Uop Lcc

Hassan Windawi

Warren R Oakdale

Gene R Grieger

Randy J Lawson

Michael H Quick

Processes for the conversion of gases into useable products as exemplified by the reaction of carbon monoxide and hydrogen to form paraffinic hydrocarbons, hydrogen and nitrogen to form ammonia, and water and carbon monoxide to form carbon dioxide and hydrogen may be effected at reaction conditions which include temperatures in the range of from about 200.degree. to about 700.degree. C. and pressures ranging from atmospheric to about 1000 atmospheres. The catalyst system which is to be employed to effect these reactions will comprise an iron-containing compound admixed with elemental copper, and potassium-, aluminum- and vanadium-containing compounds.

Conversion of gases to useable products

Catalyst systems for the conversion of gases into useable products will comprise an iron-containing compound consisting essentially of elemental iron and a minimal amount of iron oxide. The system will also include the presence of from about 0.5% to about 4% by weight of elemental copper, from about 0.5% to about 4% by weight of aluminum oxide, from about 0.2% to about 5.0% by weight of vanadium oxide and from about 0.5% to about 5.0% by weight of a potassium-containing compound such as potassium oxide. This system will exhibit greater activity in the conversion of nitrogen and hydrogen to form ammonia, hydrogen and carbon monoxide to produce hydrocarbons, or water and carbon monoxide to form carbon dioxide and hydrogen.

Catalyst systems for the conversion of gases

Gas conversion catalysts which possess a high resistance to catalyst poisoning such as sulfur and/or chlorine-containing compounds, comprise a catalyst composite of copper, zinc and aluminum compounds containing at least one metal selected from the metals consisting of groups IVB, VB, VIB and VIIB of the Periodic Table. This catalyst composition may be used to synthesize methanol from a feedstock of carbon monoxide and hydrogen.

Gas conversion catalysts

Aqueous alcoholic solutions such as hydrous alkanols may be converted to the corresponding aldehyde in a process which involves high conversion levels and high selectivity levels by treating the solution with an oxygen-containing gas in the presence of a catalyst comprising at least two oxides of metals selected from the group consisting of molybdenum, tungsten, cobalt, nickel, manganese, iron and chromium, one of said oxides being molybdenum oxide or tungsten oxide composited on a high surface area support. Reaction conditions which are employed in the process will include temperatures in the range of from about 200.degree. to about 400.degree. C. and a pressure in the range of from about atmospheric to about 50 atmospheres.

Preparation of aldehydes

Improved catalyst systems which may be used for a wide variety of chemical reactions such as gas conversion reactions may be prepared by impregnating a transition metal compound which may contain a structural promoter with a nonaqueous solution of an alkali metal superhydride in order to provide a more uniform distribution of the chemical promoter on the active surface of the catalyst. As an example, iron oxide which has been structurally promoted with aluminum may be impregnated with a nonaqueous solution of potassium triethyl-borohydride to prepare an active gas conversion catalyst.

Method for obtaining improved catalyst systems

Alcohols such as those containing from about 1 to about 10 carbon atoms may be converted to aldehydes by treating the alcohols with an oxygen-containing gas such as air or oxygen in the presence of a catalyst comprising at least two oxides of metals selected from the group consisting of molybdenum, tungsten, cobalt, nickel, manganese, iron and chromium, at least one of said oxides being molybdenum oxide or tungsten oxide composited on a high surface area support. The conversion reaction may be effected at a temperature ranging from about 200.degree. to about 400.degree. C. and a pressure in the range of from about atmospheric to about 50 atmospheres. By employing this particular catalyst, good conversion rates and high selectivity to the aldehydes will be obtained.

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Arlington Heights, IL, United States of America

Hassan Windawi