Catalyst for dehydrogenating primary alcohols

Abstract

This invention is directed to a process for making a salt of a carboxylic acid. The process comprises contacting a catalyst with an alkaline mixture comprising a primary alcohol. In one embodiment, for example, the catalyst comprises a metal support (preferably a metal sponge support) having a copper-containing active phase at the surface thereof. The support is resistant to deformation under the conditions of the dehydrogenation reaction. In another embodiment, the catalyst comprises a metal sponge having a copper-containing active phase at the surface thereof and a supporting structure containing at least 10% non-copper metal. This invention is also directed to copper-containing catalysts which may, for example, be used in the above process. This invention is further directed to processes for making such catalysts.

1 - 138 . (canceled)  
     
     
         139 . A catalyst comprising: 
 a metal support comprising (a) from about 2% to about 30% by weight copper, and (b) at least about 50% by weight non-copper metal; and    a copper-containing coating.    
     
     
         140 . A catalyst as set forth in  claim 139  wherein the metal support comprises a metal sponge.  
     
     
         141 . A catalyst as set forth in  claim 140  wherein said non-copper metal is selected from the group consisting of nickel, zinc, tin, cobalt, iron and combinations thereof.  
     
     
         142 . A catalyst as set forth in  claim 141  wherein said non-copper metal is nickel.  
     
     
         143 . A catalyst as set forth in  claim 141  wherein said non-copper metal is cobalt.  
     
     
         144 . A catalyst as set forth in  claim 140  wherein said copper-containing coating comprises a copper-containing active phase.  
     
     
         145 . A catalyst as set forth in  claim 144  wherein said copper-containing active phase has a copper concentration of at least about 50% by weight copper.  
     
     
         146 . A catalyst as set forth in  claim 144  wherein said copper-containing active phase has a copper concentration of at least about 75% by weight copper.  
     
     
         147 . A catalyst as set forth in  claim 144  wherein said copper-containing active phase has a copper concentration of at least about 90% by weight copper.  
     
     
         148 . A catalyst as set forth in  claim 144  wherein said copper-containing active phase has a copper concentration of at least about 95% by weight copper.  
     
     
         149 . A catalyst as set forth in  claim 140  wherein said metal sponge support comprises at least about 65% by weight non-copper metal.  
     
     
         150 . A catalyst as set forth in  claim 149  wherein said non-copper metal is selected from the group consisting of nickel, zinc, tin, cobalt, iron and combinations thereof.  
     
     
         151 . A catalyst as set forth in  claim 150  wherein said non-copper metal is nickel.  
     
     
         152 . A catalyst as set forth in  claim 150  wherein said non-copper metal is cobalt.  
     
     
         153 . A catalyst as set forth in  claim 140  wherein said metal sponge support comprises at least about 80% by weight non-copper metal.  
     
     
         154 . A catalyst as set forth in  claim 153  wherein said non-copper metal is selected from the group consisting of nickel, zinc, tin, cobalt, iron and combinations thereof.  
     
     
         155 . A catalyst as set forth in  claim 154  wherein said non-copper metal is nickel.  
     
     
         156 . A catalyst as set forth in  claim 154  wherein said non-copper metal is cobalt.  
     
     
         157 . A catalyst as set forth in  claim 140  wherein said metal sponge support comprises at least about 85% by weight non-copper metal.  
     
     
         158 . A catalyst as set forth in  claim 157  wherein said non-copper metal is selected from the group consisting of nickel, zinc, tin, cobalt, iron and combinations thereof.  
     
     
         159 . A catalyst as set forth in  claim 158  wherein said non-copper metal is nickel.  
     
     
         160 . A catalyst as set forth in  claim 158  wherein said non-copper metal is cobalt.  
     
     
         161 . A catalyst as set forth in  claim 140  wherein said metal sponge support comprises at least about 90% by weight non-copper metal.  
     
     
         162 . A catalyst as set forth in  claim 161  wherein said non-copper metal is selected from the group consisting of nickel, zinc, tin, cobalt, iron and combinations thereof.  
     
     
         163 . A catalyst as set forth in  claim 162  wherein said non-copper metal is nickel.  
     
     
         164 . A catalyst as set forth in  claim 162  wherein said non-copper metal is cobalt.  
     
     
         165 . A catalyst as set forth in  claim 140  wherein said copper-containing coating comprises from about 0.005 to about 0.5 grams of copper per gram of said metal sponge support.  
     
     
         166 . A catalyst as set forth in  claim 140  wherein said copper-containing coating comprises from about 0.03 to about 0.5 grams of copper per gram of said metal sponge support.  
     
     
         167 . A catalyst as set forth in  claim 140  wherein said copper-containing coating comprises from about 0.08 to about 0.35 grams of copper per gram of said metal sponge support.  
     
     
         168 . A catalyst as set forth in  claim 140  wherein said catalyst further comprises about 0.002 to about 5% by weight of a metal selected from the group consisting of chromium, titanium, niobium, tantalum, zirconium, vanadium, molybdenum, manganese, tungsten, bismuth, tin, antimony, lead, germanium and combinations thereof.  
     
     
         169 . A catalyst comprising: 
 a metal sponge support comprising (a) from about 2% to about 30% by weight copper, and (b) at least about 10% by weight non-copper metal; and    a copper-containing coating.    
     
     
         170 . A catalyst as set forth in  claim 169  wherein said non-copper metal is selected from the group consisting of nickel, zinc, tin, cobalt, iron and combinations thereof.  
     
     
         171 . A catalyst as set forth in  claim 169  wherein said copper-containing coating comprises a copper-containing active phase.  
     
     
         172 . A catalyst as set forth in  claim 171  wherein said copper-containing active phase has a copper concentration of at least about 50% by weight copper.  
     
     
         173 . A catalyst as set forth in  claim 171  wherein said copper-containing active phase has a copper concentration of at least about 75% by weight copper.  
     
     
         174 . A catalyst as set forth in  claim 171  wherein said copper-containing active phase has a copper concentration of at least about 90% by weight copper.  
     
     
         175 . A catalyst as set forth in  claim 171  wherein said copper-containing active phase has a copper concentration of at least about 95% by weight copper.  
     
     
         176 . A catalyst as set forth in  claim 170  wherein said non-copper metal is nickel.  
     
     
         177 . A catalyst as set forth in  claim 170  wherein said non-copper metal is cobalt.  
     
     
         178 . A catalyst as set forth in  claim 169  wherein said copper-containing coating comprises from about 0.005 to about 0.5 grams of copper per gram of said metal sponge support.  
     
     
         179 . A catalyst as set forth in  claim 169  wherein said copper-containing coating comprises from about 0.03 to about 0.5 grams of copper per gram of said metal sponge support.  
     
     
         180 . A catalyst as set forth in  claim 169  wherein said copper-containing coating comprises from about 0.08 to about 0.35 grams of copper per gram of said metal sponge support.  
     
     
         181 . A catalyst as set forth in  claim 169  wherein said catalyst further comprises about 0.002 to about 5% by weight of a metal selected from the group consisting of chromium, titanium, niobium, tantalum, zirconium, vanadium, molybdenum, manganese, tungsten, bismuth, tin, antimony, lead, germanium and combinations thereof.  
     
     
         182 . A catalyst comprising: 
 a metal support comprising a metal selected from the group consisting of zinc, cobalt, iron, tin and combinations thereof; and    a copper-containing coating.    
     
     
         183 . A catalyst as set forth in  claim 182  wherein the metal support comprises a metal sponge.  
     
     
         184 . A catalyst as set forth in  claim 183  wherein said copper-containing coating comprises a copper-containing active phase.  
     
     
         185 . A catalyst as set forth in  claim 184  wherein said copper-containing active phase has a copper concentration of at least about 50% by weight copper.  
     
     
         186 . A catalyst as set forth in  claim 184  wherein said copper-containing active phase has a copper concentration of at least about 75% by weight copper.  
     
     
         187 . A catalyst as set forth in  claim 184  wherein said copper-containing active phase has a copper concentration of at least about 90% by weight copper.  
     
     
         188 . A catalyst as set forth in  claim 184  wherein said copper-containing active phase has a copper concentration of at least about 95% by weight copper.  
     
     
         189 . A catalyst as set forth in  claim 183  wherein said metal sponge support comprises at least about 10% by weight of a metal selected from the group consisting of zinc, cobalt, iron, tin and combinations thereof.  
     
     
         190 . A catalyst as set forth in  claim 189  wherein said metal is cobalt.  
     
     
         191 . A catalyst as set forth in  claim 183  wherein said metal sponge support comprises at least about 50% by weight of a metal selected from the group consisting of zinc, cobalt, iron, tin and combinations thereof.  
     
     
         192 . A catalyst as set forth in  claim 191  wherein said metal is cobalt.  
     
     
         193 . A catalyst as set forth in  claim 183  wherein said metal sponge support comprises at least about 65% by weight of a metal selected from the group consisting of zinc, cobalt, iron, tin and combinations thereof.  
     
     
         194 . A catalyst as set forth in  claim 193  wherein said metal is cobalt.  
     
     
         195 . A catalyst as set forth in  claim 183  wherein said metal sponge support comprises at least about 80% by weight of a metal selected from the group consisting of zinc, cobalt, iron, tin and combinations thereof.  
     
     
         196 . A catalyst as set forth in  claim 195  wherein said metal is cobalt.  
     
     
         197 . A catalyst as set forth in  claim 183  wherein said metal sponge support comprises at least about 85% by weight of a metal selected from the group consisting of zinc, cobalt, iron, tin and combinations thereof.  
     
     
         198 . A catalyst as set forth in  claim 197  wherein said metal is cobalt.  
     
     
         199 . A catalyst as set forth in  claim 183  wherein said metal sponge support comprises at least about 90% by weight of a metal selected from the group consisting of zinc, cobalt, iron, tin and combinations thereof.  
     
     
         200 . A catalyst as set forth in  claim 199  wherein said metal is cobalt.  
     
     
         201 . A catalyst as set forth in  claim 183  wherein said metal sponge support further comprises copper.  
     
     
         202 . A catalyst as set forth in  claim 201  wherein said metal sponge support comprises from about 2% to about 30% by weight copper.  
     
     
         203 . A catalyst as set forth in  claim 201  wherein said metal sponge support comprises at least about 10% by weight copper.  
     
     
         204 . A catalyst as set forth in  claim 201  wherein said metal sponge support comprises at least about 50% by weight copper.  
     
     
         205 . A catalyst as set forth in  claim 201  wherein said metal sponge support comprises from about 60% to about 80% by weight copper.  
     
     
         206 . A catalyst as set forth in  claim 201  wherein said metal sponge support further comprises nickel.  
     
     
         207 . A catalyst as set forth in  claim 183  wherein said metal sponge support further comprises nickel.  
     
     
         208 . A catalyst as set forth in  claim 207  wherein said metal sponge support comprises at least about 10% by weight nickel.  
     
     
         209 . A catalyst as set forth in  claim 207  wherein said metal sponge support comprises at least about 50% by weight nickel.  
     
     
         210 . A catalyst as set forth in  claim 207  wherein said metal sponge support comprises at least about 65% by weight nickel.  
     
     
         211 . A catalyst as set forth in  claim 207  wherein said metal sponge support comprises at least about 80% by weight nickel.  
     
     
         212 . A catalyst as set forth in  claim 207  wherein said metal sponge support comprises at least about 85% by weight nickel.  
     
     
         213 . A catalyst as set forth in  claim 207  wherein said metal sponge support comprises at least about 90% by weight nickel.  
     
     
         214 . A catalyst as set forth in  claim 183  wherein said copper-containing coating comprises from about 0.005 to about 0.5 grams of copper per gram of said metal sponge support.  
     
     
         215 . A catalyst as set forth in  claim 183  wherein said copper-containing coating comprises from about 0.03 to about 0.5 grams of copper per gram of said metal sponge support.  
     
     
         216 . A catalyst as set forth in  claim 183  wherein said copper-containing coating comprises from about 0.08 to about 0.35 grams of copper per gram of said metal sponge support.  
     
     
         217 . A catalyst as set forth in  claim 183  wherein said catalyst further comprises about 0.002 to about 5% by weight of a metal selected from the group consisting of chromium, titanium, niobium, tantalum, zirconium, vanadium, molybdenum, manganese, tungsten, bismuth, tin, antimony, lead, germanium and combinations thereof.