 ℃, or from about 100 ℃ to about 400 ℃. The heating is typically carried out for a period of time ranging from about 1 hour to about 5 hours or from about 2 hours to about 4 hours. The reduction reaction may also be carried out in the liquid phase. For example, the catalyst composition may be treated in a fixed bed with a liquid containing the reducing agent pumped through a stationary catalyst.

In other embodiments, the catalyst composition of the invention is prepared by depositing the catalytically active component or a precursor thereof on carbon black prior to shaping the shaped porous carbon product. In one such method, a carbon black slurry with a soluble metal complex is prepared. The carbon black may be initially dispersed in a liquid, such as water. The soluble metal complex can then be added to the slurry containing the carbon black. The heterogeneous mixture of solids and liquid can then be stirred, mixed and/or shaken to increase the uniformity of dispersion of the catalyst, which in turn allows the metal to be more uniformly deposited on the surface of the carbon black after the liquid is removed. After deposition, the metal complex on carbon black is heated and reduced with the above-mentioned reducing agent. The metal-loaded carbon black particles can then be shaped according to the method for shaping the porous carbon product. The slurry may also be wash coated onto an inert support instead of being formed into bulk catalyst pellets.

Catalyst compositions containing the shaped porous carbon product as catalyst support can be used in various reactor types, particularly suitable liquid phase media such as batch slurry, continuous slurry based stirred tank reactors, stirred tank reactor series, bubble slurry reactors, fixed bed reactors, ebullating bed reactors and other known industrial reactor types. Thus, in various aspects, the invention also relates to a method of making a reaction vessel for liquid phase catalytic reactions. In other aspects, the invention also relates to methods of making a reactor vessel for gas phase catalytic reactions. The method comprises filling a reaction vessel with a catalyst composition comprising a shaped porous carbon product as described herein as a catalyst support. In some embodiments, the reaction vessel is a fixed bed reactor.

Various methods for preparing the catalyst composition according to the present invention include mixing water and a water-soluble organic binder and heating to form a binder solution, wherein the water and binder are heated to a temperature of at least about 50 ℃, and wherein the binder comprises: (i) a saccharide selected from the group consisting of: a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof, and (ii) a polymeric carbohydrate, a derivative of a polymeric carbohydrate, or a non-carbohydrate synthetic polymer, or any combination thereof; mixing carbon black particles with a binder solution to produce a carbon black mixture; shaping the carbon black mixture to produce a shaped carbon black composite; heating the shaped carbon black composite to carbonize the binder into a water-insoluble state and produce a shaped porous carbon product; and depositing a catalytically active component or precursor thereof on the shaped porous carbon product to produce the catalyst composition.

Other methods include mixing water, carbon black, and a water-soluble organic binder to form a carbon black mixture, wherein the binder comprises: (i) a saccharide selected from the group consisting of: a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, and any combination thereof, and (ii) a polymeric carbohydrate, a derivative of a polymeric carbohydrate, or a non-carbohydrate synthetic polymer, or any combination thereof; shaping the carbon black mixture to produce a shaped carbon black composite; heating the shaped carbon black composite to carbonize the binder into a water-insoluble state and produce a shaped porous carbon product; and depositing a catalytically active component or precursor thereof on the shaped porous carbon product to produce the catalyst composition.

A further method for preparing the catalyst composition according to the invention comprises mixing water, carbon black and a binder to form a carbon black mixture, wherein the binder comprises a saccharide selected from the group consisting of: a monosaccharide, a disaccharide, an oligosaccharide, a derivative thereof, or any combination thereof, and wherein the weight ratio of binder to carbon black in the carbon black mixture is at least about 1; shaping the carbon black mixture to produce a shaped carbon black composite; heating the shaped carbon black composite to carbonize the binder into a water-insoluble state and produce a shaped porous carbon product; and depositing a catalytically active component or precursor thereof on the shaped porous carbon product to produce the catalyst composition.

Other methods include mixing water, carbon black, and a binder to form a carbon black mixture, wherein the binder comprises a saccharide selected from the group consisting of: a monosaccharide, disaccharide, oligosaccharide, derivative thereof, or any combination thereof, and wherein the water content of the carbon black mixture is no more than about 80 wt.%, no more than about 55 wt.%, no more than about 40 wt.%, or no more than about 25 wt.%; shaping the carbon black mixture to produce a shaped carbon black composite; heating the shaped carbon black composite to carbonize the binder into a water-insoluble state and produce a shaped porous carbon product; and depositing a catalytically active component or precursor thereof on the shaped porous carbon product to produce the catalyst composition.

Still further methods include depositing a catalytically active ingredient or precursor thereof on a shaped porous carbon product to produce the catalyst composition, wherein the shaped porous carbon product comprises: (a) Carbon black and (b) a carbonising binder, the binder comprising the carbonising product of a water-soluble organic binder, and wherein the shaped porous carbon product has a BET specific surface area of about 20m ² G to about 500m ² A mean pore diameter of greater than about 5nm and a specific pore volume of greater than about 0.1cm ³ (ii)/g, the radial component crush strength is greater than about 4.4N/mm (1 lb/mm), the carbon black content is at least about 35 wt%, and the carbonized binder content is from about 20 wt% to about 50 wt%.

Catalytic process

Catalyst compositions containing the shaped porous carbon products of the invention can be used in a variety of catalytic conversion reactions, including oxidation reactions, reduction reactions, dehydration reactions, hydrogenation reactions, and other known conversion reactions utilizing suitable active metal preparations and which can be carried out in gaseous or liquid media. Thus, in other aspects, the invention relates to a method for catalytically converting a reactant.

The process of the invention comprises contacting a liquid medium containing the reactants with a catalyst composition comprising a shaped porous carbon product as a catalyst support. In various embodiments, a shaped porous carbon product comprises (a) carbon black and (b) a carbonized binder comprising a carbonized product of a water soluble organic binder, wherein the shaped porous carbon product has a BET specific surface area of about 20m ² G to about 500m ² In the range of/g or about 25m ² G to about 250m ² A mean pore diameter of greater than about 10nm and a specific pore volume of greater than about 0.1cm ³ (ii)/g, the radial component crush strength is greater than about 4.4N/mm (1 lb/mm) and the carbon black content is at least about 35 wt%. In other embodiments, the shaped porous carbon product comprises carbon agglomerates, wherein the shaped porous carbon product has an average diameter of up toLess than about 50 μm, and a BET specific surface area of about 20m ² G to about 500m ² In the range of/g or about 25m ² G to about 250m ² Per gram, average pore diameter greater than about 10nm, and specific pore volume greater than about 0.1cm ³ (ii) a/g, and a radial component crush strength greater than about 4.4N/mm (1 lb/mm). Generally, the catalyst compositions have excellent mechanical strength (e.g., mechanical part crush strength and/or radial part crush strength) and are sufficiently stable under liquid medium continuous flow and reaction conditions for at least about 500 hours or about 1,000 hours without substantial loss of catalyst productivity, selectivity, and/or yield.

Furthermore, it has been unexpectedly discovered that catalyst compositions containing the shaped porous carbon products of the present invention are highly productive and selective catalysts for certain chemical conversion reactions, such as the conversion of highly functionalized and/or nonvolatile molecules, including but not limited to biorenewable derived molecules and intermediates for commercial applications.

Catalytic oxidation reaction

A suitable series of chemical conversion reactions for the catalyst composition of the present invention is the selective oxidation of hydroxyl groups to carboxyl groups in a liquid or gaseous reaction medium. For example, a particularly suitable series of chemical conversion reactions for the catalyst composition of the invention is the selective oxidation of aldoses to aldaric acids. Thus, the catalyst compositions of the present invention described herein can be used as oxidation catalysts. Aldoses include, for example, pentoses and hexoses (i.e., C-5 and C-6 monosaccharides). Pentoses include ribose, arabinose, xylose, and lyxose, while hexoses include glucose, allose, altrose, mannose, gulose, idose, galactose, and talose. Thus, in various embodiments, the present invention also relates to a method for the selective oxidation of an aldose to an aldaric acid comprising reacting an aldose with oxygen in the presence of a catalyst composition described herein to form an aldaric acid. Generally, the catalyst composition comprises at least platinum as the catalytically active component.

The catalyst composition of the present invention has been found to be selective for the oxidation of glucose to glucaric acid in particular. Accordingly, the present invention relates to a method of selectively oxidizing glucose to glucaric acid comprising reacting an aldose sugar with oxygen in the presence of a catalyst composition described herein to form glucaric acid. U.S. patent No. 8,669,397, the entire contents of which are incorporated herein by reference, discloses various catalytic processes for the oxidation of glucose to glucaric acid. Generally, glucose can be converted to glucaric acid in high yield by reacting glucose with oxygen (e.g., air, oxygen-enriched air, oxygen, or oxygen with other components that are substantially inert to the reaction) in the presence of an oxidation catalyst according to the following reaction:

the oxidation reaction can be carried out under the following conditions: in the absence of added base (e.g., KOH), or wherein the initial pH of the reaction medium and/or the pH of the reaction medium at any point in the reaction is not greater than about 7, not greater than about 7.0, not greater than about 6.5, or not greater than about 6. The initial pH of the reaction mixture is the pH of the reaction mixture prior to contact with oxygen in the presence of the oxidation catalyst. In fact, catalytic selectivity can be maintained to achieve glucaric acid yields in excess of about 30%, about 40%, about 50%, about 60%, and even in some cases, in excess of 65% or higher. The absence of added base advantageously allows glucaric acid to be easily isolated and precipitated, thereby providing a process that is more suitable for industrial applications and improving overall process economics by removing a reaction component. As used herein, "the absence of added base" means that the base, if present (e.g., as a component of the starting material), is present at a concentration that has substantially no effect on the efficiency of the reaction; that is, the oxidation reaction is carried out substantially without an added base. The oxidation reaction can also be carried out in the presence of a weak carboxylic acid (e.g., acetic acid) in which glucose is soluble. The term "weak carboxylic acid" as used herein denotes any unsubstituted or substituted carboxylic acid having a pKa value of at least about 3.5, more preferably at least about 4.5, and more particularly selected from unsubstituted acids, such as acetic, propionic or butyric acid, or mixtures thereof.

The oxidation reaction may be conducted at an increased oxygen partial pressure and/or at a higher temperature of the oxidation reaction mixture, which reaction has a tendency to increase the yield of glucaric acid when the oxidation reaction is conducted in the absence of added base or at a pH below about 7. Typically, the oxygen partial pressure is at least about 15 pounds absolute pressure (psia) (104 kPa), at least about 25psia (172 kPa), at least about 40psia (276 kPa), or at least about 60psia (414 kPa) per square inch. In various embodiments, the oxygen partial pressure may be up to about 1,000psia (6895 kPa), more typically within the following ranges: about 15psia (104 kPa) to about 500psia (3447 kPa), about 75psia (517 kPa) to about 500psia (3447 kPa), about 100psia (689 kPa) to about 500psia (3447 kPa), about 150psia (1034 kPa) to about 500psia (3447 kPa). Typically, the oxidation reaction mixture temperature is at least about 40 ℃, at least about 60 ℃, at least about 70 ℃, at least about 80 ℃, at least about 90 ℃, at least about 100 ℃ or higher. In various embodiments, the oxidation reaction mixture temperature is from about 40 ℃ to about 200 ℃, from about 60 ℃ to about 200 ℃, from about 70 ℃ to about 200 ℃, from about 80 ℃ to about 180 ℃, from about 80 ℃ to about 150 ℃, from about 90 ℃ to about 180 ℃, or from about 90 ℃ to about 150 ℃. Surprisingly, the catalyst composition containing the shaped porous carbon product as a catalyst support oxidizes glucose at high temperatures (e.g., about 100 ℃ to about 160 ℃ or about 125 ℃ to about 150 ℃) without thermally degrading the catalyst. In particular, it has been found that reactor types (e.g., fixed bed reactors) that can provide relatively high liquid throughput in combination with catalyst compositions comprising shaped porous carbon products containing carbon black allow for oxidation reactions at temperatures in excess of 140 ℃ (e.g., 140 ℃ to about 150 ℃).

The oxidation of glucose to glucaric acid can also be carried out in the absence of nitrogen as the active reaction component. Some methods use a nitrogen compound (e.g., nitric acid) as the oxidizing agent. The use of nitrogen in the form of an active reaction component (e.g. nitrate or nitric acid) leads to the need for NO _x Reduction techniques and acid regeneration techniques which significantly increase the cost of producing glucaric acid by these known methods, as well as providing the possibility of having available equipment for carrying out the methodA hostile corrosive environment. In contrast, for example, where air or oxygen-enriched air is used as the source of oxygen in the oxidation reaction of the present invention, nitrogen is essentially an inactive or inert component. Therefore, the oxidation reaction using air or oxygen-enriched air is a reaction which proceeds substantially without nitrogen in the form of an active reaction component.

According to various embodiments, glucose is oxidized to glucaric acid in the presence of a catalyst composition comprising a shaped porous carbon product as a catalyst support as described herein and a catalytically active ingredient at the surface of the support. In certain embodiments, the catalytically active component comprises platinum. In some embodiments, the catalytically active component comprises platinum and gold.

Applicants have found that oxidation catalyst compositions comprising the shaped porous carbon products of the present invention unexpectedly provide greater selectivity and yield for the production of glucaric acid from glucose when compared to similar catalysts comprising similar support materials (e.g., activated carbon). In particular, applicants have unexpectedly found that increased selectivity and yield to glucaric acid can be achieved using an oxidation catalyst composition comprising a shaped porous carbon product as a catalyst support and a catalytically active component (comprising platinum and gold) on a surface of the shaped porous carbon product (i.e., on a surface of the catalyst support).

The oxidation catalyst can comprise any of the shaped porous carbon products described herein. For example, in various embodiments, a shaped porous carbon product comprises (a) carbon black and (b) a carbonized binder comprising a carbonized product of a water-soluble organic binder, wherein the shaped porous carbon product has a BET specific surface area of about 20m ² G to about 500m ² G or about 25m ² G to about 250m ² A mean pore diameter of greater than about 10nm and a specific pore volume of greater than about 0.1cm ³ (ii)/g, the radial component crush strength is greater than about 4.4N/mm (1 lb/mm) and the carbon black content is at least about 35 wt%. In other embodiments, the shaped porous carbon product comprises carbon agglomerates, wherein the shaped porous carbon product has an average diameter of at least about 50 μm and a BET specific surface area of about20m ² G to about 500m ² In the range of/g or about 25m ² G to about 250m ² Per gram, average pore diameter greater than about 10nm, and specific pore volume greater than about 0.1cm ³ (ii) a/g, and a radial component crush strength greater than about 4.4N/mm (1 lb/mm). Another shaped porous carbon product according to the invention has a pore volume measured on the basis of pores having a diameter of 1.7nm to 100nm and at least about 35% of said pore volume is also attributable to pores having a mean pore diameter of about 10nm to about 50 nm.

The increased glucaric acid yield is typically at least about 30%, at least about 35%, at least about 40%, at least about 45%, or at least about 50% (e.g., about 35% to about 65%, about 40% to about 65%, or about 45% to about 65%). In addition, the increased selectivity to glucaric acid is typically at least about 70%, at least about 75%, or at least about 80%.

In various embodiments, the catalytically active ingredient or precursor thereof (comprising platinum and gold) is in the form described in U.S. patent application publication No. 2011/0306790, the entire contents of which are incorporated herein by reference. This publication describes various oxidation catalysts comprising catalytically active components (comprising platinum and gold) which can be used for the selective oxidation of a composition consisting of a primary alcohol group and at least one secondary alcohol group (e.g. glucose).

In various embodiments, the oxidation catalyst composition according to the present invention comprises as a catalyst support the shaped porous carbon product described herein comprising gold particles in the form of a gold-containing alloy and particles consisting essentially of platinum (0) as the catalytically active ingredient on the surface of the catalyst support. Typically, the total metal loading of the catalyst composition is about 10 wt% or less, about 1 wt% to about 8 wt%, about 1 wt% to about 5 wt%, or about 2 wt% to about 4 wt%.

In order for glucose to be oxidized to glucaric acid, a sufficient amount of catalytically active component must be present relative to the amount of reactant (i.e., glucose). Thus, in one of the inventive methods for oxidizing glucose to glucaric acid described herein (wherein the catalytically active component comprises platinum), the mass ratio of glucose to platinum is typically from about 10.

In various embodiments, the oxidation catalyst of the present invention may be prepared according to the following method. The gold component of the catalyst is typically added to the shaped porous carbon product in the form of a soluble component to enable the formation of a homogeneous suspension. A base is then added to the suspension in order to form an insoluble gold complex which can be deposited more uniformly on the support. For example, a soluble gold component in the form of a gold salt (e.g., HAuCl 4) is added to the slurry. After the well-dispersed heterogeneous mixture is formed, a base is added to the slurry to form an insoluble gold complex, which is then deposited on the surface of the shaped porous carbon product. Although any base that affects the formation of insoluble gold complexes may be utilized, bases such as KOH, naOH are typically utilized. Although not required, it may be desirable to collect the shaped porous carbon product with the insoluble gold complex deposited thereon prior to addition of the platinum-containing component, the collection being readily accomplished by any of a variety of means known in the art (such as, for example, centrifugation). The collected solids may optionally be washed and then heated to dryness. Heat may also be applied to reduce the gold complex on the support to gold (0). The heating may be conducted at a temperature in the range of about 60 c (to dry) to about 500 c (at which the gold is effectively reduced). In various embodiments, the heating step may be conducted in a reducing or oxidizing atmosphere in order to facilitate the reduction of the complex to deposit gold as gold (0) on the support. The heating time varies depending on, for example, the purpose of the heating step and the rate of decomposition of the base added to form the insoluble complex, and may range from several minutes to several days. More typically, the heating time for drying purposes ranges from about 2 to about 24 hours, while the heating time for reducing the gold complex ranges from about 1 to about 4 hours.

In various embodiments, the concentration of the shaped porous carbon product in the slurry can range from about 1 to about 100g solids per liter of slurry, while in other embodiments, the concentration can range from about 5 to about 25g solids per liter of slurry.

The slurry containing the soluble gold-containing compound is continuously mixed for a period of time sufficient to form an at least reasonably homogeneous suspension. Suitable times may range from a few minutes to a few hours. After the addition of the base to convert the gold-containing compound to an insoluble gold-containing complex, the uniformity of the slurry should be maintained for a time sufficient for the insoluble complex to form and deposit on the shaped porous carbon product. In various embodiments, the time may range from a few minutes to a few hours.

Platinum may be added to the shaped porous carbon product or slurry thereof after deposition of gold on the shaped porous carbon product or after heat treatment to reduce the gold complex on the support to gold (0). Alternatively, platinum may be added to the shaped porous carbon product or slurry thereof prior to addition of the soluble gold compound, provided that the platinum present on the support is in a form that does not re-dissolve upon addition of the base (to promote deposition of gold on the support). Platinum is typically added in a soluble precursor solution or colloidal form. Platinum may be added in the form of a compound selected from the group consisting of: platinum (II) nitrate, platinum (IV) nitrate, platinum oxynitrate, platinum (II) acetylacetonate (acac), platinum (II) nitrate tetraamine, platinum (II) hydrogen phosphate, platinum (II) hydrogen carbonate, platinum (II) hydroxide tetraamine, and H ₂ PtCl ₆ 、PtCl ₄ 、Na ₂ PtCl ₄ 、K ₂ PtCl ₄ 、(NH ₄ ) ₂ PtCl ₄ 、Pt(NH ₃ ) ₄ Cl ₂ Mixed Pt (NH) ₃ ) _x Cl _y 、K ₂ Pt(OH)6、Na ₂ Pt(OH) ₆ 、(NMe ₄ ) ₂ Pt(OH) ₆ And (EA) ₂ Pt(OH) ₆ (where EA = ethanolamine). More preferred compounds include platinum (II) nitrate, platinum (IV) nitrate, acetylacetone (acac) platinum (II), tetraamineplatinum (II) hydroxide, K ₂ PtCl ₄ And K ₂ Pt(OH) ₆ 。

After the platinum compound is added, the support slurry and the platinum-containing compound are dried. Drying may be carried out at room temperature or at temperatures up to about 120 ℃. More preferably, the drying is carried out at a temperature in the range of about 40 ℃ to about 80 ℃ and more preferably at about 60 ℃. The drying step may be performed for a time ranging from about several minutes to several hours. Typically, the drying time ranges from about 6 hours to about 24 hours. Drying may also be carried out on a belt calciner or belt dryer (preferably for commercial use) with a continuous or staged temperature increase from about 60 ℃ to 120 ℃.

After drying the support having the platinum compound deposited thereon, at least one heat treatment is carried out to reduce the platinum deposited as platinum (II) or platinum (IV) to platinum (0). The heat treatment may be carried out in air or in any reducing or oxidizing atmosphere. In various embodiments, the heat treatment is performed under a forming gas atmosphere. Alternatively, a liquid reducing agent may be utilized to reduce the platinum; for example, hydrazine or formaldehyde or formic acid or salts thereof (e.g., sodium formate) or NaH may be utilized ₂ PO ₂ To achieve the necessary platinum reduction. The atmosphere in which the heat treatment is carried out depends on the platinum compound used, and the purpose thereof is to substantially convert the platinum on the carrier into platinum (0).

The temperature at which the heat treatment is carried out is generally in the range of about 150 ℃ to about 600 ℃. More typically, the temperature of the heat treatment ranges from about 200 ℃ to about 500 ℃, and preferably ranges from about 200 ℃ to about 400 ℃. The heat treatment is typically carried out for a period of time ranging from about 1 hour to about 8 hours or from about 1 hour to about 3 hours.

In various embodiments, for the oxidation catalyst, the metal deposited on the shaped porous carbon product forms an outer shell that at least partially covers the surface of the carbon product. In other words, the metal deposited on the shaped porous carbon product covers the outer surface of the carbon product. In various embodiments, the metal infiltrates the surface porosity of the shaped porous carbon product to form an outer shell ("eggshell") having a thickness of from about 10 μm to about 400 μm, or from about 50 μm to about 150 μm (e.g., about 100 μm). In certain embodiments, the shell may be created subsurface to create a catalytically active metal-containing subsurface region ("egg yolk") of 10 μm to about 400 μm.

Catalytic hydrodeoxygenation reaction

A suitable series of chemical conversion reactions for the catalyst composition of the present invention is the hydrodeoxygenation of carbon-hydroxyl groups to carbon-hydrogen groups in a liquid or gaseous reaction medium. For example, a particularly suitable series of chemical conversion reactions for the catalyst composition of the present invention is the selective halide-promoted hydrodeoxygenation of aldaric acids or salts, esters, or lactones thereof to dicarboxylic acids. Thus, the catalyst compositions of the invention described herein can be used as hydrodeoxygenation catalysts. Accordingly, the present invention also relates to a process for the selective halide-promoted hydrodeoxygenation of aldaric acids comprising reacting an aldaric acid or a salt, ester, or lactone thereof with hydrogen in the presence of a halogen-containing compound and a catalyst composition described herein to form a dicarboxylic acid. Typically, the catalyst composition comprises at least one noble metal as catalytically active component.

The catalyst composition of the present invention has been found to be particularly selective for the hydrodeoxygenation promoted by glucaric acid or salt, ester, or lactone halide thereof to adipic acid. U.S. patent No. 8,669,397, cited above and incorporated herein by reference, describes a chemocatalytic process for hydrodeoxygenation of glucaric acid to adipic acid.

Adipic acid or salts and esters thereof may be prepared by reacting glucaric acid or salts, esters, or lactones with hydrogen in the presence of a hydrodeoxygenation catalyst and a halogen source according to the following reaction:

in the above reaction, glucaric acid or a salt, ester, or lactone thereof is catalytically hydrodeoxygenated to an adipic acid product, wherein carbon-hydroxy groups are converted to carbon-hydrogen groups. In various embodiments, the catalytic hydrodeoxygenation reaction is hydroxyl-selective, wherein the reaction is completed without substantially converting one or more other non-hydroxyl functional groups in the substrate.

The halogen source may be in a form selected from the group consisting of: ions, molecules, and mixtures thereof. The halogen source comprises a hydrohalic acid (e.g., HCl, HBr, HI, and mixtures thereof; preferably HBr and/or HI), a halide salt, an (substituted or unsubstituted) alkyl halide, or a molecular (diatomic) halogen (e.g., chlorine, bromine, iodine, or mixtures thereof; preferably bromine and/or iodine). In various embodiments, the halogen source is in a diatomic form, a hydrohalic acid, or a halide salt, and more preferably is in a diatomic form or a hydrohalic acid. In certain embodiments, the halogen source is a hydrohalic acid, particularly hydrogen bromide.

Typically, the molar ratio of halogen to glucaric acid or salt, ester, or lactone thereof is about 1 or less. In various embodiments, the molar ratio of halogen to glucaric acid or salt, ester, or lactone thereof is typically from about 1 to about 0.1.

Generally, the reaction allows the halogen source to be recovered and a catalytic amount of halogen (where the molar ratio of halogen to glucaric acid or salt, ester, or lactone thereof is less than about 1) can be utilized, recovered, and recycled to continue to serve as the halogen source.

Typically, the temperature of the hydrodeoxygenation reaction mixture is at least about 20 ℃, typically at least about 80 ℃, and more typically at least about 100 ℃. In various embodiments, the hydrodeoxygenation reaction is conducted at a temperature in the range of from about 20 ℃ to about 250 ℃, from about 80 ℃ to about 200 ℃, from about 120 ℃ to about 180 ℃, or from about 140 ℃ to about 180 ℃. Typically, the hydrogen partial pressure is at least about 25psia (172 kPa), more typically at least about 200psia (1379 kPa) or at least about 400psia (2758 kPa). In various embodiments, the hydrogen partial pressure is from about 25psia (172 kPa) to about 2500psia (17237 kPa), from about 200psia (1379 kPa) to about 2000psia (13790 kPa), or from about 400psia (2758 kPa) to about 1500psia (10343 kPa).

The hydrodeoxygenation reaction can be carried out in the presence of a solvent. Solvents suitable for the selective hydrodeoxygenation reaction include water and carboxylic acids, amides, esters, lactones, sulfoxides, sulfones, and mixtures thereof. Preferred solvents include water, mixtures of water and weak carboxylic acids, and weak carboxylic acids. The preferred weak carboxylic acid is acetic acid.

Applicants have found that hydrodeoxygenation catalyst compositions comprising the shaped porous carbon products of the present invention provide increased selectivity and yield for the production of adipic acid. In particular, the applicant has surprisingly found that increased selectivity and yield for adipic acid can be achieved by means of a catalyst composition comprising the shaped porous carbon product of the invention as a catalyst support and a catalytically active component at the surface of the shaped porous carbon product, i.e. at the surface of the catalyst support.

The catalyst can comprise any of the shaped porous carbon products described herein. For example, in various embodiments, a shaped porous carbon product comprises (a) carbon black and (b) a carbonized binder comprising a carbonized product of a water-soluble organic binder, wherein the shaped porous carbon product has a BET specific surface area of about 20m ² G to about 500m ² In the range of/g or about 25m ² G to about 250m ² Per gram, average pore diameter greater than about 5nm, and specific pore volume greater than about 0.1cm ³ (iv)/g, the radial part crush strength is greater than about 4.4N/mm (1 lb/mm) and the carbon black content is at least about 35 weight percent. In other embodiments, the shaped porous carbon product comprises carbon agglomerates, wherein the shaped porous carbon product has a mean diameter of at least about 50 μm and a BET specific surface area of about 20m ² G to about 500m ² In the range of/g or about 25m ² G to about 250m ² A mean pore diameter of greater than about 5nm and a specific pore volume of greater than about 0.1cm ³ (ii) a/g, and a radial component crush strength greater than about 4.4N/mm (1 lb/mm). Another shaped porous carbon product according to the invention has a pore volume measured on the basis of pores having a diameter of 1.7nm to 100nm and at least about 35% of said pore volume is also attributable to pores having a mean pore diameter of about 10nm to about 50 nm.

The catalytically active component or precursor thereof may comprise a noble metal selected from the group consisting of: ruthenium, rhodium, palladium, platinum, and combinations thereof. In various embodiments, the hydrodeoxygenation catalyst comprises two or more metals. For example, in some embodiments, the first metal is selected from the group consisting of: cobalt, nickel, ruthenium, rhodium, palladium, osmium, iridium, and platinum (more particularly ruthenium, rhodium, palladium, and platinum), and the second metal is selected from the group consisting of: titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, molybdenum, ruthenium, rhodium, palladium, silver, tungsten, iridium, platinum, and gold (more particularly, molybdenum, ruthenium, rhodium, palladium, iridium, platinum, and gold). In selected embodiments, the first metal is selected from the group consisting of platinum, rhodium, and palladium, and the second metal is selected from the group consisting of ruthenium, rhodium, palladium, platinum, and gold. In certain embodiments, the first metal is platinum and the second metal is rhodium. In these and other embodiments, the molar ratio of platinum to rhodium in the catalyst composition of the invention ranges from about 3.

In various embodiments, for the hydrodeoxygenation catalyst, the metal deposited on the shaped porous carbon product forms an outer shell that at least partially covers the surface of the carbon product. In other words, the metal deposited on the shaped porous carbon product covers the outer surface of the carbon product. In various embodiments, the metal infiltrates the surface pores of the shaped porous carbon product to form an outer shell ("eggshell") having a thickness of from about 10 μm to about 400 μm, or from about 50 μm to about 150 μm (e.g., about 100 μm). In certain embodiments, the shell may be created subsurface to create a catalytically active metal-containing subsurface region ("egg yolk") of 10 μm to about 400 μm.

Hydrodeoxygenation reaction of 1,2, 6-hexanetriol

Another chemical conversion reaction for which the catalyst composition of the present invention is suitable is the selective hydrodeoxygenation of 1,2, 6-hexanetriol to 1, 6-Hexanediol (HDO) and the selective hydrodeoxygenation of 1,2,5, 6-hexanetetraol to 1, 6-HDO). Accordingly, one process of the present invention involves the selective hydrodeoxygenation reaction of 1,2, 6-hexanetriol which comprises reacting 1,2, 6-hexanetriol with hydrogen in the presence of the catalyst composition disclosed herein to form HDO. In an embodiment of this method, the catalytically active component of the catalyst composition comprises platinum. In some embodiments, the catalytically active component of the catalyst composition comprises platinum and at least one metal (M2) selected from the group consisting of: molybdenum, lanthanum, samarium, yttrium, tungsten, and rhenium. In certain embodiments, the catalytically active component of the catalyst composition comprises platinum and tungsten.

Typically, the total weight of metal is from about 0.1% to about 10%, or from 0.2% to 10%, or from about 0.2% to about 8%, or from about 0.2% to about 5% of the total weight of the catalyst. In a more preferred embodiment, the total weight of metals in the catalyst is less than about 4%. For example, the molar ratio of platinum to (M2) may vary from about 20. In various embodiments, the molar ratio of M1 to M2 ranges from about 10. In a more preferred embodiment, the molar ratio of M1: M2 ranges from about 8.

Typically, the conversion of 1,2, 6-hexanetriol to HDO is carried out at a temperature in the range of from about 60 ℃ to about 200 ℃ or from about 120 ℃ to about 180 ℃ and at a hydrogen partial pressure in the range of from about 200psig to about 2000psig or from about 500psig to about 2000 psig.

Catalytic amination of 1, 6-hexanediol

In addition, the catalyst composition of the present invention can also be used for the selective amination of 1, 6-Hexanediol (HDO) to 1, 6-Hexamethylenediamine (HMDA). Accordingly, another process of the present invention involves the selective amination of 1, 6-hexanediol to 1, 6-hexamethylenediamine, which comprises reacting HDO with an amine in the presence of a catalyst composition as disclosed herein. In various embodiments of this process, the catalytically active component of the catalyst composition comprises ruthenium.

In some embodiments of this method, the catalytically active component of the catalyst composition comprises ruthenium and optionally a second metal (e.g., rhenium or nickel). One or more other d-block metals, one or more rare earth metals (e.g., lanthanides), and/or one or more main group metals (e.g., al) can also be present in combination with ruthenium and rhenium mixtures. In selected embodiments, the catalytically active phase consists essentially of ruthenium and rhenium. Typically, the total weight of metals is from about 0.1% to about 10%, from about 1% to about 6%, or from about 1% to about 5% of the total weight of the catalyst composition.

When the catalyst of the present invention comprises a combination of ruthenium and rhenium, the molar ratio of ruthenium to rhenium is important. A by-product of the process for converting HDO to HMDA is pentylamine. Pentylamine is an off path by-product that cannot be converted to HMDA during the conversion of HDO to HMDA or an intermediate that can be further reacted in the presence of the catalyst of the present invention to HMDA. However, the presence of too much rhenium can have a detrimental effect on the HMDA yield per unit area time (commonly referred to as space time yield or STY). Therefore, the molar ratio of ruthenium to rhenium should be maintained in the range of about 20. In various embodiments, the molar ratio of ruthenium to rhenium ranges from about 10. In some embodiments, the molar ruthenium to rhenium ratio yield of about 8 to about 4 is at least 25% HMDA, wherein the HMDA/pentylamine ratio is at least 20.

According to the invention, HDO is converted to HMDA by reacting HDO with an amine (e.g. ammonia) in the presence of the catalyst of the invention. Generally, in some embodiments, the amine may be added to the reaction in gaseous or liquid form. Typically, the molar ratio of ammonia to HDO is at least about 40. In various embodiments, the molar ratio ranges from about 40. The reaction of HDO with the amine in the presence of the catalyst composition of the present invention is carried out at a temperature of less than or equal to about 200 ℃. In various embodiments, the catalyst composition is contacted with the HDO and the amine at a temperature of less than or equal to about 100 ℃. In some embodiments, the catalyst is contacted with HDO and the amine at a temperature in the range of from about 100 ℃ to about 180 ℃ or from about 140 ℃ to about 180 ℃.

Generally, according to the present invention, the reaction is carried out at a pressure of no more than about 1500psig. In various embodiments, the reaction pressure ranges from about 200psig to about 1500psig. In other embodiments, the pressure ranges from about 400psig to about 1200psig. In certain preferred embodiments, the pressure ranges from about 400psig to about 1000psig. In some embodiments, the disclosed pressure ranges include NH ₃ Gases and inert gases (e.g. N) ₂ ) The pressure of (a). In some embodiments, NH ₃ The gas has a pressure in the range of about 50 to 150psig and an inert gas (e.g., N) ₂ ) Is in the range of about 700psig to about 1450psig.

In some embodiments, the catalyst is contacted with HDO and ammonia at a temperature in the range of from about 100 ℃ to about 180 ℃ and a pressure in the range of from about 200psig to about 1500psig. In other embodiments, the catalyst is contacted with HDO and ammonia at a temperature in the range of about 140 ℃ to about 180 ℃ and a pressure in the range of about 400psig to about 1200psig. In some embodiments, the disclosed pressure ranges include NH ₃ Gases and inert gases (e.g. N) ₂ ) Of the pressure of (a). In some embodiments, NH ₃ The gas has a pressure in the range of about 50 to 150psig and an inert gas (e.g., N) ₂ ) Is in the range of about 500psig to about 1450psig.

The process of the present invention may be carried out in the presence of hydrogen. Generally, in embodiments wherein HDO and amine are reacted in the presence of hydrogen and the catalyst of the present invention, the hydrogen partial pressure is equal to or less than about 100psig.

The conversion of HDO to HMDA can also be carried out in the presence of a solvent. Solvents suitable for converting HDO to HMDA in the presence of the catalyst of the present invention may include, for example, water, alcohols, esters, ethers, ketones, or mixtures thereof. In various embodiments, the preferred solvent is water.

The chemical catalytic conversion of HDO to HMDA may produce one or more byproducts, for example, pentylamine and hexylamine. The by-product which can then be further reacted in the presence of the catalyst of the invention for conversion to HMDA is considered as an on-path by-product. Other by-products (such as, for example, pentylamine and hexylamine) are considered to be abnormal pathway by-products for the reasons set forth above. According to the present invention, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, or at least 70% of the product mixture resulting from a single pass reaction of HDO with an amine (e.g., ammonia) is HMDA in the presence of the catalyst of the present invention.

The product mixture may be separated into one or more products by any suitable method known in the art. In some embodiments, the product mixture may be separated by fractional distillation at sub-atmospheric pressure. For example, in some embodiments, HMDA may be separated from the product mixture at a temperature between about 180 ℃ and about 220 ℃. HDO can be recovered from any remaining other products of the reaction mixture by one or more conventional methods known in the art, including, for example, solvent extraction, crystallization, or evaporation. The normal pathway by-products, which are further reacted with ammonia in the presence of the catalyst of the present invention to produce additional HMDA, can be recycled back to the reactor used to produce the product mixture or, for example, supplied to a second reactor.

Hydrogenolysis of glycerol

Another chemical conversion that is advantageous for the catalyst support and catalyst composition of the present invention is the hydrogenolysis of glycerol to various diols, particularly propylene glycol (1, 2-propanediol) and/or ethylene glycol (1, 2-ethanediol). For example, methods for hydrogenolysis of glycerol are described in U.S. Pat. nos. 6,479,713 and 7,928,148 and U.S. patent application publication No. 2018/0201559, the contents of which are incorporated herein by reference. Thus, in various embodiments, a process for hydrogenolysis of glycerol comprises feeding a feed composition comprising glycerol to a reaction zone and reacting the glycerol with hydrogen in the reaction zone in the presence of a catalyst composition as described herein to form a reaction product comprising propylene glycol and/or ethylene glycol.

In some embodiments, a process for hydrogenolysis of glycerol comprises feeding a feed composition comprising glycerol to a reaction zone and reacting the glycerol with hydrogen in the presence of a catalyst composition in the reaction zone to form a reaction product comprising propylene glycol and/or ethylene glycol, wherein the catalyst composition comprises a catalytically active ingredient comprising a metal selected from the group consisting of chromium, cobalt, nickel, copper, zinc, ruthenium, rhodium, palladium, silver, rhenium, osmium, iridium, platinum, gold, and any combination thereof, and a catalyst support comprising a shaped porous carbon product comprising carbon black. The shaped porous carbon product can include one or more features as described herein (e.g., specific surface area, average pore diameter, specific pore volume, mesoporosity, pore size distribution, radial and mechanical part crush strength, average diameter, attrition index, attrition loss, and the like). The shaped porous carbon product can also include a carbonized product (e.g., carbonized sugars, cellulose compounds, etc.) of a binder as described herein.

For example, catalysts comprising shaped porous carbon products as catalyst supports, which exhibit high levels of mesoporosity, have been found to be particularly effective catalysts for this reaction. The shaped porous carbon product advantageously has a high concentration of mesopores between about 10nm and about 100nm, between about 20nm and about 100nm, or between about 10nm and about 50 nm. Thus, in various embodiments, at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, at least about 95% of the pore volume of the shaped porous carbon product, as measured by the BJH method on the basis of pores having a diameter of 1.7nm to 100nm, is attributable to pores having a mean pore diameter of about 10nm to about 100 nm. For example, about 50% to about 99%, about 50% to about 95%, about 50% to about 90%, about 50% to about 80%, about 60% to about 99%, about 60% to about 95%, about 60% to about 90%, about 70% to about 99%, about 70% to about 95%, about 70% to about 90%, about 70% to about 80%, about 80% to about 99%, about 80% to about 95%, about 80% to about 90%, or about 90% to about 99% of the pore volume of the shaped porous carbon product as measured by the BJH method on the basis of pores having a diameter of 1.7nm to 100nm is attributed to pores having a mean pore diameter of about 10nm to about 100 nm. Moreover, in various embodiments, at least about 35%, at least about 40%, at least about 45%, or at least about 50% of the pore volume of the shaped porous carbon product, as measured by the BJH method on the basis of pores having a diameter from 1.7nm to 100nm, is attributable to pores having a mean pore diameter of from about 20nm to about 90nm, or from about 10nm to about 50 nm. For example, from about 35% to about 80%, from about 35% to about 75%, from about 35% to about 65%, from about 40% to about 80%, from about 40% to about 75%, or from about 40% to about 70% of the pore volume of the shaped porous carbon product as measured by the BJH method on the basis of pores having a diameter of from 1.7nm to 100nm is attributable to pores having a mean pore diameter of from about 20nm to about 90nm or from about 10nm to about 50 nm.

Further, in various embodiments, the shaped porous carbon product has a relatively low concentration of macropores. For example, in some embodiments, about 10% or less, at least about 5% or less, or about 3% or less of the pore volume of the shaped porous carbon product as measured by mercury porosimetry is attributable to pores having a mean pore diameter of about 100nm or greater. In certain embodiments, about 0.1% to about 10%, about 0.1% to about 5%, about 0.1% to about 3%, about 1% to about 10%, about 1% to about 5%, or about 1% to about 3% of the pore volume of the shaped porous carbon product as measured by mercury porosimetry is attributable to pores having a mean pore diameter of about 100nm or greater. Further details regarding mercury manometry analysis are provided in the examples.

It has been found that the process for the hydrogenolysis of glycerol of the present invention advantageously provides high yields of propylene glycol. For example, various methods provide a propylene glycol yield of at least about 50%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, or at least about 80%.

As described above, in these hydrogenolysis processes, glycerol reacts with hydrogen. In various embodiments, the hydrogen partial pressure in the reaction zone is at least about 2.1MPa (300 psi), at least about 6.9MPa (1000 psi), at least about 12.4MPa (1800 psi), or at least about 13.8MPa (2000 psi). In some embodiments, the hydrogen partial pressure in the reaction zone is from about 2.1MPa (300 psi) to about 13.8MPa (2000 psi), from about 6.9MPa (1000 psi) to about 13.8MPa (2000 psi), or from about 12.4MPa (1800 psi) to about 13.8MPa (2000 psi). In some cases, it has been found that increasing the hydrogen flow relative to the flow of glycerol in the reaction zone increases the yield of propylene glycol.

As mentioned above, the catalyst composition typically comprises at least one catalytically active ingredient comprising a metal selected from the group consisting of chromium, cobalt, nickel, copper, zinc, ruthenium, rhodium, palladium, silver, rhenium, osmium, iridium, platinum, gold and any combination thereof. In some embodiments, the catalytically active component comprises rhenium. In various embodiments, the catalytically active component comprises nickel. In further embodiments, the catalytically active component comprises copper. In various embodiments, the catalytically active component comprises a combination of metals. For example, the combination of metals may be selected from the group consisting of: nickel and rhenium, copper and rhenium, and cobalt and rhenium. In certain embodiments, the catalyst composition further comprises manganese, molybdenum, and/or zinc.

The catalyst composition may have a loading of catalytically active ingredient as described herein. In some embodiments, the loading of the catalytically active component of the catalyst composition is about 0.1 wt% or greater, about 1 wt% or greater, about 2 wt% or greater, about 3 wt% or greater, about 4 wt% or greater, or about 5 wt% or greater. In various embodiments, the loading of the catalytically active component of the catalyst composition is from about 0.1 wt% to about 10 wt%, from about 0.1 wt% to about 7.5 wt%, from about 0.1 wt% to about 5 wt%, from about 0.5 wt% to about 10 wt%, from about 0.5 wt% to about 7.5 wt%, from about 0.5 wt% to about 5 wt%, from about 1 wt% to about 10 wt%, from about 1 wt% to about 7.5 wt%, or from about 1 wt% to about 5 wt%.

The catalyst composition for hydrogenolysis of glycerol may have a catalyst structure as described herein. For example, the catalytically active component may form an outer shell layer at least partially covering the surface of the shaped porous carbon product. In some embodiments, the catalytically active component is present predominantly in the surface porosity of the shaped porous carbon product to form an outer shell layer having a thickness of from about 10 μm to about 400 μm, or from about 50 μm to about 150 μm. In these and other embodiments, the catalyst composition comprises an inner region (e.g., core) and an outer region (e.g., shell), and the outer region has a higher concentration of the catalytically active component than the inner region. See, for example, fig. 14 and 16. In some embodiments, the outer region concentration of the catalytically active component is at least 2,5, 10, or 100 times the inner region concentration of the catalytically active component. In further embodiments, the catalyst composition has an average diameter and the outer region comprises at least about 5%, at least about 10%, at least about 20%, from about 5% to about 50%, or from about 10% to about 40% of the average diameter. Further, in some embodiments, the inner region comprises at least about 20%, at least about 30%, at least about 40%, from about 20% to about 80%, or from about 20% to about 70% of the average diameter.

The hydrogenolysis process described herein can also be carried out in the presence of a cocatalyst. An example of a cocatalyst is a base. Thus, in some embodiments, the reaction zone may further comprise a promoter comprising a base. In various embodiments, the base comprises sodium hydroxide. Further, the base (e.g. sodium hydroxide) may be co-fed to the reaction zone with the feed composition comprising glycerol, or may start at the inlet and at one or more additional points along the length of the continuous flow tubular reactor or at one or more times at and after the start of the batch process as described in US 9,938,215.

The hydrogenolysis process described herein can be carried out under neutral or basic conditions (e.g., slightly basic to basic). For example, the reaction may be carried out at a pH of about 7 to about 11, about 7.5 to about 10, about 8 to about 14, or about 10 to about 13.

The hydrogenolysis process described herein can be carried out at a temperature of about 150 ℃ to about 300 ℃, about 175 ℃ to about 250 ℃, about 190 ℃ to about 250 ℃, or about 190 ℃ to about 225 ℃.

Further, the feed composition may comprise an aqueous glycerol solution. In some embodiments, the glycerol concentration of the feed composition is about 10 wt.% or greater, about 20 wt.% or greater, about 30 wt.% or greater, about 40 wt.% or greater, about 10 wt.% to about 50 wt.%, or about 20 wt.% to about 40 wt.%. In certain embodiments, the feed composition further comprises at least one additional polyol selected from the group consisting of five and six carbon sugars and sugar alcohols.

Examples

Surface Area is determined from the nitrogen adsorption data using the BET Method as described in S.Brunauer, P.H.Emmett, E.Teller, J.Am.chem.Soc.1938,60,309-331 and ASTM D3663-03 (2008) Standard Test Method for Surface areas of Catalysts and Catalysts Carriers. Average pore diameters and pore volumes were determined according to the procedures described in E.P. Barrett, L.G.Joyner, P.P.Halenda, J.Am.chem.Soc.1951,73,373-380, and ASTM D4222-03 (2008) Standard Test Method for Determination of Nitrogen Adsorption and Desorption Isotherms of Catalysts and Catalysts Carriers by dynamic Volumetric Measurements.

Mercury pressure porosimetry was performed using an AutoPore V Mercury Porosimeter from Micromeritics Instrument Corporation. The appropriate amount of carbon extrudate was charged into a suitable penetrometer and mercury intrusion porosities were measured in two successive stages: first low pressure analysis (0 to 50 psia) followed by high pressure analysis (50 to 33,000psia). A total of 712 data points were collected over the entire pressure range with a contact angle of 154.0 °.

Radial part Crush Strength was measured according to ASTM D6175-03 (2013) Standard Test Method for Radial Crush Strength of Extruded Catalyst and Catalyst Carrier Partics using an extrusion apparatus equipped with a Dillon GS100 Digital Force Gauge. The average radial part crush strength is the average of independent measurements of at least 10 different extrudate particles.

Single part Crush Strength was measured according to ASTM D4179-03 (2013) Standard Test Method for Single Pellet blast Crush Strength of Formed Catalysts and Catalyst Cariers using an extrusion apparatus equipped with a Dillon GS100 Digital Force Gauge. The single part crush strength is the average of independent measurements of at least 10 different extrudate particles.

EXAMPLE 1 preparation of carbon Black extrudates

36.4g of carbon black powder (Cabot Vulcan XC72,224m 2/g) were added in portions to a heated (overnight at 80 ℃) aqueous solution (136.5 g) containing 24.3% by weight of cellulose dioxide from Ingregation and 4.7% by weight of hydroxyethyl cellulose from Sigma-Aldrich (SKU 54290, viscosity 80 to 125cP, 2% (20 ℃) in H2O). The mixture was stirred thoroughly with a spatula to give a paste. The paste was loaded into a syringe and the material was extruded into pasta strands of about 1.5mm diameter. After drying in an oven at 70 ℃ for 5 hours under a dry air purge, the wires were cut into small segments of about 1.0cm in length. Then in the continuous N ₂ Flow these small segments were treated with a 10 ℃/minute ramp rate at 350 ℃ for 2 hours to carbonize the binder and produce carbon black extrudates.

Table 1 shows the characteristics of the obtained extrudates.

Table 1.

EXAMPLE 2 characterization of the carbon Black powder composition

The characteristics of the various carbon black powders used to form the porous carbon black products were characterized.

A. Physical Properties of carbon Black powder

The BET specific surface area, average pore diameter and specific pore volume of these carbon black powder starting materials were measured by the methods described above, and such characteristics are shown in table 2.

Table 2.

B. Catalytic performance

Carbon black powder as a catalyst support material in an oxidation reaction for converting glucose to glucaric acid was evaluated as follows.

(i) Oxidation of glucose to glucaric acid (scheme 1)

The appropriate concentrated Me is obtained by incipient wetness impregnation ₄ NAuO ₂ And PtO (NO) ₃ ) The aqueous solution was added together to the carbon black powder and agitated to impregnate the support. The samples were dried in an oven at 70 ℃ overnight and under forming gas (5% H) ₂ And 95% N ₂ ) The sample was reduced under an atmosphere at 350 ℃ for 4 hours with a ramp rate of 2 ℃/minute to yield a catalyst (composition of 2.0 wt.% Au and 2.0 wt.% Pt). Catalysts with different loadings of Au and Pt on various commercial carbon black powders or particles, different from the extrudates, were prepared in a similar manner using other carbon black supports Au and Pt precursors and adjusting the amount of Au and Pt in the solution.

These catalysts were tested for glucose oxidation using the following test protocol. The catalyst (8 mg) was weighed into a glass vial insert, followed by the addition of 0.55M aqueous glucose solution (250. Mu.l). The vial insert was loaded into the reactor and the reactor was closed. The atmosphere inside the reactor was replaced with oxygen at room temperature and pressurized to 75psig. The reactor was heated to 110 ℃ and kept at the corresponding temperature for 2 hours while shaking the glass bottle. The shaking was then stopped and the reactor was allowed to cool to 40 ℃. The pressure in the reactor was then slowly released. The vial insert was removed from the reactor and centrifuged. The solution was diluted with deionized water and analyzed by ion chromatography to determine glucaric acid yield. Selectivity is defined as 100%x (glucaric acid)/(glucaric acid and the sum of all abnormal pathway species). Non-normal pathway classes that cannot be converted to glucaric acid include 2-ketogluconic acid, 3-ketogluconic acid, 4-ketogluconic acid, 5-ketogluconic acid, trihydroxyglutaric acid, tartaric acid, tartronic acid, and oxalic acid. Normal pathway classes include glucose, gluconic acid, guluronic acid, and glucuronic acid. The normal pathway species are not used in the selectivity calculations, as these intermediates can be partially converted to glucarates and are not considered to be abnormal pathway species. Table 3 shows the results.

Table 3.

(ii) Oxidation of glucose to glucaric acid (scheme 2)

The appropriate concentrated K is impregnated by incipient wetness impregnation ₂ Pt(OH) ₆ And CsAuO ₂ The aqueous solution was added together to the carbon black powder and agitated to impregnate the support. The samples were dried in a 40 ℃ oven overnight and under formation of gas (5% H) ₂ And 95% N ₂ ) The sample was reduced at 250 ℃ for 3 hours under an atmosphere with a ramp rate of 5 ℃/minute. The final catalyst was washed with deionized water and finally dried at 40 ℃ to yield a catalyst (composition of 2.44 wt.% Pt and 2.38 wt.% Au). Catalysts with different loadings of Au and Pt on various commercial carbon black powders or particles, different from the extrudates, were prepared in a similar manner using other carbon black supports Au and Pt precursors and adjusting the amount of Au and Pt in the solution.

The following test protocol was used to test these catalysts for glucose oxidation. The catalyst (10 mg) was weighed into a glass vial insert followed by the addition of 0.55M aqueous glucose solution (250. Mu.l). The vial insert was loaded into the reactor and the reactor was closed. The atmosphere inside the reactor was replaced with oxygen at room temperature and pressurized to 75psig. The reactor was heated to 90 ℃ and kept at the corresponding temperature for 5 hours while shaking the glass bottle. The shaking was then stopped and the reactor was allowed to cool to 40 ℃. The pressure in the reactor was then slowly released. The vial insert was removed from the reactor and centrifuged. The solution was diluted with deionized water and analyzed by ion chromatography to determine glucaric acid yield and selectivity as defined herein. Table 4 shows the results.

Table 4.

EXAMPLE 3 preparation of shaped porous carbon Black products Using various carbon Black powders and Binders

Different carbon black extrudates were prepared as described in example 1 using other carbon black powders and carbohydrate binders. Other Carbon BLACK powders include, but are not limited to, orion Carbon HI-BLACK 40B2, orion HI-BLACK 50LB, orion Hi-Black 50L, orion HP-160, orion Carbon HI-BLACK N330, timcal Ensaco 150G, timcal Ensaco 250G, timcal Ensaco 260G, timcal Ensaco 250P, cabot Vulcan 72R, cabot Monarch 120, cabot Monarch 280, cabot Monarch 570, cabot Monarch700, ashry 5365R, ashbury 5353R, ashry 5345R, ashry 5352, ashry 5374, ashry 5348R, ashry 5358R, sid Richardson SC159, and Sid Richardson SR155. Other Carbohydrate binders include, but are not limited to, cargill clearrow 60/44IX (80% Carbohydrate), casco Lab fructise 90 (70% Carbohydrate), and molases (80% Carbohydrate). Formulations with these variations provide illustrative examples of the shaped carbon products of the present invention. Some of the features of these embodiments are described in more detail below.

EXAMPLE 4 crush resistance testing of carbon Black extrudates

Extrudate pellets (numbered 1 to 8 below) of about 1.5mm in diameter were prepared according to the method described in example 1, but the final pyrolysis time and temperature varied in the extrudate description column as listed in table 5. After the pyrolysis step, the extrudate is cut into sizes ranging from 2 to 6mm in length. The percentage of carbonized binder (after pyrolysis) present in the shaped carbon product was determined by mass balance, [ i.e., [ (weight) _{Shaped carbon products} -weight of _{Carbon black (in the formulation)} Weight/weight _{Shaped carbon product} )×100]. The total binder content after pyrolysis (i.e. total carbonized binder) varies between 15 to 50 wt. -%。

Additional extrudate pellets (numbers 9 to 11 below) were prepared according to the following procedure. About 24.0g of carbon black powder (Timcal Ensaco 250G, 65m) ² /g) was added in portions to an aqueous solution (100.0 g) containing 25.0 wt.% Cerelose Dextrose from Ingredion. The mixture was stirred thoroughly with a spatula to produce a paste. This paste was loaded into a syringe and the material was extruded into pasta strands of 1.5mm diameter. The strands were dried in an oven at 100 ℃ for 3 hours under a dry air purge and then cut into small segments (2 to 6mm long). The small line segments are then treated under one of the following conditions to produce a carbon black extrudate: (1) In the sequence of N ₂ Treating the mixture at 250 ℃ for 3 hours at a heating rate of 10 ℃/min under the flowing-down condition; (2) In the sequence of N ₂ Treating the mixture at 800 ℃ for 4 hours at a heating rate of 10 ℃/min under the flowing condition; (3) Treated at 200 ℃ for 3 hours in air with a temperature ramp rate of 10 ℃/minute. The binder content varied between 15 wt% and 50 wt%. Table 5 shows the crush strength data of the extrudates produced.

Table 5.

EXAMPLE 5 preparation of catalyst composition

The Cabot Vulcan XC72 carbon black extrudate from example 1 was further cut into small segments of about 0.5cm in length for testing. Will contain 0.17g Me ₄ NAuO ₂ Au in the form and 0.26g PtO (NO) ₃ ) An aqueous solution of Pt in the form (13 ml) was mixed with 21.5g of these extrudates. The mixture was agitated to impregnate the carbon black support and dried in an oven at 60 ℃ overnight under a dry air purge. Then forming gas (5% H) ₂ And 95% N ₂ ) The sample was reduced at 350 ℃ for 4 hours under an atmosphere with a ramp rate of 2 ℃/min. The final catalyst consisted of about 0.80 wt% Au and 1.2 wt% PAnd (t) composition.

With other carbon black extrudates made by the above process, a range of Pt-Au extrudate catalysts can be made that span the range of Au and Pt loadings, pt/Au ratios, and metal distribution (e.g., eggshell, uniform, subsurface region).

The cross-section of a sample of catalyst extrudate prepared with Cabot Vulcan XC72 carbon black was analyzed by scanning electron microscopy. Figure 1 provides an image of this assay. The image shows platinum and gold metal deposited on the outer surface of the carbon black extrudate, forming a shell covering the outer surface of the carbon black extrudate. FIG. 2 provides an enlarged view of a cross-section of a catalyst extrudate with a measure of the soot extrudate diameter (i.e., 1.14 mm) and the platinum and gold shell thickness (on average about 100 μm) on the outer surface of the soot extrudate.

Example 6 testing of Au/Pt carbon Black extrudate catalyst (using Cabot Monarch 700) in a fixed bed reactor for the oxidation of glucose to glucaric acid

Extrudates based on carbon black Cabot Monarch700 with glucose and hydroxyethylcellulose binder were prepared by mixing 42.0g of carbon black Cabot Monarch700 with 145.8g of binder solution (prepared by heating a solution containing 3.4 wt% hydroxyethylcellulose and 28.6 wt% glucose overnight at 80 ℃) and subsequently preparing a catalyst with 0.80 wt% Au and 1.20 wt% Pt. The resulting paste was loaded into a syringe and the material was extruded into pasta strands of 1.5mm diameter. After drying in an oven at 100 ℃ for 3 hours under a dry air purge, the strands were cut into small segments of 2 to 6mm in length and pyrolyzed at 350 ℃ for 2 hours under a nitrogen atmosphere. The final carbonised binder content in the carbon extrudate was 31 wt%. The catalyst was then prepared using the method described in example 5. The glucose oxidation reaction was carried out using a gas-liquid downward co-current flow in a 316 stainless steel tube 12.7mm (0.5 inch) in outside diameter multiplied by 83cm in length. 1.0mm glass beads about 8cm deep were vibration packed at the top of the catalyst bed, followed by 67cm deep catalyst (20.0 g, which is a 0.5cm long and 1.5mm diameter Cabot Monarch700 carbon black pellet catalyst loaded with 0.80 wt% Au +1.2 wt% Pt prepared using the method described in example 3), followed by 1.0mm glass beads about 8cm deep at the bottom of the catalyst bed. The catalyst bed was separated from the glass beads by a quartz wool plug.

The packed bed reactor tubes were fixed in an aluminum starting heater equipped with a PID controller. The gas (dry compressed air) and liquid flows were regulated by mass flow controllers and HPLC pumps, respectively. The back pressure regulator controls the reactor pressure as indicated in table 6. The catalyst was tested for a Time On Stream (TOS) of about 350 hours.

Table 6 describes the fixed bed reactor conditions and resulting extrudate catalyst performance. The catalyst productivity in Table 6 is per gram (Pt + Au) ^-1 35 g (glucaric acid) or per gram (catalyst) per hour ^-1 0.70 g (glucaric acid) per hour.

Table 6.

The following carbon black and extrudate samples were subjected to BET surface area measurements and BJM pore volume distribution measurements:

sample 1.

Sample 2 fresh Monarch700 extrudate prepared according to this example.

Sample 3 Monarch700 extrudate of example 4 (described in example 6) after 350 hours of operation in a fixed bed reactor.

Sample 4A mixture of 36.6g hydroxyethyl cellulose and 561.7g glucose Monohydrate (Dextrose Monohydrate) in 316.7ml deionized water was stirred at 80 deg.C for 16 hours to prepare a gel containing 4.0 wt% hydroxyethyl cellulose (Sigma-Aldrich, SKU 54290, viscosity 80 to 125cP in H ₂ 2% in O (20 ℃) and 56.0% by weight of glucose (ADM Corn processing, glucose monohydrate 99.7DE, glucose content 91.2255% by weight) in water (915.0 g). After cooling to ambient temperature, this viscous solution was added to 400.0g of carbon black powder (Cabot Monarch 700) in a blender/kneader and the material was mixed/kneaded for 1 hour. The material was then charged into a 1' bonnot BB Gun Extruder and extruded into spaghetti having a cross-sectional diameter of about 1.5mmAnd (4) forming a line. The strands were dried in a 120 ℃ oven for 16 hours under a dry air purge, followed by pyrolysis at 800 ℃ for 2 hours with a 5 ℃/minute ramp rate under a nitrogen purge. The final carbonised binder content was 36 wt%.

Sample 5 prepared as described in example 9.

Sample 6 was prepared as described in example 12.

Sample 7A sample containing 4.0 wt.% hydroxyethyl cellulose (Sigma-Aldrich, SKU 54290, viscosity 80 to 125cP in H) was prepared by stirring 6.64g of hydroxyethyl cellulose and 84.8g of glucose monohydrate in 74.6ml of deionized water at 80 deg.C for 16 hours ₂ 2% in O (20 ℃) and 56.0% by weight of glucose (ADM Corn Processing, glucose monohydrate 99.7DE, glucose content 91.2255% by weight) in water (166.0 g). After cooling to ambient temperature, this viscous solution was added to 60.0g of carbon black powder (Ashry 5368) in a blender/kneader and the materials were mixed/kneaded for 1 hour. The material was then charged into a 1' bonnot BB Gun Extruder and extruded into pasta-like strands having a cross-sectional diameter of about 1.5 mm. The strands were dried in a 120 ℃ oven for 16 hours under a dry air purge, followed by pyrolysis at 800 ℃ for 2 hours under a nitrogen purge with a 5 ℃/minute ramp rate. The final carbonized binder content was 40 wt%.

Sample 8, commercially available activated carbon extrudate Sud Chemie G32H-N-75.

Sample 9, a commercially available activated carbon extrudate, donau Superborn K4-35.

Table 7 shows the results.

Table 7.

FIG. 3 shows a plot of the cumulative pore volume (%) of crude Monarch700 carbon black material as a function of average pore diameter. FIG. 4 shows a plot of cumulative pore volume (%) as a function of average pore diameter for fresh catalysts prepared from carbon black extrudates using Monarch700 and glucose/hydroxyethylcellulose binder. Fig. 5 shows a plot of cumulative pore volume (%) of the catalyst extrudates of fig. 2 as a function of average pore diameter after 350 hours of use in a fixed bed reactor for the oxidation of glucose to glucaric acid. FIG. 6 shows a plot of cumulative pore volume (%) as a function of average pore diameter for extrudates utilizing Monarch700 carbon black and glucose/hydroxyethylcellulose binder. Figure 7 shows a plot of cumulative pore volume (%) as a function of average pore diameter for extrudates using Sid Richardson SC159 carbon black and glucose/hydroxyethylcellulose binder. Figure 8 shows a plot of cumulative pore volume (%) as a function of average pore diameter for extrudates using Sid Richardson SC159 carbon black and glucose/hydroxyethylcellulose binder prepared according to example 12. Figure 9 shows a plot of cumulative pore volume (%) as a function of average pore diameter for extrudates using the attribute 5368 carbon black and glucose/hydroxyethylcellulose binder. FIG. 10 shows a graph of the cumulative pore volume (%) of commercially available activated carbon extrudates of Sud Chemie G32H-N-75 as a function of the average pore diameter. FIG. 11 shows a plot of cumulative pore volume (%) as a function of average pore diameter for a commercially available activated carbon extrudate of Donau Superglass K4-35.

Figure 12 shows the pore size distribution of extrudates using Sid Richardson SC159 carbon black and glucose/hydroxyethylcellulose binder as measured by mercury porosimetry. These figures show that the ratio of pore distribution to pore volume of the carbon black extrudate catalyst (fresh or used) is low. In particular, these figures show that the micropore distribution (pores <3 nm) accounts for less than 10% of the BJH pore volume. In some cases, the micropore distribution (pores <3 nm) comprises less than 6% of the BJH pore volume, and in some cases, the micropore distribution (pores <3 nm) comprises less than 4% of the BJH pore volume. In contrast, the activated carbon extrudate catalyst has a micropore distribution ratio of up to 40% by pore volume. Further, these figures show that the ratio of the pore distribution of the carbon black catalyst having an average diameter of about 10nm to 50nm to the pore volume is about 40% or more. On the other hand, the activated carbon catalyst has a pore distribution having an average diameter of about 10nm to 50nm in a ratio of less than 15% by volume of pores. These figures show that the ratio of the pore distribution of the carbon black catalyst having an average diameter of about 10nm to 100nm to the pore volume is about 70% or more. On the other hand, the activated carbon catalyst has a pore distribution having an average diameter of about 10nm to 100nm at a pore volume ratio of 15% or less.

Example 7 testing of Au/Pt carbon Black extrudate catalyst in a fixed bed reactor for the oxidation of glucose to glucaric acid (Using Cabot Vulcan XC 72)

Extrudates based on carbon black Cabot Vulcan XC72 were prepared by mixing 36.4g of carbon black Cabot Vulcan XC72 with 136.5g of binder solution (prepared by heating a solution containing 3.7 wt% hydroxyethyl cellulose and 24.4 wt% glucose at 80 ℃ overnight), followed by a catalyst with 0.80 wt% Au and 1.20 wt% Pt. The resulting paste was loaded into a syringe and the material was extruded into pasta strands of 1.5mm diameter, followed by drying in air at 120 ℃ for 4 hours and pyrolysis at 350 ℃ for 2 hours under nitrogen atmosphere. The final binder content in the pyrolyzed carbon extrudate was 30 wt%. The catalyst was prepared using the method described in example 3. The catalyst was tested in the same 12.7mm (0.5 inch) outer diameter fixed bed reactor as in example 6. Table 8 describes the fixed bed reactor conditions and the properties of the resulting extrudate catalyst. The catalyst productivity in Table 8 is per gram (Pt + Au) ^-1 36 g (glucaric acid) or per gram (catalyst) per hour ^-1 0.72 g (glucaric acid) per hour.

Table 8.

EXAMPLE 8 Oxidation of glucose to glucaric acid-high surface area activated carbon (comparative example)

The same synthetic procedure as described in example 6 was used to prepare a Pt-Au catalyst supported on high surface area activated carbon. The activated carbon extrudates were crushed and sieved to <90 μm prior to catalyst preparation and sieving. The catalyst was screened in the same reactor under the same conditions as described in example 2 (B) (ii). As shown in table 9, the high surface area activated carbon support was found to have lower activity and lower selectivity (as defined herein).

Table 9.

EXAMPLE 9 preparation of carbon Black extrudate catalyst-attrition and attrition testing

A composition containing 4.0 wt% hydroxyethyl cellulose (Sigma-Aldrich, SKU 54290, viscosity 80 to 125cP in H.sub.1 mL deionized water was prepared by stirring 4.5g hydroxyethyl cellulose and 69.4g glucose Monohydrate (Dextrose Monohydrate) in 39.1mL deionized water overnight at 80 deg.C ₂ 2% in O (20 ℃) and 56.0% by weight of glucose (ADM Corn Processing, glucose monohydrate 99.7DE, glucose content 91.2255% by weight) in water (113 g). After cooling to room temperature, this viscous solution was added to 50g of carbon black powder (Sid Richardson SC159, 231m) in a blender/kneader ² /g) and mixing/kneading the materials for 1 hour. The material was then charged into a 1"bonnot BB Gun Extruder and extruded into pasta-like strands having a cross-sectional diameter of about 1.5 mm. The strands were dried in a 120 ℃ oven overnight under a dry air purge, followed by pyrolysis at 800 ℃ for 4 hours under a nitrogen purge with a 5 ℃/minute ramp rate. The extruded and pyrolyzed sample was cut into small pieces about 0.5cm long for testing.

Table 10 shows the properties of the resulting extrudates. BET and crush strength were measured as described in the present invention.

Table 10.

The extrudates prepared in accordance with this example were tested for abrasion index (ASTM D4058-96) and wear determination according to the following procedure.

And (4) measuring the abrasion index.

ASTM attrition index (ATTR) is a measure of the catalyst or extrudate particle resistance to attrition and abrasion due to repeated contact of the particles with a hard surface in a designated test drum. The drum is similar in diameter and length to those described in ASTM D4058, with a turning device capable of tumbling the test drum at 55 to 65 RPM. The percentage of the original sample remaining on the 20 mesh screen is referred to as the "percent remaining" result of the test. On a relative basis, the test results can be used as a measure of fines generation during handling, transport and use of the catalyst or extrudate material. Results with a residual percentage >97% are desirable for industrial applications.

Approximately 100g of the extrudate material prepared in example 9 above was transferred to the test drum, the test drum was closed and transferred to the rotating apparatus and tumbled at 55 to 65RPM for 35 minutes. The residual weight percentage after the test was 99.7%.

And measuring abrasion loss.

Attrition loss (ABL) is an alternative measure of attrition resistance of catalyst or extrudate particles due to vigorous horizontal agitation of the particles within a 30 mesh screen. On a relative basis, the results of this step can be used as a measure of fines generation during handling, transport and use of the catalyst or sorbent material. For industrial applications it is desirable to have abrasion levels of <2 wt.%. About 100g of the extrudate material prepared in example 9 above was first placed on a 20 mesh screen and gently shaken side to side at least about 20 times to remove dust. The dust-removed sample was then transferred to a clean 30 mesh screen stacked on a clean sieve tray for collection of fines. The complete screen stack was then assembled onto a RO-Tap RX-29 vibratory screening machine, securely covered and vibrated for 30 minutes. The resulting fine powder was weighed to obtain a sample abrasion amount of 0.016 wt%.

Example 10 the Au/Pt carbon black extrudate catalyst of example 9 was tested in a fixed bed reactor for the oxidation of glucose to glucaric acid.

The carbon black extrudate obtained by the process described in example 9 was further cut into small line segments of approximately 0.5cm in length for testing. Will contain 0.16g Me ₄ NAuO ₂ Au in the form of and 0.24g PtO (NO) ₃ ) An aqueous solution of Pt in the form (8.0 ml) was added to 27.0g of these extrudatesIn the above-mentioned material. The mixture was agitated to impregnate the carbon black support and dried in an oven at 70 ℃ for 1 hour under a dry air purge. Then forming gas (5% H) ₂ And 95% N ₂ ) The sample was reduced at 350 ℃ for 4 hours under an atmosphere with a ramp rate of 2 ℃/min. The final catalyst consisted of about 0.60 wt% Au and 0.90 wt% Pt. With other carbon black extrudates made by the methods described herein, a range of Pt-Au extrudate catalysts can be made that span the range of Au and Pt content, pt/Au ratio, and metal distribution (e.g., eggshell, uniform, subsurface region).

The oxidation of glucose to glucaric acid was carried out using a gas-liquid co-current flow down in a 316 stainless steel tube of 1/2 "outer diameter multiplied by 83cm length. 1.0mm glass beads about 10cm deep were packed at the top of the catalyst bed by shaking, followed by 63cm bed depth of catalyst (27.4 g of Sid Richardson SC159 carbon black pellet catalyst loaded with 0.60 wt% Au +0.90 wt% Pt, 0.5cm long and 1.4mm diameter prepared by the above method), followed by about 10cm deep of 1.0mm glass beads at the bottom of the catalyst bed. The catalyst bed was separated from the glass beads by a quartz cotton plug.

The packed bed reactor tubes were fixed in an aluminum starting heater equipped with a PID controller. The gas (dry compressed air) and liquid flows were regulated by mass flow controllers and HPLC pumps, respectively. The back pressure regulator controls the reactor pressure as indicated in table 11. The catalyst was tested by running for about 920 hours and showed stable performance. Table 11 describes the fixed bed reactor conditions and resulting extrudate catalyst performance. The catalyst productivity in Table 11 is per gram (Pt + Au) ^-1 23 grams per hour (glucaric acid) or per gram (catalyst) ^-1 0.35 g (glucaric acid) per hour.

Table 11.

After 920 hours of operation, the catalyst extrudates were removed and resubmitted for mechanical crush strength testing. The average single part crush strength and average radial part crush strength data were found to be within experimental error of the data listed in table 10, thereby demonstrating that the extrudate catalyst produced by the process is high productivity, selective, and stable under the continuous flow conditions.

Example 11 testing of Au/Pt carbon Black extrudate catalyst (with Ashry 5368) in a fixed bed reactor for the oxidation of glucose to glucaric acid

The reaction was carried out in a 1/2' OD by 83cm long 316 stainless steel tube with co-current flow down gas-liquid. 1.0mm glass beads about 8cm deep were vibration packed at the top of the catalyst bed, followed by 73cm deep catalyst (35.0 g, 0.5cm long and 1.4mm diameter 0.50 wt% Au +0.85 wt% Pt loaded Aspury 5368 extruded pellet catalyst prepared using the method described in example 9 above) (as previously described for sample 7 of example 6)), followed by about 8cm deep 1.0mm glass beads at the bottom of the catalyst bed. The catalyst bed was separated from the glass beads by a quartz cotton plug.

The packed bed reactor tubes were fixed in an aluminum starting heater equipped with a PID controller. The gas (dry compressed air) and liquid flows were regulated by mass flow controllers and HPLC pumps, respectively. The back pressure regulator controls the reactor pressure as indicated in table 12. The catalyst was tested for a Time On Stream (TOS) of about 240 hours and showed stable performance. Table 12 describes the fixed bed reactor conditions and the properties of the resulting extrudate catalyst. The catalyst productivity in Table 12 is per gram (Pt + Au) ^-1 20 g (glucaric acid) or per gram (catalyst) per hour ^-1 0.27 g (glucaric acid) per hour.

TABLE 12.0.50 wt.% Au +0.85 wt.% Pt/Ashry 5368 extrudates (stable performance over 240 hours of operation)

EXAMPLE 12 preparation of carbon Black extrudate catalyst on partially oxidized support

The Sid Richardson SC159 carbon black extrudate prepared as described in example 9 was oxidized in air at 300 ℃ with a 5 ℃/minute ramp rate for 3 hours to provide partially oxidized extrudate pellets. An aqueous solution (9.0 ml) containing 0.18g of Au in the form of Me4NAuO2 and 0.31g of Pt in the form of PtO (NO 3) was added to 36.0g of these partially oxidized extrudates. The mixture was agitated to impregnate the carbon black support and dried in an oven at 60 ℃ overnight under a dry air purge. The sample was then reduced at 350 ℃ for 4 hours under a forming gas (5% H2 and 95% N2) atmosphere with a 2 ℃/minute ramp rate. The final catalyst consisted of about 0.50 wt% Au and 0.85 wt% Pt. With other carbon black extrudates made by the methods described herein, a range of Pt-Au extrudate catalysts can be made that span the range of Au and Pt content, pt/Au ratio, and metal distribution (e.g., eggshell, uniform, subsurface region). The oxidation of glucose to glucaric acid was carried out by co-current downward gas-liquid flow in a 316 stainless steel tube of 1/2 "external diameter multiplied by 83cm length. 1.0mm glass beads about 6cm deep were packed at the top of the catalyst bed with shaking, followed by 70.4cm deep catalyst (34.5 g of partially oxidized Sid Richardson SC159 carbon black pellet catalyst loaded with 0.50 wt% Au +0.85 wt% Pt, made using the method described in example 2, 0.5cm long and 1.5mm diameter) followed by 1.0mm glass beads about 6cm deep at the bottom of the catalyst bed. The catalyst bed was separated from the glass beads by a quartz cotton plug.

The packed bed reactor tubes were fixed in an aluminum starting heater equipped with a PID controller. The gas (dry compressed air) and liquid flows were regulated by mass flow controllers and HPLC pumps, respectively. The back pressure regulator controls the reactor pressure as indicated in table 13. The catalyst was tested for a Time On Stream (TOS) of about 230 hours and showed stable performance. Table 13 describes the fixed bed reactor conditions and the properties of the resulting extrudate catalyst. The catalyst productivity in Table 13 is per gram (Pt + Au) ^-1 26g (glucaric acid) or per gram (catalyst) per hour ^-1 0.36 g (glucaric acid) per hour.

Table 13.

EXAMPLE 13 preparation of carbon Black extrudates using Poly (vinyl alcohol) pore Forming agent

An aqueous solution (490.0 g) containing 8.0 wt% Mowiol 8-88 poly (vinyl alcohol) (Mw 67k, sigma-Aldrich 81383) and 36.0 wt% glucose (ADM Corn Processing, glucose monohydrate 99.7DE, glucose content 91.2255 wt%) was prepared by stirring 39.2g Mowiol 8-88 poly (vinyl alcohol) and 193.4g glucose monohydrate in 257.4ml deionized water overnight at 70 ℃. After cooling to room temperature, this solution was added to 230g of carbon black powder (Sid Richardson SC 159) in a blender/kneader and the material was mixed/kneaded for 1 hour. The material was then charged into a 1' bonnot BB Gun Extruder and extruded into pasta-like strands having a cross-sectional diameter of about 1.5 mm. The strands were dried in a 90 ℃ oven overnight under a dry air purge, followed by pyrolysis at 600 ℃ for 4 hours under a nitrogen atmosphere with a 5 ℃/minute ramp rate. The final carbonised binder content was 24 wt%. The surface area of the resulting extrudate (length 3 to 5 mm) was 149m ² Per g, pore volume 0.35cm ³ G and an average pore diameter of 16nm. The average radial part crushing strength of these pellets was measured to be 11.5N/mm. The measured crushing strength of the single part was 42N.

EXAMPLE 14 testing of Au/Pt activated carbon extrudate catalyst (with Clariant Donau Supersorbon K4-35 activated carbon extrudate) in a fixed bed reactor for the oxidation of glucose to glucaric acid

A catalyst based on activated carbon Clariant Supersorb K4-35 was prepared using the same procedure as described in example 7. The glucose oxidation reaction was carried out by the same method as described in example 2 (B) (ii). A catalyst bed 73cm deep (containing 27.0g of catalyst, 0.53 wt% Au +0.90 wt% Pt loaded Clariant Superglass K4-35 activated carbon particle catalyst 0.5cm long and 1.4mm diameter) was tested for a run Time (TOS) of about 40 hours. Table 14 describes the fixed bed reactor conditions and the properties of the resulting extrudate catalyst. After 40 hours of operation, the glucaric acid yield and catalyst productivity were measured to be lower than the shaped carbon black catalyst of the present invention.

Table 14.

EXAMPLE 15 preparation of carbon Black extrudates

A solution containing 4.0 wt.% hydroxyethyl cellulose (HEC) (Sigma-Aldrich, SKU 54290, viscosity 80 to 125cP in H was prepared by stirring 36.6g hydroxyethyl cellulose and 561.7g glucose monohydrate in 316.7ml deionized water for 2 hours at about 80 deg.C ₂ 2% in O (20 ℃) and 56.0% by weight of glucose (ADM Corn Processing, glucose monohydrate 99.7DE, glucose content 91.2% by weight) in water (915 g). 400.1g of Sid Richardson SC159 carbon black powder was added to this viscous solution and the mixture was then mixed for a further 10 minutes. The material was then charged into a 1 "diameter Bonnot extruder (equipped with a 1/4 inch washer and a die with a 1.6mm cylindrical hole) and extruded into pasta-like strands. The extrudates were dried in a 110 ℃ oven overnight and then pyrolyzed at 800 ℃ for 4 hours (after reaching the target temperature with a 5 ℃/minute ramp rate) in a stationary pilot furnace under a nitrogen purge (table 15).

TABLE 15 characteristics of the pyrolyzed extrudates from example 15

EXAMPLE 16 preparation of carbon Black extrudates

A composition containing 4.0 wt.% hydroxyethyl cellulose (HEC) (Sigma-Aldrich, SKU 54290, viscosity 80 to 125cP in H was prepared by stirring 153g of hydroxyethyl cellulose and 2340g of glucose monohydrate in 1320mL of deionized water for 3 hours at about 80 deg.C ₂ 2% in O (20 ℃) and 56.0% by weight of glucose (ADM Corn Processing, glucose monohydrate 99.7DE, glucose content 91.2% by weight) in water (3813 g). This viscous solution was added over 3.5 minutes to 1670g of Sid Richardson SC159 carbon black powder in a roller mixer, followed by stirring the mixture inMix in the roller mixer for 20 minutes. The material was then charged into a 2 "diameter Bonnot extruder (equipped with 5 dies with 26 cylindrical holes each 1/16" id (JMP Industries, part No. 0388P 062) without gaskets) and extruded into pasta-shaped strands. 1515g of the extrudate was dried overnight in a 110 ℃ oven to give 1240g of dry extrudate. The product was then pyrolyzed in a fixed tube furnace at 800 ℃ for 4 hours under a nitrogen purge (table 16).

TABLE 16 characteristics of the pyrolized extrudates from example 2

EXAMPLE 17 preparation of carbon Black extrudates by batch pyrolysis in a rotating tube furnace

A composition containing 4.0 wt.% Dow Cellosize HEC QP 40 hydroxyethyl cellulose (viscosity 80 to 125cP in H) was prepared by stirring 153g hydroxyethyl cellulose and 2340g glucose monohydrate in 1320ml deionized water for 3 hours at about 80 deg.C ₂ 2% in O (20 ℃) and 56.0% by weight of glucose (ADM Corn Processing, glucose monohydrate 99.7DE, glucose content 91.2% by weight) in water (3813 g). This viscous solution was added over 3.5 minutes to 1670g of Sid Richardson SC159 carbon black powder in a roller mixer, followed by mixing the mixture in a roller mixer for an additional 20 minutes. The material was then charged into a 2 "diameter Bonnot extruder (equipped with 5 dies with 26 cylindrical holes, each 1/16" inside diameter (JMP Industries, part No. 0388P 062) without a gasket) and extruded into pasta strands. 3.9kg of the extrudate was dried overnight in a 110 ℃ oven to produce 2.93kg of dried extrudate. The dried extrudate was then screened on an 18 mesh screen and 2.91kg of the screened material was collected.

The above mixing, extrusion, drying and screening steps were repeated 3 more times to give a total of 4 combined screened dry extrudates as outlined in table 17.

TABLE 17 production of carbon Black extrudates in a 2 "extruder

Each batch of 650g of the combined screened dry extrudates was then pyrolyzed in a rotary tube furnace under a nitrogen purge at 800 deg.C for 2 hours, yielding about 350g of pyrolysis product per batch. For each batch, 650g of carbon black extrudate (made from Sid Richardson SC159 with glucose and hydroxyethyl cellulose binder) was charged into the Quartz Tube Three Zone Tube Furnace (OTF-1200X-5L-R-III-UL) of MTI Corporation 5. The carbon black extrudate was pyrolyzed at 800 ℃ for 2 hours in a nitrogen atmosphere at the following ramp rates using a 5"quartz tube rotating at 4.0 rpm: from ambient temperature to 200 ℃ at 10 ℃/min, from 200 ℃ to 600 ℃ at 5 ℃/min, from 600 ℃ to 800 ℃ at 10 ℃/min, held at 800 ℃ for 2 hours, then cooled to ambient temperature, again under a nitrogen purge. 350g of pyrolyzed carbon black extrudate were recovered in a yield of 51.5 mass%. Table 18 shows the characteristics of the batch pyrolysis extrudate. Other carbon black extrudates may be pyrolyzed at various temperatures in a similar manner or using a continuously operating rotary kiln as described in the next example.

TABLE 18 characteristics of carbon black extrudates pyrolyzed in batch in a rotary tube furnace

EXAMPLE 18 preparation of carbon Black extrudates by continuous pyrolysis in a Rotary kiln

The mixing, extrusion, drying and screening steps described in example 17 were repeated 10 more times to obtain a further 33.4kg of combined screened dry extrudate. Then 25.7kg of combined screened dry extrudate was pyrolyzed by continuously feeding dry extrudate at about 0.5 kg/hour under a continuous nitrogen sweep (countercurrent flow with respect to the extrudate) in a continuous rotary kiln, collecting the product under some set point conditions outlined in table 19. The rotary kiln is of an electronic heating type; table 19 shows the temperature set points for the external heaters along with the calculated material residence times in the heating zone. The temperature and residence time are adjusted to affect the surface area of the product. A total of 12.5kg of pyrolysis product was collected, and the total yield was 48.5 mass%.

TABLE 19 characteristics of carbon black extrudates pyrolyzed in a continuously operating rotary kiln

EXAMPLE 19 hydrodeoxygenation of glucaric acid dilactone to adipic acid

The appropriate concentrated rhodium nitrate and platinum nitrate aqueous solution were added together to carbon black powder (pulverized from carbon black particles) by the incipient wetness impregnation method and agitated to impregnate the support. The samples were dried in an oven at 60 ℃ overnight and under formation of gas (5% H) ₂ And 95% N ₂ ) The sample was reduced at 350 ℃ for 4 hours under an atmosphere with a temperature ramp rate of 2 ℃/minute to yield a catalyst (composition of 1.0 wt% Rh and 2.0 wt% Pt). Catalysts with various Rh and Pt loadings on various particles different from the extrudates were prepared in a similar manner using other carbon black supports Rh and Pt precursors and adjusting the amount of Rh and Pt in the solution.

These catalysts were tested for the hydrodeoxygenation reaction of glucaric acid dilactone using the following test protocol. The catalyst (16 mg) was weighed into a glass vial insert, followed by addition of a solution (125. Mu.l) containing glucaric acid dilactone (0.80M), HBr (0.80M) and water (2.0M). The vial insert was loaded into the reactor and the reactor was closed. The atmosphere inside the reactor was replaced with hydrogen at room temperature and pressurized to 900psig. The reactor was heated to 120 ℃ and held at 120 ℃ for 1 hour while shaking the glass bottle. The reactor was then heated to 160 ℃ and held at 160 ℃ for 2 hours while shaking the glass vial. The shaking was then stopped and the reactor was cooled to 40 ℃. The pressure in the reactor was slowly released. The vial insert was removed from the reactor and centrifuged. The clear solution was hydrolyzed with NaOH, diluted with deionized water, and analyzed by ion chromatography to determine adipic acid yield. Table 20 shows the characteristics of the carbon black starting materials and the results of the reaction screening.

Table 20.

Example 20 testing of Rh/Pt carbon Black extrudate catalyst in a fixed bed reactor for the Hydrodeoxygenation of glucaric acid to adipic acid

The Cabot Vulcan XC72 carbon black particles used in this experiment were particles with a particle size of 150 to 300 μm, obtained by crushing and sieving the extrudate particles obtained by the method described in the preceding examples. The reaction was carried out using gas-liquid downward co-current flow in a 6.4mm (0.25 inch) outside diameter by 38cm long zirconium tube. About 5cm deep of glass beads 200 to 300 μm in particle size were packed with vibration at the top of the catalyst bed, followed by packing (1.9 g of a 28cm deep catalyst, which is a carbon black particle catalyst loaded with 0.90 wt% Rh +2.1 wt% Pt, of particle size 150 to 300 μm), followed by about 5cm deep of glass beads 200 to 300 μm in particle size at the bottom of the catalyst bed. The catalyst bed was separated from the glass beads by a quartz wool plug.

The packed bed reactor tubes were fixed in an aluminum starting heater equipped with a PID controller. The gas (compressed hydrogen) and liquid flows were regulated by mass flow controllers and HPLC pumps, respectively. The substrate solution contained 0.80M D-glucaric acid-1, 4. The back pressure regulator controls the reactor pressure as indicated in table 21. The outside temperatures of the upper and lower half reactors were controlled at 110 ℃ and 160 ℃ respectively. The catalyst showed stable performance on 350 hours of test run. Table 21 describes the fixed bed reactor conditions and resulting catalyst performance.

Table 21.

Example 21 hydrodeoxygenation of 1,2, 6-hexanetriol to 1, 6-hexanediol

Appropriate concentrated Pt (NO) ₃ ) _X And H ₄ SiO ₄ *12WO ₃ Or PtONO ₃ And H ₄ SiO ₄ *12WO ₃ The aqueous solution was added to about 50mg of Ensaco 250G carbon and agitated to impregnate the support. The samples were dried in a 40 ℃ oven under static air overnight, followed by formation of a gas (5% H) ₂ And 95% N ₂ ) The sample was reduced at 350 ℃ for 3 hours under an atmosphere. The final catalyst had a metal content of about 4.09 wt.% Pt and 3.42 wt.% W.

These catalysts were tested for the 1,2,6-hexanetriol hydrodeoxygenation reaction using the following catalyst test protocol. The catalyst (about 10 mg) was weighed into a glass vial insert, followed by the addition of 0.8M aqueous 1,2, 6-hexanetriol (200. Mu.l). The vial insert was loaded into the reactor and the reactor was closed. The atmosphere inside the reactor was replaced with hydrogen at room temperature and pressurized to 670psig. The reactor was heated to 160 ℃ and kept at the corresponding temperature for 150 minutes while shaking the glass bottle. After 150 minutes the shaking was stopped and the reactor was cooled to 40 ℃. The pressure in the reactor was then slowly released. The vial insert was removed from the reactor and centrifuged. The solution was diluted with methanol and analyzed by gas chromatography using flame ionization detection. Table 22 shows the results.

Table 22.

EXAMPLE 22 hydrodeoxygenation of 1,2, 6-hexanetriol to 1, 6-hexanediol

Adding proper concentrated ammonium metatungstate H ₂₆ N ₆ W ₁₂ O ₄₀ The aqueous solution was added to about 500mg of Ensaco 250G and agitated to impregnate the carbon black support. The samples were heat treated at 600 ℃ for 3 hours with a ramp rate of 5 ℃/minute in a nitrogen atmosphere. The appropriate concentrated Pt (NMe) ₄ ) ₂ (OH) ₆ The aqueous solution was added to the sample of 50mg or more and stirred to impregnate the carbon support. The samples were dried in static air at 40 ℃ oven overnight, followed by forming gas (5% H) ₂ And 95% of N ₂ ) The sample was reduced at 250 ℃ for 3 hours under an atmosphere with a ramp rate of 5 ℃/minute.The final catalyst had a metal content of about 4.5 wt.% Pt and 2 wt.% W.

These catalysts were tested for the 1,2,6-hexanetriol hydrodeoxygenation reaction using the following catalyst test protocol. The catalyst (about 10 mg) was weighed into a glass vial insert, followed by the addition of 0.8M aqueous 1,2, 6-hexanetriol (200. Mu.l). The vial insert was loaded into the reactor and the reactor was closed. The atmosphere inside the reactor was replaced with hydrogen at room temperature and pressurized to 670psig. The reactor was heated to 160 ℃ and kept at the corresponding temperature for 150 minutes while shaking the glass bottle. After 150 minutes the shaking was stopped and the reactor was cooled to 40 ℃. The pressure in the reactor was then slowly released. The vial insert was removed from the reactor and centrifuged. The clear solution was diluted with methanol and analyzed by gas chromatography using flame ionization detection. Table 23 shows the results.

Table 23.

EXAMPLE 23 hydrodeoxygenation of 1,2, 6-hexanetriol to 1, 6-hexanediol

Adding proper concentrated ammonium metatungstate H ₂₆ N ₆ W ₁₂ O ₄₀ The aqueous solution was added to about 500mg of carbon black material and agitated to impregnate the carbon black support. The samples were heat treated at 600 ℃ for 3 hours with a ramp rate of 5 ℃/minute in a nitrogen atmosphere. Appropriate concentrated Pt (NMe) ₄ ) ₂ (OH) ₆ The aqueous solution was added to about 50mg or more of the sample and agitated to impregnate the carbon support. The samples were dried in a 60 ℃ oven under static air followed by forming gas (5% H) ₂ And 95% N ₂ ) The sample was reduced at 350 ℃ for 3 hours under an atmosphere with a ramp rate of 5 ℃/min. The final catalyst had a metal content of about 5.7 wt.% Pt and 1.8 wt.% W.

These catalysts were tested for the 1,2,6-hexanetriol hydrodeoxygenation reaction using the following catalyst test protocol. The catalyst (about 10 mg) was weighed into a glass vial insert, followed by the addition of 0.8M aqueous 1,2, 6-hexanetriol (200. Mu.l). The vial insert was loaded into the reactor and the reactor was closed. The atmosphere inside the reactor was replaced with hydrogen at room temperature and pressurized to 670psig. The reactor was heated to 160 ℃ and kept at the corresponding temperature for 150 minutes while shaking the glass bottle. After 150 minutes the shaking was stopped and the reactor was cooled to 40 ℃. The pressure in the reactor was then slowly released. The vial insert was removed from the reactor and centrifuged. The clear solution was diluted with methanol and analyzed by gas chromatography using flame ionization detection. Table 24 shows the results.

Table 24.

EXAMPLE 24 Small Scale batch reactor experiment for amination of 1, 6-hexanediol to 1, 6-hexamethylenediamine

Amination of 1, 6-hexanediol to produce 1, 6-hexamethylenediamine-analytical details

The product composition was determined by HPLC analysis using a Thermo Ultimate 3000 dual analytical chromatography system. By H ₂ The mobile phase consisting of O/MeCN/TFA elutes Hexamethylenediamine (HMDA), hexamethyleneimine (HMI) and pentylamine and is detected by a Charged Aerosol Detector (CAD). By H ₂ The mobile phase consisting of O/MeCN/TFA eluted 1, 6-Hexanediol (HDO) and was detected with a differential Refractometer (RI). In certain embodiments, an internal standard, N-methyl-2-pyrrolidone (NMP), is used in the substrate feed to correct product effluent concentration for NH ₃ Gas induced changes. By H ₂ NMP was eluted with mobile phase of O/MeCN/TFA and detected by UV at 210 nm. All products were quantified by comparison with calibration standards. The selectivity is reported as HMDA yield divided by the sum of HMDA and pentylamine.

Experimental example 1

Preparation of supported Ru catalyst

Adding appropriate concentrated Ru (NO) ₃ ) ₃ The aqueous solution was added to an array of 96 bottles of carbon support, each bottle containing 10 or 20mg of support. Making the body of ruthenium solutionThe product is equal to the pore volume of the support. Each sample was agitated to impregnate the support. The samples were dried in an oven at 60 ℃ for 12 hours under a dry air purge. In the formation of gas (5% H) ₂ And 95% N ₂ ) The catalyst was reduced at 250 ℃ for 3 hours under an atmosphere with a temperature rise rate of 2 ℃/min. The final catalyst consisted of 2 wt% ruthenium.

Catalyst screening step

Concentrated NH from 0.7M 1, 6-hexanediol ₄ The substrate solution consisting of aqueous OH solution was added to the catalyst array prepared as described above. The bottles were covered with a Teflon pinhole sheet, a silicone pinhole pad, and a gas diffusion steel plate. Placing the reactor insert in a pressure vessel and applying NH ₃ Gas purging was performed 2 times. NH for the pressure vessel ₃ Gas fill to 100psi followed by N at ambient temperature ₂ Fill to 680psi. The reactor was placed on a shaker and vortexed at 800rpm at 160 ℃. After 3 hours, the reactor was cooled to room temperature, vented, and purged with nitrogen, and then unsealed. The sample was diluted with water, mixed, and then centrifuged into individual catalyst particles. An aliquot was removed from the supernatant and further diluted with dilute aqueous trifluoroacetic acid for HPLC analysis. Table 25 below summarizes the results.

Table 25.

Experimental example 2

Preparation of supported Ru/Re catalyst

Will contain different amounts of HReO ₄ Suitable concentrated Ru (NO) ₃ ) ₃ The aqueous solution was added to 0.15g of the carrier and stirred to impregnate the carrier. The volume of the metal solution is made equal to the pore volume of the support. Sample 3 h dried in a 60 ℃ oven under a dry air purgeThen (c) is performed. 10 to 20mg of catalyst was weighed into a glass vial of a 96 vial array. At 60 ℃ in forming gas (5% H) ₂ And 95% N ₂ ) The catalyst was then reduced for 3 hours and then at 250 ℃ for 3 hours at a ramp rate of 2 ℃/minute. The final catalyst consisted of 4.04 wt% ruthenium with varying loadings (0 wt%, 0.4 wt%, 0.7 wt%, and 1.9 wt%) of rhenium.

Catalyst screening step

Concentrated NH from 1.549M 1, 6-hexanediol ₄ A substrate solution consisting of an aqueous OH solution was added to the catalyst array prepared as described above. The bottles were covered with Teflon pinhole sheet, silicone pinhole pad and gas diffusion steel plate. Placing the reactor insert in a pressure vessel and using NH ₃ Gas purging was performed 2 times. NH for the pressure vessel ₃ Gas fill to 100psi followed by N at ambient temperature ₂ Fill to 680psi. The reactor was placed on a shaker and vortexed at 800rpm at 160 ℃. After 3 hours, the reactor was cooled to room temperature, vented, and purged with nitrogen, and then unsealed. The sample was diluted with water, mixed, and then centrifuged into individual catalyst particles. An aliquot was removed from the supernatant and further diluted with dilute aqueous trifluoroacetic acid for HPLC analysis. The results are summarized in table 26 below.

TABLE 26 conversion of hexanediol to hexamethylene diamine using a Ru/Re/carbon HP-160 catalyst

Experimental example 3

Preparation of Ensaco 250G catalyst loaded with Ni/Ru

The appropriate concentrated Ni (NO) is impregnated by incipient wetness impregnation ₃ ) ₂ And/or Ru (NO) ₃ ) ₃ The aqueous solution was added to about 0.4g of carbon black support and agitated to impregnate the support. The volume of the metal solution is made equal to the pore volume of the support. In a tube furnace at N ₂ Each catalyst was heat-treated at 60 ℃ for 12 hours under an atmosphere, followed byThe heat treatment was carried out at 300 ℃ for 3 hours at a temperature rise rate of 5 ℃/min.

Weigh 15-25mg of catalyst into a glass vial of a 96 vial array. In the formation of gas (5% ₂ And 95% N ₂ ) The catalyst was reduced at 450 ℃ for 3 hours at a temperature rise rate of 2 ℃/min under an atmosphere. At room temperature with 1% O ₂ /N ₂ The catalyst was passivated and then removed from the tube furnace.

Catalyst screening step A

Concentrated NH from 0.7M 1, 6-hexanediol ₄ The substrate solution consisting of aqueous OH solution was added to the catalyst array prepared as described above. The bottles were covered with a Teflon pinhole sheet, a silicone pinhole pad, and a gas diffusion steel plate. Placing the reactor insert in a pressure vessel and applying NH ₃ Gas purging was performed 2 times. NH for the pressure vessel ₃ Gas fill to 100psi followed by N at ambient temperature ₂ Fill to 680psi. The reactor was placed on a shaker and vortexed at 800rpm at 160 ℃. After 3 hours, the reactor was cooled to room temperature, vented, and purged with nitrogen, and then unsealed. The sample was diluted with water, mixed, and then centrifuged into individual catalyst particles. An aliquot was removed from the supernatant and further diluted with dilute aqueous trifluoroacetic acid for HPLC analysis. Table 27 below summarizes the results.

Table 27.

Catalyst screening step B

At 180 ℃ in H ₂ The passivated catalyst was reactivated in water under an atmosphere for 3 hours. Most of the water was removed from each catalyst, leaving enough water to act as a protective layer. The catalyst was then screened as described above in step a. Table 28 below summarizes the results.

Table 28.

Fixed bed experiment

Preparation of 2 wt% Ru loaded carbon Ensaco 250G

Carbon extrudates prepared from carbon black Ensaco 250G and carbohydrate binder were crushed and classified into 150 to 300um. Adding appropriate concentrated Ru (NO) ₃ ) ₃ The aqueous solution was added to 4.77g of the pulverized extrudate and stirred to impregnate the support. The volume of the metal solution is made equal to the pore volume of the support. The samples were dried in an oven at 60 ℃ for 12 hours under a dry air purge. In the formation of gas (5% H) ₂ And 95% N ₂ ) The catalyst was reduced at 250 ℃ for 3 hours under an atmosphere with a temperature rise rate of 2 ℃/min. The catalyst is washed with water and re-classified to 106 to 300um to remove any fines that may be generated during the metal impregnation step.

Preparation of carbon Ensaco 250G carrying 10.5 wt% Ni and 0.45 wt% Ru

Carbon extrudates prepared from carbon black Ensaco 250G and carbohydrate binder were crushed and classified to 106 to 300um. Adding appropriate concentrated Ni (NO) ₃ ) ₂ ·6H ₂ O and Ru (NO) ₃ ) ₃ The aqueous solution was added to 10g of the pulverized extrudate and stirred to impregnate the support. The volume of the metal solution is made equal to the pore volume of the support. The catalyst was dried in an oven at 60 ℃ for 12 hours under a dry air purge, followed by N at 300 ℃ ₂ Heat treatment was carried out under an atmosphere for 3 hours. In the formation of gas (5% H) ₂ And 95% N ₂ ) The catalyst was reduced at 450 ℃ for 3 hours at a temperature rise rate of 2 ℃/min under an atmosphere. After cooling to room temperature, 1% O was used at room temperature ₂ /N ₂ The catalyst was passivated and then removed from the tube furnace. The catalyst is washed with water and re-classified to 106 to 300um to remove any fines that may be generated during the metal impregnation step.

2 wt% Ru-loaded carbon catalyst

The reaction was carried out in a 316 stainless steel tube (2 um 316 stainless steel frit at the bottom of the catalyst bed) of 0.25 inch outside diameter by 570mm length. The reactor was shake-packed with 1G of SiC beads (90 to 120 um), followed by 3G of carbon Ensaco 250G catalyst loaded with 2 wt% ruthenium (100 to 300 um), and finally 2.5G of SiC beads on top. A 1/4 inch glass wool layer was used between each layer. The packed bed reactor tubes were mounted vertically in an aluminum starting heater equipped with a PID controller. The liquid feed was fed to the top of the reactor using an HPLC pump and the reactor pressure was controlled using a back pressure regulator. The reaction was carried out at 160 ℃. The product effluent was collected periodically for HPLC analysis. No decrease in catalyst activity was observed after 1650 hours.

Three different feed compositions were investigated at 160 ℃ using reactor pressures ranging from 800 to 1000 psi. In all cases, N-methyl-2-pyrrolidone (NMP) was used as an internal standard.

Feed 1.

Feed 2, 0.7

m

1,6 hexanediol, 0.14M hexamethyleneimine and 0.14M NMP in concentrated NH4 OH.

Feed 3 ₄ 0.308M NMP in OH.

Table 29 below summarizes the results.

Carbon catalyst supporting 10.5 wt% Ni/0.45 wt% Ru

The catalyst supporting only Ru was reacted as described above. A total of 3g of Ni/Ru catalyst was charged to the reactor in H ₂ Reactivation was carried out at 180 ℃ under an atmosphere, followed by introduction of the feed solution. No decrease in catalyst activity was observed after 650 hours. The results are summarized in table 29 below.

Table 29.

EXAMPLE 25 preparation of carbon Black extrudates

Carbon black extrudates were prepared according to the following procedure. To prepare the binder solution, 552.67 grams of glucose monohydrate (ADM cornn Processing,91.22 wt% glucose content) was dissolved in 455.63 grams of DI water at 70 ℃. The solution was then cooled to 50 ℃. 20.51 grams of hydroxyethyl cellulose was added to the mixture and stirred overnight.

Subsequently, 450 g of the binder solution was mixed with 200.6 g of carbon black powder using a Winkworth mixer (model 1Z) (mixing about 1 hour) and extruded using a Diamond America 1 inch single screw extruder (model TT100 CS). The same mixing/extrusion procedure was repeated the same day again using an additional 450 gram portion of carbon. The strands were dried in a strong wind type drying oven at 120 ℃ for about 2 hours and then broken by hand. The extrudate was then dried overnight.

The carbon was divided into 4 portions of about 250 grams each and pyrolyzed in a rotary kiln. Each fraction is treated separately in a rotary kiln. The temperature of the kiln is increased at a rate of 30 c/min until a maximum of 800 c is reached. The temperature was maintained for 2 hours, after which it was cooled. The kiln was set to rotate at 6.6 rpm. During the temperature increase, large amounts of water vapor and other pyrolysis products are formed. From about 350 c to 450 c, a large amount of gas is formed.

After pyrolysis and cooling, the extrudate is washed. The required amount of DI water was heated to 60 ℃ in a beaker. The extrudate was then added and the slurry was stirred at 300-350rpm for 4h while maintaining the water temperature at 60 ℃. The beaker was covered with a watch glass to avoid excessive evaporation. The initial water to carbon ratio was maintained at 10. The extrudates were separated and rinsed with DI water and dried in an oven at 80 ℃ overnight.

0.31g of extrudate sample (total volume 0.33 cm) was analyzed by mercury intrusion ³ ) Various physical properties of (a). Table 30 shows the overall results of the analysis. A plot of pore diameter versus pore volume is shown in fig. 13.

Table 30.

The extrudate samples were also analyzed for various physical properties by nitrogen adsorption (BJH method). The shaped carbon black extrudate was added to a tared Tristar II sample holder and placed under vacuum at 120 ℃ overnight to remove any volatiles. The mass of the carbon support after this pretreatment was 154.7mg. Nitrogen isotherm data were collected at 77.3K. Data were collected using a TriStar II 3020 instrument from micromeritics and analyzed using the software provided by the supplier (version 3.02). For BJH analysis of all desorption data for pore diameters between 1.7 and 300nm, faas corrections were applied and the following Halsey thickness equation and default parameters were used: t =3.54 [ (-5.000/ln (p/p 0)) ^0.333]. The BET specific surface area was found to be 178.5m ² (ii) in terms of/g. Table 31 shows the nitrogen isotherm data collected during the analysis. Table 32 shows the t-Plot data. Table 33 shows BJH desorption pore distribution.

Table 31.

Table 32.

Table 33.

EXAMPLE 26 preparation of Nickel-rhenium catalyst

Approximately 8.87 grams of nickel nitrate hexahydrate, 1.79 grams of perrhenic acid and nitric acid were added to water to a volume of 5.81 mL. The carbon extrudate prepared in example 25 was poured into a small drum and the solution containing the nickel and rhenium precursors was gradually sprayed onto the carbon using a Sonaer nozzle and syringe pump. The beaker and spray apparatus were rinsed to obtain any residual metal solution and to bring the total volume to 9.96mL. The catalyst was spun under a stream of air for approximately 30 minutes and then dried in an oven at 80 ℃ and 75 torr under vacuum overnight.

The second catalyst was prepared using the same method except that nitric acid was not added during the metal deposition.

EXAMPLE 27 hydrogenolysis of Glycerol

The first nickel rhenium catalyst prepared in example 26 (with nitric acid added during metal deposition) was evaluated for hydrogenolysis of glycerol. The catalyst was loaded into a 30cc reactor. The reactor was then purged with hydrogen at a flow rate of 100 ml/min. After purging the reactor, the reactor was pressurized to 1800psi with hydrogen. Subsequently, hydrogen and glycerol were supplied to the reactor as a 40 wt% solution with sodium hydroxide promoter. The evaluation details are provided in table 34. The catalysts were evaluated at various reaction temperatures, various hydrogen flow rates, and various promoter concentrations. Periodic liquid samples were analyzed by HPLC and GC. All samples had a pH between 7.5 and 9.9. The catalyst can be used for improving the yield and selectivity of the propylene glycol and the conversion rate of the glycerol.

Table 34.

Samples selected from the above evaluations were analyzed for various products (EG = ethylene glycol; PG = propylene glycol) and by-products (BDO = butylene glycol). Table 35 shows the results of this analysis. These samples were also analyzed for catalyst metals, where the presence of the metal indicated that it leached from the catalyst. The results showed that the detection of nickel and rhenium did not exceed the detection limit (0.5 mg/kg). Therefore, no leaching of the catalyst metal was observed in this evaluation.

Table 35.

The second nickel rhenium catalyst prepared in example 26 was also evaluated for glycerol hydrogenolysis. The evaluation details are provided in table 36. Periodic liquid samples were analyzed by HPLC and GC. As the hydrogen flow rate increased, the conversion increased significantly.

Table 36.

EXAMPLE 28 analysis of Ni-Re on carbon Black extrudates

The Ni — Re catalyst prepared in example 26 was analyzed using energy dispersive X-ray spectroscopy (EDX) and Scanning Electron Microscopy (SEM).

FIG. 14 shows an SEM image of Ni-Re on a carbon black extrudate catalyst. No nitric acid was added during the nickel deposition of the catalyst. Figure 15 shows the EDX analysis results of the catalyst. EDX results indicated that nickel reached the inner region of the extrudate support (see sample 2).

FIG. 16 shows an SEM image of a second Ni-Re on a carbon black extrudate catalyst. Nitric acid is added during the nickel deposition of the catalyst. Figure 17 shows the EDX analysis results of the catalyst. EDX results show that nickel is not deposited in the inner region of the extrudate support (see samples 2 and 3). Instead, the nickel is concentrated in the outer region of the catalyst in the form of a shell.

When introducing elements of the present invention or the preferred embodiments thereof, the articles "a" and "an" and "the" are intended to mean that there are one or more of the elements. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements.

In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.

As various changes could be made in the above compositions, methods and procedures without departing from the scope of the invention, it is intended that all matter contained in the above invention and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Having now described the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.

Claims

1. A process for the hydrogenolysis of glycerol comprising feeding a feed composition comprising glycerol to a reaction zone and reacting the glycerol with hydrogen in the presence of a catalyst composition in the reaction zone to form a reaction product comprising propylene glycol and/or ethylene glycol, wherein the catalyst composition comprises a shaped porous carbon product as a catalyst support and a catalytically active ingredient or precursor thereof, wherein the shaped porous carbon product comprises:

(a) Carbon black, and

(b) A carbonized binder comprising a carbonized product of a water soluble organic binder.

2. The process as set forth in claim 1 wherein the catalyst composition comprises a catalytically active component comprising a metal selected from the group consisting of chromium, cobalt, nickel, copper, zinc, ruthenium, rhodium, palladium, silver, rhenium, osmium, iridium, platinum, gold, and any combination thereof.

3. A process for the hydrogenolysis of glycerol comprising feeding a feed composition comprising glycerol to a reaction zone and reacting the glycerol with hydrogen in the presence of a catalyst composition in the reaction zone to form a reaction product comprising propylene glycol and/or ethylene glycol, wherein the catalyst composition comprises a catalytically active ingredient comprising a metal selected from the group consisting of chromium, cobalt, nickel, copper, zinc, ruthenium, rhodium, palladium, silver, rhenium, osmium, iridium, platinum, gold, and any combination thereof, and a catalyst support comprising a shaped porous carbon product comprising carbon black.

4. The method of any one of claims 1 to 3, wherein about 10% or less, at least about 5% or less, or about 3% or less of the pore volume of the shaped porous carbon product as measured by mercury porosimetry is attributable to pores having a mean pore diameter of about 100nm or greater.

5. The method of any one of claims 1 to 4, wherein about 0.1% to about 10%, about 0.1% to about 5%, about 0.1% to about 3%, about 1% to about 10%, about 1% to about 5%, or about 1% to about 3% of the pore volume of the shaped porous carbon product as measured by mercury porosimetry is attributable to pores having a mean pore diameter of about 100nm or greater.

6. The process of any one of claims 1 to 5 wherein the hydrogen partial pressure in the reaction zone is at least about 2.1MPa (300 psi), at least about 6.9MPa (1000 psi), at least about 12.4MPa (1800 psi), or at least about 13.8MPa (2000 psi).

7. The process of any one of claims 1 to 6, wherein the hydrogen partial pressure in the reaction zone is about 2.1MPa (300 psi) to about 13.8MPa (2000 psi), about 6.9MPa (1000 psi) to about 13.8MPa (2000 psi), or about 12.4MPa (1800 psi) to about 13.8MPa (2000 psi).

8. The process of any one of claims 1 to 7, wherein propylene glycol yield is at least about 50%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, or at least about 80%.

9. The method of any one of claims 1 to 8, wherein the catalytically active component comprises rhenium.

10. The method of any one of claims 1 to 9, wherein the catalytically active component comprises nickel.

11. The method of any one of claims 1 to 10, wherein the catalytically active component comprises copper.

12. The method of any one of claims 1 to 11, wherein the catalytically active component comprises a combination of metals selected from the group consisting of: nickel and rhenium, copper and rhenium, and cobalt and rhenium.

13. The method of any one of claims 1 to 12, wherein the catalyst composition further comprises manganese, molybdenum and/or zinc.

14. The process of any one of claims 1 to 13, wherein the loading of the catalyst composition is about 0.1 wt% or greater, about 1 wt% or greater, about 2 wt% or greater, about 3 wt% or greater, about 4 wt% or greater, or about 5 wt% or greater.

15. The process of any one of claims 1 to 14, wherein the loading of the catalytically active component of the catalyst composition is from about 0.1 wt% to about 10 wt%, from about 0.1 wt% to about 7.5 wt%, from about 0.1 wt% to about 5 wt%, from about 0.5 wt% to about 10 wt%, from about 0.5 wt% to about 7.5 wt%, from about 0.5 wt% to about 5 wt%, from about 1 wt% to about 10 wt%, from about 1 wt% to about 7.5 wt%, or from about 1 wt% to about 5 wt%.

16. The method of any one of claims 1 to 15, wherein the catalytically active component forms an outer shell layer at least partially covering the surface of the shaped porous carbon product.

17. The method of any one of claims 1 to 16, wherein the catalytically active component is present predominantly on the surface layer pores of the shaped porous carbon product to form an outer shell having a thickness of from about 10 μ ι η to about 400 μ ι η, or from about 50 μ ι η to about 150 μ ι η.

18. The process of any one of claims 1 to 17, wherein the catalyst composition comprises an inner zone and an outer zone and the outer zone has a higher concentration of the catalytically active component than the inner zone.

19. The method of claim 18, wherein the outer region concentration of the catalytically active component is at least 2,5, 10, or 100 times the inner region concentration of the catalytically active component.

20. The process of claim 18 or 19, wherein the catalyst composition has an average diameter and the outer region comprises at least about 5%, at least about 10%, at least about 20%, from about 5% to 50%, or from about 10% to about 40% of the average diameter.

21. The method of any one of claims 18 to 20, wherein the inner region comprises at least about 20%, at least about 30%, at least about 40%, about 20% to about 80%, or about 20% to about 70% of the average diameter.

22. The process of any one of claims 1 to 21, wherein the reaction zone further comprises a promoter comprising a base.

23. The method of any one of claims 1 to 22, wherein the base comprises sodium hydroxide.

24. The process of any one of claims 1 to 23, wherein the reaction is carried out at a pH of about 7 to about 11, about 7.5 to about 10, about 8 to about 14, or about 10 to about 13.

25. The process of any one of claims 1 to 24, wherein the reaction is carried out at a temperature of about 150 ℃ to about 300 ℃, about 175 ℃ to about 250 ℃, about 190 ℃ to about 250 ℃, or about 190 ℃ to about 225 ℃.

26. The method of any one of claims 1 to 25, wherein the feed composition comprises an aqueous glycerol solution.

27. The method of any one of claims 1 to 26, wherein the glycerol concentration of the feed composition is about 10 wt% or greater, about 20 wt% or greater, about 30 wt% or greater, about 40 wt% or greater, about 10 wt% to about 50 wt%, or about 20 wt% to about 40 wt%.

28. The method of any one of claims 1 to 27, wherein the feed composition further comprises at least one other polyol selected from the group consisting of five and six carbon sugars and sugar alcohols.

29. The method of any one of claims 1 to 28, wherein the shaped porous carbon product comprises a carbon agglomerate comprising carbon black.

30. The method of any one of claims 1 to 29, wherein the shaped porous carbon product has a BET specific surface area of about 20m ² G to about 500m ² G, about 20m ² G to about 350m ² G, about 20m ² G to about 250m ² G, about 20m ² G to about 225m ² G, about 20m ² G to about 200m ² G, about 20m ² A/g to about 175m ² G, about 20m ² G to about 150m ² G, about 20m ² G to about 125m ² In g, or about 20m ² G to about 100m ² G, about 25m ² G to about 500m ² A,/g, about 25m ² G to about 350m ² A,/g, about 25m ² G to about 250m ² G, about 25m ² G to about 225m ² A,/g, about 25m ² G to about 200m ² A,/g, about 25m ² A/g to about 175m ² A,/g, about 25m ² G to about 150m ² G, about 25m ² A/g to about 125m ² A,/g, about 25m ² G to about 100m ² G, about 30m ² G to about 500m ² G, about 30m ² G to about 350m ² G, about 30m ² G to about 250m ² G, about 30m ² G to about 225m ² G, about 30m ² G to about 200m ² G, about 30m ² A/g to about 175m ² G, about 30m ² G to about 150m ² G, about 30m ² A/g to about 125m ² In g, or about 30m ² G to about 100m ² /g。

31. The method of any one of claims 1 to 30, wherein the shaped porous carbon product has an average pore diameter greater than about 5nm, greater than about 10nm, greater than about 12nm, or greater than about 14nm.

32. The method of any one of claims 1 to 31, wherein the shaped porous carbon product has a mean pore diameter of from about 5nm to about 100nm, from about 5nm to about 70nm, from about 5nm to about 50nm, from about 5nm to about 25nm, from about 10nm to about 100nm, from about 10nm to about 70nm, from about 10nm to about 50nm, or from about 10nm to about 25nm.

33. The method of any one of claims 1 to 32, wherein the carbon black has a specific pore volume greater than about 0.1cm ³ A/g, greater than about 0.2cm ³ In g, or greater than about 0.3cm ³ /g。

34. The method of any one of claims 1 to 33, wherein the carbon black has a specific pore volume of about 0.1cm ³ G to about 1.5cm ³ Per g, about 0.1cm ³ G to about 0.9cm ³ Per g, about 0.1cm ³ G to about 0.8cm ³ G, about 0.1cm ³ G to about 0.7cm ³ G, about 0.1cm ³ G to about 0.6cm ³ G, about 0.1cm ³ G to about 0.5cm ³ Per g, about 0.2cm ³ G to about 1cm ³ G, about 0.2cm ³ G to about 0.9cm ³ G, about 0.2cm ³ G to about 0.8cm ³ Per g, about 0.2cm ³ G to about 0.7cm ³ G, about 0.2cm ³ G to about 0.6cm ³ G, about 0.2cm ³ G to about 0.5cm ³ Per g, about 0.3cm ³ G to about 1cm ³ G, about 0.3cm ³ G to about 0.9cm ³ G, about 0.3cm ³ G to about 0.8cm ³ G, about 0.3cm ³ G to about 0.7cm ³ G, about 0.3cm ³ G to about 0.6cm ³ In terms of grams, or about 0.3cm ³ G to about 0.5cm ³ /g。

35. The method of any one of claims 1 to 34, wherein the shaped porous carbon product has a specific pore volume of pores with a diameter of 1.7nm to 100nm as measured by the BJH method of greater than about 0.1cm ³ A/g, greater than about 0.2cm ³ Per gram, or greater than about 0.3cm ³ /g。

36. The method of any one of claims 1 to 35, wherein the shaped porous carbon product has a diameter of 1.7 as measured by the BJH methodThe specific pore volume of the pores of nm to 100nm is about 0.1cm ³ G to about 1.5cm ³ G, about 0.1cm ³ G to about 0.9cm ³ G, about 0.1cm ³ G to about 0.8cm ³ Per g, about 0.1cm ³ G to about 0.7cm ³ Per g, about 0.1cm ³ G to about 0.6cm ³ Per g, about 0.1cm ³ G to about 0.5cm ³ Per g, about 0.2cm ³ G to about 1cm ³ Per g, about 0.2cm ³ G to about 0.9cm ³ G, about 0.2cm ³ G to about 0.8cm ³ Per g, about 0.2cm ³ G to about 0.7cm ³ G, about 0.2cm ³ G to about 0.6cm ³ G, about 0.2cm ³ G to about 0.5cm ³ G, about 0.3cm ³ G to about 1cm ³ G, about 0.3cm ³ G to about 0.9cm ³ Per g, about 0.3cm ³ G to about 0.8cm ³ Per g, about 0.3cm ³ G to about 0.7cm ³ G, about 0.3cm ³ G to about 0.6cm ³ In g, or about 0.3cm ³ G to about 0.5cm ³ /g。

37. The method of any one of claims 1 to 36, wherein at least about 35%, at least about 40%, at least about 45%, or at least about 50% of the pore volume of the shaped porous carbon product, as measured by the BJH method on the basis of pores having a diameter of 1.7nm to 100nm, is attributable to pores having a mean pore diameter of about 20nm to about 90nm or about 10nm to about 50 nm.

38. The method of any one of claims 1 to 37, wherein about 35% to about 80%, about 35% to about 75%, about 35% to about 65%, about 40% to about 80%, about 40% to about 75%, or about 40% to about 70% of the pore volume of the shaped porous carbon product, as measured by the BJH method on the basis of pores having a diameter of 1.7nm to 100nm, is attributable to pores having a mean pore diameter of about 20nm to about 90nm, or about 10nm to about 50 nm.

39. The method of any one of claims 1 to 38, wherein at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, at least about 95%, or at least about 99% of the pore volume of the shaped porous carbon product, as measured by the BJH method on the basis of pores having a diameter from 1.7nm to 100nm, is attributable to pores having a mean pore diameter of from about 10nm to about 100 nm.

40. The method of any one of claims 1 to 39, wherein about 50% to about 99%, about 50% to about 95%, about 50% to about 90%, about 50% to about 80%, about 60% to about 99%, about 60% to about 95%, about 60% to about 90%, about 60% to about 80%, about 70% to about 99%, about 70% to about 95%, about 70% to about 90%, about 70% to about 80%, about 80% to about 99%, about 80% to about 95%, about 80% to about 90%, or about 90% to about 99% of the pore volume of the shaped porous carbon product, as measured by the BJH method on the basis of pores having a diameter of 1.7nm to 100nm, is attributable to pores having a mean pore diameter of about 10nm to about 100 nm.

41. The method of any one of claims 1 to 40, wherein about 10% or less, at least about 5% or less, or about 3% or less of the pore volume of the shaped porous carbon product as measured by mercury porosimetry is attributable to pores having a mean pore diameter of about 100nm or greater.

42. The method of any one of claims 1 to 41, wherein the shaped porous carbon product has a pore size distribution such that a peak of the distribution is at a diameter of less than about 100nm, less than about 90nm, less than about 80nm, or less than about 70 nm.

43. The method of any one of claims 1 to 42, wherein the shaped porous carbon product has a radial part crush strength greater than about 4.4N/mm (1 lb/mm), greater than about 8.8N/mm (2 lb/mm), or greater than about 13.3N/mm (3 lb/mm).

44. The method of any one of claims 1 to 43, wherein the shaped porous carbon product has a radial part crush strength of from about 4.4N/mm (1 lb/mm) to about 88N/mm (20 lb/mm), from about 4.4N/mm (1 lb/mm) to about 66N/mm (15 lb/mm), or from about 8.8N/mm (2 lb/mm) to about 44N/mm (10 lb/mm).

45. The method of any one of claims 1 to 44, wherein the shaped porous carbon product has a mechanical part crush strength greater than about 22N (5 lb), greater than about 36N (8 lb), or greater than about 44N (10 lb).

46. The method of any one of claims 1 to 45, wherein the shaped porous carbon product has a mechanical part crush strength of from about 22N (5 lb) to about 88N (20 lb), from about 22N (5 lb) to about 66N (15 lb), or from about 33N (7.5 lb) to about 66N (15 lb).

47. The method of any one of claims 1 to 46, wherein the shaped porous carbon product has a mean diameter of at least about 50 μm, at least about 500 μm, at least about 1,000 μm, or at least about 10,000 μm.

48. The method of any one of claims 1 to 47, wherein the shaped porous carbon product has a carbon black content of at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, or at least about 70% by weight.

49. The method of any one of claims 1 to 48, wherein the shaped porous carbon product has a carbon black content of from about 35% to about 80%, from about 35% to about 75%, from about 40% to about 80%, or from about 40% to about 75% by weight.

50. The method of any one of claims 1-49, wherein the shaped porous carbon product has a drum attrition index measured according to ASTM D4058-96 such that the percent residue is greater than about 85%, greater than about 90%, greater than about 92%, or greater than about 95%.

51. The method of any one of claims 1-50, wherein the shaped porous carbon product has a drum attrition index measured according to ASTM D4058-96 such that the percent residue is greater than about 97 wt%, or greater than about 99 wt%.

52. The method of any one of claims 1 to 51, wherein the shaped porous carbon product has a horizontal agitation sieve attrition of less than about 5%, or less than about 3%.

53. The method of any one of claims 1 to 52, wherein the shaped porous carbon product has a horizontal agitation screen abrasion loss of less than about 2%, less than about 1%, less than about 0.5%, less than about 0.2%, less than about 0.1%, less than about 0.05%, or less than about 0.03% by weight.

54. The method of any one of claims 1 to 53, wherein the shaped porous carbon product further comprises a carbonized product of a binder.

55. The method of claim 54, wherein the binder comprises a saccharide selected from the group consisting of: monosaccharides, disaccharides, oligosaccharides, or any combination thereof.

56. The method of claim 55, wherein the binder comprises a monosaccharide.

57. The method of claim 55 or 56, wherein the monosaccharide is selected from the group consisting of: glucose, fructose, hydrates thereof, syrups thereof, and combinations thereof.

58. The method of any one of claims 55-57, wherein the binder comprises a disaccharide.

59. The method of any one of claims 55 to 58, wherein the disaccharide is selected from the group consisting of: maltose, sucrose, syrups thereof, and combinations thereof.

60. The method of any one of claims 54 to 59, wherein the binder comprises a polymeric carbohydrate, a derivative of a polymeric carbohydrate, or a non-carbohydrate synthetic polymer, or any combination thereof.

61. The method of any one of claims 54-60, wherein the binder comprises a polymeric carbohydrate, a derivative of a polymeric carbohydrate, or any combination thereof.

62. The method of any one of claims 60 or 61, wherein the polymeric carbohydrate or derivative of the polymeric carbohydrate comprises a cellulosic compound.

63. The method of claim 62, wherein the cellulosic compound is selected from the group consisting of: methyl cellulose, ethyl methyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, methyl hydroxyethyl cellulose, ethyl hydroxyethyl cellulose, hydroxypropyl methyl cellulose, carboxymethyl cellulose, and mixtures thereof.

64. The method of any one of claims 60 to 63, wherein said polymeric carbohydrate or derivative of said polymeric carbohydrate is selected from the group consisting of: alginic acid, pectin, aldonic acids, aldaric acids, uronic acids, alditols, as well as salts, oligomers and polymers thereof.

65. The method of any one of claims 60 to 64, wherein the polymeric carbohydrate or derivative of the polymeric carbohydrate comprises starch.

66. The method of any one of claims 60 to 65, wherein the polymeric carbohydrate or derivative of the polymeric carbohydrate comprises a soluble gum.

67. The method of any one of claims 60 to 66, wherein the binder comprises a non-carbohydrate synthetic polymer.

68. The method of any one of claims 60 to 67, wherein said non-carbohydrate synthetic polymer is selected from the group consisting of: polyacrylic acid, polyvinyl alcohol, polyvinyl pyrrolidone, polyvinyl acetate, polyacrylates, polyethers, and copolymers derived therefrom.

69. The method of any one of claims 54 to 68, wherein the binder comprises one or more ingredients selected from the group consisting of: a water-soluble cellulose; a water-soluble alcohol; a water-soluble acetal; a water-soluble acid; polyvinyl acrylic acid; a polyether; and salts, esters, oligomers, or polymers of any of these.

70. The method of any one of claims 54 to 69, wherein the binder comprises a saccharide selected from the group consisting of glucose, fructose or a hydrate thereof and a polymeric carbohydrate or derivative of the polymeric carbohydrate selected from the group consisting of hydroxyethyl cellulose, methyl cellulose and starch.

71. The method of any one of claims 54 to 70, wherein the weight ratio of (i) the saccharide to (ii) the polymeric carbohydrate, derivative of the polymeric carbohydrate, or the non-carbohydrate synthetic polymer, or combination thereof is from about 5 to about 50.

72. The method of any one of claims 54-71, wherein the carbonized product content of the shaped porous carbon product is from about 10% to about 50%, from about 20% to about 50%, from about 25% to about 40%, or from about 25% to about 35% by weight.