US 8,138,115 B2 · Precipitated iron catalyst for hydrogenation of carbon monoxide

Abstract

A method of producing an iron catalyst for catalyzing the hydrogenation of carbon monoxide is disclosed. The method comprises using a reduced amount of acid for iron dissolution compared to certain previous methods. The resulting acidic iron mixture is heated without boiling to obtain a nitrate solution having a Fe2+:Fe3+ ratio in the range of about 0.01%:99.99% to about 100%:0% (wt:wt). Iron phases are precipitated at a lower temperature compared to certain previous methods. The recovered catalyst precursor is dried and sized to form particles having a size distribution between 10 microns and 100 microns. In embodiments, the Fe2+:Fe3+ ratio in the nitric acid solution may be in the range of from about 3%:97% to about 30%:70% (wt:wt) and the calcined catalyst may comprise a maghemite:hematite ratio of about 1%:99% to about 70%:30%.

Claims35

Dependent claims

A method of manufacturing a catalyst comprising iron, copper and potassium, comprising:

preparing an iron nitrate solution having a Fe2+:Fe3+ ratio (wt %/wt %) in the range of from about 0.01% Fe2+:99.99% Fe3+ to about 100% Fe2+:0%Fe3+ and comprising copper;
heating the iron nitrate solution to a temperature in the range of about 20° C. to 80° C.;
preparing a precipitating agent solution;
reducing the temperature of the iron nitrate solution to a temperature in the range of from about 25° C. to 35° C. to obtain low temperature iron nitrate solution and reducing the temperature of the precipitation agent solution to a temperature in the range of 25° C. to 80° C. to obtain low temperature precipitating agent solution;
and
precipitating a precipitate comprising iron phases and optionally copper phases by reacting the low temperature nitrate solution with the low temperature precipitating agent at a temperature not exceeding 40° C.

3 more elements

A method of manufacturing a catalyst comprising iron, copper and potassium, comprising:

mixing together a selected amount of metallic iron or an iron-containing compound, to obtain an iron nitrate solution having a Fe2+:Fe3+ ratio (wt %/wt %) in the range of from about 3% Fe2+:97% Fe3+ to about 30% Fe2+:70% Fe3+;
heating the iron nitrate solution to a temperature in the range of about 20° C. to 80° C.;
preparing a precipitating agent solution;
reducing the temperatures of the iron nitrate solution and the precipitation agent solution to respective temperatures in the range of 25° C. to 35° C., to obtain respective low temperature solutions;
and
precipitating a precipitate comprising Fe2+ and Fe3+ hydroxides by reacting the low temperature nitrate solution with the low temperature precipitating agent at a temperature not exceeding 40° C.

3 more elements

Dependencies are inferred from the claim text.

Facts

Application

12/713,358Filed 26 Feb 2010 · division

Priority

10 Aug 2007

Published

US 2010/0152036 A117 Jun 2010

Granted

20 Mar 2012

Term ends

Not estimatedThe source records don’t support an estimate.

Classification15 codes

B01J 23/78
Combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36: with alkali- or alkaline earth metals
B01J 35/30
Catalysts, in general, characterised by their form or physical properties: characterised by their physical properties
B01J 35/40
Catalysts, in general, characterised by their form or physical properties: characterised by dimensions, e.g. grain size
B01J 35/45
Characterised by dimensions, e.g. grain size: nanoparticles

Family

Application60/955,142Us provisional application · filed 10 Aug 2007

Application61/022,566Us provisional application · filed 22 Jan 2008

Application12/189,424Parent of this division · filed 11 Aug 2008

US 2010/0152036 A1Pre-grant publication · published 17 Jun 2010

US 7,879,756 B2Parent of this division

US 2009/0069451 A1Published application

US 8,138,115 B2This patent

From the US filing history. Foreign family members aren’t listed.

Precipitated iron catalyst for hydrogenation of carbon monoxide

Life of this patent

Precipitated iron catalyst for hydrogenation of carbon monoxide

Life of this patent

Abstract

Claims35