Process for preparing a hydrogenation catalysts

Abstract

Copper compositions that are useful as hydrogenation catalysts are disclosed. In particular, the copper compounds are catalysts for the selective hydrogenation of oils that contain unsaturated fatty acyl components such as unsaturated vegetable oils. Methods of preparing the copper compositions are also disclosed. Methods of hydrogenating unsaturated compositions that contain at least two sites of unsaturation using the hydrogenation catalysts, along with products obtained from the hydrogenation reactions described herein are also disclosed.

1 - 15 . (canceled) 
     
     
         16 . A process of preparing a hydrogenation catalyst comprising:
 (a) preparing a mixture by contacting copper carbonate/copper hydroxide material with a hydrogen peroxide solution, wherein said mixture is maintained at temperatures from about −5° C. to about 100° C.; and   (b) separating a solid material from said mixture;   wherein a hydrogen peroxide-treated copper carbonate/copper hydroxide hydrogenation catalyst is prepared.   
     
     
         17 . The process of  claim 16 , wherein said hydrogen peroxide solution is about 1% to 90% hydrogen peroxide. 
     
     
         18 . The process of  claim 17 , wherein said hydrogen peroxide solution is about 40% to 60% hydrogen peroxide. 
     
     
         19 . The process of  claim 16 , wherein said mixture is maintained at temperatures from about −5° C. to about 30° C. 
     
     
         20 . The process of  claim 16 , wherein separating said solid material from said mixture comprises centrifugation, settling, decantation, filtration, or any combination thereof. 
     
     
         21 . The process of  claim 16 , further comprising slurry grinding the solid material of step (b) with a hydrogen peroxide solution. 
     
     
         22 . A hydrogenation catalyst made by the process of  claim 16 . 
     
     
         23 . The catalyst of  claim 22 , wherein the catalyst is unsupported. 
     
     
         24 - 38 . (canceled) 
     
     
         39 . A process of preparing a hydrogenation catalyst comprising:
 (a) preparing a mixture by contacting a copper hydroxide material with a hydrogen peroxide solution, wherein said mixture is maintained at temperatures from about −5° C. to about 100° C.; and   (b) separating a solid comprising said catalyst,   wherein a hydrogen peroxide-treated copper hydroxide hydrogenation catalyst is prepared.   
     
     
         40 . The process of  claim 39 , wherein said hydrogen peroxide solution is about 1% to about 90% hydrogen peroxide. 
     
     
         41 . The process of  claim 39 , wherein said temperatures in step a) are from about −5° C. to about 30° C. 
     
     
         42 . The process of  claim 39 , further comprising heating the hydrogen peroxide-treated copper hydroxide hydrogenation catalyst in an oil in the absence of additional hydrogen. 
     
     
         43 . A process of preparing a hydrogenation catalyst comprising heating a copper carbonate/copper hydroxide material at a temperature of not less than about 100° C. until said material is black in color, wherein a heat treated copper carbonate/copper hydroxide hydrogenation catalyst is prepared. 
     
     
         44 . The process of  claim 43 , comprising:
 (a) heating a copper carbonate/copper hydroxide material at a temperature from about 100° C. to about 320° C., and   (b) heating the material of step a) at a temperature at least about 5° C. higher than the temperature in step a).   
     
     
         45 . A process of preparing a hydrogenation catalyst comprising:
 (a) heating a copper metal powder material at a temperature from about 50° C. to about 500° C.; and   (b) subjecting said copper powder from step a) to a process that disrupts agglomerates and clumps,   wherein a heat-treated copper powder hydrogenation catalyst is prepared.   
     
     
         46 . The process of  claim 45 , wherein said copper powder has an average particle size of about 0.5 micron. 
     
     
         47 . The process of  claim 45 , further comprising:
 c) subjecting the product of step b) to a vacuum and/or drying step.   
     
     
         48 . The process of  claim 45 , further comprising:
 c) heating the product of step b) at a temperature from about 50° C. to about 500° C.