Porous shaped metal-carbon products

Abstract

The present invention provides a porous metal-containing carbon-based material that is stable at high temperatures under aqueous conditions. The porous metal-containing carbon-based materials are particularly useful in catalytic applications. Also provided, are methods for making and using porous shaped metal-carbon products prepared from these materials.

We claim: 
     
         1 . A porous shaped metal-carbon product comprising a porous carbon matrix and a metal component, wherein the metal component of the porous, shaped metal-carbon product is present at a metal loading of at least about 10 wt %. 
     
     
         2 . The product of  claim 1 , wherein the metal loading is at least about 15 wt %. 
     
     
         3 . The product of  claim 1 , wherein the metal component of the porous, shaped metal-carbon product is a base metal. 
     
     
         4 . The product of  claim 1 , wherein the metal component of the porous, shaped metal-carbon product is selected from the group consisting of Cu, Pb, Ni, Zn, Fe, Mo, Al, Sn, W, Ta, Co, Bi, Cd, Ti, Zr, Sb, Mn, Be, Cr, Ge, V, Ga, Hf, In, Nb, Rh, Tl, Ru, Rh, Pd, Ag, Os, Ir, Pt, Au, and combinations thereof. 
     
     
         5 . The product of  claim 1 , wherein the metal component of the metal-carbon product is selected from the group consisting of Cu, Pb, Ni, Zn, Fe, Mo, Al, Sn, W, Ta, Co, Bi, Cd, Ti, Zr, Sb, Mn, Be, Cr, Ge, V, Ga, Hf, In, Nb, Rh, Tl, and combinations thereof. 
     
     
         6 . The product of  claim 1 , wherein the metal component of the metal-carbon product is selected from the group consisting of Ni, Co, W, Nb, Mo, and combinations thereof. 
     
     
         7 . The product of  claim 1 , wherein the metal component of the metal-carbon product is selected from the group consisting of Ni, W, and combinations thereof. 
     
     
         8 . The product of  claim 1 , further comprising a second metal deposited on the surfaces of the porous shaped metal-carbon product. 
     
     
         9 . The product of  claim 8 , wherein the second metal is different from the metal component of the metal-carbon product. 
     
     
         10 . The product of  claim 9 , wherein the second metal is a noble metal. 
     
     
         11 . The product of  claim 10 , wherein the noble metal is selected from the group consisting of Pt and Au. 
     
     
         12 . The product of  claim 1 , wherein the product is a carbonization product of a carbonaceous material with water, a water-soluble organic binder, and a metal precursor selected from the group consisting of a metal carbonate, a metal oxide, a metal hydroxide, a salt of a metal acid, a heteropoly acid, a metal carboxylate, a metal carbide, a metal chloride, a metal amine complex-containing compound, a hydrate thereof, and a mixture of any two or more thereof. 
     
     
         13 . The product of  claim 12 , wherein the carbonaceous material comprises a carbon black. 
     
     
         14 . The product of  claim 12 , wherein the carbonaceous material comprises an activated carbon. 
     
     
         15 . The product of  claim 12 , wherein the carbonaceous material comprises a graphite. 
     
     
         16 . The product of  claim 12 , wherein the carbonaceous material is a mixture of any two or more materials selected from the group consisting of a carbon black, an activated carbon, and a graphite. 
     
     
         17 . The product of  claim 1 , wherein the product exhibits a radial piece crush strength of greater than about 4.4 N/mm (1 lb/mm). 
     
     
         18 . The product of  claim 1 , wherein the product comprises a BET specific surface area in the range of from about 20 m 2 /g to about 500 m 2 /g and a specific pore volume of pores having a diameter in the range of from 1.7 nm to 100 nm, as measured by the BJH process, that is from about 0.1 cm 3 /g to about 1.5 cm 3 /g. 
     
     
         19 . A process for producing a dicarboxylic acid from an aldaric acid, or salt, ester, or lactone thereof, the process comprising:
 contacting the aldaric acid, or salt, ester or lactone thereof with hydrogen in the presence of a halogen-containing compound and a hydrodeoxygenation catalyst comprising the porous, shaped metal-carbon product of  claim 1  to form the dicarboxylic acid.   
     
     
         20 . The process of  claim 19 , wherein the porous, shaped metal-carbon product further comprises a noble metal deposited thereon.