Catalyst and process for direct catalystic production of hydrogen peroxide, (H2O2)

A method for making a supported metal catalyst for direct catalytic production of hydrogen peroxide (H2O2) product from hydrogen and oxygen-containing feedstreams, comprising the steps of:

• (a) providing a first solution containing a salt of a noble metal including palladium(Pd) in combination with platinum(Pt), gold(Au), iridium(Ir), osmium(Os), rhodium(Rh), or ruthenium(Rh), or and combinations thereof dissolved in a dilute acid;
• (b) providing a second solution of an ionic control polymer dissolved in water, said control polymer having molecular weight of 300-8000;
• (c) mixing said first and second solutions together and forming a combined controlling precursor solution, the molar ratio of the first solution metal to the second solution polymer being in range of 1:0.1 to 1:10, and then reducing the precursor solution with hydrogen;
• (d) mixing the combined precursor solution with a particulate support material having 50-500 m2/g surface area, and impregnating said particulate support material with the combined precursor solution so as to provide an orderly dispersed metal crystal structure on the support material;
• and
• (e) drying the metal impregnated particulate support material and then reducing it with hydrogen gas at 250-350° C. temperature for 10-20 hours to make the catalyst having active minute noble metal crystals provided in an atomic structure of 110 and/or 220 phase exposition.

A method for making a supported metal catalyst for direct catalytic production of hydrogen peroxide (H2O2) product from hydrogen and oxygen-containing feedstreams, comprising the steps of:

• (a) providing a first solution containing palladium chloride (Pd Cl2) dissolved in dilute hydrochloric acid (HCl);
• (b) providing a second solution of sodium polyacrylate ionic control polymer dissolved in water, the molar ratio of said first solution metal to the second solution polymer being in a range between 1:0.5 and 1:5;
• (c) providing a third solution containing a platinum salt;
• (d) mixing said first, second and third solutions together and forming a combined controlling precursor solution, reducing the combined precursor solution with hydrogen at 10-40° C. temperature, then mixing the combined precursor solution with carbon black support material powder having 100 250 m2/g surface area and impregnating said support material with the precursor solution;
• and
• (e) drying the metal impregnated carbon black support material and then reducing it with hydrogen gas at 250-350° C. temperature for 12-18 hours to make the catalyst having palladium metal crystals oriented so as to provide a 110 and/or 220 phase exposition, and which has atoms of the palladium exposed in an orderly linear alignment pattern on the metal crystals.