Cobalt catalysts reaction products

This idea was confirmed by studies on the reaction of ethylene with synthesis gas, (H2 + CO), at 150°-200°C and 150 bar using the standard Fischer-Tropsch cobalt catalyst. Reaction products included propanaldehyde and isopro-panaldehyde. In 1945 Ruhrehemie opened a plant with a capacity of 10,000 toimes/year at Molten, to produce Cn-Cn alcohols from Fischer-Tropsch olefins. These were subsequently converted to detergent sulfates. 

Carbon monoxide and excess steam are normally passed over a cobalt catalyst at about 250-300 C resulting in greater than 99% conversion of CO to COj. This conversion reaction is widely used in oil or solid fuel gasification processes for the production of town gas or substitute natural gas. ... 

Prior to 1975, reaction of mixed butenes with syn gas required high temperatures (160—180°C) and high pressures 20—40 MPa (3000—6000 psi), in the presence of a cobalt catalyst system, to produce / -valeraldehyde and 2-methylbutyraldehyde. Even after commercialization of the low pressure 0x0 process in 1975, a practical process was not available for amyl alcohols because of low hydroformylation rates of internal bonds of isomeric butenes (91,94). More recent developments in catalysts have made low pressure 0x0 process technology commercially viable for production of low cost / -valeraldehyde, 2-methylbutyraldehyde, and isovaleraldehyde, and the corresponding alcohols in pure form. The producers are Union Carbide Chemicals and Plastic Company Inc., BASF, Hoechst AG, and BP Chemicals. 

The basic process usually consists of a large reaction vessel in which air is bubbled through pressuri2ed hot Hquid toluene containing a soluble cobalt catalyst as well as the reaction products, a system to recover hydrocarbons from the reactor vent gases, and a purification system for the ben2oic acid product. 

A Belgian patent (178) claims improved ethanol selectivity of over 62%, starting with methanol and synthesis gas and using a cobalt catalyst with a hahde promoter and a tertiary phosphine. At 195°C, and initial carbon monoxide pressure of 7.1 MPa (70 atm) and hydrogen pressure of 7.1 MPa, methanol conversions of 30% were indicated, but the selectivity for acetic acid and methyl acetate, usehil by-products from this reaction, was only 7%. Ruthenium and osmium catalysts (179,180) have also been employed for this reaction. The addition of a bicycHc trialkyl phosphine is claimed to increase methanol conversion from 24% to 89% (181). 

This procedure is useful for avoiding secondary reactions of the aldehydes leading to high-boihng products. It is particularly advisable when linear aliphatic aldehydes are synthesized using cobalt catalysts. ... 

In 1996, consumption in the western world was 14.2 tonnes of rhodium and 3.8 tonnes of iridium. Unquestionably the main uses of rhodium (over 90%) are now catalytic, e.g. for the control of exhaust emissions in the car (automobile) industry and, in the form of phosphine complexes, in hydrogenation and hydroformylation reactions where it is frequently more efficient than the more commonly used cobalt catalysts. Iridium is used in the coating of anodes in chloralkali plant and as a catalyst in the production of acetic acid. It also finds small-scale applications in specialist hard alloys. 

Where sodium sulfite is added as a component of multifunctional or one-drum products designed for smaller boilers, no cobalt catalyst is added because of the cobalt alkaline precipitation problem. Consequently, if the FW temperature is low this type of formulation is unsuitable because the sulfite requirement will be too high and the available reaction time too short. Probably a tannin-based, one-drum product would be more suitable (although here again there may be a problem because tannin-based products, unlike sulfite cannot be mixed with amines). 

The formation of isomeric aldehydes is caused by cobalt organic intermediates, which are formed by the reaction of the olefin with the cobalt carbonyl catalyst. These cobalt organic compounds isomerize rapidly into a mixture of isomer position cobalt organic compounds. The primary cobalt organic compound, carrying a terminal fixed metal atom, is thermodynamically more stable than the isomeric internal secondary cobalt organic compounds. Due to the less steric hindrance of the terminal isomers their further reaction in the catalytic cycle is favored. Therefore in the hydroformylation of an olefin the unbranched aldehyde is the main reaction product, independent of the position of the double bond in the olefinic educt ( contrathermodynamic olefin isomerization) [49]. 

Cobalt carbonyl complexes with tertiary phosphine ligands are not volatile. This makes possible a distillative separation of the reaction products from the cobalt catalyst system (Fig. 5). 

The paraffin wax is oxidized by air in a liquid phase process at 110-130°C. Catalysts for this radical reaction are cobalt or manganese salts [54]. The quality of the obtained mixture of homologous carboxylic acids is impaired by numerous byproducts such as aldehydes, ketones, lactones, esters, dicarboxylic acids, and other compounds. These are formed despite a partial conversion of the paraffin and necessitate an expensive workup of the reaction product [50,55]. 

Carbonylation of alkynes is a convenient method to synthesize various carbonyl compounds. Alper et al. found that carbonylation of terminal alkynes could be carried out in aqueous media in the presence of 1 atm CO by a cobalt catalyst, affording 2-butenolide products. This reaction can also be catalyzed by a cobalt complex and a ruthenium complex to give y-keto acids (Scheme 4.8).92... 

The first stage of the process is a hydroformylation (oxo) reaction from which the main product is n-butyraldehyde. The feeds to this reactor are synthesis gas (CO/H2 mixture) and propylene in the molar ratio 2 1, and the recycled products of isobutyraldehyde cracking. The reactor operates at 130°C and 350 bar, using cobalt carbonyl as catalyst in solution. The main reaction products are n- and isobutyraldehyde in the ratio of 4 1, the former being the required product for subsequent conversion to 2-ethylhexanol. In addition, 3 per cent of the propylene feed is converted to propane whilst some does not react. 

The type of intermediate shown in structure (B) has also been supported by Muller and Gault (119) who showed that in the reaction of 1,1-dimethylcyclopropane with deuterium over a series of thick evaporated metal film catalysts, it was only on platinum that 1,1,3-da-neopen-tane (and 1,1,3,3-d4-neopentane) were dominant products. On palladium, iron, rhodium, nickel, and cobalt the major product was 1,3-d2-neopentane. 

The oxidation of cobalt metal to inactive cobalt oxide by product water has long been postulated to be a major cause of deactivation of supported cobalt FTS catalysts.6 10 Recent work has shown that the oxidation of cobalt metal to the inactive cobalt oxide phase can be prevented by the correct tailoring of the ratio Ph2cJPh2 and the cobalt crystallite size.11 Using a combination of model systems, industrial catalyst, and thermodynamic calculations, it was concluded that Co crystallites > 6 nm will not undergo any oxidation during realistic FTS, i.e., Pi[,()/I)i,2 = 1-1.5.11-14 Deactivation may also result from the formation of inactive cobalt support compounds (e.g., aluminate). Cobalt aluminate formation, which likely proceeds via the reaction of CoO with the support, is thermodynamically favorable but kinetically restricted under typical FTS conditions.6... 

Although the FTS is considered a carbon in-sensitive reaction,30 deactivation of the cobalt active phase by carbon deposition during FTS has been widely postulated.31-38 This mechanism, however, is hard to prove during realistic synthesis conditions due to the presence of heavy hydrocarbon wax product and the potential spillover and buildup of inert carbon on the catalyst support. Also, studies on supported cobalt catalysts have been conducted that suggest deactivation by pore plugging of narrow catalyst pores by the heavy (> 40) wax product.39,40 Very often, regeneration treatments that remove these carbonaceous phases from the catalyst result in reactivation of the catalyst.32 Many of the companies with experience in cobalt-based FTS research report that these catalysts are negatively influenced by carbon (Table 4.1). 

Along with catalyst activity, product selectivity is a key issue in cobalt-based FTS.1 For GTL processes the preferred product is long-chain waxy hydrocarbons. It is well known that FT reaction conditions have an important effect on product selectivities. High temperatures and H2/CO ratios are associated with higher methane selectivity, lower probability of hydrocarbon chain growth, and lower olefinicity in the products.105... 

FIGURE 9.24 Molar radioactivity of the reaction products when co-feeding n-hexa-decene-(l)-(l-14C) together with the synthesis gas to FT synthesis on cobalt. Catalyst 100Co-18Th02-100Kieselguhr (by weight), precipitated, 190°C, 1 bar, H2/CO = 2, Xc0 = 70%, 0.1 vol% of hexadecene-14C in the synthesis gas. 

The most difficult problem to solve in the design of a Fischer-Tropsch reactor is its very high exothermicity combined with a high sensitivity of product selectivity to temperature. On an industrial scale, multitubular and bubble column reactors have been widely accepted for this highly exothermic reaction.6 In case of a fixed bed reactor, it is desirable that the catalyst particles are in the millimeter size range to avoid excessive pressure drops. During Fischer-Tropsch synthesis the catalyst pores are filled with liquid FT products (mainly waxes) that may result in a fundamental decrease of the reaction rate caused by pore diffusion processes. Post et al. showed that for catalyst particle diameters in excess of only about 1 mm, the catalyst activity is seriously limited by intraparticle diffusion in both iron and cobalt catalysts.1... 

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