Method for deposition of noble metal nanoparticles on catalysts to promote same, and the compositions so produced
09873110 ยท 2018-01-23
Assignee
Inventors
- Abbas Ali Khodadadi (Tehran, IR)
- Yadollah Mortazavi (Tehran, IR)
- Mohammad Javad Parnian (Shahryar, IR)
- Ali Taheri Najafabadi (Tehran, IR)
Cpc classification
B01J37/34
PERFORMING OPERATIONS; TRANSPORTING
B01J35/77
PERFORMING OPERATIONS; TRANSPORTING
B01J2235/30
PERFORMING OPERATIONS; TRANSPORTING
B01J35/30
PERFORMING OPERATIONS; TRANSPORTING
B01J2235/00
PERFORMING OPERATIONS; TRANSPORTING
B01J35/70
PERFORMING OPERATIONS; TRANSPORTING
International classification
B01J35/00
PERFORMING OPERATIONS; TRANSPORTING
B01J37/34
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A method for promoting the supported catalysts using noble metal nanoparticles. Different noble metal precursors are preferentially deposited onto the supported metal catalysts through Chemical vapor deposition (CVD), and compositions so produced. Further, the promoted catalyst is used for CO and CO.sub.2 hydrogenation reactions, increasing the reaction conversion, C.sub.5+ compounds selectivity and chain growth probability. The active phase of catalyst can be either cobalt oxide, nickel oxide or their reduced format (Co.sup.0 or Ni.sup.0), and the noble metal is preferably Ruthenium.
Claims
1. A method for producing a catalyst comprising: forming, on a support surface, an active metal surface of a precursor catalyst, wherein: the active metal surface of the precursor catalyst is selected from the group consisting of cobalt oxide, nickel oxide, reduced formats (Co.sup.0 or Ni.sup.0) and combinations thereof, and the support surface of the precursor catalyst is made of a material selected from the group consisting of -Al.sub.2O.sub.3, TiO.sub.2, carbon nanotubes or CNT, and combinations thereof; and depositing, via chemical vapor deposition, ruthenium metal nanoparticles onto the active metal surface, the depositing including reacting on the active metal surface of the precursor catalyst a ruthenium metal precursor vapor with a reactant gas, at a reacting temperature at which the precursor catalyst catalyzes a decomposition of the ruthenium metal precursor vapor into ruthenium metal nanoparticles, wherein the reacting temperature is below a temperature at which the ruthenium metal precursor vapor substantially deposits ruthenium metal nanoparticles upon the support surface of said precursor catalyst, and wherein the reacting temperature is within the range of about 150 C. to about 200 C.
2. The method according to claim 1, wherein the precursor catalyst is an alumina-supported cobalt catalyst.
3. The method according to claim 1, wherein said ruthenium is about 0.01% to 1% by weight of active metal.
4. The method according to claim 3, wherein said ruthenium is about 0.05% to 0.3% by weight of active metal.
5. The method according to claim 1, wherein the ruthenium metal nanoparticles are carried by Argon gas to said precursor catalyst.
6. The method according to claim 1, further comprising heating a sublimation zone of a chemical vapor deposition assembly to about 80 C.
7. The method according to claim 1, further comprising obtaining an Fourier Transform Infrared (FTIR) pattern of the ruthenium metal nanoparticles that have decomposed during the chemical vapor deposition.
8. A method for producing a catalyst comprising: depositing ruthenium metal nanoparticles onto first support surfaces using chemical vapor deposition of a ruthenium metal precursor to produce a first effluent; depositing ruthenium metal nanoparticles onto a first precursor catalyst using chemical vapor deposition of the ruthenium metal precursor to produce a second effluent, the first precursor catalyst including first active metal surfaces and second support surfaces; obtaining an Fourier Transform Infrared (FTIR) pattern of the first effluent and the second effluent for temperatures between 100 C. and 280 C.; and determining a preferential temperature range that extends between a first temperature and a second temperature, the first temperature corresponding to a temperature at which decomposition of the ruthenium metal precursor is detected in the second effluent, the second temperature corresponding to a temperature at which decomposition of the ruthenium metal precursor is detected in the first effluent, wherein the chemical vapor deposition of the ruthenium metal precursor in the preferential temperature range preferentially deposits ruthenium metal nanoparticles upon the first active metal surfaces and minimally deposits ruthenium metal nanoparticles upon the second support surfaces of the first precursor catalyst.
9. The method of claim 1, wherein the ruthenium metal precursor vapor includes ruthenocene vapor.
10. The method of claim 1, wherein the reactant gas includes hydrogen.
11. The method of claim 1, wherein the depositing further includes: concurrently carrying the ruthenium metal precursor vapor and the reactant gas onto the active metal surface of the precursor catalyst.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter that is regarded as forming the present invention, it is believed that the invention will be better understood from the following description taken in conjunction with the accompanying DRAWINGS, where like reference numerals designate like structural and other elements, in which:
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DETAILED DESCRIPTION OF THE INVENTION
(10) The following detailed description is presented to enable any person skilled in the art to make and use the invention. For purposes of explanation, specific nomenclature is set forth to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that these specific details are not required to practice the invention. Descriptions of specific applications are provided only as representative examples. Various modifications to the preferred embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the scope of the invention. The present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest possible scope consistent with the principles and features disclosed herein.
(11) As discussed, prior art and traditional methods for the preparation of promoted catalysts generally result in promoter impregnation on both the active phase of the catalyst and the support. However, Applicant has found that the highest promoting role of precious noble metals occur when the promoter is only impregnated on the active phase, with close contacts but not onto the surfaces of the support. The present invention cures the serious impediments found in the prior art and traditional techniques.
(12) As discussed, chemical vapor deposition (CVD) is preferably used for the addition of a promoter on the active phase surface of a catalyst with high bimetallic interaction, which, as noted, leads to higher catalytic performance than the prior art. Applicant has found that by fine tuning the temperature in a CVD temperature window, the noble metal precursor decomposes preferentially on the surface of the cobalt or nickel as the active phase of carbon oxides hydrogenation catalyst, with minimal amounts of noble metal deposition onto the surface of the support. Indeed, using the improved techniques of the present invention, the close contact between the catalyst active phase and the noble metal promoter greatly enhances the reducibility of the promoted catalysts and improves their activity and selectivity during hydrogenation reactions.
(13) In a first embodiment of the present invention, chemical vapor deposition of ruthenocene is applied for preferential deposition of ruthenium onto the cobalt of a Fischer-Tropsch synthesis catalyst. The close contact between cobalt and ruthenium greatly enhances the reducibility of the Ru-promoted cobalt catalysts and improves their Fourier Transform Spectroscopy (FTS) activity and selectivity.
(14) A preferred experimental procedure designed to find the CVD temperature window is illustrated in an exemplary hierarchical chart in
(15) As noted, the thermochemical decomposition byproducts of noble metal precursors, on the support and the catalyst at various temperatures are detected by FTIR or GC. The special sublimation and decomposition temperature ranges which the noble metal precursor decomposition rates on the surface of catalyst (supported Co.sub.3O.sub.4 or NiO) are much higher than the surface of support, promise an intimate contact between the catalyst active phase and deposited noble metal. This temperature range is termed the Preferential CVD Temperature Window, and is a central feature and object of the present invention. A detailed example, based on the aforesaid hierarch, is now presented for a CO hydrogenation (FTS) reaction.
(16) Co.sub.3O.sub.4/-Al.sub.2O.sub.3 Catalyst Preparation
(17) In this exemplary embodiment, an alumina-supported cobalt catalyst was prepared by impregnation of -Al.sub.2O.sub.3 with a cobalt nitrate aqueous solution. A sufficient amount of the cobalt nitrate was dissolved in de-ionized water to prepare about 15 wt % of cobalt onto the -Al.sub.2O.sub.3. The -Al.sub.2O.sub.3 was then immersed in a nitrate solution for about 1 hr, filtered, and dried in an evacuated oven at about 70 C. for about 4 hours, and then at about 120 C. overnight, afterwards calcined at about 400 C. for about 4 hours in air.
(18) CVD Precursor Selection
(19) In the present invention, ruthenocene was preferably used as precursor for the chemical vapor deposition of ruthenium. The ruthenocene vapor pressure equation is presented in equation (1):
log.sub.10(P[kPa])=135249.99/T[K](1)
(20) According to equation (1), the vapor pressures of ruthenocene are 0.013 and 0.084 kPa, respectively, at 80 and 100 C., which are the temperatures of a ruthenocene sublimation zone employed in this study.
(21) A thermal gravimetric analysis (TGA) of ruthenocene is illustrated in
(22) CVD Reactant Gas Selection
(23) Hydrogen (H.sub.2) was utilized to accelerate the decomposition of ruthenocene in the decomposition zone of the CVD reactor. A sample FTIR spectrum of ruthenocene thermo-chemical destruction products in the region of about 400-4000 cm.sup.1 is depicted in
(24) CVD setup for Ru deposition on Co.sub.3O.sub.4/-Al.sub.2O.sub.3
(25) With reference now to
(26) As shown in
(27) Preferential CVD of Ruthenium on Cobalt of Co/-Al.sub.2O.sub.3
(28) As discussed, the present invention is directed to improved techniques to preferentially decompose ruthenocene on the surface of the cobalt, as the active phase of Co/-Al.sub.2O.sub.3 catalyst, with minimal or no amounts of ruthenium being deposited onto the surface of the alumina support. As discussed, this objective can be achieved by fine-tuning the temperature in a CVD temperature window. The following experimental procedure was designed to find the preferred CVD temperature windows pursuant to the teachings of the present invention.
(29) Either a -Al.sub.2O.sub.3 support or a Co.sub.3O.sub.4/-Al.sub.2O.sub.3 catalyst sample was placed in the deposition zone of CVD reactor, as shown and described in connection with
(30) With reference now to
(31) Applicant has found that for all sublimation and decomposition temperatures, the ruthenocene decomposition rates on the Co.sub.3O.sub.4/-Al.sub.2O.sub.3 catalyst are significantly higher than those on -Al.sub.2O.sub.3., with the effect more pronounced at lower temperatures. In all cases, in the range of about 150-200 C., no ruthenocene decomposition occurs on the -Al.sub.2O.sub.3, while significant decomposition occurs on the Co.sub.3O.sub.4/-Al.sub.2O.sub.3. This temperature range, illustrated more particularly within the boxed sections within the two graphs, are labeled Preferential CVD Temperature Window. Cobalt oxide dispersed on the -Al.sub.2O.sub.3 seems to catalyze the ruthenocene decomposition. This promises an intimate contact between the cobalt active phase and deposited ruthenium.
(32) CVD Operating Conditions
(33) It should be understood that CVD experiments were performed at a sublimation temperature of about 80 C. and at a decomposition temperature of about 180 C. in about 15 sccm argon and about 50 sccm hydrogen, respectively. Also, 0.4 g calcined 15 wt % Co/-Al.sub.2O.sub.3 catalysts were promoted by Ru-contents of 0.05, 0.1, 0.15, 0.2 and 0.3 wt % Co by varying the preferential CVD times.
(34) As Applicant can be their own lexicographer, for convenience and clarity, the abbreviated name for 15 wt % Co.sub.3O.sub.4/-Al.sub.2O.sub.3 is CoRu0 and the promoted catalysts with 0.05 to 0.3 wt % of ruthenium are termed CoRu1 to CoRu5 (denoted CoRu5-180), respectively. Another CoRu5 sample was prepared by ruthenocene CVD at 225 C. (denoted as CoRu5-225), which is beyond the preferential CVD temperature window and ruthenocene decomposes on both alumina and cobalt oxide on alumina. FTIR spectrum shows the presence of ruthenocene decomposition products on alumina, as shown in
(35) For comparison of a preferential CVD with the usual impregnation method, the CoRu5-SI, corresponding to a CoRu5 sample prepared by the CVD method, was prepared by impregnation of a RuCl3 solution onto the calcined Co.sub.3O.sub.4/-Al.sub.2O.sub.3. The sample was dried and then calcined at the same temperature of 400 C.
EXAMPLE 1
Properties of the Prepared CoRux Containing Catalysts
(36) With reference now to
(37) Lattice fringes of CoRuO unpromoted catalyst and CoRu5 sample promoted with 0.3 wt % Ru are shown in
(38) An X-Ray diffraction (XRD) analysis, along with respective selected area electron diffraction analyses (SAEDs), was applied to investigate the effect of ruthenium on average Co.sub.3O.sub.4 crystallite sizes of the calcined Ru-Co/-Al.sub.2O.sub.3 catalysts. As shown, the crystallite size of Co.sub.3O.sub.4 decreases from about 15.8 to 8.9 nm, as the Ru content increases from about 0 to 0.3 wt % of cobalt, respectively. Table 1 hereinbelow indicates that the cobalt dispersion increases with the ruthenium content of catalysts. Also, as the ruthenium content of the catalysts increases to about 0.3 wt %, the surface area of the catalysts increases by about 37%. This may be due to a decrease in the cobalt oxide particle sizes, in accordance with the aforesaid XRD results.
(39) TABLE-US-00001 TABLE 1 Average Co.sub.3O.sub.4 crystallite size, Co crystallite size, dispersion and specific surface area of the catalysts samples. Nominal CVD Specific Co.sub.3O.sub.4 Co.sup.0 Hydrogen Ru content time Surface area Crystallite Crystal Dispersion.sup.c consumption in TPR Catalyst (wt % Co) (mn) (m.sup.2/gr) size.sup.a (nm) size.sup.b (nm) (%) (mol H.sub.2/g. catal.) -Al.sub.2O.sub.3 195 CoRu0 0.00 138 15.8 11.9 8.1 1772 CoRu1 0.05 5 178 14.2 10.7 9.0 2300 CoRu2 0.1 10 180 12.9 9.7 9.9 2474 CoRu3 0.15 15 183 11.8 8.9 10.8 2599 CoRu4 0.2 20 184 10.1 7.6 12.6 2757 CoRu5 0.3 30 189 8.9 6.7 14.3 3167 CoRu5-SI 0.3 182 12 9 10.6 2698 .sup.aCo.sub.3O.sub.4 crystallite size is determined using Scherrer's equation at 2 = 36.8 .sup.bCo and Co.sub.3O.sub.4 crytstallites size are related by d(Co) = 0.75d(Co.sub.3O.sub.4) .sup.c% D = 96/d(Co)
(40) With reference now to
EXAMPLE 2
The use of Promoted Catalyst for CO Conversion
(41) CO conversion, product selectivity and chain growth probability (a), as well as olefin to paraffin ratio in C.sub.2-C.sub.4 hydrocarbons, for the Fischer-Tropsch synthesis (FTS) on the various catalysts at 220 C. and H.sub.2/CO=2, and mean space time of 4 s are summarized in Table 2 hereinbelow.
(42) As shown, as the ruthenium content increases from 0 in CoRu0 to 0.3 wt % Ru in CoRu5, several things occur: (a) the CO conversion increases by 2.8 times, (b) the selectivity to methane (as one of the most undesirable products) decreases by about 28%, (c) in accordance to a, the selectivity to C.sub.5+ as the most desirable FTS products increases by 46.4%, (d) the O/P ratio decreases by 2.4 times, and (e) the selectivity to C.sub.2-C.sub.4 does not change significantly.
(43) It is also observed that, in addition to the beneficial aspects noted hereinabove, C.sub.5+ selectivity increases by adding ruthenium by the preferential CVD method. As compared to CoRu5-180, the corresponding CoRu5-SI prepared by the traditional impregnation method has higher CH.sub.4 and lower C.sub.5+ selectivities and about 45% lower CO conversion. Also, significantly lower CO conversion and C.sub.5+ selectivity are observed for CoRu5-225.
(44) Therefore, the CoRu5-180 catalyst has 270% higher C.sub.5+ yields than the CoRuO unpromoted cobalt catalyst which is much higher than C.sub.5+ yields of CoRu5-SI prepared by the traditional impregnation method that has 82% higher C.sub.5+ yields with respect to CoRuO sample.
(45) TABLE-US-00002 TABLE 2 Catalytic performances of Co/-Al.sub.2O.sub.3 with different Ru content. CO Conver- sion Selectivity (O/P) Carbon Catalysts (%) C.sub.1 C.sub.2-C.sub.4 C.sub.5+ % Balance CoRu0 15.3 37 29 34 0.64 8.1 99.9 CoRu1 24.7 29.9 28 42.1 0.70 5.1 99.6 CoRu2 26.8 27.9 28.2 43.9 0.73 4.7 99.2 CoRu3 31.1 26.9 26.7 46.4 0.73 4.6 99.4 CoRu4 40.1 26.8 28.9 44.3 0.73 3.4 99.5 CoRu5-180 42.9 26.6 28.5 44.9 0.74 3.4 99.9 CoRu5-225 28.8 27.1 30.6 42.3 0.72 4.4 99.1 CoRu5-SI 23.7 28 32 40 0.68 5.1 99.3 *Reaction Conditions: T = 220 C., P = 1 bar, H.sub.2/CO = 2, = 4 s
(46) While the present invention has been illustrated by the description of the embodiments thereof, and while the embodiments have been described in detail, it is not the intention of the Applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, representative apparatus and method, and illustrative examples shown and described. Accordingly, departures may be made from such details without departure from the breadth or scope of the applicant's concept. Furthermore, although the present invention has been described in connection with a number of exemplary embodiments and implementations, the present invention is not so limited but rather covers various modifications and equivalent arrangements, which fall within the purview of the appended claims.