CATALYST AND PROCESS USING THE CATALYST FOR MANUFACTURING FLUORINATED HYDROCARBONS

Abstract

A catalyst comprising one or more metal oxides, wherein the catalyst has a total pore volume equal to or greater than 0.3 cm.sup.3/g and a mean pore diameter greater than or equal to 90 , where in the pore volume is measured using N.sub.2 adsorption porosimetry and the mean pore diameter is measured using N.sub.2 BET adsorption porosimetry.

Claims

1. A catalyst comprising one or more metal oxides, wherein the catalyst has a total pore volume equal to or greater than 0.3 cm.sup.3/g and a mean pore diameter greater than or equal to 90 , where in the pore volume is measured using N.sub.2 adsorption porosimetry and the mean pore diameter is measured using N.sub.2 BET adsorption porosimetry.

2. A catalyst according to claim 1, wherein the total pore volume is equal to or greater than 0.4 cm.sup.3/g.

3. A catalyst according to claim 1, wherein the average pore width of the catalyst is greater than or equal to 100 when measured by N.sub.2 BET adsorption porosimetry.

4. A catalyst according to claim 1, wherein the average pore width of the catalyst is greater than or equal to 130 when measured by N.sub.2 BJH adsorption porosimetry.

5. A catalyst according to claim 1, wherein the average pore width of the catalyst is greater than or equal to 90 when measured by N.sub.2 BJH desorption porosimetry.

6. A catalyst according to claim 1 provided in the form of pellet or pellets comprising a plurality of catalyst particles.

7. A catalyst according to claim 6, wherein the pellets comprise graphite.

8. A catalyst according to claim 6, wherein the pellets have a longest dimension from about 1 mm to about 100 mm.

9. A catalyst according to claim 1, wherein the metal is a transition metal.

10. A catalyst according to claim 9, wherein the transition metal comprises chromium.

11. A catalyst according to claim 9, wherein the transition metal comprises zinc.

12. A catalyst according to claim 1 which comprises at least 80 wt % chromia.

13. A catalyst according to claim 1, wherein the catalyst is unused.

14. A method of preparing a catalyst as defined in claim 1, comprising the steps of: a) preparing a metal salt solution and a hydroxide solution; b) combining the solutions at a pH of greater than 7.5 in order to precipitate the metal hydroxide(s); c) drying the precipitated metal hydroxides; d) calcining the metal hydroxides to form the metal oxide(s).

15. A method according to claim 14, wherein step b) is carried out at a pH of greater than 8.

16. A method according to claim 15, wherein step b) is carried out at a pH of greater than or equal to 8.5.

17. A method according to claim 14, wherein the metal salt comprises a nitrate salt.

18. A method according to claim 14, wherein the hydroxide solution may comprise ammonium hydroxide (NH.sub.4OH).

19. A method according to claim 14, wherein the metal salt solution is provided at a concentration of from about 1 mol/l to about 10 mol/l.

20. A method according to claim 14, wherein the hydroxide solution is provided at a concentration of from 1 mol/l to about 10 mol/l.

21. A method according to claim 14 wherein step is performed by combining the solutions in a body of solvent, such as water.

22. A method according to claim 14, wherein step is carried out at a substantially constant temperature, such as from 0 to 50 C.

23. A method according to claim 14, wherein step (b) is performed while agitating the combined solutions.

24. A method according to claim 14, wherein the precipitate formed during step (b) preferably comprises particles having average longest dimensions of from about 5 to about 20 m.

25. A method according to claim 14, wherein step (c) includes removing liquid from the slurry of metal hydroxide precipitate(s) to produce a wet cake.

26. A method according to claim 25, wherein the cake is washed prior to any drying or calcining.

27. A method according to claim 25, wherein step (c) includes removing liquid, ex, residual liquid, from the wet metal hydroxide(s) cake by exposing it to elevated temperature, preferably where such elevated temperature is between 50 C. and 200 C. and more preferably may be between 80 C. and 150 C., e.g. around 90 C. to around 120 C.

28. A method according to claim 27, wherein the precipitate is preferably exposed to the elevated temperature for at least 15 mins.

29. A method according to claim 14, wherein step (d) includes a step of calcining the metal hydroxide, preferably after liquid removal and/or drying.

30. A method according to claim 14, wherein die calcining step includes heating the metal hydroxides to a temperature between around 200 C. and around 550 C.

31. A method according to claim 14, wherein the calcining step is performed for a sufficient period to produce a catalyst having a TGA loss on ignition (LOI) of less than around 15%.

32. A method according to claim 14 further comprising combining the calcined metal oxide with graphite to provide a catalyst composition comprising around 0.1 wt % to around 10 wt % graphite.

33. A method according to claim 14, wherein the calcined metal oxide and/or catalyst composition is pressed to form catalyst pellets.

34. A method according to claim 33, wherein the pressing takes place under a load of around 1 to 100 tonnes.

35. A method according to claim 34, wherein the pellets so formed have a longest dimension from about 1 mm to about 100 mm.

36. A process for fluorinating a C.sub.2-3 hydrohalocarbon species, comprising contacting the species with a catalyst according to claim 1.

37. A process according to claim 36, comprising contacting trichloroethylene the catalyst in the presence of HF to produce 1,1,1,2-tetrafluoroethane (134a).

38. A process according to claim 36 wherein the species is a C.sub.3 hydrohalocarbon species.

39. A process for dehydrohalogenating a C.sub.2-3 hydrohalocarbon species, comprising contacting the species with a catalyst according to claim 1.

40. A process according to claim 39, comprising contacting a hydro(halo)fluoropropane with the catalyst to produce a fluoropropene.

41. A process according to claim 40, wherein the fluoropropene is a tetrafluoropropene (1234).

42. A process according to claim 41, wherein the hydro(halo)propane comprises a compound selected from t re group consisting of: 1,1,1,2,3-pentafluoropropane, 1,1,1,2,2-pentafluoropropane and/or 1,1,1,3,3-pentafluoropropane.

43. A process according to claim 41, wherein the tetrafluoropropene comprises 1,3,3,3-tetrafluoropropene and/or 2,3,3,3-tetrafluoropropene.

44. A process for manufacturing a tetrafluoropropene comprising contacting a hydro(halo)propene with HF in the presence of a catalyst according to claim 13.

45. A process according to claim 44, wherein the hydro(halo)propene comprises a hydrochlorofluoropropene.

46. A process for eliminating HF from a saturated C.sub.2-3 hydrohalocarbon species, comprising contacting the species with a catalyst according to claim 13.

47. A process for adding HF to an unsaturated C.sub.2-3 hydrohalocarbon species, comprising contacting the species with a catalyst according to claim 1.

48. A process according to claim 36, wherein the method is conducted in the vapour phase.

49. Use of a catalyst according to claim 13 in the fluorination and/or dehydrofluorination of a C.sub.2-3 hydrohalocarbon species.

50. A fluorinated catalyst according to claim 13.

Description

[0055] The present invention will now be illustrated by the following non-limiting Examples, illustrated by the following drawings:

[0056] FIG. 1 shows a plot of the particle size distribution at temporal points during the reaction of Comparative Example 8, unweighted to emphasise smaller particles;

[0057] FIG. 2 shows a plot of the particle size distribution at temporal points during the reaction of Comparative Example 8, weighted to emphasise larger particles;

[0058] FIG. 3 shows a plot of the particle size distribution at temporal points during the reaction of Example 9, unweighted to emphasise smaller particles;

[0059] FIG. 4 shows a plot of the particle size distribution at temporal points during the reaction of Example 9, weighted to emphasise larger particles;

[0060] FIG. 5 shows a plot of the particle size distribution at temporal points during the reaction of Comparative Example 10, unweighted to emphasise smaller particles;

[0061] FIG. 6 shows a plot of the particle size distribution at temporal points during the reaction of Comparative Example 10, weighted to emphasise larger particles;

[0062] FIG. 7 shows a plot of the particle size distribution at temporal points during the reaction of Example 11, unweighted to emphasise smaller particles;

[0063] FIG. 8 shows a plot of the particle size distribution at temporal points during the reaction of Example 11, weighted to emphasise larger particles;

[0064] FIG. 9 shows a plot of the presence of fine particles during the reactions of Examples and Comparative Examples 8 to 11;

[0065] FIG. 10 shows a plot of the particle size distributions at completion of the reactions of Examples and Comparative Examples 8 to 11 unweighted to emphasise smaller particles;

[0066] FIG. 11 shows a plot of the particle size distributions at completion of the reactions of Examples and Comparative Examples 8 to 11 weighted to emphasise larger particles.

EXAMPLES

[0067] Catalysts of examples 1 to 7 were produced by the following method:

[0068] 500 mL deionised water heel was added to a 1.7 L jacketed glass vessel, fitted with an overflow, overhead stirrer, pH probe and thermocouple and cooled to 15 C. The stirrer was actuated at 500 rpm, save for in example 5, where it was turned at 250 rpm.

[0069] Zn(NO.sub.3).sub.2.6H.sub.2O (19.03 g) was dissolved into a solution of Cr(NO.sub.3).sub.2(OH).sub.(aq) (500 g) in a 600 mL beaker. In another beaker, 500 g 17% NH.sub.4OH solution was provided.

[0070] The metal and ammonia solutions were pumped into the chilled water at 5 ml/min.

[0071] Precipitation of a green/blue solid occurs immediately. The pH of the mixture was monitored and the reactant flow rates adjusted to maintain the target pH for each example as shown in Table 1, below. The reaction was run until all of the metal solution was added.

[0072] The slurry was filtered under vacuum until a filter cake formed then washed four times with de-ionised water (a examples) or dilute aqueous ammonia solution (b examples).

[0073] The filter cake was then dried at 105 C. overnight in a standard oven, followed by calcining under flowing nitrogen (200 ml/min) at 300 C. for 12 hours to produce 6.5% ZnO/Cr.sub.2O.sub.3, the heating rate on the chamber furnace being set to 2 C./min. The percentage mass loss was on calcination was noted.

[0074] 2 wt % graphite was blended with the cooled, calcined catalyst precursor in a waring blender, and the resultant mixture was sieved to <250 m. The sieved mixture was formed into pellets under a load of 5 tonne in a 32 mm pellet die, 3 g per pellet.

[0075] The pellets were then ground to mesh size 0.5-1.4 mm for catalyst testing. Surface area, pore volumes and sizes were measured by N.sub.2 adsorption/desorption porosimetry. Zn content was measured by X-ray fluorescence spectroscopy. The results are shown in Table 1, alongside results for Comparative Example 1, a chromia catalyst having a specified surface area of 160 to 200 m.sup.2/g and pore volume of greater than 0.22 cm.sup.3/g.

TABLE-US-00001 TABLE 1 N.sub.2 Porosimetry (200-500 m, outgassed 300 C., 3 h, N.sub.2) Pore Volume BET Ads BJH Ads BJH Des Actual Water Stirrer BET SA (cm.sup.3/g) @ Average pore Average pore Average pore Example pH Heel/g speed/rpm Temp/ C. Slurry Wash Sol.sup.n (m.sup.2/g) 0.99P/P width () width () width () CE1 180 0.282 63 107 65 CE2a 7.2-7.3 500 500 15-17 DI H.sub.2O 171 0.259 60 112 63 CE2b NH.sub.4OH 125 0.221 71 124 72 3a 7.5-8.1 500 500 15-16 DI H.sub.2O 125 0.327 105 147 102 3b NH.sub.4OH 127 0.382 121 169 116 4 8.3 500 500 15-16 DI H.sub.2O 129 0.442 137 184 129 5a 8.3-8.4 500 500 17-18 DI H.sub.2O 111 0.449 162 190 143 5b NH.sub.4OH 111 0.464 167 195 147 6a 8.3-8.4 500 500 15-16 DI H.sub.2O 172 0.506 118 192 127 6b NH.sub.4OH 138 0.447 129 189 131 7a 8.2-8.4 500 500 15-17 DI H.sub.2O 132 0.512 155 198 148 7b NH.sub.4OH 151 0.508 135 191 138

[0076] The data clearly shows that a significant raising of the pore volume of a precipitated catalyst is provided when the pH of precipitation is raised.

[0077] The pelleted catalysts were tested for their efficacy in converting trichloroethylene to 134a. An atmospheric pressure screening rig was equipped with four reactor tubes, each with independent HF, organic and nitrogen feeds. The organic feed system was charged with trichloroethylene. Each reactor was charged with 2 g of catalyst with a particle size in the range 0.5-1.4 mm. Initially the nitrogen flow (60 ml/min) was directed to the reactor inlet and the catalysts dried at 250 C. for 1 hour.

[0078] Following the catalyst drying operation HF vapour was fed to each reactor at a flow of 30 ml/min, diluted with nitrogen (60 ml/min), and passed over the catalysts at 250 C. for approximately 30 minutes until HF was observed in the reactor off gases. At this point the nitrogen flows (reduced to 30 ml/min) were redirected to the reactor exits. The catalysts were then exposed to the HF:N.sub.2 (30:5-ml/min) stream for a further hour at 250 C. before the temperatures were ramped to 450 C. at 40 C. per hour. These temperatures were held for ten hours.

[0079] The reactors were initially cooled to 350 C. and trichloroethylene was fed over the catalysts by sparging nitrogen (8 ml/min) through liquid trichloroethylene at 10 C. This gave a 0.5 ml/min flow of trichloroethylene gas. The catalysts were allowed to equilibrate in the HF:trichloroethylene:N.sub.2 (30:0.5:10-ml/min) gas stream for about 2 hours before the reactor temperatures were reduced to 300 C. The catalysts were again allowed to equilibrate for about 1 hour before the production of 133a and 134a from each was measured. The temperatures and yields across the reactors were monitored.

[0080] The organic feed was then turned off and with 30 ml/min HF flowing over the catalyst the reactor temperatures were ramped to 490 C. at 40 C./hr this was held for ten hours and cooled to 350 C. Trichloroethylene was then provided as above. This process was repeated for a stress temperature of 514 C. and, for some examples 522 C.

[0081] The activity and stability results are presented as a comparison to the results for Comparative Example 1, a commercial catalyst tested under the same conditions.

[0082] Activity is determined according to the calculation

Activity=50(S2RT)

[0083] where S2 is the predicted reaction temperature to obtain 10% 134a yield at Stress Temperature 2 and where RT is 287.5 C.

[0084] Stability is determined according to the calculation

Stability=50(S3RT)

[0085] where S3 is the predicted reaction temperature to obtain 10% 134a yield at Stress Temperature 3 and where RT is 287.5 C.

[0086] The results are shown in Table 2, below.

TABLE-US-00002 TABLE 2 Predicted Reaction Temp to Obtain Precip- 10% 134a Yield Exam- itation Stress 1 Stress 2 Stress 3 Stress 4 Ac- ple pH 450 C. 490 C. 514 C. 522 C. tivity Stability CE 1 288.90 287.50 295.50 318.90 50 42 CE2a 7.2-7.3 296.00 297.04 308.61 40.5 28.9 CE2b 307.64 292.58 301.11 44.9 36.4 3a 7.5-8.1 287.22 284.37 291.35 53.1 46.2 3b 279.71 281.90 57.8 55.6 4 8.3 284.70 286.04 284.79 304.00 51.5 52.7 5a 8.3-8.4 288.46 286.80 290.93 308.82 50.7 46.6 5b 286.78 284.96 289.00 308.18 52.5 48.5 6a 8.3-8.4 282.16 279.32 283.17 301.29 58.2 54.3 6b 281.68 285.05 288.90 306.29 52.5 48.6 7a 8.2-8.4 281.48 282.46 288.26 303.83 55.0 49.2 7b 282.35 278.32 282.84 297.90 59.2 54.7

[0087] The results show a clear correlation between increased pore volume and width and increased stability and activity over prior art catalysts. This activity appears to be sustained even where there is a decrease in surface area compared to the commercial catalyst.

Examples 8 and 9 and Comparative Examples 10 and 11

[0088] Catalysts were prepared substantially according to the method of Examples 1 to 7, adapted as described below with reference to Table 3.

[0089] A Mettler Toledo Optimax automated laboratory reactor was fitted with Focussed Beam Reflective Measurement (FBRM) G400 14 mm probe with overhead stirring and charged with 500 ml a deionised water heel.

[0090] The metal solution was pumped to the reactor at 5 ml/min. 17% Ammonium hydroxide solution was also added at 5 ml/min. The pH was closely monitored and the flow rates of the reactants altered to maintain the target pH. The reaction was run until 300 g of the metal solution was added. The particle size of the precipitate was monitored during the reaction using the FBRM G400 probe.

TABLE-US-00003 TABLE 3 Target Example Metal solution pH CE8 300 g Chromium hydroxide nitrate (~10% Cr) pH 7 9 300 g Chromium hydroxide nitrate (~10% Cr) pH 8.5 CE10 300 g Chromium hydroxide nitrate (~10% Cr) + pH 7 11.4 g Zn(NO.sub.3).sub.26H.sub.2O 11 300 g Chromium hydroxide nitrate (~10% Cr) + pH 8.5 11.4 g Zn(NO.sub.3).sub.26H.sub.2O

[0091] The resulting slurries were vacuum filtered and washed three times with de-ionised water. The filter cake was dried at 110 C. then, calcined under flowing nitrogen (200 ml/min) at 300 C. for 12 hours to produce Cr.sub.2O.sub.3 and 6.5% ZnO/Cr.sub.2O.sub.3. This was milled and mixed with 2% graphite before being pelleted at 5 tonne.

Comparative Example 8

[0092] FIGS. 1 and 2 and table 4 show the measured particle size distribution 2, 6 and 15 minutes after the start of dosing and once dosing is complete. 2 minutes after the start there are mostly very small particles, but also a few large particles present. These large particles are not present 6 minutes after the start of dosing, by which time the small particle population is at its greatest. Thereafter, the distribution shows a gradual shift to large size.

TABLE-US-00004 TABLE 4 Statistic 2 min. 6 min. 15 min. End Median No Wt 3.7 4.3 6.2 8.7 Mean Sq Wt 67.8 12.6 16.6 24.4 Counts <5 m 45949 66179 42031 21046 Counts 5-8 m 12838 25269 27048 19349 Counts 8-25 m 10920 22241 37550 42532 Counts 25-300 m 1493 357 1576 5377

Example 9

[0093] FIGS. 3 and 4 and table 5 show the measured particle size distribution 2, 6 and 15 minutes after the start of dosing and once dosing is complete. 2 minutes after the start there are mostly large particles present. But by 6 minutes, the number of large particles has reduced, and the number of small particles has increased significantly. The particle system shows very little change for the final 15 minutes of dosing.

TABLE-US-00005 TABLE 5 Statistic 2 min. 6 min. 15 min. End Median No Wt 8.6 4.3 4.0 3.9 Mean Sq Wt 30.1 13.4 11.8 11.5 Counts <5 10732 60239 77458 81366 Counts 5-8 7135 22430 26103 26522 Counts 8-25 16259 21560 20603 20341 Counts 25-300 3858 460 233 228

Comparative Example 10

[0094] FIGS. 5 and 6 and table 6 show the measured particle size distribution 2, 6 and 15 minutes after the start of dosing and once dosing is complete. 2 minutes after the start there are mostly small particles present which increase in number as 6 minutes is reached. After that, the population of those small particles gradually decreases, and the number of larger particles increases.

TABLE-US-00006 TABLE 6 Statistic 2 min. 6 min. 15 min. End Median No Wt 5.9 5.3 6.8 7.3 Mean Sq Wt 19.7 17.0 23.4 26.7 Counts <5 m 29859 46790 32806 28764 Counts 5-8 m 15510 22717 20755 19240 Counts 8-25 m 23382 28384 35207 35337 Counts 25-300 m 1798 1346 4113 5314

Example 11

[0095] FIGS. 7 and 8 and table 7 show the measured particle size distribution 2, 6 and 15 minutes after the start of dosing and once dosing is complete. The distributions show that over the course of dosing, there is a gradual increase in the numbers of smaller particles. For the final 15 minutes of dosing, there is a decrease in the number of larger particles.

TABLE-US-00007 TABLE 7 Statistic 2 min. 6 min. 15 min. End Median No Wt 5.7 4.3 4.1 3.6 Mean Sq Wt 16.8 13.2 12.4 10.4 Counts <5 m 12933 52574 61877 87005 Counts 5-8 m 7197 19203 21662 24208 Counts 8-25 m 9559 17822 19193 16282 Counts 25-300 m 352 297 284 112

[0096] FIG. 9 shows the real time data collection for the fines count (less than 5 m and 8 m to 25 m) for Comparative Examples 8 and Example 9. From this it was possible to see instantly the effect of any flow disturbances or pH fluctuations. It also demonstrates that leaving the final slurry to stir for an extended period had no effect on particle size or distribution.

[0097] A comparison of the final particle size distributions of the slurries is shown in FIGS. 10 and 11 and Table 8. The results clearly show that increasing the pH of precipitation has a significant effect on the particle population and size. Both runs at pH 8.5 have a smaller average size than those at pH 7.0, and more small particles. Changing the metal composition also has an effect but much smaller in scale. Both runs with zinc show a slightly smaller average size compared to the chromium only counterparts.

[0098] The resulting dried, calcined and pelleted catalysts were tested by N.sub.2 adsorption/desorption porosimetry to determine surface area, total pore volume and average pore diameter. The results are shown in Table 8, below.

TABLE-US-00008 TABLE 8 Pore Mean particle volume BJH Ads length (slurry) BET cm.sup.3/g Average pore Example pH Microns m.sup.2/g @P/P0.99 diameter CE8 7 24.5 243.75 0.21 51.2 9 8.5 11.4 207.69 0.64 189.2 CE10 7 26.5 241.00 0.45 100.1 11 8.5 10.5 200.98 0.72 206.7

[0099] It is clear that the catalysts of Comparative Examples 8 and 10 (prepared at pH 7) had a larger particle size in the slurry and a larger BET surface area and a smaller pore diameter and volume. In contrast, the catalysts of Examples 9 and 11 (prepared at pH 8.5) had a smaller particle size in the slurry which resulted in a smaller BET surface area and a larger pore diameter and volume.

[0100] The catalysts of Examples 9 and 11 and Comparative Examples 8 and 10 were subjected to the same performance testing as Examples 1 to 7. The results are shown in Table 9 below.

TABLE-US-00009 TABLE 9 Predicted temp to Obtain 10% 134a Yield Stress 1 Stress 2 Stress 3 Example Activity Stability 450 C. 490 C. 514 C. CE8 42.4 34.33 285.03 295.10 303.17 9 50.27 48.38 287.36 287.23 289.12 CE10 45.89 46.93 295.66 291.61 290.57 11 59.08 46.27 274.38 278.42 291.23

[0101] These results show improved stability of the catalysts of Examples 9 and 11 over the comparative Examples 8 and 10. This demonstrates that the favouring of larger pore sizes, larger pore volumes and/or smaller precipitated particle diameter upon precipitation over BET surface area provides for improved performance in the catalysts. These parameters may be controlled by controlling the pH of precipitation.

[0102] Preferences and options for a given aspect, feature or parameter of the invention should, unless the context indicates otherwise, be regarded as having been disclosed in combination with any and all preferences and options for all other aspects, features and parameters of the invention.

Example 12 and Comparative Example 13

[0103] In Example 12, chromia catalyst pellets were made according to the following method. 500 mL deionised water heel was added to a 1.7 L jacketed glass vessel, fitted with an overflow, overhead stirrer, pH probe and thermocouple and cooled to 15 C. The stirrer was actuated at 500 rpm

[0104] A solution of Cr(NO.sub.3).sub.2(OH).sub.(aq) (1036 g) was measured into a 2000 mL beaker. In another beaker, 599 g 17% NH.sub.4OH solution was provided.

[0105] The metal and ammonia solutions were pumped into the chilled water at 5 ml/min. Precipitation of a green/blue solid occurs immediately. The pH of the mixture was monitored and the reactant flow rates adjusted to maintain the target of pH 8.5. The reaction was run until all of the metal solution was added.

[0106] The chromium hydroxide slurry was divided into two portions and filtered separately under vacuum until a filter cake formed then each washed three times with de-ionised water (3500 mL). The resulting filter cakes were combined, then divided into four. One portion of cake was then dried at 80 C. for 3-days in a standard oven, followed by calcining under flowing nitrogen (200 ml/min) at 300 C. for 12 hours to produce Cr.sub.2O.sub.3, the heating rate on the chamber furnace being set to 2 C./min. The percentage mass loss was on calcination was noted.

[0107] 2 wt % graphite was blended with the cooled, calcined catalyst precursor in a waring blender, and the resultant mixture was sieved to <250 m. The sieved mixture was formed into pellets under a load of 5 tonne in a 32 mm pellet die, 3 g per pellet.

[0108] The pellets were then ground to mesh size 0.5-1.4 mm for catalyst testing. Surface area, pore volumes and sizes were measured by N.sub.2 adsorption/desorption porosimetry.

[0109] Production of 1234yf from 243db

[0110] The performance of the catalyst of Example 12 was tested for the production of 1234yf from the fluorination of 243db by contact with HF and compared to the performance for a commercially available chromia catalyst containing no promoter. The pore volumes and diameters for each catalyst were also tested.

[0111] An atmospheric pressure screening rig was equipped with four reactor tubes, each with independent HF, organic and nitrogen feeds. The organic feed system was charged with 243db. Each reactor was charged with 2 ml of catalyst with a particle size in the range 0.5

[0112] 1.4 mm. Initially the nitrogen flow (60 ml/min) was directed to the reactor inlet and the catalysts dried at 200 C. for 2 h.

[0113] Following the catalyst drying operation HF vapour was fed to each reactor at a flow of 30 ml/min, diluted with nitrogen (60 ml/min), and passed over the catalysts at 300 C. for approximately 60 minutes until HF was observed in the reactor off gases. At this point the nitrogen flows (reduced to 30 ml/min) were redirected to the reactor exits. The reactor temperatures were ramped to 360 C. at 40 C. per hour. These temperatures were held for ten hours.

[0114] The reactors were cooled to 350 C. and 243db was fed over the catalysts by sparging nitrogen (4-6 ml/min) through liquid 243db at 10 C. This gave a 0.5-1 ml/min flow of 243db gas. The catalysts were allowed to equilibrate in the HF:243db:N.sub.2 (30:0.5-1.0:4-6 ml/min) gas stream for about 1 h before sampling reactor off-gas into a glass burette with DI water for GC analysis. The results are shown in Table 10 below.

TABLE-US-00010 TABLE 10 Pore volume 243db 1243yf pre test (N.sub.2 conversion selectivity absorption)/ Pore volume post test Average BJH ads pore Average BJH ads pore Example Catalyst Temperature/ C. % % cm.sup.3/g (N.sub.2 absorption)/cm.sup.3/g diameter pre test/ diameter post test/ 12 Cr.sub.2O.sub.3 350 100 40.26 0.44 0.34 147 261 CE13 Cr.sub.2O.sub.3 350 100 17.95 0.28 0.21 101 167

[0115] The results show a clear improvement in selectivity for 1234yf when the catalyst of the present invention is utilised. Furthermore, the results show that the catalyst of the invention shows significant pore widening once used, which without wishing to be bound by any theory, may amplify the effect of providing a high pore volume and average pore diameter in the unused catalyst.

Example 14

[0116] 500 mL deionised water heel was added to a 1.7 L jacketed glass vessel, fitted with an overflow, overhead stirrer, pH probe and thermocouple and cooled to 15 C. The stirrer was actuated at 430 rpm. A solution of Cr(NO.sub.3).sub.2(OH).sub.(aq) (332 g) was measured into a 600 mL beaker and 17% NH.sub.4OH solution (476 g) into another beaker.

[0117] The metal and ammonia solutions were pumped into the chilled water at 5 ml/min. Precipitation of a green/blue solid occurs immediately. The pH of the mixture was monitored and the reactant flow rates adjusted to maintain the target pH 8.5. The reaction was run until all of the solutions were added.

[0118] The chromium hydroxide slurry was filtered under vacuum until a filter cake formed then washed with de-ionised water (3500 mL). The filter cake was then dried at 105 C. overnight in a standard oven, followed by calcining under flowing nitrogen (200 ml/min) at 300 C. for 12 hours to produce Cr.sub.2O.sub.3, the heating rate on the chamber furnace being set to 2 C./min.

[0119] 2 wt % graphite was blended with the cooled, calcined catalyst precursor in a waring blender, and the resultant mixture was sieved to <250 m. The sieved mixture was formed into pellets under a load of 5 tonne in a 32 mm pellet die, 3 g per pellet. The pellets were then ground to mesh size 0.5-1.4 mm for catalyst testing.

[0120] Analysis showed a BET surface area of 211 m.sup.2/g, a Pore Volume @0.99P/P of 0.731 cm.sup.3/g and average BJH adsorption pore diameter of 199 .

Example 15

[0121] A further catalyst was produced according to the method of Examples 1 to 7, targeting a pH of 8 to 8.5 during production.

[0122] Production of 1234yf and 245cb from 1233xf

[0123] The performance of the catalyst of Examples 12, 14 and 15 was tested for the production of 1234yf and 245cb from the fluorination of 1233xf by contact with HF. The results were compared to those of a commercially available chromia catalyst (Comparative Example 16).

[0124] Each catalyst (3 mL, 0.5-1.4 mm) was charged to an 0.5 OD Inconel 625 reactor supported by Inconel mesh. The catalysts were dried at 250 C. under 60 ml/min flowing nitrogen for at least 2 hours prior to pre-fluorination. HF vapour flowing at 30 ml/min was then passed over the catalyst along with 30 ml/min nitrogen at 250 C. for one hour. The nitrogen was then directed to the reactor exit leaving neat HF passing over the catalyst. The temperature was slowly ramped to 380 C. and held for 10 hours. The temperature was then reduced to 350 C. and the HF flow reduced to 25 mL/min. A co-feed of 1233xf (2-chloro-3,3,3-trifluoropropene) was fed by its own vapour pressure and the flow controlled to 1 mL/min through an orifice plate. Reactor off-gas was sampled periodically from 0.5 to 7 h of continuous running, into deionised water and analysed by GC to determine reaction progress. Results are shown in Table 11.

TABLE-US-00011 TABLE 11 Average. Conv. Pore BJH Ads Activity Product Yield Decay Conv. Conv. Volume Pore 1233xf 1234yf 245cb rate Half-life Half-life Catalyst @0.99P/P Diameter Conv. mol mol (Stability) (Stability) (Stability) Example (cm.sup.3/g) () (%) (%) (%) k (h.sup.1) t.sub.0.5 (h) t.sub.0.5 (h .Math. g.sup.1) CE16 0.284 101 27.8 18.8 5.4 0.13 5.6 2 12 0.440 147 82.8 43.6 13.9 0.04 16.5 9.7 14 0.731 199 84.3 45.4 14.3 0.12 5.8 4.5 15 0.606 205 70.9 50.8 13.6 0.13 5.5 3.4

[0125] It appears from the results shown in Table 11 that increasing the pore volume and average pore diameter of the pure chromia catalysts relative to the catalyst of Comparative Example 16 led to an increase in the catalyst activity and product yield. There was also an improvement in catalyst stability.

[0126] Production of 1234yf from 245cb

[0127] The performance of the catalyst of Examples 12, 14 and 15 was tested for the production of 1234yf from the dehydrofluorination of 245cb. The results were compared to those of a commercially available chromia catalyst (Comparative Example 17).

[0128] Each catalyst (3 mL, 0.5-1.4 mm) was charged to an 0.5 OD Inconel 625 reactor supported by Inconel mesh. The catalysts were dried at 250 C. under 60 ml/min flowing nitrogen for at least 2 hours prior to pre-fluorination. HF vapour flowing at 30 mL/min was then passed over the catalyst along with 30 mL/min nitrogen at 250 C. for one hour. The nitrogen was then directed to the reactor exit leaving neat HF passing over the catalyst. The temperature was slowly ramped to 380 C. and held for 10 hours. The temperature was then reduced to 250 C. and the HF flow reduced to 25 mL/min. A co-feed of 245cb (1,1,1,2,3-pentafluoropropane) vapour was fed by sparging nitrogen (1 ml/min) through the liquid at 9 C. and resulting in a 245eb flow of 1 mL/min. Reactor off-gas was sampled periodically from 0.5 to 7 h of continuous running into deionised water and analysed by GC to determine reaction progress. Results are shown in Table 12.

TABLE-US-00012 TABLE 12 Average. Pore BJH Ads Activity Volume Pore 245cb Catalyst @0.99P/P Diameter Conversion Example Mass/g (cm.sup.3/g) () (%) CE17 2.7 0.284 101 78.5 12 1.7 0.440 147 82.7 14 1.4 0.731 199 81.7 15 1.7 0.606 205 79.3

[0129] It appears from the data in Table 12 that the catalyst activity of the high pore volume and large pore catalysts was higher than that of the catalyst of Comparative Example 17. The Zn promoted catalyst of Example 15 also increased the yield of 1234yf. All of the catalysts were equally stable.

[0130] Production of 1234yf from 245eb

[0131] The performance of the catalyst of Example 12 was tested for the production of 1234yf and 245cb from the dehydrofluorination of 245eb. The results were compared to those of a commercially available chromia catalyst (Comparative Example 16).

[0132] Each catalyst (3 mL, 0.5-1.4 mm) was charged to an 0.5 OD Inconel 625 reactor supported by Inconel mesh. The catalysts were dried at 250 C. under 60 mL/min flowing nitrogen for at least 2 hours prior to pre-fluorination. HF vapour flowing at 30 ml/min was then passed over the catalyst along with 30 mL/min nitrogen at 250 C. for one hour. The nitrogen was then directed to the reactor exit leaving neat HF passing over the catalyst. The temperature was slowly ramped to 380 C. and held for 10 hours. The temperature was then reduced to 250 C. and the HF flow reduced to 25 mL/min. A co-feed of 245eb (1,1,1,2,3-pentafluoropropane) vapour was fed by sparging nitrogen (1 mUnnin) through the liquid at 9 C. and resulting in a 245eb flow of 1 mL/min. Reactor off-gas was sampled periodically from 0.5 to 7 h of continuous running into deionised water and analysed by GC to determine reaction progress. The results are shown in Table 13.

TABLE-US-00013 TABLE 13 Rate of Pore Average. increase in Volume BJH Ads Activity activity Yield @0.99P/ Pore 245eb 245eb 1234yf Catalyst P Diameter Conversion Conversion mol Example Mass/g (cm.sup.3/g) () (%) gain (%/h) (%) CE16 2.7 0.284 101 18.7 0.5 15.3 12 1.7 0.440 147 36.5 6.8 22.1

[0133] It appears from the results in Table 13 that the catalyst activity and 1234yf yield was higher over the high pore volume/large pore catalyst than it was over the catalyst of Comparative Example 16. In addition the activity of the high pore volume/large pore catalyst steadily increased over time and produced a higher yield of 1234yf.

[0134] Preferences and options for a given aspect, feature or parameter of the invention should, unless the context indicates otherwise, be regarded as having been disclosed in combination with any and all preferences and options for all other aspects, features and parameters of the invention.